Vectrix VX 2 scooter Service manual
The Vectrix VX-2 is a powerful and efficient electric scooter. It features a sleek design, advanced technology, and a wide range of features. The VX-2 is perfect for commuting, running errands, or simply enjoying a fun and eco-friendly ride.
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VECTRIX VX-2 SERVICE MANUAL
www.vectrix.com [email protected]
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VECTRIX VX-2 SERVICE MANUAL
CONTENTS
SECTION A:
1 Tools Needed
Tools
2 VX-2 Major Components Identification
SECTION B:
1
2
Front Fairing
Mechanical Parts
Front Console Cover/Wind Deflector
3
4
5
6
Speedometer Cover
Front Vertical Panel Cover-Lower
Front Vertical Panel Cover-Upper
Center Step-Through Cover
7
8
Front Fender
Seat
9 Under Board/Belly Pan
10 Foot Rest
11 Crossover/Tail Light Assembly
12 Rear Side Body Panels/Side Emblem
13 Rear Fender-Top
14 Side Cover/Swing Arm Cover
15 Front Wheel
16 Front Brake Master Cylinder/Line/Caliper
17 Rear Brake Master Cylinder/Line/Caliper
18 Rear Shock
19 Rear Swing Arm/Motor Assembly
20 Handlebar
SECTION C:
1
2
Speedometer
Throttle
Electrical Parts
3
4
5
6
Brake Switch
Handlebar-Left Switch Assembly
Handlebar-Right Switch Assembly
Ignition Switch
7
8
Horn
Position Light/Headlamp Assembly
9 Front Turn Indicator Assembly
10 Side Stand Switch
11 Rear Tail Light Assembly
12 License Plate Light Assembly
13 Rear Turn Indicator Light Assembly
14 Motor Controller
15 Motor
16 Battery
17 Battery Charger
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SECTION D:
1
Adjustments
Front Headlamp/Position Light Adjustment
SECTION E:
1
Troubleshooting
Indication on Speedometer Display & Controller LED
2
3
Malfunctions
Check of Charger Function
SECTION F:
Technical Information
1
2
3
Cable Assembly-Front Brake/Turn Indicators + BOM
Cable Assembly-Front Headlamp/Horn + BOM
Cable Assembly-Rear Brake/Indicators/Tail Light/Battery/Side Stand + BOM
4 Torque List for Bolts/Nuts
SECTION G:
1
Unpacking/Prep
Unpacking Instructions
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SECTION A-1: TOOLS NEEDED
For repairing and testing of the VX-2 scooter the following tools are needed:
Tools:
Description
Open wrench
Open wrench/Turned Fullcontact (#S02445)
Open wrench
Open wrench
Open wrench
Open wrench
Open wrench
Open wrench
Open wrench
Open wrench
Open wrench
Open wrench
Special tool/Motor Nut
(contact
)
Specification
5.5mm
8mm
10mm
12mm
13mm
14mm
16mm
17mm
18mm
19mm
32mm
45mm
42mm spanner socket with
22mm relief slot
Torque wrench
Torque wrench
Spanner socket
Spanner socket
Spanner socket
Spanner socket
Allen key
Allen key
Allen key
Allen key
Phillips screwdriver
Phillips screwdriver
Phillips screwdriver
Screwdriver, flat
Screwdriver, flat
Security TORX Screwdriver
0-20Nm
10-100Nm
12mm
13mm
14mm
17mm
2.5mm
4mm
5mm
6mm
#1
#2
#3
4.5mm
9mm
TX10
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SECTION A-2: VX-2 MAJOR COMPONENTS IDENTIFICATION
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SECTION B
The following SECTION B instructions are for the VX-2 MECHANICAL disassembly/assembly. Unless otherwise noted in each procedure, assemble all parts in the reverse order in which they were taken apart. If you have any questions regarding VX-2 Mechanical disassembly/assembly procedures, please contact [email protected].
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SECTION B-1: FRONT FAIRING
To protect the front fender, put plastic wrap or other soft material onto the fender
Unscrew the 6 Phillips screws 1 to 6 in order as seen in the picture with a Phillips screwdriver PH2
Remark:
While loosening screws 7 and 8 hold the front fairing otherwise it drops down and could break!
4
1
8
5
Remark:
While loosening screws 7 and 8 hold the front fairing otherwise it drops down and could break!
To unplug the headlight assembly
, hold the front fairing and loosen all the connectors of the headlight
To reassemble after unplugging the headlight assembly, please be sure the clamp nuts are in the correct position
7
6
2
3
Remark: For assembling the Front Fairing, please make sure the attachment points are in the right position and no edge is protruding. Insert the screws slightly and if all screws and the fairing are in the correct positions, then tighten them fully.
See also the last picture in the next Section for the correct position of the clamp screw.
