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UBCO 2x2 ADV Gen 5 Technical & Service Manual

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Technical
Service Manual
Version 1 0
Version 1 0
Version 1.0
Version 1.0
e s o
e s o
.0
.0
October 2023

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Summary of Contents for UBCO 2x2 ADV Gen 5

  • Page 1 October 2023 Technical Service Manual Version 1.0 Version 1.0 Version 1 0 Version 1 0 e s o e s o...

  • Page 2: Table Of Contents

    Application of Threadlocker ....19 Standard Torque Settings ....19 UBCO TECHNICAL SERVICE MANUAL PAGE 2 OF 159...
  • Page 3 Brakes ........52 UBCO TECHNICAL SERVICE MANUAL...
  • Page 4 Front Mudguard ......111 UBCO TECHNICAL SERVICE MANUAL PAGE 4 OF 159...
  • Page 5 Planetary Gear Set ......156 Motor Bearings and Seals ....158 UBCO TECHNICAL SERVICE MANUAL PAGE 5 OF 159...

  • Page 6: General Information

    GENERAL INFORMATION UBCO TECHNICAL SERVICE MANUAL PAGE 6 OF 159...

  • Page 7: General Information And Disclaimers

    : This manual is not a substitute for professional PROFESSIONAL GUIDANCE advice, diagnosis, or repair services. It is essential to consult with an UBCO certified technician or manufacturer-approved service personnel when dealing with complex technical repairs or maintenance tasks. The manual is meant to complement, not replace, professional expertise.

  • Page 8: Bike Identification

    Your use of this manual constitutes your acceptance of these disclaimers and limitations. BIKE IDENTIFICATION UBCO ADV and WRK bikes are manufactured with a Vehicle Identification Num- ber (VIN) and Product Identification Number (PIN) respectively. This identifier is located on the right hand side of the head tube of the frame.

  • Page 9: Brake System Identification

    BRAKE SYSTEM IDENTIFICATION The UBCO 2x2 Gen 5 is available with different braking systems. These are referred to as- “SR” or “SYS 2” Where there are variations in processes due to these different brake systems, clear instructions for each system are provided.
  • Page 10 SYSTEM 2 UBCO TECHNICAL SERVICE MANUAL PAGE 10 OF 159...

  • Page 11: Required Tools And Consumables

    • #1 Philips • 8mm Crows Foot • #2 Philips • 10mm • 5mm Flat • 17mm • 21mm SPANNERS • • 17mm • • 36mm • 10mm • 13mm • 14mm UBCO TECHNICAL SERVICE MANUAL PAGE 11 OF 159...
  • Page 12 • Dial Gauge Note - Impact drivers should not be used at any point within the assembly or dis- assembly of components on the UBCO bike. The following consumables are required for carrying out the processes defined within this manual.

  • Page 13: Bike Orientation

    Throughout this manual the bike orientation is to referred to from the rider posi- tion. For example, the right hand side refers to the right hand side of the vehicle when you are seated, facing the handlebars. Front Right UBCO TECHNICAL SERVICE MANUAL PAGE 13 OF 159...

  • Page 14: Model Specifications

    MODEL SPECIFICATIONS UBCO TECHNICAL SERVICE MANUAL PAGE 14 OF 159...

  • Page 15: Model Naming

    Model......UBCO 2x2 ADV Gen 5 (2020 to Present) ......UBCO 2x2 WRK Gen 5 (2020 to Present) DIMENSIONS Length .

  • Page 16: Brakes - Sys 2

    Rear Brake Disc Runout Limit ........0.5mm UBCO TECHNICAL SERVICE MANUAL...

  • Page 17: Front Suspension

    Trail ............95.7mm UBCO TECHNICAL SERVICE MANUAL...

  • Page 18: Service Information

    SERVICE INFORMATION WAITING FOR UBCO UBCO TECHNICAL SERVICE MANUAL PAGE 18 OF 159...

  • Page 19: Component Reuse

    To avoid warp- age, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise speci- UBCO TECHNICAL SERVICE MANUAL PAGE 19 OF 159...

  • Page 20: Use Of Cable Ties

    If the brake pads or discs do become contaminated, attempt to clean with Isopropyl alcohol and discard if unsuccessful. UBCO TECHNICAL SERVICE MANUAL PAGE 20 OF 159...

  • Page 21: Service Checks, Adjustments And Processes

    SERVICE CHECKS, ADJUSTMENTS AND PROCESSES UBCO TECHNICAL SERVICE MANUAL PAGE 21 OF 159...

  • Page 22: Sys 2 - Checking Brake Fluid Level

    1. Master Cylinder Top Surface PROCESS STEPS 1. Ensure the Master Cylinder Top Surface is parallel to the ground 2. Looking horizontally at the level indicator ensure it is above the minimum line UBCO TECHNICAL SERVICE MANUAL PAGE 22 OF 159...

  • Page 23: Sys 2 - Bleeding / Replacing Brake Fluid

    SYS 2 - BLEEDING / REPLACING BRAKE FLUID Follow the below processes to bleed the brakes. If replacing the brake fluid, carry out the optional processes clearly highlighted UBCO TECHNICAL SERVICE MANUAL PAGE 23 OF 159...
  • Page 24 12. Using a #2 Philips Head Screwdriver, tighten the Master Cylinder Cover Fas- teners securing the Master Cylinder Cover 13. Using Isopropyl Alcohol and a Lint Free Cloth, clean both the Master Cylinder Assembly and Caliper Assembly UBCO TECHNICAL SERVICE MANUAL PAGE 24 OF 159...

  • Page 25: Sys 2 - Inspecting Brake Pads

    Page 53 3. Using a Micrometer, measure the Brake Pad Thickness. If below the limit out- lined on Page 16 replace the Brake Pads using the method outlined on Page 53. UBCO TECHNICAL SERVICE MANUAL PAGE 25 OF 159...

  • Page 26: Sys 2 - Inspecting Brake Discs

    5. Using a Micrometer measure the thickness the of the Brake Disc at 6 locations spaced evenly around the circumference of the Brake Disc 6. If the thickness of the Brake Disc is below the limit outlined on Page 16 discard the Brake Disc and replace UBCO TECHNICAL SERVICE MANUAL PAGE 26 OF 159...

