Related Manuals for VOLCON Brat 2023
Summary of Contents for VOLCON Brat 2023
- Page 1 Volcon Brat Service Manual Volcon ePowersports 3121 Eagles Nest St Unit 120, Round Rock, TX 78665 www.volcon.com Tel: (512) 400-4271 Email: support@volcon.com 960-101070 Rev C...
- Page 2 Volcon ePowersports. Although every precaution has been taken to assure this publication is complete and accurate, Volcon ePowersports assumes no liability for errors or omissions. All information contained in this publication is based on the latest information available at the time of publication and is subject to change without notice.
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Page 3: Table Of Contents
VOLCON BRAT SERVICE MANUAL TABLE OF CONTENTS INTRODUCTION: ..............................6 SAFETY NOTICE ..............................7 ................................. 9 USTOMER AFETY ..............................9 NFORMATION ..................10 REVENTION OF ORKPLACE NJURIES ITHIUM ATTERIES HOW TO USE THIS MANUAL ..........................11 ................................ 11 AFETY ..........................11... - Page 4 VOLCON BRAT SERVICE MANUAL ............................... 45 NSTALLING THE ATTERY ............................... 45 EMOVING THE ATTERY ..............................46 IPS FOR HARGING ..........................47 NDERSTANDING ATTERY ANGE & S ..........................48 ATTERY AINTENANCE TORAGE ..............................51 ROUBLESHOOTING HANDLEBAR & CONTROLS ..........................52 ..............................53...
- Page 5 VOLCON BRAT SERVICE MANUAL Brake Pad Alignment ............................82 Brake Rotor ................................. 82 ................................83 RAKE LEEDING CHAIN & CRANKSET ............................86 ..............................87 OMPONENT OCATION ..................................88 HAIN Removal ................................88 Installation ................................88 ..................................89 EDALS Removal ................................89 Installation ................................
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Page 6: Introduction
Our production and service processes are equally dedicated to sustainability, quality, and efficiency. We publish our Volcon Service Manual with quarterly updates to prepare our users, distributors, and service and repair partners with concise instructions for maintaining Volcon vehicles and supporting Volcon equipment through its full field service life cycle. -
Page 7: Safety Notice
This service manual has been prepared as a guide to correctly service and repair specific systems for the Volcon Brat as described in the introduction. This edition was primarily published to be used by certified Volcon Service Technicians who are already familiar with all service procedures relating to Volcon products. - Page 8 This handbook was originally written and published in English and may have been translated into other languages as applicable. This handbook contains information about the Volcon electric bicycle the BRAT. Always store this Owner’s Manual with your Volcon vehicle and refer to it for information whenever necessary. The information contained in this publication is based on the most up-to-date information available at the time of publishing.
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Page 9: Customer Safety
(32°F) during charging. Charging in temperatures below freezing can lead to permanent metallic lithium buildup (i.e., plating) on the anode, increasing the risk of failure. ● Charging a device or battery without following Volcon’s instructions may cause damage to batteries. 960-101070... -
Page 10: Prevention Of Workplace Injuries From Lithium Batteries
VOLCON BRAT SERVICE MANUAL For example, Volcon-authorized chargers will cycle the power to the battery on and off before it is fully charged to avoid overcharging. Since ultra-fast chargers may not cycle power, do not use them. SAFETY NOTICE Prevention of Workplace Injuries From Lithium Batteries Defects or damage is preventable, and the following guidelines will assist in incorporating lithium battery safety into an employer’s Safety and Health Program:... -
Page 11: How To Use This Manual
VOLCON BRAT SERVICE MANUAL HOW TO USE THIS MANUAL For Your Safety Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (e.g., wearing gloves). If you have not... - Page 12 VOLCON BRAT SERVICE MANUAL HOW TO USE THIS MANUAL • Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack stands.
- Page 13 All information, illustrations, directions, and specifications included in this publication are based on the latest product information available at the time of approval for printing. Volcon ePowersports reserves the right to make changes at any time without notice and without incurring any obligation whatsoever.
