RE-ASSEMBLY INSTRUCTION FOR USE ON ROAD

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1 RE-ASSEMBLY INSTRUCTION FOR USE ON ROAD EM5.7 - TL01 PROCEDURE DE MONTAGE KIT HOMOLOGATION

2 EM 5.7 Configuration TYPE «TRIAL» The motorcycle equipped type «Trial» is can be use in private property only. The motorcycle has to be equipped of elementsto be homologated (EC Type approval: e24*2002/24*0275*00). In the following manual all steps to reassemble the certified elements are described: EM 5.7 configuration TYPE «HOMOLOGUEE» 2

3 Modèle Titre Date EM5.7 TL01 RE-ASSEMBLY INSTRUCTION FOR USE ON ROAD Summary HOMOLOGATION KIT DETAILS:... 4 STEP 1: STARTING POSITION OF THE MOTORCYCLE... 6 STEP 2: REAR FLAP PREPARATION... 7 PIECES... 7 ASSEMBLY PROCEDURE... 7 STEP 3: LEFT COMMUTATOR ASSEMBLY... 9 PIECES... 9 ASSEMBLY PROCEDURE... 9 STEP 4: PLATE HEADLIGHT, SPEEDOMETER, BRAKE SENSOR, AND ELECTRIC WIRING ASSEMBLY PIECES ASSEMBLY PROCEDURE STEP 5: SPEED SENSOR AND CONVERTER 48V 12V ASSEMBLY PIECES ASSEMBLY PROCEDURE STEP 6 : SEAT ASSEMBLY PIECES ASSEMBLY PROCEDURE STEP 7: MIRROR ASSEMBLY PIECES ASSEMBLY PROCEDURE APPENDIX

4 HOMOLOGATION KIT DETAILS: Homologation kit contains the main following parts: Plate headlight; Electrical wiring; Rear flap; Mirror; Speed sensor with magnetized screw; Speedometer + Horn; Front brake sensor; Left commutator; ❾Converter V; ❿Seat; Figure 1 : The main parts of homologation kit Complementary parts furnished: Heat shrink sleeve Rear flap drilling template (PDF version to print) 4

Complementary Screws andclamps furnished: 2x Screw BHCE

6x Clamp Rilsan mediumblack 2xClamp Rilsan mediumwhite 3x

Figure 3 : Screw Type BHCE Figure 4 : Nut Nylstop M5 Figure

homologation kit assembly: Allen key of 3, 4 and 6 mm

de 10 mm Phillips head screwdriver Electric Drill Cutting

5 mm Scissors Bike stand Figure 6 : ALLEN key Figure 7 :

5 Complementary Screws andclamps furnished: 2x Screw BHCE 5x16 1x Screw BHCE 5x12 5x Nut Nylstop M5 5x Wide WasherØ5 6x Clamp Rilsan mediumblack 2xClamp Rilsan mediumwhite 3x Clamp Rilsan littleblack Figure 2 : Clamp type Rilsan Figure 3 : Screw Type BHCE Figure 4 : Nut Nylstop M5 Figure 5 : Washer Type WIDE Necessary Tools no furnished, for the homologation kit assembly: Allen key of 3, 4 and 6 mm Hollow socket wrench of 24 mm Wrench of 8, 14 mm 2x wrench de 10 mm Phillips head screwdriver Electric Drill Cutting pliers Heat gun orhair-drier Drill of 5.5 mm Scissors Bike stand Figure 6 : ALLEN key Figure 7 : Wrench Figure 9 : Hollow socket wrench Figure 8 : Cutting pliers Figure 10 : Phillips head screwdriver 5

6 STEP 1: STARTING POSITION OF THE MOTORCYCLE Before starting the assembly, read a first time the instruction manual of homologation kit, to know all the steps. In order to avoid few incidents, worsening and gain comfort, please follows the following steps: 1STOP /SWITCH OFF THE MOTORCYCLE 2 PUT THE BIKE ON BIKE STAND 3REMOVE THE BONNET(VIEW ON THE USER MANUEL ) 4REMOVE THE BATTERY(VIEW ON THE USER MANUEL ) Figure 11 : Starting position of the motorcycle 6

7 STEP2: REAR FLAP PREPARATION PIECES - 1x Rear flap - 2x Screw BHCE 5x16-1x Screw BHCE 5x12-3x Wide WasherØ5-3x Nut Nylstop M5-1x Drilling templates ASSEMBLY PROCEDURE Cut the drilling template and positioning on the rear mudguard. Mark off across the crosses on the rear mudguard. Drill on the mark with a drill of 5.5mm and deburr them. Cut with cutting pliers the plastic tips which does not permit positioning of the rear flap. Figure 12 : Positioning of the drilling template Figure 13 : Marking off and drilling Figure 14 : cutting of the plastic tips 7

