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Workshop Manual
Little Star (4 Wheel)
Service and Maintenance
for Scooters
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The Little Star mobility scooter is a versatile indoor/occasional outdoor, 4-wheeled
machine.
Features include;
Folding tiller assembly, moulded lightweight padded seat with width
adjustable armrests, 2” seat height adjustment, 2-Amp off-board automatic charger,
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This product is manufactured to comply with the requirements of
EEC directives 93/42/EEC and 89/336/EEC
Chapter Subject Page
-- Product Information ................................................................. 2
-- Safety Information ................................................................... 3
-- Recommended Tools............................................................... 5
-- Service/Inspection ................................................................... 6
-- Technical Specifications........................................................... 7
1 Front Wheels (4-Wheel)........................................................... 8
2 Rear Wheels ............................................................................ 9
3 Seat & Armrests..................................................................... 10
4 Battery Box ............................................................................ 12
5 Batteries & Battery Box.......................................................... 13
6 Rear Drive Assembly Panels ................................................. 16
7 Rear Drive Assembly Motor Leads........................................ 17
8 Rear Drive Assembly Motor/Brake......................................... 18
9 Rear Drive Assembly Transaxle............................................. 20
10 Tiller Assembly ....................................................................... 22
11 Main Controller ....................................................................... 25
12 Front Panel............................................................................. 26
13 Steering Head ........................................................................ 27
14 Main Frame Steering.............................................................. 29
15 Main Frame Stub Axle............................................................ 31
16 Front Frame Bump Stops....................................................... 32
17 Tiller Assembly ....................................................................... 33
Table of Contents
Page 3
It is potentially hazardous to fit or use any parts other than genuine
Sunrise Medical parts.
The company disclaims all liability for the consequences of such use,
which in addition, voids the machine warranty.
This vehicle is for the carriage of
ONE PERSON
And MUST NOT be used for any other purpose.
Product Information
2
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Whilst working on powered mobility products, it is essential to observe good
working practice. Below are a series of safety guidelines and recommendations.
Please note that these precautions are intended to serve only as a guide and
are not intended to supersede or replace any safety statute, NHS or other safety
regulations.
General
• Always wear suitable protective clothing when handling batteries.
• Always wear suitable eye protection when drilling or inspecting.
• When safe to do so, wear protective gloves when handling the running gear
or batteries, as these parts are exposed to paths, parks etc.
• If the drive wheels have to be raised of the floor, always use a pair of axle
stands to secure the vehicle correctly.
Batteries
All work carried out on batteries or battery boxes should demand a degree of
extra caution.
• Always make sure that the batteries are disconnected from the vehicle before
commencing work.
• Always check that the battery charger is disconnected from the vehicle / batteries before commencing work.
• Do not smoke.
• Keep batteries away from all sources of ignition.
• Do not place objects on the battery tops.
• Always try to keep someone within earshot of your work area so that they
may come to your assistance if needed.
• Always wear personnel protection when handling batteries including, eye /
face protection and gloves.
• Make sure there is easy access to soap and water in case of acid spills.
• Avoid touching eyes or unprotected parts of the body while working on batteries.
• Remember that none sealed batteries can contaminate any packaging, housing, or boxes they may have been transported in, so handle all packaging
with care especially when disposing of.
• If battery acid should come into contact with bare skin or clothing, be sure to
wash immediately using plenty of soap and water. If battery acid enters the
eyes, flush with running cold water for as long as possible while medical help
is sought.
Safety Information
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Batteries
• When the tops of batteries are exposed, take extra care when working on or
around the terminals.
• Do not allow metal tools to drop on to or touch the exposed terminals of the
batteries or other exposed connections as this could cause a short circuit,
which may result in an explosion.
• Remove personnel items of jewellery such as rings, watches, chains etc. before commencing work on batteries. If such items were to cause short circuit
whist being worn, very serious burns would result.
• Batteries are constructed using very heavy materials, because of this it is
essential that correct lifting techniques be employed when moving batteries
around. It is also recommended that safety footwear be worn.
• When disposing of old batteries, please ensure that correct disposal procedures are followed. Contact your local authority for their recommendations.
Battery Chargers
• Remember battery chargers are Mains Driven Units.
• Always observe all guidelines and laws relating to mains-connected installations and equipment.
• Never operate the battery charger in wet or damp conditions.
• If you suspect that the charger has been exposed to water or excessive
damp, do not use it. Return the unit back to the dealer/supplier for inspection.
• If the battery charger is suspected of being defective or is visibly damaged,
return the unit back to the dealer for inspection.
Safety Information
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Recommended Tools
• The following list of tools should enable
any task to be dealt with. Some will only
occasionally be needed, but it is advisable to
own or have access to them.
