Sunday, January 13, 2008

Upgrades / Hacks / Mods

Overvolt
Warning: This may cause irreversible damage to your Voy. This can fry the controller or worse, the motor.

An overvolt mod involves adding a fourth battery to your Voy. Some add the fourth battery under the seat. The voltage of the Voy is 36, but the controller will accept somewhere around 40-42 before cutting out. If you have an older 12V lead acid battery, you can add the battery to your set of three in series.



Replace rear wheel and controller
This is the most cost effective choice. Most people that find this page are looking for more speed to climb hills, or keep pace with city traffic.

Don't forget that the Voy is a low power electric bicycle at heart. It was produced early on before more powerful 400-600 watt electric motors could be sold cheaply.

Because the Voy is a bicycle at heart, that means you can easily replace the rear wheel, with an Electric Bicycle conversion kit for 16" wheels. The controller will have to be replaced in the process, but you can use your existing batteries and the Voy's bicycle frame.



40 comments:

  1. I know another great mod i did to mine and didnt cost much extra maybe a few dollars at the most.I cut the two wires by the motor. Then hooked up a negative wire to the black wire ran it up to the front up under everything to a toggle switch. Then i ran a wire from the negative of the battery closest to the fuse. I ran it up to the toggle switch. You then hook up the wire from the wheel to the accessory on the toggle switch and the other to the ground on the toggle switch. So your scooter will go normal speed until you hit the switch, Mine says 18 to 20 driving normally and when i hit the switch it read about 24 sometimes beyond it. Climbs hills amazingly. An has used the same amount of battery. Oh make sure you have an 30 amp fuse.

    ReplyDelete
  2. great mod but your description does not make sense if you cut the two wires on the motor what did you do with the positive? Can you try explaining it over again? I would like to try this.

    ReplyDelete
  3. I know this mod and just finished repairing the sloppy job of the previous owner. This included mounting the toggle “Turbo” switch in the handlebar casing rather then the sorry Velcro tape they had hanging off the mirror and most of the battery packs wire connectors.

    You splice into the black ground wire for the rear hub motor; I’d recommend further up the frame then way back at the wheel where it was done so you don’t have to worry about the rear wheels swing arm and run it up to a (SPST) single pull/single throw switch. Then run another lead wire down to the battery pack from the switch; give yourself enough wire for lifting the battery pack up for disconnecting just like the main power cord has. You could get fancy and use a lighted switch, robbing voltage from the dash lights but I couldn’t see reducing what little power the thing has for a switch you would only notice at night and then it would just be distracting.

    I used a rubber sealed male/female plug for easy battery pack removal adding a hole with grommet next to the fuse holder then feed the other end of the plug into the pack; tying a couple of knots in the wire inside the case so it wont pull on the connections should the plug get tugged on.

    On the end of the wire inside the battery pack use a female spade clip which has an extra male spade also on it and swap it with the ground wire on the charge/power plug port then slide the pack ground wire on to that extra spade. I also bumped up the fuse to 25 amps.

    Apparently the controller has a limiting resister through the ground of some kind in it which keeps the speed to approximately 14mph so this mod bypasses that by giving the motor full 36 volts at the hub while still having throttle control and gets the scooter up to 24mph.

    ReplyDelete
  4. I just got my Voy and of course interested in getting a little more out of it. This mod makes sence but do you really need a switch why not just ground it that way permenantly?

    ReplyDelete
  5. I would imagine that the switch is there for safety, since it sounds like you're effectively bypassing the ground for this to work.

    ReplyDelete
  6. I added the Turbo- bypass mod and everything works great.

    Since the 48v mods don't work due to the controller, why hasn't anyone tried adding a 6v battery to make a 42v system.

    Has a good chance of working since mine worked ok with 42/43 v from the charger(without the battery load). I realize that a fully charged 42v system would run about 45/46v but I think it has a good chance of working.

    If it can handle the voltage, the Voy could have 36v for KEY 1 and 42v for Key 2 and the bypass mod could work for both voltages. 4 different power levels; very cool! What do you think?

    ReplyDelete
  7. I've just finished modifying my Voy. It had set around unused with dead batteries for 3 years and I decided to get it running for the grandkids to ride.

    After 3 new 12ah batteries, it ran like a normal Voy; which leaves a bit to be desired.

    First I added the controller by-pass mod which raised top speed by 5-6 mph and increased climbing ability by at least 100%. I added the mod so that I can totally disable it with 1 alligator clip for new, young riders.

    For still better performance I added another battery for overvoltage available only in Battery 2 Key position. Key position 1 still gives the stock 36v system.

    The by-pass mod works for both voltages. The overvoltage position gives normal throttle control and is easy to control for new riders.