  • Page 27: Sr - Checking Brake Fluid Level

    PROCESS STEPS 1. Ensure the Master Cylinder top surface is parallel to the ground 2. Looking horizontally at the level indicator ensure it is above / below the max / min line. UBCO TECHNICAL SERVICE MANUAL PAGE 27 OF 159...

  • Page 28: Sr - Bleeding / Replacing Brake Fluid

    SR - BLEEDING / REPLACING BRAKE FLUID Follow the below processes to bleed the brakes. If replacing the brake fluid, carry out the optional processes clearly highlighted UBCO TECHNICAL SERVICE MANUAL PAGE 28 OF 159...
  • Page 29 11. Install the Syringe onto the Caliper 12. Slowly press the Syringe until bubbles stop appearing in the Bleed Kit Funnel 13. If the fluid in the Bleed Kit Funnel is heavily discoloured it must be replaced UBCO TECHNICAL SERVICE MANUAL PAGE 29 OF 159...
  • Page 30 25. Using Isopropyl Alcohol and a Lint Free Cloth, clean both the Master Cylinder and Caliper thoroughly. 26. After re-installing the Brake Pads and Wheel the Caliper may need adjusted using the method outlined on Page 31 UBCO TECHNICAL SERVICE MANUAL PAGE 30 OF 159...

  • Page 31: Sr - Adjusting Brake Calipers

    4. Pull on the Brake Lever Blade and while pressure is still being applied, using a 5mm Allen Key, tighten the Caliper Fasteners 5. Release the Brake Lever Blade and test for Brake Pad rub by spinning the Wheel UBCO TECHNICAL SERVICE MANUAL PAGE 31 OF 159...
  • Page 32 6. If the Brake Pad is rubbing after adjustment, individually loosen the top and bottom fasteners and gently adjust the position of the Caliper until no rub- bing occurs 7. Using a 5mm Allen Key Socket and Torque Wrench, tighten the Caliper Fasten- ers. UBCO TECHNICAL SERVICE MANUAL PAGE 32 OF 159...

  • Page 33: Sr - Inspecting Front Or Rear Brake Pads

    Page 68 3. Using a Micrometer, measure the Brake Pad Thickness. If below the limit out- lined on Page 16 replace the Brake Pads using the method outlined on Page 68. UBCO TECHNICAL SERVICE MANUAL PAGE 33 OF 159...

  • Page 34: Sr - Inspecting Brake Discs

    5. Using a Micrometer measure the thickness the of the Brake Disc 6. If the thickness of the Brake Disc is below the limit outlined on Page 16 discard the Brake Disc and replace UBCO TECHNICAL SERVICE MANUAL PAGE 34 OF 159...

  • Page 35: Sr - Adjusting Lever Blades

    Lever Blade closer to the Grip / Throttle or clockwise to move the Lever Blade further away from the Grip / Throttle. 2. After adjusting, ensure that when fully actuated the brakes give a firm stop approximately 10mm away from the Grip / Throttle UBCO TECHNICAL SERVICE MANUAL PAGE 35 OF 159...

  • Page 36: Adjusting Front Suspension Settings

    1. Spring preload is adjusted on the left side of the fork. 2. Twist the dial clockwise to lessen the spring force and make the suspension softer and anti-clockwise to increase the spring force and make the suspen- sion stiffer. UBCO TECHNICAL SERVICE MANUAL PAGE 36 OF 159...

  • Page 37: Adjusting Rear Suspension Settings

    3. The rebound setting should be set equally on both sides of the bike. PRELOAD ADJUSTMENT 1. Preload is adjusted by winding the disc at the base of the spring. UBCO TECHNICAL SERVICE MANUAL PAGE 37 OF 159...
  • Page 38 2. Twist the disc anti-clockwise to lessen the spring force and make the suspen- sion softer and clockwise to increase the spring force and make the suspen- sion stiffer. 3. The preload setting should be set equally on both sides of the bike. UBCO TECHNICAL SERVICE MANUAL PAGE 38 OF 159...

  • Page 39: Recommended Suspension Settings

    Slow Thread 125kg Off Road 2 Clicks to 30mm Max Fast Full Soft Slow Thread 90kg Off Road 1 Full Turn to 6 Clicks to 30mm Max Fast Hard Slow Thread 125kg UBCO TECHNICAL SERVICE MANUAL PAGE 39 OF 159...

  • Page 40: Inspecting Tyres

    Tyre’s pressure should only be checked and regulated when the Tyre’s tem- perature equals the ambient temperature. 4. If the Tyre’s pressure it outside the range specified within Page 15, inflate or deflate accordingly. UBCO TECHNICAL SERVICE MANUAL PAGE 40 OF 159...

  • Page 41: Inspecting & Adjusting Wheels

    1. Using a Spoke Wrench, tighten the loose spoke until the tension is equal to that of the rest of the Wheel, then carry on inspecting both the Spoke tension and trueness UBCO TECHNICAL SERVICE MANUAL PAGE 41 OF 159...
  • Page 42 Spoke(s) to pull the wheel into true. It is preferable to tighten a Spoke rather than loosen a spoke to achieve trueness 3. Repeat this process until the Wheel Rim is within the trueness range UBCO TECHNICAL SERVICE MANUAL PAGE 42 OF 159...

  • Page 43: Adjusting Headlamp Beam

    4.16 ADJUSTING HEADLAMP BEAM Wall Mark Beam Position - 0.875m UBCO TECHNICAL SERVICE MANUAL PAGE 43 OF 159...
  • Page 44 Headlamp angle until the central point of highest intensity sits on the mark on the wall 5. Using a 3mm Allen Key Socket and Torque Wrench, tighten the 2 Headlamp Assembly fasteners UBCO TECHNICAL SERVICE MANUAL PAGE 44 OF 159...

  • Page 45: Charging The Battery

    2. Remove the Charge Port Cover and plug in the Charger ensuring the connec- tor is rotated and clicks 3. To remove the Charger pull back the tab and then rotate the connector before pulling it outwards 4. Replace the charge port cover UBCO TECHNICAL SERVICE MANUAL PAGE 45 OF 159...

  • Page 46: Removal And Replacement Operations

    REMOVAL AND REPLACEMENT OPERA- TIONS UBCO TECHNICAL SERVICE MANUAL PAGE 46 OF 159...