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SECTION B-2: FRONT CONSOLE COVER/WIND DEFLECTOR
Locate four Phillips screws underneath the Front Console
Cover/Wind Deflector and remove
Slide in a flat screwdriver into the position as seen on the picture. Hold the front console cover by hand. Carefully turn the screwdriver counter-clockwise [ccw] (left side) and clockwise [cw] (right side) until the front cover snaps out.
From the rear of the assembly, unscrew the four Phillips screws (left and right position) with a Phillips screwdriver
PH2
Remark: For assembling the Front Console Cover/Wind Deflector, please make sure the attachment points are in the correct position and no edge is protruding. Insert the screws slightly and if all screws and the cover are in the correct positions, then tighten them fully.
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SECTION B-3: SPEEDOMETER COVER
Preparations:
Disassemble Front Console Cover/Wind Deflector see Section B-2
Unplug the connector from the base of the Speedometer
Unscrew the left and right Phillips PH2 screws
Remove the Speedometer and Cover
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SECTION B-4: FRONT VERTICAL PANEL COVER-LOWER
Unscrew the four PH2 Phillips screws (Top + Bottom and
Left + Right position)
Slide a Phillips screwdriver into the hole and carefully pull back the cover slowly to the left. Use your fingers to hold the cover and pull backward
Slowly pull back the cover and remove
Remark: To assemble the Front Vertical Panel Cover-Lower, please make sure the attachment points are in the correct position and no edge is protruding. Insert the screws slightly and if all screws and the fairing are in the correct positions, then tighten them fully.
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SECTION B-5: FRONT VERTICAL PANEL COVER-UPPER
Preparations:
Disassemble Front Fairing see Section B-1 see Section B-4 Disassemble Front Vertical Panel Cover-Lower
Carefully remove Key Switch bezel using a Flathead screwdriver
Key Switch Bezel (removed)
Side view of the inner backside cover
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Unscrew the six remaining PH2 Phillips screws to remove the upper Front Panel cover
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SECTION B-6: CENTER STEP-THROUGH COVER
Preparations:
Disassemble Seat see Section B-8
Unscrew the two PH2 Phillips screws (left and right position)
Slightly press out left and right side of the cover so that they can clear the frame
Carefully move the cover forward until the cover can easily be removed
Side view of the inner backside cover
Remark: For assembling the Center Step-Through Cover, please make sure the attachment points are in the correct position and no edge is protruding. Insert the screws slightly and if all screws and the fairing are in the correct positions, tighten them fully.
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SECTION B-7: FRONT FENDER
Unscrew the four PH2 Phillips screws (left and right side)
To unscrew the Phillips screws hold the inner nut with
8mm open wrench.
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SECTION B-8: SEAT
Use side Key Latch to raise the Seat
Unscrew the two 8mm hex head screws
Hold the seat during unscrewing the second screw
Remove the seat
Make sure the Seat Latch is in the Open position before checking that the seat lock is properly aligned and works smoothly
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SECTION B-9: UNDER BOARD/BELLY PAN
Remove the two PH2 Phillips screws (left and right position)
Remove the screw (Front position) with a 8mm wrench
Remove the six PH2 Phillips screws in order as seen in the picture
While loosening Screws 5 and 6, hold the Under Board otherwise it drops down and could break!
6
1
2
4
5
3
Remark:
When assembling the Under Board/Belly Pan, please make sure the attachment points are in the correct position and no edge is protruding. Insert the screws slightly and if all screws and the fairing are in the correct positions, then tighten them fully.
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SECTION B-10: FOOT REST
Preparations:
Disassemble Center Step-Through Cover see Section B-6 see Section B-9 Disassemble Under Board
Open the two screws 1 + 2 and the two screws for the side shields with PH2 screwdriver
Same procedure for the other side if necessary
2
1
Foot Rest parts + screws
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SECTION B-11: CROSSOVER/REAR TAIL LIGHT ASSEMBLY
Remove four PH2 screws (2 upper and 2 lower)
Carefully slide Crossover/Tail Light Assembly back and upward to avoid breaking the side tab connector in the left and right Body Panels
Unplug Tail Light connector
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SECTION B-12: REAR SIDE BODY PANELS/SIDE EMBLEM
Remove the two lower PH2 Phillips screws first, then the two top screws and remove panel
Repeat procedure for the other panel
Carefully pull out left and right side until the cover can easily lift up
Note: Each Side Emblem is secured with two PH2 Phillips screws
Remark: Note seat lock location on left side panel
Put in the screws slightly and if all screws and the cover are in the correct positions tighten them.
