Gocycle G2 Gear Servo Service Document
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Gocycle G2 Gear Servo Service Document

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S
D
: G2 S
ERVICE
OCUMENT
ERVO
V
1.0
ERSION
Service Document for the G2 Gear Servo

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Summary of Contents for Gocycle G2 Gear Servo

  • Page 1 : G2 S ERVICE OCUMENT ERVO ERSION Service Document for the G2 Gear Servo...

  • Page 2: Table Of Contents

    Gocycle Service Document: G2 Servo 1.0 ONTENTS Overview........................1  Parts List........................1  Tool List.........................1  Best Practice Guidelines ....................2  Electrical System Best Practice Guidelines ................. 3  1.  Right-Hand Crank Arm Removal ................. 4  ® 2.  Cleandrive Cover Removal ..................6  3.  Chain Removal ......................8 ...

  • Page 3: Overview

    Gocycle Service Document: G2 Servo 1.0 VERVIEW This service document details the service of the G2 Servo. If you have any questions, or require any further assistance, please contact techsupport@gocycle.com. ARTS Note: When ordering replacement The following parts are referenced within this document.

  • Page 4: Best Practice Guidelines

    Ensure the Gocycle is appropriately secured to prevent injury and damage. If the Gocycle has been ridden continuously for more than 5 minutes, allow a minimum of 30 minutes before performing any maintenance or service activity on the electrical system.

  • Page 5: Electrical System Best Practice Guidelines

    0°C and 40°C (32°F and 104°F) and a humidity of 45% to 85% RH. If you wish to remove the Gocycle Light Kit, the light harness on Gocycles FN <240000 must also be removed. October 2014 © Karbon Kinetics Limited. All Rights Reserved.

  • Page 6: Right-Hand Crank Arm Removal

    Gocycle Service Document: G2 Servo 1.0 IGHT RANK EMOVAL 1.1. Invert the G2 and locate in a work stand. Remove both ® PitStopWheels 1.2. Use a wrench with an 8mm Hex bit to undo the Right-Hand Crank Arm Bolt (2283).
  • Page 7 Gocycle Service Document: G2 Servo 1.0 1.3. Use a square taper crank puller to remove the Right-Hand Crank Arm (2061). 1.4. Take care when removing the crank arm and ensure to keep all 8 dowel pins (2175) located as well as all 4 Carbon Steel Wave Springs (2225).

  • Page 8: Cleandrive ® Cover Removal

    Gocycle Service Document: G2 Servo 1.0 ® 2. C LEANDRIVE OVER EMOVAL 2.1. Using a T25 Torx Bit, unscrew the eleven Magform Bolts (11) as shown. ® 2.2. Rotate the Cleandrive upwards, as shown 2.3. Unscrew and remove the remaining Magform Bolt (11).
  • Page 9 Gocycle Service Document: G2 Servo 1.0 ® 2.4. The Cleandrive Cover can now be removed ready for internal inspection. October 2014 © Karbon Kinetics Limited. All Rights Reserved.

  • Page 10: Chain Removal

    Gocycle Service Document: G2 Servo 1.0 3. C HAIN EMOVAL 3.1. Use your thumb to apply upward pressure on the Chain Tensioner as shown. 3.2. Release the Chain from the Chain Tensioner ® and use the LockShock to secure the Chain Tensioner as demonstrated.
  • Page 11 Gocycle Service Document: G2 Servo 1.0 3.3. Allow the Chain to hang free and remove the Chainring from the Bottom Bracket Spindle as shown. October 2014 © Karbon Kinetics Limited. All Rights Reserved.

  • Page 12: Servo Removal

    Gocycle Service Document: G2 Servo 1.0 4. S ERVO EMOVAL Sleep Mode’ Note: Before commencing ensure the Gocycle battery is in ‘ or disconnected and removed 4.1. Once the Chainring has been removed, the Main Junction Board (JB) will be v as shown.
  • Page 13 Gocycle Service Document: G2 Servo 1.0 4.3. Remove the Main Junction Board PCB taking care not to touch the components on the board, as shown. 4.4. Hold the edge of the Main Junction Board PCB as shown, and remove the 2 pin white connector.
  • Page 14 Gocycle Service Document: G2 Servo 1.0 4.6. Allow the chain to rest as shown so that both balance springs are free and accessible. 4.7. Remove the Cable Guide Upper by unscrewing the two retaining bolts using a Torx T15 Note: Depending on...
  • Page 15 Gocycle Service Document: G2 Servo 1.0 4.8. With the Cable Guide Upper removed. 4.9. Pull the wires out of the Cable Guide Lower to reveal the heat-shrink- wrapped section. These wires are the Servo Controller Cable (with the flat black connector) and the Rear Sensor Cable (with the white connector).
  • Page 16 Gocycle Service Document: G2 Servo 1.0 4.11. When the shrink wrap has been removed, there may be excess wiring coiled up underneath. 4.12. Unhook the E Shift Balance Spring from its mount on the Cleandrive. 4.13. Remove the E-Shift Balance Spring from the...
  • Page 17 Gocycle Service Document: G2 Servo 1.0 4.14. With the E-Shift Balance Spring removed, the retaining bolt can also be removed. 4.15. Use a 2.5mm Allen key and take care to keep the E-Shift Spring Spacer with the bolt. 4.16. Remove the E-Shift Spring.
  • Page 18 Gocycle Service Document: G2 Servo 1.0 4.17. Unhook the Servo end first. Using pliers, rotate the E-Shift Spring towards you so that the hooked end becomes free of the Servo Horn, then pull away from the Servo. 4.18. The E-Shift Spring can be left hooked at the other end.
  • Page 19 Gocycle Service Document: G2 Servo 1.0 4.20. Remove the Cable Guide Lower along with the Servo from the Cleandrive by pulling it away. 4.21. Remove the Servo from the Cable Guide Lower. This is done by pulling the Servo out of the Cable Guide Lower and threading the cable out.

