OWNERS MANUAL
Item Numbers
Mini Electric Chopper
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BEFORE YOU BEGIN
Remove contents from box. Remove the foam separators that protect the components from damage during
shipping. Inspect the contents of the box for scratches in the paint, dents or kinked cables that may have
occurred during shipping. Because the electric chopper was 95 percent assembled and packed at the
factory, there should not be any problems, even if the box has a few scars or dents.
:
DO NOT USE NON-RAZOR
PRODUCTS WITH YOUR
RAZOR ELECTRIC CHOPPER.
The electric chopper has been
built to certain Razor design
specifications. The original
equipment supplied at the time
of sale was selected on the
basis of its compatibility with the
frame, fork and all other parts.
Certain aftermarket products
may or may not be compatible.
Estimated Assembly and Set-Up Time
Razor recommends assembly by an adult with experience in bicycle mechanics.
Allow up to 30 minutes for assembly, not including initial charge time.
Allow up to 12 hours for initial charge (see page 3 for charging information).
Brake Lever
Speed Control
Inflation Valve
Brake Lever
Adjuster
Front Fork
Wheel
Tire
Charger
On/Off
Switch
Charger
Port
Charger
Plug
Charger
Port
Kick
Stand
Required Tools
Some tools may be supplied; however, we recommend the use of mechanic’s grade tools. Use the
supplied tools only as a last resort.
5mm and 6mm
hexagonal key wrenches
(included)
Inflation valve adapter/
extender (supplied
inside hand grip)
Phillips screwdriver
Bicycle-style tire pump
for Schrader valve tires,
with pressure gauge
or call toll-free at Monday - Friday 8:00 AM - 5:00 PM Pacific Time.
2
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ASSEMBLY AND SET-UP
Charging the Battery
Always
disconnect your electric
chopper from the charger
before cleaning with liquid.
Your electric chopper may not have a fully charged battery. Therefore it is a good idea to charge the battery
prior to use.
• Initial charge time: 12 hours
• Recharge time: up to 8 hours
depending on the level of depletion.
• Run time: up to 40 minutes
• Average battery life: 250 charge/discharge cycles
If your charger does
not look like the one illustrated,
your unit has been supplied
with an alternative charger. The
specifications and charging
procedure would not change.
Charger
Port
The charger has a small
window with one LED or two
LEDs to indicate the charge
status. Refer to the illustration
on the charger unit for the
actual “charging” and “charged”
status indications for your
model charger.
Charger
Plug
Plug the charger port into
Plug the charger plug into a
the port on the chopper. The
charger works with the power
switch in either the on or off
position.
wall outlet.
Chargers have built-in over-
charge protection to prevent
battery from being over-
charged.
Attaching the Front Forks
Be sure to properly align the
groove on the charger input
plug with the corresponding
socket on the case; otherwise,
no charging action will occur.
Top Fork Crown
with Pinch Clamps
Steering Bolt
Holes for Spring
Buttons
Lower Fork Crown
with Pinch Clamps
Spring Buttons
Washer
Spacer Sleeve
Fork
Spacer Sleeve
Washer
Nut
Failing to
properly adjust and tighten the
clamps and retainers that affix
the forks can cause you to lose
control and fall.
Insert the spacer sleeves on
Slide the fork into position
and insert the steering bolt.
The bolt must go through the
washer and spacer sleeve and
between the steering bearings
inside the frame
Install washer and nut onto
steering bolt. Tighten until snug,
then back off slightly to allow
the steering to rotate freely with
no binding or end-play.
the top and bottom of the frame.
3
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ASSEMBLY AND SET-UP
Failing
to properly engage the spring
buttons that affix the handlebars
to the forks can cause you to
lose control and fall.
You may wish to ask
another person for assistance,
as it can be difficult to press
both buttons and tap the
handlebar into the fork at the
same time. A rubber mallet
is helpful to tap the bars into
place, as the fit between the
handlebar and fork can be
snug.
Tighten all four pinch
clamp screws (two in the
upper and two in the lower
crown).
When correctly engaged, the
handlebars will not disengage
from the fork.
Press the spring buttons on
each side of the handlebars and
tap the bars until the spring
buttons slide inside and engage
the corresponding holes in the
fork.
To use the brake, squeeze the lever to increase the pressure on the brake. The brake lever is fitted
with a cable adjuster to compensate for cable stretch and/or to fine-tune the lever movement to brake
engagement. If brake is not engaging properly, follow instructions for adjusting the brakes outlined below.