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SECTION B-13: REAR FENDER-TOP
Preparations:
Disassemble Crossover/Rear Tail Light Assembly see Section B-10 see Section B-11 Disassemble Side Body Panels + Side Emblems
On the right side of the bike, unplug connectors to the Left and Right Turn Indicators and License Plate Light assembly
Unscrew the 3 fasteners with a 8mm open wrench
To remove the Rear Fender Splash Guard, unscrew the two PH2 side screws
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SECTION B-14: SIDE COVER/SWING ARM COVER
Unscrew the four PH2 screws using a Phillips screwdriver
Unscrew the three PH2 screws using a Phillips screwdriver 2 (1 screw is covered by the main stand)
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SECTION B-15: FRONT WHEEL
Preparations:
Disassemble Front Fender see Section B-7
Remove both plastic covers from the fasteners
Open the two Hex fasteners (#1 + #2) with open wrench
12mm and remove the brake
Put the scooter on a motorcycle lift and elevate the scooter until the front wheel moves freely
Unscrew the nut on the left side by using open wrench
17mm and hold the fastener with open wrench 14mm on the right side (Driver Orientation)
Remove screw (axle) and the other parts and the wheel
1
2
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SECTION B-16: FRONT BRAKE MASTER CYLINDER/LINE/CALIPER
Preparations:
Disassemble Front Fairing see Section B-1
Disassemble Front Console Cover
Disassemble Speedometer Cover
Disassemble Front Fender
Remove hex fastener of the hose clamp with 8mm open wrench
Disassemble the front brake
Now it is possible to exchange the brake pads see Section B-2 see Section B-3 see Section B-7
Cut all cable ties and unplug the wiring harness of the front brake lever switch
Unscrew both hex fasteners with an Allen key 5mm
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Parts of complete front brake
Remark: For assembling the Front Brake Master Cylinder/Line/Caliper, please make sure the attachment points are in the correct position and no edge is protruding. Insert the screws slightly and if all screws and the fairing are in the correct positions, then tighten them fully.
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SECTION B-17: REAR BRAKE MASTER CYLINDER/LINE/CALIPER
Preparations:
Disassemble Left Foot Rest see Section B-14 see Section B-18 Disassemble Rear Suspension
Note: To replace the Rear Brake Rotor
Unscrew the two inner hex bolts by using an Allen key
6mm see Motor Replacement Procedure C-16
Disassemble the rear brake
Now it is possible to exchange the brake pads
Remark:
It is not necessary to disassemble the side cover of the rear fork as seen in the picture
Remove the two connectors from the brake switch
Remove all cable ties for cable and brake hose
Note: Make sure to route the replacement brake hose along the same path as the original brake hose
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Remove the two inner hex cap screws from the brake lever assembly by using an Allen key 5mm
Move the brake hose including the complete brake lever assembly through the frame
Attention:
Do not open the brake system inside the scooter. The brake fluid could damage the paint or other parts.
Move the brake hose including the complete brake lever assembly through the frame and rear suspension
Complete removed rear brake assembly
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SECTION B-18: REAR SHOCK
Preparations:
Disassemble Left Side Body Panel see Section B-12
Unscrew the nut #1 by using a open wrench 14mm
Unscrew the bolt #2 by using a open wrench 13mm
Unscrew the bolt #3 by using a open wrench 12mm and remove rear shock
Remark:
For disassembling of the rear shock it is not necessary to remove the motor and the side cover
2
3
1
All parts of removed rear shock
Tighten the bolts and the nut according to the required torque, see Section F-4
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SECTION B-19: REAR SWING ARM/MOTOR ASSEMBLY
Preparations:
Disassemble Side Cover/Swing Arm Cover see Section B-14 see Section C-15 Disassemble Motor
Unscrew 3 inner hex cap bolts and nuts by using an
Allen key 4mm and an open wrench 10mm
Remove the rear Mud Guard
Unscrew the nut #1 by using a open wrench 10mm
Unscrew the bolt #2 by using a open wrench 10mm and remove the bolt
Remark:
It is not necessary to remove any covers or battery
2
1
Unscrew the two nuts and hexagon bolts by using 18mm and 19mm open wrench and remove the rear suspension
Remark:
It is not necessary to remove the batteries
Tighten the bolts and the nut according to the required torque, see Section F-4
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SECTION B-20: HANDLEBAR
Preparations:
Disassemble Front Console Cover see Section B-2
Disassemble Front Vertical Panel-Lower see Section B-4
Disassemble Front Vertical Panel-Upper
Open the connector from the Speedometer
Remove the two cross screws by using a Phillips screwdriver #2 and remove the complete Speedometer cover see Section B-5
Remove all parts of the handlebar
- Left- and right switch assembly
- Left- and right brake handle assembly
- Throttle
- Hand grips + Handlebar weights
Unscrew the nut #2 by using a open wrench 13mm
Unscrew the bolt #1 by using a open wrench 13mm and remove the bolt
1
Tighten the bolts and the nut according to the required torque, see Section F-4
2
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SECTION C
The following SECTION C instructions are for the VX-2 ELECTRICAL disassembly/assembly. Unless otherwise noted in each procedure, assemble all parts in the reverse order in which they were taken apart. If you have any questions regarding VX-2 Electrical disassembly/assembly procedures, please contact [email protected].