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Page 14: General Information
VOLCON BRAT SERVICE MANUAL GENERAL INFORMATION TABLE OF CONTENTS Service Rules Intended Use Serial Number and Safety Label locations Component location Display & D-Pad Error Codes Terms Lubricants Threadlock Special Tools 960-101070 Rev D 14 of 104... -
Page 15: Service Rules
Parts that do not meet Volcon’s design specifications may cause damage to the motorcycle. 2. Use only the special tools designed for Volcon products to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts, and screws are not interchangeable with Imperial fasteners. -
Page 16: Intended Use
● Using third-party, Non-Volcon-Approved parts or aftermarket accessories. ● Your Volcon Brat is designed to be used on paved paths and light off-road trails. Therefore, you should never ride over stairs, perform wheelies, take it off jumps, or do stunt/trick-like activities. -
Page 17: Serial Number And Safety Label Locations
VOLCON BRAT SERVICE MANUAL GENERAL INFORMATION Serial Number and Safety Label locations Figure 1 - Identification Code Locations 1. Manufacture Label 2. Vehicle QR Code (under storage compartment cover) 3. Display QR Code 4. Controller QR Code (on battery cradle underneath the battery) 5. - Page 18 VOLCON BRAT SERVICE MANUAL GENERAL INFORMATION Figure 2 - Class 2 Label Location Figure 3 - Warning Label Location 960-101070 Rev D 18 of 104...
- Page 19 VOLCON BRAT SERVICE MANUAL GENERAL INFORMATION Figure 4 - Safety Label Location 960-101070 Rev D 19 of 104...
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Page 20: Component Location
VOLCON BRAT SERVICE MANUAL GENERAL INFORMATION Component Location Figure 5 - Component Location A 1. Display 8. Pedal 2. Throttle 9. Crankset 3. “Tank” Storage compartment 10. Kickstand 4. Headlight 11. Swingarm 5. Electronic speed controller (ESC) 12. Motor 6. Battery 13. - Page 21 VOLCON BRAT SERVICE MANUAL GENERAL INFORMATION Figure 6 - Component Location B 960-101070 Rev D 21 of 104...
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Page 22: Display & D-Pad
VOLCON BRAT SERVICE MANUAL GENERAL INFORMATION Display & D-pad NOTE: If the e-bike is not used for more than 10 minutes, the display will automatically shut down Figure 7 - Display & D-Pad 960-101070 Rev D 22 of 104... -
Page 23: Error Codes
VOLCON BRAT SERVICE MANUAL GENERAL INFORMATION Error Codes Error Code Description Possible Cause E001 Controller Fault 1. Disconnected Cable 2. Controller MOS is damaged or abnormal E002 Communication Fault 1. Backward connected cable or broken cable 2. Protocol mismatch between the controller and display 3. -
Page 24: Terms
VOLCON BRAT SERVICE MANUAL GENERAL INFORMATION Terms Left and Right Most of the time left and right in this manual refers to the rider’s point of view when seated on the E-Bike and facing forward. The one exception to this rule involves the brake calipers. -
Page 25: Special Tools
VOLCON BRAT SERVICE MANUAL GENERAL INFORMATION Special Tools The following special tools are needed for servicing this E-Bike Tool Part # Allen wrench set: 2mm, 2.5mm, 3mm, 4mm, 5mm, 6mm, Chain checker Park CC-2C Tire lever set Park TL-1C Torque Sensor cartridge tool... -
Page 26: Specification
VOLCON BRAT SERVICE MANUAL SPECIFICATION TABLE OF CONTENTS Technical specifications Features Electrical Specifications Torque Specifications Frame Specifications 960-101070 Rev D 26 of 104... -
Page 27: Technical Specifications
VOLCON BRAT SERVICE MANUAL SPECIFICATIONS Technical Specifications Top speed *28+ mph Range **70+ Miles Weight 86 lbs. Motor 750w/1200w max Tires 20x4.0 Tubes 20x4 Front Suspension Adjustable Inverted Fork Rear Suspension Adjustable Mono-shock Brakes Hydraulic Disc 4 Ride Modes, Bluetooth Compatible... -
Page 28: Electrical Specifications
VOLCON BRAT SERVICE MANUAL SPECIFICATIONS Electrical Specifications Component Specification Battery Lithium-ion Capacity 48 V, 15.6 Ah Removable Charger Model: CP546200 Input 100-240 V, 50/60 Hz, 3 A Output 54.6 V, 2 A Charge time 6-7 hrs USB charge port 960-101070... -
Page 29: Torque Specification Table
VOLCON BRAT SERVICE MANUAL SPECIFICATIONS Torque Specification Table Item Metric Imperial Special Instructions Handlebar Riser Clamps 7-9.5 Nm 5-7 ft-lbs Apply threadlocker Handlebar Riser 7-9.5 Nm 5-7 ft-lbs Apply threadlocker Upper Triple Tree 7-9.5 Nm 5-7 ft-lbs Apply threadlocker Lower Triple Tree 7-9.5 Nm... - Page 30 VOLCON BRAT SERVICE MANUAL Taillight 1.36 Nm 1 ft-lbs Rear Fender 1.4 Nm 1 ft-lbs Front Axle 15 Nm 11 ft-lbs Apply threadlocker Rear Axle/ Motor 33.9-40.5 Nm 25-30 ft-lbs Apply threadlocker Kickstand 7-9.5 Nm 5-7 ft-lbs Apply threadlocker Headlight 7-9.5 Nm...