The brake
is capable of skidding the tire
and throwing an unsuspecting
rider. Practice in an open area
free from obstacles until you are
familiar with the brake function.
Avoid skidding to a stop as this
can cause you to lose control or
damage the rear tire.
REPAIR AND MAINTENANCE
Check the Razor web site for any updates on the latest repair and maintenance procedures.
Turn power switch off before conducting any maintenance procedures.
The brake lever
contains a safety switch to
stop the motor when the brake
is applied. In an emergency,
applying the brake will always
stop the motor. Do not disable
or replace this lever with
Mini Chopper
anything other than a genuine
Razor replacement part.
To adjust the play, thread
the brake lever adjuster in or
out 1/4 to 1/2 turn until the
desired brake adjustment is
attained. Most adjustments are
complete at this step. If brake
still needs further adjustment,
proceed to step 2.
If the brake lever adjuster
is threaded outward and the
brake still has too much slack,
use the rear brake adjuster for
additional adjustment.
Rebellion Chopper
If the brake has too much
slack, loosen the rear anchor
bolt and pull the brake wire
tighter. The distance of the
brake wire between the end of
the cable and the anchor bolt
should be between 37-44 mm.
If the brake rotor is dragging
on the brake pads use your fin-
gers to twist the calliper adjuster
in either direction until rotor is
centered between pads
4
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REPAIR AND MAINTENANCE
Inflating the Tires
Tires are inflated when shipped, but they invariably lose some pressure between the point of
manufacturing and your purchase.
Rear Tire
Failure
to remove the valve adapter
after inflating will cause the
inner tube and/or adapter to
be severed by the rear drive
sprocket.
: If you lose the adapter,
a valve stem extender can be
purchased at almost any auto
parts store.
Use the special valve
extender/adapter supplied. This
item is concealed in the grip on
the speed control side of the
handlebar.
Align the access hole in
the drive sprocket with the
tire valve. Thread the adapter
completely onto the valve and
attach the pump. Inflate to
the PSI indicated on the tire
sidewall.
Remove valve adapter
The pressurized air
supplies found at gasoline
stations are designed to inflate
high-volume automobile tires.
If you decide to use such an air
supply to inflate your electric
chopper tires, first make sure
the pressure gauge is working,
then use very short bursts to
inflate to the correct PSI. If
you inadvertently over-inflate
the tire, release the excess
pressure immediately.
immediately after inflating.
Place the adapter back into
the handlebar grip for later use.
Using a bicycle style tire
pump equipped for a Schrader-
type valve, inflate the front tire
to the PSI indicated on the
sidewall of the tire.
Chain and Sprocket Adjustment – Mini Chopper
Note: Late model Mini Electric Choppers and Rebellion Electric Choppers are equipped with a chain
tensioner, are self adjusting and will not use this method to adjust the chain.
The chain will typically have a “loose spot” and “tight spot” corresponding with a particular sprocket
rotational position. This is normal and common to all chain-driven vehicles due to run-out tolerances of
freewheel and sprocket.
The chain should be adjusted to the ideal tension with chain in the tightest spot.
Proper chain alignment must be maintained.
The wheel must not be skewed. If the chain is noisy or rough running, check the lubrication, tension and
alignment of the sprockets, in that order.
If the wheel is skewed, follow steps on page 6 to align the wheel and adjust the chain.
5
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REPAIR AND MAINTENANCE
WARNING: To avoid
a pinch or injury, keep fingers
away from moving sprockets
and chain.
WARNING: Increasing
the tension too much can snap
the chain or bend the motor
output shaft. To avoid this, use
caution where tightening and
carefully check the tension
after each 1/8 to 1/4 turn of
adjusters.
Loosen the rear axle by
attaching wrenches to both
axle nuts and loosening
counter-clockwise.
Loosen the brake anchor
screw (attached with the small
bolt in the long slot on the left
side of the frame).
Tightening the adjusters
clockwise tightens the chain;
loosening the adjusters counter-
clockwise will relax it. When
loosening the adjusters, you will
have to nudge the axle forward
by tapping the wheel with your
hand to relax the tension on the
chain.
This system of
adjusters is common to
motorcycles and BMX bicycles.
If you are not familiar with
it or do not feel comfortable
performing the adjustment,
consult an authorized Razor
service center or a qualified
BMX bike or motorcycle
mechanic.