  • Page 47: Wheels

    WHEELS UBCO TECHNICAL SERVICE MANUAL PAGE 47 OF 159...

  • Page 48: Front Wheel

    2. Using a 21mm Socket and Breaker Bar, release and remove the 2 Axle Nuts 3. While supporting the weight of the Front Wheel remove the 2 Torque Arms from the Axle 4. Place a Brake Pad Spacer in the gap between the Brake Pads UBCO TECHNICAL SERVICE MANUAL PAGE 48 OF 159...
  • Page 49 3. Lift the Front Wheel into place and install both Torque Arms on the Axle and Fork 4. Using a 21mm Socket, Loctite 243 and Torque Wrench, tighten the 2 Axle Nuts 5. Connect the Front Motor using the Double Twist Connector UBCO TECHNICAL SERVICE MANUAL PAGE 49 OF 159...

  • Page 50: Rear Wheel

    2. Using a 21mm Socket and Breaker Bar, release and remove the 2 Axle Nuts 3. While supporting the weight of the Front Wheel remove the 2 Torque Arms from the Axle 4. Place a Brake Pad Spacer in the gap between the Brake Pads UBCO TECHNICAL SERVICE MANUAL PAGE 50 OF 159...
  • Page 51 2. Lift the Front Wheel into place and install both Torque Arms on the Axle and Fork 3. Using a 21mm Socket, Loctite 243 and Torque Wrench, tighten the 2 Axle Nuts 4. Connect the Front Motor using the Double Twist Connector UBCO TECHNICAL SERVICE MANUAL PAGE 51 OF 159...

  • Page 52: Brakes

    BRAKES WAITING FOR UBCO UBCO TECHNICAL SERVICE MANUAL PAGE 52 OF 159...

  • Page 53: Sys 2 - Brake Pads

    3. Remove the Brake Pads while retaining the Brake Pad Spring 4. Place a Brake Pad Spacer in the gap between the two sides of the Caliper REPLACE 1. If installed, remove the Brake Pad Spacer UBCO TECHNICAL SERVICE MANUAL PAGE 53 OF 159...
  • Page 54 2. Check the Brake Pad Spring for signs of wear and replace if required 3. Place replacement Brake Pads into the Brake Pad Spring then into the Caliper 4. Using a 3mm Allen Key, tighten the fastener and replace the circlip retaining the Brake Pads UBCO TECHNICAL SERVICE MANUAL PAGE 54 OF 159...

  • Page 55: Sys 2 - Brake Disc

    1. Ensure the Brake Disc Spacer is replaced 2. Using a T25 Torx Socket, Torque Wrench and Loctite 273, tighten the 6 fasten- ers attaching the Brake Disc to the Motor in a star pattern UBCO TECHNICAL SERVICE MANUAL PAGE 55 OF 159...

  • Page 56: Sys 2 - Brake Caliper

    8. Caliper Fastener PRE-REQUISITE STEPS Wheel Removal - Page 48 or Page 50 Brake Fluid Removal - Page 23 REMOVE 1. Using a T30 Torx Key, release and remove the Banjo Fastener UBCO TECHNICAL SERVICE MANUAL PAGE 56 OF 159...
  • Page 57 3. Replace and bleed the Brake Fluid using the method outlined on Page 23 4. Using Isopropyl Alcohol and a Lint Free Cloth, clean the Caliper Assembly, Mas- ter Cylinder and Brake Line Fitting UBCO TECHNICAL SERVICE MANUAL PAGE 57 OF 159...

  • Page 58: Sys 2 - Brake Master Cylinder

    9. Brake Switch Connector PRE-REQUISITE STEPS Brake Fluid Removal - Page 23 Rear View Mirror Removal - Page 120 REMOVE 1. Using a T30 Torx Key, release and remove the Banjo Fastener UBCO TECHNICAL SERVICE MANUAL PAGE 58 OF 159...
  • Page 59 5. Replace and bleed the Brake Fluid using the method outlined on Page 23 6. Using Isopropyl Alcohol and a Lint Free Cloth, clean the Caliper Assembly, Mas- ter Cylinder and Brake Line Fitting UBCO TECHNICAL SERVICE MANUAL PAGE 59 OF 159...

  • Page 60: Sys 2 - Front Brake Line

    • Flush Cutters • Cable Ties PRE-REQUISITE STEPS Brake Fluid Removal - Page 23 REMOVE 1. Using Flush Cutters, remove the Cable Ties attaching the Brake Line from the RH Cable Bundle UBCO TECHNICAL SERVICE MANUAL PAGE 60 OF 159...
  • Page 61 6. Using a 2.5mm Allen Key Socket and Torque Wrench, tighten the Fork Brake Clip Fastener 7. Check and ensure Handlebar movement is not restricted 8. Using Isopropyl Alcohol and a Lint Free Cloth, clean the Caliper, Master Cylin- der and Brake Line UBCO TECHNICAL SERVICE MANUAL PAGE 61 OF 159...

  • Page 62: Sys 2 - Rear Brake Line

    8. Tube Clamp • Flush Cutters 9. Rear Brake Line • Cable Ties PRE-REQUISITE STEPS Battery Removal - Page 123 Rear Console Cover - Page 106 Front Console Cover - Page 102 UBCO TECHNICAL SERVICE MANUAL PAGE 62 OF 159...
  • Page 63 6. Using a 5mm Allen Key Socket and Torque Wrench, tighten the Tube Clamp Fastener 7. Check and ensure Handlebar movement is not restricted 8. Using Isopropyl Alcohol and a Lint Free Cloth, clean the Caliper, Master Cylin- der and Brake Line UBCO TECHNICAL SERVICE MANUAL PAGE 63 OF 159...

  • Page 64: Sys 2 - Front Brake Set

    Front Console Removal - Page 102 & Page 104 REMOVE 1. Disconnect the Brake Switch Connector, noting the connector positioning 2. Using a T30 Torx Key, release and remove the Caliper Fasteners UBCO TECHNICAL SERVICE MANUAL PAGE 64 OF 159...
  • Page 65 6. Using Cable Ties, retain the Brake Line to the RH Cable Bundle 7. Ensure the movement of the Handlebar is not restricted by the Brake Set 8. Bleed the Brakes using the method outlined on Page 23 UBCO TECHNICAL SERVICE MANUAL PAGE 65 OF 159...

