Page 1
Grunt EVO Owner’s Manual FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only.
Page 2
California Proposition 65 WARNING. This product can expose you to chemicals known to the State of California to cause Cancer and Reproductive Harm - www.P65Warnings.ca.gov. California Perchlorate Advisory WARNING. Certain components of this motorcycle such as lithium batteries may contain perchlorate material. Special handling may apply for service or end-of-life disposal.
Page 3
100% electric vehicles for off-road use in outdoor recreation. Our vehicles reflect our company's mission to Empower Adventure and the enjoyment of the outdoors. The Volcon Grunt EVO is covered by limited 1-year parts and a 2-year battery warranty. Please visit our website at www.volcon.com to review the full warranty policy for your vehicle.
TABLE OF CONTENTS TABLE OF CONTENTS................ 3 GENERAL INFORMATION..............6 ABOUT THE OWNER’S MANUAL..........6 BEFORE YOU RIDE................6 SAFETY MESSAGES..............7 Legal Obligation................8 Requirements for Limited Warranty to Apply:......9 Exclusions:................10 Avoid Electric Shock..............12 Avoid Burns from Hot Parts............12 Lithium Battery Precautions............13 Accessories and Modifications............
Page 5
Rider Condition................28 Vehicle Condition................29 Road and Weather Conditions............29 Riding Gear..................30 Cargo and Loading................ 30 Volcon Grunt EVO Maximum Weight Capacity......31 Safety Information on the Vehicle..........32 1. Hot Surface Warning Label..........33 2. Voltage Warning Label............33 3. Tire Pressure Information Label...........34 4.
Page 6
Belt Installation................ 48 Brakes....................50 Brake pads................50 Battery................... 54 Clean and Check..............55 Maintenance Cycle..............55 Charging.................. 56 Storage..................59 Low Power Mode..............60 Battery Temperature..............60 TECHNICAL INFORMATION..............61 Pin Label..................61 SPECIFICATIONS/TROUBLESHOOTING........62 WIRING DIAGRAM................67 960-101086 Rev B Page 6 of 69...
Due to late changes, some differences between the manufactured product and the descriptions and/or specifications in this manual may occur. Volcon reserves the right, at any time, to discontinue or change specifications, designs, features, models, or equipment without incurring any liability or obligation to consumers.
Your safety and the safety of others are very important and operating this motorcycle safely is an important responsibility. You will find important safety information in a variety of forms, including safety labels on the Grunt EVO and safety messages within this manual or labels.
The recommended minimum age for operating this vehicle is 16. Riders under 16 years old are strictly prohibited from operating it. Volcon strongly advises all riders to complete an approved Motorcycle Safety Foundation (MSF) course before use. The information contained in this publication is based on the most up-to-date information available at the time of publication.
Failure to comply with any of the following requirements will immediately and automatically VOID the Limited Warranty: (1) You must be the owner of the Grunt EVO and register the unit within thirty (30) days of purchase. All fields are required to successfully submit your registration form.
GENERAL INFORMATION In the event Volcon agrees to ship the EVO, or any replacement Covered Components or batteries, to an international location, such shipment(s) will be at your sole cost, risk, and expense. (7) You must have used the EVO only for your personal use, and must not have used the EVO for any commercial purposes or in connection with a rental operation or program.
Page 12
Please visit our website at www.volcon.com to review the full warranty policy for your vehicle. Please make sure to register your Grunt EVO on our website at www.volcon.com under the owner’s section at warranty registration. https://www.volcon.com/warranty-registration Registration is fast and simple and will help with providing service, warranty, or answering general questions regarding your motorcycle.
GENERAL PRECAUTIONS Avoid Electric Shock All electronic parts on the Grunt EVO are powered by a battery source. WARNING Completing service or replacing parts while the vehicle has power can cause serious injury or death. To prevent serious injury or death from electrical shock: Never service the vehicle with power connected.
32°F (0°C) Charging a device or battery without following Volcon’s instructions. Charging in temperatures below freezing can lead to permanent metallic lithium buildup (i.e. plating) on the anode, increasing the risk for failure.
Page 15
WARNING Addition of non-authorized accessories or modifications may change the operation, function, or performance of your Grunt EVO. Such changes can cause an accident resulting in serious injury or death. 960-101086 Rev B...
VEHICLE INFORMATION Controls 1. Rear Brake Lever 6. Front Brake Fluid Reservoir 2. D-Pad 7. Safety Tether 3. Rear Brake Fluid Reservoir 8. Power Switch 4. Headlight Switch 9. Throttle 5. Display 10. Front Brake Lever **E-Mode button (not shown), in line with the battery harness, located in the battery compartment.
