EVT-168

TECHNICAL MANUAL

www.powabyke.com
© Copyright Powabyke Ltd. Bath UK 13/07/2006

Summary
I- Getting the scooter unpacked ...................................................................p 3
1- Unpacking the scooter....................................................................................p 4 2- Fitting the Left Front Signal Lamp .................................................................p 6 3- Fitting the Rear View Mirrors ........................................................................p 7

II- Parts replacement ...................................................................................p 8
1- Replacing the Batteries .................................................................................p 9 2- Replacing the Brake Sensors.........................................................................p 11 3- Replacing the Circuit Board .........................................................................p 13 4- Replacing the Covers.....................................................................................p 16 5- Replacing the Electric Motor........................................................................p 18 6- Replacing the Front Brake Cable .................................................................p 22 7- Replacing the Front Brake Linings ..............................................................p 24 8- Replacing the Fuses .......................................................................................p 26 9- Replacing the Headlamp Bulb ......................................................................p 32 10- Replacing the Rear Brake Linings ...............................................................p 33 11- Replacing the Throttle ..................................................................................p 35

III- Appendix ..............................................................................................p 37
1- Trouble Shooting and Repair..........................................................................p 38 2- Periodic Maintenance Table ...........................................................................p 41 3- Specifications.................................................................................................p 42

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1-Unpacking the scooter
Tools required : • • Scissors A 12mm spanner

Steps to follow : 1. Cut the 3 plastic straps. 3. Remove the main carton.

2. Remove the 2 cartons which are inside the main carton.

4. Remove the protective bubble wrap of the scooter.

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5. Unscrew the bar which keeps the scooter on its stand (use the 12mm spanner).

6. Remove the plastic protection which are located: - on the headlamp and the tail lamp, - on the reflectors (located on the side of the foot stand), - on the suspensions: front and rear, - on the left handle bar and the throttle, - on the seat.

Important: during the unpacking of the scooter, check you have: - the 2 rear view mirrors which are packed in a white carton box located on the foot stand of the scooter: 1 , the battery charger which is packed in a brown carton box located on the right of the rear wheel: 2 , the key of the scooter tied on the handle-bar: the Operation Manual located under the seat.
3

,

3

2

1

Time required : 30 minutes

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2-Fitting the Left Front Signal Lamp
Tools required : • • Scissors A crosshead screwdriver

Steps to follow : 1. Cut the cable tie to remove the signal lamp from the handle-bar. 3. Tighten the screw of the signal lamp.

2. Fit the tab of the signal lamp in the notch of the lower part of the handle.

Time required : 10 minutes

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3-Fitting the Rear View Mirrors
Tools required : • A 14mm spanner

Steps to follow : 1. Tighten the rear view mirror in the hole on handle bars. 3. Repeat these steps for the fitting of the second rear view mirror.

2. Tighten the locknut.

Time required : 15 minutes

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1-Replacing the Batteries
Tools required : • • A crosshead screwdriver A 10mm spanner

Steps to follow : 1. Remove the strap that retains the batteries. 3. Clutch the handles of the battery and remove it.

2. Disconnect the battery by pulling on the grey connector which is located on the left side of the scooter.

4. Disconnect the + and – connectors of the battery: unscrew the 2 screws with the spanner and then with the screwdriver.

5. Repeat for the others batteries.

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To replace the batteries, reverse the procedure. Important: check regularly the condition of the batteries and follow the manufacturers instructions to charge them. Time required : 15-30 minutes

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2-Replacing the Brake Sensors
Tools required : • • Rear brake sensor: a flat screwdriver Front brake sensor: tweezers

Steps to follow : 1. With the flat screwdriver or the tweezers, press the plastic tabs of the sensors. 2. Pull on the sensors cables whilst keeping pressure with the screwdriver or the tweezers to remove the sensors from the handles.

Front brake sensor

Rear brake sensor

3. Remove the metallic rings which are located on the rubber protection boots of the sensor connections.

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4. Pull away the rubber protection boots to enable access to the electric cables.

5. Disconnect the electric cables of the sensors.

Note 1: follow exactly the same procedure for the front brake sensor. Note 2: you can execute the steps 3, 4 and 5 before 1 and 2. It is not necessary to carry out 1 and 2 steps if the fault is not the sensor but in the electric cables or connections. To replace the brake sensors, reverse the procedure. Time required : 10 minutes for one sensor

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3-Replacing the Circuit Board
Tools required : • • • A crosshead screwdriver A flat screwdriver A 14mm spanner

Steps to follow : 1. Remove the right hand rear cover of the scooter: refer to the “Replacing the Covers” procedure. 3. Detach the accelerator cable from the handle bar twist grip: refer to the “Replacing the Throttle” procedure.