1. Metric socket set
2. Imperial socket set
3. Hexagon wrenches, (imperial & metric)
4. 3.5 - 8mm flat screwdriver
5. No. 0 cross-head screwdriver
6. No. 1 cross-head screwdriver
7. No. 2 cross-head screwdriver
8. Metric combination spanner set 5 - 25mm
9. Imperial combination spanner set 1/8 - 1”
10. Mole grips
11. Long nose pliers
12. Adjustable Spanner
13. Combination pliers
14. Circlip pliers
15. Hammer, (small & large)
16. Soft hammer, (rubber, hide or nylon)
17. Feeler gauges, (metric & imperial)
18. Stanley knife
19. Pin punches
20. Electric drill, (mains/battery)
21. Drill bits, (metric & imperial)
22. Hacksaw, (standard & junior)
23. Toque wrench
24. Steel engineering rule
25. Tape measure
26. Tyre pump
27. Tyre pressure gauge
28. Personal safety gear
29. Wire strippers/cutters
30. Tag crimper
31. Multi-meter
32. Battery tester
33. Hand held electronic programmers
34. Parts manuals & workshop manuals
35. Tyre levers
Tools Required
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Controller
• On/off Switch
• PCB Plug Connections
• Operation
• Dynamic Braking
• Programmable Settings, (where applicable)
• Test Run
Batteries
• Physical Inspection
• Connections
• Discharge Test
• Up/Down Slope
Wheels & Tyres
• Wear
• Pressure, (Pneumatic Only)
• Bearings, (Where appropriate)
• Wheel Nuts
• Castors, (Where appropriate)
• Stub Axles
Motors
• Wiring
• Noise
• Connections
• Brake
• Brushes
Chassis
• Condition, (Welded Joints etc.)
• Steering, (Twists etc.)
Upholstery / Seat
• Seat
• Back
• Arm pads
• Seat Slide Mechanism, (where fitted)
• Set Post Assy
Electrical
• Loom
• Connections
• Lights/Indicators
Drive
• Forwards
• Reverse
• Emergency Stop
• Left Turn
• Right Turn
• Up/Down Slope
• Over Obstacles
• Parking Brake
Service & Inspection (Annual)
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Little Star
Overall length 38” / 96cm
Overall width 20” / 50cm
Maximum user weight 250lbs / 18st / 113kg
Maximum gradient 6 degrees
Range 8m / 12km
Speed 4mph / 6kph
Turning radius 43” / 110cm
Weight 77lbs / 35kg including batteries.
Heaviest part 44lbs / 20kg chassis.
Battery capacity 10AH
Adjustable seat height 14” / 16”- 35cm / 41cm
Front wheel diameter 7” / 18cm
Rear wheel diameter 7.5” / 19cm
Range given represents test conditions. Please note that temperature, user weight, terrain and
battery capacity may affect overall performance.
7
Technical Specifications
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1. Use a thin-blade knife to.....
3. Use a cross-head screwdriver to undo
the centre wheel securing bolt.
4. Pull the Front Wheel from the Stub Axle.
5. Note the number of shims behind the
front wheels.
6. Front Wheel assembly.
2. carefully prize off the hubcap.
Front Wheels
CHAPTER ONE FRONT WHEELS
CHAPTER
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1. Use a thin-blade knife to lift the hub cap.
2. Undo the centre bolt using a 13.00mm
socket.
3. Remove the centre bolt, noting the posi-
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4. Carefully remove the wheel, taking care
not to lose the Drive Key.
5. Use a pair of thin-nosed pliers to remove
the Drive Key.
6. The Rear Wheel assembly & parts.
CHAPTER TWO REAR WHEELS
Rear Wheels
CHAPTER
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1. Shows the seat in operating position.
2. Fold the Backrest down.
3. Loosen the seat locking lever by turning
anti-clockwise.
4. Lift the Seat assembly off.
5. The Seat assembly clear of the scooter.
6. The underside of the Lightweight Seat
Assembly.
CHAPTER THREE SEAT & ARMRESTS
Seat & Armrests
CHAPTER
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7. Undo the hand-wheel by tuning it anticlockwise.
8. Remove the Armrests or adjust them to
the desired width.
9. Hold the top of the Seat Stem & grab
hold of the securing pin.
10. Pull the securing pin out.
11. Move the securing pin to the desired
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12. Ensure the pin is pushed fully into place.
CHAPTER THREE SEAT & ARMRESTS
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1. The Battery Box in situ.
2. Shows the power lead connected to the
battery.
3. remove the power lead by pressing in the
metal tab on the battery socket.
4. Use the handle to lift the Battery Box
away from the scooter.
5. The battery box removed.
CHAPTER FOUR BATTERY BOX
Battery Box
CHAPTER
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1. Shows the location of the 12 battery box
screws beneath the lip of the battery box.
2. Undo the screws using a long phillips
screwdriver.
