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KSR Group GmbH accepts no liability deviations from illustrations and descriptions or misprints a nd other errors. The models in this manual partly contain special equipment that does not belong to the regular scope of delivery further the illustrations and pictures are symbolic images, and may differ from the actual components.
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INDEX INTRODUCTION………………………………2 WHEELS AND TIRES/ BRAKES…………28 INDEX…………………………………………3 AIR PRESSURE INSPECTION……………28 IMPORTANT NOTES…………………………5 WHEEL BEARING AND WHEEL AXLE LOCATION OF SERIAL NUMBERS………6 DAMAGE INSPECTION…………………… 28 VIN (CHASSISNUMBER)……………………6 BRAKE FLUID LEAK INSPECTION………28 FRAME PLATE………………………………6 BRAKE OPERATION INSPECTION FRONT…… MOTOR NUMBER……………………………6 BRAKE FLUID LEVEL INSPECTION ……...
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INDEX TROUBLESHOOTING - FRONT/ REAR THROTTLE INSPECTION…………………59 BRAKE………………………………………43 SPEED LIMIT SWITCH……………………59 FRONT BRAKE LEVER……………………43 ……60 PART LOCATION - ELECTRICAL SYSTEM REAR BRAKE LEVER………………………43 PART LIST - LIGHTS / INSTRUMENTS ……………………………………60 FRONT BRAKE LEVER/ MASTER BRAKE SWITCHES ……………………44 MAIN SWITCH INSPECTION………………61 CYLINDER REPLACEMENT …44 MAIN SWITCH REPLACEMENT…………61...
It is important that you read this manual completely before the start of work. It contains useful info- mation how to repair and maintain the vehicle. SPARE PARTS AND ACCESSORIES Only use spare parts and accessory that have been approved or recommended by KSR Group GmbH. PRACTIC Special tools are required for some work but mostly professional work shop equipment is enough for service,repair and maintenance of the vehicle.
LOCATION OF SERIAL NUMBERS VIN (CHASSIS NUMBER)车架号 Remove the cover vehicle identification(1). The vehicle identification number(VIN)(2) is stamped into down-tube in front of the frame. FRAME PLATE 铭牌 The frame plate(1) is fixed on the right-side of the frame. MOTOR NUMBER 电机号 The motor number (1) is stamped into motor cover.
GENERAL SPECIFICATION MOTOR Type: Mechanical Drum brake (110 mm)/ Left hand oper Motor type: Brushless DC Electric motor ation FRONT SUSPENSION Motor voltage: 60 V Type: Telescopic fork Maximum power:2000W Spring/shock absorber type: Maximum torque:99N▪m Coil spring/oil dampe REAR SUSPENSION Motor System 80% efficiency platform:10.5N▪m-62 Type: Unit swing 类型...
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SPECIFIC TIGHTENING TORQUES TABLE OF TORQUE FORCE OF FASTENERS Name of fastening parts and fasteners Tightening torque ( N▪m Mounting bolt of front brake cylinder assembly 22-29 Fixing bolt of disc brake handle Fixing bolt of handlebar welding assembly(M10) 40-45 Front wheel spindle locking nut(M12)...
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GENERAL TIGHTENING TORQUES/ BOLTS If no specific torque is given for a bolted assembling use the table below to tighten the screws.If you release a bolted and glued assembling it must be glued in assembling again. For the bonding of screws use Loctite ® 243 ™, follow the instructions for use from the manufacturer. MAXIMUM TORQUE IN NM REFERRING ISO 898/1 FOR METRIC FASTENERS/COEFFICIENT OF FRICTION 0.12 SIZE...
SPECIAL TOOLS Special tools are required for some work but mostly professional work shop equipment is enough for service,repair and maintenance of the vehicle. After disassembly, clean the parts that are to be reused and check them for damage and wear. Re place damaged or worn parts.
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1. TIPS FOR USING THE FOUR MAJOR ELECTRICAL PARTS...
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TIPS 1. CHARGER 1. When charge the battery with a charge,first plug of the charger then the input one.During the charging, both the power indicator and charging indicator of the charge show red. The charging indicator turns to green after full charged.When stop charging,unplug the input first and then the output plug of the charger.
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FAILURE DIAGNOSIS FAILURE DIAGNOSIS PROCEDURE WHEN THE HYDRAULIC DISC BRAKE FAILS Hydraulic disc brake Check the brake fluid level in the brake primary pump liquid reserve tank The brake fluid level below the lower limit of The brake fluid level above the low liquid reserve tank er limit of liq liquid reserve tank Check if there is “sponge”...
