HV Racing HVR 50.4 MINI User manual

WARNING:
Read these operating instructions carefully before you start using your HVR!
Dear HVR customer,
Thank you and congratulations on purchasing an HVR Ele electric motorcycle.
Read the operating instructions carefully and completely to ensure safe and long-term operation of the HVR and act carefully during
operation.
The HVR is the electric motorcycle for children with a powerful electric drive that is perfectly adaptable to your child's riding skills.
Long travel times are possible thanks to the large battery capacity.
The electric drive system is almost maintenance-free and equipped with a large number of sensors to ensure easy and safe
handling.
Make sure your child is mentally and physically fit to ride a motorcycle. Safe cycling is a basic requirement for this.
Your child must always wear appropriate protective clothing when riding a motorcycle. At the beginning you explain to your child the
functions and controls of the motorcycle as well as the driving technique.
With the HVR Connect app, the power and speed of the HVR can be adjusted over a wide range.
With a low power setting, you can run alongside your child without any problems and support them with their first attempts at driving.
For experienced young racing drivers, the HVR can be transformed into a winning motorcycle with over 8000 watts of power and a top
speed of 70 km / h in a matter of seconds.
With this electric motorcycle we would like to give you and your child the opportunity to get into motorcycle off-road sport more easily and
have a lot of fun.
The parents also enjoy the low maintenance requirements and low maintenance costs. The low emissions, especially the low noise
emissions, make it possible to drive in completely new places and much more frequently.
Nina Deitermann
Manager
High Voltage Racing GmbH
Neustadterstr. 13A
91085 Weisendorf
Germany
www.HVR-bikes.com
[email protected]
Page 2 of 36 HVR instruction manual

CONTENTS
1. IMPORTANT SYMBOLS AND DESIGNATIONS page 4
2. SAFETY NOTICE page 5
3. TECHNICAL DATA page 6
4. CONTROLS
4.1 Battery indicator with on / off switch
Page 7
5. ELECTRIC DRIVE
5.1 battery
5.2 Electric motor and converter
page 8
6. LOADING Page 11
7. SETTING WITH THE HVR APP
7.1 Connection / password
7.2 Observe monitor data
7.3 Adjusting the motorcycle setting
Page 14
Page 16
Page 16
8. TRANSPORT Page 19
9. BEFORE YOUR FIRST DRIVING Page 19
10. DRIVE Page 19
11. CLEANING Page 20
12. DECOMMISSIONING FOR LONG PERIODS Page 20
13. MAINTENANCE
13.1 chain
13.1.1 Clean the chain
13.1.2 Check chain tension
13.1.3 Adjusting the chain tension
13.2 tires
13.2.1 Air pressure
13.3 Brake function and brake pads
13.3.1 Check the brake discs
13.3.2 Check the brake linings
13.3.3 Change brake fluid
13.4 Foot brake lever
13.4.1 Check the position of the foot brake lever
13.4.2 Adjust the position of the foot brake lever
13.5 fork
13.5.1 Adjust the fork height
13.5.2 Check the fork legs for leaks
Page 20
Page 20
Page 23
Page 23
Page 26
Page 27
Page 3 of 36 HVR instruction manual

13.6 Adjust rear shock
13.7 spokes
13.7.1 Check spoke tension
13.8 Handlebars
13.8.1 Adjusting the handlebar position
Page 29
Page 31
Page 32
14. SERVICE PLAN
14.1 Compulsory work
14.2 Recommended work
Page 33
15. TORQUE LIST Page 34
16. EU / EG DECLARATION OF CONFORMITY Page 36
1. IMPORTANT SYMBOLS AND DESIGNATIONS
WARNING: " WARNING “indicates a possibly dangerous situation, which is to be
Injury or death and property damage can result if the situation is not prevented. The symbol " WARNING ”must
therefore be given special attention.
DANGER: " ATTENTION “indicates a situation that could lead to damage or malfunction
can result if the situation is not prevented. Make sure you follow the instructions marked with the
"ATTENTION" symbol.
H
NOTE: " NOTE “indicates helpful information which a better use
of the motorcycle. Following the "NOTE" symbol improves or extends the range of uses for the motorcycle.
H
Page 4 of 36 HVR instruction manual

