GAS CONVERSION ENGINE KIT
for eZip Electric Scooters
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Includes:1 – 38 cc Four Stroke Engine
1 – 55 Tooth Sprocket
1 – Chain ( # 25 – 70L )
1 – Engine Bracket
1 – Spacer
1 – Throttle Cable (75 Inches)
1 – Throttle Handle with Kill Switch
1 – Kill Wire Extension
1 – Clamp ( 1 set of M5 bolt and Nut )
4 – M6 Bolts ( Bracket Bolts )
3 – M5 Bolts ( Sprocket Bolts)
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PLEASE MAKE SURE TO TURN OFF YOUR SCOOTER
AND REMOVE THE BATTERY BEFORE PERFORMING
ANY INSTALLATION OR REPAIRS.
This gasoline operated products is NOT compliant with
Environmental Protection Agency ( E.P.A. ) or California
Air Resources Board (C.A.R.B) for the use on/off Public
roads. Upon purchase, the buyer agrees to use products for
racing (closed-course competition) only and NOT for
on/off public roads.
TABLE OF CONTENTS
Section 1
• Tools Required--------------------------------------Page 4
Section 2
• Engine Setup----------------------------------------Page 5
Section 3
• Sprocket Installation------------------------------Page 6-7
Section 4
• Engine Installation--------------------------------Page 8-9
Section 5
• Throttle/Kill Handle Installation---------------Page 10-13
Section 6
• Pre-Ride Checklist----------------------------------Page 14
TOOLS REQUIRED
Listed are some of the tools you will need in the assembly of the Hybrid Kit to your Scooter
8mm box wrench
10mm box wrench
15mm box wrench
2.5mm hex wrench
4mm hex wrench
5mm hex wrench
Phillip Screwdriver
ENGINE SETUP
Engine is included in the Hybrid Kit.
Read and follow the following setup
instructions very carefully.
IMPORTANT: Adult supervision may be
required for assembly.
1. To set up the engine, you need to
first arrange the clutch bell over
the clutch so that it is aligned with
all the 4 holes.
2. Then place the engine bracket
(Plane/Non-text side outside) over
the clutch matching the holes
alignment and the DIRECTION as
shown in Figure-E1.2
3. Once bracket is set to its place, use
new M6 bracket bolts using 5mm
hex wrench to fix it as shown.
Figure-E1.1
Figure-E1.2
SPROCKET INSTALLATION
WARNING Turn Off your scooter
and remove the battery before
performing any installation or repair
actions.
1.
Start with removing the chain from
sprocket by pulling the chain
tensioner down and undoing the
chain.
2.
Then use 15mm box wrench to
remove bolts from the rear wheel
axle as shown in
3.
Now push the rear wheel down, just
enough to give yourself enough
space to setup the additional
sprocket. (Do not remove the
brakes, let it be to its original
setting). Figure-S2.1
4. Unscrew the sprocket bolts and
place the new spacer.
Figure-S2.1
5.
Now place the new sprocket over the
spacer matching the hole alignment.
Figure-S2.3
6. Then use the new set of M5 sprocket bolts
to hold the two sprocket together with the
spacer. Make sure the bolts are tight all the
way in.
7. Once the bolts are tight enough then
install the new chain (#25-70L) over the
new sprocket. Refer Figure-S2.4 (Do not
forget to put the chain on before you fix
the rear wheel back).
Figure-S2.4
8.
Reinstall the rear wheel by tightening
the screws. Now leave the right side
nut loss to the width of 3-quaters (as
shown) so that you can place the
bracket while installing the engine to
your scooter. Please refer the FigureS2.5
9.
Then recheck if both the sprocket are
aligned and the chains are installed
properly.
Figure-S2.5
ENGINE INSTALLATION
WARNING  Turn Off your scooter
and remove the battery before
performing any installation or repair
actions.
1.
Carefully lift the engine and mount
the bracket on the right side of rear
axle over the space left open from
the previous step. Refer the FigureM3.1
2.
Now install the new chain to the
clutch bell tooth properly.
3.
Then slightly tighten the bolt, just
enough to hold the bracket at its
place. (Do not tight it completely).
Figure-M3.1
4. Now use the clamp to secure the
position of the bracket by clamping
it with the frame of your scooter as
shown in the Figure-M3.2
Figure-M3.2
5. Now pull the engine backward to
the full extension of the clamp.
Figure-M3.3
6. Then adjust the bracket height by
lifting up the engine until the
chain has enough tension as
shown in Figure-M3.4
7. Now completely tighten the bolt
to fix the position of the engine.
Again make sure that the chain
still has the tension you desire.
8. For
your convenience, please
mark the position of the bracket
for your future references.
Figure-M3.3
9. In the end, make sure that both
side of real axle are completely
secured and tight.
Figure-M3.4
THROTTLE/KILL SWITCH INSTALLATION
WARNING  Turn Off your scooter and
remove the battery before performing any
installation or repair actions.
1.
In order to install a new throttle handle you
need to remove the rubber grip from right side
by rolling it outwards as shown in Figure-T4.1
2. Pierce the throttle wire through the kill switch
and fix it to the throttle handle.
Figure-T4.1
3. Then insert the new throttle handle and place
the kill switch as shown in Figure-T4.2.
4. Once you have secured the handle to a right
and comfortable position, use the bolts to fix
the kill switch.
5. Ensure the handle is installed properly by
making sure it is free in rotation while the kill
switch is tight so that is should not slide off.
Figure-T4.2
6.
Now direct the throttle wire and kill switch
wire along the other wires into the battery
compartment using the existing opening on
the frame. Make sure not to leave the wires
loss, zip-tie them. Please follow the direction
below.
a.
Start of by making sure that the throttle
handle is tight.
b.
Open the foot-rest and remove the battery so
that you have access to the front opening to
insert the wire.
c.
Now remove the bolts to open the battery
charging compartment as shown in Fig-T4.3,
so that you can insert the throttle wire and kill
switch wire easily.
d.
Use the shown opening to insert the throttle
wire and kill switch wire to the battery
compartment. Refer Fig T4.4
Figure-T4.3
Figure-T4.4
e)
Now carefully insert the wire using the rear
opening to direct them to the engine as
shown in the figure-T4.5
f)
Now for kill Switch connection, connect the
red wire to the red and black wire to the
black. Also, make sure they are tight and
secured.
g)
Throttle wire goes to the right side of the
engine and kill wire goes to the left side.
Refer Figure-A1.1
h)
Please secure all the loss wires with a zip tie
using the frame of the scooter as shown
Figure-T4.5
Figure-T4.6
 Figure A1.1
Kill wire goes
to the left
Throttle Wire
goes to the
right
PRE-RIDE CHECKLIST
It is recommended that you follow a routine check before each and every ride.
General
 Inspect and tighten all the fasteners before each and every ride.
 Check for any loss wire or connection. Zip-tie any loss wire with the frame and tighten any loss connection.
Brakes
 Squeeze the brake lever to ensure that it is effective enough to stop the rotation.
 Perform a regular check to make sure that brake pads are not worn out and are in correct position
 Check the brake wire at the bottom to make sure it is not broker or torn off.
Engine
 Ensure to check the gas and oil lever before each and every ride.
 Ensure that the engine is on its correct position and both the chains are couples with the respected sprockets.
Throttle and Kill switch
 Inspect that the throttle handle is tighten and should not slide off.
 It is very important to ensure that kill switch is working and the connection with engine is not loss.