ICM LOCATION
The Interface Control Module (ICM) is located in one of two locations on the VX-2:
If the VX-2 VIN begins with LYSE or LYSV40002B1000001 through LYSV40002B1000034, it is located in the Front Panel-Lower area in the Step-through.
If the VX-2 VIN is LYSV40002B1000035 or higher, it is located in the Front Console area.
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SECTION C-1: SPEEDOMETER
Preparations:
Disassemble Front Console Cover see Section B-2 see Section B-3 Disassemble Speedometer Cover
Unscrew both nuts with 8mm open wrench
Remove the plastic bracket
Remark: On the underside of the plastic bracket there are two plastic attachment points which fit into two holes of the plastic cover. These attachment points fixed the Speedometer in the right position.
Carefully remove the Speedometer from the plastic cover
Test functions of speedometer
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SECTION C-2: THROTTLE
Preparations:
Disassemble Front Vertical Panel-Lower see Section B-4
Disassemble Front Vertical Panel-Upper see Section B-5
Disassemble Front Console Cover
Lower Regen Throttle Box Replacement
S-XC-S00077 see Section B-2
Tools Required:
PH #2
8mm Turned Full-contact Hexagonal Socket (S02445)
Removal Procedure
1. Turn ignition key to the off position.
2. Remove three screws (#3, #3, #4) from the lower throttle box assembly.
3. Lift the kill switch housing (1) up and away from lower box.
4. Using 8mm Hexagonal Socket S02445 remove two lower box U-Bolt nuts (5).
Note the orientation of the throttle return spacers and spring for reassembly.
5. Remove the U-Bolt (6). Pull down on the lower box (2) and remove.
6. Slide the throttle assembly off of the handlebar.
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Installation Procedure
1. Install the U-Bolt (6) into the box and start one of the nuts on the first thread of the rear stud of the U-
Bolt.
2. Slide the assembly onto the handlebar; ensure that the kill switch harness is installed into the slot of the lower box.
3. With the lower box pivoted away from the handlebar slide the throttle assembly onto the handlebar.
4. Position the return spring (7) onto the spring post (8) of the lower box and twist the throttle until the throttle stop is resting on the lower box throttle stop (9).
5. Ensure that the tab (10) on the bottom of the lower box is into the hole in the handlebar.
6. Using tool 01545, install the other U-Bolt nut and tighten both nuts.
7. Twist the throttle to ensure free movement and that it returns to a neutral position.
8. Using 8mm Hexagonal Socket S02445, install the kill switch cover onto the box and install the 3 screws, tighten. Alternate tightening of the 2 nuts until reaching a torque value of 2 Nm.
9. Check the Regen Throttle adjustment. Refer to Throttle Position Checking Procedure.
Note: If needed, to remove the old throttle position magnet sensor, install the new sensor magnet and screw it in until lightly seated, then back out 1 full turn. Continue to unscrew the throttle position magnet sensor until the throttle is properly aligned.
Regen Throttle Adjustment Procedure
Note:
Key must be in “ON” position and Kill Switch in the “OFF” position
1. Remove the right handlebar end cap. Refer to Handlebar End Cap and Hand Grip Replacement.
2. Slightly loosen the set screw (1).
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3. To determine the current position of the Throttle, squeeze the left side brake lever and using a large rubber band or similar device secure the lever in the squeezed position, and observe the needle position.
4. To determine the correct position of the Throttle, squeeze the right side brake lever and observe the reading.
Note: The neutral position of the throttle is 615-639. The ideal setting for this adjustment is 625.
5. Release the right lever and adjust the screw (2) until the readings are the same.
6. Remove the large rubber band or similar to release the left side brake lever.
7. Slightly tighten the set screw; this will secure the screw from moving.
8. Install the right handlebar end cap.
Magnet Holder
LOOKING INTO THE
THROTTLE WITH THE
HANDLEBAR ENDCAP
REMOVED
Set Screw
Regen Throttle Sensor Replacement
S-XC-S00079
Removal Procedure
1. Remove the upper handlebar cover. Refer to Front Console Cover Replacement B-2.
2. Remove the right handlebar end cap and hand grip. Refer to Handlebar End Cap and Hand Grip
Replacement.
3. Remove the kill switch cover screws.
4. Twist the throttle to gain access to the throttle clamp screw (1) and loosen.
5. Remove the throttle sleeve (2) from the handlebar.
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6. Loosen the Throttle set screw (1) and remove the sensor magnet (2).
Magnet Holder
LOOKING INTO THE
THROTTLE WITH THE
HANDLEBAR ENDCAP
REMOVED
Set Screw
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7. Remove the screws (1) and slide the insert and sensor out of the handlebar.
