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UBCO 2x2 ADV Gen 5, Technical & Service Manual


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UBCO TECHNICAL SERVICE MANUAL 

PAGE 16 OF 159

Minimum Tread Depth (On Road)  . . . . . . . . . . . . .  Refer to local authorities
Recommended Tyre Pressure (On Road). . . . . . . . 207kPa / 30psi / 2.06 bar

Tyre Grip Limit (Mixed) . . . . . . . . . . . . . . . . . . . . . . .  Refer to local authorities
Recommended Tyre Pressure (Mixed) . . . . . . . . . . 207kPa / 30psi / 2.06 bar

Tyre Grip Limit (Off Road) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3mm
Recommended Tyre Pressure (Off Road) . . . . . . . .  172kPa / 25psi / 1.72 bar

2.6 

BRAKES - SYS 2

Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Single Disc Brake
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand Lever
Front Brake Disc Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240mm
Front Brake Disc Standard Thickness  . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7mm
Rear Brake Disc Minimum Thickness  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4mm
Front Brake Disc Runout Limit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5mm
Rear Brake Disc Diameter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240mm
Rear Brake Disc Standard Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7mm
Rear Brake Disc Minimum Thickness  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4mm
Rear Brake Disc Runout Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5mm
Brake Pad Thickness (Friction Material Only)  . . . . . . . . . . . . . . . . . . . . 3.2mm
Brake Pad Thickness Limit (Friction Material Only . . . . . . . . . . . . . . . .0.5mm
Recommended Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  DOT 4

2.7 

BRAKES - SR

Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Single Disc Brake
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand Lever
Front Brake Disc Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200mm
Front Brake Disc Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.0mm
Front Brake Disc Thickness Limit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8mm
Front Brake Disc Runout Limit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5mm
Rear Brake Disc Diameter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200mm
Rear Brake Disc Standard Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.0mm
Rear Brake Disc Minimum Thickness  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8mm
Rear Brake Disc Runout Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5mm

Summary of Contents for 2x2 ADV Gen 5

Page 1: ...Technical Service Manual Version 1 0 Version 1 0 e s o 0 e s o 0 Version 1 0 Version 1 0 October 2023...

Page 2: ...Consumables 11 1 5 Bike Orientation 13 2 Model Specifications 2 1 Model Naming 15 2 2 Dimensions 15 2 3 Mass 15 2 4 Front and Rear Wheel 15 2 5 Tyres 15 2 6 Brakes Sys 2 16 2 7 Brakes SR 16 2 8 Front...

Page 3: ...7 4 6 SR Bleeding Replacing Brake Fluid 28 4 7 SR Adjusting Brake Calipers 31 4 8 SR Inspecting Front or Rear Brake Pads 33 4 9 SR Inspecting Brake Discs 34 4 10 SR Adjusting Lever Blades 35 4 11 Adju...

Page 4: ...t or Rear Brake Caliper 71 SR Front or Rear Brake Master Cylinder 73 SR Front Brake Line 75 SR Rear Brake Line 77 SR Front Brake Set 79 SR Rear Brake Set 81 5 3 Steering and Suspension 83 Front Fork 8...

Page 5: ...trols 122 KxH Battery 123 Battery Plug Harness 125 On Road Harness 126 Main Harness 128 Left Hand Switch Block 130 Throttle Kill Switch 132 Headlamp 134 Dash 136 Front Indicators 138 Rear Indicators 1...

Page 6: ...UBCO TECHNICAL SERVICE MANUAL PAGE 6 OF 159 1 GENERAL INFORMATION...

Page 7: ...y not be suitable for all devices equipment or situations Always refer to UBCO documentation or guidelines for device specific repair instructions and specifications where available 4 SAFETY PRECAUTIO...

Page 8: ...using this technical repair manual you agree to abide by these terms and con ditions If you do not agree to these terms do not continue to use this manual Your use of this manual constitutes your acce...

Page 9: ...available with different braking systems These are referred to as SR or SYS 2 Where there are variations in processes due to these different brake systems clear instructions for each system are provi...

Page 10: ...UBCO TECHNICAL SERVICE MANUAL PAGE 10 OF 159 SYSTEM 2...

Page 11: ...d for carrying out the processes defined within this manual ALLEN KEYS 2mm 2 5mm 3mm 4mm 5mm 6mm 7mm 8mm ALLEN KEY SOCKETS 2 5mm 3mm 4mm 5mm 6mm 7mm 8mm TORX KEYS T20 T25 T30 TORX SOCKETS T20 T25 T30...

Page 12: ...Bar Socket Driver Hammer Punch Rubber Hammer Heat Gun Brake Pad Spacer Note Impact drivers should not be used at any point within the assembly or dis assembly of components on the UBCO bike The follo...

Page 13: ...1 5 BIKE ORIENTATION Throughout this manual the bike orientation is to referred to from the rider posi tion For example the right hand side refers to the right hand side of the vehicle when you are s...

Page 14: ...UBCO TECHNICAL SERVICE MANUAL PAGE 14 OF 159 2 MODEL SPECIFICATIONS...

Page 15: ...s 2 1kWh Battery 66kg Vehicle Mass 3 1kWh Battery 71kg Battery Mass 2 1kWh Battery 13kg Battery Mass 3 1kWh Battery 18kg Maximum Payload including Rider 150kg 2 4 FRONT AND REAR WHEEL Rim Material Alu...

