owner`s manual 2017

owner`s manual 2017
OWNER’S MANUAL
EM-TL01-J OWNER’S MANUAL
2014
1
Model
Title
Date
EMTL01-M
OWNER’S MANUAL EM
11-01
Summary
Summary ........................................................................................................................................................................... 2
INTRODUCTION OF EM TRIAL OWNER’S MANUAL ........................................................................................................... 4
AFTER THE FIRST USE ........................................................................................................................................................ 4
1.
GENERAL CHARACTERISTICS ..................................................................................................................................... 5
2.
WASHING .................................................................................................................................................................. 6
3.
REAR SUSPENSION EMSport ..................................................................................................................................... 7
HYDRAULIC SETTING ..................................................................................................................................................... 7
SPRING PRELOAD SETTING............................................................................................................................................ 7
4.
FORKS EMSport ......................................................................................................................................................... 8
FORKS OIL CHANGE ........................................................................................................................................................... 9
OIL CHANGEMENT OF HYDRAULIC FORK (RIGHT) .......................................................................................................... 10
OIL SEAL CHANGE RIGHT SIDE......................................................................................................................................... 13
OIL CHANGEMENT OF SPRING FORK (LEFT) .................................................................................................................... 16
OIL SEAL CHANGE LEFT SIDE ........................................................................................................................................... 19
MAINTENANCE DUST SEAL ............................................................................................................................................. 22
5.
REAR SUSPENSION EM5.7 ....................................................................................................................................... 23
HYDRAULIC SETTING ................................................................................................................................................... 23
SETTING OF THE SPRING PRELOAD ............................................................................................................................. 23
6.
FORK EM5.7............................................................................................................................................................. 24
FORK OIL CHANGE ....................................................................................................................................................... 24
7.
CHAIN ...................................................................................................................................................................... 25
CHAIN TENSION:.......................................................................................................................................................... 25
8.
ELS LEVER ................................................................................................................................................................ 26
(ELECTRONICS LEVER SWITCH) ....................................................................................................................................... 26
9.
FOOTREST................................................................................................................................................................ 27
Footrests Positions ...................................................................................................................................................... 27
10.
THROTTLE ............................................................................................................................................................ 28
THROTTLE ADJUSTMENT............................................................................................................................................. 28
11.
REAR AND FRONT BRAKE .................................................................................................................................... 30
FRONT BRAKE .............................................................................................................................................................. 30
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EM-TL01-M - OWNER’S MANUAL - 2017
REAR BRAKE ................................................................................................................................................................ 30
CHANGEMENT OF REAR AND FRONT BRAKE FLUID.................................................................................................... 32
CHANGEMENT OF BRAKE PAD .................................................................................................................................... 33
FRONT BRAKE .......................................................................................................................................................... 33
REAR BRAKE ............................................................................................................................................................ 33
12.
LOWER PART OF REAR SUSPENSION................................................................................................................... 34
13.
TRANSMISSION ................................................................................................................................................... 34
14.
TIRES.................................................................................................................................................................... 35
Tires dimensions : ....................................................................................................................................................... 35
Tires pressure according to the use: ........................................................................................................................... 35
15.
MAIN WIRING...................................................................................................................................................... 36
16.
CHANGING BULBS ............................................................................................................................................... 37
EM HOMOLOGATED.................................................................................................................................................... 37
Indicators bulbs ....................................................................................................................................................... 37
Position lights bulbs ................................................................................................................................................ 37
Head light bulb ........................................................................................................................................................ 38
Rear bulb ................................................................................................................................................................. 38
17.
FUSES................................................................................................................................................................... 38
18.
