Gocycle G2 Gear Servo Service Document Download Page 3

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Gocycle Service Document: G2 Servo 1.0

VERVIEW

This service document details the service of the G2 Servo. If you have any questions, or
require any further assistance, please contact

[email protected]

ARTS

IST

The following parts are referenced within this document.

Note: When ordering replacement

parts from KKL, please quote the product code and quantity required.

Part Code

Part Description

Quantity

M5 x 24 Magform

2061

Crank Arm Right-Hand

2175

M4 x 24 dowel Pin SS A4

2225

Spring WS Carbon Steel

2283

20mm Crank Arm Bolts

KKL-2081-2632-02 Servo

KKL-2082-2275-00 Servo

Horn

OOL

IST

The following tools are required to successfully service the G2 Servo.

Part Code

Tool Description

Allen Key, 2.5mm

T10

bit

T15

bit

T25 Extension Piece

Philips

screwdriver

Knife
Pliers

Crank-puller (square taper type)

Chain

splitter

Torque wrench (8mm Hex Bit)

Heat

gun

Summary of Contents for G2 Gear Servo

Page 1: ...SERVICE DOCUMENT G2 SERVO VERSION 1 0 Service Document for the G2 Gear Servo...

Page 2: ...ist 1 Best Practice Guidelines 2 Electrical System Best Practice Guidelines 3 1 Right Hand Crank Arm Removal 4 2 Cleandrive Cover Removal 6 3 Chain Removal 8 4 Servo Removal 10 5 Servo Installation 18...

Page 3: ...s from KKL please quote the product code and quantity required Part Code Part Description Quantity 11 M5 x 24 Magform 12 2061 Crank Arm Right Hand 1 2175 M4 x 24 dowel Pin SS A4 8 2225 Spring WS Carbo...

Page 4: ...stalling connecting or disconnecting the battery 4 If maintenance is being performed within 30 minutes of usage components such as the battery motor and gearbox may be hot Treat these components with...

Page 5: ...he battery to strong impacts 7 Do not attempt to disassemble or modify the battery 8 Do not expose the battery to excess water or moisture 9 Ensure battery terminals are connected securely and correct...

Page 6: ...ctober 2014 Karbon Kinetics Limited All Rights Reserved 4 1 RIGHT HAND CRANK ARM REMOVAL 1 1 Invert the G2 and locate in a work stand Remove both PitStopWheels 1 2 Use a wrench with an 8mm Hex bit to...

Page 7: ...n Kinetics Limited All Rights Reserved 5 1 3 Use a square taper crank puller to remove the Right Hand Crank Arm 2061 1 4 Take care when removing the crank arm and ensure to keep all 8 dowel pins 2175...

Page 8: ...6 2 CLEANDRIVE COVER REMOVAL 2 1 Using a T25 Torx Bit unscrew the eleven Magform Bolts 11 as shown 2 2 Rotate the Cleandrive upwards as shown 2 3 Unscrew and remove the remaining Magform Bolt 11 CHEC...

Page 10: ...humb to apply upward pressure on the Chain Tensioner as shown 3 2 Release the Chain from the Chain Tensioner and use the LockShock Pin to secure the Chain Tensioner as demonstrated Note You do not nee...

Page 11: ...Gocycle Service Document G2 Servo 1 0 October 2014 Karbon Kinetics Limited All Rights Reserved 9 3 3 Allow the Chain to hang free and remove the Chainring from the Bottom Bracket Spindle as shown...

Page 12: ...and removed 4 1 Once the Chainring has been removed the Main Junction Board JB will be v as shown 4 2 Remove the Junction Board by undoing the retaining bolts Depending on Gocycle Frame Number there m...

Page 13: ...ved 11 4 3 Remove the Main Junction Board PCB taking care not to touch the components on the board as shown 4 4 Hold the edge of the Main Junction Board PCB as shown and remove the 2 pin white connect...

Page 14: ...Rights Reserved 12 4 6 Allow the chain to rest as shown so that both balance springs are free and accessible 4 7 Remove the Cable Guide Upper by unscrewing the two retaining bolts using a Torx T15 Not...