2. Disconnect the batteries by separating the red connector located on the frame of the scooter.

4. Unscrew the 14mm nut of the accelerator cable.

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5. Remove the 4 screws which attach the circuit board box to the scooter frame.

7. Remove the back plate.

6. Remove the 12 screws from the back plate of the circuit board box.

8. Push the spring loaded accelerator rod out until the nipple is exposed and disconnect the cable. 9. Using a flat screwdriver, prise off the name plate of the circuit board box.

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10. Unscrew the 6 screws to detach the printed circuit board.

12. Remove the printed circuit board.

11. Unplug the electrical connections.

To replace, reverse the procedure. Time required : around 1-1,5 hours

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4-Replacing the Covers
Name of the different covers :

7

4

9 10

3

12 2 11 8 6

1

5

1. Front mudguard 2. White front cover 3. Light Blue/Orange/Purple/Dark Green/Silver front cover 4. “Fork T” cover 5. Foot plate 6. Exterior chest cover 7. Right side cover 8. Left side cover 9. Rear cover 10. Interior chest cover 11. Rear mudguard 12. Bib Procedure to remove the covers: It is not possible to remove each cover alone because they are joined together. Nevertheless, the mudguards, the white front cover and the “Fork T” cover can be remove alone. Follow these steps to remove the others covers:

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Rear covers 1. Remove the exterior chest cover (6): 2 screws and 1 bolt (8mm spanner). 2. Unscrew the side covers (7) and (8): 4 screws for the left cover and 5 screws for the right one. 3. Pull out of joint the side covers (7) and (8) from the rear cover (9). 4. Unscrew the rear cover (9): 4 screws (2 on each side). 5. Remove the carrier to separate the rear cover (9) from the scooter frame: 1 CHC screw (6mm Allen key) and 1 bolt (10mm spanner). Note: the steps 4. and 5. are interchangeable. 6. Remove the two covers from the scooter frame by pulling on the front of the interior chest cover (10). 7. Separate the two covers. Front covers 1. Remove the rubber protection of the foot plate (5). 2. Unscrew the foot plate (5): 4 bolts (10mm spanner). 3. Pull out of joint the foot plate (5) from the front cover (3): pull on the rear of the foot plate (5) and rotate it toward to the front of the scooter until you can remove it. 4. Remove the front cover (3). To replace the covers, reverse the procedure. Time required: around 1-1,5 hours

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5-Replacing the Electric Motor
Tools required : • • • • • A crosshead screwdriver A flat screwdriver Two 30mm spanner Ramp or rear jack assembly A 4mm Allen key

Steps to follow : 1. Remove the protection cover of the electrcial cables (3 screws). 3. Unscrew the two 17mm nuts located on the two sides of the wheel axle.

2. Remove the brake stirrup: refer to the “Replacing the Rear Brake Linings” procedure. 4. To be able to remove easily, lift up the rear of the scooter.

Note: this operation is not obligatory but is really advised to facilitate the extraction of the rear wheel later.

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5. Using the flat screwdriver, remove the part located between the nut and the oscillating arm: prise the part to remove it from the oscillating arm and then, with your other hand, push it down.

6. Push on the wheel toward to the floor to separate the axle from the oscillating arm.

7. Remove the wheel on the side.

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Note: to open the electric motor, it is necessary to unplug the connectors at the circuit board and to remove the sheath which is around the electrical cables before removing the Allen screws located on the motor cover.

Location of the electric motor connector on the frame of the scooter

Connectors of the electric motor

Interior of the electric motor

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To replace the rear wheel, reverse the procedure. Time required : around 1,5-2 hours to dismantle just the rear wheel (dismantling of the electric motor non-included)

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6-Replacing the Front Brake Cable
Tools required : • Pliers

Steps to follow : 1. Unscrew the tension brake adjustment nut. 3. Remove the cable from the brake drum.

2. Pull on the cable to remove the thread end from the brake tab.

4. Remove the rubber protection located on the brake lever.

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5. Remove the cable from the brake handle: pull on the cable to pass it in the opening located in the extension of the brake lever.

6. Finally, remove the cable from the brake lever: rotate the cable and then pull it down.

7. Using pliers, remove the lug located at the end of the cable. 8. Pull on the cable to remove it from the sheath.

To replace the front brake cable, reverse the procedure. Note: during the fitting of the new brake cable, grease it to enable easier relocation. Time required : 15-30 minutes

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7-Replacing the Front Brake Linings
Tools required : • • • • • A 14mm spanner Two 17mm spanners A hammer A flat screwdriver Pliers

Steps to follow : 1. Unscrew the 14mm screw located on the antirotation bracket. 3. Remove the screw to detach the anti-rotation bracket.

2. Using a hammer, tap the screw until the screw head is exposed on the other side.

4. Unscrew the front wheel axle: 17mm nut.

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5. Stand the wheel upright and remove the front wheel axle with your other hand. 6. Support the forks of the scooter.