8. Remove the sensor (1) from the insert.
9. Mark and remove the sensor wires from the handlebar connector and remove the sensor.
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Installation Procedure
1. Install the sensor wires through the handlebar and out the harness hole.
2. Install the sensor wires into the connector in the same location as removed.
3. Install the sensor (1) onto the insert.
4. Install the insert and tighten the screws (1).
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5. Install the throttle sleeve (2) onto the handlebar and into the plastic sleeve.
Notice: Refer to Fastener Notice in General Information.
6. Twist the throttle sleeve into the full Regen position (forward) and tighten the throttle clamp screw (1).
Tighten
Throttle clamp screw 2.5 Nm (22 lb in)
7. Install the kill switch cover, and screws and tighten.
8. Verify smooth operation of the throttle by rotating back and forth and assuring spring return to the neutral position.
9. Install the upper handlebar cover. Refer to Front Console Cover Replacement.
10. Install the sensor magnet and screw in until lightly seated then back out 1 full turn.
11. Check the adjustment of the Regen Throttle. Refer to Throttle Position Checking Procedure.
12. Install the right handlebar end cap and hand grip. Refer to Handlebar End Cap and Hand Grip
Replacement.
Regen Throttle Position Checking Procedure
S-RW-100000
Without PC
Note: This procedure is to be used when a PC is not available. This adjustment MUST be verified using the PC method.
1. Place the ignition key in the ON position and the kill switch in the ON (non-run) position.
2. Squeeze the left side brake lever and observe the speedometer needle (1). This reading is the actual setting of the Regen Throttle.
3. Continue to squeeze the left side and then squeeze the right side brake lever and observe the
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speedometer needle. This is the required setting and what the actual reading in Step 3 must be set to.
If the settings are not the same refer to Throttle Adjustment Procedure.
(1)
With PC
1. Connect the Diagnostic Hardware. Refer to Diagnostic Hardware Connections.
2. Open the Vectrix diagnostic program, by clicking on the ScooterDiag icon. This will open up the
Scooter Diagnostics Summary page.
3. Within the General Information box, click on the “Show Instrument” button. This will open up an instrument cluster page.
4. In the lower center of the page is the throttle setting. This setting color should be in the Green, if the color is Red, the throttle is out of adjustment and must be adjusted. Refer to Throttle Adjustment
Procedure.
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SECTION C-3: BRAKE SWITCH
(Both Left and Right)
Preparations:
Remove Front Console Cover (for VIN all LYSE and LYSV40002B1000001 to
LYSV40002B1000034) see Section B-2
Remove Vertical Panel Cover-Lower (for ICM access for VIN all LYSE and LYSV40002B1000001 to LYSV40002B1000034)
Remove all cable ties (1)
Remove connector from the Interface Control Module
(ICM) see Section B-4
1
Disconnect both wires at the brake switch connector and twist out (by hand) the brake switch at the brass coupling
Test functions of Brake Switch assembly
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SECTION C-4: HANDLEBAR-LEFT SWITCH ASSEMBLY
Preparations:
Remove Front Console Cover (for VIN all LYSE and LYSV40002B1000001 to
LYSV40002B1000034) see Section B-2
Remove Vertical Panel Cover-Lower (for ICM access for VIN all LYSE and LYSV40002B1000001 to LYSV40002B1000034) see Section B-4
Remove all cable strips
Open connector CN1 from the Interface Control Module
(ICM)
Additional information see Section 1 of F-1
Unscrew the PH2 Phillips screw
Unscrew the PH2 Phillips screw
Remove the Left Switch assembly
Test functions of Left Switch assembly
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SECTION C-5: HANDLEBAR-RIGHT SWITCH ASSEMBLY
Preparations:
Remove Front Console Cover (for VIN all LYSE and LYSV40002B1000001 to
LYSV40002B1000034) see Section B-2
Remove Vertical Panel Cover-Lower (for ICM access for VIN all LYSE and LYSV40002B1000001 to LYSV40002B1000034) see Section B-4
Remove all cable strips
Open connector CN3 from the Interface Control Module
(ICM)
Additional information see Section 1 of F-1
Unscrew the PH2 Phillips screw
Unscrew the PH2 Phillips screw
Remove the Right Switch assembly
Test functions of Right Switch assembly
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SECTION C-6: IGNITION SWITCH
Preparations:
Disassemble Front Fairing see Section B-1
Disassemble Front Console Cover see Section B-2
Disassemble Vertical Panel Cover-Lower
Disassemble Vertical Panel Cover-Upper
Remove all cable ties
Open connector see Section B-4 see Section B-5
Unscrew the two fasten bolts of Key switch by 10mm socket wrench
Test function of the Key switch
Remark: Since the ignition key and the lock for the seat are the same, it is recommended that they be changed as a matched set. Otherwise, two different keys are necessary.