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FAILURE DIAGNOSIS FAILURE DIAGNOSIS PROCEDURE WHEN THE DRUM BRAKE FAILS Drum brake fails Check if the free stroke of brake lever is within 10mm ~ 20mm or check if the free stroke of brake pedal is within 20mm ~ 30mm Separate the steel ropes of brake rocker arm and brake Readjust control cable, then pull the brake rocker arm by hand to check...
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FAILURE DIAGNOSIS FAILURE DIAGNOSIS PROCEDURE WHEN MOTOR STOPS RUNNING Motor stops running Check instrument Signal on Signal off abnormal abnormal Check Check input Open circuit Change the breaker connection Voltage of battery between voltage of breake Switch of breaker battery and controller normal breaker...
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FAILURE DIAGNOSIS MAINTENANCE PROCEDURE WHEN MOTOR WON’T STOP RUNNING Motor running all normal abnormal Check handle Controller fault Reconnect/handle Wrong connection or break connection insulation of handle and controller Controller fault Handle fault Replace or repair handle MAINTENANCE PROCEDURE WHEN MOTOR RUNS AND STOPS EVERY NOW AND THEN Motor runs and stops Low capacity of battery Charge or replace battery...
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FAILURE DIAGNOSIS MAINTENANCE PROCEDURE WHEN MOTOR RUNS SLOWLY Motor runs slowly abnormal normal Repair or replace Test handle Charge battery Check battery Motor fault Repair motor normally Capacity charge fault not charged Controller fault Check if motor Charge plug / Fault socket fault Change...
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FAILURE DIAGNOSIS MAINTENANCE PROCEDURE WHEN BATTERY CAN’T BE CHARGED OR CHARGED COMPLETELY Low charging mileage Expiration of battery Change battery Change charger Check charger, not output Bad connection of charger's Pull in the plug or output plug or wire replace wire Bad connection of charger's Replace output output plug or socket...
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FAILURE DIAGNOSIS MAINTENANCE PROCEDURE WHEN HORN DOESN’T SOUND No sound Replace Horn button fault Horn fault Replace Oscillator fault Repair Wrong connection Repair MAINTENANCE PROCEDURE WHEN HEADLAMP OR TURN SIGNAL OFF Headlamp and turn signal off Wiring open circuit Reconnect check line Headlights,turn signal switch Replace the handle switch is broken...
PERIODIC MAINTENANCE CHART Important maintenance work have to be carried out by an authorized workshop. The inspection intervals are required,other- 300km 2000km 4000km 6000km 8000km 10000 km wise,no guarantee can be granted PART TO DO Common check Inspect Steering handle assembly Inspect /replace Fittings, buttons and seal of vehicle Inspect /adjust...
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IMPORTANT PREPARATION REFERENCES Brakes Item Standard value [mm] Allowable limits [mm] Front brake disc thickness Front brake pad thickness Front brake disc diameter —— Inner diameter of rear drum brake —— Thickness of friction piece in rear brake pad Free stroke of front/rear brake lever 10-20 ——...
WHEELS AND TIRES/ BRAKES AIR PRESSURE INSPECTION WARNING △ ! Low tire air pressure leads to abnormal wear and overheating Of the tire. The tire pressure should be measured under cold condition. Use a conventional pressure gauge (1) to test the tire pressure. Correct tire air pressure ensures optimal riding comfort and maximun tire service life.
BRAKES WARNING △ ! Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Please consider that a dirty brake disc influence the bake performance. Please consider that the front brake lever free play is not adjustable BRAKE FLUID LEVEL INSPECTION After a certain time the brake pads start to wear out and...
BRAKES BRAKE DRUM INSPECTION 1. Check the bore of the rear disk drum at several places to see if it conforms to measurement. Allowable limit (A): Ø 111 mm 2. If the bore is more than the specified value change the drum casing (1).
BRAKES BRAKE OPERATION INSPECTION REAR 1. Operate the left hand brake lever until the brake pads lie on the brake drum and check if there is a pressure point. If there is no pressure point check the brake system. 2. While operate the rear brake lever push the vehicle forward and backward on the handlebar to check if the brake system is working.
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SUSPENSION FRONT FORK OPERATION INSPECTION At every inspection the fork should be controlled. 1. Apply the front brake and compress the front shock absorber up and down to check for correct operation. 2. When the fork stick, feel spongy or the free play between the fork tubes is too big replace the defect fork leg.
ELECTRICAL SYSTEM This model is equipped with a sealed type (MF) battery,which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. WARNING △ ! • Do not remove the battery, this can be dangerous, the battery permanently damaged. If a battery do not work correct, have a dealer to check it.
