Cross/Trial: Battery removal and installation

WARNING!

During normal use, KUBERG does not recommend removing the battery from the KUBERG Trial/Cross. In case you need to replace the battery or remove it, KUBERG highly recommends taking the motorcycle to your local selling dealer or to the nearest professional motorcycle service center. 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.

NOTE:
The Lead-Acid battery consists of 3 batteries, each with 12 V nominal voltage (above 14 V fully charged), connected in series, while the Li-Ion battery consists of 1 battery, enclosed in a metal box. Every KUBERG battery for Start/Trial/Cross has a rubber surface from below to prevent abrasion between the frame and a battery and to minimize the risk of formatting an impact cracks.

Required tools:

hex wrench #6
Torx wrench #T25
red and black insulating tape
zip ties 4 - 8 mm

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): 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.
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).
Remove the upper plastic bodywork by gentle pull up.
Using the Torx wrench #T25 loosen and remove the 4 additional bolts from the left and right plastic bodywork (2 on the left side + 2 on the right side) and with a light frame tilt on the mounting stand remove both plastic bodyworks.
Remove the main red fuse from its socket.
Next steps differ based on the battery type:

(Only for Lead-Acid battery):
a) Check, whether the 2 cables, leading to the lower battery, have red and black ends (some older models did not have it). If not, use red insulating tape to mark the end of the cable, that leads to the positive pole of the battery, and use black insulating tape to mark the end of the cable, that leads to the negative pole of the battery. Repeat the same with the 2 upper batteries.
b) Disconnect the cables with red and black ending from the lower battery.
c) Cut the zip tie and remove the velcro tape from the lower battery. Then gently pull the battery out from the frame. WARNING! PREVENT CONTACT OF THE BATTERY POLES WITH THE FRAME!
d) Repeat steps b) and c) for all 3 batteries. After the batteries are removed, you’ll have 2 separate connecting cables, each with one black and one red ending.
e) Put three new batteries into the frame, poles facing forward, and secure their position firmly with the velcro tapes (2 for each battery) and zip ties.
f) Connect the red cable from the controller to the positive pole on the upper rear battery. Double check, that the wiring is correct!
g) Connect black end of one separate connecting cable to the negative pole on the upper rear battery. Connect the other red end of this cable to the positive pole on the lower battery. Double check, that the wiring is correct!
h) Connect black end of remaining connecting cable to the negative pole on the lower battery. The other red end from this cable goes to the positive pole on the upper front battery. Double check, that the wiring is correct!
i) Connect the black cable from the controller to the negative pole on the upper front battery. Double check, that the wiring is correct!
j) Check again, that the wiring on your motorcycle corresponds to the following circuit pictures.
k) If the wiring is correct, reinstall the red fuse, removed in step #7, into its socket. A short and audible spark may appear during closing the circuit.

MY2024 and newer wiring scheme:

MY2021-2023 wiring scheme:

(Only for Li-Ion battery):
a) Disconnect the main red battery connectors.

b) Cut all zip ties on the battery, undo velcro tapes and gently pull the battery up, backward and out of the frame. Be careful and don’t damage any cable or connector.
c) To reinstall the battery, put it back gently into the frame, cables facing backward, and slide it in frame as far forward as possible.
d) Firmly secure the battery position in frame with two velcro tapes and zip ties. Put an extra zip tie on the back side of the battery to secure the battery position from any possible longitudinal movement.

e) Reconnect the main red battery connectors.
f) Reinstall the red fuse, removed in step #7, into its socket. A short spark may be audiable, when closing the circuit.
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).
Repeat the same step with the right plastic bodywork.
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).
Repeat the same step on the right side.
(Only for Cross): 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): Install the seat bolt and tighten it using the hex wrench #6 (16 - 18 Nm).
Double check, that all bolts and nuts are properly tightened.

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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Cross/Trial: Battery removal and installation

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