2. SAFETY NOTICE
WARNING:
Read these operating instructions carefully before putting the HVR into operation!
To ensure safe and long operation, please note the following:
- Your child must be mentally and physically able to ride a motorcycle
- The minimum age is 6 years
- Riding a bicycle is the basic requirement for riding a motorcycle
- Explain to your child how to handle the motorcycle and discuss this with your child so that it is safe to use he understands with the
motorcycle
- Rotating parts such as chains, sprockets, wheels etc. pose a risk of injury to fingers and other body parts, so it is essential to keep a
safe distance from them during operation
- Never let your child ride the motorcycle unattended
- Your child must always wear appropriate protective clothing (motorcycle helmet, protectors, motorcycle boots, gloves, etc.)
- The safety equipment must always be in proper condition
- Be a good role model and always wear protective clothing when riding a motorcycle
- Explain to your child the riding technique and the controls of the motorcycle
- Make sure you have the correct power and speed setting that suits your child's riding ability and check this setting
- The motorcycle may only be charged by an adult, as is the inspection before every ride and maintenance
- The charging process must be supervised by an adult
- Don't push your child to drive beyond their abilities
- In order to take part in races, your child must have the necessary experience and be in a physical and mental state
- The pull cord of the safety switch m ows are worn on the left arm while driving in order to switch off the motorcycle in the event of a fall
- The maximum driver weight is 50kg for the HVR 50.4 and 70kg for the HVR 60.4, each including full driver equipment!
- Attend a training course at a motorsport club with experienced trainers
- The brake system can get very hot while driving; do not touch it until after a long cooling phase
- When not in use, pull off the tear-off switch to protect against unauthorized use
Page 5 of 36 HVR instruction manual

3. TECHNICAL DATA HVR
HVR 50.4 MINI
50 cc (minicross)
1350 mm
930 mm
580 mm
HVR 50.4
50 cc (minicross)
1350 mm
940 mm
630 mm
HVR 50.4 PRO
50 cc (minicross)
1400 mm
980 mm
685 mm
HVR 60.4
65 cc (minicross)
1600 mm
1135 mm
770 mm
class
overall length
wheelbase
Seat height
Handlebar height 770 mm 820 mm 890 mm 990 mm
1.4x10 front /
1.4x10 rear
front 10 "2.50
rear 10 “2.50
Front:
Two-piston system
with 195mm
Brake disc
Rear:
Single piston
pliers with each
170mm disc
Brushless HVR
liquid-
chilled 3 phases
E - motor
BLDC converter
300 A peak
50.4 V 18 Ah Li Ion max.
8000 watts
Max. 70 km / h
420 chain 10:45
33 mm USD 170
mmway
Two-piston system
Brake disc
Single piston
170mm disc
Brushless HVR
liquid-
chilled 3 phases chilled 3 phases chilled 3 phases
E - motor
BLDC converter
300 A peak
50.4 V 18 Ah Li Ion 50.4 V 18 Ah Li Ion 50.4 V 18 Ah Li Ion Max. 8000 watts
Max. 8000 watts Max. 8000 watts
Max. 70 km / h Max. 70 km / h Max. 60 km / h
420 chain 10: 45 420 chain 10: 45 420 chain 9: 55
33 mm USD 170 37 mm USD 180 33 mm USD 215
mmway mmway mmway
1,4x12 front /
1.4x10 rear
front 12 “60/100
rear 10 "2.75
Front:
with 195mm
Rear:
pliers with each
1,4x12 front /
1.4x10 rear
front 12 “60/100
rear 10 "2.75
Front:
Two-piston system
with 195mm
Brake disc
Rear:
Single piston
pliers with each
170mm disc
Brushless HVR
liquid-
E - motor
BLDC converter
300 A peak
1,4x14 front /
1.4x12 rear
Front 14 "60/100
rear 12 “80/100
Front:
Two-piston system
with 210mm
Brake disc
Rear:
Single piston
pliers with each
170mm disc
Brushless HVR
liquid-
E - motor
BLDC converter
300 A peak
bikes
tires
Brakes
engine
Converter
battery
power
speed
Primary drive
Front suspension
suspension
rear:
Central strut
Weight
170 mm travel 220 mm travel 230 mm travel 275 mm travel
43 kg 43 kg 44 kg 56 kg
Page 6 of 36 HVR instruction manual