VEHICLE INFORMATION 1. Power the motorcycle off. Disconnect the battery. 2. Sitting on the vehicle, use a 6mm Allen head, to loosen bolts at handlebar clamps. 3. Move the handlebar back and forth until a comfortable position is obtained. 4. When position is obtained, re-tighten the bolts at the handlebar clamps.
(D-Pad). The D-Pad helps to toggle and select drive modes and engage reverse. The Grunt EVO will always power on in the Neutral mode. To engage Stroll mode, hold down the “OK” button located in the center of the D-Pad for 3-5 seconds then release.
It is highly recommended that new riders start in Stroll mode for their first ride. When you have become comfortable with starting and stopping the Grunt EVO as well as changing modes, then proceed to each mode until comfortable with operating all 3 modes and reverse.
NOTE: The outer ring of the headlight powers and remains on when the power switch for the Grunt EVO is engaged. It is intended as a daytime running lamp. To power on the center portion of the headlight, toggle the switch to the ON position.
Page 21
NOTE: The alert(s) will not remain in memory after 5 seconds. The display will not retain memory of alert(s) if the motorcycle is powered off. Alert(s) will appear in the Volcon app, if you have an active account and are connected to the EVO at time of alert(s). Please contact service@volcon.com...
VEHICLE INFORMATION Emergency Mode (E-Mode) Button Located in the battery compartment, the E-mode button [Fig. 2] is in line with the battery harness. The E-mode button [Fig. 2] functions just like the “OK” button on the D-Pad. It is designed to help cycle the modes manually if the motorcycle loses communication with the D-Pad or Vehicle Control Unit (VCU).
VEHICLE INFORMATION Safety Tether The Volcon Grunt EVO is equipped with a safety tether. The device acts as a “kill switch” when connection is lost. The power signal ONLY to the throttle is disrupted. The EVO remains powered, however the throttle will not engage until the tether is reconnected.
DC-DC Kickstand Knowing the location of major components is essential for maintenance and troubleshooting for your Grunt EVO. Please study the above graphic [Fig. 3] to familiarize yourself with the electrical components and locations found on your electric motorcycle. Refer to Electrical Components under the Safe Operating Instructions of this manual for more information.
SAFE OPERATING INSTRUCTION What’s Different from Other Two-Wheeled Vehicles? This section will help you understand some distinct differences and operating features of this vehicle. Response to Trail Conditions The trail behavior of this trail motorcycle may be different from other off-road vehicles on the market.
The vehicle will not move away from Neutral with use of the D-Pad. Safety Tether The Volcon Grunt EVO is equipped with a safety tether. The device acts as a “kill switch” when connection is lost. The power signal ONLY to the throttle is disrupted.
Electrical Components The Volcon Grunt EVO is fully electric with minimal mechanical components. Operators must be fully aware of hazards with respect to high and low-voltage components. Never attempt to service, modify or replace electrical components.
SAFE OPERATING INSTRUCTION HIGH VOLTAGE These components should only be serviced by a Volcon-certified technician. Do not tamper with, cut, probe, or modify high-voltage cables or wiring. Low voltage components: Headlight Tail Light Dpad Power Switch Headlight Switch SAE accessory port...
SAFE OPERATING INSTRUCTION This section presents some of the most important information and recommendations to help you ride your motorcycle safely. Please take a few moments to read these pages. Your motorcycle can provide many years of service and pleasure if you take responsibility for your own safety and understand the challenges you can have while riding.
SAFE OPERATING INSTRUCTION You must be physically able to operate all controls, turn the handlebar through the full range or steering, mount and dismount, balance the full weight of vehicle, operator and cargo and monitor your surroundings to operate the vehicle. Pushing limitations is another major cause of motorcycle crashes.
Over the Ankle Footwear Cargo and Loading Your Volcon was designed as a utility motorcycle to carry cargo. Always remember, the added weight of cargo could interfere with your ability to move around, and maintain your balance, and could make controlling your motorcycle difficult.
SAFE OPERATING INSTRUCTION Adding accessories or making modifications that change this motorcycle’s design and performance outside of Volcon-approved accessories can also make it unsafe. The weight of additional accessories will reduce the maximum load the motorcycle can carry. How much weight you put on your motorcycle, and how that load is secured, are very important to your safety.
SAFE OPERATING INSTRUCTION ⚠ CAUTION The EVO is designed as a single-rider motorcycle. Never carry a passenger. Safety Information on the Vehicle The EVO comes with hang tags and labels containing important safety information. Any person who operates this motorcycle should read and understand this information on the vehicle before riding.
SAFE OPERATING INSTRUCTION 1. Hot Surface Warning Label On the face of the motor [Fig. 4] you will find a Hot Surface warning label. CAUTION Components can be hot after use or if exposed to high temperatures. 2. Voltage Warning Label This warning label is placed on the Battery and Controller cover [Fig.