SPEEDOMETERS SETTING .................................................................................................................................... 39
BUTTON OPERATIONS................................................................................................................................................. 39
19.
MOTUL PRODUCTS.............................................................................................................................................. 40
20.
HOMOLOGATED MOTORCYCLE .......................................................................................................................... 40
21.
MAINTENANCE TABLE ......................................................................................................................................... 41
22.
CONTROLLER – LED CODES ................................................................................................................................. 42
Green LED Codes ............................................................................................................................................................. 42
Red LED Codes ................................................................................................................................................................ 43
23.
TIGHTENING TORQUE ......................................................................................................................................... 44
24.
MOTORCYCLE STORAGE...................................................................................................................................... 45
MOTORCYCLE STORAGE:............................................................................................................................................. 45
BATTERY STORAGE: ..................................................................................................................................................... 45
25.
ELECTRICAL WIRING SCHEMA OF HOMOLOGATED MOTORCYCLE .................................................................... 46
26.
SCHEMA HOMOLOGATED ELECTRIC WIRING ..................................................................................................... 47
27.
MAIN ELECTRICAL WIRING .................................................................................................................................. 48
28.
BREAKDOWN DIAGNOSIS.................................................................................................................................... 49
3
EM-TL01-M - OWNER’S MANUAL - 2017
INTRODUCTION OF EM TRIAL OWNER’S
MANUAL
This document must be read carefully, to avoid premature ageing of the motorcycle
This manual is composed of all elements of the motorcycle with their setting and maintenance. These elements
allow good use and secure of the motorcycle.
Data, specifications, and illustrations of the manual do not rendered liable ELECTRIC-MOTION, which have the
right to modify and improve their models, at any time without notice
AFTER THE FIRST USE
When the motorcycle carried out its first hours of driving , for your security and the good working of the EM, do not
forget to check the following elements:
 Tightening of brake discs front and Rear;
 Tightening of the crown;
 Tightening of wheel spokes front and rear;
 Chain tension;
 Tightening transmission unit;
 Tightening of swingarm;
 Checking of steering wear clearance.
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EM-TL01-M - OWNER’S MANUAL - 2017
1. GENERAL CHARACTERISTICS
POWER TRAIN
ENGINE
POWER
TORQUE
COOLING SYSTEM
MAP
PRIMARY DRIVE
SECONDARY DRIVE
MAXIMUM SPEED
TIME RANGE
BATTERY
CHARGING TIME
BRUSHLESS DC
5Kw Nominal / 10Kw Max
16 Nm nominal (peak 20 Nm)
Air cooled
(4) : Novice ; Trek ; Wet Trial; Dry Trial
Toothed Belt
Chain
Approximately 50 km/h
Approximately 60 à 160 min
Lithium polymere 48V / 25Ah
EM 5.7 : Approximatelty 130 min to reach 100%
EM SPORT : approximately 110 min to reach 100%
CHASSIS
FRAME
FORK
REAR SUSPENSION
BRAKE
RIMS
Perimeter
EM 5.7 : Ollé hydraulic R16V Ø 40mm
175 mm travel
EM SPORT : TECH
EM 5.7 : Sytème à biellette Ollé R16V
170mm de débattement
FRONT : Hydraulic 4 Pistons
Floating disc Ø 182 mm
REAR : Hydraulic 2 Pistons
Fixed disc Ø 150 mm
MORAD Tubeless
FRONT : 1.6 x 21’’
REAR : 2.15 x 18’’
WEIGHT & MEASURES
WEIGHT
SADDLE HEIGHT
GROUND CLEARANCE
WHEELBASE
LENGTH
HEIGHT
EM 5.7 : 72 kg
EM SPORT : 70 kg
680 mm
290 mm
1338 mm
2140 mm
1159 mm
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EM-TL01-M - OWNER’S MANUAL - 2017
EM SPORT OPTIONS
FORKS
CROWN
CHAIN
COVERING
CHARGER
TECH STD
HAASE Low friction
D .I.D low friction
Wheels protection stickers
Carbon design on swingarm & forck protection
Handle bar ends
15A (Full charge 100% : around 110 min)
2. WASHING
The utilization of high pressure machine is not advice, because it is possible to damage the stickers or other
components (electric components, battery, rolling, axes …).
The water-jet must be at 40 cm from the motorcycle to avoid damaging it, and it must be careful with the
delicate elements.
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EM-TL01-M - OWNER’S MANUAL - 2017
3. REAR SUSPENSION EMSport
HYDRAULIC SETTING
The setting is accessible from the right of the
motorcycle on the top of the suspension with
Allen key 4 mm.
20 notches exist to adjust the hydraulic system.
Table 1 : Hydraulic Setting
Number
of notchs
HARD
MIDDLE
SUPPLE
0–7
7 – 14
14 - 20
Figure 1 : Hydraulic setting
Figure 2 : Réglage hydraulique amortisseur
It is better to start to close the hydraulic screwing the screw to the stop and to unscrew to the required position.
Factory setting: 10 notches.
SPRING PRELOAD SETTING
Grooved nut
Clamping
screw
Figure 4 : Spring preload Setting
Figure 3 : Clamping screw
Rear suspension becomes accessible to lifting the rubber wheel arch, behind the rear wheel.
The preload setting can be modified screwing and unscrewing the grooved nut.
This grooved nut is camp with the clamping nut.
Factory setting: The length of the spring is 122mm.
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EM-TL01-M - OWNER’S MANUAL - 2017
4. FORKS EMSport
The TECH sport fork is composed of:
- Fork leg with spring;
- Fork leg with hydraulic system.
The hydraulic setting can be modified on the top of the fork
with a plate screwdriver.
Hydraulic setting
- 33 notches exist to adjust hydraulic.
Tableau 2 : hydraulic setting
Number of
notches
HARD
MIDDLE
SUPPLE
0 – 11
11 – 22
22 - 33
the screw
on.
Calibration of the
spring
Figure 5 : Setting of calibration of the spring
Number of
notches
HARD
MIDDLE
SUPPLE
0–4
4–7
7-11
Figure 6 : Réglage fourche
The calibration of the spring can be modified with Allen key 6 mm.
11 turns exist to adjust the calibration of the spring.
Factory setting: 6 turns.
The MARZOCCHI sport fork is composed of:
- Fork leg with spring;
- Fork leg with hydraulic system.
The hydraulic setting can be modified
on the top of the fork with a plate screwdriver.
- 27 notches exist to adjust hydraulic :
For harden the compression and extension,
you must aim the screw concerned.
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EM-TL01-M - OWNER’S MANUAL - 2017
FORKS OIL CHANGE
Oil change intervals recommended are the following:
After the 50 first hours
Every 6 months
V If the intervals of oil change are not respected, the specifications of the fork could be deteriorated. Moreover the
thickening of oil itself, which can lead to oil, leaks from the seal.
To change oil of the fork:
- Clean the fork;
- Protect the surface of the inner tubes and clamp it in vise, as you can see in the following picture.
V Tighten the vise moderately in order not distorted the inner tube.
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EM-TL01-M - OWNER’S MANUAL - 2017
OIL CHANGEMENT OF HYDRAULIC FORK (RIGHT)
 Unscrew entirely the cap to the fork
with key 17 mm.
 Remove the cap « A » in order to access the
nut « B ».
Unscrew with key 14 mm the nut « B », holding
the cap “A”
 Keep in position the nut « B » with the stem « E »
 Position the fork in vertical position and
to avoid the spilling of it.
pour 280 mL of new oil.
Flow the oil in container. To flow all the oil pump
with the stem “E”.
Oil type: OJ 01 (SAE 5)
V Collect the oil to bring in a recycling center to
reduce the environmental impact.
EM-TL01-M - OWNER’S MANUAL - 2017
 Use the stem to pump, to fill the fork.
10