Turn both adjusters the
exact same amount, 1/8 to 1/4
turn at a time, to maintain the
wheel alignment. Once the ten-
sion is correct, tighten the axle
and brake anchor bolt.
Chain and Tire Replacement – Mini Chopper
Loosen and disconnect the
brake housing anchor.
Note: Pay attention to the loca-
tion of the parts for when you
reinstall.
Loosen the rear axle by
attaching wrenches to both axle
nuts and loosening counter-
clockwise.
Loosen and disconnect the
brake cable anchor.
Slide the wheel forward to
slacken and disengage the
chain from the wheel sprocket
and motor sprocket.
Remove wheel and replace
chain or tire. To reinstall wheel,
reverse these steps.
Loosen the chain adjusters
about 3-4 turns. Be sure to
loosen both adjusters an equal
number of turns.
(Note: Your hands will get greasy
doing this.)
6
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REPAIR AND MAINTENANCE
Chain and Tire Replacement – Rebellion Chopper
Loosen the rear axle by
attaching wrenches to both axle
nuts and loosening counter-
clockwise.
Loosen screw and remove
Slide the wheel forward to
slacken the chain and disengage
the chain from the wheel sprocket
and motor sprocket.
chain guard.
(Note: Your hands will get greasy
doing this.)
Remove wheel and replace
chain or tire. To reinstall wheel,
reverse these steps.
Battery Care and Disposal
If a battery
leak develops, avoid contact
with the leaking acid and place
the damaged battery in a plastic
bag. Refer to the disposal
instructions at left. If acid comes
into contact with skin or eyes,
flush with cool water for at
least 15 minutes and contact a
physician.
Do not store the battery in temperatures above 75° or below -10° F.
CONTAINS SEALED LEAD BATTERY. BATTERY MUST BE RECYCLED.
Disposal: Your Razor product uses sealed lead-acid batteries which must be recycled or disposed of in an
environmentally sound manner. Do not dispose of a lead-acid battery in a fire. The battery may explode
or leak. Do not dispose of a lead-acid battery in your regular household trash. The incineration, land filling
or mixing of sealed lead-acid batteries with household trash is prohibited by law in most areas. Return
exhausted batteries to a federal or state approved lead-acid battery recycler or a local seller of automotive
batteries. If you live in Florida or Minnesota, it is prohibited by law to throw away lead-acid batteries in the
municipal waste stream.
Charger
The transformer/charger supplied with the chopper should be regularly examined for damage to the cord,
plug, enclosure and other parts, and, in the event of such damage, the bike must not be charged until it
has been repaired or replaced.
Use ONLY with the recommended charger.
Replacement Parts
The most frequently requested replacement parts (wheels, tires, tubes, batteries and chargers) are
contact an authorized Razor repair center.
Repair Centers
For a list of authorized Razor repair centers:
• Send e-mail to [email protected] or call 866-467-2967 for the center nearest you.
7
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SB 1918 (CALIFORNIA) DECLARATION
IF COVERAGE IS PROVIDED, YOU SHOULD CONTACT YOUR INSURANCE COM-
8
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TROUBLESHOOTING GUIDE
Vehicle does not run
Undercharged battery
Charge the battery. A new battery should have been charged for at
least 12 hours before using the vehicle for the first time and up to 8
hours after each subsequent use.
Check all connectors. Make sure the charger connector is tightly
plugged into the charging port, and that the charger is plugged into
the wall.
Make sure power flow to the wall outlet is on.
Charger is not working
You may check to see if your charger is working by using a volt meter
or asking your local Razor authorized service center to test your
charger for you.
Loose wires or connectors
Check all wires and connectors to make sure they are tight.
Vehicle was running but Burned out fuse
suddenly stopped
The fuse will burn out and automatically shut off the power if the
motor is overloaded.
An excessive overload, such as too heavy a rider or too steep a hill,
could cause the motor to overheat. Replace the fuse with a new one
of equal amperage. Correct the conditions that caused to fuse to burn
out and avoid repeatedly burning out fuse.
Motor or electrical switch damage
Contact your local Razor authorized service center for diagnosis and
repair.
Short run time (less
than 30 minutes per
charge)
Undercharged battery
Charge the battery. A new battery should have been charged for at
least 12 hours before using the vehicle for the first time and up to 8
hours after each subsequent use.