Max weight capacity is also listed on the label. 4. Safety Label The following labels are placed on the rear fender [Fig. 4] of the EVO. The Volcon EVO is an Off-Road electric motorcycle and is designed for a single operator/rider. 960-101086...
Please be aware, before operating away from trails or recreational areas, the Volcon Grunt EVO is for OFF-Road use ONLY. Volcon, Inc. strongly recommends the use of helmets for safety. Please see our section for “Riding Gear”. 5. Belt Safety Label This label is placed at the rear, on the top side of the swingarm [Fig.
Correct any problems that you discover to reduce the risk of breakdown or accidents. See you Volcon Authorized dealer as necessary. Visit www.volcon.com, to find a dealer near you. PRE-RIDE CHECKLIST...
Page 38
MAINTENANCE Display Visually inspect the display for damage, error codes, or malfunctions of any kind. Rotate the encoder ring to ensure functionality. Steering Make sure the steering turns freely without binding. Forks Check for leaks, pitting, or rust. Throttle With the power off, check to ensure the throttle moves freely and snaps closed.
MAINTENANCE MAINTENANCE SCHEDULE Frequency Item Every ride 30 Days 6 Months 1 Year Wheels & Tires Tire & Air Pressure Wheel / Tire Damage Wheel Bearing Damage Final Drive Drive Belt Condition Drive Belt Slack Drive Belt Wear Brakes Brake Fluid Inspect Brake Fluid Change / Bleed Brake Pads...
Page 40
MAINTENANCE MAINTENANCE SCHEDULE Frequency Item Every ride 30 Days 6 Months 1 Year Battery Check State of charge Discharge to 20% If below Charge Suspension Front Forks Clean / Inspect Rear Shock Clean / Inspect 960-101086 Rev B Page 40 of 69...
Due to the complexity of some maintenance procedures, good mechanical skill is required. If the procedures listed are beyond your comfort or skill level or you are not familiar/comfortable with the mechanics - please contact your local Volcon Authorized dealer. Visit www.volcon.com to find a dealer near you.
EVO. Wheels The Grunt EVO Front and Rear rims are cast aluminum and powder coated at 410°F (210°C) to maintain a durable finish for off-road use. The rims are an AT 8x12. The wheel width measures 8 inches and the diameter measures 12 inches.
Page 43
MAINTENANCE CAUTION Do not squeeze the front brake lever after the front wheel is removed. Doing so will cause difficulty in fitting the brake disc between the brake pads. Installing the Front Wheel CAUTION The installation instruction and tightening torque values must be strictly adhered to.
MAINTENANCE 13. Apply blue thread locker on caliper bolts before installing. TORQUE: 16ft-lb (25Nm) NOTE: make sure threads are free of dust/debris before installation. Clean with a dry cloth if needed. Rear Wheel Removing the Rear Wheel 1. Raise the rear wheel off the ground by placing a work stand or equivalent under the EVO.
Page 45
MAINTENANCE CAUTION Do not squeeze the rear brake lever after the rear wheel is removed. Doing so will cause difficulty in fitting the brake disc between the brake pads. 6. Remove the left and right spacers from the wheel. [Fig. 7, item 2 and Installing the Rear Wheel CAUTION The installation instruction and tightening torque values...
MAINTENANCE Belt The Grunt EVO uses a Gates® belt drive design allowing for a much quieter ride. Unlike chain drives, which require very frequent cleaning, tightening, and maintenance, belt drives are relatively maintenance-free. They run clean as they don't have to be lubricated.
The belt does not require chemicals or soaps. Never use oil, grease, or belt dressing. If debris has penetrated or pierced the belt or damaged the belt in any way, the belt must be replaced. Contact your local authorized Volcon dealer for service. Visit www.volcon.com to find a dealer near you.
Page 48
We recommend the Gates® Krikut Gauge or an ABN® ABN-5414]. belt tension gauge [model If you do not have the tools required or are unsure of your capabilities to make adjustments, please contact your local Volcon-authorized service center. Visit www.volcon.com to find a dealer near you.
The following instructions will guide you through the replacement of your Gates® belt. If you do not have the tools required or are unsure of your capabilities for installation, please contact your local Volcon-authorized service center. Visit www.volcon.com to find a dealer near you.
Page 50
MAINTENANCE 10. Adjust/Tension the belt. See Belt Adjustment section. 11. Remove the bike from the stand. 12. Replace the Front and Rear Guards removed in step 1. 960-101086 Rev B Page 50 of 69...
Ensure when brake levers are pulled the brakes are engaging the rotors, front and rear. If brake parts are damaged and need replacement or need service, please see your local Volcon authorized dealer. Please visit www.volcon.com to locate a dealer near you.
