Bravo EV EVT- 4000e Service Manual Download | Manualshive

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19

Front Caliper

1. Release three screws on the handle cover.
2. Release the screw on the front caliper. Avoid fluid leaking to the pad.

3. Release the screw on the pad, then remove the pad.
4. Release two mounting screws on the caliper.

Tools Required: Phillips screwdriver; Box wrench, 12mm; Y-bend socket wrench, 12mm
Time: Allow 10 minutes for procedure

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Summary of Contents for EVT- 4000e

Page 1: ...SERVICE MANUAL SERVICE MANUAL EVT 4000e EVT 4000e ...

Page 2: ...trol Cord 10 Flasher Relay 11 DC to DC Converter 12 Left Handle Switch 13 Right Handle Switch 14 Brake Master Cylinder 15 Front Fork 16 Rear Shock Absorber 17 Front Brake Hose 18 Rear Brake Hose 19 Front Caliper 20 Rear Caliper 21 Controller 22 Motor 23 Rear Brake Disk 24 Front Brake Disk 25 Rear Light Assembly 26 Rear Lamp Bulb 27 Troubleshooting 28 Part Summary ...

Page 3: ...on the handle cover 2 Release two mounting screws on the instrument panel and then release three screws on the head light assembly 3 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minutes for procedure ...

Page 4: ...lb 1 Release three screws on the handle cover 2 Release two mounting screws on the instrument panel 3 Follow with the reversed steps to restore Tools Required Phillips Screwdriver Time Allow 10 minutes for procedure ...

Page 5: ...ease three screws on the handle cover 2 Release signal light bulb set for replacement 3 Follow with the reversed steps to restore Tools Required Phillips screwdriver T bend socket wrench 8mm Time Allow 10 minutes for procedure ...

Page 6: ... screws on the handle cover 2 Release two mounting screws on the instrument panel 3 Release the nut for the speedometer 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minutes for procedure ...

Page 7: ...ounting screws on the instrument panel 3 Release the nut for the speedometer 4 Release three screws on the front cover 5 Release speedometer nut on the front wheel 6 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minutes for procedure ...

Page 8: ...6 Speedometer Gear 1 Release front axle nut 2 Remove the front wheel 3 Follow with the reversed steps to restore Tools Required Box wrench 17mm Time Allow 10 minutes for procedure ...

Page 9: ...ews on the front fender 3 Release three screws on the glove box 4 Release 4 pin connector and two screws on the key switch 5 Follow with the reversed steps to restore Tools Required Phillips screwdriver T bend socket wrenches 8mm and 10mm Time Allow 10 minutes for procedure ...

Page 10: ...e screws on the front cover 2 Release two connectors on the horn 3 Release the mounting screws on the horn 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minutes for procedure ...

Page 11: ...n the front cover and two screws on the right trim 2 Release all of the connectors stores inside the handle cover 3 Release all of the connectors stored inside the front cover 4 Release all of the connectors stored inside the right cover 5 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minutes for procedure ...

Page 12: ...hree screws on the handle cover and remove the rubber sleeve so can see the 2 pin connector for the flasher relay 2 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minutes for procedure ...

Page 13: ... Release three screws on the front panel 2 Release two screws and 4 pin connector for the DC to DC converter 3 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minutes for procedure ...

Page 14: ...ree screws on the handle cover 2 Release two mounting screws on the instrument panel 3 Release two screws on the left handle switch 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver open end wrench 14mm Time Allow 10 minutes for procedure ...

Page 15: ...le cover 2 Release two mounting screws on the instrument panel 3 Release two screws on the right handle switch and one screw for the throttle cable 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver Open end wrench 14mm Time Allow 10 minutes for procedure ...

Page 16: ...e headlight assembly 2 Check the fluid in reservoir for refuel or replace the blake fluid 3 Replace reservior for a gasket fail or wear out or b leaking 4 Release the screw on the brake hose 5 Release two screws on the reservoir Tools Required Phillips screwdriver Box wrench 12mm Hex key wrench 5mm Time Allow 10 minutes for procedure ...