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SECTION C-7: HORN
Preparations:
Disassemble Front Fairing see Section B-1
Disassemble Front Console Cover see Section B-2
Disassemble Vertical Panel Cover-Lower
Disassemble Vertical Panel Cover-Upper
Open the connector of the horn see Section B-4 see Section B-5
Unscrew the bolt by 10mm open end wrench
Test function of Horn
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SECTION C-8: POSITION LIGHT/HEADLAMP ASSEMBLY
Preparations:
Disassemble Front Fairing see Section B-1
Headlamp Assembly Replacement
Headlamp Assembly Part #S-XC-S00092
Removal Procedure
1. Remove the right front fairing. Refer to Front Fairing Replacement in Body Front End.
2. Remove the headlamp bolts (1).
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3. Pull the headlamp off the front sub-frame enough to remove the lamp harness connectors.
4. Remove the lower marker lamp bulb connector.
5. Disconnect Headlamp Assembly connectors and replace with new Headlamp Assembly.
6. Connect the headlamp and lower marker lamp connectors.
7. Install the headlamp assembly onto the left front fairing and install bolts (1). Tighten Headlamp bolts to 2 Nm (18 lb in)
Note: Refer to Fastener Notice in General Information.
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9. If the headlamp assembly was replaced aim the headlamp. Refer to Headlamp Adjustment
Procedure.
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SECTION C-9: FRONT TURN INDICATOR ASSEMBLY
(Both Left and Right)
Preparations:
Disassemble Front Fairing see Section B-1
Remove all cable strips
Remove connector (2-pins) of the Turn Indicator Light
Remark: Procedure is the same for both Turn Indicator
Lights (Right and Left)
Unscrew the Nut from the inside with a wrench
Remove entire Front Turn Signal Assembly and pull cord through the hole.
Replace entire Front Turn Signal Assembly
Remark: Since the assembly is LED, you must replace the whole assembly.
Test function of Front Turn Indicator Light Assembly
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SECTION C-10: SIDE STAND SWITCH
Preparations:
Disassemble Center Step-Through Cover see Section B-6
Remove the connector inside of the electronic box under the seat
Unscrew the bolt by 8mm open end wrench
Test function of Side Stand Switch
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SECTION C-11: REAR TAIL LIGHT ASSEMBLY
Preparations:
Disassemble Crossover Tail Light Assembly see Section B-11
Remove all cable strips
Open 3-pin connector
Unscrew the two side screws and one middle screw with
Phillips screwdriver
Replace entire Tail Light Assembly
Note: The Rear Tail Light is LED, you must replace the whole assembly.
Test function of Brake and Position lights
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SECTION C-12: LICENSE PLATE LIGHT ASSEMBLY
Unscrew the two PH2 Phillips screws
Remove plastic cover
Pull out the defect bulb
Remark:
Don’t touch the glass body of the new bulb with your fingers, use a tissue
Test function of License Plate Light
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SECTION C-13: REAR TURN INDICATOR LIGHT ASSEMBLY
Remove all cable ties
Open 2-pin connector
Cut the cable of the Rear Indicator Light assembly
Remark: Connector has to be cut because the connector doesn’t fit through the hole of the plastic
Remove the nut with an open wrench 14mm
Pull out the Rear Turn Indicator assembly
Replace entire Rear Turn Indicator Assembly
Note: The Rear Turn Indicator Assembly is LED so you must replace the entire assembly.
Remark: Slightly push in the pins into the new connector. Be sure of the right position.
Refer to the old connector
Test functions of Rear Turn Indicators
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SECTION C-14: MOTOR CONTROLLER
Open the seat and remove Cover of electronic box
Turn Key Switch to
“ON” Position
Unplug blue Battery Main Connector
Turn Key Switch to
“OFF” Position
Disconnect Positive Terminals first and remove Main Fuse
(1)
Then disconnect remaining (Negative) cables and wiring harness
1
Unscrew the four Phillips bolts at the base of the Motor
Controller to remove the Motor Controller
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Install new Motor Controller and re-secure with four
Phillips bolts
Reconnect Negative Cables and Wiring Harness first
Then replace Main Fuse and Positive Cables next
Reconnect the blue Battery Connection Cable
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SECTION C-15: MOTOR
Preparations:
Disassemble Side Cover see Section B-15
Disassemble Rear Brake see Section B-16
Note: This is the same procedure to replace the Rear Brake Rotor
Open the seat and remove Cover of electronic box
Turn Key Switch to
“ON” Position
Unplug blue Battery Main Connector
Turn Key Switch to
“OFF” Position
For safety reasons, disconnect Positive Terminals first and remove Main Fuse (1)
Disconnect remaining (Negative) Cables and Wiring
Harness
1
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Unscrew the nut by using a 8mm open wrench and remove the cable clamp
Pull out the motor cables from the electronic box
Unscrew the motor nut with the Vectrix EM-90400 Special spanner socket
Remove the motor/rear wheel assembly in the direction of the arrow on the picture.