4. CONTROLS
Front brake
and throttle
Breakaway switch
Battery indicator with
E. On / off switch Front brake armature
with expansion tank
for brake fluid
Charging port
Engine control unit
Brake fluid
advertisement for the
Rear brake with
surge tank
Rear brake Electric motor battery
4.1 BATTERY DISPLAY WITH ON / OFF SWITCH
The on / off switch is located in the middle of the display.
Page 7 of 36 HVR instruction manual

GREEN LED:
YELLOW LED:
RED LED:
Nac h press de s On / Off switch, the green LEDs of the battery indicator light up one after the other, the yellow and red LEDs light up briefly
for testing. The current SOC (state of charge) is then displayed and the motorcycle is ready to drive.
Battery charge status (abbreviation: SOC) LED 1 - 7
Temperature pre-warning (flashing) / temperature shutdown (lit) 0% state of charge (SOC) or
error
NOTE:
For safety reasons, the HVR switches off automatically after 60 seconds of inactivity, unless it is connected to the APP
H
SOC battery indicator
SOC (state of charge)
0 to 16%
16 to 27%
28 to 39%
40 to 51%
52 to 63%
64 to 75%
76 to 88%
88 to 100%
LED display
LED 1 flashes
LED 1 lights up
LEDs 1 to 2 light up LEDs 1
to 3 light up LEDs 1 to 4 light
up LEDs 1 to 5 light up LEDs
1 to 6 light up LEDs 1 to 7
light up
5. ELECTRIC DRIVE
The electrical drive train of the HVR comprises the battery, the electric motor and the converter.
5.1 BATTERY
Page 8 of 36 HVR instruction manual

The traction battery is the heart of an electric vehicle, performance and range largely depend on the battery. The HVR lithium-ion battery has
a specially designed, highly developed battery management system (BMS), which ensures that the battery is always operated within the
permissible limits. A large number of sensors constantly measure the parameters of the battery such as the voltage of the individual cells,
current, temperature, state of charge (SOC) etc., the Battery becomes permanent monitored and protected by the BMS.
SOC (State of charge) Calibration:
The state of charge is calculated using the current and voltage measurement in order to precisely determine the currently available capacity
of the battery. It is recommended to discharge the battery to 0% SOC approximately every 10 charging cycles until the motorcycle switches
off. The battery should then be charged to 100%; this procedure calibrates the determination of the state of charge.
NOTE:
The BMS protects the battery from temperatures that are too cold and too warm. For driving in cold conditions, it is recommended to warm
the motorcycle in a warm place with approx. 10-25 ° before driving. This improves performance and range.
Very hot ambient temperatures and driving with high power consumption heat up the battery cells. The aluminum side covers serve
as heat sinks for the battery cells.
H
NOTE:
H
If the battery is too warm or too cold for driving or charging, the yellow LED on the display lights up and the BMS prevents driving or
charging until the battery temperature is again within the required range.
The battery temperature can be displayed with the app.
NOTE:
For safety reasons, the HVR 50.4 switches off automatically after a standstill for 60 seconds, unless it is connected to the app.
H
HVR battery specifications:
Cells
Battery case
nominal voltage
capacity
Energy content
Battery temperature range driving
Battery temperature range charging
Charging time (300 watt standard charger) Charging time
quick charger (optional)
84 Li-Ion cells in the format 18650 plastic
aluminum composite housing
50.4 volts
18 Ah
907 Wh
0 ° C to 67 ° C
5 ° C to 50 ° C
3 h
1 h (typical charge on the route 20 - 90%)
Page 9 of 36 HVR instruction manual