8 Screwing the rear flap on the rear mudguard with Allen Key 3mm, and a wrench 10mm. The screw heads are on the top of the rear mudguard. 2 screwsbhce 5x16are on the rear and screw BHCE 5x12ahead. The nylstop M5 nuts are screwed from under the rear mudguard with wide washers Ø5. Hang wire in the plastic tips. If necessary, cut or drill to enlarge hole, for the wire. Plastics tips Figure 15 : Rear mudguard with rear flap 8

9 STEP 3: LEFT COMMUTATOR ASSEMBLY PIECES - 1x Left commutator homologated - 2x ClampRilsan - 1x Heat shrink sleeve ASSEMBLY PROCEDURE Dismantle the bonnet unscrewing 3 screws with Allen key 3mm. Cut the heat shrink sleeve located front of the steering column with scissors. VBe careful do not cut the other wires on this step. Commutateur not approved Unplug connector to the actual left commutator. Cut with cutting pliers 2 clampsrilsan on the handlebar. With Phillips head screwdriver unscrew screws of left commutator not approved below it, and open it, to remove of the handlebar VOpen slowly the commutator without running the risk to break it. Unscrew the new left commutator, open it, to put instead of the not approved commutator. If necessary move the other elements on the handlebar. Commutateurapproved Figure 16 : Approved and notapproved commutator open Fasten the commutator wire with the ELS wire and the magnetic switch wire on the handlebar with 2 blackclamps Rilsan, positioning the commutator wire toward to user on the motorcycle. Left commutatorapproved Wire commutator positioned front of the 2 other little wires (ELS, magnetized switch) 2 clamps Rilsan Figure 17 : Left commutator assembly on the handlebar 9

10 Put the black connector in the heat skrink sleeve with all the other connectors that was before, EXCEPT the white connector of the commutateur. Heat shrink sleeve Plug in connectors to those before. The commutator connector is plug in instead of the old. White connector VAvoid making nodes. V Avoid making mistakes on the wiring: Connector with black and green wires, come from MAP1 / MAP2 switch is plugged in the Map Box (connector with black and black wires). The other connector with 2 wires is plugged in to the mean electric wiring. (View: Electrical drawing in ANNEXES) Connector 4 wires Connector 3 wires Figure 18 : Wires passage in the heat shrink sleeve Put away the connectors as follow : The left commutator connector (4 wires) on the bottom on the left. Electric wiring connector (3 wires) above the previous connector. The 2 connectors out of the Map box keep their vertical positions, behind the Map box. The ELS connectors are above the Map box, perpendicular of motorcycle. Position the heat shrink sleeve with all the wires behind the bonnet attachment. Heat shrink sleeve Bonnet attachment Connector out of the map box Map Figure 19 : Rangement des connecteurs 1 Heat the heat shrink sleeve with heat gun or hairdryer, to retract it when the tidying is over. ELS connector Figure 20 : Rangement des connecteurs 2 10

11 STEP 4: PLATE HEADLIGHT, SPEEDOMETER, BRAKE SENSOR, AND ELECTRIC WIRING ASSEMBLY PIECES - 1x Plate headlight, - 1x Speedometer - 1x Electric wiring - 1x Front brakesensor - 4x little black clamp Rilsan - 2x white clamprilsan - 1x Screw BHCE M5 x12-2x Screw BHC M5 x 30-2x Strut 6.2 x 10 x 20 MARZZOCHI fork Figure 21 : Screws positioning to disassemble the lateral covers and the wheel arch ASSEMBLY PROCEDURE The front wheel mustn t touch the ground (in the case of TECH or OLLE (R16V) fork). 1 Bonnet stays disassemble in this step. Disassemble the lateral covers and the wheel arch with Allen key 3mm. VDo not lose the strut in the silent block of the wheel arch. Disassemble the plate number : 1 Remove the plastic tips which are under the top fork crown by bending and pulling. 2 Rotate the plate number to bring out between the 2 fork tubes. Figure 22 : the plate number Disassembly 2 Protège guidon TECH or OLLE (R16V) FORK CASE : Rotate protects handlebar to reach 2 screwsof handlebar attachment. Unscrew these 2 screws to remove the handlebar with Allen key 6 mm (Think to note your handlebar adjustment). Let it fall on the front of the bike. Unscrew 2 clamps screws of the fork tubes and clamp screw of steering column with Allen key 6mm. Unscrew and remove steering column nut with hollow socket wrench of 24 mm and remove the upper fork crown. Insert the speedometer support on the axis of the column. Figure 23 : Clamp screws of the handlebar in the case of TECH or OLLE (R16V) fork Figure 24 : Clamp screws of the upper fork crown (3 screws) 11

