EVT-168

TECHNICAL MANUAL

www.powabyke.com

© Copyright Powabyke Ltd. Bath UK 13/07/2006

Version 07/06 2

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

Version 07/06 3

Version 07/06 4

1-Unpacking the scooter

Tools required :

• Scissors • A 12mm spanner

Steps to follow :

1. Cut the 3 plastic straps. 2. Remove the 2 cartons which are inside the main carton.

3. Remove 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: ,

- the battery charger which is packed in a brown carton box located on the right of the rear wheel: ,

- the key of the scooter tied on the handle-bar: ,

- the Operation Manual located under the seat. Time required : 30 minutes

1

2

3

1

2

3

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

3. Tighten the screw of the signal lamp.

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. 2. Tighten the locknut.

3. Repeat these steps for the fitting of the second rear view mirror.

Time required : 15 minutes

Version 07/06 8

Version 07/06 9

1-Replacing the Batteries

Tools required :

• A crosshead screwdriver • A 10mm spanner

Steps to follow :

1. Remove the strap that retains the batteries.

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

3. Clutch the handles of the battery and remove it.

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.

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

Rear brake sensor

Front brake sensor

Version 07/06 12

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.

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

3. Detach the accelerator cable from the handle bar twist grip: refer to the “Replacing the Throttle” procedure.

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

Version 07/06 14

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

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

7. Remove the back plate. 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.

Version 07/06 15

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

11. Unplug the electrical connections.

12. Remove the printed circuit board.

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 : 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:

10

11

12

7

1

9

2

3

4

5

6

8

Version 07/06 17

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). 2. Remove the brake stirrup: refer to the “Replacing the Rear Brake Linings” procedure. Note: this operation is not obligatory but is really advised to facilitate the extraction of the rear wheel later.

3. Unscrew the two 17mm nuts located on the two sides of the wheel axle. 4. To be able to remove easily, lift up the rear of the scooter.

Version 07/06 19

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.

Version 07/06 20

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.

Interior of the electric motor

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

Connectors of the electric motor

Version 07/06 21

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)

Version 07/06 22

6-Replacing the Front Brake Cable

Tools required :

• Pliers Steps to follow :

1. Unscrew the tension brake adjustment nut. 2. Pull on the cable to remove the thread end from the brake tab.

3. Remove the cable from the brake drum.

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

Version 07/06 23

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

Version 07/06 24

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 anti-rotation bracket.

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

3. Remove the screw to detach the anti-rotation bracket.

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

Version 07/06 25

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, ...). Time required : between 45 minutes and 1 hour

Surfaces which need to be grease

Version 07/06 26

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 :

• On the front of the scooter:

• On the right side of the scooter:

• Inside the chest: Tools required :

• Fuse : 2 crosshead screwdriver

• Fuse : a crosshead srewdriver and a 8mm spanner

• Fuse : no tools required Steps to follow :

1

2

3

1

2

3

1

2

3

Version 07/06 27

Fuse

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

2. Locate the fuse box.

3. Open it and remove the fuse.

Fuse 2

1

Version 07/06 28

1. Remove the exterior chest cover and the right side cover: refer to the “Replacing the Covers” procedure. 2. Disconnect the batteries by separating the red connector located on the frame of the scooter.

3. Unscrew the 3 screws that hold the box to the scooter frame. 4. Unscrew the 4 little screws that hold the dissipator to the box. 5. Pull on the dissipator to remove it from the box.

Version 07/06 29

6. Locate the fuse on the printed circuit.

7. Remove the fuse.

Fuse

1. Open the chest of the scooter.

2. Remove the strap that retains the battery.

3

Version 07/06 30

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

4. Remove the second battery using the same procedure.

5. Locate the fuse box. 6. Open it and remove the fuse.

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 31

• Fuse : 15 minutes

• Fuse : 30-45 minutes

• Fuse : 15 minutes

1

2

3

Version 07/06 32

9-Replacing the Headlamp Bulb

Tools required :

• A crosshead screwdriver Steps to follow :

1. Remove the screw located under the headlamp. 2. Remove the crown located around the headlamp: remove it by pulling towards you.

3. Separate the 2 parts of the headlamp. 4. Push and then turn the ring to remove the part where the bulb is fitted. 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. 2. Unscrew the other 12mm screw (gold color).

3. Unscrew the Allen screw. 4. Hold the brake stirrup and pull upwards to remove it from the brake disk.

Version 07/06 34

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. Time required : 30 minutes Time required: 30 minutes

washers

Version 07/06 35

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. 2. Separate the assembly

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.

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

Version 07/06 36

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)

Version 07/06 37

Version 07/06

38

1-Trouble Shooting and R

epair (1)

Conditions

Inspect R

epair D

isplay Panel indicator light is working, but

bike will not go w

hen twist throttle.

1. The power w

ill cut off when brake is

applied 2. B

rake switch breakdow

n 3. C

heck Controller cable is fixed

4. Check M

otor cable is fixed 5. M

otor breakdown.

6. Controller breakdow

n

1. Release the brake and then gently tw

isting throttle 2. ~ 6. See our agent

Display Panel indicator light is not w

orking or no starting beep sound w

hen you turn the sw

itch to the “ON

” position.