7. Remove the brake drum from the wheel.

To replace the set, reverse the procedure. Important: during the replacing of the brake drum in the wheel, check that there is enough grease where the wheel axle pass. Always clean the contact surface between the brake linings and the interior of the wheel (dust, foreign particles, ...).

Surfaces which need to be grease

Time required : between 45 minutes and 1 hour

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8-Replacing the Fuses
The scooter has 3 fuses: 2 fuses of 15A and 1 fuse of 7.5A. The 2 fuses of 15 protect the lighting circuit and the different handle controls. The 7.5A fuse protects the “general circuit”: lighting circuit and the different handle controls plus the power circuit (electric motor, battery). Location of the fuses :

2

1

3

• • •

On the front of the scooter: Inside the chest:

1 2

On the right side of the scooter:
3

Tools required : • • • Fuse Fuse Fuse
1 2 3

: 2 crosshead screwdriver : a crosshead srewdriver and a 8mm spanner : no tools required

Steps to follow : Version 07/06 26

Fuse

1

1. Remove the white front cover: refer to the “Replacing the Covers” procedure.

3. Open it and remove the fuse.

2. Locate the fuse box.

Fuse

2

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1. Remove the exterior chest cover and the right side cover: refer to the “Replacing the Covers” procedure.

3. Unscrew the 3 screws that hold the box to the scooter frame.

2. Disconnect the batteries by separating the red connector located on the frame of the scooter.

4. Unscrew the 4 little screws that hold the dissipator to the box.

5. Pull on the dissipator to remove it from the box.

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6. Locate the fuse on the printed circuit.

7. Remove the fuse.

Fuse

3

1. Open the chest of the scooter.

2. Remove the strap that retains the battery.

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3. Disconnect the battery by pulling on the grey connector which is located on the left side of the scooter.

5. Locate the fuse box.

6. Open it and remove the fuse.

4. Remove the second battery using the same procedure.

To replace the fuses, reverse the procedure. Important: check that the new fuse is the same that the old one (written on the head of the fuse: resistance in ampere). Time required : Version 07/06 30

• • •

Fuse Fuse Fuse

1 2 3

: 15 minutes : 30-45 minutes : 15 minutes

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9-Replacing the Headlamp Bulb
Tools required : • A crosshead screwdriver

Steps to follow : 1. Remove the screw located under the headlamp. 3. Separate the 2 parts of the headlamp. 4. Push and then turn the ring to remove the part where the bulb is fitted.

2. Remove the crown located around the headlamp: remove it by pulling towards you. 5. Remove the bulb: push on the bulb and then turn it until you can remove it.

To replace the headlamp bulb, reverse the procedure. Time required : 15-30 minutes

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10-Replacing the Rear Brake Linings
Tools required : • • • A 12mm A 6mm Allen key A flat screwdriver or tweezers

Steps to follow : 1. Unscrew the 12mm black head screw. 3. Unscrew the Allen screw.

2. Unscrew the other 12mm screw (gold color).

4. Hold the brake stirrup and pull upwards to remove it from the brake disk.

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5. Rotate the part where the brake linings are fitted.

6. To remove the brake linings, place the screwdriver under them and then lever out. Or you can pull on the brake linings, if loose enough.

To replace the rear brake linings and refit the brake stirrup, reverse the procedure. Important: during the fitting of the brake stirrup, check that you have 3 washers behind each of the 2 screw which assure the liaison between the stirrup and the oscillating arm. If not you could probably seriously damage the brake disk. Furthermore, remove any dust on the brake stirrup before refitting.

washers

Time required : 30 minutes Time required: 30 minutes

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11-Replacing the Throttle
Tools required : • • • A crosshead screwdriver Small pliers Replacing the cable: wire cutters

Steps to follow : 1. Unscrew the 2 screws located on the handle. 3. Remove the accelerator cable from its notch in the handle: turn the cable to remove it from the guide, then pull on the cable to remove the lug from the notch.

2. Separate the assembly

4. Unscrew the screw which holds a small tab to remove the cable from the « half body » of the assembly.

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5. Finally, pull on the cable to remove it from the body of the assembly.