Page 17: ...t axle nut to remove the wheel 6 Release two screws on the caliper 7 Release two screws on the front fork and check the steel balls to see if they are missing 8 Properly adjust the front fork clearance and follow the reversed steps to restore Tools Required Phillips screwdriver T bend socket wrench 8mm Box wrenches 14mm and 17mm Y bend socket wrench 12mm Time Allow 10 minutes for procedure ...

Page 18: ...h left and right side 2 Release two screws on the left shock absorber 3 Repeat to replace right shock absorder 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver T bend socket wrenches 12mm and 14mm Time Allow 10 minutes for procedure ...

Page 19: ...of the front wheel Avoid fuel leaking to the pad 4 Release the screw on the right side brake hose 5 Release three screws on the front cover 6 Cut off the band then carefully pull out the hose 7 Follow with the reverse steps to restore Tools Required Phillips screwdriver Box wrench 12mm diagonal cutting pliers Time Allow 10 minutes for procedure ...

Page 20: ... the pad 4 Release the screw on the left side brake hose 5 Release three screws on the front cover 6 Release six screws on the front fender 7 Release two screws on the left trim 8 Cut off the band and carefully pull out the hose 9 Follow with the reversed steps to restore Tools Required Phillips screwdriver Box wrench 12mm Diagonal cutting pliers Time Allow 10 minutes for procedure ...

Page 21: ...the screw on the front caliper Avoid fluid leaking to the pad 3 Release the screw on the pad then remove the pad 4 Release two mounting screws on the caliper Tools Required Phillips screwdriver Box wrench 12mm Y bend socket wrench 12mm Time Allow 10 minutes for procedure ...

Page 22: ...2 Release the screw on the rear caliper Avoid fluid leaking to the pad 3 Release the screw on the pad 4 Release two mounting screws on the caliper Tools Required Phillips screwdriver Box wrench 12mm Y bend socket wrench 12mm Time Allow 10 minutes for procedure ...

Page 23: ...k 1 red 1 black 9 pin 1 white 9 pin Release the copper nut of the throttle cable and pull it out Put a nail through the hold to prevent pillar from drawing back 3 Release four screws on the controller and cut off the band to remove the controller Tools Required Phillips screwdriver Time Allow 10 minutes for procedure ...

Page 24: ...s on the motor cord cover 4 Release two nuts for the motor shaft 5 Release the rear caliper to remove the motor 6 Follow with the reversed steps to restore Tools Required Phillips screwdriver Open end wrench 24mm Y bend socket wrench 12mm Diagonal cutting pliers Time Allow 10 minutes for procedure ...

Page 25: ...e two nuts for the motor shaft 5 Release the rear caliper to remove the motor 6 Release three screws on the brake disk to remove the disk 7 Follow with the reversed steps to restore Tools Required Phillips screwdriver Open end wrench 24mm Y bend socket wrench 12mm Hex key wrench 6mm Diagonal cutting pliers Time Allow 10 minutes for procedure ...

Page 26: ...ase the screw for the front axle nut to remove the front wheel 2 Release three screws on the disk 3 Follow with the reversed steps to restore Tools Required Box wrench 17mm Hex key wrench 6mm Time Allow 10 minutes for procedure ...

Page 27: ... Release the screw on the center cover 4 Release three screws on the side cover on the left and right sides 5 Release two screws on the tail fender 6 Follow with the reversed steps to restore Tools Required Phillips screwdriver Hex key wrench 6mm Y bend socket wrench 10mm T bend socket wrench 10mm Time Allow 10 minutes for procedure ...

Page 28: ... Lamp Bulb 1 Release two screws on the rear lamp cover 2 Remove the cover to replace the bulb 3 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minutes for procedure ...

Page 29: ...1 Recharge battery immediately 2 Replace the battery The second yellow light blinking 2 1 Insufficient energy left 1 Recharge battery With the power cut off while driving switch the power to OFF position and wait for several minutes then restart You may still drive a short distance The third green light blinking while driving 3 1 Over current 2 Controller breakdown 1 Switch the power to OFF positi...

