Bravo EVT-168 Service Manual Download Page 59

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Accessories

Item NO. Part NO.

Description

0268-24000301

STORAGE CASE, LIGHT BLUE

0268-24000302

STORAGE CASE, LIGHT ORANGE

0268-24000303

STORAGE CASE, DARK GREEN

0268-24000304

STORAGE CASE, PURPLE RED

0268-24000309

STORAGE CASE, SILVER

0268-01004702

EVT-168 CARGO CASE BRACKET

0268-13000408

FRONT FENDER, CHROME

0241-80901

FRONT BASKET

0241-305211

BRAKE PAD, BLUE (UNCUT)

0268-41002

BRAKE CABLE, FRONT (1206MM)

0242-41001

BRAKE CABLE, REAR

745-956-20-006

EV-500 SOLAR CHARGER

875-738-20-001

WIRE KIT W/CONNECTOR FOR EV-500

PB-360P-48

LITHIUM BATTERY CHARGER

0241-80821

WINDSHIELD

0241-808022

WINDSHIELD - ASSEMBLY KIT

02A9-05000400

MOTOR BRUSH 8PC SET (BEFORE 2006)

02A9-05000500

MOTOR BRUSH 16PC SET (2006-2008)

6257-101500

REFURBISHED MOTOR (BRUSH - MODELS THROUGH 2008)

Summary of Contents for EVT-168

Page 1: ...SERVICE MANUAL SERVICE MANUAL EVT 168 EVT 168...

Page 2: ...t Lock Assembly 19 Horn 20 Flasher Relay 21 DC to DC Converter 22 Controller 23 Rear Shock Absorber 24 Rear Caliper 25 Brake Master Cylinder 26 Brake Hose 27 Brake Fluid 28 Brake Pad 29 Direct Driven...

Page 3: ...the screw on the front cover 2 Release four screws on the back of the front cover 3 Remove the front cover 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 1...

Page 4: ...2 Seat 1 Release two nuts on the seat 2 Remove the seat 3 Follow with the reversed steps to restore Tools Required T bend socket wrench 10mm Time Allow 10 minutes for procedure...

Page 5: ...3 Center Cover 1 Release the screw on the center cover 2 Remove the center cover 3 Follow with the reversed steps to restore Tools Required T bend socket wrench 8mm Time Allow 10 minutes for procedure...

Page 6: ...1 Remove the center cover 2 Release four screws on the left side cover 3 Remove the left side cover 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minut...

Page 7: ...ide Cover 1 Release the screw on the cover 2 Remove the cover 3 Release four screws on the right side cover 4 Remove the right side cover Tools Required Phillips screwdriver Time Allow 10 minutes for...

Page 8: ...trest Board 1 Release four screws on the footrest board 2 Remove the footrest board 3 Follow with the reversed steps to restore Tools Required T bend socket wrench 10mm Time Allow 10 minutes for proce...

Page 9: ...crew on the tail bracket 2 Release two nuts on the tail bracket 3 Remove the tail bracket 4 Follow with the reversed steps to restore Tools Required Y bend socket wrench 10mm hex key wrench 6mm Time A...

Page 10: ...rear cover 2 Remove the plastic cover on the seat lock 3 Release the 6 pin connector and 2 pin connectors 4 Remove the rear cover 5 Follow with the reversed steps to restore Tools Required Phillips s...

Page 11: ...move the footrest board and release the screw on the front of the lower cover 2 Remove the lower cover 3 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 min...

Page 12: ...the footrest board and the hanger on the back of the fairing 2 Remove the fairing 3 Follow with the reversed steps to restore Fairing Tools Required T bend socket wrench 8mm Time Allow 10 minutes for...

Page 13: ...se three screws on the rear front fender 2 Release the screw on the top of the rear front fender and remove 3 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 1...

Page 14: ...move the right and left side covers and release two screws on the rear fender 2 Remove the rear fender 3 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 min...

Page 15: ...e head lamp ring 2 Release the head lamp ring 3 Release the spring on the bulb base 4 Remove the bulb base and replace the bulb 5 Follow with the reversed steps to restore Tools Required Phillips scre...

Page 16: ...on the base of the direction lamp 2 Release the screw on the cover of the bulb 3 Replace the bulb and follow the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minutes for...

Page 17: ...ail Lamp Bulb 1 Release two screws on the tail lamp cover and remove 2 Replace the light bulb 3 Follow the reversed steps to restore Tools Required Phillips screwdriver Time Allow 10 minutes for proce...

Page 18: ...1 Release the screw on the base of the direction lamp 2 Remove the cover of the direction lamp 3 Replace the bulb and follow the reversed steps to restore Tools Required Phillips screwdriver Time All...

Page 19: ...nt covers 2 Release the 4 pin connector 3 Release two screws on the main switch and remove the key switch 4 Follow with the reversed steps to restore Tools Required T bend socket wrench 10mm Time Allo...

Page 20: ...the seat box rim 3 Release two screws on the seat lock 4 Release two screws on the seat lock switch 5 Remove the seat lock and seat lock switch 6 Follow with the reversed steps to restore Tools Requir...

