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Summary of Contents for RFN ARES RALLY PRO 2023
- Page 1 RFN ARES RALLY PRO Maintenance Manual Electric Motorcycle...
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Page 2: Table Of Contents
// Table Of Contents 1. Important Cautions................3.1.7 Lithium Battery, Step for removing the 1.1 Serial No. Position................battery..................1.1.1 Vehicle Identification No.1.1.2 Motor No....3.1.8 Description of Lithium Battery Interface....1.1.2 Motor No..................3.1.9 Charge..................1.1.3 Definition of Vehicle Identification No...... 3.1.10 Motor.................. -
Page 3: Important Cautions
// 1. Important Cautions Guarantee The work specified in the service plan must be performed in an authorized workshop and in accordance with the scope of the customer’s service card, otherwise no warranty claims can be made. The damage caused by operation and/ or vehicle modifications can not be covered by the warranty claim service. -
Page 4: Serial No. Position
1.1 Serial No. Position 1.1.1 Vehicle Identification No. Frame number (VIN) (1) on the right side of the front riser 1.1.2 Motor No. Motor number is engraved on the right side of the motor 1.1.3 Definition of Vehicle Identification No. VIN code figures sequential production... -
Page 5: General Technological Conditions
1.2 General Technological Conditions 1.2.1 Vehicle Specification Battery Capacity: 35Ah / 2.5kWh LG Premium 21700 lithium cells Cells: Features: Removable, can be charged when installed in bike or separately. Voltage Brake modes Brake mode 1: Freewheel, no motor brake Brake mode 2: Motor brake with energy regeneration Brakes Disc:... -
Page 6: Torque
1.2.2 Torque Fastening 14 15 serial Position of installation specification quantity torque number value brake bottom pump 13-15 Front axle side cover 28-30 Shock- 8-10 absorber Lower Cylinder Front and rear brake discs 16-18 shock-absorber decorate cover Motor guard support 43-45 Third gear switch 3.5-4.5... -
Page 7: Regular Maintenance
// 2. Regular Maintenance *The inspection frequency must be observed, otherwise the warranty will be invalid. The 1st Every Every Every Every 2 1000KM 1000 KM 3000KM year years component activity display switch Check Check ， electric system Check Check Check battery Check... -
Page 8: Vehicle Wheel Maintenance
Electrical System Part Item Technological Parameter Rated Voltage Capacity 35Ah/2590Wh Voltage Over-voltage Under-voltage Charging Current Standard Battery Fast Charging Duration Standard ～ Fast ～ Work Temperature ～ ℃ Peak Power 11KW/1400RPM Motor Type TOLL Encapsulated power tube Controller Control Method FOC SVPWM Battery Charging Voltage 2.1 Vehicle Wheel Maintenance... -
Page 9: Inspection On Wheel Axle And Damage Of Wheel Axle
2.1.2 Inspection on Wheel Axle and Damage of Wheel Axle 1. Di cult wheel rotation, or wheel rotation with a strange noise, may be caused by the failure of the axle bearing (1) or hub (2) . 2. See (Replacement of front wheel bearing) and (Replacement of rear wheel bearing) for the steeps of replacing the wheel bearing. -
Page 10: Inspection On And Replacement Of Brake Pad
2.2.3 Inspection on and Replacement of Brake Pad *Reduce the braking e ciency due to worn brake pads. Replace worn brake pads immediately. If need to replace the brake pads, please replace a pair of such brake pads at the same time, do not just replace a single brake pad. 1. -
Page 11: Inspection On And Replacement Of Rear
2.2.5 Inspection on and Replacement of Rear Brake Disc 1. Replace the brake disc when the thickness of the disc is less than 1.5mm (limit value) at any position or if it is damaged, cracked or deformed 2. Place a suitable bracket under the vehicle to lift the rear wheels. 3. -
Page 12: Replacement Of Brake Calliper
2.2.7 Replacement of Brake Calliper 1. Remove the oil pipe (1) from the brake caliper. 2. Drain the brake fluid from the hydraulic brake system. 3. Unscrew and remove the two bolts (2) connecting the brake caliper. 4. Replace the brake caliper. 5. -
Page 13: Adjustment Of Brake Rod