Page 16: ...ke Disc Minimum Thickness 2 4mm Front Brake Disc Runout Limit 0 5mm Rear Brake Disc Diameter 240mm Rear Brake Disc Standard Thickness 2 7mm Rear Brake Disc Minimum Thickness 2 4mm Rear Brake Disc Runo...

Page 17: ...5mm Recommended Fluid DOT 4 2 8 FRONT SUSPENSION Type Telescopic Fork Spring Shock Absorber Type Coil Spring Gas Damper Fork Travel 130mm 2 9 REAR SUSPENSION Type Swingarm Linkage Number 2 Spring Shoc...

Page 18: ...UBCO TECHNICAL SERVICE MANUAL PAGE 18 OF 159 3 SERVICE INFORMATION WAITING FOR UBCO...

Page 19: ...facturers specifications for the application of threadlocker If these are unavailable follow the below process 1 Prepare the threads using an appropriate aqueous or solvent based cleaner Wipe the thre...

Page 20: ...BRAKE COMPONENT HANDLING When handling brake pads and discs ensure that the active surfaces of the com ponents do not come in contact with contaminants Do not allow the brake pad surface or portion o...

Page 21: ...UBCO TECHNICAL SERVICE MANUAL PAGE 21 OF 159 4 SERVICE CHECKS ADJUSTMENTS AND PROCESSES...

Page 22: ...1 SYS 2 CHECKING BRAKE FLUID LEVEL NUMBERED ITEMS 1 Master Cylinder Top Surface PROCESS STEPS 1 Ensure the Master Cylinder Top Surface is parallel to the ground 2 Looking horizontally at the level ind...

Page 23: ...RVICE MANUAL PAGE 23 OF 159 4 2 SYS 2 BLEEDING REPLACING BRAKE FLUID Follow the below processes to bleed the brakes If replacing the brake fluid carry out the optional processes clearly highlighted 1...

Page 24: ...build pressure 6 Using a 8mm Spanner gently release then tighten the Caliper Bleed Port Fas tener Some fluid should be able to escape but all pressure shouldn t be lost 7 Check to ensure Brake Reserv...

Page 25: ...PROCESS STEPS 1 Remove the Brake Pads using the method outlined on Page 53 2 Inspect for signs of wear and damage If present replace the Brake Pads using the method outlined on Page 53 3 Using a Micro...

Page 26: ...to ensure the Brake Disc is running true 3 If un true using a Dial Gauge measure the runout of the Brake Disc 4 If the runout of the Brake Disc is above the limit outlined on Page 16 discard the Brak...

Page 27: ...SR CHECKING BRAKE FLUID LEVEL NUMBERED ITEMS 1 Master Cylinder Top Surface PROCESS STEPS 1 Ensure the Master Cylinder top surface is parallel to the ground 2 Looking horizontally at the level indicat...

Page 28: ...SERVICE MANUAL PAGE 28 OF 159 4 6 SR BLEEDING REPLACING BRAKE FLUID Follow the below processes to bleed the brakes If replacing the brake fluid carry out the optional processes clearly highlighted 2...

Page 29: ...imes to stabilise Piston position 5 Ensure the Caliper is the lowest part of the system and the Master Cylinder is the highest part of the system Ensure that no kinks exist in the system where bubbles...

Page 30: ...Brake Lever Blade 10 times or until air bubbles stop being released into the Bleed Kit Funnel 20 Repeat Steps 6 7 8 10 11 14 and 15 21 Actuate the Brake Lever Blade until resistance is firm If this do...

Page 31: ...e 34 2 If there is a large quantity of lateral movement of the Brake Disc while turning the Wheel it may not be possible to adjust the Brake Caliper and the Brake Disc may need replacement 3 Using a 5...

Page 32: ...If the Brake Pad is rubbing after adjustment individually loosen the top and bottom fasteners and gently adjust the position of the Caliper until no rub bing occurs 7 Using a 5mm Allen Key Socket and...

Page 33: ...meter PROCESS STEPS 1 Remove the Brake Pads using the method outlined on Page 68 2 Inspect for signs of wear and damage If present replace the Brake Pads using the method outlined on Page 68 3 Using a...

Page 34: ...ly through the Caliper space check to ensure the Brake Disc is running true 3 If un true using a Dial Gauge measure the runout of the Brake Disc 4 If the runout of the Brake Disc is above the limit ou...

Page 35: ...2mm Allen Key PROCESS STEPS 1 Using a 2mm Allen Key rotate the Adjustment Grub Screw anti clockwise to bring the Lever Blade closer to the Grip Throttle or clockwise to move the Lever Blade further aw...

Page 36: ...ITEMS 1 Rebound Adjustment Dial 2 Preload Adjustment Dial REBOUND ADJUSTMENT 1 Rebound speed is adjusted on the right hand side of the fork crown 2 Twist the dial clockwise to slow the rebound and ant...

Page 37: ...d on Page 43 NUMBERED ITEMS 1 Rebound Adjustment Dial 2 Preload Adjustment Disc 3 Adjustment Thread REBOUND ADJUSTMENT 1 Rebound is adjusted using the dial at the top of the suspension unit 2 Turning...

