After-Sales Service Manual

G01

V1.0

1
2
 Foreword

This maintenance manual is prepared by Keeway for exclusive use by G01 series

motorcycle distributors and service outlets. This manual does not contain all knowledge about

motorcycles. It is only applicable for the repairman to understand the principles, maintenance

procedures and maintenance techniques of motorcycles during its repair and maintenance. If

the repairman does not have such knowledge, improper assembly and dangerous conditions

after assembly will occur.

G01 Series Motorcycles

EZI MINI Maintenance Manual

June 2022

3
 Contents

Chapter I General ........................................................................................................................6

Chapter Ⅱ Service Information ..................................................................................................8

Parameters of EZI MINI Motorcycle .............................................................................8

Chapter Ⅲ Parts List................................................................................................................. 11

Chapter IV Disassembly and Assembly Guide of Components ...............................................25

Section I: Disassembly of plastic components ...................................................................27

Section II: Disassembly of wheel components ...................................................................34

Section Ⅲ: Disassembly of steering components ..............................................................36

Section IV: Disassembly and assembly of electrical components ......................................40

Section V: Disassembly of frame component .....................................................................45

Chapter V Definition of Electrical Wiring ................................................................................48

Chapter VI Instrument Display Analysis ..................................................................................76

Chapter VII Error Code Analysis ..............................................................................................78

Chapter VIII Inspection and Maintenance ................................................................................80

Electrical Wiring Diagram of Vehicle .......................................................................................88

4
5
 Chapter I General
Vehicle Information

Three Views

6
VIN code marking position

VIN code located in the right lower corner of the main beam tube of the frame

Marking position of motor number

The motor number is marked on the motor end cover

Tire pressure label

The tire pressure label is placed on the left side of the chain stay

7
 Chapter Ⅱ Service I nformation
Parameters of EZI MINI Motorcycle
Item Standard Value

Length 1720mm
Width 690mm
Height 1030mm
Overall parameters Seat height 750mm
Wheelbase 1190mm
Ground clearance 150mm
Frame material Steel tube frame
Material of front rim Cast aluminum
Size of front rim 14”
Type of front tire Vacuum tire
Parameters of front wheel
Front tire size 2.25-14
Standard tire pressure of front 280kPa
tire
Material of rear rim Cast aluminum
Size of rear rim 14”
Type of rear tire Vacuum tire
Parameters of rear wheel
Size of rear tire 2.25-14
Standard tire pressure of rear 280kPa
tire
Brake type Hydraulic disc brake
Operating mode Right hand operation
Parameters of front brake Brake fluid DOT4
Sizes of brake disc 180mm*3.5mm
Thickness of brake pad 4.5mm
Brake type Drum brake
Operating mode Left hand operation
Rear brake parameters
Diameter 110mm
Thickness of brake pad 6mm
8
 Item Standard Value

Front suspension type Telescopic

Front fork type Spring + hydraulic damper
Front suspension Travel of front fork 60mm
parameters Type of bearing Steel shot headset
Rotation angle (levorotation) 60°
Rotation angle (right rotation) 60°
Parameters of rear Type of rear suspension Rocker arm
suspension Travel of rear suspension 40mm

9
 Electrical Parameters
Item Standard Value

Battery type Lithium battery

Battery parameters Battery capacity 20Ah
Battery voltage 48V
Control mode Field oriented control (FOC)
Controller parameters Undervoltage value 41V±1V
Overcurrent value 25A
Motor type Brushless DC permanent
magnet
Rated power 1000W
Motor parameters
Maximum torque 120N*m
Motor energy consumption 1.5Kwh/100km
Driving mileage 60KM
Rated output voltage 54.6V
Charger parameters
Rated output current 3A
Head lamp 12V LED
Rear lamp 12V LED
Parameters of lighting system
Turn signal lamp 12V LED
License plate lamp 12V LED
Instrument 12V LCD
USB 5V
Horn 12V

* Driving mileages are internal test results of the laboratory, and the actual driving mileage will also be affected by wind
speed, road conditions, driving habits and other factors. The driving mileage values on this parameter page are for

reference only.

10
 Chapter Ⅲ Parts L ist

This chapter gives a detailed description of the locations and names of the parts of this

model for the repairman to accurately understand the parts of this model and facilitate

repair and replacement.

In case of parts replacement, please be sure to use the original parts, for the parts of other

brands may have similar functions or appearance, but the use of them will greatly

damage the quality of the motorcycle.

11
Frame

12
No. Part Description
1 Frame weld assembly (black)
2 Lock set assembly
3 Head lock
4 Blank key
5 Seat cushion lock [D] suite
6 Lock plate
7 Rear luggage carrier weld assembly
8 Hexagon socket head cap screw M8*20
9 Hexagon flange bolt M8*20
10 Hexagon flange lock nut M10*1.25
11 Hexagon flange bolt M10*1.25*40
12 Plain washer 10
13 Rear cushion
14 Chain stay press fitting assembly
15 Center stand buffer stopper
16 Chain stay shaft
17 Center stand weld assembly
18 Hexagon flange bolt M10*1.25*80
19 Center stand spacer bush
20 Middle spacer bush of center stand
21 Center stand spring
22 Plain washer 10
23 Hexagon flange bolt M6*12
24 Hexagon socket head cap screw M5*10