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Page 31: Frame Specifications
VOLCON BRAT SERVICE MANUAL SPECIFICATIONS Frame Specifications Handlebar Head Tube Height Length Head Tube Angle Wheelbase Seat Height Length Length 1825 mm 72 Inches Wheelbase 1240 mm 49 Inches Seat Height 760 mm 30 Inches 940 mm (Black) 37 Inches (Black) -
Page 32: Seat / Body Panels
VOLCON BRAT SERVICE MANUAL SEAT / BODY PANELS TABLE OF CONTENTS Component location Seat Removal/installation Storage compartment Top Panel & Base Panel removal/installation Side Panel removal/installation Inner Storage compartment removal/installation Fenders Removal/installation Chain Guard Removal/installation 960-101070 Rev D 32 of 104... -
Page 33: Component Location
VOLCON BRAT SERVICE MANUAL SEAT / BODY PANELS Component Location Description 1A 992-101042 SEAT,BLK,BRAT 1B 992-101115 SEAT,BRWN,BRAT 992-101041 NUT,HH,M6,NYLK SS BLOX,BRAT 992-101038 LOCK,CAM,W/KEY (2),BRAT 992-101027 COVER,TOP,BLK,BRAT 992-101111 COVER,TOP,BLUE,BRAT 992-101039 SEAL,RUBBER,BLK,BRAT 992-101135 SCR,STS,PPH,M2X0.4X6,SS BLOX,BRAT 992-101020 SCR,BHSC,M5X0.8X10,SS BLK,BRAT 992-101075 REFLECTOR,REAR,BRAT 992-101077 BRACKET,REAR REFLECTOR,BRAT... - Page 34 VOLCON BRAT SERVICE MANUAL 13 992-101125 SCR,SHCS,M5x0.8X16,SS BLOX,BRAT 14 992-101030 NUT,CLIP,M5,BRAT 15 992-101113 COVER,LEFT,BLUE,BRAT 15 992-101031 COVER,LEFT,BLK,BRAT 16 992-101107 SCR,HHCS,M5X0.8X10,SS BLOX,BRAT 17 992-101032 COVER,REAR,BLK,BRAT 17 992-101114 COVER,REAR,BLUE,BRAT 18 992-101035 SCR,HHCS,M5X0.8X8,SS BLOX,BRAT 19 992-101118 SCR,STS,PPH,M4.5X0.7X14,SS,BRAT 20 992-101033 BASE,INNER,BRAT 21 992-101112 COVER,RIGHT,BLUE,BRAT 21 992-101028 COVER,RIGHT,BLK,BRAT 22 992-101029 SCR,SHCS,M5X0.8X14,SS BLOX,BRAT...