Page 38: ...159 2 Twist the disc anti clockwise to lessen the spring force and make the suspen sion softer and clockwise to increase the spring force and make the suspen sion stiffer 3 The preload setting should...

Page 39: ...load rider load TABLE 2 RECOMMENDED SUSPENSION SETTINGS RIDE TYPE VEHICLE LOAD FRONT REBOUND FRONT PRELOAD REAR REBOUND REAR PRELOAD On Road 90kg Max Fast Full Soft Max Fast 20mm Thread On Road 125kg...

Page 40: ...pth Gauge measure the Tyre tread If it is below either the local legal limit for On Road registered vehicles or the limit outlined on Page 15 replace the Tyre 3 Using a Tyre Pressure Gauge measure the...

Page 41: ...repair 2 Visually check the Spokes if any are damaged replace If any are loose follow the below process for adjusting Spokes 3 Using a Dial Gauge measure the Wheel trueness If it is greater than the...

Page 42: ...eel Rim and the Spoke s responsi ble for the highest deflection 2 In that region using a Spoke Wrench and small adjustments tighten the Spoke s to pull the wheel into true It is preferable to tighten...

Page 43: ...UBCO TECHNICAL SERVICE MANUAL PAGE 43 OF 159 4 16 ADJUSTING HEADLAMP BEAM 1 2 2 1 Wall Mark Beam Position 0 875m...

Page 44: ...ll on level ground 2 On the wall mark a point 0 875m from the floor 3 Chock the Wheel so the Headlamp is pointing directly at the wall and turn on the Headlamp Low Beam 4 Using a 3mm Allen Key loosen...

Page 45: ...EPS 1 The Battery can be charged while either installed or uninstalled in the bike 2 Remove the Charge Port Cover and plug in the Charger ensuring the connec tor is rotated and clicks 3 To remove the...

Page 46: ...UBCO TECHNICAL SERVICE MANUAL PAGE 46 OF 159 5 REMOVAL AND REPLACEMENT OPERA TIONS...

Page 47: ...UBCO TECHNICAL SERVICE MANUAL PAGE 47 OF 159 5 1 WHEELS...

Page 48: ...ench Breaker Bar Brake Pad Spacer PRE REQUISITE STEPS Battery Removal Page 123 REMOVAL 1 Disconnect the Front Motor using the Double Twist Connector 2 Using a 21mm Socket and Breaker Bar release and r...

Page 49: ...Brake Pad Spacer 2 Place the 2 Fork Spacers on to the Axle 3 Lift the Front Wheel into place and install both Torque Arms on the Axle and Fork 4 Using a 21mm Socket Loctite 243 and Torque Wrench tigh...

Page 50: ...MABLES REQUIRED Loctite 243 21mm Socket Torque Wrench Breaker Bar Brake Pad Spacer PRE REQUISITE STEPS Battery Removal Page 123 REMOVAL 1 Disconnect the Front Motor using the Double Twist Connector 2...

Page 51: ...installed remove the Brake Pad Spacer 2 Lift the Front Wheel into place and install both Torque Arms on the Axle and Fork 3 Using a 21mm Socket Loctite 243 and Torque Wrench tighten the 2 Axle Nuts 4...

Page 52: ...UBCO TECHNICAL SERVICE MANUAL PAGE 52 OF 159 5 2 BRAKES WAITING FOR UBCO...

Page 53: ...50 REMOVE 1 Using a suitable tool gently return the old Brake Pads and Pistons to full retraction and adjust the Brake Lever Blades to the original position 2 Using a 3mm Allen Key release and remove...

Page 54: ...2 Check the Brake Pad Spring for signs of wear and replace if required 3 Place replacement Brake Pads into the Brake Pad Spring then into the Caliper 4 Using a 3mm Allen Key tighten the fastener and...

Page 55: ...ue Wrench T25 Torx Key Loctite 273 PRE REQUISITE STEPS Wheel Removal Page 48 or Page 50 REMOVAL 1 Using a T25 Torx Key release and remove the 6 fasteners attaching the Brake Disc to the Motor REPLACE...

Page 56: ...m if required 6 Swing Arm Assembly 7 Caliper Spacer 8 Caliper Fastener TOOLS CONSUMABLES REQUIRED T30 Torx Key T30 Torx Socket Torque Wrench Isopropyl Alcohol Lint Free Cloth Loctite 243 PRE REQUISITE...

Page 57: ...REPLACE 1 Using a T30 Torx Socket and Torque Wrench tighten the Banjo Fastener 2 Using a T30 Torx Socket Torque Wrench and Loctite 243 tighten the Caliper Fasteners 3 Replace and bleed the Brake Fluid...

Page 58: ...Brake Switch Fastener 8 Brake Switch Body 9 Brake Switch Connector TOOLS CONSUMABLES REQUIRED 5mm Allen key 5mm Allen Key Socket T30 Torx Key T30 Torx Socket Torque Wrench 1 Philips Screwdriver Isopr...

Page 59: ...CE 1 Using a 5mm Allen Key Socket and Torque Wrench tighten the Handlebar Clamp Fasteners 2 Using a 1 Philips Screwdriver release and remove the Brake Switch Fastener 3 Connect the Brake Switch Connec...