WARNING:
Risk of fire and fire
- NEVER open, damage or burn the battery.
- NEVER short-circuit the battery poles.
- NEVER reverse the polarity of the battery.
- NEVER bring it near heat or fire.
- NEVER try to use any charger other than the original HVR charger.
5.2 ELECTRIC MOTOR AND MOTOR CONTROL UNIT (INVERTER)
The HVR electric motor and the converter ensure that the power delivery is easy to control. No clutch or gear shift is required for driving, the
power is available when the driver wants it.
NOTE:
The HVR's electric motor has an innovative liquid cooling system to dissipate the temperature from the inside to the housing. The cooling is
designed for the life of the motorcycle and therefore does not have to be changed.
H
DANGER:
H
Do not open the motor, otherwise coolant will leak out. The motor may only be removed as a whole using the 4 screws at the bottom of the
mounting brackets, the mounting brackets remain on the motor.
Should any oil leak out, it can be refilled through the central screw 1 in the engine block. Use only HVR coolant
and only fill up to the hole.
1
Page 10 of 36 HVR instruction manual

WARNING:
The motor housing can get very warm after driving at high power, so do not touch it.
NOTE:
H
The coolant is a special oil that is completely non-toxic and does not attack any components or is environmentally
hazardous.
NOTE:
H
The coolant only serves to better dissipate the heat from inside the engine, even if the vehicle is driven without any coolant,
the vehicle will not be damaged. However, it can cause the engine to get too hot under heavy load and the motorcycle
switches off to protect the engine from damage.
6. LOADING
WARNING:
The HVR charger is operated with 230 V, make sure that the housing and the cables are not damaged before each use, never use the
charger if the charger or the cables are damaged, but send it to HVR for repair. Never open the charger, there is high voltage inside. The
HVR charger is only approved for indoor use, never use the charger in the wet. The air inlets and the fan must not be blocked and the air
flow hinder . Only use an original HVR charger to charge the HVR. The charging process must always be carried out by an adult, never
allow a child to charge the motorcycle. The charging process must be supervised by an adult.
NOTE:
H
Driving while charging s will you rch the vehicle electronics prevented.
NOTE:
In order to start the charging process, the battery must have a temperature in the range of 5-50 °.
H
CHARGING PROCESS HVR:
▷ Connect the Schuko plug of the HVR charger to the 230 V household socket.
▷ Open the dust cap (bayonet lock) on the HVR's charging port.
Page 11 of 36 HVR instruction manual

▷ Connect the charging plug of the charger to the charging connection of the motorcycle (bayonet lock), charging now begins automatically
and the LED on the HVR charger lights up red.
▷ The flashing green LED on the motorcycle shows the current SOC.
SOC (state of charge)
0 to 16%
16 to 27%
28 to 39%
40 to 51%
52 to 63%
64 to 75%
76 to 88%
88 to 100%
LED display on the motorcycle
LED 1 flashes
LED 1 lights up LED 2 flashes LED 1 to 2
lights LED 3 flashes LED 1 to 3 lights LED 4
flashes LED 1 to 4 lights LED 5 flashes LED 1 to
5 lights LED 6 flashes LED 1 to 6 lights LED 7
flashes
LED 1 to 7 lights
Page 12 of 36 HVR instruction manual

Normal charging Motorcycle completely
loaded
The battery is too warm or too cold
to charge
The battery is being charged, gradually
more and more green LEDs light up
(the
last flashes) depending on the SOC
(state of charge) see table.
The lights up on the charger
LED red.
The battery is fully charged. 60
seconds later the motorcycle switches
off and the green LEDs are on
Go out motorcycle.
The lights up on the charger
LED green.
When the yellow LED on the
motorcycle and the green LED
light up on the charger
means that that the
Battery too warm or too cold
for loading is.
Cools the battery down within the next
hour,
starts loading
automatically. Is the battery
too cold you bring that
Motorbike to a warmer one
Place and start the
Loading again when the
Battery is warm enough.
NOTE:
H
If the battery is too warm for charging, wetting the black aluminum side cover helps
the battery with water, for example with a simple spray bottle.
The cooling effect caused by the evaporating water quickly removes the heat from the battery.
NOTE:
H
The exact state of charge and other parameters can be viewed with the HVR app during the charging process.
Page 13 of 36 HVR instruction manual