Check all wires and connectors. Make sure the battery connector is
tightly plugged into the charger connector, and that the charger is
plugged into
the wall.
Make sure power flow to the wall outlet is on.
Even with proper care, a rechargeable battery does not last forever.
Average battery life is 1 to 2 years depending on vehicle use and
conditions. Replace only with a Razor replacement battery.
Battery is old and will not accept full
charge
Refer to adjusting the brakes instructions on page 4 to properly
adjust brakes.
Brakes are not adjusted properly
Driving conditions are too stressful
Use only on solid, flat, clean and dry surfaces such as pavement or
level ground.
Vehicle runs sluggishly
The tires are inflated when shipped, but they invariably will lose some
pressure between the point of manufacturing and your purchase.
Refer to instructions on page 5 of this manual to properly inflate tires.
Tires are not properly inflated
Vehicle is overloaded
Make sure you do not overload the vehicle by allowing more than
one rider at one time, exceeding the 220 lb. maximum weight limit,
going up a hill or towing objects behind the vehicle. If the vehicle is
overloaded, the circuit breaker may trip and shut off power to the
motor. Correct the driving conditions that caused the overload, wait
a few seconds, and then push the breaker to reset the circuit. Avoid
repeatedly tripping the circuit breaker.
Brake rotor is dragging on pads
(Rebellion Electric Chopper only)
Use your fingers to twist the calliper adjuster in either direction until
rotor is centered between pads
Brakes are not adjusted properly
Refer to adjusting the brakes instructions on page 4 to properly
adjust brakes.
9
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TROUBLESHOOTING GUIDE
Check all wires around the motors and all connectors to make sure
they are tight.
Sometimes the vehicle
doesn’t run, but other
times it does
Loose wires or connectors
Contact your local Razor authorized service center for diagnosis and
repair.
Motor or electrical switch damage
Normal response to charger use
Charger gets warm
during use
No action required. This is normal for some chargers and is no cause
for concern. If your charger does not get warm during use, it does not
mean that it is not working properly.
Vehicle does not stop
when applying the brake
Refer to adjusting the brakes instructions on page 4 to properly
adjust brakes.
Brakes are not adjusted properly
Vehicle makes loud
noises or grinding
sounds
Refer to instructions on page 5 and 6 of this manual to properly
adjust chain and sprocket.
Chain adjustment is too tight or
too loose
Apply a lubricant such as WD-40® to the chain.
Chain is too dry
Use your fingers to twist the calliper adjuster in either direction until
rotor is centered between pads
Brake rotor is dragging on brake
pads (Rebellion Electric Chopper
only)
10
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MINI ELECTRIC CHOPPER PARTS
Keep your Mini Electric Chopper running for years with genuine Razor parts. Visit our web site or e-mail us for more information on spare part
availability. (Specifications subject to change without notice.)
1. Handlebar, drag-style
38. Screw, 6mm button head socket cap screw
39. Tank, tear-drop
2. Valve stem extender/inflator
3. Handlebar end cap, extender holder
4. Grip, half length
40. Screw, 5mm button head socket cap screw
41. U-bar
5. Speed control, twist grip
42. Screw, pan head
6. Washer, flat 10mm
43. Seat
7. Sleeve, bearing adapter and spacer
8. Spacer, steering
44. Screw, seat to frame, 6mm socket head cap screw
45. Motor
9. Bolt, steering 10mm
46. Screw, motor frame, 6mm socket head cap screw
47. Kickstand
10. Nut, nylock-type self-locking 10mm
11. Brake lever w/cut-off switch and electric wire
12. Grip
48. Nut, 10mm rear axle
49. Washer, rear axle
13. Bearing, 6202 steering
50. Bearing, 6200
14. Fork crown, upper
51. Spacer, outside brake
52. Axle, rear
15. Fork crown, lower
16. Fork legs
53. Spacer, inside brake
17. Screws, 5mm fender
54. Spacer, outside chain
55. Brake sub-assembly (brake housing, band and lever)
56. Screw, 5mm brake anchor
57. Wheel, rear sub-assembly (wheel, tube, tire, brake drum-A)
58. Fender, rear
18. Fender, front
19. Front wheel sub-assembly (hub, spokes, tube, rim strip, tire)
20. Nut, 10mm front axle
21. Washer, front axle safety
22. Electronic control module
23. Screws, 5mm control module
24. Battery set (24v 7AH set) pre-wired with connecting wires
