I would begin by disconnecting the battery and removing the old control module and then follow the wiring diagram below to install the new relay and throttle. The battery should be the last component that is connected to the circuit after it is completed.
The original PC board was designed so the motor would not start until the scooter was pushed off to around walking speed. When replacing the original PC board with a relay the scooter should be pushed off to around walking speed before the throttle is engaged. If the scooter is not pushed to walking speed before it is started the motor and relay will have a very high Amp load placed on them which could cause these parts to fail prematurely.
The terminal numbers on automotive relays are clearly marked on their bottom side. Either a four terminal SPST (single pole single throw) or five terminal SPDT (single pole double throw) automotive relay could be used. If using a five terminal SPDT relay the middle terminal marked 87a should not be connected to any wires.
12 Volt automotive relays are available on our Relays Page and they are also available at all auto parts stores. If you need a new throttle the original yellow finger-pull On-Off throttles are discontinued and no longer available however we sell an upgrade On-Off twist throttle on the Zappy Classic Parts Page.
This PC board to automotive relay conversion will also work on Zappy SX electric bicycles and electric bicycle conversion kits.
How much speed will aquire and millage. Will You please help me to make this.
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