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Page 35: Seat
VOLCON BRAT SERVICE MANUAL SEAT / BODY PANELS Seat It is not possible to adjust the seat height of the Brat. It is fixed to the frame by bolts. The minimum seat clamping torque on the frame is 2 lb/ft. (1.36Nm.) For maintenance, use a cloth and water with gentle soap for cleaning. -
Page 36: Storage Compartment Replacement
VOLCON BRAT SERVICE MANUAL SEAT / BODY PANELS Storage Compartment Replacement Top & Base Panel Removal ● Use the supplied key to remove the top panel (4) from the storage compartment. ● Remove the seat as per the previous section ●... -
Page 37: Side Panels
VOLCON BRAT SERVICE MANUAL SEAT / BODY PANELS Side Panels Removal ● Start by removing the 6 Phillips- head screws from the inside of the storage compartment. (3 for each side panel) ● Remove the front and rear outer retaining bolts (22) from each panel using a 3mm Allen wrench. -
Page 38: Fenders
VOLCON BRAT SERVICE MANUAL SEAT / BODY PANELS Fenders Removal ● Remove the single 3mm bolt securing the front fender bracket to the frame in between the front forks located on the lower triple tree. ● Remove the two 3mm bolts securing... -
Page 39: Battery & Charger
VOLCON BRAT SERVICE MANUAL BATTERY & CHARGER TABLE OF CONTENTS Service Information Battery Safety Precautions Battery Technology & Capacity Battery Cold Weather Operation Battery Connectors & Display Charger / Power Supply Battery Charging procedure Installing the Battery Removing the battery... -
Page 40: Service Information
● Locate chargers and batteries charging, in locations where there are no flammable materials adjacent or above. ● Modern advanced batteries are very safe and very unlikely to catch fire. Volcon only uses quality Lithium cells, and a quality BMS (Battery management system). -
Page 41: Battery Technology & Capacity
Storage Temp range 0°C - 25°C (32°F - 77°F) The Volcon battery’s operating temperatures range from 0°C (32°F) to 45°C (113°F). At the lower temperature range, the discharge capacity will be reduced to 30% of the standard capacity at 21°C (69°F). Below 0°C (32°F) the battery’s chemical reactions drop below the practical use threshold. -
Page 42: Battery Connectors & Display
Charge Watts = 110W • 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. 960-101070 Rev D... -
Page 43: Battery Charging Procedure
CAN LEAD TO INJURY OR DAMAGE TO YOU AND THE BIKE. Battery charging Procedure You may either remove the battery from the bike or charge it while in the bike. Volcon recommends removing the battery to charge whenever possible 1. Plug the charger into a standard wall outlet. The charger will operate on standard and GFIC outlets. - Page 44 VOLCON BRAT SERVICE MANUAL BATTERY & CHARGER 5. The charger has an LED status indicator(see table below) 6. Depending on the degree of discharge the battery will charge in 6-8 hours. 7. When charging is complete, remove the charger from the battery.
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Page 45: Installing The Battery
VOLCON BRAT SERVICE MANUAL BATTERY & CHARGER Battery Warning Installing the Battery ● Insert the battery into the center of the frame. Note: (It is easiest to insert it from the non-chain side) ● Slide the battery into the battery receptacle making sure it is fully seated to the bottom. -
Page 46: Tips For Charging
Volcon directly at service@volcon.com. The Battery is not repairable by users. If there is any abnormal occurrence, ● please contact the after-sales department for maintenance or Volcon directly at service@volcon.com. ● Disassembling the battery without permission will void your warranty. -
Page 47: Understanding Battery Range
WARNING Riding downhill or pedaling when not using the throttle will not recharge the battery pack. The Volcon Brat does NOT have Regenerative braking. Range It’s important to remember all electric bicycles have a riding range that can vary greatly depending on the age of your battery, riding style, amount of pedaling, speed, terrain, tire pressure, temperature, payload, and wind. -
Page 48: Battery Maintenance & Storage
VOLCON BRAT SERVICE MANUAL BATTERY & CHARGER Factors That Will Decrease Your Range ● Rapid accelerations using the motor ● Uphill riding ● Heavy payloads ● Headwinds ● Underinflated tires ● Extreme hot or cold weather How To Increase Your Range ●... - Page 49 VOLCON BRAT SERVICE MANUAL BATTERY & CHARGER Suggested Temperature Range Discharge Temp Range 0°C - 45°C 32°F - 113°F Charge Temp Range 0°C - 45°C 32°F - 113°F Storage Temp range 0°C - 25°C 32°F - 77°F How to optimize your battery Make sure that the battery is completely exhausted when you use the battery •...
- Page 50 VOLCON BRAT SERVICE MANUAL BATTERY & CHARGER If the battery is stored for longer than a month connected to the vehicle, • excessive battery depletion may occur that cannot be repaired. If the e-bike is not used for a long period and the battery is stored separately (disconnected from the e-bike).
