Polaris EV206PH-B Technical And Service Manual Download

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Electric Bicycle

Technical/Service Manual

Polaris and its vehicle body designs and names are registered trademarks of Polaris Industries Inc. used under license.
Polaris designs, engineers, manufactures and markets snowmobiles, all-terrain vehicles (ATVs), Victory motorcycles and

the Polaris RANGER for recreational and utility use. Information about the complete line of Polaris products, apparel

and vehicle accessories is available from authorized Polaris dealers or anytime from the Polaris homepage at www.

polarisindustries.com.

Servicemanual_101212.indd 40-1

10/12/2012 12:25:43 am

Summary of Contents for EV206PH-B

Page 1: ...nufactures and markets snowmobiles all terrain vehicles ATVs Victory motorcycles and the Polaris RANGER for recreational and utility use Information about the complete line of Polaris products apparel and vehicle accessories is available from authorized Polaris dealers or anytime from the Polaris homepage at www polarisindustries com Servicemanual_101212 indd 40 1 10 12 2012 12 25 43 am ...

Page 2: ...tion 13 BRAKE CABLE INNER WIRE 14 Removal 14 Installation 14 Brake caliper removal installation 16 Brake Caliper Removal 16 Installation 16 Brake pad replacement 16 Brake disc removal installation 17 Chapter 4 18 Shifter and Derailleur 18 Removal 18 Installation 18 Shifter cable inner wire removal installation 19 Removal 19 Installation 20 DERAILLEUR 21 Derailleur Lubrication 21 Derailleur Adjustm...

Page 3: ...onal information to make a procedure easier or clearer A CAUTION emphasizes precautions that must be taken to avoid damage to tools or the Polaris electric bicycle Disregarding a CAUTION could lead to mechanical damage A WARNING emphasizes a situation where negligence could lead to injury or death Take WARNINGS seriously Failure to heed a WARNING could result in serious personal injury or death Co...

Page 4: ... to cut motor when engaged Check wires for damage Check controller connections Replace brake switch handles as needed Replace controller as needed Replace motor as needed Motor engages and operates with abnormal noise Check connectors and controller Check motor wheel axle for damage Replace controller accordingly Replace motor wheel axle Motor does not engage and has abnormal noise Check connector...

Page 5: ...rranty or service claims Tools The following special tools are needed when servicing the Vector EV200PH Tool Part Number Star shaped wrench set Park TWS 2 Head cup remover Park RT 1 Bearing cup press Park HHP 3 Hex wrench set 4mm 5mm 6mm Park AWS 1 Hex wrench set Park AWS 11C Hex wrench set 2mm 5mm 3mm Park AWS 3 Fourth hand cable stretcher Park BT 2 Chain checker Park CC 2C Chain breaker screw ty...

Page 6: ...y to help you diagnose the problem and find the accurate solution All motor system parts are stocked in our warehouse and can be made available to you as needed All non motor system parts are not stocked in warehouse Please order replacement bicycle parts either from your local parts distributor or through our parts distribution network If ordered directly by you component costs can be used as cre...

Page 7: ... handlebar stem Use a bungee cord to suspend the handlebar from the frame 2 Loosen the handlebar stem bolt from the top of the handlebar stem A Figure 2 4 You may remove bolt and cap Figure 2 4 B C A Chapter 2 Steering and Suspension WARRANTY NOTE Steering and front suspension fall under non electric component warranty Applicable warranty is 6 months from date of purchase Any service issue resulti...

Page 8: ...move the upper bearing by performing the following a Lower the fork within the head tube as needed and remove headset spacer seal and bearing cover Figure 2 5 b First remove the upper bearing with Park RT 1 head cup remover then the lower bearing Figure 2 6 Installation 1 If removed install the upper bearing by performing the following a Press top and bottom bearing cup and bearing using Park HHP ...

Page 9: ...ve the handlebar from the handlebar end Installation 1 Slide the new brake lever onto the end of the handlebar 2 Make sure the slots in the adjuster barrel and the locknut align with the slot in the brake lever housing Figure 3 1 Figure 3 1 B A C 3 Connect the end of the brake cable inner wire B Figure 3 2 to the anchor A Figure 3 2 on the brake lever Figure 2 9 B A Figure 2 10 5 Remove the handle...

Page 10: ...the brake lever Figure 3 3 B A C 4 Pull the cable housing and slide the cable inner wire C Figure 3 1 through the slots in the brake lever adjuster barrel B Figure 3 1 and locknut A Figure 3 1 Seat the cable housing ferrule into the adjuster barrel 5 At the caliper turn the barrel adjust all the way into the caliper 6 Feed the inner wire through the caliper barrel adjuster and seat the cable housi...