All parts of removed motor
Test function of Motor
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SECTION C-16: BATTERY
Preparations:
Disassemble Front Vertical Panel Cover-Lower
Disassemble Center Step-Through Cover see Section B-4 see Section B-6
Note: Photos in this section show the electronic box removed which makes the procedure easier to complete but is not necessary if only the Step-Through panel is removed.
VX-2 BATTERY LAYOUT
Disconnect Blue Battery Power Cable
Disconnect Blue Battery Power Cable
Unscrew the hexagon bolts from Battery #1 and #3
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Note: After disconnecting Battery #3, use electrical tape to insulate the loose terminal end from Battery #4
Lift up the Middle Battery (#2) as shown and remove it.
Each battery typically weighs XXXX pounds/XXXX kg.
Remark:
Batteries are fixed to the battery case with strong Velcro.
Move the batteries sideways to loosen them from the
Velcro before removal.
Lift up Front Battery (#1) as shown and remove it
Lift up Middle Rear Battery (#3) as shown and remove it
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Slide forward then lift up Rear Battery (#4) and remove it
Empty battery case for 60AH
After replacing the Batteries:
- Measure the voltage of each battery. It should be higher than 12.0 VDC.
- Charge the battery before use!
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SECTION C-17: BATTERY CHARGER
Put Key into key hole on the side of the VX-2 to open
Under Seat Storage Area.
Turn Key to open Under Seat Storage Area
Remove Battery Charger from Under Seat Storage Area
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Plug blue Battery Charger male connector cord into onboard blue Battery Charger female connection.
Plug Battery Charger AC connector into a AC main.
Turn on Battery Charger Unit power switch.
Recharge until Battery Charger Output LED reaches 100%
(Green).
Note: Recharge process can be discontinued and restarted at any time during the charge cycle
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SECTION D-1: FRONT HEADLAMP/POSITION LIGHT ADJUSTMENT
Headlamp Aiming
S-ST-100000
Properly aim the headlamp for maximum road illumination and safety. With halogen headlamps, proper aiming is very important. The increased range and power of these lamps make even the slightest variations from the recommended aiming hazardous to approaching motorists.
Observe the following conditions when you inspect or adjust the headlamp aim:
• The scooter is on a level surface.
• The tires are uniformly inflated to the specified pressure.
• One person is sitting on the driver's seat.
• The scooter is in the vertical position.
• Clean the headlamp before aiming.
• Follow your state's requirements for headlamp aiming.
Headlamp Aiming Location
• The aiming area should be darkened and large enough to allow for the scooter and an additional 10 m
(33 ft), measured from the face of the headlamp to the front of the screen.
• The floor on which the vehicle rests must be parallel with the bottom of the screen. If the floor is not level, compensate accordingly.
Headlamp Aiming Procedure
1. Position the scooter square with the screen, with the headlamp directly over the 10 m (33 ft) reference line (5).
2. Ensure that the vehicle is on a level surface.
3. Draw a horizontal reference line (2) that is in the center of the headlamp.
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4. Draw a vertical reference line (1) that is in line with the scooter axis.
5. With the headlamp low beam on the height spot (4) should 9/10th of the headlamp center line (3).
Adjusting the headlamp
1. To adjust the light beam up and down turn the right lower side adjustment screw. Clockwise to raise the beam and counterclockwise to lower the beam.
2. To adjust the light beam side-to-side turn the upper left adjustment screw. Clockwise to move the beam to the right and counterclockwise to move the beam to the left.
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SECTION E-1: INDICATION ON SPEEDOMETER DISPLAY & CONTROLLER LED
Indication on LCD Reason Solution
Accelerator turn at power up
Controller
LED Flash
Count
1 Accelerator is not in zero position
Release accelerator or turn power
“OFF” and then to “ON” or proceed to the Accelerator troubleshooting diagram
Error
Accelerator Volt
2 Accelerator voltage too high
Release accelerator or turn power
“OFF” and then to “ON” or proceed to the Accelerator troubleshooting diagram
Stop scooter
Battery empty!
Error
Overcurrent
Error
Hall sensor
Scooter
Disabled
3
4
5
6
Battery voltage is under 42V permanently
Controller defect
Hall sensor
Malfunction of the motor
This messages comes after Stop scooter
Battery voltage is over 63V
Charge the Battery
Exchange controller and check motor for short winding against housing
Proceed to Hall Sensor check
Section 4 of Section E
Solve malfunction before this message
Error
Voltage too high
Error
High temperature
Stop scooter
High temperature
7
9
10
Temperature of the controller is >85 o
C
Temperature of the controller is >110 o
C
Use the scooter carefully until message is over, if not, check if the real voltage of the battery is lower than 63V and setting of controller.
