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!

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....

The Miracle in Chicago

My TravelScoot and I have done alot of traveling recently. Today in Chicago the belt decided it was the end of the road. I started noticing a thump and after inspection realized I had a tear in the belt. I luckily had bought an extra belt and had my wrenches in my trusty TravelScoot bag. Being at the IFT Food Show I was wondering how I would find someone to help me. A man walked up and got a sample of a sandwich which was being given next door and asked if he could sit on our couch we had put there just for that occurrence. I said Sure. He asked me what was wrong with my scooter and I told him my tale of woe. He happened to be a mechnical engineer from Guadalajara Mexico and he quickly figured out how to do it....5 minutes later I was like new. You should know that I am married to a woman from Mexico and we have always had good luck in Mexico with people helping us when we had car trouble so I guess I should have expected this but it made me tearful. I was sort of frightened about the idea of having to walk my scooter a couple of blocks and then figuring out how to get it fixed. I am one lucky person: help comes my way when I need it. The lesson here is all folks with TravelScoot keep an extra belt with you at all times and your little Allen wrenches. You never know.......Dean Hughson

Tip from Elizabeth: Print out these instructions too!

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.