Here is a Zappy Classic electric scooter wiring diagram and a wiring diagram showing how to replace the original PC board with a standard 12 Volt 30/40 Amp automotive relay. 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.
Four Terminal Automotive Relay
We sell 12 Volt automotive relays on our relays page and they are also available at all auto parts stores. If you need a new throttle switch the original yellow finger-pull throttles are no longer available however we sell an upgrade twist throttle switch for the Zappy Classic electric scooter on this page.
This PC board to automotive relay conversion will also work on Zappy SX electric bicycles and electric bicycle conversion kits.