2.2.9 Adjustment of Brake Rod 1. Adjust the brake rod adjusting bolt (1). 2. Narrow the gap between the tie rod and handlebar by twisting in a counterclockwise way (1), and enlarge the gap between the tie rod and handlebar by twisting in a clockwise way (1) 【Note】... -
Page 14: Inspection On Abrasion Of Transmission Chain
2.3.4 Inspection on Abrasion of Transmission Chain 1. Stretch the chain to a taut state and measure the center distance of ten links (A) 2. When the measurement result exceeds the maximum value 129.1mm, replace the chain immediately. 2.3.5 Replacement of Transmission Chain 1. -
Page 15: Inspection On Rear Shock Absorber
2.4.3 Inspection on Rear Shock Absorber 1. Check that each screw is tightened. 2. Compress the rear shock absorber up and down to check for proper function (arrows). 3. Check whether the shock core of the rear shock absorber is damaged or loose. 4. -
Page 16: Electrical Maintenance
2.6 Electrical Maintenance 2.6.1 Maintenance of Battery 1. Always keep the battery to be charged. Storing a depleted battery will cause permanent damage to the battery. 2. If the vehicle has not been used for more than one month, remove the battery from the vehicle to recharge it, as described in the (Lithium Battery) section, and store it in a dry place at 0-40°... -
Page 17: Inspection On Operation Of Key Sets
2.6.3 Inspection on Operation of Key Sets 1. Place the vehicle on the stand so that the rear wheels are o the ground, and then start the vehicle. 【Note】Please unlock the vehicle P gear and enter the “ready” gear 2. Test the function of all switches one by one 3. -
Page 18: Repair And Diagnosis
// 3. Repair and Diagnosis 3.1 Electric System Motor Parameter Item Type / Specification Rated Busbar Voltage Rated Power 5 kW Peak Power (10min) 11kW@1400rpm Rated Service Speed 2200rpm Max Service Speed 3000rpm Rated Torque 21.7N•m Peak Torque 58N•m Rated Phase Current Peak Phase Current 350A Max Motor E ciency... -
Page 19: Caution For Operation
3.1.1 Caution for Operation 1. When checking the lithium battery to be used, make sure there is no abnormality in the lithium battery first. 2. The on/o test of the switch can be inspected and measured in the car body installation state of the switch. 3. -
Page 20: Fault Phenomenon And Fault Shooting
3.1.3 Fault Phenomenon and Fault Shooting Fault Instrument Serial No. Cause for Fault Shooting Method Phenomenon Code 1.Single brace fails to be retracted 1.Retract the single brace or replace the single brace switch or single brace switch encounters a failure Turn on the power, the ready 2. -
Page 21: Instrument
3.1.4 Instrument Definition of Function of Instrument Interface Green (72V-) Red (72V+) Yellow (Pass signal through one line) One line with three cores (0.5mm) DJ7031J-1-21 Color of Line Function Remarks Electric door lock signal DC72V + Green Power source - Yellow Data communication One line pass data line... -
Page 22: Lithium Battery, Step For Removing The Battery
3.1.7 Lithium Battery, Step for removing the battery 1. Open the seat cushion 5. Unplug the power supply 2. Open the locking mechanism 6. Lift up the battery 3. Take o the battery cover Insert the battery 4. Unplug the communication plug Insert the battery in the reverse order. -
Page 23: Description Of Lithium Battery Interface
3.1.8 Description of Lithium Battery Interface Communication port Discharge port Discharge+ Charging port Discharge- Power lock Empty Dust cover signal 72V+ CAN-H Charge+ Charge- Empty Ventilation valve Empty CAN-L Empty Empty Power down activation CAN-H Empty CAN-L Charging port Communication port definition definition 【Note】... -
Page 24: Charger
3.1.12 Charger Empty 【Note】 1. Prohibit flushing by water gun and being immersed in water. 2. Keep the vehicle body neat and tidy to prevent the heat sink from being blocked. Empty 3. The voltage output will be available only after the charging output port is successfully communicated by CAN. -
Page 25: Electrical Schematic Diagram
3.1.13 Electrical Schematic Diagram... -
Page 26: Chassis
3.2 Chassis 3.2.1 Chassis Exploded View / Parts Location - Chassis Hexagon socket flower- Battery Front side plate fixing Frame reinforcement Foot assembly Subframe assembly shaped flange face bolt mount left bracket plate right right M8X1.25X205mm Hexagon socket flower- Motor left Flange face Knurled implosion Cap nut M8 X 1.25... -