Page 60: ...Clip Fastener 7 Front Brake Line 8 Caliper Assembly TOOLS CONSUMABLES REQUIRED 2 5mm Allen Key 2 5mm Allen Key Socket T30 Torx Key T30 Torx Socket Torque wrench Isopropyl Alcohol Lint Free Cloth Flush...

Page 61: ...ake line through the Front Console U Bolt 3 Using a T30 Torx Socket and Torque Wrench tighten the Brake Line Banjo Bolts 4 Replace the Brake Fluid using the method outlined on Page 23 5 Using Cable Ti...

Page 62: ...ssembly 6 Tube Clamp Fastener 7 Tube Clamp Washer 8 Tube Clamp 9 Rear Brake Line TOOLS CONSUMABLES REQUIRED 5mm Allen Key 5mm Allen Key Socket Torque wrench 8mm Spanner 8mm Crows Foot Socket Isopropyl...

Page 63: ...replace if required 2 Thread the brake line through the Front Console and Rear Console replacing the Ducting 3 Using a T30 Torx Socket and Torque Wrench tighten the Brake Line Banjo Bolts 4 Replace th...

Page 64: ...stener 6 Caliper Assembly 7 U Bolt Nut 8 U Bolt TOOLS CONSUMABLES REQUIRED T30 Torx Key T30 Torx Bit 10mm Socket Socket Driver Flush Cutters Cable Ties PRE REQUISITE STEPS Battery Removal Page 123 Fro...

Page 65: ...nt Brake Set through the Frame REPLACE 1 Thread the Front Brake Set through the Frame 2 Using a T30 Torx Socket and Torque Wrench tighten the Master Cylinder Fas teners 3 Using a 10mm Socket and Torqu...

Page 66: ...tener TOOLS CONSUMABLES REQUIRED T30 Torx Key T30 Torx Bit 10mm Socket Socket Driver Flush Cutters Cable Ties PRE REQUISITE STEPS Battery Removal Page 123 Front Console Removal Page 102 Page 104 Rear...

Page 67: ...nt Brake Set through the Frame REPLACE 1 Thread the Front Brake Set through the Frame 2 Using a T30 Torx Socket and Torque Wrench tighten the Master Cylinder Fas teners 3 Using a 10mm Socket and Torqu...

Page 68: ...release and remove the fastener and circlip retaining the Brake Pads 2 Remove the Brake Pads while retaining the Brake Pad Spring 3 Using a suitable tool gently return the Pistons to full retraction a...

Page 69: ...ICE MANUAL PAGE 69 OF 159 3 Place replacement Brake Pads into the Brake Pad Spring then into the Caliper 4 Using a 3mm Allen Key Socket and Torque Wrench tighten the fastener and fit the circlip retai...

Page 70: ...ITE STEPS Wheel Removal Page 48 or Page 50 REMOVAL 1 Using a T25 Torx Key release and remove the 6 fasteners attaching the Brake Disc to the Motor NOTE Variations with different specific components st...

Page 71: ...Caliper 3 Washer 4 Brake Caliper Fastener TOOLS CONSUMABLES REQUIRED 5mm Allen key 5mm Allen Key Socket Torque Wrench 8mm Spanner 8mm Crows Foot Socket Isopropyl Alcohol Lint Free Cloth Loctite 243 P...

Page 72: ...the Hose Connect Screw 2 Replace the Brake Pad in the Caliper using the method outlined on Page 53 3 Using a 5mm Allen Key Socket Torque Wrench and Loctite 243 tighten the 2 fasteners attaching the C...

Page 73: ...dlebar Clamp Fastener TOOLS CONSUMABLES REQUIRED 3mm Allen key 3mm Allen Key Socket Torque Wrench 7mm Spanner 8mm Spanner 8mm Crows Foot Socket Isopropyl Alcohol Lint Free Cloth PRE REQUISITE STEPS Br...

Page 74: ...n Key Socket and Torque Wrench tighten the 2 fasteners holding the Master Cylinder Assembly to the Handlebar 3 Replace the Brake Fluid using the method outlined on Page 28 4 Bleed the Brakes using the...

Page 75: ...Torque wrench 8mm Spanner 8mm Crows Foot Socket Isopropyl Alcohol Lint Free Cloth Flush Cutters Cable Ties PRE REQUISITE STEPS Brake Fluid Removal Page 28 REMOVE 1 Using Flush Cutters remove the Cabl...

Page 76: ...d Torque Wrench tighten the Hose Connect Screws 3 Replace the Brake Fluid using the method outlined on Page 28 4 Bleed the Brake using the method outlined on Page 28 5 Using Cable Ties retain the Brak...

Page 77: ...OOLS CONSUMABLES REQUIRED Torque wrench 8mm Spanner 8mm Crows Foot Socket Isopropyl Alcohol Lint Free Cloth Flush Cutters Cable Ties PRE REQUISITE STEPS Battery Removal Page 123 Rear Console Cover Pag...

Page 78: ...LACE 1 Thread the Brake Line through the Frame Ducting and Rear Console 2 Using a 8mm Crow Foot Socket and Torque Wrench tighten the Hose Connect Screws 3 Using Cable Ties retain the Brake Line to the...

Page 79: ...mp Fastener 6 Handlebar Clamp 7 Fork Clip 8 Fork Clip Fastener 9 Front Brake Line 10 Caliper Assembly 11 Washer 12 Caliper Fastener TOOLS CONSUMABLES REQUIRED 5mm Allen Key 5mm Allen Key Socket 4mm Al...

