Table of Contents
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Electric Bicycle
Technical/Service Manual
Polaris and its vehicle body designs and names are registered trademarks of Polaris Industries Inc. used under license.
Polaris designs, engineers, manufactures and markets snowmobiles, all-terrain vehicles (ATVs), Victory motorcycles and
the Polaris RANGER for recreational and utility use. Information about the complete line of Polaris products, apparel
and vehicle accessories is available from authorized Polaris dealers or anytime from the Polaris homepage at www.
polarisindustries.com.
Servicemanual_101212.indd 40-1
10/12/2012 12:25:43 am
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Table of Contents
Related Manuals for Polaris EV206PH-B
Summary of Contents for Polaris EV206PH-B
- Page 1 Electric Bicycle Technical/Service Manual Polaris and its vehicle body designs and names are registered trademarks of Polaris Industries Inc. used under license. Polaris designs, engineers, manufactures and markets snowmobiles, all-terrain vehicles (ATVs), Victory motorcycles and the Polaris RANGER for recreational and utility use. Information about the complete line of Polaris products, apparel and vehicle accessories is available from authorized Polaris dealers or anytime from the Polaris homepage at www.
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Page 2: Table Of Contents
TABLE OF CONTENTS brake pad replaCement........................... brake dISC removal/InStallatIon ......................Chapter 1 ..........................Chapter 4 ..........................General InformatIon ......................ShIfter and deraIlleUr ..................... termS left and rIGht ..........................removal ............................... noteS, CaUtIonS and WarnInGS ......................InStallatIon ............................... troUbleShootInG / dIaGnoStIC GUIde ....................ShIfter Cable Inner WIre removal/InStallatIon ................ - Page 3 Smart Controller removal ......................Smart Controller InStallatIon ...................... TErmS LEFT ANd rIGhT pro-rIde lIthIUm battery ServICe ....................... the terms left and right in this manual refer to the rider’s point of view when seated on the polaris ® electric IC daShboard ServICe ..........................
- Page 4 TrOUBLEShOOTING / dIAGNOSTIC GUIdE Servicemanual_101212.indd 2-3 10/12/2012 12:25:44 am...
- Page 5 TOOLS Item Ft.-Lb. Special Instructions brake caliper mounting 40-60 apply loctite 242 the following special tools are needed when servicing the vector ev200ph: bolt Tool part Number brake disc bolt apply loctite 242 Star shaped wrench set park tWS-2 brake lever clamp bolt 3-3.9 26.5-34.7 head cup remover...
- Page 6 If ordered directly by you, component costs can be used as credit towards your next polarIS electric bicycle purchase, only if the product is still under warranty.
- Page 7 ChApTEr 2 FIGUrE 2-3 STEErING ANd SUSpENSION WArrANTy NOTE: Steering and front suspension fall under “non-electric” component warranty. applicable warranty is 6 months from date of purchase. any service issue resulting from misuse of bicycle is not covered under this warranty and user shall be responsible for all charges . hANdLEBAr rEpLACEmENT removal 1.
- Page 8 FIGUrE 2-5 FIGUrE 2-6 c. With the front wheel off the ground, turn the handlebar from full stop to full stop. the fork should turn smoothly. d. torque the handlebar stem clamp bolts (a, Figure 2-4) to the specification in table 5. e.
- Page 9 ChApTEr 3 FIGUrE 2-9 BrAkES WArrANTy NOTE: brakes fall under “non-electric” component warranty. applicable warranty is 6 months from date of purchase. any service issue resulting from misuse of bicycle is not covered under this warranty and user shall be responsible for all charges. BrAkE LEVEr rEmOVAL/INSTALLATION removal 1.
- Page 10 FIGUrE 3-2 FIGUrE 3-3 4. pull the cable housing, and slide the cable inner wire (C, Figure 3-1) through the slots in the brake lever, adjuster barrel (b, Figure 3-1) and locknut (a, Figure 3-1). Seat the cable housing ferrule into the adjuster barrel.