13
Steering Components

14
No. Part Description
1 Handlebar
2 Right combination switch
3 Left handlebar grip
4 Front disc brake
4-1 Right brake handle
4-2 Brake pad
4-3 Broken cable of right brake
4-4 Upper pump body
4-5 Oil tube
4-6 Lower pump body
5 Rearview mirror
6 Instrument
7 Rear brake cable
8 Left combination switch
8-1 Left brake handle
9 Headset
10 Stem
10-1 Stem body
10-2 Stem end cover
10-3 Stem hanging block
10-4 Socket head screw M8*23
10-5 Socket head screw M8*23
11 Front fork assembly
11-1 Lower bracket
11-2 Front cushion (left)
11-3 Front cushion (right)
11-4 Hexagon socket head cap screw M8*40
12 Side reflector
13 Brake cable clamp
14 Hexagon flange bolt M6*12
15 Lock cylinder baffle

15
Wheel

16
No. Part Description
1 Outer tube18*2.5
2 Front hub
3 Disc brake disc
4 Hexagon socket head cap screw M8*35
5 Front axle
6 Left axle sleeve of front wheel
7 Right axle sleeve of front wheel
8 Hexagon flange lock nut M12*1.25
9 Motor component
10 Rear brake drum cover
10-1 Brake shoe
10-2 Tension spring
11 Hexagon nut M6
12 Hexagon flange bolt M6*25
13 Small air valve

17
Electrical Components

18
No. Part Description

1 Controller (45km/h)
2 Charger
3 Alarm (*2 remote controls)
4 DC converter
5 Battery assembly
6 Main cable
7 Head lamp
8 headlamp bracket
9 Left front turn signal lamp
10 Right front turn signal lamp
11 Hexagon flange bolt M6*55
12 Hexagon flange nut M6
13 Rear lamp
13-1 Left rear turn signal lamp
13-2 Right rear turn signal lamp
14 Horn
15 Air switch
16 Flasher
17 Hexagon socket head cap screw M5*16
18 Hexagon flange bolt M6*12

19
Plastic Components

20
No. Part Description
1 Top cover of head tube
2 Left cover of head tube
3 Right cover of head tube
4 Cross recessed pan head screw M5*16
5 Cross recessed pan head tapping screw ST2.9*12
6 Seat cushion (black)
7 Top cover of main beam tube
8 Passive Start button
9 USB charging port
10 Seat cask
11 Cross recessed pan head screw M 6*12
12 Left side cover
13 Baseplate
14 Right side cover
15 Self-tapping screw clip
16 Cross recessed pan head tapping screw ST4.8*16
17 Cross recessed pan head tapping screw ST4.2*13
18 Front wheel mudguard
19 Rear wheel mudguard
20 Pedal
21 Pedal hole plug (front)
22 Pedal hole plug (RR)
23 Pedal hole plug (LR)
24 Rear lower gland
25 Rear upper gland
26 Seat cushion lock [D] suite
27 Cushion lock cable
28 Front wall of seat cask
29-1 Front wall panel of seat cask (black)
29-2 Front wall panel of seat cask (white)
29-3 Front wall panel of seat cask (red)
29-4 Front wall panel of seat cask (blue)

21
30 Charging socket
31 Cover plate of lower yoke plate (black)
32 Rear seat backing plate
33 Front pedal mounting bracket
34 Front pedal (left)
35 Front pedal (right)
36 Hexagon socket head cap screw M6*12

22
Accessories

23
No. Part Description
1 Front basket assembly
1-1 Front basket
1-2 Front basket bracket assembly
1-3 Lock block 1
1-4 Lock block 2
1-5 Hexagon socket head cap screw M6*12
2 Center stand suite
2-1 Center stand
2-2 Center stand spacer bush
2-3 Hexagon flange bolt M6*30
3 Auxiliary seat cushion suite
3-1 Children's seat cushion (black)
3-2 Rear pedal
3-3 Hexagon socket head cap screw M6*16
3-4 Hexagon socket head cap screw M5*10
4 Backrest suite
5 Rear box
6 Vehicle toolkit

24
Chapter IV Disassembly and Assembly Guide of Components
Important Notes for Disassembly and Assembly
This chapter gives a description of the disassembly process of all parts of this motorcycle.

Preparation before disassembly:

1. Before dismantling the motorcycle, remove all dust and dirt from the motorcycle.

2. The motorcycle should be disassembled with appropriate tools to avoid damage to

motorcycle parts.

3. During disassembly, clean all parts and place them in the tray according to the disassembly

sequence. Such way can save assembly time and ensure that the parts should be installed

correctly.

4. Before disassembly of the motorcycle, be sure to cut off the power supply of the motorcycle,

remove the battery and turn the air switch to OFF position.

25
 General Specifications for Locking Torques
The locking torque can be specified for standard fasteners according to the thread depth

specified in the ISO. The locking torques of special components or assemblies are described in

this manual.
A B General torque

(nut) (bolt) Nm Kgf*cm

A: Plane width
10mm 6mm 6 60
B: Thread diameter
12mm 8mm 15 150

14mm 10mm 30 300

17mm 12mm 55 550

19mm 14mm 85 850

22mm 16mm 130 1300

Locking Torques of Main Components for Motorcycle

Name Type Thread Size Qty. Torque (Nm)

Stem Bolt M8 3 25

Front axle Bolt M10 1 50

Chain stay shaft Bolt M10 1 45

Center support rotating shaft Bolt M10 1 45

Rear luggage carrier Bolt M8 3 45

Rear cushion Bolt M10 4 45

Rear wheel motor Nut M14 2 90

Disc brake disc Bolt M8 4 25

Drum brake seat Bolt M6 1 10

Rear seat pedal Bolt M6 4 10

26
 Section I: Disassembly of plastic components
1-1: Pedal

1. Take down the four pedal hole

plugs on the pedal.