  • Page 66: Sys 2 - Rear Brake Set

    Rear Console Removal - Page 106 & Page 108 REMOVE 1. Disconnect the Brake Switch Connector, noting the connector positioning 2. Using a T30 Torx Key, release and remove the Caliper Fasteners UBCO TECHNICAL SERVICE MANUAL PAGE 66 OF 159...
  • Page 67 6. Using Cable Ties, retain the Brake Line to the RH Cable Bundle 7. Ensure the movement of the Handlebar is not restricted by the Brake Set 8. Bleed the Brakes using the method outlined on Page 23 UBCO TECHNICAL SERVICE MANUAL PAGE 67 OF 159...

  • Page 68: Sr - Brake Pads

    4. Place a Brake Pad Spacer in the gap between the two sides of the Caliper REPLACE 1. If installed, remove the Brake Pad Spacer 2. Check the Brake Pad Spring for signs of wear and replace if required UBCO TECHNICAL SERVICE MANUAL PAGE 68 OF 159...
  • Page 69 3. Place replacement Brake Pads into the Brake Pad Spring then into the Caliper 4. Using a 3mm Allen Key Socket and Torque Wrench, tighten the fastener and fit the circlip retaining the Brake Pads UBCO TECHNICAL SERVICE MANUAL PAGE 69 OF 159...

  • Page 70: Sr - Brake Disc

    1. If previously present, ensure the Brake Disc Spacer is replaced 2. Using a T25 Torx Socket, Torque Wrench and Loctite 243, tighten the 6 fasten- ers attaching the Brake Disc to the Motor in a star pattern UBCO TECHNICAL SERVICE MANUAL PAGE 70 OF 159...

  • Page 71: Sr - Front Or Rear Brake Caliper

    • Isopropyl Alcohol • Lint Free Cloth • Loctite 243 PRE-REQUISITE STEPS Wheel Removal - Page 48 or Page 50 Brake Pad Removal - Page 53 Brake Fluid Removal - Page 28 UBCO TECHNICAL SERVICE MANUAL PAGE 71 OF 159...
  • Page 72 5. Bleed the Brake using the method outlined on Page 28 6. Adjust the Caliper position using the method outlined on Page 31 7. Using Isopropyl Alcohol and a Lint Free Cloth, clean the Caliper, Master Cylin- der and Brake Line UBCO TECHNICAL SERVICE MANUAL PAGE 72 OF 159...

  • Page 73: Sr - Front Or Rear Brake Master Cylinder

    Lint Free Cloth PRE-REQUISITE STEPS Brake Fluid Removal - Page 28 REMOVE 1. Using a 3mm Allen Key, release and remove the 2 fasteners holding the Master Cylinder Assembly to the Handlebar UBCO TECHNICAL SERVICE MANUAL PAGE 73 OF 159...
  • Page 74 6. Using a 7mm Spanner, tighten the Brake Reed Switch. Adjust the position and ensure the switch activates with approximately 10 to 15mm Brake Lever actu- ation. 7. Using Isopropyl Alcohol and a Lint Free Cloth, clean the Caliper, Master Cylin- der and Brake Line UBCO TECHNICAL SERVICE MANUAL PAGE 74 OF 159...

  • Page 75: Sr - Front Brake Line

    1. Using Flush Cutters, remove the Cable Ties attaching the Brake Line from the RH Cable Bundle 2. Using a 8mm Spanner, release and remove fittings the Hose Connect Screw and fittings from the Caliper and Master Cylinder UBCO TECHNICAL SERVICE MANUAL PAGE 75 OF 159...
  • Page 76 4. Bleed the Brake using the method outlined on Page 28 5. Using Cable Ties, retain the Brake Line to the RH Cable Bundle 6. Using Isopropyl Alcohol and a Lint Free Cloth, clean the Caliper, Master Cylin- der and Brake Line UBCO TECHNICAL SERVICE MANUAL PAGE 76 OF 159...

  • Page 77: Sr - Rear Brake Line

    Rear Console Cover - Page 106 Front Console Cover - Page 102 REMOVE 1. Using Flush Cutters, remove the Cable Ties attaching the Rear Brake Line from the LH Cable Bundle and Swing Arm UBCO TECHNICAL SERVICE MANUAL PAGE 77 OF 159...
  • Page 78 4. Replace the Brake Fluid, using the method outlined on Page 28 5. Bleed the Brake using the method outlined on Page 28 6. Using Isopropyl Alcohol and a Lint Free Cloth, clean the Caliper, Master Cylin- der and Brake Line UBCO TECHNICAL SERVICE MANUAL PAGE 78 OF 159...

  • Page 79: Sr - Front Brake Set

    • Flush Cutters 8. Fork Clip Fastener • Cable Ties 9. Front Brake Line • Loctite 243 10. Caliper Assembly 11. Washer 12. Caliper Fastener PRE-REQUISITE STEPS Battery Removal - Page 123 UBCO TECHNICAL SERVICE MANUAL PAGE 79 OF 159...
  • Page 80 7. Adjust the Caliper position using the method outlined on Page 31 8. Using a 7mm Spanner, tighten the Brake Reed Switch. Adjust the position and ensure the switch activates with approximately 10 to 15mm Brake Lever actu- ation. UBCO TECHNICAL SERVICE MANUAL PAGE 80 OF 159...

  • Page 81: Sr - Rear Brake Set

    Cable Ties • Loctite 243 PRE-REQUISITE STEPS Battery Removal - Page 123 Front Console Panel Removal - Page 102 & Page 104 Rear Console Panel Removal - Page 106 & Page 108 UBCO TECHNICAL SERVICE MANUAL PAGE 81 OF 159...
  • Page 82 7. Adjust the Caliper position using the method outlined on Page 31 8. Using a 7mm Spanner, tighten the Brake Reed Switch. Adjust the position and ensure the switch activates with approximately 10 to 15mm Brake Lever actu- ation. UBCO TECHNICAL SERVICE MANUAL PAGE 82 OF 159...

  • Page 83: Steering And Suspension

    STEERING AND SUSPENSION WAITING FOR UBCO UBCO TECHNICAL SERVICE MANUAL PAGE 83 OF 159...

