LITTLE GEM 2: TILLER ASSEMBLY

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Irma Haynes
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2 Table Of Contents STERLING Little Gem LITTLE GEM 2: TILLER ASSEMBLY... 3 LITTLE GEM 2: FRONT FRAME ASSEMBLY... 6 LITTLE GEM 2: FRONT AXLE ASSEMBLY... 9 LITTLE GEM 2: FRONT WHEEL ASSEMBLY LITTLE GEM 2: FRONT PANEL ASSEMBLY LITTLE GEM 2: REAR FRAME ASSEMBLY LITTLE GEM 2: BATTERY PACK ASSEMBLY LITTLE GEM 2: SEAT ASSEMBLY LITTLE GEM 2: LABELLING

.. 9 LITTLE GEM 2: FRONT WHEEL ASSEMBLY... 10 LITTLE GEM 2: FRONT PANEL ASSEMBLY.

3 LITTLE GEM 2: TILLER ASSEMBLY LITTLE GEM 2: TILLER ASSEMBLY A1-C16 ELASM008R TILLER ASSEMBLY - RED A1-C16 ELASM008B TILLER ASSEMBLY - BLUE A1 ELC003-7 HANDLE BAR - 3 -

4 LITTLE GEM 2: TILLER ASSEMBLY A2 ELI036 HAND GRIP A5 ELI026R TILLER FRONT COVER - RED A5 ELI026B TILLER FRONT COVER - BLUE A8 ELI027 TILLER REAR PANEL, BLACK TEXTURE A16 ELT010-1 HYDRAULIC CYLINDER A17 MNCO13 BASKET B1-B5 ELSUB024 TILLER BASE JOINT KIT C1-C16 ELSUB025 CONSOLE SUB ASSEMBLY C4 B SPEED VOLUME ASSY A12, C5 ELSUB004 WIG WAG ASSY C5 MNSUB025 THROTTLE 3P ASSY C6 IDT012 SPEED POTENTIOMETER KNOB C8 IDE021 KEY SWITCH WIRE (WITH KEY) C14 IDE013-1 HORN S/W WIRE (YELLOW) C16 IDE TILLER CONTROL LOOM N/S IDEC08 SPARE KEY - - THESE PARTS ARE FOR REFERENCE ONLY - - A1-A25 N/A TILLER SUB ASSEMBLY A3 N/A HAND GRIP PLUG A4 N/A FRONT LIGHT LENS (Cr Plated) A6 N/A FRONT LIGHT HOUSING A7 N/A GROMMET A9 N/A JOY STICK A10 N/A GROMMET A11 N/A P+T/S, M4X12L, BLACK A12 N/A SET SCREW, M4X6L A13 N/A P+M/S, M3X12L A14 N/A NYLON NUT, M3 A15 N/A BASKET BRACKET(POWDER COAT) A18 N/A P+M/S, M5X42L A19 N/A T+T/S, M4X8L A20 N/A SHOULDER BOLT, M6X48LX8S A21 N/A SHOULDER BOLT, M6X43LX8S A22 N/A TILLER BUSHING A23 N/A PLAIN WASHER, M6 A24 N/A NYLON NUT, M6 A25 N/A P+M/S, M5X16L B1 N/A TILTING CONNECTOR (POWDER COAT) B2 N/A HEX BOLT, M8X120LX50S - 4 -

POTENTIOMETER KNOB C8 IDE021 KEY SWITCH WIRE (WITH KEY) C14 IDE013-1 HORN S/W WIRE (YELLOW) C16 IDE302-02 TILLER CONTROL LOOM N/S IDEC08 SPARE KEY - - THESE PARTS ARE FOR REFERENCE ONLY - - A1-A25

5 LITTLE GEM 2: TILLER ASSEMBLY B3 N/A TAPER NUT B4 N/A PLAIN WASHER B5 N/A SPRING WASHER, M8, BLACK C1 N/A CONSOLE TOP COVER C2 N/A V-METER SUPPORT PLATE C3 N/A C+T/S, M4X12L, 2 BLACK C7 N/A V-METER (LED/BLUE) C9 N/A KEY S/W SPACER, SPS, 22.2X1.5t, Zn C10 N/A CHARGER CAP C11 N/A P+T/S, M3X8S C12 N/A PLAIN WASHER, M3 C13 N/A BUZZER WIRE C15 N/A HOLE PLUG - 5 -

BLACK C7 N/A V-METER (LED/BLUE) C9 N/A KEY S/W SPACER, SPS, 22.2X1.