2. Loosen the four cross recessed

Disassembly screws in the pedal with a cross

method: screwdriver.

3. Loosen the two self-tapping screws

in the front of the pedal with a cross

screwdriver, and remove the clips.

Used tools: Cross screwdriver

1-2: Baseplate

1. Loosen the four self-tapping screws

that fix the baseplate to the frame with

a cross screwdriver, and remove the

Disassembly
clips and gaskets.
method:
2. Loosen the cross recessed screws

on both sides of the baseplate with a

cross screwdriver.

Used tools: Cross screwdriver

27
1-3: Left and right side covers and baseplate

1. Loosen the six internal self-tapping

screws on both sides of the baseplate

with a cross screwdriver.

Disassembly
2. Loosen the self-tapping screws in
method:
the front middle of the baseplate with a

cross screwdriver, and remove the

clips.

Used tools: Cross screwdriver

1-4: Left and right side covers of head tube

1. Loosen the two cross recessed

screws in the left cover of the head

Disassembly tube with a cross screwdriver.

method: 2. Loosen the three self-tapping

screws in the right cover of the head

tube with a cross screwdriver.

Used tools: Cross screwdriver

28
1-5: Seat cask

1. Loosen the four cross recessed large

pan head screws of the seat cask with a

Disassembly cross screwdriver.

method: 2. Loosen the two cross recessed large

pan head screws inside the seat cast

with a cross screwdriver.

Used tools: Cross screwdriver

1-6: Rear luggage carrier

1. Loosen the hexagon bolts on both

sides of the rear luggage carrier that fix

the luggage carrier to the frame with a

14# open-end wrench.

Disassembly
2. Loosen the hexagon socket-head cap
method:
screws in the middle that fix the rear

luggage carrier to the frame with a 6#

Allen wrench and then remove the lower

gasket.

Used tools: 14# open-end wrench, 6# Allen wrench

29
1-7: Seat cask front wall component

1. Loosen the self-tapping screws on

Disassembly
both sides in the rear of the seat cask
method:
front wall with a cross screwdriver.

Used tools: Cross screwdriver

1-8: Front wall panel of seat cask

1. Loosen the four self-tapping screws

Disassembly inside the seat cast front wall with a

method: cross screwdriver and remove the seat

cast front wall panel

Used tools: Cross screwdriver

30
1-9: Top cover of main beam tube

1. Loosen the two cross recessed bolts

in the lower end of the top cover of

main beam tube with a cross

Disassembly
screwdriver.
method:
2. Push the top cover of the main

beam tube upward hard to remove the

top cover.

Used tools: Cross screwdriver

1-10: Front mudguard

1. Loosen the four hexagon bolts

Disassembly
fixing the front mudguard on the front
method:
cushion with a 10# socket wrench.

Used tools: 10# socket wrench

31
1-11: Rear mudguard

1. Loosen the three hexagon bolts on

both sides and the front end of the rear

Disassembly
mudguard that fix the mudguard to the
method:
chain stay with a 10# open end

wrench.

Used tools: 10# Open-end wrench

1-12: Rear upper gland

1. Loosen the cross recessed large pan

head screws that fix the upper gland to

Disassembly the frame with a cross screwdriver.

method: 2. Loosen the self-tapping screws that

fix the rear upper gland to the rear

lower gland with a cross screwdriver.

Used tools: Cross screwdriver

32
1-13: Rear lower gland

1. Loosen the hexagon bolt that fixes

Disassembly
the rear lower gland to the frame with
method:
a 10# open-end wrench.

Used tools: 10# Open-end wrench

33
 Section II: Disassembly of wheel components
2-1: Front wheel

1. Loosen the front axle with a 14#

open-end wrench.
Disassembly
2. Pull out the front axle and remove
method:
the front wheel and left and right axle

sleeve.

Used tools: 14# Open end wrench

2-2: Front disc brake disc

1. Loosen the three hexagon

socket-head cap screws fixed on the

Disassembly
front wheel with a 6# Allen wrench.
method:
(Thread locker shall be added for

re-fastening)

Used tools: 6# Allen wrench

34
2-3: Motor component

1. Loosen the two hexagon bolts on

the stop plate on both sides of the

motor with a 10# socket wrench.

2. Loosen the set screw nuts on the

motor shafts on both sides of the motor

with a 24# socket wrench.

3. Loosen the cross recessed bolt that

Disassembly
fixes the motor cable on the controller
method:
with a cross screwdriver.

4. Loosen the hexagon bolts that fix

the rear brake drum cover to the frame

with a 10# socket wrench.

5. Remove the set screw nut, spring

pad and stop plate and remove the

motor backward.

10# socket wrench, 24# open-end

Used tools: wrench

Cross screwdriver

35
 Section Ⅲ: Disassembly of steering components
3-1: Left combination switch and brake handle

3. Loosen the two cross recessed

fixing bolts in the rear of the left

Disassembly combination switch with a cross

method: screwdriver.