  • Page 84: Front Fork

    8. Steerer Lock • Punch 9. Star Nut • Rubber Hammer 10. Fork Locking Pin 11. Upper Headset Crown Race 12. Lower Headset Bearing Cup 13. Lower Headset Bearing 14. Lower Headset Bearing Race UBCO TECHNICAL SERVICE MANUAL PAGE 84 OF 159...
  • Page 85 4. Using a 5mm Allen Key, lightly tighten the Stem Fasteners 5. Using a 5mm Allen Key Socket and Torque Wrench, tighten the Headset Cap Fastener 6. Using a 5mm Allen Key Socket and Torque Wrench, tighten the Stem Fasten- UBCO TECHNICAL SERVICE MANUAL PAGE 85 OF 159...

  • Page 86: Disassemble Front Fork

    7. Fork Boot Retaining Clips • Red Rubber Grease 8. Fork Boot • Loctite 243 9. Lower Fork 10. Lower Fork Fasteners PRE-REQUISITE STEPS Front Wheel Removal - Page 48 Front Fork Removal - Page 84 UBCO TECHNICAL SERVICE MANUAL PAGE 86 OF 159...
  • Page 87 Lower Fork Fasteners. NOTE - The adjustment dial may need to be held while performing this operation 5. Tighten the Fork Boot Retaining Clips, ensuring the Fork Boot holes are facing outwards and away from the Tyre UBCO TECHNICAL SERVICE MANUAL PAGE 87 OF 159...

  • Page 88: Stem

    5. Stem Fastener 6. Stem Clamp Lower 7. Headlight Clamp Assembly 8. Handlebar 9. Headlight Clamp Lower 10. Headlight Clamp Fastener PRE-REQUISITE STEPS Dash Removal - Page 136 Headlight Clamp Assembly - Page 134 UBCO TECHNICAL SERVICE MANUAL PAGE 88 OF 159...
  • Page 89 2. Using a 5mm Allen Key Socket and Torque Wrench, tighten the Headset Cap Fastener 3. Using a 5mm Allen Key Socket and Torque Wrench, tighten the 4 Headlight Clamp Assembly Fasteners UBCO TECHNICAL SERVICE MANUAL PAGE 89 OF 159...

  • Page 90: Rear Shock Absorber

    Absorbers to the Swing Arm and Bike REPLACE 1. Using a 5mm Allen Key Socket, Torque Wrench, 5mm Allen Key and Loctite 243 tighten the 4 Barrel Nuts attaching the Rear Shock Absorbers to the Swing UBCO TECHNICAL SERVICE MANUAL PAGE 90 OF 159...

  • Page 91: Swing Arm

    5. Barrel Nut • Breaker Bar 6. Swing Arm Fastener • 17mm Socket 7. Barrel Nut Fastener • Torque Wrench 8. Swing Arm • Flush Cutters • Cable Ties • Loctite 243 UBCO TECHNICAL SERVICE MANUAL PAGE 91 OF 159...
  • Page 92 2. Using a 5mm Allen Key Socket, Torque Wrench, 5mm Allen Key and Loctite 243 tighten the 2 Barrel Nuts attaching the Rear Shock Absorbers to the Swing 3. Using Cable Ties, retain the Rear Brake Line and Rear Motor Cable to the Swing Arm UBCO TECHNICAL SERVICE MANUAL PAGE 92 OF 159...

  • Page 93: Steering Lock

    2. Slide the Headset Bearing Top Cap and Handlebar Assembly off the Steerer Tube 3. Using a T25 Torx Key, release and remove the 2 fasteners holding the Steering Lock to the Headset Top Cap UBCO TECHNICAL SERVICE MANUAL PAGE 93 OF 159...
  • Page 94 4. Using a 5mm Allen Key Socket and Torque Wrench, tighten the Headset Cap fastener to the Star Nut 5. Using a 5mm Allen Key Socket and Torque Wrench, tighten the Stem fastener UBCO TECHNICAL SERVICE MANUAL PAGE 94 OF 159...

  • Page 95: Handlebar

    3mm Allen Key Socket 7. Headlight Clamp • M8 Spring Washer 8. Stem Clamp • Torque wrench 9. Stem Fastener 10. Headlight Assembly PRE-REQUISITE STEPS Dash Removal - Page 136 Mirror Removal - Page 120 UBCO TECHNICAL SERVICE MANUAL PAGE 95 OF 159...
  • Page 96 9. Using a 5mm Allen Key Socket and Torque Wrench, tighten the 2 Bar Clamp Fasteners. 10. Attach the Headlight to the Handlebar using the method outlined on Page 134 11. Attach the Dash to the Handlebar using the method outlined on Page 136 UBCO TECHNICAL SERVICE MANUAL PAGE 96 OF 159...

  • Page 97: Lever Guards

    2. Using a 5mm Allen Key Socket and Torque Wrench, tighten the Handlebar End Cap fastener REPLACE 1. Using a 5mm Allen Key, loosely tighten the Lever Guard Bar Clamps on the Handlebar UBCO TECHNICAL SERVICE MANUAL PAGE 97 OF 159...
  • Page 98 Throttle approximately 2-3mm axially towards the Dash. Tighten the Throttle Grub Screw. 8. If the Throttle is still not moving freely, undo this process to step 2, installing a M8 Spring Washer between the End Cap and Handlebar UBCO TECHNICAL SERVICE MANUAL PAGE 98 OF 159...

  • Page 99: Body

    BODY WAITING FOR UBCO UBCO TECHNICAL SERVICE MANUAL PAGE 99 OF 159...

  • Page 100: Front Carrier

    1. Using a 4mm Allen Key and 10mm Spanner, tighten the 2 nuts/fasteners attaching the Front Carrier to the Steerer Tube Flange. Ensure the Brake Hose P-Clip and Brake Hose are attached. UBCO TECHNICAL SERVICE MANUAL PAGE 100 OF 159...
  • Page 101 2. Using a 5mm Allen Key, tighten the 2 nuts/fasteners attaching the Front Car- rier to the Frame Down Tube UBCO TECHNICAL SERVICE MANUAL PAGE 101 OF 159...

