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All models: Jammed, loud or not responding motor, sprocket movement
WARNING!
If You don’t have suffcient mechanical knowledge, experience and proper tools, we strongly recommend, that You have these operations done by Your selling dealer or at Your local motorcycle service center! Making mistake during the disassembly or assembly of the electric system will void the warranty and may cause a hazardous situation, resulting in fire, severe injury or death and damage to property.
For safety reasons it is strongly recommended to leave the battery discharged before handling any component of the motorcycle's electrical system!
Do not let the battery to stay fully discharged for longer than neccessary, as it may have a negative impact on its capacity. Charge the battery after each ride.
Table of contents:
Faulty motor
Movement/play in motor sprocket
1. Faulty motor
Follow these steps to check the motor function
:
Required tools:
hex wrench #6
Torx wrench #T25
white marker, ducktapes with various colours or zip ties
multimeter
Make sure, that the magnetic kill switch is in OFF position (magnet NOT attached) and the battery state of charge is very low.
Place the motorcycle on a solid and level surface of a mounting stand, so that both wheels are on the ground.
(Only for Cross/X-Force):
Using the hex wrench #6 loosen and remove the underseat bolt, located on the underside of the upper plastic bodywork (above the rear wheel), slide the seat forward and remove it from the motorcycle.
(Only for Start/Trial/Cross/X-Force):
Using the Torx wrench #T25 loosen and remove the upper 4 bolts from the upper plastic bodywork (2 on the left side + 2 on the right side).
(Only for Start/Trial/Cross/X-Force):
Remove the upper plastic bodywork by gentle pull up.
(Only for Start/Trial/Cross/X-Force):
Using the Torx wrench #T25 loosen and remove the 2 additional bolts from the right plastic bodywork and with a light frame tilt on the mounting stand remove the plastic bodywork.
(Only for Start/Trial/Cross):
Disconnect the main
yellow
motor connector between the motor and the controller.
(Only for Challenger):
Using the hex wrench #3 loosen and remove 2 bolts on the right side panel and gently slide this panel up to remove it.
(Only for Ranger/Challenger/FreeRider/X-Force):
Very gently remove the shrink tube from 3 main motor power connectors, located close to the motor. If the connectors are not distincted by a different colours, please use a ducktape with various colors to mark the pairs (or white marker or 1, 2 and 3 zip ties on both sides of each connector). Then unplug all 3 main motor power connectors.
(Only for Start/Trial/Cross):
Use a multimeter to measure DC voltage output from the motor directly on the
yellow
connecor. The correct function is:
No rear wheel rotation: 0 V
Light rear wheel rotation: above 0 V depending on the RPMs
(Only for Ranger/Challenger/FreeRider/X-Force):
Use a multimeter to measure AC voltage output from the motor directly on any 2 from the 3 main motor power connecors. The correct function is:
No rear wheel rotation: 0 V
Light rear wheel rotation: above 0 V depending on the RPMs
NOTE:
If You saw a voltage increase with wheel speed, then the motor windings are most likely in good condition. If there's no voltage output during the rear wheel rotation, the motor is probably faulty. Also listen carefully, whether there are no weird sounds from motor during rear wheel rotation (or any uncomfortable smell), which would also point to the faulty motor.
Follow these steps to reassemble the motorcycle:
Reconnect and isolate all the unplugged connectors and use a zip tie to fix them to the frame.
(Only for Start/Trial/Cross/X-Force):
With a light frame tilt on the mounting stand reinstall the left plastic bodywork and using the Torx wrench #T25 install and tighten the 2 lower bolts (5 - 6 Nm).
(Only for Start/Trial/Cross/X-Force):
Repeat the same step with the right plastic bodywork.
(Only for Start/Trial/Cross/X-Force):
Reinstall the upper plastic bodywork, align its 2 left holes with the holes on the frame and on the left side bodywork, reinstall 2 bolts and using the Torx wrench #T25 tighten them (5 - 6 Nm).
(Only for Start/Trial/Cross/X-Force):
Repeat the same step on the right side.
(Only for Cross/X-Force):
Install the seat by sliding it backward on the bolt, located close to the Torque & Speed control button, and align the hole in the seat and the upper plastic bodywork with its corresponding hole on the frame just above the rear wheel.
(Only for Cross/X-Force):
Install the seat bolt and tighten it using the hex wrench #6 (18 - 20 Nm).
(Only for Challenger):
Reinstall the right side panel and its 2 bolts and using the hex wrench #3 tighten them (5 - 6 Nm).
Double check, that all bolts and nuts are properly tightened.
2. Movement/play in motor sprocket
Follow these steps to check the motor axle:
There may be various factors, that can cause a motor sprocket to be able to move in relation to a motor axle:
Hard impacts from jumps, falls or rough landings with a subsequent motor revving, caused by the rear wheel spinning violently on landing
Repeated excessively hard acceleration
Improper chain tension (please see the knowledgebase article "
Cleaning motorcycle and adjusting chain tension
")
Worn chain(s) and sprocket(s)
The front and rear sprocket (including the Ranger's double sprocket) should be checked after each ride
for
any damage
during regular cleaning and maintenance of Your motorcycle.
If found any, please contact Your local selling dealer or the KUBERG Customer Service.
If Your motorcycle is under warranty, please register it on our website, if You have not already done so:
https://www.kuberg.com/en/bike-registration
If the problem persists, please contact Your dealer or KUBERG customer service (support@kuberg.com). For the fastest possible resolution please send:
VIN of Your motorcycle (it is stamped on the right side of the steering column).
Detailed information on actions taken so far, a few photos and preferably a video.
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