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UBCO TECHNICAL SERVICE MANUAL

PAGE 7 OF 159

1.1

GENERAL INFORMATION AND DISCLAIMERS

Please read this disclaimer carefully before using the technical repair manual. By

accessing and utilizing this manual, you acknowledge and agree to the following

terms and conditions:

USE AT YOUR OWN RISK

: This technical repair manual is provided for informa

tional and educational purposes only. The information contained herein is

intended for skilled technicians and professionals who have the necessary

tools, equipment, and expertise to safely and accurately perform the repairs

described. The use of this manual is entirely at your own risk, and the manual's

publisher, authors, and contributors shall not be held liable for any damages or

losses arising from its use.

PROFESSIONAL GUIDANCE

: This manual is not a substitute for professional

advice, diagnosis, or repair services. It is essential to consult with an UBCO

certified technician or manufacturer-approved service personnel when dealing

with complex technical repairs or maintenance tasks. The manual is meant to

complement, not replace, professional expertise.

APPLICABILITY:

The procedures and instructions in this manual are generic in

nature and may 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.

SAFETY PRECAUTIONS:

Motorcycle repairs can be dangerous and may involve

exposure to electrical hazards, moving parts, and other potential risks. Prior to

attempting any repair, please ensure that you are adequately trained and

equipped with the necessary safety gear. Follow all safety warnings provided

by the manufacturer as well as industry health and safety guidelines.

WARRANTY IMPLICATIONS:

Attempting repairs on a product covered by a war

ranty or service agreement may void such coverage. Always check UBCO’s

warranty terms and conditions before undertaking any repair work.

COPYRIGHT AND INTELLECTUAL PROPERTY:

This technical repair manual is

protected by copyright law. You may use it for personal, non-commercial pur

poses only. Reproduction, distribution, or modification of the manual's con

tent for commercial use is prohibited without prior written consent from the

ACCURACY AND UPDATES:

The information within this manual may become

outdated over time due to evolving technology and product changes. The

authors and publisher do not guarantee the accuracy, reliability, or complete

ness of the information. It is the user’s responsibility to verify and cross-refer

ence the information.

Содержание 2x2 ADV Gen 5

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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UBCO 2x2 ADV Gen 5, Техническое и сервисное руководство

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