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ELECTRICAL SYSTEM LIGHT AND SWITCHES OPERATION INSPECTION 1. Place the vehicle on the main stand and start the engine. Some functions do not work as long the engine is not running. 2. Now you can test one by one the functions of all switches, the function of the rear and front light and the brake light.
WHEELS AND TIRES EXPLODED VIEW/ PART LOCATION - FRONT WHEEL PART LIST - FRONT WHEEL 1. Nut M12×1.25 6. Disc TORQUE LIST 2. Speedometer drive 7. Bolts for disc PART NO. TORQUE 68-85Nm 3. Tyre 8. Spacer short 4. Tyre valve 9.
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WHEELS AND TIRES EXPLODED VIEW/ PART LOCATION - REAR WHEEL PART LIST - REAR WHEEL TORQUE LIST 1. Motor with rear rim 5.Holder PART NO. TORQUE 2. Nut M16×1.5—8 6. Rear brake assy complete 100-113Nm 3. Nut M16×1.5—12 7.Tyre 4. Bolt M6×16 8.Tyre valve For screws that are not listed use standard values (page 10).
WHEELS AND TIRES FRONT WHEEL REPLACEMENT 1. Place an appropriate supporting stand under the engine In order to raise the front wheel up. 2. Remove the nut (1) to pull out the axle (2). 3. Remove the front wheel. 4. Reassemble in reverse order. NOTE Controll the correct position of the speedometer drive (circle).
WHEELS AND TIRES WHEELS (RIMS) The wheel rims should be checked for cracks, bends. If any damage is found replace the rim. Do not attempt even the smallest repair of the wheel. The wheel should be balanced whenever either the tire or the rim has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characters, and a shortened tire life.
BRAKES PART LOCATION - FRONT BRAKE WARNING △ ! THE BRAKING COMPONENTS MAY NOT BE SPOIL BY OIL DURING INSTALLATION OR DISASSEMBLY. RINSE WITH STIPULATED CLEANING AGENT IN ORDER TO AVOID REDUCTION OF BRAKING QUALITY. PART LIST - FRONT BRAKE 1.
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BRAKES EXPLODED VIEW/ PART LOCATION - REAR BRAKE PART LIST - REAR WHEEL Rear brake drum 2. Brake pads 3. Brake arm TORQUE LIST PART NO. TORQUE 22-29Nm For screws that are not listed use standard values (page 8). SPECIFICATION - FRONT/ REAR BRAKE ITEM STANDARD VALUE [mm] ALLOWABLE LIMIT [mm]...
BRAKES SPECIAL TOOLS See page 11 - 13 TROUBLESHOOTING - FRONT/ REAR BRAKE FAILURE CAUSE TO DO Unfavourable brake adjustment Adjust the brake system Brake pads worn Replace the brake pads Brake pads installed improperly Install the brake pads proper Poor brake performance Brake pads or brake disc conta- Clean or replace the brake pads...
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BRAKES FRONT BRAKE LEVER/ MASTER BRAKE CYLINDER REPLACEMENT When the performance of the front brake is poor it could be possible that the plunger module gaskets are defect. 1. Remove the handlebar covers. 2. Drain the brake fluid from the hydraulic brake system. 3.
BRAKES BRAKE PAD WEAR INSPECTION Reduced braking efficiency caused by worn brake pads. Change worn brake pads immediately. Always replace the brake pads in pair. Front: See page:29 Rear: See page: 30 BRAKE DISC INSPECTION Check the thickness of the front disc (1) at several places on the Disc to see if it confirms to measurement.
BRAKES BRAKE HOSE 1. When the front brake hose is leaking, cracked or worn you must replace it. NOTE Please consider that there is no need to remove the brake calliper when you need to replace the brake hose. 2. When the brake hose need to be replaced use only genuine parts. 3.
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CHASSI EXPLODED VIEW/ PARTS LOCATION - CHASSIS * 21 20 * PART LIST - CHASSIS TORQUE LIST 1. Frame PART NO. TORQUE 2. Bolt M10×25 3,11 40-45Nm 3. Nut M10 4. Rear brake rod 5. Spring side stand 17. Bracket between frame and rear cover 6.
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SUSPENSION EXPLODED VIEW/ PART LOCATION - FRONT SUSPENSION × × × × × × × × PART LIST - REAR WHEEL TORQUE LIST 1. Brake hose cable bracket PART NO. TORQUE 2. Bolt M6×12 55-62Nm 3. Left fork leg 4. Right fork leg 5.