- Page 11 BrAkE CALIpEr rEmOVAL/INSTALLATION FIGUrE 3-5 Brake Caliper removal the following procedure shows the removal of a front caliper. this procedure also applies to a rear caliper. 1. If the caliper is being replaced, perform the following: a. Clip the cable ferrule from the brake cable inner wire. b.
- Page 12 ChApTEr 4 ShIFTEr CABLE INNEr WIrE rEmOVAL/INSTALLATION ShIFTEr ANd dErAILLEUr removal the cable inner wire can be replaced without removing the cable housing. WArrANTy NOTE: Shifter and derailleur fall under “non-electric” component warranty. applicable warranty 1. operate the shifter and move the chain to the smallest cog (high gear). is 6 months from date of purchase.
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Page 13: Derailleur Lubrication
FIGUrE 4-4 4. Check shifter operation by pulling the wire and clicking the shifter. the inner wire should move in and out, and the shifter should click. 5. Insert the inner wire through the ferrule in the upper end of the cable housing. feed the wire through the housing until the wire emerges from the housing end at the derailleur. -
Page 14: Setting Cable Tension
5. torque the derailleur anchor bolt (b, Figure 4-2) to the specification in table 5. Check that the inner wire 1. Secure the polarIS electric bicycle in a stand at an angle that matches the angle when the bike sits still sits within the pinch-mechanism groove. -
Page 15: Crank Arm
5. turn the tool handle five full turns, and remove the tool. 2. If the chain is installed on the polarIS electric bicycle, back pedal for 30 seconds. If the chain is not 6. flex the chain laterally as needed to separate the links. - Page 16 4. Inspect the spokes (spider arms) (Figure 5-8) on the right crank arm. replace the crank arm if any spoke 6. Carefully turn the crank-wrench body onto the crank arm. finger-tighten the body until it bottoms in the arm. Use an adjustable wrench to snug the body into the crank arm, and turn in the crank- wrench handle is cracked or shows signs of damage.
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Page 17: Chainring Wobble Check
BOTTOm-BrACkET CArTrIdGE removal the polaris electric bicycle uses a bottom-bracket cartridge. the bottom-bracket on the polaris electric ® ® 1. rotate the crank so the arm with the pedal being removed points rearward. -
Page 18: Installation
ChApTEr 6 Installation mOTOr SySTEm NOTE: the bottom-bracket cartridge has very fine threads. these can be easily damaged. Check the threads in the bottom- bracket shell before installation. dress the threads as necessary. WArrANTy NOTE: motor system falls under “electric” component warranty. applicable warranty is 12 1. - Page 19 4. Use a phillips head screwdriver to remove all screws from the 7. loosen the lug nuts on rear axle. control cover cap (4 total). Screws 8 Unscrew the security latch holding down axle on both sides. 5. remove the left and right control cover cap sides (pay attention to how cables are routed through control cover cap).
- Page 20 4. Secure and tighten security latch (Figure 3). 5. disconnect all quick disconnect plugs. 6. Unscrew 4 bolts holding control box onto bicycle frame. 5. run cable to control box area of bike. 6. Connect quick disconnect plugs into same ports you disconnected the old motor from.
- Page 21 IC dAShBOArd SErVICE ThrOTTLE SErVICE IC dAShBOArd SErVICE: If, after your customer service call, you have concluded that the IC dashboard is If your contact with customer service has concluded that the throttle is the source of an issue, follow the the problem, you can easily replace the display.
- Page 22 ILLUSTrATION INdEx SteerInG and SUSpenSIon fIGUre 2-1 ................................ fIGUre 2-2 ................................ fIGUre 2-3 ................................ fIGUre 2-4 ................................ fIGUre 2-5 ................................ fIGUre 2-7 ................................ fIGUre 2-6 ................................ fIGUre 2-8 ................................ fIGUre 2-9 ................................ fIGUre 2-10 ..............................brakeS fIGUre 3-1 ................................ fIGUre 3-2 ................................ fIGUre 3-3 ................................