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Page 51: Troubleshooting
+/- to read the battery voltage. If your fully charged battery measures between 56.4 V-50.4 V, it is OK. ● If the Voltage reading is below 50.4 V, contact Volcon at service@volcon.com for ● further battery diagnostics. If the charger light does not illuminate upon plugging into a power source ●... -
Page 52: Handlebar & Controls
VOLCON BRAT SERVICE MANUAL HANDLEBAR & CONTROLS Table of Contents Component location Handlebar Position Handlebar Replacement Throttle & Grips Brakes Display & D-pad Headset 960-101070 Rev D 52 of 104... -
Page 53: Component Location
VOLCON BRAT SERVICE MANUAL HANDLEBAR & CONTROLS Component Location 960-101070 Rev D 53 of 104... -
Page 54: Handlebar Position
VOLCON BRAT SERVICE MANUAL HANDLEBAR & CONTROLS Handlebar Position NOTE: The handlebar may be adjusted to suit the rider’s preference. The following procedure describes how to set the handlebar to the desired position. ● Loosen the Handlebar riser bolts slightly until the handlebar rotates with ease. -
Page 55: Handlebar Replacement
VOLCON BRAT SERVICE MANUAL HANDLEBAR & CONTROLS Handlebar Replacement Note: Take note of how the brake cables and electrical wires are routed around the headlight. Note how they are routed past the fork tubes. All wires and cables will have to be rerouted along their original paths during installation. -
Page 56: Throttle & Grips
VOLCON BRAT SERVICE MANUAL HANDLEBAR & CONTROLS Throttle & Grips Removal ● Remove the wire harness wrap that goes around the throttle and brake cable. ● Follow the wire from the throttle to the throttle connector behind the display and unplug the throttle wire. -
Page 57: Brakes
VOLCON BRAT SERVICE MANUAL HANDLEBAR & CONTROLS ● Route the throttle wire to the corresponding connector on the wiring harness. Align the connectors properly and press them together until properly seated. ● Install wire harness wrap. ● check to make sure the throttle rotates freely without binding. -
Page 58: Headset
VOLCON BRAT SERVICE MANUAL HANDLEBAR & CONTROLS Headset Removal. ● Remove the front wheel. (see wheel section of this manual) ● Remove the front brake caliper and line from the front fork leg. (see the braking section of the manual) ●... - Page 59 VOLCON BRAT SERVICE MANUAL HANDLEBAR & CONTROLS NOTE: Each bearing must be reinstalled with the proper orientation during assembly. Look for the lower bearing when removing the lower triple tree. The bearing may come out with the steering stem or it could remain behind in the head tube.
- Page 60 VOLCON BRAT SERVICE MANUAL HANDLEBAR & CONTROLS ● Install the upper triple tree onto the stem. ● Install the center cap and 5mm bolt into the upper triple tree. ● Tightening the center bolt slightly to hold the assembly in place.
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Page 61: Suspension
VOLCON BRAT SERVICE MANUAL SUSPENSION TABLE OF CONTENTS Component location Front Forks Removal/Installation Adjusting compression Rear Shock Removal/Installation Preload adjustment 960-101070 Rev D 61 of 104... -
Page 62: Component Location
VOLCON BRAT SERVICE MANUAL SUSPENSION Component Location 960-101070 Rev D 62 of 104... -
Page 63: Front Forks
VOLCON BRAT SERVICE MANUAL SUSPENSION Front Forks Note: Take note of how the brake cables and electrical wires are routed around the headlight and past the fork tubes. All wires and cables will have to be rerouted along their original paths during installation. -
Page 64: Installation
VOLCON BRAT SERVICE MANUAL SUSPENSION Installation ● Install the fork leg into the lower triple tree. ● Install the headlight bracket and steering bumper onto the fork leg. ● Slide the fork leg up into the upper triple tree until the top is flush with the top of the triple tree. -
Page 65: Adjusting Compression
VOLCON BRAT SERVICE MANUAL SUSPENSION Adjusting Compression The Brat suspension comes set to a baseline setting. Follow the instructions to adjust the suspension to your desired comfort. The Brat is equipped with an adjustable Inverted Fork. The rear suspension is an adjustable mono-shock. -
Page 66: Rear Shock
VOLCON BRAT SERVICE MANUAL SUSPENSION Rear Shock Removal ● Support the brat underneath the bottom bracket. ● Lift the rear wheel up off the ground ● Remove the upper and lower shock Bolts (1) ● Remove the rear shock (2) from the frame and swingarm. -
Page 67: Wheels
VOLCON BRAT SERVICE MANUAL WHEELS TABLE OF CONTENTS Wheels Component Location Safety Notice Front Wheel Removal/Installation Rear Wheel Removal/Installation 960-101070 Rev D 67 of 104... - Page 68 VOLCON BRAT SERVICE MANUAL Component Location Description 992-101146 NUT COVER 992-101140 NUT, HUB MOTOR 992-101141 WASHER, CAPTIVE 992-101142 SPACER,HUB 992-101063 FLYWHEEL,16T,BRAT 992-101026 ASSY,WHEEL,REAR W/MOTOR,BLK 992-101024 REFLECTOR,WHEEL,WHITE, BRAT 992-101025 LINER, WHEEL, BLK 992-101131 TUBE,20X4,BRAT 992-101021 TIRE,20X4,ANTI-PNCTR,GUMWALL 992-101023 TIRE,20X4,ANTI-PNCTR,BLK 13/15 992-101144 KIT,AXLE W/NUT, FRONT WHEEL, BRAT...