Page 15: ...moved 4 9 Pull the wires out of the Cable Guide Lower to reveal the heat shrink wrapped section These wires are the Servo Controller Cable with the flat black connector and the Rear Sensor Cable with...

Page 16: ...shrink wrap has been removed there may be excess wiring coiled up underneath 4 12 Unhook the E Shift Balance Spring from its mount on the Cleandrive 4 13 Remove the E Shift Balance Spring from the ser...

Page 17: ...Karbon Kinetics Limited All Rights Reserved 15 4 14 With the E Shift Balance Spring removed the retaining bolt can also be removed 4 15 Use a 2 5mm Allen key and take care to keep the E Shift Spring S...

Page 18: ...Using pliers rotate the E Shift Spring towards you so that the hooked end becomes free of the Servo Horn then pull away from the Servo 4 18 The E Shift Spring can be left hooked at the other end 4 19...

Page 19: ...eserved 17 4 20 Remove the Cable Guide Lower along with the Servo from the Cleandrive by pulling it away 4 21 Remove the Servo from the Cable Guide Lower This is done by pulling the Servo out of the C...

Page 20: ...le Guide Lower then back up through the smaller upper hole Whilst pulling the wire through fit the servo back into its mounting hole 5 2 Front view of the Servo correctly mounted into the Cable Guide...

Page 21: ...e Cleandrive 5 5 Secure the Servo in position with the three M3 x 25 Caphead bolts ensuring the washers are present 5 6 The Chain must now be looped back over the Servo before the Servo springs can be...

Page 22: ...inetics Limited All Rights Reserved 20 5 8 This shows the E Shift Spring correctly installed 5 9 Locate the E Shift Balance Spring Link into the Servo Horn as shown 5 10 Connect the end of the E Shift...

Page 23: ...l the E Shift Balance Spring retaining bolt along with E Shift Spring Spacer using a 2 5mm Allen Key 5 12 Hook the hooped end of the E Shift Balance Spring on to the bolt as shown This shows both E Sh...

Page 24: ...nction Board Fold over any excess cable to achieve this length 5 15 Cover both the Servo Cable and Rear Sensor Cable with the shrink wrap ensuring all of the folded wiring is covered 5 16 Insert the c...

Page 25: ...Insert the Rear Brake Hose and the combination of Servo and Rear Sensor Cable in to the Cable Guide Lower channels and mount the Cable Guide Upper to secure them in place by hand as shown 5 19 Install...

Page 26: ...le Ensure that the brown cable aligns with the negative pin Note On some models the negative cable will be black 6 2 Connect the Rear Sensor Cable and ensure it is fully closed 6 3 Begin to close the...

Page 27: ...rvice Document G2 Servo 1 0 October 2014 Karbon Kinetics Limited All Rights Reserved 25 6 4 Align the Main Junction Board PCB Board flush against the Cleandrive and reinstall the securing screws as de...

Page 28: ...install the Chainring on to the Bottom Bracket Spindle and locate the Chain on to the Chainring as shown 7 2 Apply light upward pressure to the Chain Tensioner in order to remove the Lockshock pin 7 3...

Page 29: ...ins are installed correctly and that the chain runs through them as shown 8 2 Check the Servo Balance Springs are installed correctly as shown Be careful to ensure the Rear Sensor cable will not get t...

Page 30: ...ll Rights Reserved 28 9 CLEANDRIVE COVER INSTALLATION 9 1 Align the Cleandrive cover ready for reassembly 9 2 Take care to line up the brake hose seal correctly as shown 9 3 Install the 11 Magform Bol...

Page 32: ...l as the 8 Dowel Pins 2175 as shown Note Your Gocycle may have 1 3 Carbon Wave Springs 10 2 Hold the Left Hand Crank Arm vertical as shown and have the Right Hand Crank Arm ready to install 10 3 Align...

Page 33: ...UST CARRY OUT THE ABOVE REMOVAL AND REPLACEMENT STEPS IN ORDER FAILING TO DO SO MAY RESULT IN DAMAGE TO THE GOCYCLE If you have any further queries or comments please contact Gocycle Technical Support...

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Gocycle G2 Gear Servo, Service Document

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