Page 30: ... TUBELESS 1 3 6162 63004 BEARING 2 4 6222 351671 OIL SEAL 1 5 6279 100117 SPEEDOMETER GEAR SET 1 6 0241 10601 TIRE VALVE 1 7 0241 10701 BRAKE DISK FRONT 1 8 6109 080171 SCREW 3 9 6142 080855 NUT DOME HEAD 3 10 0241 10311 COLLAR LARGE 1 11 0241 10321 COLLAR SMALL 1 12 6113 101901 BOLT 1 13 6143 100801 NUT DOME HEAD 1 ...

Page 31: ... 0241 30101 FRONT FORK SET 1 2 0241 30501 CALIPER FRONT 1 3 6112 080258 SCREW NYLOK 2 4 0241 30401 RACE BALL SET 1 5 0241 71601 FENDER FRONT 1 6 6112 060208 SCREW HEX HEAD 2 7 0241 30601 CABLE GUIDE LEFT 1 8 0241 30602 CABLE GUIDE RIGHT 1 9 6112 060126 SCREW HEX HEAD 2 ...

Page 32: ...001204 REAR FORK SET 1 8 6113 103001 BOLT 1 9 6143 100801 NUT DOME 1 10 6150 1030305 WASHER 1 11 0299 010016C3 COVER MOTOR CORD 1 12 6126 041001 SCREW PAN 3 13 0299 01001501 SHOCK ABSORBER REAR 2 14 6112 080358 SCREW HEX FLANGE 2 15 6151 0815208 WASHER 2 16 6111 100407 SCREW HEX FLANGE 2 17 0241 30501 CALIPER REAR 1 18 6112 080258 SCREW NYLOK 2 19 6274 100110 BRACKET REAR FENDER LEFT 1 20 6274 110...

Page 33: ... Qty 1 0241 501011 FRAME 1 2 6266 100103 MAIN STAND 1 3 6111 081255 BOLT 1 4 6142 080855 NUT FLANGE 1 5 0241 50302 SPRING MAIN STAND 2 6 6266 200103 SIDE STAND 1 7 0241 50801 LOCK SET 1 8 6111 060408 SCREW HEX 2 9 6111 060185 SCREW HEX 1 10 6123 060251 SCREW HEX 1 ...

Page 34: ...002 CONNECTOR RED 1 3 6126 052005 SCREW 4 4 6255 00001 HORN 1 5 6112 060126 SCREW HEX HEAD 1 6 6141 060608 NUT HEX FLANGE 1 7 0268 05002301 DC DC CONVERTER 1 8 6126 051031 SCREW 2 9 6140 050408 NUT 2 10 0268 05000101 MAIN CONTROL CORD 1 11 6256 00280 TIE BAND 2 12 6256 00200 TIE BAND 10 13 6256 00120 TIE BAND 10 ...

Page 35: ...FT 1 7 0241 41001 MASTER CYLINDER RIGHT 1 8 0241 41101 BRAKE HOSE LEFT 1 9 0241 41201 BRAKE HOSE RIGHT 1 10 0241 41901 SCREW HEX HEAD 4 11 0241 41902 WASHER 8 12 0241 41401 SIGNAL LIGHT LEFT 1 13 0241 41403 SIGNAL LIGHT RIGHT 1 14 0241 41402 BRACKET LEFT 1 15 0241 41404 BRACKET RIGHT 1 16 6126 051008 SCREW 2 17 0241 010009A1 REAR VIEW MIRROR SET 1 0241 010009B1 REAR VIEW MIRROR R 1 0241 010009C1 R...

Page 36: ...HANDLE COVER UPPER RED 1 0241 40204 HANDLE COVER UPPER GREEN 1 0241 40205 HANDLE COVER UPPER BLUE 1 0241 40208 HANDLE COVER UPPER DK GREEN 1 2 0241 40301 HANDLE COVER LOWER 1 3 0241 05000500 HEADLIGHT COMP 1 4 0241 05000200 DASHBOARD SET 1 5 6126 501511 SCREW TAPPING 7 6 6241 00001 FLASHER RELAY 1 7 0241 41701 CABLE SPEEDOMETER 1 ...

Page 37: ...Item NO Part NO Description Qty 1 0241 05000400 TAIL LIGHT SET 1 2 0241 71511 LICENSE PLATE HOLDER 1 3 6112 060208 SCREW HEX FLANGE 2 4 0241 41411 SIGNAL LIGHT REAR LEFT 1 5 0241 41412 SIGNAL LIGHT REAR RIGHT 1 6 6141 060608 NUT HEX FLANGE 2 ...