    At present I am only adding 4v over normal (total 40v)(app 45v fully charged) but can easily go up to 6v with just a battery change.(Controller is said not to work at 48v) Performance with the extra 4v is: Top speed increased by 3 mph and climbing ability by ~50%. Bypass mod and extra 4v together gives ~25mph top speed.

    Would like to hear from anyone with Voy mods especially those running overvoltages to compare notes and plan my next mod.

    -Ken
    fordisoman@aol.com

    ReplyDelete
  8. Hello everyone. I need a little help. I just purchased a fine working Voy and, of coarse, it has little power. I would like to do the rewire mod but, after reading the above twice, I am confused as to where to hook up the wires. I think I understand one goes to blk on the motor but am unsure about other wire in battery box. Could someone please clarify? Thanks a bunch, BILL

    ReplyDelete
  9. I also have a couple troubleshooting questions. I have a power cord type cable hanging free by the control box. It looks identical to the battery box cord plug. It travels up and into the front console. Does anyone know what that cord is supposed to have been for? And the speedo no work. Any troubleshooting techniques would be much appreciated. Thanks, BILL

    ReplyDelete
  10. Black wire to ground does nothing but make appearance to speedo of higher speed. Follow black wire from motor to controller and you will find a blue wire connected at same junction. The blue wire goes to speedo. By putting ground there its only forcing the speedo to max, not actually giving motor speed boost. I just upgraded to a 250-300 watt controller. I've had to trace every wire on my own. I have now found my throttle to be bad. Once replaced, I will follow up with performance testimony.

    ReplyDelete
  11. New throttle installed and I was off! I installed the 12ah batteries under primary battery tray and some 8-9ah batteries under seat for emergency. I just rode around with lights on for solid 45min on primary batteries. About 15-20 on spare set. The speedo is COMPLETELY stupid and inaccurate! On takeoff it says 15-18. Then once going full speed it still reads 15-18. Judging from the speed of traffic at 30mph I really believe that I was doing about 20mph. I wouldn't want to ride this thing in traffic but for sidewalks etc, its a great toy! My next adventure is figuring out where to oil, then seeing if I can make the crank gear larger so the pedals are more functional! I will post if I find out more! Safe scooting to you all!

    ReplyDelete
  12. Thanks for posting your finds! Keep them coming!

    ReplyDelete
  13. Rod Dec 27,2012 1:45pm
    I'm real confussed can you put it in a little simpler about how to wire up the up grade to my voy. Got it for my son at christmas and we can't figure out how to wire it up eather. Do I cut the black wire into at the back wheel or do I splice into it and run it to the toggle switch. Then the wire that runs from the toggle switch to the negtive of the battery is there another wire that needs to be hooked up? Please help. Thanks

    ReplyDelete
  14. i bought a voy -phantom scooter. has the 180 watt rear hub motor.i want to upgrade this to a 48 volt system with a 600 watt brushless motor from an extreme x-610 scooter . i have the controller that was used with the motor from the 610. is there anything else i will need to change electrical on the phantom 4 or add. this is my first electric scooter . any input would be a great help . thank you . dennis

    ReplyDelete
  15. This comment has been removed by a blog administrator.

    ReplyDelete
  16. There are not many voy owners, I've attempted to make this a place where the discussion can be centralizaed rather than spread out on different websites.

    ReplyDelete
  17. I Got one of Craigslist for $150. I found 3 16ah batteries for $117 after shipping. I used 6 7ah emergency light batteries just for giggles. I actually got over 20 minutes of ruin time. Can't wait till Tue. for the new batteries.

    ReplyDelete
  18. Haven't quite figured out the bypass. But FYI, I have simply added a 4th battery under the seat and I didn't blow anything up! My scooter goes longer and has more power than the 36v setup. Still trying to get more power for uphill. If anyone has any suggestions, I'm listening.

    ReplyDelete
    Replies
    1. Tom,
      Glad to hear you added a 4th battery. I run an extra 6v battery because I read that an extra 12v was too much for the controller. Did you add an extra 6v or 12v? I can help you with more power for hills. Ken at fordisoman@aol.com

      Delete
    2. Did you add a 6v or 12v battery? I added a 6v and it works well. Will the controller handle 12v? I can help you with more power for hills. Ken at fordisoman@aol.com

      Delete
  19. Hi all, I hope people still visit here...:)

    Im taking a look at the bypass mod and im a little bit confused. If I were to splice into the black motor, and connect that to a dash switch, what do I do with the other end of the motor wire? It can't just be left there...am i leaving that connection solid, and then connecting the bypass wire to the copper? Essentially creating a 'T' Shape?

    My next question has to do with the battery wiring, from the switch to the ground specifically. I drill the hole in the battery box to allow the bypass wire into it, knot it off, and then what do I connect it to? My voy does not have anything connecting to the ground on the plug. It is unwired...can i just connect the wire directly to the ground? Or is something missing...? I did get my voy second hand.