NOTE:
H
Charging over 90% of the charge is much slower due to the balancing of the cells, so it is advisable, for example, to only charge the
motorcycle to 90% full during the break on the route in order to maximize the training time.
▷ Remove the charging plug on the motorcycle and close the dust cap of the charging connection.
▷ Remove the Schuko plug from the household socket.
NOTE:
H
Charging can be interrupted and restarted at any time with the on / off switch; the charger must be connected to the Schuko socket and the
motorcycle.
NOTE:
H
The BMS in the HVR battery provides optimal performance ability and service life of the battery safe. Charging is only possible with the
original HVR charger.
NOTE:
H
For charging, the temperature of the battery must be between 5 ° C and 50 ° C, otherwise the yellow LED on the battery indicator lights up
and charging is not possible. This serves to ensure a long battery life and to protect the battery cells. Should the battery be too why and If it
cools down within the next hour, charging starts automatically. Is the
Battery too cold Take the motorcycle to a warmer place and start the charging process again when the battery is warm enough.
7. SETTING WITH THE HVR APP
NOTE:
H
For safety reasons, the HVR automatically switches off after 60 seconds of inactivity. As long as the motorcycle is connected to
the app, it remains permanently active.
7.1 CONNECTION / PASSWORD REGISTRATION
To connect to the HVR and your Android smartphone (Android 5.0 or higher), download the HVR Connect app from the Google Play
Store.
Open the HVR Connect app, turn on the motorcycle and press CONNECT.
The motorcycle is found as "HVR", select this device in the list to register it.
Assign any name to the motorcycle, enter the APP code and confirm this with OK.
Page 14 of 36 HVR instruction manual

NOTE:
H
The APP code can be found in the delivery certificate and on the converter under the seat.
The motorcycle is now registered and available in the list of registered motorcycles. When it is within range you can connect by pressing
the name of your motorcycle in the APP.
This process is also described in the quick guide!
Page 15 of 36 HVR instruction manual

7.2 OBSERVE MONITOR DATA
The MONITOR function shows the current parameters such as SOC, temperatures, voltage, current etc. of the motorcycle:
Press CONNECT Tap her motorcycle Monitor screen
7.3 ADJUSTING THE MOTORCYCLE SETTING
DANGER:
The motorcycle must be jacked up (with the rear wheel in the air) and must be stationary during the adjustment. The tear-off switch
must be removed for the adjustment process. The HVR Connect app shows you when the tear-off switch is still on the vehicle.
Adjustment is only possible after removing the tear-off switch.
H
Select SET to adjust the motorcycle's performance data.
3 preset mappings can be selected, these mappings make it easier to get started. If necessary, they serve as a starting point and can be
changed individually and saved as new custom mappings in order to optimally adapt the HVR to your child's driving ability and the route
conditions.
Page 16 of 36 HVR instruction manual

Press Tuning Tap her motorcycle
There are 3 preset mappings available:
LET'S START
For beginners
LET'S GO
For advanced
LET'S WIN
For real racers
Page 17 of 36 HVR instruction manual