6 LITTLE GEM 2: FRONT FRAME ASSEMBLY LITTLE GEM 2: FRONT FRAME ASSEMBLY A6 ELF077 REAR LIGHT BASE HOUSING A10 IDEC04 DEDOCK LOCK UP ASS'Y, Cr C1-C5 ELSUB028 FRONT STEM SUB D1-D6 ELSUB029 SEAT POST SUB D4-D6 ELSUB030 LOCKING PIN ASSY D4 IDF029 LOCKING PIN, Φ8X56L, Zn(WITH RING) - 6 -

C1-C5 ELSUB028 FRONT STEM SUB D1-D6 ELSUB029 SEAT POST SUB D4-D6

7 LITTLE GEM 2: FRONT FRAME ASSEMBLY E1-E9 ELSUB031 CONTROLLER & WIRE SUB ASSY E4-E6 ELSUB032 LOOM 8 WAY E6 IDI039 PIN - CONNECTOR N/S PGDT SP1A PROGRAMMER - - THESE PARTS ARE FOR REFERENCE ONLY - - A1-G8 N/A FRONT ASSY COMPLETE A1-A11 N/A FRONT FRAME SUB A1 N/A FRONT FRAME (POWDER COAT) A2 N/A LOWER HEAD CONE, SBC31/Ø42X18L/Cr A3 N/A UPPER HEAD CONE, SBC31/Ø42X15L/Cr A4 N/A C+T/S, M4X12L, 2 BLACK A5 N/A SET SCREW, M4X6L A7 N/A REAR LIGHT LENS, RED A8 N/A P+M/S, M5X16L A9 N/A PLAIN WASHER, M5 A11 N/A FLANGE NUT, M5 B1-B12 N/A 4W-FRONT AXLE SUB B1 N/A TIE ROD (BLACK Zn) B2 N/A TIE ROD (BLACK Zn) B3 N/A HEX NUT, M8 (RH) B4 N/A HEX NUT, M8 (LH) B5 N/A FRONT AXLE SUB B6 N/A WAVE WASHER B7 N/A HEX BOLT, M12(1.5P)X72LX25S B8 N/A PLAIN WASHER, M12x2t B9 N/A STEEL NUT, M12 C1 N/A STEM (Zn) C2 N/A RETAINER BALL BEARING, 5/32X6 C3 N/A UPPER HEAD CUP, SHP/Φ47X7.5L/Cr C4 N/A LOCK WASHER, Ø33X4.5L C5 N/A LOCK NUT, SBC31/Cr D1 N/A SEAT POST, Zn D2 N/A SEAT POST GUIDE BUSHING, STS304 D3 N/A LOCKING PIN SUB D5 N/A BUNGEE CORD D6 N/A BATTERY LOCKING PIN E1 N/A S-DRIVE CONTROLLER, 45A (with COVER) E2 N/A P+M/S, M4X28L E3 N/A LOOM - MAIN CONTROL - 7 -

A3 N/A UPPER HEAD CONE, SBC31/Ø42X15L/Cr A4 N/A C+T/S, M4X12L, 2 BLACK A5 N/A SET SCREW, M4X6L A7 N/A REAR LIGHT LENS, RED A8 N/A P+M/S, M5X16L A9 N/A PLAIN WASHER, M5 A11 N/A FLANGE NUT, M5 B1-B12

