Vectrix VX-2 2011 Service Manual Download Page 2

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VECTRIX VX-2 SERVICE MANUAL

CONTENTS

SECTION A:

Tools

1 Tools

Needed

SECTION B:

Mechanical Parts

1 Front

Fairing

Front Console Cover

3 Speedometer

Cover

Front Vertical Panel Cover-Lower

Front Vertical Panel Cover-Upper

Center Step-Through Cover

7 Front

Fender

8 Seat

Under Board

Rear Side Body Side Emblem Replacement

11 Rear

Fender

12 Front

Brake

13 Front

Wheel

14 Foot

Rest

15 Side

Cover

16 Rear

Brake

Rear Shock

18 Rear

Suspension

19 Handlebar

SECTION C:

Electrical Parts

1 Speedometer
2 Throttle
3 Brake

Switch

Handlebar-Left Switch Assembly

Handlebar-Right Switch Assembly

6 Ignition

Switch

7 Horn
8

Position Light/Headlamp Assembly Replacement

Front Turn Indicator Assembly

Side Stand Switch

Rear Light Assembly

License Plate Light Assembly

Rear Turn Indicator Assembly

Sevcon Motor Controller

15 Motor
16 Battery
17 Battery

Charger

Version 1.0/May 2011

VECTRIX, LLC

Summary of Contents for VX-2 2011

Page 1: ...VECTRIX VX 2 SERVICE MANUAL www vectrix com Version 1 0 May 2011 VECTRIX LLC...

Page 2: ...ont Brake 13 Front Wheel 14 Foot Rest 15 Side Cover 16 Rear Brake 17 Rear Shock 18 Rear Suspension 19 Handlebar SECTION C Electrical Parts 1 Speedometer 2 Throttle 3 Brake Switch 4 Handlebar Left Swit...

Page 3: ...ontroller LED Indication 2 Malfunctions 3 Check of Charger Function SECTION F Technical Information 1 Cable Assembly Front Brake Turn Indicators BOM 2 Cable Assembly Front Headlamp BOM 3 Cable Assembl...

Page 4: ...wrench 17mm Side stand Front axle Battery Open wrench 18mm Rear fork Open wrench 19mm Rear fork Open wrench 32mm Steering nut top Open wrench 45mm Steering nut bottom Special tool Motor nut Torque wre...

Page 5: ...ould break 8 7 1 5 4 6 3 2 Remark While loosening screws 7 and 8 hold the front cover otherwise it drops down and could break Assemble all parts in the other direction Remark For assembling the cover...

Page 6: ...front cover and loosen all the connectors of the lamps Assemble all parts in the other direction Remark For assembling the cover please take care of the noses being in the right position and no edge i...

Page 7: ...de in a flat screwdriver into the position as seen on the picture Hold the front cover by hand Carefully turn the screwdriver counter clockwise ccw left side and clockwise cw right side until the fron...

Page 8: ...g see Section B 1 Disassemble Front Console Cover see Section B 2 Open the connector from Speedometer Unscrew the Phillips screw with Phillips screwdriver PH2 Unscrew the Phillips screw with Phillips...

Page 9: ...Phillips screwdriver PH2 Unscrew the two Phillips screws right and left position with a Phillips screwdriver PH2 Slide a Phillips screwdriver PH2 into the hole and pull out carefully the cover to the...

Page 10: ...Assemble all parts in the other direction Remark For assembling the cover please take care of the noses being in the right position and no edge is standing out Put in the screws slightly and if all s...

Page 11: ...B 5 FRONT VERTICAL PANEL COVER UPPER Preparations Disassemble Front Fairing see Section B 1 Carefully move the cover of Key Switch out Remove the cover of Key Switch Side view of the inner backside co...

Page 12: ...RIX VX 2 SERVICE MANUAL Unscrew the two Phillips screws left and right position with a Phillips screwdriver PH2 Remove the cover Assemble all parts in the other direction Version 1 0 May 2011 VECTRIX...

Page 13: ...e Section B 8 Unscrew the two Phillips screws left and right position with a Phillips screwdriver PH2 Slightly press out left and right side of the cover so that they can pass the metal holder Careful...

Page 14: ...16mm Assemble all parts in the other direction Remark For assembling the cover please take care of the noses being in the right position and no edge is standing out Put in the screws slightly and if a...

Page 15: ...RONT FENDER Unscrew the four Phillips screws left and right side with a Phillips screwdriver PH2 To unscrew the Phillips screw hold the inner nut with 8mm open wrench Assemble all parts in the other d...

Page 16: ...s screw with a Phillips screwdriver PH2 Hold the seat during unscrewing the second Phillips screw Remove the seat The two Phillips screws are M6 x 16mm Assemble all parts in the other direction Test i...