  • Page 20: Servo Installation

    Gocycle Service Document: G2 Servo 1.0 5. S ERVO NSTALLATION 5.1. To fit the new Servo, first loop the Servo Controller Cable through the large lower hole in the Cable Guide Lower, then back up through the smaller upper hole. Whilst pulling the wire through, fit the servo back into its mounting hole.
  • Page 21 Gocycle Service Document: G2 Servo 1.0 5.4. Reattach the Cable Guide Lower with Servo to the Cleandrive. 5.5. Secure the Servo in position with the three M3 x 25 Caphead bolts, ensuring the washers are present. 5.6. The Chain must...
  • Page 22 Gocycle Service Document: G2 Servo 1.0 5.8. This shows the E- Shift Spring correctly installed. 5.9. Locate the E-Shift Balance Spring Link into the Servo Horn as shown. 5.10. Connect the end of the E-Shift Balance Spring to the E-Shift Balance Spring Link as shown.
  • Page 23 Gocycle Service Document: G2 Servo 1.0 5.11. Install the E-Shift Balance Spring retaining bolt along with E-Shift Spring Spacer using a 2.5mm Allen Key. 5.12. Hook the hooped end of the E-Shift Balance Spring on to the bolt as shown.
  • Page 24 Gocycle Service Document: G2 Servo 1.0 5.14. Check the length of the new Servo Controller Cable by running it up through the Cable Guide Lower so that the connector block is near its mounting location on the Main Junction Board.
  • Page 25 Gocycle Service Document: G2 Servo 1.0 5.18. Insert the Rear Brake Hose and the combination of Servo and Rear Sensor Cable in to the Cable Guide Lower channels and mount the Cable Guide Upper to secure them in place by hand as shown.

  • Page 26: Main Pcb Refit

    Gocycle Service Document: G2 Servo 1.0 PCB R EFIT 6.1. Reconnect the Servo Cable. Ensure that the brown cable aligns with the negative pin. Note: On some models the negative cable will be black. 6.2. Connect the Rear Sensor Cable and ensure it is fully closed.
  • Page 27 Gocycle Service Document: G2 Servo 1.0 6.4. Align the Main Junction Board PCB Board flush against the Cleandrive and reinstall the securing screws as demonstrated. October 2014 © Karbon Kinetics Limited. All Rights Reserved.

  • Page 28: Chain Installation

    Gocycle Service Document: G2 Servo 1.0 7. C HAIN NSTALLATION 7.1. Re-install the Chainring on to the Bottom Bracket Spindle and locate the Chain on to the Chainring as shown. 7.2. Apply light upward pressure to the Chain Tensioner in order to ®...

  • Page 29: Cleandrive ® Inspection

    Gocycle Service Document: G2 Servo 1.0 ® 8. C LEANDRIVE NSPECTION 8.1. Ensure the three Chain Pins are installed correctly and that the chain runs through them as shown. 8.2. Check the Servo Balance Springs are installed correctly as shown.

  • Page 30: Cleandrive Cover Installation

    Gocycle Service Document: G2 Servo 1.0 ® 9. C LEANDRIVE OVER NSTALLATION ® 9.1. Align the Cleandrive cover ready for reassembly. 9.2. Take care to line up the brake hose seal correctly, as shown. 9.3. Install the 11 Magform Bolts back into the ®...
  • Page 31 Gocycle Service Document: G2 Servo 1.0 9.4. Rotate the ® Cleandrive in order to install the final Magform Bolt. October 2014 © Karbon Kinetics Limited. All Rights Reserved.

  • Page 32: Crank Arm Installation

    Gocycle Service Document: G2 Servo 1.0 10. C RANK NSTALLATION 10.1. Before assembling the Right-Hand Crank Arm, ensure that the Carbon Wave Springs (2225) are installed as well as the 8 Dowel Pins (2175), as shown. Note: Your Gocycle may have 1-3 Carbon Wave Springs.
  • Page 33 35-40Nm torque. IMPORTANT NOTE: YOU MUST CARRY OUT THE ABOVE REMOVAL AND REPLACEMENT STEPS 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...

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