4. Take the brake cable out of the

brake handle neck.

Used tools: Cross screwdriver

3-2: Front disc brake upper pump

1. Loosen the two hexagon bolt on the

bracket of the front disc brake upper

Disassembly
pump with an 8# open-end wrench and
method:
then remove the upper and lower

pumps and bracket.

Used tools: 8# open-end wrench

36
3-3: Right combination switch

1. Loosen the two cross recessed

fixing bolts in the rear of the right

Disassembly combination switch with a cross

method: screwdriver.

2. Pull out the handle and combination

switch.

Used tools: Cross screwdriver

3-4: Front disc brake lower pump

1. Loosen the hexagon bolt that fixes

the oil tube clamp to the front cushion

with a 10# open-end wrench and then

Disassembly remove the oil tube clamp.

method: 2. Loosen the hexagon bolt that fixes

the front disc brake lower pump to the

front cushion with a 14# open-end

wrench.

10# open-end wrench, 14# open-end

Used tools:
wrench

37
3-5: Instrument

1. Loosen the four cross recessed bolts

Disassembly
in the instrument and the bracket with
method:
a cross screwdriver.

Used tools: Cross screwdriver

3-6: Handlebar

1. Loosen the hexagon socket-head

cap screws in the stem end cover with

Disassembly
a 5# Allen wrench.
method:
2. Remove the stem end cover and the

handlebar.

Used tools: 5# Allen wrench

38
3-7: Front fork

1. Use a 36# open-end wrench to

loosen the upper compression nut on

the steering column.

2. Remove nuts and gaskets.

Disassembly
3. Continue to loosen the lower
method:
compression nut with a 36# open-end

wrench and remove the steel ball.

4. Pull out the front fork downward

and remove the lower steel ball.

Used tools: 36# Open-end wrench

39
 Section IV: Disassembly and assembly of electrical
components
4-1: Rear lamp

1. Loosen the set screw nuts for fixing

Disassembly
the rear lamp inside rear luggage
method:
carrier with a 10# open-end wrench.

Used tools: 10# Open-end wrench

4-2: Headlamp

1. Loosen the hexagon bolts that fix

the headlamp to the headlamp bracket

with a 10# open-end wrench and then

Disassembly remove the gaskets.

method: 2. Press down the buckle to

disconnect the connector and remove

the connector from the inside of the

frame.

Used tools: 10# Open-end wrench

40
4-3: Left/right front turn signal lamp

1. Loosen the two hexagon bolts in the

middle that fix the headlamp bracket to

the frame with a 10# socket wrench.

2. Press down the buckle to disconnect

the connector of the turn signal lamp and

Disassembly remove the connector from the inside of

method: the frame and then take out the headlamp

bracket.

3. Loosen the set screw nuts that fix the

turn signal lamp to the headlamp bracket

with a 17# open-end wrench and then

remove the gaskets and spring pad.

Used tools: 10# socket wrench, 17# open-end wrench

4-4: Horn

1. Loosen the hexagon bolts that fix the

horn to the frame with a 10# open-end

Disassembly
wrench.
method:
2. Disconnect the horn connector and

remove the horn.

Used tools: 10# Open-end wrench

41
4-5: Alarm

1. Loosen the two hexagon

socket-head cap screws that fix the

Disassembly alarm to the frame with a 4# Allen

method: wrench.

2. Press down the buckle to loosen the

connector and then remove the alarm.

Used tools: 4# Allen wrench

4-6: DC converter

1. Loosen the two hexagon

socket-head cap screws that fix the DC

converter to the frame with a 4# Allen

Disassembly
wrench.
method:
2. Press down the buckle to loosen the

connector and then remove the DC

converter.

Used tools: 4# Allen wrench

42
4-7: Controller

1. Loosen the two self-tapping screws

in the controller with a cross

screwdriver and remove the controller.

2. Loosen the cross recessed bolt that

fixes the cable on the controller with a

cross screwdriver.

Disassembly 3. Loosen the hexagon socket-head

method: cap screws that fix the four corners of

the controller to the frame with a 4#

Allen wrench.

4. Press down the buckles on both

sides of the connector to disconnect

the connector on the controller and

then remove the controller.

Used tools: Cross screwdriver, 4# Allen wrench

43
4-8: Air switch

5. Loosen the hexagon bolts that fix

both sides of the air switch bracket to
the frame with a 10# open-end
Disassembly wrench.
6. Loosen the cross recessed screws on
method:
both sides of the air switch with a
cross screwdriver, and take out the
cable.

10# open-end wrench and cross

Used tools:
screwdriver

44
 Section V: Disassembly of frame component
5-1: Rear cushion

1. Loosen the hexagon bolts at the

Disassembly
upper and lower ends of the rear
method:
cushion with a 14# open-end wrench.

Used tools: 14# Open end wrench

5-2: Center stand

1. Loosen the hexagon bolts that fix

Disassembly the center stand to the frame with a

method: 14# open-end wrench, and remove the

bush and the spacer bush.

Used tools: 14# Open end wrench

45
5-3: Chain stay

1. Use a 17# open-end wrench to

loosen the chain stay shaft fixing the

Disassembly
front end of the chain stay to the
method:
frame, and pull out the chain stay

shaft.