❻ Complete the topping out of oil: Bring the oil level suitable 55 mm from the top edge of the tube
❼ Screw entirely the cap to the stem « E ».

Hold the cap « A » and screw the nut
« B » with a tightening torque of 14.7Nm.
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EM-TL01-M - OWNER’S MANUAL - 2017

With key 17 mm, screw the cap in the
fork tube with a tightening torque between
11.7 and 13.7 Nm.
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EM-TL01-M - OWNER’S MANUAL - 2017
OIL SEAL CHANGE RIGHT SIDE
Proceed as follows:
 Remove of the motorcycle and clean the suspension;
 Protect the surface of the inn as shown in figure.
V Tighten the vice moderately in order not to ovalize the inner tube.
Follow the steps ❶, ❷ and ❸ of oil change of the right fork.
❶ Insert a tube into the hole for the wheel
and unscrew the cartridge with a 12 mm a
socket wrench.
❸ Remove the cartridge from the inner
tube.
❷ Remove the locking screw pump with
sealing washer oil.
❹ Turn the fork and remove the hydraulic
cone limit.
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EM-TL01-M - OWNER’S MANUAL - 2017
❺ Push in the compression group and
remove the snap ring from its seat.
❼ Insert the cone end of stroke in the
bottom cartridge.
❿ Tighten the upper part
of protecting hose clamp
(see figure), exercising the
decisive blows on the leg.
Remove oil seal and
bushing from the outer
tube itself.
❻ Remove the compression unit:
- Place the cartridge on a basin for collecting oil and slide the rod
into the tube of the cartridge until complete discharge of oil.
- Replace the hydraulic unit in the cartridge.
- Replace the snap ring in its housing (see figure), making sure they
fit well.
❽ Pry up the edge of the
scraper and remove it from
the seat of the leg.
❾ Remove the snap ring from its
seat.
⓫ Remove the tube all the
above parties (A-B-C-D-E).
Replace the “A” with a new
one.
⓬ Grease the base in
the bushing and seal the
outer tube.
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EM-TL01-M - OWNER’S MANUAL - 2017
⓭ Tighten the pipe in the vise with the
special shells "X" side without checking that
the drain is against bush "B".
·With decisive blows of the outer tube, the
bushing “B” in place N.B.: check that it is fully
entered into here.
⓯ Insert the oil seal in the tube (with the
spring upward view) and close the hose
clamp with the shells “X” with the drain to
the oil seal.
·With moderate shots of the leg, insert the oil
seal in the “D”.
N.B.: This does not need a lot of strength.
Avoid hitting the seal once it is in place.
⓮ Insert the nut "C" against bushing "B",
making sure that the lip of the collar is
upwards.
⓰ Insert the snap ring in place
⓱ Follow “maintenance of dust seal” instructions step 4 to 6, to assembly the dust seal in the manual
⓲ Insert the cartridge into the tube up to
send her home in the bottom of the leg.
⓳ With holding cartridge rod on the bottom
of the leg, send the parcel cartridge life.
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EM-TL01-M - OWNER’S MANUAL - 2017
⓴ Moderately tighten the leg in the vice
for not ovalize that, protecting it with a
clotch.
Insert a tube into the hole axle and tighten
with the torque of 23.5 – 25.5 Nm.
To finish the maintenance, follow “Oil changement of hydraulic fork (right)” above in the manual
instructions, step ❻ to ❾, to fill oil, and reassembly the fork.
OIL CHANGEMENT OF SPRING FORK (LEFT)
 Unscrew entirely the cap « A » to the
fork tube with key 17 mm.
 Remove the following elements:
Pull the conical spacer « B » and put in a clean place.
EM-TL01-M - OWNER’S MANUAL - 2017
Remove the cap « A », and put it in clean
place.
Pull the spacer « C » and put in a clean place.
16
Pull slowly spring « E » and at the same time dry it with
a cloth.
Put all the elements in a clean place.
 Pour the oil in a container.
V Collect the oil to bring in a recycling center
to reduce the environmental impact.
 Place the suspension in a vertical position,
and put some oil.
Oil type : OJ 01 (SAE 5)
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EM-TL01-M - OWNER’S MANUAL - 2017
 Pump for few times the inner tube and place
it to the end of the stroke.
Bring the oil level up to the appropriate level:
The oil level suitable 55 mm from the top edge of
the tube
 Insert in sequence all the elements in the following:
- The spring;
- The washer;
- The spacer;
- The conical spacer.

Screw entirely the cap with key 17 mm, with a
tightening torques 11.7 – 13.7 Nm.
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EM-TL01-M - OWNER’S MANUAL - 2017
OIL SEAL CHANGE LEFT SIDE
Proceed as follows:
 Remove of the motorcycle and clean the suspension;
 Protect the surface of the inn as shown in figure.
V Tighten the vice moderately in order not to ovalize the inner tube.
Follow the steps ❶, ❷ and ❸ of oil change of the right fork.
❶ Protect with cloth the brake support
and clamp it in a vise.
Unscrew with a wrench 12 mm.
❸ Remove entirely the stem with the
spring.
EM-TL01-M - OWNER’S MANUAL - 2017
❷ Remove the screw with the oil seal.
❹ Turn over the fork and remove the
stop mechanical cone.
19
❽
Remove
with
screwdriver the dust seal.
a
❾ Remove the snap rise from
its seat.
⓫ Remove all the components (A-BC-D-E).
❿ Tighten the inner tube in
a clamp with cloth and
exercising the decisive blows
on the leg.
Remove oil seal and bushing
from the outer tube itself.
Replace « A » with a new one.
⓬ Grease the seat of the oil
seal.
« A »: Bearing bushing of the inner tube;
« B »: Bearing bushing of the upper tube;
« C »: Washer;
« D »: Oil seal to replace;
« E »: Dust seal.
⓭ Tighten the pipe in the vise with the special shells
"X" side without checking that the drain is against
bush "B".
·With decisive blows of the outer tube, the bushing
“B” in place N.B.: check that it is fully entered into
here.
⓮ Insert the washer "C" against bushing "B",
making sure that the lip of the collar is upwards.
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EM-TL01-M - OWNER’S MANUAL - 2017
⓯ Insert the oil seal in the tube (with the spring
upward view) and close the hose clamp with the
shells “X” with the drain to the oil seal.
·With moderate shots of the leg, insert the oil
seal in the “D”.
N.B.: This does not need a lot of strength. Avoid
hitting the seal once it is in place.
⓰ Insert the snap ring in place.
⓱ Follow “Maintenance of dust seal” instructions step 4 to 6, to assembly the dust seal in the manual.
⓲ Insert the stem with the spring after the
stop mechanical cone in the inner tube.
⓳ Position the brake support in the vise.
Hold the tube all the way and with the help of the
fork spring screw pump pack life.
⓴ Screw with a tightening torque 23.5 to 25.5 Nm.
To finish the maintenance, follow “Oil changement of hydraulic fork (left)” above in the manual instructions, step ❻ to
❿, to fill oil, and reassembly the fork.
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EM-TL01-M - OWNER’S MANUAL - 2017
MAINTENANCE DUST SEAL
The table below shows the recommended cleaning intervals of the dust seal:
V The non-periodic cleaning of the dust seal induces infiltration of mud in the fork. Such infiltration
compromises the smoothness of the fork and cause serious leaks from seals.
Cleaning of the dust seal
After three races in
the presence of dust
❶ Pry up the spring of the dust seal and
remove the seal from the seat of the leg.
❸ Force the one hand to introduce the dust seal and
the cloth. Do swirling the dust on the cloth to wipe off
any dirt to the inside of the sealing lips.
❺ Place the dust seal on the grease and
rotate it on itself.
EM-TL01-M - OWNER’S MANUAL - 2017
After each race in the
presence of mud
❷ With a cloth clean from any trace of mud the base
of the dust seal and the upper edge of the oil seal.
❹ Lubricate the tube with a grease seal.
❻ Put in place the dust seal helping with
the flat side of a screwdriver.
22
5. REAR SUSPENSION EM5.7
The hydraulic setting can be modified on the top of the fork with a Allen key 4 mm.
HYDRAULIC SETTING
23 clotches exist to set the hydraulic.
It is accessible on the left of the motorcycle.
Number of
clotches
HARD
MIDDLE
SUPPLE
0-8
8 – 16
16-23
Figure 9 : Setting of the hydraulic system
It is better to start to close the hydraulic screwing the screw to the stop and to unscrew to the required position.
Setting Factory position: 12 clotches.
SETTING OF THE SPRING PRELOAD
The modification of the preload can be change to screw or unscrew the double grooved nuts.
The inferior grooved nut tightens the superior grooved nut.
The superior grooved nut sets the length of the spring for the spring preload.
Rear suspension becomes accessible to lifting the rubber wheel arch, behind the rear wheel.
Double grooved nut
Figure 10 : setting of the spring preload
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EM-TL01-M - OWNER’S MANUAL - 2017
6. FORK EM5.7
The 2 tubes are similar; they are each composed of hydraulic and spring system.
Adjustment doesn’t exist in this fork.
Carry out the fork venting regularly, to conserve the technical specifications
Unscrew the screw with a flat screwdriver on the top of the inner tube to allow escape the air. And screw again
after.
Figure 11 : Position of venting screw.
FORK OIL CHANGE
Take off the wheel, and the fork of the fork crown.
① Unscrew the cap with key 24 mm on the top of each fork;
② take off spacer and spring in the fork;
③ Pump to empty oil in a container;
260 mm
V Collect the oil to bring in a recycling center to reduce the environmental
impact.
④ Fill the fork with: 310 mm of oil (SAE 5), or Bring the oil level up to the
appropriate level:
The oil level suitable 260 mm from the top edge of the tube;
Huile SAE 5
Figure 12 : Oil level
⑤ Re-insert spring and spacer;
⑥ Screw the cap on the top of the fork.
Assembly the forks in the crown at the same height, and assembly the wheel.
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EM-TL01-M - OWNER’S MANUAL - 2017
7. CHAIN
The chain tension must be often checking in order to avoid premature wear of transmission elements (chain, sprocket,
crown…)



