How to change the belt on a TravelScoot

How to change the belt on a TravelScoot

These instructions were written by Tony at TravelScoot. His email address is mail@travelscoot.com. Print these instructions and keep a copy with your spare belt and toolkit. 

Open http://sizepositive.com/changingtravelscootbelt.htm for a printer friendly version.

With the scooter opened (without the seat and yoke or battery) and sitting on the ground or on a raised surface,

- Remove the 2 screws attaching the aluminum belt guard from around the small gear (on the motor shaft).

- Raise the left rear side of the scooter up (by placing a block of wood or something under the leg) so the wheel can be rotated by hand.

- While applying side pressure to the belt (away from the wheel), turn the wheel backwards and roll the belt off the big gear (on the wheel).

- With the two 5mm Allen wrenches supplied in your tool kit, loosen the axle bolts on the rear wheel. With luck the inner bolt will come out while the outer bolt stays in, but this is no big deal.

- Grab whichever axle bolt is still in place and pull the axle out PART WAY until the wheel can be cocked enough to allow the drive belt to pass between it and the fork.

- Get a good look how the belt is installed so you have an easier time installing the new one.

- Remove old, install new.

- Install the rear wheel, being careful to align the axle shaft with the holes in the wheel and fork. Tighten the axle bolts.

- Place the belt over the small gear on the motor shaft.

- Roll the belt over the big gear on the wheel similar to the removal process.

- Check belt tension: the belt should deflect approx. 1/2 inch with moderate finger pressure. The tension can be adjusted by moving the belt tensioner pulley up or down.

- Reinstall the belt guard. Align it so the bolt head for the small gear is centered in the hole. Otherwise the gear can scrape and make noise.

Changing the TravelScoot Belt

Changing the TravelScoot Belt
	As part of preventive maintenance we decided to change the belt on my TravelScoot. Melissa came so she could help and learn more about how to perform maintenance on her own scoot. In this picture Alan is reading the belt change instructions. Click any picture to see a larger version
	This is the hex tool that came with the scoot.
	Alan and Melissa decided the wheel needed to be propped up, so they turned the seat upside down and propped it on the u-bar part of the yoke.
	Melissa is rolling the old belt off.
	Tada!
	Now they're working together (each with a hex tool) to get the wheel off.
	There was some cursing involved because they were having a hard time getting the wheel loose.
	Alan went and got the big guns -- his ratchet set.
	Success!
	Now Melissa is rolling the new belt on.
	Alan is putting the pin back that holds the wheel on.
	There's that ratchet again.
	All done!

And where do you carry the spare belt?

From Krystal:


As an old bike rider, I like to have things handy “just in case” so I got to wondering – how do I carry the spare belt? I have the tools (and a copy on how to change the belt in the tool pouch) attached to the V-bag. There must be a way that won’t fold, spindle, or mutilate the belt.

To add insult to injury, the trim is starting to come loose on the seat and I really don’t like the idea of those staple sticking out in that area. :-)

Being a crafty person, I decided that a new seat cover was in order. And that’s when I also figured out just where to carry a spare belt.

I’m working on my second cover as I realized that there was too much cloth on the back.

To make the cover:

1) Using newspaper (so you can make adjustments and have a pattern to make more), place the seat face down and trace. Add a half inch for seam allowance.

2) measure around the outer edge of the seat and add one inch. Now make a strip of newspaper the length of the outer edge+1 and about 9.5 inches wide. You might want to taper the ends for the last 8 (or so) inches or so to keep from having that puff in the back. I’m trying a two inch taper.

Your pattern is now created.

For the small seat, it takes about 2/3 a yard of 45 inch material and 3 feet of cord for the drawstring. I’m not sure about using stretch stuff.

When putting the pieces together. I found that it is best to finish the ends of the side piece – quarter fold, quarter fold. Do a quarter inch then half inch fold for the drawstring casing along the un-tapered edge of the side piece. Then sew on the top. (Don’t forget to center the side piece to the center of the front of the top. This creates the slit in the back for the seat back.) I added a second seam around the top of the seat to give it more strength and to hold the seam allowance in place. Thread the drawstring through the casing. That’s it.

E’voila! A new seat. Just think, now you can make ones to match your outfits and the seasons. Yes, that’s what I’m planning.

I just realized also, that for everyone that wants more padding, if they made two copies of the top and put foam between before sewing that may help.

In case you are wondering about the black strap poking out from the back of the seat. It’s a loop of belt webbing. Yep, it’s a handle.

Hope the New Year is wonderful to you!

More belt changing details

You mechanical wizards might just want to skip this post because you're going to be laughing at the rest of us (or at least me!) after you read it...

I think changing the belt is something the non-mechanical among us are always worrying about in the back of our minds. (Or maybe we're just worrying about getting stranded!) I've had my scoot for 18 months, and my original belt is still good, so it's probably not a reasonable concern, but I seem to grab onto any bit of information I can get about it, just to prepare myself for the possibility.

Tony at TravelScoot wrote out instructions for us which are posted here. Dean has also posted a comment about his recent belt change, and since not everyone reads the comments sections, I thought I'd post it here too.

From Dean:

To be honest it is easier than posted. My guy took the wrenches and first loosened and took off the protector piece of metal. Then he loosened both sides of the axle on the tire and the belt came right off....you put the new one on and tighten it back up. That was it....would be easier on a table perhaps but my 'angel' did it on the carpet of McCormick Place Convention Center....

Preventive Maintenance

Rhonda posted a comment about an idea for a preventive maintenance list. I'd be happy to compile it if you guys want to give your input. How about it, you experienced TravelScooters?

Rhonda commented...

I have always been lucky when it comes to getting help from a stranger, my worry is that it will happen when there are well meaning strangers who aren't mechanically inclined. Dave has decided that my scoot will undergo regular preventive maintenance in the form of a belt check. He said that short of a catastrophic event breaking the belt that regular use will produce cracks on the teeth side of the belt before it breaks. When you see cracks on the belt, it's time for a change. I bet there are several items that could be checked and fixed prior to breakage, we should start a preventive maintenance list.

Tips for Getting Up a Ramp or Incline

I haven't faced many ramps yet. The tallest one I've been on was 2 - 3 foot tall. I made it about 75% of the way up, then had to put my feet down and help push. Lynn Ellen says the hill up to the church near her house is a bit steeper at first and then is fairly gentle so she just leaned forward and off she went.

Ramps going into stores have been easy to handle. I have not yet tried mine on a handicap ramp that takes the place of stairs.

Tips for Getting Up a Ramp or Incline

1) Get a good running start.
2) Approach the incline straight on, not from the side.
3) Lean forward. It changes your center of gravity and helps you go forward.
4) If you have to, put your feet down and help propel yourself up.
5) If all else fails, get off and walk your TravelScoot the short distance up the incline.
6) If this is a continual problem, there is an alternate motor that has 11 teeth instead of 13. This motor has its drawbacks though, so it might not be right for you. It cuts down on the total distance you can go on one battery charge, and it lessens your top speed. It's also harder on the belt. You did buy spare belts for an emergency, right? I'd rather just walk my scoot up the occasional steep ramp if I need to. And as far as I know, the 11 teeth motor hasn't been tested by a supersize person.

Added note: Empress Bee says that Sarge has one of the lower teeth motors and he wished he didn't. "He had to change the belt on our cruise this past week. my scooter has the other one and the belt is much older than his and still going strong. but we both love our scooters. so many people want them on the ships!"