Used tools: 17# open-end wrench

5-4: Head lock

1. Loosen the two hexagon

Disassembly socket-head cap screws below the

method: head lock that fix the head lock to the

frame with a 4# Allen wrench.

Used tools: 4# Allen wrench

46
5-5: Lock plate

1. Loosen the hexagon bolt that fixes

Disassembly the lock plate to the frame with a 10#

method: open-end wrench and then remove the

lock wires.

Used tools: 10# Open-end wrench

47
 Chapter V Definition of Electrical Wiring
Component Name Controller Disassembly Method 4-7

Wiring Definition

PIN Color Definition

1 White Motor Hall Sensor A

2 Blue white Gear

4 Red Motor Hall Sensor 5V

6 Black Motor Hall sensor ground terminal

10 Yellow Electric door lock

11 Green/yellow High-level brake

12 Green Motor Hall Sensor B

13 Gray/ white TX

14 Light brown Anti-theft signal

15 Purple/ white Side stay signal

19 Deep green Rolling alarm of motor

22 Blue Motor Hall Sensor C

23 Green/ black RX

26 Black/ white Handle power supply ground terminal

27 Green/ white Handle signal

48
 28 Red/ white Handle power supply 5V

How to Check Power Input of FOC Controller

Step 1: Turn off the power supply.

Step 2: Check the voltage of the main power line by disconnecting the following

connectors:-FOC controller connector- red and black wires

Step 3: Check the DC voltage between the red wire and the black wire (negative pole) on the

wiring harness side.

Step 4: Turn on the power supply, and check and make sure that the DC voltage reading on the

multimeter should be the same as the battery voltage

49
Component Name Head lamp Disassembly Method 4-2

Wiring Definition

PIN Color Definition

1 Blue High beam

2 Green GND

3 Brown Position lamp

4 White Low beam

50
How to Check Power Input of headlamp
Step 1: Turn on the power supply

Step 2: Check the DC voltage between the green wire and the black wire

Step 3: If there is a voltage of 12V but the headlamp is not on, the DC voltage reading of the

multimeter should be approximately 12V. If there is no a voltage of 12V, replace the headlamp

and disconnect the wiring harness

Component Name Left/right front turn Disassembly Method 4-3

signal lamp

51
 Wiring Definition

PIN Color Definition

1 Light blue Right turn signal

2 Green Ground

1 Orange Left turn signal

2 Green Ground

52
How to check Right Turn Signal Lamp
Step 1: Turn on the left (right) turn signal lamp

Step 2: Turn on the power supply, and then turn on the left (right) steering switch

Step 3: Check the DC voltage between the orange (light blue) wire and the green wire on the

wiring harness side

Step 4: The DC voltage reading on the multimeter should be approximately 12 V

Component Name Rear lamp Disassembly Method 4-1

53
 Wiring Definition

PIN Color Definition

1 Light blue Right turn signal lamp

2 Green GND

3 Orange Left turn signal lamp

5 Yellow/ green Brake light

6 Brown Position lamp

54
Component Name Left combination Disassembly Method 3-1

switch

Wiring Definition

PIN Color Definition

1 White Headlamp signal

3 Yellow Headlamp

4 Red Horn signal

5 Green Horn

7 Gray GND

8 Black Turn left

9 Brown Turn right

1 Yellow Brake signal

2 Black Brake

55
Component Name Right combination Disassembly Method 3-3

switch

Wiring Definition

PIN Color Definition

1 White High beam

2 Red Low beam

3 Blue Day light

4 Green Mode signal

5 Black MODE

1 Red Positive pole of handlebar

2 Green Negative pole of handlebar

3 Black Handlebar output

56
How to check Signal output of Handlebar
Step 1: Turn the electric door lock switch to OFF position.

Step 2: Remove the front panel.

Step 3: Connect the multimeter with the black signal output wire and the green ground wire of

the handlebar. Start the motorcycle (turn on it) with the remote control. Slowly turn the handle

from the start angle to the end angle and check the signal output voltage between them.

Standard: Voltage at start angle: 0.83-0.9 V; voltage at end angle: 3.5-3.85 V; the voltage

should vary smoothly between the standard values and it is equipped with a rotating torque

handle.

57
Component Name Motor component Disassembly Method 2-3

Wiring Definition

PIN Color Definition

1 Black Hall sensor

2 Red Hall sensor

3 Blue Hall sensor

4 Green Hall sensor

5 Yellow Hall sensor

1 Yellow Phase U

2 Green Phase V

3 Blue Phase W

58
Component Name Horn Disassembly Method 4-4

Wiring Definition

PIN Color Definition

1 Light green Horn signal

2 Green GND

59
Component Name Alarm Disassembly Method 4-5

Wiring Definition

PIN Color Definition

1 Orange +5V

2 Gray Signal

3 Black/ white GND

4 Yellow Weak current lock

5 Blue Lock motor

6 Green Phase line signal

7 Brown Turning tone signal

8 Red 48V

9 Black GND

4
5
6
7

8
9

60
How to Check Power Input of Alarm
Step 1: Turn on the power supply.

Step 2: Check the DC voltage between the red wire and the black wire (negative pole) on the

component side.