The transmission must be often cleaned and lubricate with Motul Chain Clean and Motul Chain Off Road.
The distance between the swingarm and the chain must be 30 and 35 mm.
Assembly the quick link as shown in the picture below, the opened side toward of rear when it is located on
the top of chain passage.
Rotation direction of chain
CHAIN TENSION:
Figure 13 : Position of the quick link
Distance between axle chain and swingarm
Spring of Tensioner
Tendeur
The tension chain must be check after each disassembly of wheel
rear.
Excentric adjuster
Escargot Tende
Figure 14 : Elements to extend the chain
The tension of the chain can be modifying with the 2 excentric adjusters of each side of the motorcycle.
The indication of each excentric adjuster on the swingarm must be the same.
The spring of tensioner must be cleaned and lubricated regurlarly, because it has an important role.
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EM-TL01-M - OWNER’S MANUAL - 2017
8. ELS LEVER
(ELECTRONICS LEVER SWITCH)
 The position of the ELS lever must be adjusted according the owner.
Adjustment of position lever and handlebar
Adjustment of the ELS position: On/Off
Protection
Figure 15 : Adjustment of ELS lever
Check before and after each washing the good-positioning of the protection.
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EM-TL01-M - OWNER’S MANUAL - 2017
9. FOOTREST
 The footrests must be always had the
capacity to be retracted, and take it
always these initial position (choc for
example).
 To keep their function the footrests
must be always cleaned and
lubricated.
Figure 16 : Footrest
Footrests Positions
The footrests have 2 positions (front and rear position):
- Remove the footrests;
- Position the spacer (Above or below the footrest) the spacers must be lubricate;
- Switch springs (right/left);
Figure 18 : Front position on the right side
Figure 19 : Order of elements front position on the right side
Figure 20 : Rear position on the right side
Figure 17 : Order of elements rear position on the right side
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EM-TL01-M - OWNER’S MANUAL - 2017
10. THROTTLE
The throttle must be well maintains:
 The throttle must be cleaned and lubricate;
 The wire mustn’t get caught by the handlebar;
 The wire mustn’t be taut at rest;
THROTTLE ADJUSTMENT
The throttle adjustment can be modified if:
① Engine is working without turn the throttle;
② The throttle work too late.
Handlebar screw
Bonnet screw
Potentiometer screw
Figure 21 : Throttle screws
V
DURING THE ADJUSTMENT OF THE THROTTLE THE MOTORCYCLE HAS TO BE ON A BIKE STAND AND THE
REAR WHEEL DOES NOT TOUCH THE GROUND.
These operations can be done directly on the handlebar.
❶ Remove the little bonnet screw and the bonnet:
Figure 23 : Bonnet screw removed
Figure 22 : tighten potentiometer screw unscrew not entirely
❷ Unscrew the potentiometer screw but not entirely:
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EM-TL01-M - OWNER’S MANUAL - 2017
❸ Put the security magnet => the wheel turn.
❹ With a little flat screwdriver, turn lightly the potentiometer to adjust the contact of the throttle.
-If the throttle works too early: turning clockwise: Increase angle without action.
- If the throttle works too late: Turning counterclockwise: Decrease angle without action.
Figure 24 : Potentiometer adjustment
❺ When the adjustment is correct screw the potentiometer.
❻ Assembly and screw the bonnet.
❼ Check all is correct testing the throttle when the motorcycle is on the bike stand.
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11. REAR AND FRONT BRAKE
FRONT BRAKE