  • Page 102: Front Console Cover

    1. Ensure all cables are correctly aligned within the console and will not become pinched when replacing the Cover 2. Align the bottom section of the Front Console, then lift and rotate the top section into place UBCO TECHNICAL SERVICE MANUAL PAGE 102 OF 159...
  • Page 103 4. To align the Front Console Cover, install the Battery within the Bike using the method outlined on Page 123 5. Using a T25 Torx Socket and Torque Wrench, tighten the 6 fasteners attaching the Front Console Cover to the Front Console Rear Panel UBCO TECHNICAL SERVICE MANUAL PAGE 103 OF 159...

  • Page 104: Front Console Rear Panel

    Battery Plug Harness Removal - Page 125 VMS Removal - Page 145 Horn Removal - Page 143 REMOVE 1. Using a T25 Torx Key, remove the 4 fasteners attaching the Front Console Rear Panel to the Frame UBCO TECHNICAL SERVICE MANUAL PAGE 104 OF 159...
  • Page 105 1. Ensure all cables and brake line are correctly aligned within the console and will not become pinched when replacing the cover 2. Using a T25 Torx Socket and Torque Wrench, tighten the 4 fasteners attaching the Front Console Rear Panel to the Frame UBCO TECHNICAL SERVICE MANUAL PAGE 105 OF 159...

  • Page 106: Rear Console Cover

    1. Using a T25 Torx Key, remove the 8 fasteners attaching the Rear Console Cover to the Rear Panel and Frame 2. Using a T25 Torx Key, remove the 2 fasteners attaching the Battery Lock to the Front Panel UBCO TECHNICAL SERVICE MANUAL PAGE 106 OF 159...
  • Page 107 4. To align the Rear Console Cover, install the Battery within the bike using the method outlined on Page 123 5. Using a T25 Torx Socket and Torque Wrench, tighten the two fasteners attaching the Rear Console Cover to the Rear Panel and Frame UBCO TECHNICAL SERVICE MANUAL PAGE 107 OF 159...

  • Page 108: Rear Console Rear Panel

    Rear Console Cover - Page 106 REMOVE 1. If installed, using a 5mm Allen Key, remove the 2 fasteners retaining the P Clips to the Rear Panel 1.ONLY PRESENT ON SOME MODELS UBCO TECHNICAL SERVICE MANUAL PAGE 108 OF 159...
  • Page 109 2. Using a T25 Torx Socket and Torque Wrench, tighten the 2 fasteners retaining the Rear Console Rear Panel to the Frame 3. Using a 5mm Allen Key Socket and Torque Wrench, tighten the 2 fasteners retaining the P Clips to the Rear Panel UBCO TECHNICAL SERVICE MANUAL PAGE 109 OF 159...

  • Page 110: Seat

    Using a 4mm Allen Key and 10mm Spanner, release and remove the 2 fasteners attaching the Seat to the Frame REPLACE Using a 4mm Allen Key Socket, Torque Wrench and 10mm Spanner, tighten the 2 fasteners attaching the Seat to the Frame UBCO TECHNICAL SERVICE MANUAL PAGE 110 OF 159...

  • Page 111: Front Mudguard

    1. Using a 4mm Allen Key and 8mm Spanner, remove the 2 fasteners attaching the Upper Mudguard to the Fork 2. Using a T25 Torx Key, remove the 2 fasteners attaching the Mudguard Stay to the Fork UBCO TECHNICAL SERVICE MANUAL PAGE 111 OF 159...
  • Page 112 1. Using a T25 Torx Socket and Torque Wrench, tighten the 2 fasteners attaching the Mudguard Stay to the Fork 2. Using a 4mm Allen Key Socket, Torque Wrench and 8mm Spanner, tighten the 2 fasteners attaching the Upper Mudguard to the Fork UBCO TECHNICAL SERVICE MANUAL PAGE 112 OF 159...

  • Page 113: Swing Arm Mudguard

    1. Using a T20 Torx Key, remove the 2 fasteners attaching the Swing Arm Mud Flap to the Bike REPLACE 1. Using a T20 Torx Socket and Torque Wrench, tighten the 2 fasteners attaching the Swing Arm Mud Flap to the Bike UBCO TECHNICAL SERVICE MANUAL PAGE 113 OF 159...

  • Page 114: Rear Mudguard

    Swing Arm Mud Flap Removal - Page 113 Tailight Removal - Page 142 REMOVE 1. Using Flush Cutters, remove any Cable Ties retaining the Rear Light Harness and any connected cables to the Mudguard UBCO TECHNICAL SERVICE MANUAL PAGE 114 OF 159...
  • Page 115 3. Using a #1 Philips Head Screwdriver, tighten the 2 fasteners attaching the Rear Light to the Mudguard 4. Using Cable Ties, retain the Rear Light Harness and any connected cables to the Mudguard UBCO TECHNICAL SERVICE MANUAL PAGE 115 OF 159...

  • Page 116: Kickstand

    1. If installed, unplug the Kickstand Switch connector from the On Road Harness inside the Rear Console 2. Using a 5mm Allen Key and 13mm Spanner, release and remove the 2 fasteners attaching the Kickstand to the Bike UBCO TECHNICAL SERVICE MANUAL PAGE 116 OF 159...
  • Page 117 1. Using a 5mm Allen Key Socket, Torque Wrench, 13mm Spanner and Loctite 243, tighten the 2 fasteners attaching the Kickstand to the Bike 2. If installed, plug the Kickstand Switch connector into the On Road Harness UBCO TECHNICAL SERVICE MANUAL PAGE 117 OF 159...

  • Page 118: Footpegs

    1. Using a 6mm Allen Key and 13mm Spanner, remove the 2 fasteners attaching the Footpeg to the Bike REPLACE 1. Using a 6mm Allen Key Socket, Loctite 243, Torque Wrench and 13mm Spanner tighten the 2 fasteners attaching the Footpeg to the Bike UBCO TECHNICAL SERVICE MANUAL PAGE 118 OF 159...

  • Page 119: Reflectors

    2. Using a 10mm Spanner, remove the nuts from the Reflectors. REPLACE 1. Using a 10mm Spanner, tighten the nuts on the Reflectors ensuring the locat- ing pin of the Reflector matches the Mount Panel UBCO TECHNICAL SERVICE MANUAL PAGE 119 OF 159...

  • Page 120: Sys 2 - Mirrors

    1. Using a 14mm Spanner, release the Rear View Mirror Nut and remove the Mir- REPLACE 1. Thread the Mirror Assembly into the correct position for the rider 2. Using a 14mm Spanner, tighten the Rear View Mirror Nut UBCO TECHNICAL SERVICE MANUAL PAGE 120 OF 159...