Page 38: ...0241 70101 SEATBOX RIM 1 2 0241 70201 HINGE SEAT 1 3 6110 060158 SCREW HEX HEAD 2 4 0241 70301 PIN SEAT 1 5 0241 70401 SEAT 1 6 0241 723011 BRACKET SEAT 1 7 6141 060608 NUT HEX FLANGE 2 8 0241 72501 BATTERY COVER 1 9 6111 060408 SCREW HEX 2 10 0241 72201 HANGER HELMET 1 ...

Page 39: ...1 0241 70803 COVER FRONT RED 1 0241 70804 COVER FRONT GREEN 1 0241 70805 COVER FRONT BLUE 1 0241 70808 COVER FRONT DK GREEN 1 3 6132 501511 SCREW TAPPING 8 4 6127 0613125 SCREW TAPPING 1 5 6150 0613125 WASHER 1 6 0241 70902 GLOVE BOX 1 7 0268 24000100 REFLECTER AMBER 2 8 0241 71201 HANGER GLOVE BOX 1 9 6112 060148 SCREW HEX FLANGE 1 ...

Page 40: ...VER LEFT RED 1 0241 70504 COVER LEFT GREEN 1 0241 70505 COVER LEFT BLUE 1 0241 70508 COVER LEFT DK GREEN 1 2 6132 501511 SCREW TAPPING 7 3 0241 70602 COVER RIGHT SILVER 1 0241 70603 COVER RIGHT RED 1 0241 70604 COVER RIGHT GREEN 1 0241 70605 COVER RIGHT BLUE 1 0241 70608 COVER RIGHT DK GREEN 1 4 0241 20402 STICKER SET 1 ...

Page 41: ...CENTER SILVER 1 0241 71403 COVER CENTER RED 1 0241 71404 COVER CENTER GREEN 1 0241 71405 COVER CENTER BLUE 1 0241 71408 COVER CENTER DK GREEN 1 4 0241 71901 TRIM LEFT 1 5 6132 501511 SCREW TAPPING 4 6 0241 72001 TRIM RIGHT 1 7 0268 24000101 REFLECTOR RED 2 8 0241 24000200 BASE REFLECTOR 2 0241 240002A1 BASE REFLECTOR L 1 0241 240002AB1 BASE REFLECTOR R 1 ...

Page 42: ...AIL COVER UPPER RED 1 0241 71824 TAIL COVER UPPER GREEN 1 0241 71825 TAIL COVER UPPER BLUE 1 0241 71828 TAIL COVER UPPER DK GREEN 1 3 0241 71831 TAIL COVER LOWER 1 4 0241 71841 LENS THIRD BRAKE LIGHT 1 5 6132 501511 SCREW TAPPING 4 6 6144 060601 NUT DOME 2 7 0241 72401 CAP FAST CHARGING 1 8 6132 401211 SCREW TAPPING 4 9 6100 080201 SCREW SOCKET 1 ...

Page 43: ... FIG 14 BATTERY Item NO Part NO Description Qty 1 181 400 10 BATTERY LEV 12500 4 2 6261 040621 BATTERY CORD SET LONG 1 6261 050621 BATTERY CORD SET SHORT 1 3 0299 05000400 CONNECTION CORD BATTERY 1 4 0299 05000308 CHARGER 1 ...

Page 44: ...0E STORAGE CASE WHITE 8 0241 24000107 4000E STORAGE CASE BLACK 9 0241 24000108 4000E STORAGE CASE DARK GREEN 10 0237 00001 4000E CARGO CASE BRACKET 11 0241 80901 FRONT BASKET 12 0241 80821 WINDSHIELD 13 0241 808022 WINDSHIELD ASSEMBLY KIT 14 745 956 20 006 EV 500 SOLAR CHARGER 15 875 738 20 001 WIRE KIT W CONNECTOR FOR EV 500 16 PB 360P 48 LITHIUM BATTERY CHARGER 17 02A9 05000400 MOTOR BRUSH 8PC S...

Page 45: ...43 ...

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