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Gocycle MOTORFORK G2 Manual

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G
G2 M
F
G
OCYCLE
OTOR
ORK
UIDE
Version 1.0
Servicing of the Gocycle G2 MotorFork

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Summary of Contents for Gocycle MOTORFORK G2

  • Page 1 G2 M OCYCLE OTOR UIDE Version 1.0 Servicing of the Gocycle G2 MotorFork...
  • Page 2 ARTS Note: You may To successfully complete the procedure you will require the following parts. be able to re-use parts on your Gocycle and as such only need to order parts specific to your repair. Part Code Part Description...

  • Page 3: Table Of Contents

    Gocycle G2 MotorFork Guide 1.0 ONTENTS Front Disk Cover Removal ....................4 Front Hub Relocation...................... 5 MotorGearbox and Controller Removal ................8 Controller Removal ......................9 MotorGearbox Rework ....................11 Controller Replacement ....................14 MotorGearbox and Controller Installation ............... 16...

  • Page 4: Front Disk Cover Removal

    Gocycle G2 MotorFork Guide 1.0 RONT OVER EMOVAL EFORE COMMENCING ENSURE THE OCYCLE IS IN SLEEP MODE 1.1. For ease of assembly, invert the Gocycle and locate on a stand as demonstrated. Note: Ensure the battery pack is in sleep mode. Consult your Owner’s Manual...

  • Page 5: Front Hub Relocation

    Gocycle G2 MotorFork Guide 1.0 RONT ELOCATION 2.1. Use the 2.5mm Allen key to undo the Controller securing bolt (2164). 2.2. Use a 3mm Allen key to undo the 4 bolts (2162) that secure the Fork Brace (2100). 2.3. Once all 4 bolts...
  • Page 6 Gocycle G2 MotorFork Guide 1.0 2.4. Now the MotorFork Separator Tool (3177) must be located in the MotorGearbox fins as demonstrated. The top half of the tool should align against the Front Upright. Note: Before installing the tool ensure the lower...
  • Page 7 Gocycle G2 MotorFork Guide 1.0 2.6. Support the Front Hub and Locate the Motor Holder (3178). This fits onto the MotorFork as shown. 2.7. Slide the Motor Holder up the Fork into the fins of the Motor and use the...

  • Page 8: Motorgearbox And Controller Removal

    Gocycle G2 MotorFork Guide 1.0 OTOR EARBOX AND ONTROLLER EMOVAL 3.1. With the Front Hub relocated the MotorGearbox and Controller assembly can now be removed. Carefully begin to push the unit upwards as shown. 3.2. As the Anderson connectors as well as...

  • Page 9: Controller Removal

    Gocycle G2 MotorFork Guide 1.0 ONTROLLER EMOVAL 4.1. Use a sharp blade and with extreme caution, carefully cut the Heat Shrink (2345) on the three phase wires from the Motor to Controller. 4.2. Pull the heat shrink back to reveal the three connectors.
  • Page 10 Gocycle G2 MotorFork Guide 1.0 4.4. Finally remove the Heat Shrink from the phase wires of the Motor. © Karbon Kinetics Limited. All Rights Reserved.

  • Page 11: Motorgearbox Rework

    Gocycle G2 MotorFork Guide 1.0 OTOR EARBOX EWORK 5.1. Use the T25 bit to unscrew 3 of 4 Gearbox securing screws (2256) as shown. 5.2. There is 1 screw that requires the removal of 1 Motor Torque Bung as shown.
  • Page 12 Gocycle G2 MotorFork Guide 1.0 5.4. If this occurs then carefully remove the Gears and reinstall into the Gearbox. Take great care to not contaminate the grease or gears. 5.5. In order to refit a Gearbox and Motor press the Gearbox...
  • Page 13 Gocycle G2 MotorFork Guide 1.0 5.7. Ensure to reinstall the Motor Torque Bung. Rework Complete. © Karbon Kinetics Limited. All Rights Reserved.

  • Page 14: Controller Replacement

    Gocycle G2 MotorFork Guide 1.0 ONTROLLER EPLACEMENT 6.1. Install the three pieces of Heat Shrink (2345) over each of the three phase wires as shown. 6.2. Align the three phase wires as shown ready to connect to the three Motor wires.
  • Page 15 Gocycle G2 MotorFork Guide 1.0 6.4. Use a heat gun on the Heat Shrink to enclose the phase wires. Ensure to have the Heat Shrink pushed as close to the Motor as possible. If there is a gap it should be no longer than 3mm.

  • Page 16: Motorgearbox And Controller Installation

    Gocycle G2 MotorFork Guide 1.0 OTOR EARBOX AND ONTROLLER NSTALLATION 7.1. Carefully lower the Assembled MotorGearbox and Controller into the MotorFork as shown. Plug in the two Anderson and one white connector as it is lowered. 7.2. Ensure the Controller is fully...
  • Page 17 Gocycle G2 MotorFork Guide 1.0 7.4. Ensure the MotorGearbox and Front hub assembly are fully inserted and the edge of the fork is on the shoulder of the Hub assembly as shown here. 7.5. Install the Fork Brace and the four securing bolts.
  • Page 18 2Nm. IMPORTANT NOTE: THE ABOVE REMOVAL AND REPLACEMENT STEPS MUST BE CARRIED OUT IN ORDER. FAILING TO DO SO MAY RESULT IN DAMAGE TO THE GOCYCLE. If you have any further queries or comments, please contact Gocycle Technical Support: techsupport@gocycle.com...