Page 17: ...in order as seen on the picture with a Phillips screwdriver PH2 While loosening screws 5 and 6 hold the Under board otherwise it drops down and could break 5 3 Assemble all parts in the other directi...

Page 18: ...op left and right position with a Phillips screwdriver PH2 Unscrew the four Phillips screws left and right position with a Phillips screwdriver PH2 Carefully pull out left and right side until the cov...

Page 19: ...ll screws and the cover are in the correct positions tighten them Rear Side Panel Emblem Nameplate Replacement S XC S00329 Removal Procedure 1 Right side Remove the right rear cheek panel Refer to Rea...

Page 20: ...te and install the 2 screws 1 2 Right side Install the right rear cheek panel Refer to Rear Cheek Panel Right Replacement in Body Rear End 3 Left side Install the left rear cheek panel Refer to Rear C...

Page 21: ...parations Disassemble Side Body Panels Side Emblems see Section B 10 Disconnect all connectors of the lights Unscrew the 3 screws with a 8mm open wrench and open all the connections Assemble all parts...

Page 22: ...Console Cover see Section B 2 Disassemble Speedometer Cover see Section B 3 Disassemble Front Fender see Section B 7 Remove hex screw of the hose clamp with 8mm open wrench Remove the brown cables of...

Page 23: ...in the other directions Remark For assembling the cover please be careful of the noses are in the right position and no edge is outstanding Put in the screws a little bit and if all screws and the co...

Page 24: ...2011 Remove both plastic covers from the screw Open the two Hex screw with open wrench 12 mm and remove the brake 1 2 Put the scooter on a supporter and lift up the scooter until the front wheel is mo...

Page 25: ...VECTRIX VX 2 SERVICE MANUAL Remove screw axle and the other parts and the wheel Version 1 0 May 2011 VECTRIX LLC...

Page 26: ...ep Through Cover see Section B 6 Disassemble Under Board see Section B 9 Open the two screws 1 2 and the two screws for the side shields with PH2 screw driver Same procedure for the other side if nece...

Page 27: ...15 SIDE COVER Unscrew the 4 screws by using a Phillips screwdriver 2 Unscrew the 3 screws by using a Phillips screwdriver 2 1 screw is covered by the main stand Assemble all parts in the other direct...

Page 28: ...dure C 16 Unscrew the two inner hexagon bolts by using an Allen key 6mm Disassemble the rear brake Now it is possible to exchange the brake pads Remark It is not necessary to disassemble the side cove...

Page 29: ...e the connector from the Speedometer Remove the two cross screws by using a Phillips screwdriver 2 and remove the complete Speedometer cover Remove the two connectors from the brake switch Remove all...

Page 30: ...cooter The brake liquid could damage the paint or other parts Move the brake hose including the complete brake lever assembly through the frame and rear suspension Version 1 0 May 2011 Complete remove...

Page 31: ...a open wrench 13mm Unscrew the bolt 3 by using a open wrench 12mm and remove rear shock Remark For disassembling of the rear shock it is not necessary to remove the motor and the side cover 3 1 2 All...

Page 32: ...n Remark Put up the back of the battery case on a supporter Unscrew the nut 1 by using a open wrench 14mm Unscrew the bolt 2 by using a open wrench 13mm and remove the bolt Remark It is not necessary...

Page 33: ...X VX 2 SERVICE MANUAL All parts of rear suspension Assemble all parts in the other direction and tighten the bolts and nuts according to the regulated torque see Section F 4 Version 1 0 May 2011 VECTR...

Page 34: ...s screwdriver 2 and remove the complete Speedometer cover Version 1 0 May 2011 VECTRIX LLC Remove all parts of the handlebar Left and right switch assembly Left and right brake handle assembly Acceler...

Page 35: ...ng see Section B 1 Disassemble Front Console Cover see Section B 2 Remove connector from Speedometer Unscrew the Phillips screw with Phillips screwdriver PH2 Unscrew the Phillips screw with Phillips s...

Page 36: ...f the plastic bracket there are two plastic noses which fit into two holes of the plastic cover These noses fixed the Speedometer in the right position Carefully remove the Speedometer out of the plas...

Page 37: ...H 2 8mm Turned Full contact Hexagonal Socket S02445 Removal Procedure 1 Turn ignition key to the off position 2 Remove three screws 3 4 from the lower throttle box assembly 3 Lift the kill switch hous...

Page 38: ...he bottom of the lower box is into the hole in the handlebar 6 Using tool 01545 install the other U Bolt nut and tighten both nuts 7 Twist the throttle to ensure free movement and that it returns to a...

Page 39: ...e secure the lever in the squeezed position and observe the needle position 4 To determine the correct position of the Throttle squeeze the right side brake lever and observe the reading Note The neut...