Page 11: ...re Installation this chapter Brake pad replacement The following procedure shows brake pad replacement on a rear caliper This procedure also applies to a front caliper 1 Turn the inboard pad adjuster with 5mm allen bolt A Figure 3 5 counterclockwise out from the cali per 2 Pull the pad spreader from between the brake pad arms 3 Remove the outboard brake pad B Figure 3 5 and then the inboard pad C ...

Page 12: ...ng a Slide the brake lever so its bracket rests against the shifter b Rotate the brake lever to the position noted during removal and torque the brake lever clamp bolt B Figure 4 1 to the specification in Table 5 5 Rotate the shifter so its barrel seats against the brake lever and torque the shifter set screw A Figure 4 1 to the specification in Table 5 Shifter cable inner wire removal installatio...

Page 13: ...inch plate should be inboard of the inner wire 10 Loosen the anchor bolt as seen in Figure 4 9 Pull the slack from the inner wire with the fourth hand tool and torque the derailleur anchor bolt B Figure 4 2 to the specification in Table 5 Make sure the inner wire still sits in the pinch mechanism groove 11 Cut the excess from the inner wire Leave a couple of inches for future adjust ment 12 Fit a ...

Page 14: ...lt into the hanger Finger tighten the bolt 5 Rotate the derailleur counterclockwise until the derailleur stop tab presses against the stop tab on the hanger 6 Torque the derailleur mounting bolt C Figure 4 2 to the specification in Table 5 CHAPTER 5 Chain and Crankset WARRANTY NOTE Chain and crankset fall under non electric component warranty Applicable warranty is 6 months from date of purchase A...

Page 15: ...Slip the non riveted end of the chain over the rivet protruding from the other end of the chain 5 Install the chain tool onto the chain Pay attention to the following a If the tool has two cradles use the cradle furthest away from the tool handle b Fully seat the rollers on the tool cradle c Center the drive pin on the rivet d Make sure the side plates are properly aligned 6 Turn the tool handle a...

Page 16: ...t crank arm so it is oriented 180 degrees from the right arm 1 When installing a new right crank arm or a new chainring check chainring wobble as described in this chapter 2 Use acetone or alcohol to clean the flats of the spindle 3A When reinstalling an old crank arm line up the spindle to the crank arm hole Tap the crank arm onto the spindle with a plastic mallet 3B If installing a new right cra...

Page 17: ...edaling motion and remove the pedal 5 Repeat this procedure for the opposite pedal Installation 1 Inspect the threads of the pedal stud Install the pedal with the right hand thread onto the right side Install the pedal with the left hand threads onto the left side 2 Apply grease the threads of the pedal stud 3 Turn the pedal into the crank arm Tighten the pedal stud as far as possible by hand 4 Fa...

Page 18: ... specification in Table 5 CHAPTER 6 Motor System WARRANTY NOTE Motor system falls under electric component warranty Applicable warranty is 12 months from date of purchase Any service issue resulting from misuse of bicycle is not covered under this warranty and user shall be responsible for all charges Troubleshooting Diagnostic Guide Refer to Pages 3 4 Controller cap removal installation NOTE Most...

Page 19: ...ontroller cap removal installation above 4 Locate the cables leading to the control box from the rear wheel motor There should be two wires 5 Disconnect the quick disconnect plugs on both cables 6 Cut off the zip ties holding motor cable to rear fork of bicycle be careful not to cut cable 7 Loosen the lug nuts on rear axle 8 Unscrew the security latch holding down axle on both sides 9 Remove the w...

Page 20: ... display to purge stored energy 3 Remove the control box cover You will need a phillips head screwdriver 4 Locate the cables running from the controller to both the motor and leading into the bike frame Disconnect all cables leading into the control box No two sets of cables are the same size so reinstallation should not be confusing 5 Disconnect all quick disconnect plugs 6 Unscrew 4 bolts holdin...

Page 21: ... halfway through full motion 4 Close the housing and reseal with the 3 small screws 5 Turn on the unit to test IC Dashboard service IC DASHBOARD SERVICE If after your customer service call you have concluded that the IC Dashboard is the problem you can easily replace the display IC Dashboard Removal TOOLS REQUIRED Phillips head screwdriver 1 Turn off the unit and remove the battery 2 Press the pow...

Page 22: ...es Figure 3 1 14 Figure 3 2 15 Figure 3 3 16 Figure 3 4 17 Figure 3 5 18 Figure 3 6 18 Shifter and Derailleur Figure 4 1 19 Figure 4 2 20 Figure 4 3 20 Figure 4 4 21 Figure 4 5 21 Chain and Crankset Figure 5 1 24 Figure 5 2 24 Figure 5 3 25 Figure 5 4 26 Figure 5 5 26 Figure 5 6 27 Figure 5 7 27 Figure 5 8 28 Figure 5 9 30 Figure 5 10 30 Servicemanual_101212 indd 38 39 10 12 2012 12 25 59 am ...

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