Page 21: ...Remove the front cover 2 Release two connectors on the horn 3 Release the screw on the horn 4 Follow with the reversed steps to restore Tools Required Open end wrench 10mm Time Allow 10 minutes for p...

Page 22: ...20 Flasher Relay 1 Remove the front cover 2 Release the 2 pin connector on the flasher relay 3 Follow with the reversed steps to restore Time Allow 10 minutes for procedure...

Page 23: ...side covers and footrest board 2 Release the 4 pin connector for the converter 3 Release three screws on the converter 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver T...

Page 24: ...wire harness 3 Release the copper nut throttle cable and remove replace with nail to prevent pillar drawing back 4 Release four screws on the controller cut off band 5 Follow with reversed steps to r...

Page 25: ...ock Absorber 1 Remove the rear body cover 2 Release two screws on the rear shock absorber 3 Follow with the reversed steps to restore Tools Required T bend socket wrench 10mm Time Allow 10 minutes for...

Page 26: ...caliper Avoid leaking fuel onto the pad 2 Release the screw on the pad 3 Release two mounting screws on the caliper 4 Follow with the reversed steps to restore Tools Required Box wrench Y bend socket...

Page 27: ...if leakage occurs or if gasket fails or wears out 3 Release the screw on the brake hose 4 Release two screws on the reservoir 5 Release two connectors and remove the master cylinder 6 Follow with the...

Page 28: ...of the rear caliper Avoid leaking fuel onto the pad 3 Release the screw on the brake hose of master cylinder 4 Cut off the band on the brake hose and remove 5 Follow with the reversed steps to restor...

Page 29: ...ew 3 Pour brake fluid into the master cylinder 4 Release the screw on the rear caliper and operate the fluid vacuum 5 Pull the brake lever several times Ensure brake is functioning normally and brake...

Page 30: ...screw on the rear caliper 2 Remove the rear caliper 3 Remove the brake pad from the base of the caliper 4 Follow with the reversed steps to restore Tools Required Y bend socket wrench 12mm Time Allow...

Page 31: ...lease the black connector of the motor cord 4 Remove the rear caliper 5 Release two nutes for the motor shaft 6 Remove the orientation boards 7 Remove the motor 8 Follow with the reversed steps to res...

Page 32: ...1 Remove the motor from the frame 2 Release three screws on the brake disk 3 Remove the brake disk 4 Follow with the reversed steps to restore Tools Required Hex key wrench 6mm Time Allow 10 minutes...

Page 33: ...r motor and rear shock absorber 2 Cut off the band on the brake hose and release the screw on the rear fork 3 Remove the rear fork 4 Follow with the reversed steps to restore Tools Required Box wrench...

Page 34: ...elease the screw on the front fork cover and remove 3 Release two screws on the front shock absorber and remove 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver Y bend s...

Page 35: ...p 1 Remove the front cover 2 Release the 6 pin connector 3 Release the screw on the head lamp holder 4 Follow with the reversed steps to restore Tools Required Box wrench 14mm Time Allow 10 minutes fo...

Page 36: ...e the 2 pin connector on the front direction lamp Green left red right 3 Release the screw on the handle switch and remove the direction lamp 4 Follow with the reversed steps to restore Tools Required...

Page 37: ...nnector and the 2 pin connector on the meters 3 Release two screws on the instrument panel 4 Release the nut for the speedometer and remove the instrument panel 5 Follow with the reversed steps to res...

Page 38: ...the front cover 2 Release all connectors for the left handle switch 3 Release two screws on the left handle switch 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver Time...

Page 39: ...the front cover 2 Release all connectors for the right handle switch 3 Release two screws on the right handle switch 4 Follow with the reversed steps to restore Tools Required Phillips screwdriver Tim...

Page 40: ...fender 2 Release the three screws on the base of the tail lamp assembly 3 Release all connectors for the tail lamp assembly 4 Follow with the reversed steps to restore Tools Required Open end wrench 1...

Page 41: ...ve the front cover 2 Release the adjusting bolt on the brake cable and pull out the brake cable 3 Remove the brake cable from the brake cable head 4 Follow with the reversed steps to restore Time Allo...

Page 42: ...age 37 step 1 to step 3 to remove the handle switch 3 Remove the throttle cable head on the handle grip 4 Release the screw on the right handle switch 5 Remove the throttle cable 6 Follow with the rev...

Page 43: ...nel handle switches right and left and brake master cylinder 2 Release four screws on the handle Clamp 3 Remove the handle 4 Follow with the reversed steps to restore Tools Required hex key wrench 5mm...

Page 44: ...teering bracket cover 3 Remove the steering bracket cover 4 Release the screw on the steering bracket 5 Remove the steering bracket 6 Follow with the reversed steps to restore Tools Required Phillips...

Page 45: ...eering bracket 2 Remove front wheel 3 Release the nut on the ball race and check the steel balls to see if they are missing 4 Properly adjust the front fork clearance and follow with the reversed step...