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SUSPENSION EXPLODED VIEW/ PART LOCATION - REAR SUSPENSION PART LIST - REAR SUSPENSION 1. Left shock absorber 2. Right shock absorber 3.Bolt M10×1.25×40 ( only left side illustrated ) 4. Nut M10 ( only left side is illustrated ) SPECIFICATION ITEM DESCRIPTION VALUE...
SUSPENSION SPECIAL TOOLS There are no special tools recommended because defect suspension elements may not be dissembled. Always´s replace defect suspension elements. TROUBLESHOOTING FAILURE CAUSE TO DO Insufficient tire pressure Adjust the tire pressure Broken or bent fork leg Replace the affected fork leg Vehicle difficult to steer Uneven front shock Control and adjust or replace affected...
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SUSPENSION 4. Lift the handle bar up (arrow) and away. 5. Remove the fixing nut (7) and remove the adjustment nut. 6.Remove the bearing components. Details see chapter steering. 7. Remove the front fork. 8. Reassemble in reverse order. NOTE Before the assembling grease the bearing race and the front axle.
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STEERING EXPLODED VIEW - PART LOCATION / STEERING PART LIST FRONT- STEERING 1. Handlebar 6. Upper Bearing race - 10. Bearing set - below 2. Bolt M10×45 above(Adjustment nut) 11. Lower bearing race - below 3. Bush 7. Bearing set - above 12.
STEERING STEERING REPLACEMENT 1. Place an appropriate supporting stand under the engine in order to raise the front wheel up. 2. Remove the front and rear handlebar cover (1), the front middle cover (2), the front mudguard (3), the front wheel (4) and the front brake calliper (5). NOTE 1.
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STEERING STEERING PLAY INSPECTION Worn or loose steering bearings may cause danger. Therefore,the operation of the steering must be checked as follows at the intervals specified in the Periodic maintenance and lubrication chart. 1. Place a stand under the vehicle to raise the front wheel off the ground.
ELECTRICAL SYSTEM/ GENERAL PART LOCATION - ELECTRICAL SYSTEM PART LIST - ELECTRICAL SYSTEM 1. Brake light switch - front 6. Seat Lock 2. Flasher 7. Controller 3. Power lock module/ main switch 8. Converter 4. Brake light switch - rear 9.
ELECTRICAL SYSTEM/ GENERAL SPECIFICATION BATTERY ITEM STANDARD VALUE Full voltage 67.2V Rated capacity 20Ah Weight 8.5kg Length Lithium battery Width Height 0~45℃ Charging Operating Temperature Discharging -10~60℃ BATTERY GENERAL INFORMATION 1. Please read the battery instructions and the label on its surface before use. 2.
ELECTRICAL SYSTEM/ GENERAL GENERAL INSPECTION 1. Controller 2. Converter MOTOR CABLE INSPECTION 1. Remove the connection box cover. 2. Set the multimeter on the plug and measure as show in the table below. 1.6Ω 1.6Ω 1.6Ω 1.6Ω 1.6Ω 1.6Ω Y—Yellow 黄色 L—Blue 蓝色...
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ELECTRICAL SYSTEM/ GENERAL/ SWITCHES CONVERTER INSPECTION 1. Switch on the ignition. 2. Measure the converter (1) as shown in the illustration below. C onvert er P l ug D C / D C P l ug B—Black Y—Yellow R—Red G—Green THROTTLE INSPECTION 1.
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ELECTRICAL SYSTEM/ GENERAL/ SWITCHES PART LOCATION - ELECTRICAL SYSTEM Stop Lamp Rear Reflector ⑤ ⑥ Rear Position Lamp Rear Registration Plate Lamp Front Direction lndicator ③ Rear Direction lndicator ④ Heed Lamp ①② Front Position lamp Side Reflector ⑦ PART LIST - LIGHTS / INSTRUMENTS SWITCHES PART Component Corresponding...
ELECTRICAL SYSTEM/ GENERAL/ SWITCHES MAIN SWITCH INSPECTION 1. Remove the side covers and the leg protection with floor panel. 2. Disconnect the main switch plug (3P) (1). 3. Use a continuity tester to measure the main switch as shown in the illustration. 4.
ELECTRICAL SYSTEM/ GENERAL/ SWITCHES HANDLE SWITCH INSPECTION Left brake 1. Remove the head cover with speedometer and switch plug winkers. 2. Disconnect the related handle switch cable. 3. Use a continuity tester to measure the switches as shown in the illustrations below. 4.
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ELECTRICAL SYSTEM/ GENERAL/ SWITCHES LEFT HANDLE SWITCH INSPECTION 1. Remove the rear handlebar cover. 2. Use a continuity tester to measure the switches as shown in the illustrations below. 3. In case of damage the handle switch need to be replaced.