Step 3: The DC voltage reading on the multimeter should be the same as the battery voltage (~

60 V)

Component Name DC converter Disassembly Method 4-6

Wiring Definition

61
 PIN Color Definition

1 Red DC5V

2 Black GND

1 Black GND

2 Yellow DC12V output

3 Red DC48V input

How to Check Power Input of DC-DC Converter

Step 1: Turn on the power supply.

Step 2: Check the DC voltage between the yellow wire and the green wire (negative pole) on

the component side.

Step 3: The DC voltage reading on the multimeter should be the same as the battery voltage (~

60 V)

62
63
How to Check Power Output of DC-DC Converter
Step 1: Turn on the power supply.

Step 2: Check the DC voltage between black wire and green wire (negative pole) on the

component side.

Step 3: The DC voltage reading on the multimeter should be approximately 12 V

64
Component Name Instrument Disassembly Method 3-5

Wiring Definition

PIN Color Definition

1 Red 48VDC+

2 Black GND

3 Green Instrument RX

4 Yellow Instrument TX

5 Brown High beam

6 Blue Turn right

7 White Turn left

8 Orange Dipped headlight

65
Component Name Charging socket Disassembly Method

Wiring Definition

PIN Color Definition

1 Red Positive pole

2 Black Negative pole

3 Black line GND

4 Red line Positive pole

5 Black line GND

1 3
2 4
5

66
How to Check Charging Port in Closed Circuit
Step 1: Remove the storage box under the seat and locate the charging port connector

Step 2: Test the closed circuit between the positive pole of the seat storage box and the

component

Step 3: If the charging port works normally, the multimeter should beep

67
Component Name Flasher Disassembly Method

Wiring Definition

PIN Color Definition

1 Purple 12 V pulse output

2 Yellow 12 V pulse input

3 Green line GND

68
How to Check Flasher
Step 1: Remove the storage box under the seat and locate the flasher

Step 2: Upon the normal power supply, use oscilloscope to test the waveforms of purple and

green lines

Step 3: If the flasher works normally, the waveform is shown in the figure below

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How to Check for Battery Failure
Step 1: Install the driver

Step 2: Prepare the required tools: adapter box; power harness adapter plug;

Step 3: Insert the adapter pins of the battery power harness into the TX, RX and GND ends of

the adapter box

The other end of the adapter box is connected with the USB interface connected to the PC;

Insert the battery power harness socket into the battery socket;

As shown in the figure below:

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Step 4: Open the host computer software, select to open the folder of the single-wire host and

apply left-click to the battery_test_record to pop up a blank page;

71
Step 5: Check the port location before connecting (Sequency: Local

Computer-Properties-Device Manager-Port COM8)

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Step 6: Click Connect button-Connection Settings-Select the serial port number. The port of

this case is COM8

Step 7: Click Read button and start the battery button within 5 seconds; the two indicator lights

of the converter will flash (indicating that the communication information is being

transmitted);

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Step 8: View the screen of the test software as shown in the figure below

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On the two pages, you can query the basic information, charging records and battery error

records of the battery.

Note: The Activate Battery button should also be pressed during the process of reading or

clearing the message.

(Tips: After you click the Function button on the software, you need to press the switch button

on the battery within 3-5 seconds to keep the smooth battery communication)

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 Chapter VI Instrument Display Analysis

Ready
Dipped headlight Fault light
High beam Battery low

Turn left Turn right

Gear display

Speed display

Mileage display

Power display

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 Definitions of Instrument Indicators

Left turn indicator It is on when the left turn signal is enabled.

Right turn indicator It is on when the right turn signal is enabled.

Ready indicator It is on when the motorcycle is ready to start.

It is on when the motorcycle has a fault and the instrument reports

Fault light
an error.

High beam indicator It is on when the high beam is used.

Dipped headlight
It is on when dipped headlights are used.
indicator
Low battery warning
It is on in case of low battery.
light

Mileage indicator It displays the total mileage and single mileage of the motorcycle.

Displays the information of battery such as residual capacity and

Battery level indicator
power percentage, battery location and charging status.

Speed indicator Displays the current driving speed of motorcycle.

If the gear is switched to ECO, MODE and ECO indicators are on

Gear shift: ECO
at the same time.
If the gear is switched to POWER, MODE and POWER
Gear switching: POWER
indicators are on simultaneously.

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 Chapter VII Error Code Analysis

Fault Code: 01 Symptom Motor Hall element does not work

No. Possible Cause Solution
Poor connection between motor Remove the seat cask and check the pins in the connector; if
1
Hall phase line and controller finding poor connection, repair or re-tighten it
2 Open circuit or short circuit In case of open or short circuit, repair or replace the cables

Fault Code: 02 Symptom Failure of motorcycle handlebar

No. Possible Cause Solution
Loose pin in the connector or In case of poor connection, repair or re-tighten it
1
poor contact of the connector
Open circuit or short circuit Use a multimeter to test whether the cable is in open circuit
2
or short circuit. If so, repair or replace the cable
Damage to motorcycle In case of damage, replace the handlebar
3
handlebar

Fault Code: 03 Symptom Controller fault

No. Possible Cause Solution
Phase loss Remove the seat cask and check the pins in the connector; if
1 Incorrect connection of phase finding poor connection, repair or re-tighten it
lines of motor and controller
2 Damage to controller In case of damage, replace the controller