- Page 69 VOLCON BRAT SERVICE MANUAL WHEELS Tires / Wheels Safety Notice The Brat front and rear wheels are a set of laced - 20"x4" wheels. The tires are 20" x 4.0" low rolling resistance hybrid tires suitable for mixed terrain use with inner tubes and a rim liner.
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Page 70: Front Wheel
VOLCON BRAT SERVICE MANUAL WHEELS Front wheel Removal ● Loosen the two Axle pinch bolts on the bottom of each fork leg. ● Use a 6mm Allen to loosen the axle on the throttle side (rounded head). NOTE: The opposite side will remain in keyway space until enough threads have been loosened, pushing the keyed fastener out just enough to finish spinning by hand to remove. -
Page 71: Rear Wheel
VOLCON BRAT SERVICE MANUAL WHEELS Rear Wheel Removal ● Remove the faux caps from the rear axle on both sides. ● Use a 6mm Allen head to loosen the fastener on the tensioner assembly. NOTE: The tensioner is on the chain side of the bike. Make sure to hold/grasp the tensioner as you loosen the fastener. - Page 72 VOLCON BRAT SERVICE MANUAL ● Disconnect the hub motor plug by unscrewing the barrel connector and pulling to unplug it. NOTE: There is a zip tie holding the plug wire & brake line in place located on the kickstand side, behind the swingarm. Cut and replace the zip tie when removing the rear wheel.
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Page 73: Installation
VOLCON BRAT SERVICE MANUAL WHEELS Installation ● Make sure the non-rotational washers are oriented the correct way on the axle. NOTE: These washers should be installed on the axle just to the outside of the swingarm on both sides when you install the rear wheel into the swingarm. They should line up with the slots on the swingarm. -
Page 74: Brakes
VOLCON BRAT SERVICE MANUAL BRAKES TABLE OF CONTENTS Component Location Front Brake Removal/Installation Rear Brake Removal/Installation Brake Levers Brake Lever Adjustment Brake Pads Brake Pad Alignment Brake Rotor Brake Bleeding 960-101070 Rev D 74 of 104... -
Page 75: Component Location
VOLCON BRAT SERVICE MANUAL BRAKES Component Location Description 992-101001 ASSY, FRONT (LEFT) BRAKE W/DISC BRAT 992-101000 ASSY, REAR (RIGHT) BRAKE W/DISC BRAT DISC,BRAKE, BRAT Not Sold Separately 992-101132 SCR,BHSC,M5X0.8X8,STL,BLOX,BRAT 992-101109 PAD,BRAKE,SET, BRAT LEVER,BRAKE,BRAT Not Sold Separately 960-101070 Rev D 75 of 104... -
Page 76: Safety Notice
For better ergonomics and safety, we advise you to adjust the brake levers in a position that places them as a natural extension of the user’s arms. If you have any questions or concerns, please contact us at support@volcon.com. 960-101070... -
Page 77: Front Brake
VOLCON BRAT SERVICE MANUAL BRAKES Front Brake Removal ● Use a 5mm Allen wrench to remove the two front brake caliper retaining bolts. (Keep track of how the washers and bracket are oriented as these need to be assembled in the same order) ●... -
Page 78: Rear Brake
VOLCON BRAT SERVICE MANUAL BRAKES Rear Brake Removal ● Use a 5mm Allen wrench to remove the two Rear brake caliper retaining bolts. (Keep track of how the washers and bracket are oriented as these need to be assembled in the same order) ●... -
Page 79: Brake Lever Replacement
VOLCON BRAT SERVICE MANUAL BRAKES ● Reinstall the wire harness wrap around the wiring and the brake line. ● Zip tie the brake line to the frame in the same places it originally was. ● Install the controller cover. ● Adjust the brake lever to the correct angle and tighten the bolt on the bottom of the master cylinder. -
Page 80: Brake Pads
VOLCON BRAT SERVICE MANUAL BRAKES Brake Pads Before every ride: confirm the brake pad thickness is greater than 0.8mm. If the pads and rotors become contaminated you must discard them and replace them with a new set. Brake Pad Replacement ●... - Page 81 VOLCON BRAT SERVICE MANUAL 4. Now repeat the process for the Front Brake. 960-101070 Rev D 81 of 104...