Page 27: Replacement Of Pedal
3.2.3 Replacement of Pedal 1. Unscrew the foot pedal fixing bolt (1) 2. Replace the new foot pedal 3.2.4 Exploded Vide / Part Location - Seat Cushion Seat cushion assembly Left center side trim panel Seat cushion retaining pin Right center side panel Center side panel mounting bolts M6 x 12 List of Part 3.2.5 Replacement of Seat Cushion... -
Page 28: Wheel And Tyre
3.3 Wheel and Tyre 3.3.1 Exploded Vide / Part Location - Front Wheel Parts list: 1. Front wheel axle screw plug 2. Front wheel axle 3. Front wheel right spacer 4. 26 x 37 x 7 oil seal 5. 61904 bearing 6.Tyre 70/100-19 7. -
Page 29: Clearing Of Fault
3.3.3 Clearing of Fault Fault Cause for Fault Solution Damage of wheel axle Replace the wheel axle Di cult to move the wheel or front wheel Tyre pressure is over low Adjust the tyre pressure The rim is damaged Adjust the spoke or replace the rim Wheel is unbalance The tyre is wore Replace the dynamic balance level of tyre or wheel... -
Page 30: Disassembly Of Front Wheel And Replacement Of Front Wheel Axle
3.3.7 Disassembly of Front Wheel and Replacement of Front Wheel Axle 1. Lift up the front wheels of the vehicle and stabilize the vehicle body. 2. Unscrew the bottom foot bolt (1) of the shock absorber. 3. Remove the front axle (2) and front wheel. . 4. -
Page 31: Inspection On Wheel Axle
3.3.9 Inspection on Wheel Axle 1. Check the rolling condition of the bearing. Rotate the inner ring of the bearing with your finger. 2. If it does not roll, or the bearing is damaged, or there is a gap (A, B) or the bearing rotates sticking, replace the bearing. -
Page 32: Clearing Of Fault
3.4.2 Clearing of Fault Fault Cause Solution Improperly adjusted brakes Adjuste the brake system Worn brake pads Replace brake pads Improper installation of brake Install the brake pads correctly Poor brake pads performance Contaminated brake pads or Clean or replace the brake pads and discs clean the brake discs Air in the front brake hose... -
Page 33: Replacement Of Brake Rod
3.4.6 Replacement of Brake Rod 【Note】If the brake rod is deformed, broken and any other damage, please replace the damaged brake rod immediately 1. Loosen the brake rod top wire (1) 2. Use 1.5mm hexagonal wrench to jack out the brake rod spindle (2) 3. -
Page 34: Torque Table
3.5.1 Torque Table Bolt Torque 10-15 Nm 3.5.2 Specification of Front Shock Absorber Item Description Parameter Journey Journey of shock absorber 200mm Damping Oil Type of damping oil 15w Capacity 220ml ± 5ml 3.5.3 Replacement of Front Shock Absorbe 1. Place a suitable bracket under the vehicle to lift the front wheels. 2. -
Page 35: Replacement Of Shock Absorbing Yoke Plate
3.5.4 Replacement of Shock Absorbing Yoke Plate and Steering Axle 1. Place a suitable bracket under the vehicle to lift the front wheels. 2. Remove the front shock absorber (see “Replacement of Front Shock Absorber” for steps) 3. Remove the instrument and gauge bracket 5. -
Page 36: Exploded View/ Part Location - Rear Suspension
3.5.6 Exploded View/ Part Location - Rear Suspension Hexagonal step bolt M10 Hexagon socket flat round head Chain adjuster left Rear fork reinforcement beam X 1.25 X 30 screws M6 X 30 Hexagon head bolt full Hexagon socket flat round head Fork protection sleeve Foot support bushings thread M8 X 60 X 1.25... -
Page 37: Clearing Of Fault
3.5.8 Clearing of Fault Fault Cause Solution Insu cient tyre pressure Adjust the tyre pressure Broken or bent fork legs Replace the a ected fork leg Steering vehicle deviation Uneven support of the front shock Adjust the shock damping or replace absorber from left to right damaged fork legs Front shock... -
Page 38: Replacement Of Rear Swing Arm
3.5.10 Replacement of Rear Swing Arm 【Note】To replace the rear swing arm, please follow the steps below: 1. Raise the vehicle until the rear wheels are o the ground. 2. Open the chain lock, then remove the chain. 3. Remove the rear brake parts attached to the swing arm or rear wheel. 4. - Page 39 NOTES:...
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