Page 46: ...278 100205 COVER SHAFT 1 6 0268 0100550A DUST COVER LARGE 1 7 0268 0100550B DUST COVER SMALL 4 8 0268 01006500 COVER METER GEAR 1 9 0268 01002900 SCREW SHAFT 1 10 0268 01003700 BEARING 2 11 0268 04000...

Page 47: ...0268 01003601 FRONT FORK 1 2 0168 01001300 SWING ARM SET LEFT RIGHT 1 3 0268 010046A1 SHOCK ABSORBER FRONT 2 4 6112 080358 SCREW HEX FLANGE 4 5 6141 080758 NUT HEX FLANGE 2 6 0268 01003400 RACE BALL S...

Page 48: ...3001 BOLT M10 300 1 9 6143 100801 NUT DOME M10 8 1 10 6150 1030305 PLAIN WASHER 4 11 0299 01001501 SHOCK ABSORBER REAR 2 12 6112 080358 BOLT HEX FLANGE 2 13 6111 100407 BOLT HEX FLANGE 2 14 0268 30501...

Page 49: ...100104 MAIN STAND 1 3 6111 081255 BOLT M8 125 1 4 6142 080855 NUT FLANGE M8 1 5 0268 50301 SPRING MAIN STAND 2 6 6266 200103 SIDE STAND 1 7 0268 05002200 LOCK SET 1 8 6112 060146 SCREW HEX FLANGE M6 1...

Page 50: ...W PAN HEAD M5 20 4 3 6255 00001 HORN 1 4 6112 060126 SCREW HEX FLANGE M6 12 1 5 0268 05003000 FLASHER RELAY DOT 1 6 0268 05002300 DC DC CONVERTER DOT 1 7 0268 05000101 MAIN CONTROL CORD DOT 1 8 6256 0...

Page 51: ...0 HANDLE SWITCH LEFT 1 10 0268 05002001 HANDLE SWITCH RIGHT DOT 1 11 0268 40900 MASTER CYLINDER LEFT 1 12 6283 200141 BRAKE HOSE REAR 1 13 0241 41901 SCREW BRAKE HOSE 2 14 0241 41902 WASHER BRAKE HOSE...

Page 52: ...60608 NUT HEX FLANGE 2 4 0268 05003100 HEADLIGHT COMP DOT 1 5 6113 080406 SCREW HEX FLANGE 1 6 6141 080756 NUT HEX FLANGE 1 7 0268 050025A1 CURRENT METER 1 8 0268 05002601 SPEEDOMETER DOT 1 9 0268 010...

Page 53: ...5003300 DIRECTIONAL LAMP REAR L DOT 1 5 0268 05003301 DIRECTIONAL LAMP REAR R DOT 1 6 0268 71104 MOUNTING PLATE TAIL LAMP 1 7 0268 71701 REAR FENDER 1 8 6246 10002 REFLECTOR 1 9 6112 060146 SCREW HEX...

Page 54: ...AT Item NO Part NO Description Qty 1 0268 70101 SEATBOX RIM 1 2 0268 01004900 SEAT HINGE 1 3 6112 060126 SCREW HEX FLANGE 2 4 0268 24000200 SEAT 1 5 0268 01004910 PIN SEAT 1 6 0268 72301 BRACKET SEAT...

Page 55: ...6269 210261 FRONT TRIM CAP RIGHT 1 8 6132 501511 SCREW TAPPING 8 9 6112 060126 SCREW HEX FLANGE 1 10 0268 70701 FRONT COVER 1 11 0268 70702 EMBLEM CAP EVT 1 12 0268 70703 HORN COVER 1 13 0268 71601 F...

Page 56: ...PLE RED 1 2 0268 70601 RIGHT COVER LIGHT BLUE 1 0268 70608 RIGHT COVER LIGHT ORANGE 1 0268 70605 RIGHT COVER DARK GREEN 1 0268 70604 RIGHT COVER PURPLE RED 1 3 6269 200361 OUTER TRIM CAP L COVER 1 4 6...

Page 57: ...LIGHT BROWN 1 2 6112 060126 SCREW HEX FLANGE 4 3 0268 71401 FRONT BODY COVER WHITE 1 0268 13001309 FRONT BODY COVER SILVER 1 4 0268 70102 COVER LOWER 1 5 6127 061511 SCREW HEX FLANGE 2 6 6113 0603561...

Page 58: ...FIG 13 BATTERY Item NO Part NO Description Qty 1 181 460 10 BATTERY LEV 12500 4 2 6261 040621 BATTERY CORD SET LONG 1 6261 050621 BATTERY CORD SET SHORT 3 3 0299 05000400 CONNECTION CABLE BATTERY 1 4...

Page 59: ...FRONT FENDER CHROME 8 0241 80901 FRONT BASKET 9 0241 305211 BRAKE PAD BLUE UNCUT 10 0268 41002 BRAKE CABLE FRONT 1206MM 11 0242 41001 BRAKE CABLE REAR 12 745 956 20 006 EV 500 SOLAR CHARGER 13 875 73...

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