12 Figure 27 : Speedometer support positioning on the steering column Figure 26 : Assembly of the upper fork crown. Figure 25 : Inclination factory setting of the handlebar Reassemble the upper fork crown screwing the nut of 24 mm with the hollow socket wrench(tightening torque: 18Nm). Screw the clamp screw of the steering column with Allen key 6 mm. Pull up the fork tubes, their chamfers must be just above the upper fork crown, unscrewing and screwing 2 clamp screws of lower fork crown on each tube with Allen key 6 mm(tightening torque: 18Nm). Reassemble the handlebar taking account of the inclination setting (factory setting:between the landmark 1 and 2 under the 0). Figure 28 : Assembly of the speedometer support for MARZOCCHI fork. MARZOCCHI FORK CASE : Insert on the screw BHC M5 x 30 the speedometer support and 2 struts 6.2 x 10 x 20. Screw the speedometer support on the upper fork crown. The brake hose passes above. After assembly of the speedometer support depending of the fork continue the procedure here: Plug in the white connector of the left commutator to the electric wiring homologated. Figure 29 : Position of strut and the brake hose for the MARZZOCHI fork. Position the electric wiring (See Figure 35 : Top view of the electric wiring passage in the frame with its ). Plugging plate headlight to the electric wiring : Plug inheadlight connectors to the electric wiring: Blue wire: HIGH Green wire: LOW Black wire: GROUND Plug in indicators connectors: Green wire of RIGHT indicator White/bleu wire of electric wiring Green wire of LEFT indicator White/blackof electric wiring Black wire of each indicator Black wire of electric wiring Figure 30 : Passage of electric wiring front the steering column on the right, the adhesive tape at the level of serial numbers. 12

Figure 31 : Plate headlight assembly Plug in the speedometer and the horn to the electric wiring: Black and purple wires: no matter the connector for the horn.

13 Figure 31 : Plate headlight assembly Plug in the speedometer and the horn to the electric wiring: Black and purple wires: no matter the connector for the horn. Whitemale and female connectors of the speedometer. Figure 32 : Passage of white connector of left commutator Assembly the plate headlight with the fork tubes with rubber straps above the lower fork crown. Assemble the plate headlightwith the speedometer support with screw BHCE M5 x 12 in thethreaded fastenerpositioning on the plate headlight. Adjust the height of headlight in according to the user, by using screwing position of the plate headlight on the slotted hole of the speedometer support. Pass the electric wiring on the right of the steering column, the adhesive tape must be at the level of serial numbers. Screw by hand the brake sensor next to the brake handle. Pass the brake sensor wire between the horn and the fork crown. Plug in the 2 connectors of the brake sensor wire to the brake sensor, no matter the connector. Cover the connectors with the protection Cut the clamps Rilsan attached on the handlebar. Fix 2black clamps Rilsan to the handlebar withall the wires (brake sensor, commutator map, throttle) Brake sensor screws in the brake handle Plugging connector of brake sensor Connectors Protection Figure 33 : Passage of brake sensor wire Figure 34 : Plugging of brake sensor 13

14 Behind the motorcycle : Metal attachment to wind in the electric wiring Electric wiring passage Positions des Colliers Rilsan blancs Figure 35 : Top view of the electric wiring passage in the frame with its attachment Figure 37 : Metal attachment to wind in the electric wiring Remove black cap on the right of battery fuse holder and unscrew nut with wrench 14 mm Remove the locking washer and put red terminal of the electric wiring. Put back the locking washer, screw back on the nut, and do not forget the black cap after. Figure 36 : Positioning of the red terminal Contrôleur Accessible behind the motorcycle, unscrew and remove the nut down on the left of the controller. Slide the black terminal of the electric wiring. Position the black terminal on the right. Figure 38 : Positioning of the black terminal 14

15 STEP5:SPEED SENSOR AND CONVERTER 48V 12V ASSEMBLY PIECES - 1x Speed sensor - 1x Magnetized nut - 4xlittle black clamp Rilsan - 1x Black clamp Rilsan ASSEMBLY PROCEDURE Disassemble one of rear brake disk screw with wrench 8mm, to replace it by magnetic screw with wrench 10 mm (tightening torque: 8Nm) Fixing of speed sensor to the disk protect: Figure 39 : Replacement of one rear brake disk by magnetized screw 1 Fixing of speed sensor to the disk protect: 1.1) Fix speed sensor on the disk protect the curve side in direction of the disc. See figure below. 1.2) Slide little black Rilsan clamp between the protect disk and the brake caliper with a little flat screwdriver and tighten the Rilsan. It must be passing in the groove of speed sensor. 2 Fix the speed sensor wire on the protect disk with a little black Rilsan clamp. 3 Pass the wire through the cap of bleeding screw Figure 40 : Tighten of little black clamp Rilsan on the protect disk Figure 41 : Passage of the clamp Rilsan between the protect disk and brake caliper. 15

Passage of the speed sensor through swingarm with a metal wire : 1 Pass the wire from the front to the rear of the swingarm accessible under the motorcycle.