Or exchange Controller.
Wait until temperature goes down under 85 o
C.
Or exchange Controller
Wait until temperature goes down under 110 o
C.
Or exchange Controller
Charge the Battery Low Battery
Recharge!
Error
Side Stand out
System
Error 01
11
12
Battery voltage is under 42V
> 15 seconds
Side stand switch is active
Memory of speedometer defect
The LED on the controller flashes if a malfunction is active.
Check correct function of side stand switch.
Exchange Side Stand Switch or controller
Exchange Speedometer if message is still there.
Example: LED flash 6 times with 1 Hz, LED off for 2 sec. and starts again.
This means: Disable function active
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SECTION E-2: MALFUNCTIONS
- No Top Speed
- Check setting of the controller
- Check correct function of the throttle, adjust or exchange if needed
- No function and no indication on Speedometer
- Check Fuse 1 (15A) of the converter
- Check voltage on Controller power in line (red and black thick wire) should be higher than 36 V.
- Converter broken
- Full function but no indication on Speedometer
- Check connection of the speedometer
- Speedometer broken
- No indication of the energy bar on Speedometer
- Check Voltage of the battery
- Check Voltage on Pin 1 of the speedometer connector. Should be the battery
Voltage
- Speedometer or controller broken or wire between controller and speedometer
- No indication of the consumption bar on Speedometer
- Check Voltage of the battery
- Check Voltage on pin 1 of the Speedometer connector. Should be the battery
Voltage
- Speedometer or Controller broken or wire between Controller and Speedometer
- No change of battery voltage and mph/kph on Speedometer
- Check correct function of MODE switch
- Mode switch or Speedometer broken
- No indication of speed on Speedometer but motor running is okay
- Check if the Voltage on Pin 5 of the speedometer connector. Should change if
Motor is turned by hand.
Speedometer or Controller broken or wire between Controller and Speedometer
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SECTION E-3: CHECK OF CHARGER FUNCTION
1. Normal function
If the Charger is connected and the indication led on the charger is at 60%, turn on the scooter and the battery voltage indication of the speedometer should show 59.5 V + 1.0 V.
During the charging process at 60%, the current should be 10.0 A + 0.8 A, measured with a clamp ampere meter on the brown wire close to the charger DC-plug.
If not, check the voltage with a digital voltmeter on the Controller power in line (red and black thick wire). The value should be 59.5 V + 1.0 V. If yes, exchange speedometer, if not, exchange Charger.
2.
Charger didn’t start
Using a Digital Multi meter:
- Open the cover seat
- Measure on the charger connector of the scooter if the voltage is like the battery voltage indication of the speedometer. If the voltage is zero, check the fuse #2 (30A) of the converter or the connection cable. If the voltage is lower than 33 V check the voltage of each battery and exchange the battery which is lower than 10.0V.
- Exchange Charger
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SECTION F-1: CABLE ASSEMBLY-FRONT BRAKE/INDICATORS + BOM
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SECTION F-2: CABLE ASSEMBLY-FRONT HEADLAMP/HORN + BOM
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SECTION F-3: CABLE ASSEMBLY-REAR BRAKE/INDICATORS/TAIL
LIGHT/BATTERY/SIDE STAND + BOM
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SECTION F-4: TORQUE LIST FOR BOLTS/NUTS
Description
Front axle self locking, nut
Front brake housing on front shock , bolt
Rear brake housing on rear fork, bolt
Motor axle, nut
Front shock, bolt
Brake disc on front rim, bolt
Brake disc on motor, bolt
Ring on motor, bolt
Handle bar, nut
Rear fork, left and right nut
Front fork, top nut, 32mm
Rear shock, top bolt
Rear shock, bottom nut
Battery, bolt
All plastic parts
Force
65 NM
30 NM
25 NM
80 NM
70 NM
25 NM
15 NM
15 NM
50 NM
80 NM
60 NM
45 NM
40 NM
25 NM
16 kgf.cm
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SECTION G-1: UNPACKING INSTRUCTIONS
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Key features
Electric powered
Sleek design
Advanced technology
Wide range of features
Efficient and powerful
Eco-friendly
Easy to use
Durable
Frequently asked questions
Unscrew the 6 Phillips screws 1 to 6 in order as seen in the picture with a Phillips screwdriver PH2. While loosening screws 7 and 8 hold the front fairing otherwise it drops down and could break!
To adjust the light beam up and down turn the right lower side adjustment screw. Clockwise to raise the beam and counterclockwise to lower the beam. To adjust the light beam side-to-side turn the upper left adjustment screw. Clockwise to move the beam to the right and counterclockwise to move the beam to the left.
The speedometer display will show various indications, such as the battery voltage, speed, and consumption. If the LED on the controller flashes, it indicates a malfunction.