Page 40: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

Page 41: ...2 2 Remove the right handlebar end cap and hand grip Refer to Handlebar End Cap and Hand Grip Replacement 3 Remove the kill switch cover screws 4 Twist the throttle to gain access to the throttle cla...

Page 42: ...Remove the screws 1 and slide the insert and sensor out of the handlebar 8 Remove the sensor 1 from the insert 9 Mark and remove the sensor wires from the handlebar connector and remove the sensor Ver...

Page 43: ...ion Procedure 1 Install the sensor wires through the handlebar and out the harness hole 2 Install the sensor wires into the connector in the same location as removed 3 Install the sensor 1 onto the in...

Page 44: ...MANUAL 4 Install the insert and tighten the screws 1 5 Install the throttle sleeve 2 onto the handlebar and into the plastic sleeve Notice Refer to Fastener Notice in General Information Version 1 0...

Page 45: ...smoother operation of the throttle 9 Install the upper handlebar cover Refer to Front Console Cover Replacement 10 Install the sensor magnet and screw in until lightly seated then back out 1 full tur...

Page 46: ...eedle This is the required setting and what the actual reading in Step 3 must be set to If the settings are not the same refer to Throttle Adjustment Procedure 1 With PC 1 Connect the Diagnostic Hardw...

Page 47: ...M access see Section B 4 Remove Vertical Panel Cover Upper see Section B 5 Remove all cable strips 1 Remove connector from the Interface Control Module ICM 1 Disconnect both wires at the brake switch...

Page 48: ...Section B 5 If newer VX 2 model Remove Front Console Cover for ICM see Section B 2 Remove all cable strips Open connector CN1 from the Interface Control Module ICM Additional information see Section 1...

Page 49: ...Section B 5 If newer VX 2 model Remove Front Console Cover for ICM see Section B 2 Remove all cable strips Open connector CN3 from the Interface Control Module ICM Additional information see Section 1...

Page 50: ...Cover Lower see Section B 4 Disassemble Vertical Panel Cover Upper see Section B 5 Remove all cable strips Open connector Unscrew the two fasten bolts of Key switch by 10mm socket wrench Assemble all...

Page 51: ...ront Console Cover see Section B 2 Disassemble Vertical Panel Cover Lower see Section B 4 Disassemble Vertical Panel Cover Upper see Section B 5 Open the connector of the horn Unscrew the bolt by 10mm...

Page 52: ...reparations Disassemble Front Fairing see Section B 1 Headlamp Assembly Replacement Headlamp Assembly Part S XC S00092 Removal Procedure 1 Remove the right front fairing Refer to Front Fairing Replace...

Page 53: ...connector 5 Disconnect Headlamp Assembly connectors and replace with new Headlamp Assembly 6 Connect the headlamp and lower marker lamp connectors 7 Install the headlamp assembly onto the left front f...

Page 54: ...VECTRIX VX 2 SERVICE MANUAL 9 If the headlamp assembly was replaced aim the headlamp Refer to Headlamp Adjustment Procedure Version 1 0 May 2011 VECTRIX LLC...

Page 55: ...Remark Procedure is the same for both Turn Indicator Lights Unscrew the Nut from the inside with a wrench Remove entire Front Turn Signal Assembly and pull cord through the hole Replace entire Front T...

Page 56: ...Disassemble Center Step Through Cover see Section B 6 Remove the connector inside of the electronic box under the seat Unscrew the bolt by 8mm open end wrench Assemble all parts in the opposite direct...

Page 57: ...connector Unscrew the two side screws and one middle screw with Phillips screwdriver Pull out the Tail Light assembly backwards and disconnect plug Replace entire Tail Light Assembly Note Since the Re...

Page 58: ...s with a Phillips screwdriver PH2 Pull out the License Plate Light assembly License Plate Bulb Unscrew the two Phillips screws with a Phillips screwdriver PH2 Remove plastic cover Pull out the defect...

Page 59: ...t assembly Remark Connector has to be cut because the connector doesn t fit through the hole of the plastic Remove the nut with an open wrench 14mm Pull out the Rear Turn Indicator assembly Remark Sli...

Page 60: ...bly necessary Replace entire Rear Turn Indicator Assembly Note Since the Rear Turn Indicator Assembly is LED you must replace the entire assembly Assemble all parts in the other directions Test functi...

Page 61: ...seat and remove Cover of electronic box by using Phillips screwdriver old version Special secure Torx screwdriver new version Turn Key Switch in ON Position Unplug blue Battery Main Connector Turn Ke...

Page 62: ...ntroller to remove the Motor Controller stall new Motor Controller and re secure with four hillips bolts gative Cables and Wiring Harness first In P Reconnect Ne Then replace Main Fuse and Positive Ca...

Page 63: ...rake Rotor Open the seat and remove Cover of electronic box by using Phillips screwdriver old version Special secure Torx screwdriver new version Turn Key Switch in ON Position Unplug blue Battery Mai...