Page 80: ...Cylinder Assembly through the Frame REPLACE 1 Thread the Master Cylinder Assembly through the Frame 2 Using a 4mm Allen Key Socket and Torque Wrench tighten the 2 fasteners holding the Master Cylinde...

Page 81: ...Caliper Fastener 5 Washer 6 Caliper Assembly TOOLS CONSUMABLES REQUIRED 5mm Allen Key 5mm Allen Key Socket 4mm Allen key 4mm Allen Key Socket Torque Wrench 7mm Spanner Flush Cutters Cable Ties Loctite...

Page 82: ...Set REPLACE 1 Thread the Master Cylinder Assembly through the Frame 2 Using a 4mm Allen Key Socket and Torque Wrench tighten the 2 fasteners holding the Master Cylinder Assembly to the Handlebar 3 Us...

Page 83: ...UBCO TECHNICAL SERVICE MANUAL PAGE 83 OF 159 5 3 STEERING AND SUSPENSION WAITING FOR UBCO...

Page 84: ...ly 6 Headset Fastener 7 Headset Cap 8 Steerer Lock 9 Star Nut 10 Fork Locking Pin 11 Upper Headset Crown Race 12 Lower Headset Bearing Cup 13 Lower Headset Bearing 14 Lower Headset Bearing Race TOOLS...

Page 85: ...in from the Fork 5 Remove the Upper and Lower Headset Crown Races and inspect both Upper and Lower Bearings for signs of damage or wear REPLACE 1 Seat the Lower Headset Bearing Cup into the Headtube 2...

Page 86: ...6 Rubber Stoppers 7 Fork Boot Retaining Clips 8 Fork Boot 9 Lower Fork 10 Lower Fork Fasteners TOOLS CONSUMABLES REQUIRED Flush Cutters 5mm Allen Key 5mm Allen Key Socket Torque Wrench 36mm Spanner F...

Page 87: ...ing Adjustment Dial and Damper Adjustment Dial REPLACE 1 Assemble the Spring Rod through the Left Hand Stanchion onto the Rubber Stoppers 2 Using an 36mm Spanner tighten the Spring Adjustment Dial and...

Page 88: ...Clamp Upper 5 Stem Fastener 6 Stem Clamp Lower 7 Headlight Clamp Assembly 8 Handlebar 9 Headlight Clamp Lower 10 Headlight Clamp Fastener TOOLS CONSUMABLES REQUIRED 5mm Allen Key 5mm Allen Key Socket...

Page 89: ...release and remove the Headset Cap Fastener and 2 Stem Fasteners REPLACE 1 Using a 5mm Allen Key Socket and Torque Wrench tighten the 2 Stem Fasten ers 2 Using a 5mm Allen Key Socket and Torque Wrenc...

Page 90: ...cket Torque Wrench Loctite 243 PRE REQUISITE STEPS 1 Rear Wheel Removal Page 50 REMOVE 1 Using 2 x 5mm Allen Keys remove the 4 Barrel Nuts attaching the Rear Shock Absorbers to the Swing Arm and Bike...

Page 91: ...Bearing 4 Swing Arm Bearing Spacer 5 Barrel Nut 6 Swing Arm Fastener 7 Barrel Nut Fastener 8 Swing Arm TOOLS CONSUMABLES REQUIRED 2 x 5mm Allen Key 5mm Allen Key Socket 8mm Allen Key 8mm Allen Key Soc...

Page 92: ...sing 2 x 5mm Allen Keys remove the 2 Barrel Nuts attaching the Rear Shock Absorbers to the Swing Arm 3 Using a 8mm Allen Key and 17mm Socket with Breaker bar remove the Swing Arm fastener REPLACE 1 Us...

Page 93: ...RED 5mm Allen Key 5mm Allen Key Socket T25 Torx Key T25 Torx Socket Torque Wrench PRE REQUISITE STEPS Dash Removal Page 136 REMOVE 1 Using a 5mm Allen Key release and remove the Headset Cap fastener a...

Page 94: ...Cap 2 Clean and inspect the Bearing Top Cap Seal and O Ring and replace if dam aged or signs of wear are present 3 Assemble the Headset Bearing Top Cap Stem and Headset Cap onto the Steerer Tub 4 Usi...

Page 95: ...Fastener 7 Headlight Clamp 8 Stem Clamp 9 Stem Fastener 10 Headlight Assembly TOOLS CONSUMABLES REQUIRED 5mm Allen Key 5mm Allen Key Socket 4mm Allen Key 4mm Allen Key Socket 3mm Allen Key 3mm Allen...

Page 96: ...e 4 Stem Fasteners from the Handlebar REPLACE 1 Using a 5mm Allen Key Socket and Torque Wrench tighten the 4 Stem Fas teners 2 Insert the Spreader Spacers into the Handlebar 3 Attach the Throttle Body...

Page 97: ...astener TOOLS CONSUMABLES REQUIRED 5mm Allen Key 5mm Allen Key Socket 3mm Allen Key M8 Spring Washer Torque Wrench REMOVE 1 Using a 5mm Allen Key release and remove the Handlebar End Cap and Bar Clamp...