1. Key sw

itch breakdown

2. Check m

ain switch cable is fixed

3. Hase the fuse blow

n? 4. Serious insufficient energy left 5. C

ontroller breakdown

6. Display panel breakdow

n 7. The starting beeper breakdow

n 8. C

heck the battery connector is fixed

1. 2. See your agent 3. R

emove the fuse and replace

4. Recharge battery

5. ~ 7. See your agent 8. Fixed the battery connector

The first red light blinking (1)

1. Serious insufficient energy left 2. The battery is aged or useless

1. Recharge battery im

mediately

2. Replace the battery

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39

1-Trouble Shooting and R

epair (2)

Conditions

Inspect R

epair The second yellow

light blinking (2)

1. Insufficient energy left 1. R

echarge the battery (The power cut off

while driving, please sw

itch the power to

“OFF” position, and w

ait for several minutes

then restart. You m

ay still drive a short distance.)

The third green light blinking while driving

(3)

1. Over current

2. Controller breakdow

n

1. Switch the pow

er to “OFF” position, and

wait for few

seconds to restart 2. See your agent

The fourth green light blinking (4) Throttle stuck Tw

ist throttle and let go before the panel indicator stops blinking or the starting beep sound stops 2. C

ontroller breakdown

1. See your agent 2. Sw

itch the power to “O

FF” position, and w

ait for few seconds to restart

3. See your agent

The OH

indicator blinking 1. O

ver heat 2. C

ontroller breakdown

1. Switch the pow

er to “OFF” position, and

wait for several m

inutes 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

Version 07/06

40

Instrument Panel

Version 07/06

41

2-Periodic Maintenance T

able A

: Inspection C: C

lean R: R

eplace T: Tighten Item

1

2 3

4 5

6 7

8 9

10 11

12 13

14

Mileage (K

M)

400 1000

2000 3000

4000 5000

6000 7000

8000 9000

10000 11000

12000 M

ore

1. Brush

A

A

. Motor

2. Bearing

A

B. Controller

A

A

C. Battery

A

A

A

A

D. C

harger

A

A

A

A

1. Pressure

A

A

A

A

A

A

A

A

A

A

A

A

2. Tire

A

A

A

3. Brakes A

A

A

A

A

A

A

A

A

A

A

A

A

E. Safety

4. Brakes Linings

A

A

A

F. Lamp, H

orn A

A

A

A

A

A

A

A

A

A

A

A

A

G. Screw

s T

T T

T T

T T

T T

T T

T T

H. Turning, Transm

ission A

A

C

A

C

REPEAT ITEM 2-13

Directions for the Inspetcions:

Points to check 1. Tire: pressure, gaps, cuts, dam

aged 2. B

rakes: gaps of left and right brakes are normal (1-2cm

is normal), Sufficient brake fluid

3. Lamps: D

irection Lamps, Brake Lam

ps, Head Lam

p 4. Turning B

ar: Operating sm

oothly 5. M

otor: Operating sm

oothly, No particular noise

Version 07/06

42

3-Specifications (1)

BRA

ND

EV

T FR

AM

E U

ND

ER B

ON

E

MO

DEL

EVT-168

TYPE

DIR

ETC D

RIV

EN

LENG

TH

165 cm

TXS

GEA

R R

ATIO

D

IRETC

DR

IVEN

WID

TH

74 cm

TYPE

SEALED

LEAD

AC

ID

HEIG

HT

109 cm

DIM

ENSIO

N (m

m)

197(L)x165(W)x170(H

)

DIMENSION

AX

LE LENG

HT

121 cm

WEIG

HT

15kg x 4

FRO

NT

43 kg

BATTE

RY

VO

LUM

E 12V

/50AH

x 4

REA

R

85 kg FR

ON

T

HY

DR

AU

LIC SH

OC

K

AB

SOR

BER

UNLOAD

TOTA

L 128 kg

SUSPEN

SION

REA

R

SPRIN

G SH

OC

K

AB

SOR

BER

FRO

NT

30PSI

WEIGHT

RID

ERS/W

EIGH

T 1P (75 kg)

TIRE

PRESSU

RE

REA

R

36PSI

MA

X. SPEED

E/35km

/h P/45km/h

F 3.00-10,6pr

SPEC

CLIM

BIN

G

23.8km/h at 8° Slope/lp

TIRE SIZ

E & PA

IRS (p.r)

R

3.00-10,6pr

Version 07/06

43

3-Specifications (2)

TY

PE 48V

BR

USH

ED

FRO

NT

DR

UM

BR

AK

E

CO

NTR

OLLER

PW

M

BRA

KE

REA

R

DISK

BR

AK

E

MOTOR

MA

X .H

.P

MA

X.R

.P.M.

3.0hp

755rpm

SPEEDO

METER

80 km

/h

50 mph

CH

AR

GIN

G TIM

E 5 hrs (up to 90%

) FR

ON

T (HI, LO

) H

I 12V/35W

LO 12V

/35W

POW

ER

500W

PLATE LA

MP

12V/5W

INPU

T A

C110V

/220V

BR

AK

E LAM

P 12V

/21W

CHARGER

OU

TPUT

48V

LAM

PS

DIR

ECTIO

N LA

MP

12V/10W

x 4