Fault Code: 04 Symptom Brake power failure

No. Possible Cause Solution
Loose pin in the connector or In case of poor connection, repair or re-tighten it
1
poor contact of the connector
Open circuit or short circuit Use a multimeter to test whether the cable is in open circuit
2
or short circuit. If so, repair or replace the cable
Damage to brake power-off In case of damage, replace the brake power-off switch
3
switch

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Fault Code: 05 Symptom Phase loss of motor
No. Possible Cause Solution
Poor connection between motor Remove the seat cask and check the pins in the connector; if
1
Hall phase line and controller finding poor connection, repair or re-tighten it
Open circuit or short circuit Use a multimeter to test whether the cable is in open circuit
2
or short circuit. If so, repair or replace the cable

Fault Code: 06 Symptom Undervoltage protection

No. Possible Cause Solution
Insufficient voltage or Charge the battery. If the battery cannot be charged again due
1
under-voltage of battery to insufficient voltage, repair or replace the battery

Fault Code: 07 Symptom Battery communication fault

No. Possible Cause Solution
Check whether the Use a multimeter to test whether the cable is in open circuit
communication line between the or short circuit. If so, repair or replace the cable
1
battery and the controller is
disconnected
Damage to battery Replace or repair the communication module
2
communication module

Fault Code: CH Symptom Charging mode

No. Possible Cause Solution
When the battery is in charging Wait until the battery is fully charged, or unplug the charging
1 mode, the motorcycle cannot be plug and ride it
driven

Fault Code: 30 Symptom Instrument communication fault

No. Possible Cause Solution
Poor connection between Remove the seat cask and check the pins in the connector; if
1
instrument and controller finding poor connection, repair or re-tighten it
Open circuit or short circuit Use a multimeter to test whether the cable is in open circuit
2
or short circuit. If so, repair or replace the cable

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 Chapter VIII Inspection and Maintenance
This chapter contains the information on the required inspection and maintenance of the motorcycle.
Regular maintenance can make the motorcycle driving more smoothly and prolong its service life.

Maintenance Items and Period:

4,000 km 10,000 km or
Every 7,000 km 13,000 km or
Component Action 1,000 km or half a a year and a
Ride or one year two years
year half
Routine
inspection
I √ √ √ √ √ √
Steering and
control
I/E √ √ √ √ √ √
Steering
bearing
I/C/L √ √
Electrical
system
I √ √ √ √ √ √
Lamps and
switches
I/E √ √ √ √ √ √
Wheel bearing I/E √ E √ E

Hub I √ √ √ √ √ √
Tire I* √ √
Braking
system
I/C/E √ √ √ √ √ √
Brake fluid E Replace it every two years

Front fork I √ √ √
Rear cushion I √ √ √
Handlebar I/L √ √ √ √
Center stand I/C/E √ √ √ √

I... Control (Check) E.. Replacement C... Cleaning L... Lubrication *Check: tread depth, pressure
Notes:
Regarding the "control": It is necessary to check whether the component works correctly. Instructions such as
"cleaning" or "lubrication" mean that this work shall be additional and implemented separately. If finding a
fault /defect, correct it in time.

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Steering and Control
Check whether the front fork moves and whether the handlebar is faulty, and replace the components with certain
wear so as to avoid affecting the safety of driving.
Step 1: Hold the front shock cushion with both hands, shake it hard back and forth, and feel whether there is play,
looseness or gap of front fork.
In case of front fork play, refasten or replace the front fork headset according to Section 3-7 of the Disassembly and
Assembly Guide.

Step 2: Turn the handlebar to check whether the handlebar rotates smoothly and whether it can rebound
automatically after releasing it.
If the handlebar does not rotate smoothly and cannot rebound automatically, repair or replace the
handlebar according to the Section 3-3 of the Disassembly and Assembly Guide.
Step 3: Hold the handlebar forcefully and push and pull it to check whether the handlebar is fastened.
If the handlebar moves by pushing, re-tighten the four hexagon socket-head cap screws on the upper lock block of the
handlebar.
If the problem still exists after fastening the bolts, check whether the knurls of the handlebar and the lock
block are worn down and replace the handlebar or lock block when necessary.

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Steering bearing
Check, clean and lubricate the front fork steering bearing to avoid serious wear and tear of the bearing due to no
maintenance for a long time, for the serious wear of the bearing will reduce its service life and affect riding safety.
Step 1: In case of finding no abnormality in the steering bearing during riding, it is recommended to lubricate the
bearing after riding for one and a half years and two years, respectively.
Step 2: Turn the handlebar back and forth to check whether the rotation is smooth.
If finding rotation not smooth, remove the front fork headset be reference to Section 3-7.
Check whether the bearing is intact and then clean and lubricate it.
If find that the bearing is worn, replace the bearing

Electrical system
Check the vehicle power supply and other electrical systems work normally to prevent the failure of the electrical
system from affecting the safety of riding.
Step 1: Check whether the main cable is worn and whether the connectors fall off or are about to fall off.
Check the electrical parts of the whole motorcycle according to the Disassembly and Assembly Guide to
ensure that there is no risk of failure of the electrical parts.

Lamps and switches

Lighting lamps and combination switches should be checked to ensure that the lighting lamps work normally and
the combination switches are triggered normally to avoid failing to provide corresponding indications in time and
affecting the safety of riding.
Step 1: Power on the whole motorcycle and check whether the head lamp, rear lamp and license plate lamp are
turned on normally.
If only a single lamp can not be on normally, please check whether the connector is loose.
If finding that the connector is intact but the lamp still fails to be on, please replace the lamp.