Page 64: ...wrench nd remove the cable clamp Pull out the motor cable slightly of the electronic box Remark a It is not necessary to remove the parts as it can be seen on the picture Unscrew the motor nut with a...

Page 65: ...VECTRIX VX 2 SERVICE MANUAL All parts of removed motor Assemble all parts in the other direction est function of Motor T Version 1 0 May 2011 VECTRIX LLC...

Page 66: ...ved which makes the procedure easier to complete but is not necessary if only the Step Through panel is removed Version 1 0 May 2011 Unscrew the hexagon bolts from Battery 1 und 3 Lift up battery 2 an...

Page 67: ...it Lift up battery 4 and remove it Empty battery case for 60AH Assemble all parts in the other direction After assembling Measure the voltage of each battery It should be higher than 12 0 VDC Charge...

Page 68: ...NUAL SECTION C 17 BATTERY CHARGER Preparations Open Under Seat Storage Put Key into key hole on the side of the VX 2 to open Under Seat Storage Area Turn Key to open Under Seat Storage Area Version 1...

Page 69: ...move Battery Charger from Under Seat Storage Area Plug blue Battery Charger male connector cord into on board blue Battery Charger female connection Plug Battery Charger AC connector into a AC main Ve...

Page 70: ...Turn on Battery Charger Unit power switch Recharge until Battery Charger Output LED reaches 100 Yellow Note Recharge process can be discontinued and re started at any time during the charge cycle Vers...

Page 71: ...RVICE MANUAL SECTION D 1 MIRRORS ADJUSTMENT If mirrors are not tightened remove Left and Right mirrors refer to Section C Section C 1 and tighten the nut by using a 14mm open wrench Version 1 0 May 20...

Page 72: ...SERVICE MANUAL Coarse adjustment Turn the mirror in the correct position by using the mirror housing The movement should be done with some force otherwise proceed as figure before Version 1 0 May 2011...

Page 73: ...VECTRIX VX 2 SERVICE MANUAL Fine adjustment Move the mirror in the correct position Version 1 0 May 2011 VECTRIX LLC...

Page 74: ...dlamp aim The scooter is on a level surface The tires are uniformly inflated to the specified pressure One person is sitting on the driver s seat The scooter is in the vertical position Clean the head...

Page 75: ...e line 1 that is in line with the scooter axis 5 With the headlamp low beam on the height spot 4 should 9 10th of the headlamp center line 3 Adjusting the headlamp 1 To adjust the light beam up and do...

Page 76: ...lve malfunction before this message Error Voltage too high 7 Battery voltage is over 63V Use the scooter carefully until message is over if not check if the real voltage of the battery is lower than 6...

Page 77: ...ometer connector Should be the battery Voltage Speedometer or controller broken or wire between controller and speedometer No indication of the consumption bar on Speedometer Check Voltage of the batt...

Page 78: ...he voltage with a digital voltmeter on the Controller power in line red and black thick wire The value should be 59 5 V 1 0 V If yes exchange speedometer if not exchange Charger 2 Charger didn t start...

Page 79: ...VECTRIX VX 2 SERVICE MANUAL SECTION F 1 CABLE ASSEMBLY FRONT BRAKE INDICATORS BOM Version 1 0 May 2011 VECTRIX LLC...

Page 80: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

Page 81: ...VECTRIX VX 2 SERVICE MANUAL SECTION F 2 CABLE ASSEMBLY FRONT HEADLAMP HORN BOM Version 1 0 May 2011 VECTRIX LLC...

Page 82: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

Page 83: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

Page 84: ...VECTRIX VX 2 SERVICE MANUAL SECTION F 3 CABLE ASSEMBLY REAR BRAKE INDICATORS TAIL LIGHT BATTERY SIDE STAND BOM Version 1 0 May 2011 VECTRIX LLC...

Page 85: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

Page 86: ...ng on rear fork bolt 25 NM Motor axle nut 80 NM Front shock bolt 70 NM Brake disc on front rim bolt 25 NM Brake disc on motor bolt 15 NM Ring on motor bolt 15 NM Handle bar nut 50 NM Rear fork left an...

Page 87: ...VECTRIX VX 2 SERVICE MANUAL SECTION G 1 UNPACKING INSTRUCTIONS Version 1 0 May 2011 VECTRIX LLC...

Page 88: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

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Page 92: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

Page 93: ...VECTRIX VX 2 SERVICE MANUAL SECTION G 2 PREP INSTRUCTIONS Version 1 0 May 2011 VECTRIX LLC...

Page 94: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

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Page 96: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

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Page 98: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

Page 99: ...VECTRIX VX 2 SERVICE MANUAL Version 1 0 May 2011 VECTRIX LLC...

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