Page 98: ...ition then tighten the Handlebar End Cap fas tener 5 Using a 5mm Allen Key Socket and Torque Wrench first tighten the fastener attaching the Lever Guard to the Bar Clamp then the Bar Clamp to the Han...

Page 99: ...UBCO TECHNICAL SERVICE MANUAL PAGE 99 OF 159 5 4 BODY WAITING FOR UBCO...

Page 100: ...Key 10mm Spanner REMOVE 1 Using a 4mm Allen Key and 10mm Spanner release and remove the 2 nuts fasteners attaching the Front Carrier to the Steerer Tube Flange 2 Using a 5mm Allen Key release and rem...

Page 101: ...UBCO TECHNICAL SERVICE MANUAL PAGE 101 OF 159 2 Using a 5mm Allen Key tighten the 2 nuts fasteners attaching the Front Car rier to the Frame Down Tube...

Page 102: ...5 Torx Key remove the 6 fasteners attaching the Front Console Cover to the Front Console Rear Panel 2 Lifting and rotating the upper portion of the Front Console Front Cover towards the rear of the Bi...

Page 103: ...ching the Front Con sole Cover to the Front Console Rear Panel 4 To align the Front Console Cover install the Battery within the Bike using the method outlined on Page 123 5 Using a T25 Torx Socket an...

Page 104: ...Torx Socket Torque Wrench PRE REQUISITE STEPS Battery Removal Page 123 Front Console Cover Removal Page 102 Motor Controllers Removal Page 147 Main Harness Removal Page 128 Battery Plug Harness Remova...

Page 105: ...CE 1 Ensure all cables and brake line are correctly aligned within the console and will not become pinched when replacing the cover 2 Using a T25 Torx Socket and Torque Wrench tighten the 4 fasteners...

Page 106: ...Plate 6 Washer 7 Battery Lock Fastener TOOLS CONSUMABLES REQUIRED T25 Torx Key T25 Torx Socket Torque Wrench PRE REQUISITES Battery Removal Page 123 REMOVE 1 Using a T25 Torx Key remove the 8 fastene...

Page 107: ...ghten the two fasteners attaching the Battery Lock to the Front Panel 3 Using a T25 Torx Key lightly tighten the 8 fasteners attaching the Rear Con sole Cover to the Rear Panel and Frame 4 To align th...

Page 108: ...p Washer 6 Rear Console Rear Panel TOOLS CONSUMABLES REQUIRED 5mm Allen Key 5mm Allen Key Socket T25 Torx Key T25 Torx Socket Torque Wrench PRE REQUISITES Battery Removal Page 123 Rear Console Cover P...

Page 109: ...e REPLACE 1 Ensure all cables are correctly aligned and will not become pinched when replacing the Rear Panel 2 Using a T25 Torx Socket and Torque Wrench tighten the 2 fasteners retaining the Rear Con...

Page 110: ...EQUIRED 4mm Allen Key 4mm Allen Key Socket Torque Wrench 10mm Spanner REMOVE Using a 4mm Allen Key and 10mm Spanner release and remove the 2 fasteners attaching the Seat to the Frame REPLACE Using a 4...

Page 111: ...r TOOLS CONSUMABLES REQUIRED T25 Torx Key T25 Torx Socket 4mm Allen Key 4mm Allen Key Socket Torque Wrench 8mm Spanner PRE REQUISITES Front Wheel Removal Page 48 REMOVE 1 Using a 4mm Allen Key and 8mm...

Page 112: ...9 REPLACE 1 Using a T25 Torx Socket and Torque Wrench tighten the 2 fasteners attaching the Mudguard Stay to the Fork 2 Using a 4mm Allen Key Socket Torque Wrench and 8mm Spanner tighten the 2 fastene...

Page 113: ...ap Retention Plate TOOLS CONSUMABLES REQUIRED T25 Torx Key T25 Torx Socket Torque Wrench REMOVE 1 Using a T20 Torx Key remove the 2 fasteners attaching the Swing Arm Mud Flap to the Bike REPLACE 1 Usi...

Page 114: ...LES REQUIRED T25 Torx Key T25 Torx Socket Torque Wrench 4mm Allen Key 4mm Allen Key Socket Flush Cutters Cable Ties PRE REQUISITES Rear Wheel Removal Page 50 Swing Arm Mud Flap Removal Page 113 Tailig...

Page 115: ...PLACE 1 Using a T25 Torx Socket and Torque Wrench tighten the 8 fasteners attaching the Mudguard to the Bike 2 Connect the Tail Light to the Rear Light Harness 3 Using a 1 Philips Head Screwdriver tig...

Page 116: ...Socket 13mm Spanner Torque Wrench Loctite 243 PRE REQUISITE STEPS Battery Removal Page 123 Rear Console Cover Removal Page 106 REMOVE 1 If installed unplug the Kickstand Switch connector from the On R...

Page 117: ...GE 117 OF 159 REPLACE 1 Using a 5mm Allen Key Socket Torque Wrench 13mm Spanner and Loctite 243 tighten the 2 fasteners attaching the Kickstand to the Bike 2 If installed plug the Kickstand Switch con...

Page 118: ...Key Socket 13mm Spanner Torque Wrench Loctite 243 PRE REQUISITES Battery Removal Page 123 REMOVE 1 Using a 6mm Allen Key and 13mm Spanner remove the 2 fasteners attaching the Footpeg to the Bike REPL...