V
Brake lever distance: Adjustment is according to the user.
Trigger guard brake lever: Adjustment is according the user.
The trigger guard has to present, for the security of the user and to avoid a premature wear of the motorcycle
(brakes overheating and after brakes blocking)
 Level of brake fluid: check the level of the brake fluid on the main cylinder. Brake fluid type : DOT 4.
 Filling of the brake fluid is accessible unscrewing the 2 screw on the top of the main cylinder.
V The brake fluid is very corrosive, protect all the components around the main cylinder and avoid falling drop water
on the motorcycle may damage it.
 A lack of brake fluid may be a wear indicator of pads.
Main cylinder with the brake fluid level
Adjustement of the distance brake lever /
handlebar.
Adjustment of the trigger guard
Figure 25 : Adjustment of the front brake lever.
BRAKE FLUID TYPE : DOT 4
REAR BRAKE



V
The brake lever can be adjustable in height;
Operating clearance can be modify by using the piston stroke of the main cylinder, is according of the user.
The trigger guard of rear brake is according the user.
The trigger guard has to present, for the security of the user and to avoid a premature wear of the motorcycle
(brakes overheating and after brakes blocking)
 The filling of brake fluid can be made unscrewing the cap of the plastic container.
V The brake fluid is very corrosive, protect all the components around the main cylinder and avoid falling drop water
on the motorcycle may damage it.
 A lack of brake fluid may be a wear indicator of pads.
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EM-TL01-M - OWNER’S MANUAL - 2017
Tank of rear brake fluid with the
indicator of level
Main cylindre of rear brake
Adjutment trigger guard
Rear brake lever
Figure 26 : Rear brake system
Figure 27 : Rear break lever
Figure 28: Adjustment of the main
cylinder piston
Clean and lubricate regularly the spring of the
rear brake lever, to ensure that it work
correctly;
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EM-TL01-M - OWNER’S MANUAL - 2017
CHANGEMENT OF REAR AND FRONT BRAKE FLUID
After change the fluid brake, air in the circuit brake must be remove with the bleeder screw:
V Do not fill brake fluid on the brake disc or on the caliper, because it may damaged their and could reduce a lot the
efficiency of the system.


Open the main cylinder bonnet, fill it with brake fluid type: DOT 4;
Link the bleeder screw to hose compatible with the bleeder screw.
Bleeder screw protected by plastic cap
Figure 30 : Bleeder screw of front brake
Figure 29 : Bleeder screw of rear brake
BRAKE FLUID TYPE : DOT 4
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CHANGEMENT OF BRAKE PAD
The brake pad must be check regularly to keep the efficiency of the brake system.
The brake pads must be changed if the lining is inferior at 1.5 mm.
1,5 mm MINI
Of lining
Follow the instruction to change the brake pads:
V Do not touch brake levers during the brake pad changing.
Screw
Clip
FRONT BRAKE
- Remove the caliper to the fork;
- Remove the clip and unscrew the screw
- Proceed in the reverse order to put back together.
REAR BRAKE
Figure 31 : Disassembly of the front caliper
- Remove the rear wheel;
- Remove the caliper;
- Remove the clip;
- Remove the brake pad;
Clip
Proceed in the reverse order to put back together.
Figure 32 : Disassembly of the rear caliper
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EM-TL01-M - OWNER’S MANUAL - 2017
12. LOWER PART OF REAR SUSPENSION

The lower part of rear suspension is
important elements to a good working of
the suspension ;

Maintain clean and lubricate to avoid a
premature wear.

Check the operating clearance regularly.
V Do not wash with high pressure washing
because it removes all lubrication.
Figure 33 : Bottom view of lower part of rear suspension
13. TRANSMISSION
We recommend after each washing of the motorcycle to lubricate the ball bearing (Engine, transmission axis…) with
Motul Chain, to avoid the corrosion and a premature wear of ball bearing.
Figure 34 : Engine Ball bearing right side
Figure 35 : Transmission ball bearings
Control and dry the belt after washing
Figure 36 : Secondary axis of ball bearing
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EM-TL01-M - OWNER’S MANUAL - 2017
14. TIRES
Tires dimensions :
DIMENSIONS
FRONT TIRES
FRONT TIRES
80/100 R21
2.75 – 21’’
120/100 R18
4.00 - 18‘’
Tires pressure according to the use:
Trial / Trek Use
Competition Trial Use
FRONT TIRES
FRONT TIRES
0.7 bar
0.5 bar
0.5 bar
0.4 bar
For your security:
□
□
□
□
When the tires is wear, the tires has to be changed;
The wear tires deteriorates the driving;
Over pressure or under pressure of tires involve a premature wear, and deteriorate the driving;
Check the pressure when the tires at room temperature.
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EM-TL01-M - OWNER’S MANUAL - 2017
15. MAIN WIRING
Tidying of the connectors on the map box:
 Connector before tidying;
 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;
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EM-TL01-M - OWNER’S MANUAL - 2017
 The ELS connectors are above the Map
box, perpendicular of motorcycle.
Position the heat shrink sleeve with all the
wires behind the bonnet attachment
16. CHANGING BULBS
EM HOMOLOGATED
Indicators bulbs
□
□
□
Unscrew and remove the orange glass;
Remove the bulb and put a new one;
Reassemble when the bulb was changed.
Headlitght bulb holder: Unscrew to remove
and screw to hold.
Screw to remove the orange glass
Position headlight holder
Figure 37 : Changing bulb of headlight
Position lights bulbs



Unscrew the headlight of the speedometer support on the top;
Take off the rubber strap and disconnect the connector;
Remove lightly the bulb holder;
V Do not tears the holder wires.

