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Bravo EVT-4000e Maintenance Manual

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EVT-4000e
Maintenance Manual
EVT TECHNOLOGY CO., LTD.
1

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Summary of Contents for Bravo EVT-4000e

  • Page 1 EVT-4000e Maintenance Manual EVT TECHNOLOGY CO., LTD.

  • Page 2: (Picture 1)

    (1) HEAD LIGHT ASSY Replace Head Light Assy (1) Release three screws on the handle cover (Picture 1) (2) Release two mounting screws on the instrument panel, and then release three screws on the head light assy (Picture 2) (3) Follow with the reversed steps to restore Tools! "...
  • Page 3 (Picture 2) Replace Head Light Bulb" (1) Release three screws on the handle cover (Picture 1) (2) Release two mounting screws on the instrument panel so can easily replace the bulb (Picture 2) (3) Follow with the reversed steps to restore Tools! "...

  • Page 4: Release Two Mounting Screws On The Instrument Panel

    (2) SPEEDOMETER ASSY Replace Instrument Panel : (1) Release three screws on the handle cover……(Picture 1) (2) Release two mounting screws on the instrument panel……(Picture 2) (3) Release the nut for the speedometer……(Picture 3) (4) Follow with the reversed steps to restore ＜Tools＞：(1) (2) screwdriver Three screws on the handle cover...

  • Page 5: Table Of Contents

    Speedometer bolt Speedometer nut Speedometer cable (Picture 3) Replace Speedometer Cable: (1) Release three screws on the handle cover …………………(Picture 1) (2) Release two mounting screws on the instrument panel …………………(Picture 2) (3) Release the nut for the speedometer …………………(Picture 3) (4) Release three screws on the front cover …………………(Picture 4) (5) Release speedometer nut on the front wheel...

  • Page 6: (Picture 4)

    Three screws on the front cover (Picture 4) Speedometer nut Front axle nut (Picture 5) Replace Speedometer Gear: (1) Release front axle nut ……………(Picture 5) (2) Remove the front wheel (3) Follow with the reversed steps to restore ＜Tools＞：(1) box wrench（17mm） Speedometer gear...
  • Page 7 (3) KEY SWITCH AND HORN Replace Key Switch : (1) Release three screws on the front cover ………………(Picture 1) (2) Release six screws on the front fender ………………(Picture 1) (3) Release three screws on the glove box ………………(Picture 2) (4) Release 4 pin connector and two screws on the key switch ………………(Picture 3) (5) Follow with the reversed steps to restore ＜Tools＞：(1) (2) screwdriver；(3) T-bend socket wrench（8mm）&...
  • Page 8 Three screws on the glove box (Picture 2) Two screws for the key switch on left and right side 4 pin connector (Picture 3)
  • Page 9 Replace Horn: (1) Release three screws on the front cover ………………(Picture 1) (2) Release two connectors on the horn ………………(Picture 2) (3) Release the mounting screws on the horn ………………(Picture 4) (4) Follow with the reversed steps to restore ＜Tools＞：(1) screwdriver；(3) open-end wrench（10mm） Two mounting screws on the horn Two connectors on...
  • Page 10 (4) MAIN CONTROL CORD Replace Main Control Cord : (1) Release three screws on the handle cover, two mounting screws on the instrument panel, three screws on the head light, three screws on the front cover and two screws on the right trim ………………(Picture 1 &...
  • Page 11 Three screws on the head light Two mounting screws on the instrument panel (Picture 2) Connectors inside the handle cover 6 pin connector for left handle switch Connectors for power cut off and brake functions 6 pin connector for the head light assy 4 pin connector for right handle switch...
  • Page 12 Connectors inside the front cover 4 pin connector for key switch 4 pin connector for DC to DC converter Two connectors for the horn (Picture 4) Connectors inside the right cover 6 pin connector for the tail light assy 9 pin black connector 9 pin white connector 2 pin white connector (Picture 5)
  • Page 13 Replace Flasher Relay: (1) Release three screws on the handle cover, remove the rubber sleeve so can see the 2 pin connector for the flasher relay ………………(Picture 1 & 6) (2) Follow with the reversed steps to restore ＜Tools＞：(1) screwdriver Rubber sleeve and 2 pin connector for flasher relay...
  • Page 14 DC to DC converter (Picture 7) Replace DC to DC converter: (1) Release three screws on the front cover so can see the DC to DC converter ………………(Picture 7) (2) Release two screws and 4 pin connector for the DC to DC converter ………………(Picture 7 &...
  • Page 15 HANDLE SWITCH LEFT AND RIGHT Replace Left Handle Switch: Remove left rear view mirror and release three screws on the handle cover ………………(Picture 1) (1) Release two mounting screws on the instrument panel ………………(Picture 1) (2) Release two screws on the left handle switch ………………(Picture 1) (4) Follow with the reversed steps to restore ＜Tools＞：(1) open-end wrench（14mm）&...
  • Page 16 Replace Right Handle Switch: (1) Remove the right rear mirror and three screws on the handle cover ………………(Picture 2) (2) Release two mounting screws on the instrument panel ………………(Picture 1) (3) Release two screws on the right handle switch and one screw for the throttle cable ………………(Picture 2) (4) Follow with the reversed steps to restore ＜Tools＞：(1) open-end wrench（14mm）&...
  • Page 17 (6) BRAKE MASTER CYLINDER R & L Replace Master Cylinder Right and Left: (1) Release three screws on the handle cover, two mounting screws on the instrument panel and three screws on the head light assy ………………(Picture 1 & 2) (2) Check the fluid in reservoir for refuel or replace the brake fluid ………………(Picture 2) (3) Replace reservoir...
  • Page 18 Three screws on the head light assy The screw on the brake hose Two mounting screws on the instrument panel (Picture 2) Two screws on the reservoir (Picture 3)