8 LITTLE GEM 2: FRONT FRAME ASSEMBLY E4 N/A 8WAY APP HOUSING E5 N/A MOTOR/BATTERY EXTENSION WIRE E7 N/A CHARGER WIRE E8 N/A BRAKE WIRE E9 N/A HORN - 8 -

9 LITTLE GEM 2: FRONT AXLE ASSEMBLY LITTLE GEM 2: FRONT AXLE ASSEMBLY DRAWING TO BE ADDED SOON F1-F13 ELSUB034 STUB AXLE KIT F14 ELC009-3 FRONT AXLE B1 - B4, F7 - F8 ELSUB036 CONNECTION ROD KIT F1-F14 N/A FRONT AXLE SUB F1 N/A KNUCKLE (Zn) F2 N/A BALL BEARING, 6001Z - - THESE PARTS ARE FOR REFERENCE ONLY - - F3 N/A HEX BOLT, M12(1.5P)X72LX25S F4 N/A PLASTIC WASHER, PEM/Φ22x3t F5 N/A PLAIN WASHER, M12x2t F6 N/A STEEL NUT, M12 F7 N/A TIE ROD END BEARING, JFT8R F8 N/A TIE ROD END BEARING, JFT8L F9 N/A HEX BOLT, M8X40LX25S F10 N/A HEX BOLT, M8X58LX25S F11 N/A TIE ROD SPACER, Zn F12 N/A TIE ROD SPACER, Zn F13 N/A NYLON NUT, M8-9 -

10 LITTLE GEM 2: FRONT WHEEL ASSEMBLY LITTLE GEM 2: FRONT WHEEL ASSEMBLY B12 ELF051 FRONT WHEEL ASSY - - THESE PARTS ARE FOR REFERENCE ONLY - - B10 N/A SOCKET HEAD BOLT, M8X15S, Zn B11 N/A SPRING WASHER, M8-10 -

11 LITTLE GEM 2: FRONT PANEL ASSEMBLY LITTLE GEM 2: FRONT PANEL ASSEMBLY DRAWING TO BE ADDED SOON G1-G8 ELSUB035R FRONT PANEL SUB - RED G1-G8 ELSUB035B FRONT PANEL SUB - BLUE G2 ELI031 FOOTMAT (BLACK) N/S IDEC05 TOUCH UP PAINT - RED N/S IDEC06 TOUCH UP PAINT - BLUE - - THESE PARTS ARE FOR REFERENCE ONLY - - G1 N/A FRONT COVER (RED OR BLUE) G3 N/A C+T/S, M4X7L, BLACK G4 N/A GROMMET G5 N/A LOCATION POST INSERT, PE, BLACK G6 N/A C+T/S, M4X12L, BLACK G7 N/A T+T/S, M4X8L G8 N/A T+M/S, M5X16L

UP PAINT - BLUE - - THESE PARTS ARE FOR REFERENCE ONLY - - G1 N/A FRONT COVER (RED OR BLUE) G3 N/A C+T/S, M4X7L, BLACK G4

12 LITTLE GEM 2: REAR FRAME ASSEMBLY LITTLE GEM 2: REAR FRAME ASSEMBLY

13 LITTLE GEM 2: REAR FRAME ASSEMBLY Remark/Qty A1-C13 ELASM011R REAR ASSY - RED A1-C13 ELASM011B REAR ASSY - BLUE A ANTI-TIP WHEEL, SMALL without hardware (if required please order A2, A4, A5 and A6) A HEX BOLT, M6X58LX40S QTY REQ 1 A M PLAIN WASHER, M6 QTY REQ 2 A M NYLON NUT, M6 QTY REQ 1 A HEX NUT, M6 QTY REQ 1 B1 ELR028 DRIVE TRAIN ASSY B2 ELR043 KEY DRIVE SHAFT B3 ELR024 REAR WHEEL ASSY C1-C13 ELSUB040R REAR PANEL SUB - RED C1-C13 ELSUB040B REAR PANEL SUB - BLUE C8-C10 ELSUB041 MOTOR BRAKE CONNECTION ASSY C12 IDI020 REFLECTOR, RED N/S ELSUB042 MOTOR AND BRAKE ASSY NOTE: Please contact Technical Support for further information if Scooter Serial number is earlier than Blue - LTGM Red - LTGM NOTE: Please contact Technical Support for further information if Scooter Serial number is earlier than Blue - LTGM Red - LTGM NOTE: Please contact Technical Support for further information if Scooter Serial number is earlier than Blue - LTGM Red - LTGM