16 Passage of the speed sensor through swingarm with a metal wire : 1 Pass the wire from the front to the rear of the swingarm accessible under the motorcycle. The wire comes out next to the brake caliper Fix speed sensor connector to the wire. 3 Pull the wire that across the swingarm to come out the connector under the motorcycle. Help the wire to come out because the break hose could obstruct the swingarm hole. Figure 42 : Step 1 & 2: Passage of wire through the swingarm Plug in the speed sensor with the electric wiring. Fix with a little blackclamp Rilsan the speed sensor wire to the brake hose. 3 Position the left lateral cover on the frame. Position the converter 48V 12V the box downward and plug in to the electric wiring. Pass discharge wire of the battery to the side of the converter. Screw the converter with the left lateral with Allen key 3mm. Figure 43 : Step 3 : Le fils ressort à l'avant du bras oscillant Controller fuse Discharging battery wire Converter fuse Figure 44 : Fuses and discharging wire positioning Figure 45 : Fix the speed sensor to the brake hose 16

17 Assembly the rear mudguard positioning the wheel arch. Pass rear mudguard wire above the frame and screw 2 screws located in the side with Allen key 4mm and screw through the wheel arch under the rear mudguard. Figure 46 : Passage of wire between the rear mudguard and the frame Plug in white connector to the electric wiring. Assemble number plate. Fix wires with a blackclamp Rilsan. Figure 47 : Tidying up wires behind the right lateral cover Reassemble the lateral covers and screw it, fuses must be visible and accessible when the bonnet is removed. Screw the wheel arch. Check struts are present in the silent block. Fuse Figure 48 : Reassembly lateral covers with the fuse visible and accessible 17

18 STEP 6 : SEAT ASSEMBLY PIECES - 1x Seat - 2x Wide washer Ø5 ASSEMBLY PROCEDURE Reassembly the bonnet screwing firstly front screw. Position the seat front of bonnet the fixation hole. Put the wide washers Ø5 in the bonnet screws, and screw in their original location with Allen key of 3mm. Figure 49 : Rear fixing of the bonnet and the seat. STEP 7: MIRROR ASSEMBLY PIECES - 1x Mirror ASSEMBLY PROCEDURE Distord mirror clamp to pass around the handlebar and screw. Position the mirror on the right side in accordance with your legislation. Figure 50 : Distord mirror clamp 18

19 STEP 8: SPEEDOMETER SETTING BUTTON OPERATIONS: Functions of the speedometer are: Odometer Trip 1 Trip 2 Overall time Overall time of trip Average Wheel circumference setting: o To set the wheel circumference, press RESET and MODE buttons simultaneously for few second, when the display is not in TRIP 1 or TRIP 2 mode. o C XXXX appears on the screen. o Press RESET to upper the number and MODE to pass on the following number. (Factory setting: C 2168) o To quit the setting press MODE for few second. TRIP 1 & 2 Reset: o Press MODE to appear TRIP 1 or TRIP 2. o Press simultaneously on MODE and RESET buttons o When you reset one of the trips, you reset automatically the average, the overall time of trip Bouton «RESET» Bouton «MODE» Figure 51 : Acewell Speedometer 19

20 Figure 52 : Homologated motorcycle ready for the public road! EM5.7 - TL01 PROCEDURE DE MONTAGE KIT HOMOLOGATION

21 APPENDIX Figure 53 : Homologated Electric wiring schema 21

22 Figure 54 : Mean electric wiring schema 22

24 Before to road on public road, make sure you have the registration of the vehicle, an insurance in accordance with your country and the protect material for your security If you have any question or any doubt, please contact us by phone or Electric Motion s team wishes you to enjoy riding your electric motorcycle. EM5.7 - TL01 PROCEDURE DE MONTAGE KIT HOMOLOGATION

Disassembling and Assembling

Disassembling and Assembling How to disassemble and assemble the controller box 1. Disassembling of controller box Phillips screwdriver, 8# wrench, scissors or penknife. 1) First dismantle the rear bottom