  • Page 19: Shock Absorber

    (7) FRONT FORK AND REAR SHOCK ABSORBER Replace Front Fork: (1) Release three screws on the front cover ………………(Picture 1) (2) Release six screws on the front fender ………………(Picture 2) (3) Release three screws on the glove box ………………(Picture 3) (4) Release clamping screw for the handle ………………(Picture 4) (5) Release front axle nut to remove the wheel...
  • Page 20 Three screws on (Picture 1) Six screws on the front fender (Picture 2)
  • Page 21 Three screws (Picture 3) The clamping screw on the handle Two screws on (Picture 4)
  • Page 22 Front axle nut (Picture 5) Two screws (Picture 6)
  • Page 23 Replace Rear Shock Absorber: (1) Release two screws on the trim on each left and right side ………………(Picture 7) (2) Release two screws on the left shock absorber ………………(Picture 9) (3) Same as above mentions to replace the right shock absorber (4) Follow with the reversed steps to restore ＜Tools＞：(1) screwdriver；(2) T-bend socket wrench（12mm,14mm）...
  • Page 24 Left and Right shock absorber (Picture 8) Two screws on the shock absorber (Picture 9)
  • Page 25 (8 ) BRAKE HOSE FRONT & REAR Replace Front Brake Hose: (1) Release three screws on the handle cover ………………(Picture 1) (2) Release two screws on the right reservoir ………………(Picture 2) (3) Release the screw on the brake hose of the front wheel, avoid fluid leaking to the pad ………………(Picture 3) (4) Release the screw on the right side brake hose ………………(Picture 2)
  • Page 26 Two screws on the reservoir The screw on the right side brake hose (Picture 2) The screw on the brake hose of the front wheel (Picture 3)
  • Page 27 Three screws on the front cove Six screws on the front fender (Picture 4) Two screws on the reservoir The screw on the right side brake hose (Picture 5)
  • Page 28 Replace Rear Brake Hose: (1) Release three screws on the handle cover ………………(Picture 1) (2) Release two screws on the left reservoir ………………(Picture 5) (3) Release the screw on the brake hose of the rear wheel, avoid fluid leaking to the pad ………………(Picture 6) (4) Release the screws on the left side brake hose ………………(Picture 5)
  • Page 29 (9) CALIPER FRONT & REAR Replace Front Caliper: (1) Release three screws on the handle cover ………………(Picture 1) (2) Release the screw on the front caliper, avoid fluid leaking to the pad ………………(Picture 2) (3) Release the screw on the pad, and then remove the pad ………………(Picture 2) (4) Release two mounting screws on the caliper ………………(Picture 2)
  • Page 30 The screw on the front caliper The screw on the pad Two mounting screws on the caliper (Picture 2) Replace Rear Caliper: (1) Release three screws on the handle cover ………………(Picture 1) (2) Release the screw on the rear caliper, avoid fluid leaking to the pad ………………(Picture 3) (3) Release the screw on the pad ………………(Picture 3)
  • Page 31 The screw on the rear caliper The screw on the pad Two mounting screws on the rear caliper (Picture 3)