Page 119: ...PRE REQUISITES Battery Removal Page 123 REMOVE 1 If installed remove the Battery from the Bike using the method outlined on Page 123 2 Using a 10mm Spanner remove the nuts from the Reflectors REPLACE...

Page 120: ...Mirror Boot Nut 3 Master Cylinder Assembly TOOLS CONSUMABLES REQUIRED 14mm Spanner REMOVE 1 Using a 14mm Spanner release the Rear View Mirror Nut and remove the Mir ror REPLACE 1 Thread the Mirror As...

Page 121: ...anner Torque Wrench REMOVE 1 Using a 14mm Spanner release the Rear View Mirror Fastening Nut and remove the Mirror 2 Using a 4mm Allen Key release and remove the 2 fasteners attaching the Mir ror Clam...

Page 122: ...UBCO TECHNICAL SERVICE MANUAL PAGE 122 OF 159 5 5 ELECTRONICS AND CONTROLS WAITING FOR UBCO...

Page 123: ...g the Charger 2 Ensure the Charge Port Cover is securely installed in the Charge Port 3 If the Battery Harness is plugged in to the Battery unplug the Battery Har ness 4 If the Bike has a Battery Lock...

Page 124: ...4 OF 159 3 Ensure the Charge Port Cover is securely installed in the Charge Port 4 Install and secure the Battery by applying tension using the Battery Retention Strap 5 Connect the Battery Harness in...

Page 125: ...e Wrench PRE REQUISITES Battery Removal Page 123 Front Console Cover Page 102 REMOVE 1 Disconnect the VMS and Motor Controllers from the Battery Plug Harness 2 Using a T20 Torx Key remove the 2 fasten...

Page 126: ...QUISITES Battery Removal Page 123 Front Console Cover Page 102 Rear Console Cover Page 106 Dash Removal Page 136 REMOVE 1 Using Flush Cutters remove any Cable Ties retaining the On Road Harness 2 Remo...

Page 127: ...nnect the Dash to the On Road Harness 2 Connect the Kickstand Kill Switch to the On Road Harness 3 Connect the Front Indicators to the On Road Harness 4 Install the Cable Duct onto the Bike 5 Using Ca...

Page 128: ...tor Controller Connector TOOLS CONSUMABLES REQUIRED T25 Torx Key T25 Torx Socket Torque Wrench Flush Cutters Cable Ties PRE REQUISITES Battery Removal Page 123 Front Console Cover Removal Page 102 Rea...

Page 129: ...the RH Cable Bundle REPLACE 1 Connect the On Road Harness to the VMS Dash Front Indicators and Kick stand 2 Using a T25 Torx Key tighten the fastener retaining the P Clip on the back side of the Head...

Page 130: ...Left Hand Switch Block 6 Grip 7 Handlebar End Cap 8 Bar Clamp Fastener TOOLS CONSUMABLES REQUIRED 5mm Allen Key 5mm Allen Key Socket 3mm Allen Key 3mm Allen Key Socket Torque Wrench Flush Cutters Cab...

Page 131: ...dlebar 5 Using a 3mm Allen Key loosen the Switch Block Clamp Fastener and remove the Left Hand Switch Block REPLACE 1 Connect the Left Hand Switch Block to the Main Harness 2 Place the Left Hand Switc...

Page 132: ...ONSUMABLES REQUIRED 3mm Allen Key 3mm Allen Key Socket 5mm Allen Key 5mm Allen Key Socket Flush Cutters Cable Ties Torque Wrench PRE REQUISITES Battery Removal Page 123 Front Console Cover Removal Pag...

Page 133: ...Torque Wrench tighten the fastener attaching the Bar End Cap to the Handlebar 2 Using a 3mm Allen Key Socket and Torque Wrench tighten the Throttle Grub Screw 3 Test to make sure the Throttle can tur...

Page 134: ...y 7 Headlamp TOOLS CONSUMABLES REQUIRED 3mm Allen Key 3mm Allen Key Socket 4mm Allen Key 4mm Allen Key Socket Torque Wrench Flush Cutters Cable Ties PRE REQUISITES Battery Removal Page 123 Front Conso...

Page 135: ...adlight to the Headlight Clamp ensuring the Headlight Cable is threaded through the Headlight Clamp P Clip 2 Using a 4mm Allen Socket and Torque Wrench tighten the 4 fasteners attach ing the Headlight...

Page 136: ...10mm Spanner REMOVE 1 Using a T20 Torx Key remove the 4 fasteners attaching the Dash Mount Plate to the Dash Cover 2 Using a T20 Torx Key remove the 4 fasteners attaching the Dash Cover to the Bike 3...

Page 137: ...the 3 nuts attaching the Dash to the Dash Mount Plate 3 Using a T20 Torx Socket and Torque Wrench tighten the 4 fasteners attaching the Dash Mount Plate to the Dash Cover 4 Using a T20 Torx Socket an...

Page 138: ...dicator 9 Left Indicator TOOLS CONSUMABLES REQUIRED T20 Torx Key T20 Torx Socket Torque Wrench 17mm Spanner REMOVE 1 Using a T20 Torx Key remove the 4 fasteners attaching the Dash Cover to the Bike 2...