Page 52
MAINTENANCE Front Brake Pad Replacement 1. Loosen and remove the two allen head bolts [Fig. 10] attaching the front brake caliper to the fork leg. 2. Remove the caliper [Fig. 10] from the wheel and rotor. 3. Push the caliper pistons all the way in, to remove the existing pads and allow for new pads to be installed.
Page 53
MAINTENANCE 7. Install the allen head brake pad pins. [Fig. 11] (removed in step 5) Make sure the pads are installed correctly against the retaining ring. Torque the pins down. TORQUE: 13 ft-lbs (8 Nm) 8. Apply the front brake lever until pressure builds. Rear Brake Pad Replacement 1.
Page 54
MAINTENANCE 1. Determine your rider weight in pounds. 2. Refer to the following table for recommended preload settings in millimeters (mm) based on your rider weight and the stock spring rate [400 lbs/in]. NOTE: All measurements are from the top most threads to the top of the lower adjuster ring;...
MAINTENANCE Battery The Grunt EVO battery is a 2.0kWH, 60V, 35Ah Lithium-Ion (NMC chemistry). Critical cell data (voltage, current, temperature) is monitored internally by the battery via a Battery Management System (BMS). The battery display provides both the state-of-charge and voltage of the battery. Press the power button on the battery display to toggle between either.
Maintenance Cycle After every ride, check the state-of-charge and voltage of your battery via the Grunt EVO’s display [Fig. 14]. If the battery is fully discharged and reads below 5%, it is advised to recharge the battery before storing or putting away.
Removing the battery from the EVO whenever possible is suggested. The Grunt EVO uses a switchable power supply/charger with inputs at 110V/60Hz or 220V/50Hz. The charger output is 67.2V, the charge current at 10A, and the charge watts of 670W. Check the rear of the charger to see if the switch has “110V”...
Page 58
MAINTENANCE If the charger light does not illuminate or the charger stops working, replace the charger. Battery Safety Label The battery has a safety label placed on the head of the battery. 960-101086 Rev B Page 58 of 69...
Page 59
MAINTENANCE Recommended step for charging: 1. Loosen the port cap from the charge port. 2. Plug the charger cable into the charge port. NOTE: There are key features on the charger that help align the connection and port. [Fig. WARNING DO NOT force the connection of the charger and port as you may cause damage to your battery or the charger.
Storage The Volcon battery has operating temperatures ranging from -4°F (-20°C) to 131°F (55°C). At the lower temperature range, the discharge capacity will be reduced to 45% of the standard capacity at 70°F (21°C). Below -4°F (-20°C) the battery’s chemical reactions drop below the practical use threshold.
While the actual cooling time depends on previous run time and ambient temperature, generally the battery will cool to an operational temperature in approximately 10 minutes. Please make sure to register your Grunt EVO on our website at www.volcon.com under the owner’s section at warranty registration.
TECHNICAL INFORMATION Pin Label Traditional two-wheeled vehicles have a VIN number to establish a unique identifier set forth by NHTSA and ISO. In 2005, NHTSA stated new VIN numbers will no longer be issued for “Off-Road” vehicles. With the help of SAE, a new standard was created following the 17-digit identification standards - called a PIN.
TECHNICAL INFORMATION SPECIFICATIONS/TROUBLESHOOTING Item Standard Troubleshooting Battery lithium-ion battery with NMC (Nickel, Check SOC (State Of Type Manganese, Cobalt) Charge) Once a month. If Capacity 35Ah SOC drops below 30%, charge the battery. Nominal 60v Range Voltage 67.2v - 45.2v 960-101086 Rev B Page 63 of 69...
TECHNICAL INFORMATION SPECIFICATIONS/TROUBLESHOOTING Item Standard Troubleshooting Charger Charge Output 67.2v Check the voltage switch on the side of the Charge Current charger. Make sure it's set to the appropriate Charge Watts 670W voltage for your region. - 110V / 60Hz 220V / If the small green LED *Input Voltage light does not come on...
Page 65
TECHNICAL INFORMATION SPECIFICATIONS/TROUBLESHOOTING Item Standard Troubleshooting 12v Electrical System Measure 12V coming from the accessory plug. DC-DC converter 60v to 12v converter No voltage, check the fuses in fuse box OR replace the part. Vehicle Control Check the display for any alert codes.
Page 66
Fuses 2x 7.5 fuse Check Continuity *Mexico and Canada operate on outlet voltages of 110V to 127V and 60 Hz. The Volcon charger accommodates this variation. Outside of North America, the charger will support 220V and 50 Hz. 960-101086 Rev B...
Page 67
When changing ownership, please ensure proper documentation is provided to the new owner. I.e. Signed MCO or Bill of Sale. Disconnect the bike from your Volcon App prior to releasing the unit to the new owner. Encourage the new owner to register the unit in their name.
Need help?
Do you have a question about the Grunt EVO and is the answer not in the manual?
Questions and answers