To replace the throttle, reverse the procedure. Important: during the replacing of the throttle, check that the throttle operates smoothly, otherwise grease the handle-bar. Note: to replace the accelerator cable, it is necessary to disconnect the cable at the circuit board: refer to the “Replacing the Circuit Board” procedure. Furthermore, to remove the cable from his sheath, it’s necessary to cut one end (handle side: lug / circuit board side: ball). Time required : 30 minutes just to replace the throttle (accelerator cable non-included)

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1-Trouble Shooting and Repair (1)
Conditions Display Panel indicator light is working, but bike will not go when twist throttle. 2. Brake switch breakdown 3. Check Controller cable is fixed 4. Check Motor cable is fixed 5. Motor breakdown. 6. Controller breakdown Display Panel indicator light is not working or no starting beep sound when you turn the switch to the “ON” position. 1. Key switch breakdown 2. Check main switch cable is fixed 3. Hase the fuse blown? 4. Serious insufficient energy left 5. Controller breakdown 6. Display panel breakdown 7. The starting beeper breakdown 8. Check the battery connector is fixed The first red light blinking (1) 1. Serious insufficient energy left 2. The battery is aged or useless Inspect 1. The power will cut off when brake is applied

Repair

1. Release the brake and then gently twisting throttle

2. ~ 6. See our agent

1. 2. See your agent

3. Remove the fuse and replace

4. Recharge battery

5. ~ 7. See your agent

8. Fixed the battery connector

1. Recharge battery immediately

2. Replace the battery

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1-Trouble Shooting and Repair (2)
Conditions The second yellow light blinking (2) 1. Insufficient energy left Inspect

Repair

1. Recharge the battery (The power cut off while driving, please switch the power to “OFF” position, and wait for several minutes then restart. You may still drive a short distance.)

The third green light blinking while driving (3)

1. Over current 2. Controller breakdown Throttle stuck Twist throttle and let go before the panel indicator stops blinking or the starting beep sound stops 2. Controller breakdown

1. Switch the power to “OFF” position, and wait for few seconds to restart

2. See your agent The fourth green light blinking (4)

1. See your agent

2. Switch the power to “OFF” position, and wait for few seconds to restart

3. See your agent 1. Over heat 2. Controller breakdown

The OH indicator blinking

1. Switch the power to “OFF” position, and wait for several minutes then restart

2. See your agent Charging indicator is not on 1. Are the outlet and inlet plugs secure? 2. Check the fuse is fixed

1. Pull out and insert again or change outlet

2. Press the fuse button

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Instrument Panel

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2-Periodic Maintenance Table
A: Inspection Item Mileage (KM) A. Motor 2. Bearing A A A 1. Pressure E. Safety 3. Brakes 4. Brakes Linings F. Lamp, Horn G. Screws H. Turning, Transmission Directions for the Inspetcions: Points to check 1. Tire: pressure, gaps, cuts, damaged 2. Brakes: gaps of left and right brakes are normal (1-2cm is normal), Sufficient brake fluid 3. Lamps: Direction Lamps, Brake Lamps, Head Lamp 4. Turning Bar: Operating smoothly 5. Motor: Operating smoothly, No particular noise Version 07/06 A T A A T A T A A T A T A T A A A 2. Tire A A A A A A A A A A A A A A A T C A T A T A A A A B. Controller C. Battery D. Charger 1. Brush 400 1000 2000 3000 4000 5000 6000 1 2 3 4 5 6 7 C: Clean R: Replace T: Tighten 8 7000 9 8000

10

11

12

13

14

9000

10000

11000

12000

More

A

A

A

A

A

REPEAT ITEM 2-13

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

T

T

T

T

A

C

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3-Specifications (1)
BRAND MODEL LENGTH WIDTH HEIGHT AXLE LENGHT FRONT UNLOAD REAR 85 kg SUSPENSION TOTAL 128 kg TIRE PRESSURE 1P (75 kg) E/35km/h P/45km/h 23.8km/h at 8° Slope/lp TIRE SIZE & PAIRS (p.r) REAR FRONT REAR F R RIDERS/WEIGHT MAX. SPEED CLIMBING SPEC Version 07/06 43 kg 121 cm 109 cm BATTERY 74 cm 165 cm TXS DIMENSION WEIGHT EVT-168 EVT FRAME TYPE

UNDER BONE

DIRETC DRIVEN

GEAR RATIO TYPE

DIRETC DRIVEN

SEALED LEAD ACID

DIMENSION (mm) WEIGHT VOLUME FRONT

197(L)x165(W)x170(H)

15kg x 4

12V/50AH x 4

HYDRAULIC SHOCK

ABSORBER

SPRING SHOCK

ABSORBER

30PSI

36PSI

3.00-10,6pr

3.00-10,6pr

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3-Specifications (2)
TYPE CONTROLLER MAX .H.P MAX.R.P.M. CHARGING TIME POWER INPUT OUTPUT 48V AC110V/220V 500W 5 hrs (up to 90%) LAMPS 755rpm 3.0hp PWM BRAKE MOTOR Version 07/06 CHARGER 48V BRUSHED FRONT REAR SPEEDO METER

DRUM BRAKE

DISK BRAKE

80 km/h

50 mph

FRONT (HI, LO)

HI 12V/35W

LO 12V/35W

PLATE LAMP

12V/5W

BRAKE LAMP

12V/21W

DIRECTION LAMP

12V/10W x 4

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