Reassemble when the bulb was changed.
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EM-TL01-M - OWNER’S MANUAL - 2017
Head light bulb




Unscrew the headlight of the speedometer support on the top;
Take off the rubber strap and disconnect 3 connectors;
Turn in the clockwise to remove the bulb holder;
Reassemble when the bulb was changed: turn in the counter clockwise to hold the bulb holder.
Plug in headlight connectors to the electric wiring:
Blue wire: HIGH
Green wire: LOW
Black wire: GROUND
Rear bulb
The rear bulbs are LED, and have a long lifetime.
If it is deficient check corrosion of the connector, or deposit on the connectors. In this case rub the connectors with
wire brush
17. FUSES
Check the fuses if there are an electric problem, they can be wear (broke)
 Battery fuse
Strong cap 300 A
 Controller fuse
Little blade fuse Car type: 2 A
Figure 38 : Fuse position
 Converter fuse (homologated motorcycle)
Body glass: 32 mm Ø : 6,3 mm ; 5 A
V Do not wash with high pressure system
Figure 39 : Converter
(homologated motorcycle)
EM-TL01-M - OWNER’S MANUAL - 2017
fuse
support
38
18. SPEEDOMETERS 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
o
o
Press “MODE” to appear “TRIP 1” or “TRIP 2”.
Press simultaneously on “MODE” and “RESET” buttons
When you reset one of the trips, you reset automatically the average, the overall time of trip
.
Button « RESET »
Button « MODE »
Figure 40 : Acewell Speedometer
V Do not wash with high pressure system
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EM-TL01-M - OWNER’S MANUAL - 2017
19. MOTUL PRODUCTS
It is recommended to lubricate or maintain the EM motorcycle with MOTUL products for the good working of
it.
They offer the best way to maintain the motorcycle in the origin condition, and to extend it lifetime, whatever the
situation.
20. HOMOLOGATED MOTORCYCLE
REMEMBER:
The motorcycle equipped type « Trial » is can be use in private property only. The motorcycle has to be equipped
of elements to be homologated (EC Type approval: e24*2002/24*0275*00).
V Only the motorcycle sold « homologated » can be homologated.
If you want homologated the vehicle, please contact us, for more details.
In the manual « Re-reassembly instruction for use on road » is written the assembly of all the elements
certified.
Please contact us to receive the manual.
EM 5.7 TYPE « HOMOLOGATED »
40
EM-TL01-M - OWNER’S MANUAL - 2017
21. MAINTENANCE TABLE
After each use it had better to wash the motorcycle, and to lubricate the required mechanical elements.
CHECK
ADJUST
CHANGE /
REPLACE
Rear suspension
All years
If necessary
When worn
Footrest
Each use
-
When worn
Chain
Each use
Couronne
Each use
Disque de frein
Each use
Durite de frein
Etrier de frein AV et
AR
Each use
If necessary
tension chain
Screwing check
after the first 5h
Screwing check
after the first 5h
If necessary
Each use
-
Jantes AV et AR
Each use
Jeu de direction
Liquide de frein
COMPOSANTS
When worn
When worn
LUBRICATE
After each washing
lubricate springs
After each trip or
washing
-
Every 2 ans
After washing, clean
with clean discs Motul
-
Every 60h
-
When worn
-
-
Each use
Each use
Spoke tension
every 5h
If necessary
Check the level
When worn
Every 2 ans
Pédale de frein
Each use
If necessary
When worn
Pignon de sortie
Every 10h
-
When worn
Every 20h
After each washing
lubricate the spring
After each washing
lubricate the Roll
bearings
Each use
-
When worn
-
Every 60h
-
When worn
-
Each use
Check the pressure
When worn
-
When worn or
broken
After each washing
lubricate the pivot
After each washing
-
Plaque protection
moteur
Plaquettes de frein
AR et AR
Pneu AV et AR
Poignée
d’embrayage et de
frein AV
Roulement de roue
Roulement moteur
Suspension AV
Each use
If necessary
Every 10h
Every years
If necessary
Système de biellette
Each use
-
Tendeur de chaîne
Each use
-
When worn
When worn
When worn
Change Slide
bearing when worn
or 60h
When worn
Transmission par
courroie
Every 10h
-
When worn
After each washing
After each washing
After each washing
lubricate the roll
bearingsn axes
primary et secondary
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EM-TL01-M - OWNER’S MANUAL - 2017
22. CONTROLLER – LED CODES
In an electric power train, the controller acts as a carburetor for an internal combustion engine (ICE).
It’s like the brain of the battery, it is necessary to:





