Gocycle G2 Service Document
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Gocycle G2 Service Document

Front hub rework
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S
D
: G2 F
H
R
ERVICE
OCUMENT
RONT
UB
EWORK
V
1.0
ERSION
Servicing of the Gocycle G2 Front Hub

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Summary of Contents for Gocycle G2

  • Page 1 : G2 F ERVICE OCUMENT RONT EWORK ERSION Servicing of the Gocycle G2 Front Hub...

  • Page 2: Table Of Contents

    Gocycle Service Document: G2 Front Hub Rework 1.0 ONTENTS Overview ......................1 Parts List ......................1 Tool List ......................1 1. Front Disk Cover Removal ................2 2. Front Hub Removal ..................3 3. Front Hub Clutch Replacement ................. 6 4.

  • Page 3: Overview

    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 4: Front Disk Cover Removal

    Gocycle Service Document: G2 Front Hub Rework 1.0 RONT OVER EMOVAL Sleep Note: Before commencing ensure the Gocycle is in 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.

  • Page 5: Front Hub Removal

    Gocycle Service Document: G2 Front Hub Rework 1.0 RONT EMOVAL 2.1. Use a 5mm Allen key to unscrew and remove the two calliper securing bolts. 2.2. Use a 3mm Allen key to undo the 4 bolts (2162) that secure the Fork Brace (2100).
  • Page 6 Gocycle Service Document: G2 Front Hub Rework 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...
  • Page 7 Gocycle Service Document: G2 Front Hub Rework 1.0 2.6. Support the MotorGearbox 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: Front Hub Clutch Replacement

    Gocycle Service Document: G2 Front Hub Rework 1.0 RONT LUTCH EPLACEMENT 3.1. Slide the Front hub assembly into the Hub Bearing Jig as demonstrated. Ensure it is fully located within the jig. 3.2. If the Clutch gear cog is still...
  • Page 9 Gocycle Service Document: G2 Front Hub Rework 1.0 3.4. Hold the slide hammer as demonstrated and using a quick strong action slide the weight up to the stop. This action will exert a force on the lower edge of the gear cog and extract 3.5.
  • Page 10 Gocycle Service Document: G2 Front Hub Rework 1.0 3.7. Install the slide hammer and extractor so it sits within the inner race of the clutch. Hold the extractor still and tighten the top nut as demonstrated. This protrudes into the...

  • Page 11: Fork Upright Disassembly

    Gocycle Service Document: G2 Front Hub Rework 1.0 PRIGHT ISASSEMBLY 4.1. Place the Fork blade jig into the Fork upright as demonstrated. 4.2. Attach the Fork brace and install the 4 securing bolts using a 3mm Allen key. 4.3. Clamp the Fork...
  • Page 12 Gocycle Service Document: G2 Front Hub Rework 1.0 4.4. Press the tool into the axle as demonstrated. 4.5. Install a breaker bar as shown and turn clockwise order to undo the hub assembly from the Fork upright. 4.6. The Fork Upright...

  • Page 13: Front Hub Disassembly

    Gocycle Service Document: G2 Front Hub Rework 1.0 RONT ISASSEMBLY 5.1. Place the front hub assembly into the jig and use a flat screwdriver to remove the circlip that retains the front shaft and bearings. Use one flat screwdriver to...
  • Page 14 Gocycle Service Document: G2 Front Hub Rework 1.0 5.4. Grip the lower portion of the extractor and tighten the top nut as demonstrated. Ensure the extractor is located beneath the outer bearing and lower edge of the axle. 5.5. Now install the...
  • Page 15 Gocycle Service Document: G2 Front Hub Rework 1.0 5.7. The whole axle assembly should come free as shown. 5.8. Undo the split collet extractor nut and the shaft and two bearings should be free as shown. © Karbon Kinetics Limited. All Rights Reserved.

  • Page 16: Front Hub Reassembly

    Gocycle Service Document: G2 Front Hub Rework 1.0 RONT EASSEMBLY 6.1. Install the clutch Gear cog into the clutch bearing as shown. Ensure the keyway is installed correctly. This push fit can be completed by hand or through the use of a vice.
  • Page 17 Gocycle Service Document: G2 Front Hub Rework 1.0 6.4. Rotate the hub from side to side until the hub locates on the outer keyway of the clutch. 6.5. Press down onto the jig until the clutch is fully located within the front hub.
  • Page 18 Gocycle Service Document: G2 Front Hub Rework 1.0 6.6. Place the front shaft and bearing assembly into the front hub. 6.7. Place the front shaft bearing press tool onto the Hub assembly as shown. 6.8. Place this into a vice with soft jaws...
  • Page 19 Gocycle Service Document: G2 Front Hub Rework 1.0 6.9. Place the assembled Front hub into the jig and reinstall the circlip. Note the orientation of the open end. 6.10. With the fork upright and jig secured in the vice offer the front hub and shaft tool as shown.

  • Page 20: Fitting The Front Hub To The Motorfork

    Gocycle Service Document: G2 Front Hub Rework 1.0 ITTING THE RONT UB TO THE OTOR 7.1. Line up the 6 Spring pins with the Motor Torque Bungs. The Clutch will need to be manually aligned with the output shaft of the MotorGearbox.
  • Page 21 Gocycle Service Document: G2 Front Hub Rework 1.0 7.4. Install the Fork Brace and the four securing bolts. Tighten in the order demonstrated to 4- 5Nm. 7.5. Now install the brake calliper alignment tool as shown. 7.6. Pull the brake...
  • Page 22 Gocycle Service Document: G2 Front Hub Rework 1.0 7.7. Press on the calliper to align with the brake rotor and tighten the two securing bolts starting with the bottom bolt. 7.8. Locate the Front Disk Cover and align the securing bolt holes.
  • Page 23 Gocycle Service Document: G2 Front Hub Rework 1.0 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...

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