25. Plug, charger input pre-wired w/connector
26. Circuit breaker, pre-wired with connectors
27. Switch, main on/off power
28. Cover, left side battery and motor
29. Grommet, wire harness
59. Screw, 5mm fender mounting
60. Chain
61. Freewheel
62. Sprocket, rear
63. Screw and nut, 6mm mounting for sprocket-to-freewheel
64. Screw, 3mm chainguard mounting
65. Chainguard
66. Rubber insert, chainguard
67. Cover, thread protector
68. Nut, 6mm nylock-type self-locking
69. Stop plate, axle adjuster
70. Bolt, kickstand fixing
30. Cover, right side battery and motor
31. Screw, 3mm button head Phillips self-taping for plastic cover
32. Strap, battery hold-down
33. Screw, cover-to-frame, 5mm socket head cap screw
34. Footrest, left
71. Spring and button for handlebar
72. Washer, 6mm
35. Spring, detent
36. Bearing, detent
73. Frame
37. Dowel nut, 6mm
74. Axle adjuster
11
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MINI ELECTRIC CHOPPER PARTS
12
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REBELLION ELECTRIC CHOPPER PARTS
Keep your Rebellion Electric Chopper running for years with genuine Razor parts. Visit our web site or e-mail us for more information on spare
part availability. (Specifications subject to change without notice.)
17. Chain
1. Front wheel, tire, tube, axle, nut
2. Front fender w/screws
3. Fork legs (2) with both clamps and screws
4. Steering bolt assembly
5. Spring buttons
18. Chain tensioner w/screws
19. Sprocket, 66t and freewheel w/screws
20. Rear wheel, tire, tube, axle and nuts
21. Rear tire, tube
22. Rear tube only
6. Tire inflator
23. Rear brake w/screws
24. Rear brake pads only
25. Rotor, adapter w/screws
26. Rear fender
7. Speed control
8. Tank w/screws
9. Handlebar
10. Brake lever
27. Pivot bolt, spacers, nut
28. Kickstand w/screws
29. Motor cover w/screws
30. Footrest w/screws
11. Grips
12. Frame
13. Seat
14. Backrest w/pad and screws
15. Motor, 350W w/screws
16. Chainguard w/screws
31. 12V 10Ah battery
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REBELLION ELECTRIC CHOPPER PARTS
14
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SAFETY REMINDERS
There should not be any unusual rattles or sounds from
loose parts or broken components. If you are not sure, ask
an experienced mechanic to check.
Periodically inspect the tires for excess wear and replace
as required, and regularly check the tire pressure and re-
inflate as necessary. If you get a flat tire, the inner tube can
be patched or a new tube can be purchased from Razor or
an authorized repair center.
Check the brake for proper function. When you squeeze
the lever, the brake should provide positive braking action.
When you apply the brake with the speed control on, the
brake cut-off switch will stop the motor.
Safety Gear
Always wear proper protective equipment such as an
approved safety helmet, elbow pads and kneepads.
Always wear shoes, never drive barefooted or in sandals,
and keep shoelaces tied and out of the way of the wheels,
motor and drive system.
Frame, Fork and Handlebars
Check for cracks or broken connections. Although broken
frames are rare, it is possible for an aggressive driver to
bash into a curb or wall and wreck and bend or break a
frame. Get in the habit of inspecting yours regularly.
WARRANTY
Razor Limited Warranty
For your records, save your original sales receipt with this manual
and write the serial number below.
The manufacturer warranties this product to be free of manufacturing
defects for a period of 90 days from date of purchase. This Limited
Warranty does not cover normal wear and tear, tires, tubes or
cables, or any damage, failure or loss caused by improper assembly,
maintenance, or storage or use of the Razor electric chopper.
Item Numbers
Mini Electric Chopper
This Limited Warranty will be void if the product is ever
• used in a manner other than for recreation;
• modified in any way;
• rented.
The manufacturer is not liable for incidental or consequential loss or
damage due directly or indirectly to the use of this product.
Razor does not offer an extended warranty. If you have purchased an
extended warranty, it must be honored by the store at which it was
purchased.
call toll-free at Monday - Friday 8:00 AM - 5:00 PM Pacific Time.
Patent Pending
Printed in China for:
Razor USA LLC
PO Box 3610
Cerritos, CA 90703
© Copyright 2005 Razor USA. All rights reserved.
082605
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