How to use Spare Parts
To Build a Performance Scooter
We are taking an X-treme X360 chassis (frame) to add a new larger 24 volt 750 watt motor, reliable 80 amp control box, and 80 tooth sprocket rear wheel (if the 65 tooth 12 inch tire is used then a shorter chain is needed, but the top speed is 25% higher with insignificant acceleration loss). Normally the X360 has a 350 watt 36 volt motor that is bracket mounted using four bolts into a tapped flange attached to the motor, an adequate 20 amp control box, and a standard 80 tooth sprocket 12 inch rear wheel. The new motor is band mounted so the metal band is attached to the frame to secure the round motor body using a spacer block and sheet steel cut and formed to the diameter of the motor (a reinforcement and alignment rod is also added for our installation to stabilize and align the band mounted motor). It should also be noted that this chassis could be used with a 36 volt 800 watt motor and 85 control box to produce the best speed and acceleration, but that could be more power and acceleration than one would want producing wheelies and possible dangereous driving conditions unless the gear ration is further changed. This is what Rad2Go did with the E36 scooter that uses the 800 watt motor to prevent dangerous wheelies, but higher top speed.
Below we have installed a fabricated band of simple sheet metal to attach the new motor (shown in rust color in the series of pictures below) with additional installation of wheels, control box, batteries, and throttle and brake lever:
Just as easily we could have installed the 800 watt motor and 85 amp control box with three 12v 12ah batteries in this scooter chassis.
After initial trial runs we allowed for the motor mounting to shift and adjust to the installation, then retightened the chain to take up the slack produced. The scooter now has very high acceleration and climbing power (inclination) that was not available before. When we install the new 65 tooth rear sprocket the speed is 25% faster, too. A new shorter chain is required.
Necessary parts for this project: X360 chassis (body) including kickstand, 600 watt motor, 80 amp control box, two 12 volt 12AH batteries, 12 inch rear wheel with 80 or 65 tooth sprocket (a shorter chain is required for the 65 tooth sprocket wheel) and 70mm brake hub and drum, 12 inch front wheel and axle, front lower X360 fork/strut assembly with fork bearings, upper front handlebar with clamp, throttle, brake lever and cable, switch (on/off heavy duty with ON connection to battery, OFF connection to charger port), three prong charger port, wiring connectors and wire to connect batteries, controller, switch, and charger port, plus one seat pole assembly and seat. X360 body (used or scratch and dent) to install over chassis with battery access cover and key.
We first cut and installed the spacer block so the motor could mount flush against the rear of the frame near where the old bracket mounted motor installed. The flat steel plating was hand moulded around the diameter of the motor, and flanges were bent to install one lip against the spacer block. The diameter of the mounting bracket was less than necessary to allow the other mounting flange to be tightened through the existing holes on the chassis against the motor with the addition of a steel rod across the chassis and spacer block that kept the motor aligned to the chassis and upcoming rear wheel sprocket. The steel rod prevented the motor from been drawn down the spacer block on the right side (as viewed from the rear) since the motor did not span the entire width of the chasis square tube frame. Other options were available to support the bottom right side of the motor's sprocket end, but a simple support rod was all that was necessary for maintaining the alignment of the motor's sprocket end where the chassis was not originally produced for this installation.
The rear wheel and chain were then attached and chain alignment made with the motor, moving the motor left or right to align the sprockets and chain. Once aligned the chain was tensioned with the rear wheel forward/back adjusters.
The control box was installed and attached to the motor (blue and red wires), the switch in between the positive (red) wires of the control box and positive terminal of the battery where the center switch terminal was connected to the battery plus terminal. The charger port was connected to the black wire of the control box to the negative terminal of the battery set (the two batteries were wired together, plus to negative, for a 24 volt battery set). The charger port positive or red wire was to the pin one connector of the port from the OFF connector of the switch (placing the charger in the ON position to the battery positive terminal through it's center connector on the switch). Now the battery can be charged from the 24 volt battery charger when connected to the charger port as the switch rests in the OFF position.
The brake lever switch is connected to the two wires of the control box (red, black, white unused) to provide cut out of the motor when the lever is engaged. The cable is connected to the brake drum and the wire attached at the point that full slack has been removed from the cable - squeezing the lever places the drum against the brake hub immediately. The throttle three wire connector is matched to the red, green, and black wires of the control box.
Now testing the installation with the switch in the ON position shows the throttle will advance the speed of the motor.
A hole is drilled for the ON/OFF switch installation in the X360 body. The switch and charger port are mounted and wired to the control box and battery - it helps to use connectors that can be unplugged from the switch and charger port when the need to remove the body might occur. However the X360 allows access through the keyed battery compartment access.
Be sure to clamp the steering fork to the lower fork, install the seat and pole assembly and clamp. Make sure the tires are fully pressurized. The completed project with new motor and control box can support up to 300 pound riders with fast acceleration and speed.
This project can be accomplished with many variations. A new X360 can be altered or the individual components can be purchased and the modifications made for installation/alterations, or you can order a scratch and dent X-360 scooter as they are available.
All projects are subject to the builders' own ability and skill at tasks of this undertaking and this article is simply provided to reveal one method of accomplishing a performance upgrade to an existing scooter design and component parts. No warranty or guaranty or success in making your own modification or improvements is provided. This article is only information supplied from our own efforts at improving performance using our spare parts from an existing scooter model.