Control the maximum power
Set the acceleration
Set the reverse
Manage the behavior of the vehicle
Recover energy;
Figure 41 : Controller position
LED Red
J2 plug
LED Green
Figure 42 : RED LED and green LED position
LED Red
LED Green
The following tables allow to know the
LED signification on the controller in case
of good or bad operating.
Figure 43 : LED Localization behind the J2 plug
Correspondance des fils sur le contrôleur :
A: Yellow wire
B: Blue wire
C: Green wire
B+: Plug to the wire come from battery fuse (300 A)
B-: Plug to the terminal (-) of the battery.
J2 Plug : Plug and screw.
J2 plug
42
EM-TL01-M - OWNER’S MANUAL - 2017
Green LED Codes
LED code
Green Off
Green On
Green and Red LED
Keep on
Explanation
No power or
operating
Normal operation
Solution(s)
not 1. Check if all wires are correct.
2. Check fuse and power supply.
That’s great! You got the solution
1. Software is upgrading.
2. Supply voltage too low or battery too high.
3. The controller is damaged. Please contact Kelly for
warrantee.
Red LED Codes
LED code
Explanation
1, 2
●
●●
Over voltage error
1, 3
● ●●●
Low voltage error
1, 4
● ●●●●
Over temperature
warning
2, 1
●●
●
Motor fails to start
●●
●●
Internal voltage fault
2, 3
●●
●●●
Over temperature
2, 4
●● ●●●●
3, 1
●●●
●
Frequent reset
3, 2
●●●
●●
Internal reset
3, 3
●●●
●●●
3, 4
●●● ●●●●
2, 2
Throttle error at
power up
Hall throttle short or
open circuit
The throttle works
on change (or try to
change) direction
Solution(s)
1. Battery voltage is higher than max operating of the controller.
Please check the battery voltage configuration.
2. Over voltage at regeneration. Controller will cut back or stop
regeneration.
3. Please note there could be 2% error with overvoltage setting.
1. The controller will attempt to clear the fault code automatically
after 5 second if battery voltage returns to normal.
2. Check the battery voltage.
3. Charge battery if necessary.
1. The controller temperature is over 90°C. The controller will cut
back current in the case. Stop or reduce output current to ensure
the motor temperature fall.
1. Motor hasn’t reached 25 electrical RPM after 2 second from
starting. Most likely the hall or phase wiring problem.
1. Check if the B+ and PWR voltage are correct, refer to B- or RTN.
Could be the battery voltage low.
2. Please check load on 5V supply and the wire are correct.
3. The controller is damaged. Please contact Kelly for warrantee.
1. The controller is over 100°C. Controller stops driving in the case.
2. Stop driving and wait for temperature fall. The controller will
restart if temperature drops below 80°C
1. The throttle signal is higher than configured dead zone at poweron.
2. The fault will disappear if restarts or releases throttle.
3. Configure throttle model as “HALL Active” throttle if you use that
throttle model.
1. The controller will stop driving when detects too many resets.
2. Mostly because of B- or return wiring. Use the heavier and cleaner
return wires.
May be caused by some transient fault condition like a temporary overcurrent, momentarily high or low battery voltage.
This can happen during normal operation
1. Check whether the throttle is short or open circuit
2. When the throttle is normal / repaired, a restart will clear error.
Controller won’t allow a motor direction change unless the throttle or
speed at zero. Fault clear when throttle is released.
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EM-TL01-M - OWNER’S MANUAL - 2017
●●●●
4, 2
●●●● ●●
Hall sensor signal
error
4, 3
●●●● ●●●
Motor overtemperature
4, 4
●
Over voltage at
startup or
regeneration
4, 1
●●●● ●●●●
Motor locked rotor
Motor drive is disabled if an over-voltage is detected at start-up or
during regeneration.
The voltage threshold detection level is set during configuration.
1. Incorrect hall wiring, wrong pin or loose wire.
2. Intermittent or damaged hall sensor.
3. Incorrect hall angle configuration (60 or 120 degree)
1. The motor temperature has exceeded the configured maximum.
The controller will shut down and wait for motor temperature
dropping.
2. Can change the temperature setting with configuration program.
When in locked rotor condition, the max output phase current of the
motor will be limited to 90% of previous current.
Once the problem disappears the fault will clear and the max output
phase current will return to normal.
The RED Led flashes once at power ON as a confidence check then keep off for normal operation.
“1, 2” means the red flashes once then flashes twice after 1 second.
The time between 2 flashes is 0.5 second. The pause time between multiple flash code groups is 2
seconds.
23. TIGHTENING TORQUE
It had better to respect the tightening torque because it can affect your safety:
 Significant screwing can damage screws, and breaking them;
 Light screwing can lead to unscrewing them.
ELEMENTS
THREADING
TIGHTENING TORQUE
Rear suspension/ Frame
Rear wheel axle
Front wheel axle
Lower part of rear suspension
Swingarm / axle
Clamping of the upper wrown fork on
the pivot
Transmission cover / Transmission
support
Plug 120 A / Frame
Crown
Rear and Front disc
Steering pivot Nut
Front caliper
Front Mudguard / Support mudguard
Rear main cylinder / Frame
Engine / Transmission support
Rear brake lever
Transmission support / Frame
Banjo bolt of Rear caliper
M10
M17
M14
M10
M14
40 Nm
60 Nm
30 Nm
40Nm
40 Nm
M8
17 Nm
M5
4 Nm
M5
M8
M6
M18
M8
M6
M6
M8
M8
M8
M10
3 Nm
23 Nm
12 Nm
20 Nm
24 Nm
10 Nm
10 Nm
18 Nm
24 Nm
20 Nm
22 Nm
ON THE
THREADING
Normal LOCTITE
Copper grease
Copper grease
Normal LOCTITE
Copper grease
Normal LOCTITE
Normal LOCTITE
Copper grease
Copper grease
Normal LOCTITE
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EM-TL01-M - OWNER’S MANUAL - 2017
Banjo bolt of Front caliper
Main cylinder banjo bolt of front and
rear break
Crown fork / Fork
Pulley engine / Engine axle
Converter / Frame
Engine protector/ Frame
Footrest
M8
20 Nm
-
M10
22 Nm
-
M8
M8
M5