0216 HEX NUT, M6 QTY REQ 1 B1 ELR028 DRIVE TRAIN ASSY B2 ELR043 KEY DRIVE SHAFT B3 ELR024 REAR WHEEL ASSY C1-C13 ELSUB040R REAR PANEL SUB - RED C1-C13 ELSUB040B REAR PANEL SUB - BLUE C8-C10 ELSUB041

14 LITTLE GEM 2: REAR FRAME ASSEMBLY Remark/Qty N/S ELR044 MOTOR BRAKE NOTE: Please contact Technical Support for further information if Scooter Serial number is earlier than Blue - LTGM Red - LTGM C2-C4 IDEC20 REAR HANDLE ASSEMBLY QTY REQ 2 A1-A13 N/A REAR FRAME SUB - - THESE PARTS ARE FOR REFERENCE ONLY - - A1 N/A REAR FRAME (POWDER COAT) A7 N/A HEX BOLT, M6X42LX20S A8 N/A HEX BOLT, M6X50LX20S A9 N/A REAR CROSS BRACKET (POWDER COAT) A10 N/A PLASTIC WASHER, M8XΦ22X3t A11 N/A NYLON NUT, M6 A12 N/A HEX BOLT, M8X20S A13 N/A HEX NUT, M8 (RH) B1-B8 N/A REAR WHEEL AND TRANSAXLE SUB B1 N/A TRANSAXLE ASSY B2 N/A HALF ROUND KEY B4 N/A PLAIN WASHER, M12XØ32X2t, Zn B5 N/A NYLON NUT, M12 B6 N/A BRAKE SWING LEVER, COLOUR Zn PLATED B7 N/A P+M/S, M5X12L B8 N/A FERRITE C1 N/A REAR COVER (RED OR BLUE) C2 N/A REAR HANDLE - A C3 N/A REAR HANDLE - B C4 N/A P+T/S, M4X16L C5 N/A P+M/S, M5X30L C6 N/A T+T/S, M4X8L C7 N/A BRAKE LEVER CAP, YELLOW C8 N/A MOTOR/BRAKE EXTENSION WIRE C9 N/A APP INSTALL PIN C10 N/A 4WAY APP HOUSING C11 N/A T+M/S, M5X16L C13 N/A NYLON NUT, M5-14 -

BOLT, M6X50LX20S A9 N/A REAR CROSS BRACKET (POWDER COAT) A10 N/A PLASTIC WASHER, M8XΦ22X3t A11 N/A NYLON NUT, M6 A12 N/A HEX BOLT, M8X20S A13 N/A HEX NUT, M8 (RH) B1-B8 N/A REAR WHEEL AND TRANSAXLE