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Page 82: Brake Pad Alignment
VOLCON BRAT SERVICE MANUAL BRAKES Brake Pad Alignment ⚠ WARNING When pads are worn, make sure to adjust both clearances between the rotor and pad so that they are equal and balanced. If only one side is adjusted, it will cause braking failure. -
Page 83: Brake Bleeding
VOLCON BRAT SERVICE MANUAL (Check the torque specification table in this manual). BRAKES Brake Bleeding ⚠ WARNING: Only when a rotor or brake bleeding block is in the middle of two brake pads can you depress the brake lever. Disc brake pads, calipers, and rotors may become extremely hot when used. - Page 84 VOLCON BRAT SERVICE MANUAL BRAKES If the hydraulic brakes are feeling spongy at the lever, you can usually improve braking performance by bleeding the system. Keeping the brakes clean is an essential part of routine maintenance. If the pads or rotors are contaminated by oil or dirt, the braking performance will be dramatically reduced.
- Page 85 VOLCON BRAT SERVICE MANUAL BRAKES ● Depress the brake lever 4-5 times. Loosen the outlet valve slowly 3-4 turns. Then quickly tighten the outlet valve after depressing the brake lever 4-5 times. Repeat this process until no more bubbles come out.
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Page 86: Chain & Crankset
VOLCON BRAT SERVICE MANUAL CHAIN & CRANKSET TABLE OF CONTENTS Component Location Chain Pedals Crank Arm Chainring Bottom-Bracket Cartridge Torque Sensor 960-101070 Rev D 86 of 104... -
Page 87: Component Location
VOLCON BRAT SERVICE MANUAL CHAIN & CRANKSET Component Location Description 992-101049 SET, FOOT PEDAL,ALUM,BRAT 992-101048 SET,CRANK W/HARDWARE,127,BRAT 992-101047 TORQUE,BOTTOM BRACKET,BRAT 992-101056 BRACKET,CHAIN PROTECTOR,FETCH,BRAT 992-101050 CHAIN,S1,BRAT 7,8,9 992-101133 KIT,CHN RNG SPRKT W/SPIDER AND HDWR,BRAT 992-101058 BRACKET,CHAIN GUARD TO FRAME,BRAT 992-101096 COVER,CHAIN PROTECTOR,BLUE,BRAT... -
Page 88: Chain
VOLCON BRAT SERVICE MANUAL CHAIN & CRANKSET Chain Removal ● Locate the master link on the chain. ● Use needle nose pliers to remove the master link retaining clip. ● Split the master link and separate the chain. (Note the routing of the chain around the chain tensioner and swingarm) ●... -
Page 89: Pedals
VOLCON BRAT SERVICE MANUAL CHAIN & CRANKSET Pedals Removal ● Use a 15mm Box wrench to remove the pedals. ● For the left pedal (non-chain side) spin the pedal clockwise to loosen and remove. ● For the right pedal (chain side) spin the pedal counterclockwise Installation ●... -
Page 90: Chainring
VOLCON BRAT SERVICE MANUAL CHAIN & CRANKSET Chainring Removal ● Remove the chain guard. ● Remove the right pedal. ● loosen and remove the chainring bolts. (item 7) Park CWP-7 ● Use tool to remove the chainring off of the crank arm. -
Page 91: Installation
VOLCON BRAT SERVICE MANUAL CHAIN & CRANKSET Installation ● Install the chain ring over the crank arm and align the holes with the spider arms on the torque sensor. ● Install the chainring bolts and torque them down according to the torque specification table in this manual. -
Page 92: Installation
VOLCON BRAT SERVICE MANUAL CHAIN & CRANKSET ● Remove the right (chain side ) bottom bracket cartridge cap. Park BBT-9 (Using the bottom bracket cartridge tool ● Remove the chain guard bracket and washers. ● Carefully remove the torque sensor from the bottom bracket. - Page 93 VOLCON BRAT SERVICE MANUAL CHAIN & CRANKSET ● Install the chain guard bracket and washers. ● Install the right-side bottom bracket cartridge cap. ● Install the spider arm and retaining nut. ● Install the chain ring. ● Install the chain.