  • Page 32 (10) CONTROLLER Replace Controller: (1) Release two screws on the right side trim ………………(Picture 1) (2) Release the connectors of controller wire harness (black×1、red×1、black 9 pin×1、white 9 pin×1). Release the copper nut of throttle cable and pull it out, then you can see a small hole on the throttle pillar, put a nail through the hole so can prevent the pillar to draw back ………………...
  • Page 33 Controller wire harness (Picture 2) Tie band to prevent the pillar to draw back The Throttle pillar (Picture 3)
  • Page 34 (11) MOTOR AND BRAKE DISK Replace Motor: (1) Release the black connector of the motor cord ………………(Picture 1) (2) Cut off the band ………………(Picture 1) (3) Release three screws on the motor cord cover ………………(Picture 1) (4) Release two nuts for the motor shaft ………………(Picture 2) (5) Release the rear caliper so can remove the motor ………………(Picture 3)
  • Page 35 Two nuts for the motor shaft (Picture 2) Two screws for the brake assy (Picture 3)
  • Page 36 Replace Rear Brake Disk: (1) Release the black connector of the motor cord ………………(Picture 1) (2) Cut off the band (Picture 1) (3) Release three screws on the motor cord cover (Picture 1) (4) Release two nuts for the motor shaft (Picture 2) (5) Release the rear caliper so can remove the motor (Picture 2) (6) Release three screws on the brake disk so can remove the disk (7) Follow with the reversed steps to restore...
  • Page 37 Replace Front Brake Disk: (1) Release the screw for the front axle nut to remove the front wheel ……………(Picture 5) (2) Release three screws on the disk (3) Follow with the reversed steps to restore ＜Tools＞：(1) box wrench（17mm） ；(2) hex-key wrench（6mm） The screws for the front axle nut (Picture 5)
  • Page 38 (12) REAR LIGHT ASSY Replace Rear Light: Release three screws on the tail comp ………………(Picture 1) (1) Release four screws on the trim on each left and right side …………………(Picture 2) (3) Release the screw on the center cover …………………(Picture 3) (4) Release three screws on the side cover on each left and right side …………………(Picture 2) (5) Release two screws on the tail fender...
  • Page 39 Three screws on the side cover on each left and right side Two screws on the lamp cover Two screws on the tail fender (Picture 2) The screw on the center cover (Picture 3) Replace the bulb for Rear Lamp & Signal Light: (1) Release two screws on the rear lamp cover ………(Picture 2) (2) Remove the cover so can replace the bulb...
  • Page 40 The bulb for brake light The bulb for the signal left and right (Picture 4)
  • Page 41 EVT-4000e Trouble Shooting and Repair Conditions Inspect Repair Display Panel indicator light is working, but The power will cut off while braking. Release the brake and then gently twisting there is no move while twisting throttle. Brake switch breakdown throttle Check Controller cable is fixed 2~6.See your agent...