15 LITTLE GEM 2: BATTERY PACK ASSEMBLY LITTLE GEM 2: BATTERY PACK ASSEMBLY

16 LITTLE GEM 2: BATTERY PACK ASSEMBLY Remark/Qty A1, A3- A17 ELASM012 A2 UB12-12 BATTERY, 12V, 12AH A6 IDE CHARGER WIRE A15 IDI039 APP INSTALL PIN BATTERY BOX ASSEMBLY - BOX AND WIRES ONLY N/S MNE005 BATTERY CHARGER (2.0A) comes with mains lead uk N/S EU POWERCORD FOR CHARGER mains lead eu A1-A17 N/A BATTERY PACK SUB A1 N/A BATTERY BOX BOTTOM A3 N/A BATTERY WIRE - - THESE PARTS ARE FOR REFERENCE ONLY - - A4 N/A BATTERY / SENSOR WIRE A5 N/A CHARGER WIRE A7 N/A BATTERY 2 CONNECTOR WIRE A8 N/A BATTERY BOX TOP A9 N/A BATTERY BOX HANDLE A10 N/A T+M/S, M5X25L A11 N/A NYLON NUT, M5 A12 N/A C+M/S, M3X12, Zn A13 N/A NYLON NUT, M3 A14 N/A CIRCUIT BREAKER, 15A (WITH CAP) A16 N/A P+M/S, M4X15L A17 N/A C+M/S, M4X15L

0A) comes with mains lead uk N/S 060500 EU POWERCORD FOR CHARGER mains lead eu A1-A17 N/A BATTERY PACK SUB A1 N/A BATTERY BOX BOTTOM A3 N/A BATTERY WIRE - - THESE PARTS ARE FOR

17 LITTLE GEM 2: SEAT ASSEMBLY LITTLE GEM 2: SEAT ASSEMBLY A1-A10 ELSUB045 SEAT FRAME ASSY A10 MPCI13.I THUMB SCREW M8 B1-B11 ELSUB046 ARMREST ASSY - LEFT HAND B ARMREST PAD, DARK GREY C ELSUB047 ARMREST ASSY - RIGHT HAND D1-D10 ELSUB048 SEAT ASSY (W/O SEAT PLATE AND ARMS) D7 ELR032 SEAT BASE COVER D9 ELR033 SEAT BACK COVER - - THESE PARTS ARE FOR REFERENCE ONLY - - A1-D10 N/A SEAT ASSY A1 N/A SEAT FRAME A2 N/A SEAT LEVER A3 N/A SEAT LEVER POCKET, PVC A4 N/A PLASTIC WASHER, ACETAL A5 N/A NYLON LOCK NUT, M6 A6 N/A REAR LEVER RETURN SPRING A7 N/A SPRING WASHER, M6 A8 N/A PLAIN WASHER, M6 A9 N/A HEX BOLT, M6X25L B1 N/A ARM POST PIPE B2 N/A ARMREST WELDMENT B4 N/A HEX BOLT, M6X40LX18S B5 N/A PLASTIC WASHER B6 N/A NYLON LOCK NUT, M6 B7 N/A PLAIN WASHER, M6 B8 N/A P+M/S, M6X10L B9 N/A SPRING WASHER, M6 B10 N/A C+M/S, M6X12L D1 N/A PLASTIC SEAT BASE D2 N/A PLASTIC SEAT BACK D3 N/A T+M/S, M8X30L D4 N/A PLAIN WASHER, M8XΦ17X1.7t D5 N/A NYLON LOCK NUT, M8 D6 N/A SEAT BASE PAD D8 N/A SEAT BACK PAD D10 N/A SPRING WASHER, M8-17 -

COVER D9 ELR033 SEAT BACK COVER - - THESE PARTS ARE FOR REFERENCE ONLY - - A1-D10 N/A SEAT ASSY A1 N/A SEAT FRAME A2 N/A SEAT LEVER A3 N/A SEAT LEVER POCKET, PVC A4 N/A PLASTIC WASHER, ACETAL A5 N/A

18 LITTLE GEM 2: SEAT ASSEMBLY DRAWING TO BE ADDED SOON

19 LITTLE GEM 2: LABELLING LITTLE GEM 2: LABELLING A1-F5 ELASM014 LABEL SET COMPLETE

20 LITTLE GEM 2: LABELLING B1 IDL002 FRONT LOGO

CHAPTER 2 : STERLING MIDI JUNIOR AND STERLING MIDI JUNIOR FOUR

CHAPTER 2 : STERLING MIDI JUNIOR AND STERLING MIDI JUNIOR FOUR Sterling Midi Junior is a transportable rear wheel drive, three or four wheel electric powered Scoota with pneumatic tyres, upolstered seat