    Last question...what gauge of wire is suitable for this 36V bypass? i assume 12ag would be fine?

    Thank you so much...I also took some photos...hopefully this would be helpful...

    http://imageshack.us/photo/my-images/571/uu5p.jpg/-wiring
    http://imageshack.us/photo/my-images/837/8dod.jpg/-ground plug

    PS...from what I understand the 'x-treme 360 scooter wiring diagram' is the same for the Phantom 4...it was in the other forum, but I figured it would be good to post in this section as well

    ReplyDelete
    Replies
    1. Dave, just do the connector unplug mod discussed in the next post. I have done both and it is better. Ken

      Delete
  20. One of the easiest way of making the Voy go faster without spending any money is to unplug the speed limiter that is built into the control box. Open the seat and remove the 4 screws that holds the plastic section the seat is bolted to. This will allow you to see the wires and the control module. Look for a single blue wire attached to a single black wire that is connected with a black connector. After pushing the plastic to release the clip, turn on the scooter and give it full throttle with the rear tire off the ground. It will spin between 22-24 mph instead of 15-17 mph. You can try the throttle before and after to see and "hear" the motor wind up at a higher rpm. This works well and you do not need more than 3 batteries. I use 3 12 volt 15 aph batteries from


    http://www.batterysharks.com/12-Volt-15-Amp-Seal-Lead-Acid-Battrery-p/12v-15ah_b12-15.htm

    If you want to slow down the scooter, just reconnect the black and blue wire with the factory connector and it will only go 15-17 mph just as the factory wanted. I've been riding for 2 summers like this and have no problems with the controller or motor.

    ReplyDelete
    Replies
    1. Great info! Works Great and gives full throttle control.
      Ken

      Delete
    2. Your welcome Ken. I really don't post in places but I've been working on a couple of these scooters and I have been messing with different things. I'm using 2 converters to make my tail light/ brake light and headlights a 12 volt system instead of 36. If everything goes the way it should, I should be able to let you all know how and where to hook them up and go to Autozone or other store and get the 12 volt equivalent with higher wattage bulbs. I don't want anyone to catch on fire so I'll be doing this over the winter and should have the results by january. keep tuned.
      Headlights, tail lights, turn signals, horn, and blinker controller will all run on a 12 volt system. I'm guessing about spending 50 dollars for the conversion including all the bulbs and new blinker controller.

      Delete
    3. Good luck with your 12v conversion; it will be useful to all, especially us who run overvoltage. I run a 42v system and am concerned about the life of all the bulbs. They are also hard to find.
      My set up is:
      36v on Battery 1 key position
      42v on Battery 2 key position
      Controller bypass mod
      Your controller current limiter removal
      12 ga wire for some of the power circuits

      I would like to go to 48v for the motor. Do you have any info on whether the controller can handle 48v? Thanks, Ken

      Delete
    4. I have looked for this blue / black wire combo and cant find it. I have disconnected every connector coming off the controller and none has the result you describe. Can you give me any more info?

      Delete
    5. My Voy had a different speed limiter wire color: black wire, white wire, both really thin. Disconnected gives 15mph (handheld GPS), while connected gives 13mph (GPS). The dash mounted speedometer is poopoo. I'm about 210 pounds. This difference is hardly noticeable.

      Delete
    6. My Voy had black and blue wires and gave the results stated; about 6-7 mph no load. About 4-5 mph loaded with 130 lbs. Hill climbing is noticeably improved. The speedo shows actual voltage across the motor not actual speed.

      Delete
  21. That is why i'm converting the lighting system to 12 volts since I know I need a 48 volt controller for a 48 volt motor. I'm personally getting a standard rear wheel with no motor (36-75 dollars) and run disc brakes and a 1000 watt 48 volt motor. It will be chain drive on the left and standard chain on the right side for the pedals. I'm looking for 35-40 mph if possible on a 48 volt system . I'll be experimenting with a 36 tooth, 42 tooth, and 48 tooth sprockets for the electric motor.
    I was lucky and I bought a used "under seat" battery pack on craigslist several years ago. I only use the first "run" selection with the key. So i'm running 6 12 volt batteries in 2 36 volt packs. I run each pack in series for 36 volts then combine both packs linear to make 30 amps. 2 36 volt 15 amp packs run parallel together gives you 36 volts and 30 amps. I run a 25 amp fuse and I've tried the 30 amp fuse. I see no power difference from the 25-30 but the 20-25 gives me more torque for the hills. I've topped out just under 30mph going down a long hill (used a universal wireless bicycle spedometer). I average 18-23 on flat to slightly downhill grades. My range is about 30-40 miles with best guess.

