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 BRAKE PAD REPLACEMENT........................................................................................................................... 16 TABLE OF CONTENTS BRAKE DISC REMOVAL/INSTALLATION ........................................................................................................ 17 CHAPTER 1 ................................................................................................................................. 1 CHAPTER 4 ................................................................................................................................. 18 GENERAL INFORMATION .......................................................................................................... 1 SHIFTER AND DERAILLEUR ..................................................................................................... 18 TERMS LEFT AND RIGHT ................................................................................................................................ 1 REMOVAL ....................................................................................................................................................... 18 NOTEs, CAUTIONS AND WARNINGS ............................................................................................................ 1 INSTALLATION ............................................................................................................................................... 18 TROUBLESHOOTING / DIAGNOSTIC GUIDE ................................................................................................ 2 SHIFTER CABLE INNER WIRE REMOVAL/INSTALLATION .......................................................................... 19 TOOLS ................................................................................................................................................................ 4 REMOVAL ....................................................................................................................................................... 19 SPECIFICATIONS .............................................................................................................................................. 4 INSTALLATION ............................................................................................................................................... 20 TABLE 1: ELECTRICAL SPECIFICATIONS .................................................................................................. 4 DERAILLEUR ..................................................................................................................................................... 21 TABLE 2: PARTS............................................................................................................................................. 4 DERAILLEUR LUBRICATION ....................................................................................................................... 21 GENERAL WARRANTY INFORMATION .......................................................................................................... 6 DERAILLEUR ADJUSTMENT ....................................................................................................................... 21 COMPONENTS TO BECOME FAMILIAR WITH WHICH ARE COVERED UNDER WARRANTY ............ 6 SETTING CABLE TENSION .......................................................................................................................... 22 BICYCLE OVERVIEW .................................................................................................................................... 6 DERAILLEUR INSTALLATION....................................................................................................................... 22 WARRANTY PROGRAM DETAILS ................................................................................................................... 7 MOTOR SYSTEM COMPONENT WARRANTY ........................................................................................... 7 CHAPTER 5 ................................................................................................................................. 23 NON-ELECTRIC COMPONENT WARRANTY ............................................................................................. 7 SERVICING OF PARTS ..................................................................................................................................... 7 CHAIN AND CRANKSET ............................................................................................................ 23 CHAIN ................................................................................................................................................................. 23 CHAPTER 2 ................................................................................................................................. 8 INSPECTION .................................................................................................................................................. 23 CHECKING CHAIN LENGTH ........................................................................................................................ 23 STEERING AND SUSPENSION ................................................................................................. 8 REMOVAL ....................................................................................................................................................... 24 HANDLEBAR REPLACEMENT ......................................................................................................................... 8 CLEANING ...................................................................................................................................................... 24 REMOVAL ....................................................................................................................................................... 8 INSTALLATION ............................................................................................................................................... 24 INSTALLATION ............................................................................................................................................... 9 LUBRICATION ................................................................................................................................................ 25 HANDLEBAR STEM ......................................................................................................................................... 9 CRANK ARM ...................................................................................................................................................... 25 REMOVAL ....................................................................................................................................................... 9 REMOVAL ....................................................................................................................................................... 25 INSTALLATION ............................................................................................................................................... 10 INSPECTION .................................................................................................................................................. 26 FRONT FORK REMOVAL/INSTALLATION ....................................................................................................... 11 INSTALLATION ............................................................................................................................................... 27 REMOVAL ....................................................................................................................................................... 11 CHAINRING ........................................................................................................................................................ 27 INSTALLATION ............................................................................................................................................... 12 REMOVAL ....................................................................................................................................................... 27 CHAPTER 3 ................................................................................................................................. 13 INSTALLATION ............................................................................................................................................... 27 CHAINRING WOBBLE CHECK ......................................................................................................................... 28 BRAKES ....................................................................................................................................... 13 PEDAL ..............................................................................................................................................................