  • Page 121: Sr - Mirrors

    1. Using a 4mm Allen Key Socket and Torque Wrench, tighten the 2 fasteners 2. Thread the Mirror Arm into the correct position for the rider 3. Using a 14mm Spanner, tighten the Rear View Mirror Fastening Nut UBCO TECHNICAL SERVICE MANUAL PAGE 121 OF 159...

  • Page 122: Electronics And Controls

    ELECTRONICS AND CONTROLS WAITING FOR UBCO UBCO TECHNICAL SERVICE MANUAL PAGE 122 OF 159...

  • Page 123: Kxh Battery

    4. If the Bike has a Battery Lock unlock the Battery 5. Remove the Battery Retention Strap REPLACE 1. Apply Silicone Grease to Charge Port Pins 2. Ensure there is nothing in the chassis space where the Battery will enter UBCO TECHNICAL SERVICE MANUAL PAGE 123 OF 159...
  • Page 124 3. Ensure the Charge Port Cover is securely installed in the Charge Port 4. Install and secure the Battery by applying tension using the Battery Retention Strap 5. Connect the Battery Harness into the Battery Harness Connector Port UBCO TECHNICAL SERVICE MANUAL PAGE 124 OF 159...

  • Page 125: Battery Plug Harness

    Front Console Rear Panel REPLACE 1. Using a T20 Torx Socket and Torque Wrench, tighten the 2 fasteners 2. Connect the VMS and Motor Controllers to the Battery Plug Harness UBCO TECHNICAL SERVICE MANUAL PAGE 125 OF 159...

  • Page 126: On Road Harness

    2. Remove the Cable Duct from the Bike 3. Disconnect the Front Indicators from the On Road Harness 4. Disconnect the Kickstand Kill Switch from the On Road Harness 5. Disconnect the Dash from the On Road Harness UBCO TECHNICAL SERVICE MANUAL PAGE 126 OF 159...
  • Page 127 3. Connect the Front Indicators to the On Road Harness 4. Install the Cable Duct onto the Bike 5. Using Cable Ties retain the On Road Harness to the RH Cable Bundle UBCO TECHNICAL SERVICE MANUAL PAGE 127 OF 159...

  • Page 128: Main Harness

    Rear Console Cover Removal - Page 106 Dash Removal - Page 136 REMOVE 1. Using a T25 Torx Key, remove the fastener retaining the P Clip on the back side of the Headlamp UBCO TECHNICAL SERVICE MANUAL PAGE 128 OF 159...
  • Page 129 3. Using Cable Ties, gather the bundle of cables released within the remove stage and Cable Ties together 4. Test to ensure the motion of the Handlebar is not restricted in any way by the Cable Bundle UBCO TECHNICAL SERVICE MANUAL PAGE 129 OF 159...

  • Page 130: Left Hand Switch Block

    • Cable Ties 8. Bar Clamp Fastener PRE-REQUISITES Battery Removal - Page 123 Front Console Cover Removal - Page 102 REMOVE 1. Disconnect the Left Hand Switch Block from the Main Harness UBCO TECHNICAL SERVICE MANUAL PAGE 130 OF 159...
  • Page 131 4. Using a 3mm Allen Key Socket and Torque Wrench, tighten the Switch Block Clamp Fastener 5. Using Cable Ties, retain the Left Hand Switch Block Cable to the Left Hand Cable Bundle UBCO TECHNICAL SERVICE MANUAL PAGE 131 OF 159...

  • Page 132: Throttle/Kill Switch

    Battery Removal - Page 123 Front Console Cover Removal - Page 102 REMOVE 1. Disconnect the Throttle/Kill Switch from the Main Vehicle Harness 2. Using a 3mm Allen Key, release and loosen the Throttle Grub Screw UBCO TECHNICAL SERVICE MANUAL PAGE 132 OF 159...
  • Page 133 5. Using Cable Ties, retain the RH Cable Bundle released within the remove sta- 6. Test to ensure the motion of the Handlebar is not restricted in any way by the Cable Bundle UBCO TECHNICAL SERVICE MANUAL PAGE 133 OF 159...

  • Page 134: Headlamp

    Front Console Cover Removal - Page 102 REMOVE 1. Using Flush Cutters, remove any Cable Ties retaining the Headlamp Cable to the Left Hand Cable Bundle 2. Disconnect the Headlamp from the Main Harness UBCO TECHNICAL SERVICE MANUAL PAGE 134 OF 159...
  • Page 135 6. Using Cable Ties, retain the RH Cable Bundle released within the remove sta- 7. Test to ensure the motion of the Handlebar is not restricted in any way by the cable bundle. UBCO TECHNICAL SERVICE MANUAL PAGE 135 OF 159...

  • Page 136: Dash

    3. Disconnect the Dash from the On Road Harness 4. Using a 10mm Spanner, remove the 3 nuts attaching the Dash to the Dash Mount Plate REPLACE 1. Connect the Dash to the On Road Harness UBCO TECHNICAL SERVICE MANUAL PAGE 136 OF 159...
  • Page 137 3. Using a T20 Torx Socket and Torque Wrench, tighten the 4 fasteners attaching the Dash Mount Plate to the Dash Cover 4. Using a T20 Torx Socket and Torque Wrench, tighten the 4 fasteners attaching the Dash Cover to the Bike UBCO TECHNICAL SERVICE MANUAL PAGE 137 OF 159...

  • Page 138: Front Indicators

    1. Using a T20 Torx Key, remove the 4 fasteners attaching the Dash Cover to the Bike 2. Disconnect Front Indicators from the On Road Harness 3. Using a 17mm Spanner, release and remove the 2 nuts holding the Indicators to the Bike UBCO TECHNICAL SERVICE MANUAL PAGE 138 OF 159...
  • Page 139 2. Using a 17mm Spanner, tighten the 2 nuts holding the Indicators. 3. Using a T20 Torx Socket and Torque Wrench, tighten the 4 fasteners attaching the Dash Cover to the Bike UBCO TECHNICAL SERVICE MANUAL PAGE 139 OF 159...