    I also have a 32 tooth front sprocket ring that I welded to the factory sprocket so I can pedal uphill and maintain 20-22 mph with minor effort.

    You just have to cut out part of the lower seat box and make a new bottom for it. I'll get pics one of these days so you can see the 3 batteries running side by side in series under the rear seat.. You also need 3 inch studs with the same threads as the front lower screws. This allows you to raise the bottom of the battery box (after you cut it) and I used 1 x 4 cedar wood to make the new bottom. It is a lot of work but worth the better peddling uphill and keep the speed up.


    ReplyDelete
  22. I just tried the 48 volt test you asked for. My batteries are only 3 months old and are like now. From what I saw, the lights, turn signals, and other parts worked fine. The problem is that the wheel did not turn at all like you never engaged the throttle. After seeing this, I disconnected the 4th battery and everything worked fine again. So possibly changing to a 48 volt controller with the factory motor might work for more power and speed. I just could not guarantee how the motor would hold up.

    ReplyDelete
  23. Here is the controller i'm going with since it runs the motor only.

    http://www.electricscooterparts.com/hookup/SPD-601000Awiring.htm

    This way I can find the main power wire to the lights, brakes, turn signals, etc and only use one 12 volt converter.

    http://www.electricscooterparts.com/lamps.html

    ReplyDelete
  24. Thanks for running the 48v test. The fact that the controller apparently shut down confirms what i had heard. I read somewhere where they added a 4th battery and it worked fine but they didn't say 6v or 12v. Must have been 6. I already run an extra 6v and i'ts fine. Glad to hear the extra 12 only shuts down the controller and doesn't damage it. From what I've heard the motor is pretty heavy duty and should take 48v.

    Your planned mods sound exciting. I like the way you parallel the battery packs; more range and less voltage sag under heavy load.

    According to my info the 1000 watts should give about 33mph on level and 39mph on slight downhill (-3 degrees).

    I wonder if the pedals are going to be very useful with 1000 watts except on very steep hills? Keep up the good work and keep us posted. Ken

    ReplyDelete
    Replies
    1. Voy Scooter Mod Performance

      The following table summarizes nominal performance
      levels for the configurations noted.*

      Conf Volts OnStand Level Road Climb Max Amps
      __________mph__________mph__ Ability________
      Stock 36 18 15 v poor 11.5

      + 6v
      Batt 42 22 19 poor 11.5

      Conrl
      Bypass** 36 24 22 good 20+

      Conrl
      Bypass** 42 27 25 very good 20+

      Conrl
      Limit
      Remove 42 27 25 good ~18


      Charger
      Only-no
      Battery 42 21 6(no wgt) none 1.8

      * Some values are best estimates

      ** No throttle control; full power until added switch is shut OFF


      The Controller Bypass and Controller Limit Removal mods together along with the addition of a 6v battery provide the best performance for a low cost, easy modification. The Controller limit removal provides full throttle control and higher performance for nearly all conditions. Switching ON the bypass mod provides additional climbing power. How to do these mods is discussed in prior postings above. These configurations are also useful for troubleshooting various problems.

      Delete
    2. Sorry that the table didn't post clearly; it was fine up to the last posting step. Each line shows Battery voltage, On Stand speed in mph, Level road speed in mph, Hill Climbing ability, and Max motor amps for that modification.

      Delete
  25. http://youtu.be/qRajb0juI5U

    http://www.youtube.com/watch?v=qRajb0juI5U&feature=youtu.be

    ReplyDelete
    Replies
    1. Are there any videos of how to do the upgrades? Thanks!!

      Delete
  26. Good Info! I have recently added another 4v to my 42v Voy for a 46v system. In doing so, I have found the limit of the Voy controller; it works up to 49.2v. My fully charged 46v system reads about 50+ volts; so the controller cuts out when just off the charger. I use the 36v switch position or the bypass switch until the charge get down to 49.2v (about 90% charge). After that everything works normally. I peg the speedo but real on road doesn't seem quite that fast. I find you still need the bypass mod for best hill climb in addition to the limit removal. The motor seems robust as it was only a little warm after a few minutes of near max currents. I estimate that I am getting 400 - 500 watts from the system. So far only a few test rides so I don.'t know long term reliability.
    Ken fordisoman@aol.com

    ReplyDelete
  27. the motors are only 180 watt brushed. the magnetic pole shoes are glued to the inner armature and fall off so they need to be re glued. just got to hope they didn't ruin the stator windings. the soldering of the power wires where they meet the brushes need to be checked. replace the controller with a 36v 500w brushed with out a speed controller and you can cruise at 25mph easy.

    ReplyDelete
  28. Hi . I would like to buy a new Speed controller of Electra Voy 88911. Or a new replace speed controller .
    Anyone can help me.
    Thank you.
    Le

    ReplyDelete