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carefully lift the lid up.
4. The Batteries in situ.
5. Use thin-nosed pliers to release the posi-
tive terminals....CAUTION! Take care not to
short out the terminals.
6. and the negative terminals on both batteries.
CHAPTER FIVE BATTERIES & BATTERY BOX
Batteries & Battery Box
CHAPTER
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7. Lift each battery clear of the battery box.
8. Shows the battery box base.
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up the lid on the fuse holder and pull the
fuse out.
10. View of the battery main lead and
socket.
11. The battery connection / charging socket
is secured by 2 small bolts.
12. Using long-nosed pliers undo the small
bolts on the battery connection / charging
CHAPTER FIVE BATTERIES & BATTERY BOX
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13. Remove the charging socket.
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the cable connecting the charge socket to
the fuse holder.
15. Once removed carefully lift the tab on
the connectors ready for re-assembly.
16. Using a 14mm ring spanner undo the
power cut out nut.
17. Remove the power cut out from inside
the battery box lid.
18. Shows the batteries, fuses, power cut
out and connection / charger socket.
CHAPTER FIVE BATTERIES & BATTERY BOX
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1. With the seat removed, use a phillips
screwdriver to undo the rear panel retaining
screw.
2. Slide out the rear panel by angling it
slightly through the rear frame.
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CHAPTER SIX REAR DRIVE ASSEMBLY PANEL
Rear Drive Assembly Panel
CHAPTER
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17
1. Using long-nosed pliers bend open the
clip around the power terminal plug.
2. Disconnect the power plug & socket.
CHAPTER SEVEN REAR DRIVE ASSEMBLY MOTOR LEADS
Rear Drive Assembly
Motor Leads
CHAPTER
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1. To inspect the micro-switch, lift the plastic
end cover off the motor.
2. The micro-switch can then be accessed.
3. To release the motor studs a combination
of 5.0mm hex driver.....
4. and a 5.00mm hex key is required.
5. Note that the motor loom clamp is attached to one of the motor studs.
6. Shows the position of the rear panel
bracket on the motor.
CHAPTER EIGHT REAR DRIVE ASSEMBLY MOTOR/BRAKE
Rear Drive Assembly
Motor/Brake
CHAPTER
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7. Gently ease the motor away from the
transaxle.
8. Lift the motor clear of the chassis.
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the motor must line up with the drive shaft
coupling inside the transaxle, (see over).
10. Shows the position of the freewheel
extension lever held by 2 phillips screws.
Coupling
11. Use a 10.00mm spanner and a screw-
driver.....
12. to remove the stabiliser wheels.
CHAPTER EIGHT REAR DRIVE ASSEMBLY MOTOR/BRAKE
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Coupling
1. The drive coupling on the transaxle
gearbox, must aline with the motor drive
coupling when reassembled.
2. Location of 2 of the transaxle mounting
bolts.
3. Location of the other 2 transaxle mounting
bolts.
4. Use a 13.00mm socket/spanner to undo
the four mounting bolts.
5. Remove the motor bolts carefully taking
care not to damage the rubber mounts.
6. Carefully lift the transaxle out of the chassis.
CHAPTER NINE REAR DRIVE ASSEMBLY TRANSAXLE
Rear Drive Assembly Transaxle
CHAPTER
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7. Carefully remove the rubber mounts for
inspection.
8. The transaxle assembly without motor/
brake.
CHAPTER NINE REAR DRIVE ASSEMBLY TRANSAXLE
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1. View of the tiller locking mechanism. 2. The two lower tiller mounting studs.
3. Lower the tiller by turning the black screw
anti-clockwise.
4. Shows the tiller locking screw and locking plate removed.
5. Undo the lower tiller mounting studs using
a 4.00mm hex key and a 10.00mm spanner.
6. To release the tiller cable, remove the
battery and lift the rear panel from the
frame.
CHAPTER TEN TILLER ASSEMBLY
Tiller Assembly
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7. Move the panel over to expose the controller and main wiring looms.
8. Shows the controller and main wiring
looms.
9. Using long-nosed pliers and wire cutters
release the tiller cable from it ties.
10. Do this all the way along to the controller.
11. Cut the cable ties holding the tiller connector.
12. Cut the cable ties around the tiller
connector protective sheathing and slide it
away.
CHAPTER TEN TILLER ASSEMBLY
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13. Release the tiller loom from the control
box connector.
14. Carefully feed the tiller cable through
the front panel and lift the tiller clear.
15. Undo the upper tiller mounting studs
using a 4.00mm hex key and a 10.00mm
spanner.
16. The tiller folding mechanism.
17. The Tiller Assembly complete with Main
Loom.
CHAPTER TEN TILLER ASSEMBLY
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1. Unplug the tiller loom from the main
controller.
2. Using long-nosed pliers and wire cutters
release the motor and power cable from their
ties.