Page 139: ...Indicators to the On Road Harness and test that the Indicators are on the correct side of the Bike 2 Using a 17mm Spanner tighten the 2 nuts holding the Indicators 3 Using a T20 Torx Socket and Torque...

Page 140: ...OVE 1 Disconnect Rear Indicators from the Rear Light Harness 2 Using Flush Cutters remove any Cable Ties retaining the Rear Indicator Cables to the Bike 3 Using a 17mm Spanner release and remove the 2...

Page 141: ...UBCO TECHNICAL SERVICE MANUAL PAGE 141 OF 159 3 Using Cable Ties retain the Rear Indicator Cables to the Bike...

Page 142: ...unt Plate TOOLS CONSUMABLES REQUIRED 1 Philips Screwdriver REMOVE 1 Disconnect the Rear Tailight connector 2 Using a 1 Philips Screwdriver remove the 2 fasteners from the Rear Tailight REPLACE 1 Conne...

Page 143: ...25mm Torx Socket Flush Cutters Torque Wrench PRE REQUISITES Battery Removal Page 123 Front Console Cover Removal Page 102 REMOVE 1 Disconnect the Horn from the Main Vehicle Harness by unplugging the t...

Page 144: ...E 144 OF 159 REPLACE 1 Using a T25 Torx Socket and Torque Wrench tighten the 2 fasteners attaching the Horn to the Front Console Rear Panel 2 Connect the Horn to the Main Vehicle Harness replicating t...

Page 145: ...s Connector TOOLS CONSUMABLES REQUIRED T25 Torx Key T25 Torx Socket Torque Wrench PRE REQUISITES Battery Removal Page 123 Front Console Cover Removal Page 102 REMOVE 1 Disconnect the VMS from the On R...

Page 146: ...tighten the 4 fasteners attaching the VMS to the Front Console Rear Panel 2 Connect the VMS to the On Road Main Battery Plug Harnesses and if installed the TCU Harness 3 Using the UBCO App confirm VMS...

Page 147: ...OOLS CONSUMABLES REQUIRED T25 Torx Key T25 Torx Socket Torque Wrench PRE REQUISITES Battery Removal Page 123 Front Console Cover Removal Page 102 REMOVE 1 Disconnect the Motor Controller from the Moto...

Page 148: ...a T25 Torx Socket and Torque Wrench tighten the 2 fasteners attaching the Motor Controller to the Front Console Rear Panel 2 Connect the Motor Controller to the Motor Cable Main Vehicle Battery Plug...

Page 149: ...6 Motor Data Connector 7 Motor Controller 8 Motor Power Plug 9 Cable Clamp 10 Fastener TOOLS CONSUMABLES REQUIRED 5mm Allen Key 5mm Allen Key Socket 4mm Allen Key 4mm Allen Key Socket 10mm Spanner T2...

Page 150: ...Cable Bundle REPLACE 1 Thread the Motor Cable into place through the Front Console Rear Cover 2 Using a 4mm Allen Key Socket and Torque Wrench tighten the 2 fasteners attaching the Cable Clamp to the...

Page 151: ...en Key 5mm Allen Key Socket Torque Wrench Cable Ties Flush Cutters PRE REQUISITES Battery Removal Page 123 Rear Console Cover Removal Page 106 REMOVE 1 If installed remove the Cable Duct Lid from the...

Page 152: ...P Clip 3 Using a Cable Ties lightly attach the Motor Cable to the Swing Arm 4 Connect the Motor Cable to the Motor Controller and Rear Motor 5 Pull the slack in the cable through into the Rear Consol...

Page 153: ...UBCO TECHNICAL SERVICE MANUAL PAGE 153 OF 159 5 6 POWERTRAIN WAITING FOR UBCO...

Page 154: ...Large Motor Bearing 8 Motor Side Cover 9 Large Motor Seal 10 Motor Fasteners 11 Heatsink 12 Heatsink Fasteners TOOLS CONSUMABLES REQUIRED Heat Gun T25 T20 Torx Key Model Depen dent T25 T20 Torx Socke...

Page 155: ...mall Motor Seal and Large Motor Seal REPLACE 1 Remove all old lubricant and thoroughly clean the Motor Case 2 Apply ROCOL FOODLUBE Premier 1 EP1 Grease to the Annulus Gear 3 Ensure the Wave Washer is...

Page 156: ...p 8mm x 0 8mm ROCOL FOODLUBE Premier 1 EP1 3 Jaw Bearing Puller PRE REQUISITE STEPS Wheel Removal Page 48 or Page 50 Motor Core Removal Page 154 REMOVE 1 Using External Circlip Pliers remove the Circl...

Page 157: ...Gears 2 Using External Circlip Pliers and Circlip 8mm x 0 8mm If removed circlips are damaged replace with new retain the Planetary Gears to the Planetary Gear Frame 3 Using External Circlip Pliers a...

Page 158: ...tor Bearing 8 Motor Side Cover 9 Motor Seal TOOLS CONSUMABLES REQUIRED External Circlip Pliers UBCO Motor Seals 1 large 1 small per motor UBCO Motor Bearings 1 large 1 small per motor Hammer Punch Fla...

Page 159: ...or Housing 4 Using a Short Legged Bearing Pull remove the UBCO Large Bearing from the Motor Core Assembly REPLACE 1 Using a Hammer and Punch on the inner race gently install the UBCO Large Bearing int...

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