  • Page 140: Rear Indicators

    3. Using a 17mm Spanner, release and remove the 2 nuts holding the Indicators REPLACE 1. Connect the Indicators to the Rear Light Harness, place in position and test Indicator position is correct 2. Using a 17mm Spanner, tighten the 2 nuts holding the Indicators UBCO TECHNICAL SERVICE MANUAL PAGE 140 OF 159...
  • Page 141 3. Using Cable Ties, retain the Rear Indicator Cables to the Bike UBCO TECHNICAL SERVICE MANUAL PAGE 141 OF 159...

  • Page 142: Tailight

    2. Using a #1 Philips Screwdriver, remove the 2 fasteners from the Rear Tailight REPLACE 1. Connect the Rear Tailight after threading the wire through the hole 2. Using a #1 Philips Screwdriver, tighten the 2 fasteners UBCO TECHNICAL SERVICE MANUAL PAGE 142 OF 159...

  • Page 143: Horn

    1. Disconnect the Horn from the Main Vehicle Harness by unplugging the two spade connectors taking note of the position of each one 2. Using a T25 Torx Key, remove the 2 fasteners attaching the Horn to the Front Console Rear Panel UBCO TECHNICAL SERVICE MANUAL PAGE 143 OF 159...
  • Page 144 1. Using a T25 Torx Socket and Torque Wrench, tighten the 2 fasteners attaching the Horn to the Front Console Rear Panel 2. Connect the Horn to the Main Vehicle Harness replicating the positions from the remove step UBCO TECHNICAL SERVICE MANUAL PAGE 144 OF 159...

  • Page 145: Vms

    1. Disconnect the VMS from the On Road, Main & Battery Plug Harnesses and if installed, the TCU Harness 2. Using a T25 Torx Key, remove the 4 fasteners attaching the VMS to the Front Console Rear Panel UBCO TECHNICAL SERVICE MANUAL PAGE 145 OF 159...
  • Page 146 2. Connect the VMS to the On Road, Main & Battery Plug Harnesses and if installed, the TCU Harness 3. Using the UBCO App, confirm VMS is in correct mode for vehicle type, VIN registration is completed and VMS firmware is up to date...

  • Page 147: Motor Controller

    1. Disconnect the Motor Controller from the Motor Cable, Main Vehicle & Bat- tery Plug Harnesses 2. Using a T25 Torx Key, remove the 2 fasteners attaching the Motor Controller to the Front Console Rear Panel UBCO TECHNICAL SERVICE MANUAL PAGE 147 OF 159...
  • Page 148 Motor Controller to the Front Console Rear Panel 2. Connect the Motor Controller to the Motor Cable, Main Vehicle & Battery Plug Harnesses 3. Using the UBCO App, update the motor configuration UBCO TECHNICAL SERVICE MANUAL PAGE 148 OF 159...

  • Page 149: Front Motor Cable

    T25 Torx Socket 7. Motor Controller • Torque Wrench 8. Motor Power Plug • Flush Cutters 9. Cable Clamp 10. Fastener PRE-REQUISITES Battery Removal - Page 123 Front Console Cover Removal - Page 102 UBCO TECHNICAL SERVICE MANUAL PAGE 149 OF 159...
  • Page 150 5. Gather the bundle of cables released within the remove stage and Cable Ties together 6. Test to ensure the motion of the Handlebar is not restricted in any way by the Right Hand Cable Bundle UBCO TECHNICAL SERVICE MANUAL PAGE 150 OF 159...

  • Page 151: Rear Motor Cable

    2. Using Flush Cutters, remove the Cable Ties retaining the Motor Cable to the Swing Arm 3. Using a 5mm Allen Key, remove the fastener attaching the Motor Cable Retention P Clip to the Rear Console Rear Panel UBCO TECHNICAL SERVICE MANUAL PAGE 151 OF 159...
  • Page 152 6. Using a 5mm Allen Key Socket and Torque Wrench, tighten the Motor Cable Retention P Clip fastener 7. Tighten the cable retention Cable Ties 8. Install the Cable Duct into the bottom tray UBCO TECHNICAL SERVICE MANUAL PAGE 152 OF 159...

  • Page 153: Powertrain

    POWERTRAIN WAITING FOR UBCO UBCO TECHNICAL SERVICE MANUAL PAGE 153 OF 159...

  • Page 154: Motor Core

    • Loctite 243 8. Motor Side Cover • ROCOL FOODLUBE Premier 1, EP1 9. Large Motor Seal • Red Rubber Grease 10. Motor Fasteners • Motor O-Ring 11. Heatsink 12. Heatsink Fasteners UBCO TECHNICAL SERVICE MANUAL PAGE 154 OF 159...
  • Page 155 6. Applying even pressure, assemble the Motor Side Cover onto the Motor Hous- 7. Using Loctite 243, T25/T20 Torx Socket and Torque Wrench, tighten the 9 Motor fasteners 8. Using T20 Torx Socket and Torque Wrench, tighten the 3 Heatsink fasteners UBCO TECHNICAL SERVICE MANUAL PAGE 155 OF 159...

  • Page 156: Planetary Gear Set

    2. Using a 3 Jaw Bearing Puller, remove the Planetary Gear Frame from the Axle 3. Using External Circlip Pliers, remove the 3 Circlips retaining the Planetary Gears to the Planetary Gear Frame UBCO TECHNICAL SERVICE MANUAL PAGE 156 OF 159...
  • Page 157 Planetary Gears to the Planetary Gear Frame 3. Using External Circlip Pliers and Circlip 17mm x 1mm (If removed circlips are damaged, replace with new), retain the Planetary Gear Frame to the Axle UBCO TECHNICAL SERVICE MANUAL PAGE 157 OF 159...

  • Page 158: Motor Bearings And Seals

    TOOLS/CONSUMABLES REQUIRED • External Circlip Pliers 1. Motor Seal 2. Motor Case • UBCO Motor Seals (1 large + 1 small per motor) 3. O Ring • UBCO Motor Bearings (1 large + 1 4. Small Motor Bearing small per motor) 5.
  • Page 159 Motor Core Assembly REPLACE 1. Using a Hammer and Punch on the inner race, gently install the UBCO Large Bearing into the Motor Core Assembly 2. Using a Hammer and Punch on the outer race, gently install the UBCO Small Bearing into the Motor Housing 3.

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