ELECTRICAL SYSTEM/ LIGHTNING SYSTEM BULBS REPLACEMENT GENERAL INFORMATIONS PREPARATORY DATA Precautions on operation: While trouble shooting electric faults, please check continuity of electric component as current flowing over it. Confirm state of battery before any inspection,including battery voltage. FAULT DIAGNOSIS 1.
ELECTRICAL SYSTEM/ LIGHTNING SYSTEM POSITION LIGHT 1. If the position light (1) is defect, replace the position light (2). HEADLIGHT REPLACEMENT 1. Remove the front handlebar cover. 2. Remove the bolt (1) to remove the headlight (2). FRONT TURNING LIGHT REPLACEMENT 1.
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ELECTRICAL SYSTEM/ LIGHTNING SYSTEM REAR TURNING LIGHT REPLACEMENT 1. Remove the rear side body panel. 2. Remove the six screws (1) to remove the rear turning light (2). REAR LIGHT REPLACEMENT 1. Remove the rear side body panel. 2. Remove the three screws (1) to remove the rear mudguard (2).
ELECTRICAL SYSTEM/ SPEEDOMETER SPEEDOMETER/ INDICATOR LIGHTS REPLACEMENT 1. Remove the rear handlebar cover. 2. Remove the five screws (1) to remove the speedometer. 3. To remove the bulbs, pull out on the cables (2). SPEEDOMETER DESCRIPTION 1. High beam indicator 2.
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ELECTRICAL SYSTEM/ CABLES NOTE • Loose cable is a hidden trouble to electrical safety. After clamped check each cable to ensure electrical safety. • It is not allowed to leave any wire clip bending towards bonding points. • Bind each cable to its designated position. •...
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CHASSIS COVER REPLACEMENT BATTERY BUCKET REMOVAL 1. Open the seat bench. 2. Pull out the battery plug(1) and take out the battery(2). 3. Remove the four bolts (3). 4. Remove the two screws (4) to remove the battery connecting wire. 5.
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CHASSIS 2. After taking out the footboard decoration panel, remove the four screws (2)(B). NOTE Only one side (left side) is illustrated. 3. Use the same method to remove the other side (right side). 4. Pull the rear body panel backwards (arrows). 5.
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CHASSIS REAR DECORATIVE PLATE ASSY REMOVAL 1. Remove the eight screws (1) to remove front cover of storage box (arrows). (Refer to A) 2. Remove the eight screws (2) to remove the rear decorating plate.(Refer to B) 3. Remove the eight screws (3) to remove the Left decorating plate.(Refer to C - D) 4.
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CHASSIS REAR FORK COVER LEFT/ RIGHT REMOVAL 1. Pull out the rear fork cover chrome-plating decoration (1) and pp small cap (2) by using a screwdriver. 2. Remove the two bolts to remove the rear fork (3). NOTE Only one side (left side) is illustrated. REAR INNER MUDGUARD REMOVAL 1.
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CHASSIS FRONT HANDLEBAR COVER REMOVAL 1. Remove the two screws(1) and one bolt (2). 2. Remove the two screws (3) on the left. 3. Remove the two screws (4) on the left. 4. Remove the two screws (5) to remove the front handlebar cover.
CHASSIS FRONT MIDDLE COVER REMOVAL NOTE It is not necessary to remove the front and rear handlebar cover. 1. Remove the front bolt (1). 2. Remove the left three screws (2) ,remove the right side in the same way. 3. Remove the lower left two screws (3) ,remove the right side in the same way.
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CHASSIS TOOL BOX/FOOTPLATE REMOVAL 1. Remove the lower left two screws (1) ,remove the right side in the same way. 2. Remove the left and right pedal bolt (2),right side is not illustrated. 3. Remove the footplate four bolt (3) and the front protecting plate eight screws (4),right side is not illustrated.
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CHASSIS 6. Pull the tool box and footplate removal backwards as shown in the picture (A). 7. Remove the two screws (7) to remove the footplate small cover. 8. Remove the two screws (8) to separate the toolbox from footplate. 9.
CHASSIS FRONT MUDGUARD 1. Remove the three bolts (1) to remove the front mudguard. 2.Remove the three cap nuts (2) to remove the pvc plate.
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MIRRORS BACK VIEW MIRRORS At all repairs in the area of the handle bar is advised to remove the back view mirrors. To prevent damage during installation of the back view mirror consider that on the right side is a left-handed thread and vice versa.
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RIDE is a trademark of KSR Group GmbH Gewerbeparkstrasse 11 3500 Krems, Austria www.ksr-group.com...
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