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Page 94: Electrical
VOLCON BRAT SERVICE MANUAL ELECTRICAL TABLE OF CONTENTS Component Location Controller Motor Display Headlight Taillight Electrical Schematic 960-101070 Rev D 94 of 104... -
Page 95: Component Location
VOLCON BRAT SERVICE MANUAL ELECTRICAL Component Location Description 992-101005 ASSY,DISPLAY BLUETOOTH W/DPAD, BRAT 992-101080 CABLE,INTEGRATED,BRAT 992-101015 ASSY,HEADLIGHT,BRAT 992-101037 CONNECTOR,USB,5V,1A,BRAT 992-101045 HORN,60V,BRAT 992-101083 CONTROLLER,48V,750W,24A,BRAT 992-101073 COVER,REAR LIGHT,END,BRAT 992-101071 ASSY,LIGHT,REAR,BRAT 992-101072 COVER,REAR LIGHT,TOP,BRAT 992-101061 SCR,PPH,M4X14,BRAT 992-101084 CONDUIT,SPIRAL,BRAT 992-101062 COVER,WIRE,PLATE,BRAT 992-101047 TORQUE SENSOR,BOTTOM BRACKET,BRAT 992-101088 CHARGER,54.6V,2A.BRAT... -
Page 96: Controller
VOLCON BRAT SERVICE MANUAL ELECTRICAL Controller Removal ● Remove the 4 controller cover bolts and remove the controller cover. ● Disconnect the connections from the main harness to the controller. ● Remove the 2 controller retaining screws from the controller cover and remove the controller. -
Page 97: Motor
VOLCON BRAT SERVICE MANUAL ELECTRICAL Motor For motor removal steps see the rear wheel removal/installation steps in the Wheels section of this manual. Display Removal/installation ● For removal/installation steps see the handlebar section of this manual. NOTE: If the e-bike is not used for more than 10 minutes, the display will automatically shut down Display &... -
Page 98: Headlight
VOLCON BRAT SERVICE MANUAL ELECTRICAL Headlight Lighting System The Brat lighting system is wired into the main harness of the electric bike. For replacement, you must disconnect the cable going to the headlight and replace the entire headlight assembly. There are no batteries in the lights. Make sure the front and rear lights are clean before riding. -
Page 99: Taillight
VOLCON BRAT SERVICE MANUAL ELECTRICAL Taillight Removal ● Remove the seat (See Seat section of this manual) ● Remove the left side panel. (See the Body Panel section of this manual) ● Remove the controller cover (See the controller section of this manual) ●... -
Page 100: Electrical Schematic
VOLCON BRAT SERVICE MANUAL Electrical Schematic 960-101070 Rev D 100 of 104... -
Page 101: Maintenance
VOLCON BRAT SERVICE MANUAL MAINTENANCE TABLE OF CONTENTS Recommended Maintenance Tire & Wheels Chain Care Suspension Brakes 960-101070 Rev D 101 of 104... -
Page 102: Recommended Maintenance
VOLCON BRAT SERVICE MANUAL MAINTENANCE Recommended Maintenance To prolong the life expectancy of your Brat, here is an example of a maintenance schedule, under intended use, that we recommend following: Schedule BEFORE AND AFTER EACH RIDE Check the alignment of the wheels. -
Page 103: Tires & Wheels
VOLCON BRAT SERVICE MANUAL MAINTENANCE Tires & Wheels Tires must be inflated using a pump with a Schrader valve tip with a recommended pressure of 20 psi (1.38 bar). Always check the condition of the tires and rims for damage, cracks, or deformation. Failure to maintain the proper air pressure rating indicated in the Owner’s manual may at any time result in tire and/or wheel failure. -
Page 104: Appendix
VOLCON BRAT SERVICE MANUAL APPENDIX Volcon Brat® registered trademark of Volcon, Inc. Campagnolo® registered trademark of Campagnolo S.r.l. Finish Line® registered trademark of Finish Line Technologies. Inc. Pedros® registered trademark of Pedro's NA Shimano® registered trademark of SHIMANO INC. Muc-Off® registered trademark of Trimnell, Alexander James Tri-Flow®...
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