3. Unscrew the two screws visible from the
top of the main controller. Note: Threadlock
is used on these screws.
4. Lift out the main controller.
5. The main controller with tiller, motor and
battery wiring shown.
CHAPTER ELEVEN MAIN CONTROLLER
Main Controller
CHAPTER
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1. With the battery and tiller removed lift up
the front panel from the rear pulling it off the
frame clips and velcro.
2. Move the panel away from the velcro and
put in a position ready to lift clear.
3. Lift the panel clear of the frame. 4. Shows the position of the front panel
velcro (centre) and 4 frame clips (corners).
5. Shows the position of the 2 front velcro
pads on the panel.
CHAPTER TWELVE FRONT PANEL
Front Panel
CHAPTER
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27
1. Use a large adjustable spanner to loosen
the steering head nut.
2. Remove the steering head nut using your
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3. Undo the bearing retaining nut.
4. Using long-nosed pliers carefully remove
the steering head upper bearing.
5. Position the wheels to make access to
the steering link possible.
6. Use a 13mm spanner and socket to undo
the steering link connector.
CHAPTER THIRTEEN STEERING HEAD
Steering Head
CHAPTER
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28
7. Remove the steering link from the steering head bracket.
9. Lower the steering head bracket out of
the frame. NOTE: This is only possible when
the Front Frame Bump Stops have been
removed. (See Chapter 16).
10. The steering head bracket showing the
lower bearing in position.
8. Remove the spacer and bolt from the
steering head bracket.
CHAPTER THIRTEEN STEERING HEAD
Page 30
29
3. Lift off the steering link.
1. Use a 13mm socket and spanner to re-
move the other end of the steering link.
2 Remove the self locking nut from the top.
4. Lift off the long spacer tube.
5. Lower the bolt out of the stub axle and
remove the short spacer tube.
6. Remove the bolt from the steering link.
CHAPTER FOURTEEN MAIN FRAME STEERING
Main Frame Steering
CHAPTER
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7. Use a 13.00mm socket & spanner to
undo the other end of the steering link.
8. Remove the self-locking nut from the top.
9. Lower the bolt out of the stub axle and
remove the short spacer tube.
10. Lift the steering link off the bolt.
CHAPTER FOURTEEN MAIN FRAME STEERING
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1. The Stub Axle is secured by a 19.00mm
nut.
2. Remove the nut and the spacer.
3. The stub axle may need to be carefully
tapped with a nylon hammer and rotated to
aid removal.
4. Remove the Stub Axle assembly Repeat
the process for the other side.
5. The Stub Axle assembly, nut & spacer.
CHAPTER FIFTEEN MAIN FRAME STUB AXLES
Main Frame Stub Axles
CHAPTER
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1. Using an allen key remove the bolt holding the front axle cross member.
2. Show view from the underside of cross
member.
3. Once loose it maybe quicker to use your
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4. Pull cross member forwards remember-
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5. Show front axle cross member removed.
6. Inspect bump stopr on frame for wear and
damage, replace if necessary.
CHAPTER SIXTEEN FRONT FRAME BUMP STOPS
Front Frame Bump Stops
CHAPTER
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33
1. Remove the Tiller assembly as previously
described.
2. The Loom Clips can be removed with a
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3. Undo the four screws in the bottom of the
tiller fascia box.
4. Once removed feed the cable through the
tiller section.
5. Feed the white plug through the hole in
the tiller shaft.
6. The tiller fascia control box.
CHAPTER SEVENTEEN TILLER ASSEMBLY
Tiller Assembly
CHAPTER
Page 35
34
7. Using a small phillips screwdriver undo
the 4 screws in the underside corners of
the fascia control box.
8. Carefully lift open the fascia control box.
9. Shows the position of the key switch.
10. Disconnect the black connector from the
key switch.
11. Using an adjustable spanner undo the
large retaining nut on the back of the key
switch.
12. Carefully slide the key assembly out of
the fascia control box.
CHAPTER SEVENTEEN TILLER ASSEMBLY
Page 36
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lift off the speed control knob.
14. Undo the locking nut with a ring spanner.
15. Remove the locking nut and washer
from the speed potentiometer.
16. Shows the speed potentiometer.
17. Undo the locking nut on the horn button
with a spanner or long-nosed pliers.
18. Slide out the horn button.
CHAPTER SEVENTEEN TILLER ASSEMBLY
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36
19. Using a small phillips screwdriver undo the
wig-wag retaining screw.
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21. Using a small phillips screwdriver remove
the 4 screw holding the wig-wag potentiometer.
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23. The wig-wag potentiometer.
CHAPTER SEVENTEEN TILLER ASSEMBLY
Page 38
37
Please use this Workshop Manual
in conjunction with the
Little Star Owners Manual
and Parts Manual.
END
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