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 Step 2: Turn on the turn signal lamp, check whether it works normally, whether the flashing frequency is normal,
and whether the audio prompt is normal.
If finding that the turn signal lamp fails to work normally, the flashing frequency is abnormal and there is
no audio prompt, please check whether the connector of the turn signal lamp falls off.
If finding that the connector is intact and the fault still exits, replace the flasher or turn signal lamp.
If all lamps fail to be on, replace the DC converter.

Wheel bearing
It is recommended to check the wheel bearing every half year and replace the wheel bearing every year to avoid
long-term wear of the wheel which affects riding safety.
Step 1: If finding that the wheel bearing needs to be replaced, please remove the front wheel and replace it according to
Section 2-1 of the Disassembly and Assembly Guide.

Hub
Before each ride, check the hub for any deformation and replace it in time if finding any abnormality to avoid affecting
the safety of riding.
Step 1: Check the hub runout. The hub runout limit shall be 2mm with the vertical runout limit of 2mm and the horizontal
runout of 2mm. If the runout is greater than the runout limit, please replace the hub in time.

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Tire
Check the tire pressure and tread depth and make sure that the tire pressure should be within the standard range and the
tread depth should be not less than 2 mm, and check other possible problems to avoid affecting the safety of riding.
Step 1: Use the tire pressure gauge to measure the tire pressures of the front and rear wheels, and check whether the tire
pressure is within the standard range according to the tire labels.
If the tire pressure is too low, the tire should be inflated in time. If the tire pressure is too high, the tire should be
properly deflated.

Step 2: Check whether the appearance of the tire is intact and whether there is any damage or foreign matter.
If the tire is damaged and leaks, please replace the tire.
Step 3: Check the tread depth of the tire.
If finding that the tread depth is less than 2mm, please replace the tire in time.

During the tire replacement, the tire stripper shall be used. Do not disassemble and assemble it manually to avoid tire
damage.

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Braking system
Check the braking system regularly for the wear of the brake disc and the braking effect of the brake and clean the brake
disc to avoid affecting the safety of riding.
Step 1: Check the brake disc for foreign matter or wear.

The thickness limit of the brake disc is 3mm. If the thickness is less than the limit, please replace the brake disc in time.

Clean foreign matters in time. If finding serious wear of brake disc, please replace it in time.

Step 2: Remove the brake lower pump and check the wear of the brake pad.

The thickness limit of the brake pad is 4mm. If the thickness is less than the limit, please replace the brake pad in time.

During riding, if there is a squeal from the brake, it means that the brake pad has been completely worn; in this case, please

replace the brake pad before it is completely worn.

Step 3: If the free travel of the handle is too large (5mm-10 mm) but the brake pad is not worn, it may be caused by a large amount of

air mixed in the oil tube, therefore, you only need to discharge the air.

Exhaust method: Step 1: Repeatedly operate the brake handle for dozens of times and then hold the brake handle.

Step 2: Hold the brake handle and loosen the oil drain screw of the lower pump at the same time; then it can be seen that the brake oil

flows out with bubbles.

Step 3: Then re-tighten the oil drain screw and repeat the above operations until no bubbles are generated and the brake is restored.

(Note: Ensure that there is enough oil in the oil storage tank during operation.)

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Warning! Brake fluid is corrosive. Please wear gloves to operate; no skin exposure to it for a long time; in case of accidental skin

exposure, wash the affected part with flowing clear water in time. If you still feel uncomfortable, see a doctor in time! Be sure to clean

them in time to avoid corrosion which affects the appearance when touching other motorcycle components such as frame, handlebar,

plastic components and other painted components.

Brake fluid
It is necessary to regularly observe whether the brake fluid is sufficient through the sightglass of the oil storage tank, and
regularly add or replace the brake fluid to avoid abnormal braking caused by insufficient brake fluid, which affects the
safety of riding.
Step 1: Observe whether the brake fluid is sufficient.
If it is insufficient, open the upper cover of the oil storage tank and add DOT4 brake fluid into it.

Warning! Brake fluid is corrosive. Please wear gloves to operate; no skin exposure to it for a long time; in case of accidental skin

exposure, wash the affected part with flowing clear water in time. If you still feel uncomfortable, see a doctor in time! Be sure to clean

them in time to avoid corrosion which affects the appearance when touching other motorcycle components such as frame, handlebar,

plastic components and other painted components.

Front Fork and Rear Cushion

The front fork and rear cushion should be checked regularly for leakage, and repaired or replaced in time to avoid affecting the safety

of riding.

Step 1: Check the front fork for liquid leakage

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In case of liquid leakage, please check whether the front cushion handle tube is damaged and whether the dust cover is aged. If so,

please replace the front cushion.

Leakage occurs when the front cushion is intact. Remove the front cushion and replace the oil seal.

Reassemble the front cushion after replacement and refill with 120 ml 46# hydraulic oil.

Warning! Hydraulic oil is corrosive. Please wear gloves to operate; no skin exposure to it for a long time; in case of accidental skin

exposure, wash the affected part with flowing clear water in time. If you still feel uncomfortable, see a doctor in time!

87
Electrical Wiring Diagram of Vehicle

88