SPEED:
6 - 70 km / h
POWER:
1000 - 8000 watts
RECUPERATION:
0 no engine brake /
Recuperation
6th strong engine brake /
Recuperation
Adjust the values accordingly and press SEND to send the set parameters to the motorcycle. The display starts to flash and the motorcycle
switches off after the data has been successfully transmitted. The new parameters are activated from the next start.
Should you want to save the set values dr After you have set the parameters accordingly, click on NEW and give it a name. After
you have confirmed with OK, the new one Mapping saved.
You can choose one of the following driving modes:
BEGINNER If the mode is for complete novice drivers, it ensures a gentle throttle response even if the
throttle grip is jerked.
It cannot be set in conjunction with a high output.
Is the standard mode and should be used as soon as you have a little feel for the throttle grip. In
contrast to the beginner mode, it ensures a direct response to the throttle grip.
Is the mode for real experts, it ensures a direct and toxic throttle response and thus the
strongest acceleration.
Holeshot mode is not recommended on slippery track conditions. It cannot be set in conjunction with low
power.
NORMAL
HOLESHOT
Page 18 of 36 HVR instruction manual

WARNING:
After every adjustment with the motorcycle jacked up, check whether the motorcycle behaves as you expect and the set maximum speed windiness
is set correctly. To do this, hold the motorcycle tightly, then turn the throttle grip and let the rear wheel turn in the air, making sure that nobody
is injured on the rotating parts.
8. TRANSPORT
Pay attention to the following points during transport:
- It is best to transport the motorcycle upright and securely fixed
- If you need to transport the motorcycle on its side, lay the motorcycle on its left side (on which the chain is located)
In order to protect your vehicle from soiling, please always put a blanket under it
NOTE:
H
If you are transporting the motorcycle on its left side, it is possible that a small amount of coolant will leak out. The coolant is non-toxic.
9. BEFORE YOUR FIRST DRIVING
Before driving for the first time, familiarize your child with the controls of the motorcycle and explain to your child how to use the
motorcycle. The setting of the motorcycle must match your child's riding ability. Start with low power and slow speed. Make sure that your
child can easily reach the controls. Internalize your child an adapted and safe driving style.
10. DRIVE
WARNING:
Electric vehicles are ready to drive immediately after being switched on without a running engine or noises indicating this. Unintentional
twisting of the throttle can set the motorcycle in motion without being expected.
Driving on public roads is prohibited; only allow your child to drive on closed training grounds. The HVR is not equipped with a lighting
system, so operation in the dark is not permitted.
Before every trip, check the technical condition of the motorcycle, especially the controls and their ease of movement, the brakes (brake
pads, brake fluid level), the chain tension, the condition of the chain and the tires.
Your child must always wear the appropriate protective clothing with protectors and a motorcycle helmet when riding a motorcycle. The pull
cord of the breakaway switch must be worn on the left arm in order to switch off the motorcycle in the event of a fall.
Instruct your child on a driving style that is adapted to their driving ability and the route.
Page 19 of 36 HVR instruction manual

11. CLEANING
After driving off-road, first clean the motorcycle carefully with a scraper or spatula to remove the coarse dirt.
DANGER:
H
Do not use a metal scraper or spatula as this could damage the motorcycle.
Then wash the motorcycle with a soft water jet, do not aim the water jet directly at electronic components and cables.
Dry the motorcycle, grease the chain and check that the controls move easily.
Do not use a high pressure cleaner!
12. DECOMMISSIONING FOR LONG PERIODS
Should the motorcycle be used for a long time, e.g. B. not be used for more than a month clean the motorcycle, lubricate the chain and
charge or discharge (depending on the charge level) the battery to approx. 50% SOC. The recommended The storage temperature is
between 10 ° C to 15 ° C, do not expose the motorcycle to direct sunlight.
For a longer shutdown e.g. B. For longer than 3 months, the battery voltage should be checked once a month with the MONITOR function of
the HVR app.If it has fallen below 46V, charge the battery.
13. MAINTENANCE
13.1 CHAIN
13.1.1 CLEAN THE CHAIN
Check the chain for coarse soiling; if this is the case, it must be cleaned.
Place the motorcycle on a stand so that the rear wheel can rotate freely. Rinse off coarse dirt with a soft jet of water (not a
high-pressure cleaner). Use a suitable chain cleaning agent to remove used grease residue. After drying, chain spray must be
applied.
Page 20 of 36 HVR instruction manual