M8
M6
17 Nm
24 Nm
3 Nm
24 Nm
20 Nm
Copper grease
Normal LOCTITE
-
24. MOTORCYCLE STORAGE
MOTORCYCLE STORAGE:
When the motorcycle is going to be stored for a long or undefined period the following advice must be
respected to not damage the motorcycle:
 Clean all elements of the motorcycle;
 Lubricate all the mechanical elements (chain, Lower part of rear suspension, roll bearings, axles, pivots,
spring …).
 Apply grease or silicone on the metallic parts without paint or surface treatments;
 Deflate tires and the wheel mustn’t touch the ground;
 Cover up the motorcycle;
 Stock in dry place, away of all bad weather and sunlight.
After the Motorcycle Storage:
 Inflate the tires at the good pressure (see above in the manual);
 Check the screwing of mechanical elements (Lower parts of rear suspension, crown, brake discs…).
BATTERY STORAGE:
If you want to store the battery pack, you have to take some measures:
 Before storage, the battery pack must be charged;
 Be sure 100% the battery pack is switched off;
 Recharge the battery pack every 4 week, even it is not used;
 Do not store the battery pack under 10°C or over 40°C;
 Do not store the battery pack in wet atmosphere;
 Do not store the battery pack exposed to the sun;
 Remove the battery pack if necessary.
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EM-TL01-M - OWNER’S MANUAL - 2017
25. ELECTRICAL WIRING SCHEMA OF HOMOLOGATED MOTORCYCLE
EM-TL01-J OWNER’S MANUAL
2014
46
26. SCHEMA HOMOLOGATED ELECTRIC WIRING
47
EM-TL01-M - OWNER’S MANUAL - 2017
27. MAIN ELECTRICAL WIRING
48
EM-TL01-M - OWNER’S MANUAL - 2017
28. BREAKDOWN DIAGNOSIS
COMPOSANTS
SIGN
CAUSE
TOO COLD < 10°C
BATTERY DOES NOT CHARGE
TENSION TOO LOW
THE BATTERY DOES NOT DISCHARGE (THE TENSION TOO LOW
MOTORCYCLE IS NOT OPERATING)
TEMPERATURE TOO HOT > 55°C
BATTERY PACK BATTERY KEEP SWITCH ON
CHECK
AMBIENT TEMPERATURE
CHECK BATTERY TENSION (DISCHARGE OR GAUGE) TOO LOW
IF < 39V
TENSION IN THE BATTERY OR GAUGE
CHECK OF THE TEMPERATURE
THE BATTERY IS SWITCHED ON BUT THE
COMMUTATOR IS SWITCHED OFF
INTERN PROBLEM
MAIN FUSE HS
FUSE ELECTRICAL WIRING
CONNECTOR DISCHARGE IS NOT PLUG IN
CHARGE POSSIBLE
IF CHARGE IMPOSSIBLE
MAIN FUSE
ELECTRICAL WIRING FUSE
MOTORCYCLE SWITCH ON, WITHOUT TURN
THROTTLE NEED ADJUSTMENT
THE THROTTLE, THE REAR WHEEL TURN
THROTTLE NEED ADJUSTMENT
THROTTLE
MOTORCYCLE SWITCH ON, THE
COMMUTATOR ON, THE MAGNET ON THE
CONTACT?
THE MOTORCYCLE IS NOT
WORKING
THROTTLE TRIGGER GUARD IS TOO
IMPORTANT
POWERTRAIN
ELECTRIQUE
PROBLEM IN THE ELS BOX
PROBLEM OF LINKING FROM THE
ELECTRICAL WIRING
ELS PROBLEM
CONTROLLER IS TURNED OFF
EM-TL01-J OWNER’S MANUAL
SUPPLYING
2014
ADJUST THE THROTTLE SEE IN THE OWNER'S MANUAL
LED GOES ON AND OFF, IN FRONT OF THE CONTROLLER
REMOVE THE BOX : PLUG IN DIRECTLY THE THROTTLE TO THE
ELECTRICAL WIRING
(BE CARFUL TO NOT USE THE
MOTORCYCLE IN THIS CASE)
ADJUST THE THROTTLE SEE IN THE OWNER'S MANUAL
CHECK THE PLUGING AND THEIR CONDITION
IF WIRE IS DAMAGED CONTACT ELECTRIC MOTION
UNPLUG IN ELS
CHANGE ELS
THROTTLE NEED ADJUSTMENT
OTHER PROBLEMS
PLACE THE BATTERY IN LOCATION MORE COLD
SWITCH ON / SWITCH OFF SEVERAL TIME, IF NECESSARY TAP LIGHTLY
FRONT OF THE PACK
PLUG IN THE BATTERY
IF CHARGE POSSIBLE
INTERN PROBLEM : CONTACT ELECTRIC
MOTION
IF CHARGE IMPOSSIBLE
" THE BATTERY DOES NOT CHARGE"
CHANGER THE MAIN FUSE
CHANGER ELECTRICAL WIRING FUSE
RELAY DISCHARGE IS PAST
BATTERY NOT PLUG IN
SOLUTION
PLACE THE BATTERY IN LOCATION MORE HOT
IF THE TENSION IS TOO LOW CONTACT US TO SEND THE PACK OR TO
HAVE THE PROCEDURE BY THE IMPORTER
IF THE MOTORCYCLE IS OPERATING, THE PROBLEM COMES TO THE
BOX: CHANGE THE BOX
ADJUST THE THROTTLE SEE IN THE OWNER'S MANUAL
COMUTATOR ON, LED RED or/and LED GREEN BEHIND THE
CONTROLLER GOES ON AND OFF
MAIN FUSE
ELECTRICAL WIRING FUSE
49
IF LED GREEN OR/AND RED SWITCH ON: SEE IN THE OWNER MANUAL
ABOVE TO INDENTIFY THE PROBLEME
CHANGE THE MAIN FUSE
CHANGE THE ELECTRICAL WIRING FUSE
CHARGER
CHARGER TENSION
CHARGEUR IS NOT TURNING ON (THE LED
THE CHARGER IS NOT CORRECTLY PLUG
SWITCH OFF)
IN
THE CHARGER IS NOT CORRECTLY PLUG
THE CHARGE IS SWITCH ON NORMALLY
IN TO THE BATTERY
CHARGER WIRES ARE DAMAGED
TRANSMISSION NOISY TRANSMISSION
ELS
ELS JAMMED
FORK SET TOO HARD
FORK
FORK SET TOO SOFT
TENSION SECTEUR (230V OU 110V)
ON THE CHARGER CHANGE TENSION ACCORDING TO THE COUNTRY
CHECK PLUGGING IN THE CHARGER TO THE PLUG
PLUG IN CORRECTLY THE CHARGE ON THE PLUG
CHECK THE PLUGGING IN CHARGER TO THE BATTERY
CHECK ENTIRELY WIRES
IF THE WIRE IS DAMAGED, TO REPLACE CONTACT ELECTRIC MOTION
CLEARANCE SPROKET / SHAFT
APPLY PRODUCT TO SET THESE 2 COMPOSANTS
JAMMING
SWITCH
APPLY WD40
REPLACE SWITCH
- EXCESSIVE FRONT FORK OIL
- FRONT FORK OIL VISCOSITY TOO HIGH.
- BENT FRONT FORK
- TIRE AIR PRESSURE SET TOO HIGH
- INCORRECT REAR SHOCK ABSORBER
ADJUSTMENT
- INSUFFISCIENT FRONT FORK OIL
- FRONT FORK OIL VISCOSITY TOO LOW.
- BENT FRONT FORK
- INCORRECT REAR SHOCK ABSORBER
ADJUSTMENT
- OIL LEVEL OF THE FORK
- POUR EXCESS OIL UNTIL REACHING THE CORRECT OIL LEVEL
- DRAIN FORK OIL AND FILL WITH CORRECT FORK OIL VISCOSITY.
- REPLACE THE FRONT FORK. GO TO A SPECIALIZED WORKSHOP
- CHECK TIRE AIR PRESSURE
- ADJUST REAR SHOCK ABSORBER
- OIL LEVEL OF THE FORK
- POUR EXCESS OIL UNTIL REACHING THE CORRECT OIL LEVEL
- DRAIN FORK OIL AND FILL WITH CORRECT FORK OIL VISCOSITY.
- REPLACE THE FRONT FORK. GO TO A SPECIALIZED WORKSHOP
- FILL WITH FORK OIL UNTIL REACHING THE CORRECT OIL LEVEL
- ADJUST REAR SHOCK ABSORBER
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EM-TL01-M - OWNER’S MANUAL - 2017
Take the time to adapt your riding to the motorcycle behavior. I will allow you to ride this motorcycle in the best
conditions to discover all its capacities!
If you have any question or any doubt, please contact us by phone or email
0033 467 411 090
emotion.sav@gmail.com
Electric Motion’s team wishes you to enjoy riding your electric motorcycle.
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