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Touring battery troubleshooting and replacement

 
 

🔋 Potential Battery Issues

1. Battery Voltage Appears Low

  • A fully charged battery can read between 49V and 56V, depending on the unit and charger.

  • Fluctuations in voltage are normal for Lithium-ion batteries.

  • Your range will depend on weight, speed, and road conditions.

  • More info: Battery University – Confusion with Voltages

Check:

  • Turn on your voltmeter. Healthy voltage is 41V–56V.

  • Above 39V: Battery is likely fine; check for other issues.

  • Below 37V: Battery health is compromised → replacement may be needed.

Normal Battery Aging:

  • After 3+ months or >100 miles, voltage slightly below max is normal battery degradation.

  • Warranty does not cover normal degradation, only battery failure.

⚡ Voltage Drops When Turning On

  • Ask about water damage.

    • Yes: Customer may need to replace the battery: Replacement Battery

    • No: Request a video showing the issue. Technicians will advise if a warranty replacement is needed.

🔑 Voltmeter Issues

  • Stays on and cannot turn off: Likely a damaged voltmeter key housing.

    • Replacement is needed.

    • If order is <30 days, replacement is free.

    • The customer must be comfortable performing the replacement, or we can assist.

📺 LCD Battery Display Issues

  • LCD shows 100% constantly:

    • First, check P1 & P2 settings (Factory: P1 = 41.5, P2 = 15).

    • If issue persists, the LCD may need replacement.

🌡 Scooter Shuts Down Early / Feels Hot

  • Usually caused by LCD or controller.

  • If those are fine, check the battery with a multimeter.

  • Technicians can inspect and advise on replacement or repair.

🔌 Battery Doesn’t Charge After Port Replacement

  • Verify multimeter readings for charger and battery.

  • If charging port is fine, try replacing the charger first, then battery if needed.

  • Technicians can inspect battery if issues persist.

✅ Key Takeaways

  • Healthy battery voltage: 41–56V

  • Below 37V → replace battery

  • Voltage fluctuations are normal

  • Check for water damage before warranty claims


How to replace the battery? 

Step 1: The customer will first have to unfasten these 4 screws from the front deck.
 
Step 2: The customer will first have to unfasten these 4 screws from the top of the folding mechanism. (These screws have been changed on newer models from flatheads that screw into the deck, to socket screws with nuts that screw upwards from inside the deck)
 
Step 3: The customer will first have to unfasten these 4 screws from under the deck.
 
Step 4: The customer will then have to ensure that all the screws have been removed from this black component within the deck.
 
Step 5: Once all screws have been confirmed to be removed, the customer will then pull out the black component from the deck.
 
Step 6: Upon removal of this component, the customer will then grab the wiring attached to the battery from within the deck. Once the wiring is in-hand, have customer slowly and carefully pull the battery's wiring so the full battery comes out as well.
 
Step 7: Inspect the battery for any disconnections or shorted wires, as one wire can render the scooter inoperable.
Step 8: The new battery can now be inserted back into the deck the way you removed this. Afterwards, the components(controller + other wiring) will need to be carefully inserted back as well.
Battery Replacement Video Tutorial: https://www.youtube.com/watch?v=4WQlZUwi2ww&t=1s *Be advised that when unplugging/plugging battery there can be a spark*
 
 
Please also be advised that there are older versions of the Touring battery. The green cased one above ^ and there is black cased one that used battery pin connections as opposed to the yellow tipped connection shown above. Image below for reference.