UBCO 2x2 ADV Gen 5 Operating manual

Technical
Service Manual
Version 1.0
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UBCO TECHNICAL SERVICE MANUAL PAGE 2 OF 159
TABLE OF CONTENTS
1 General Information
1.1 General Information And Disclaimers . . . . . . . 7
1.2 Bike Identification. . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Brake System Identification. . . . . . . . . . . . . . . . 9
1.4 Required Tools and Consumables . . . . . . . . . . . 11
1.5 Bike Orientation . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Model Specifications
2.1 Model Naming . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Front and Rear Wheel . . . . . . . . . . . . . . . . . . . . 15
2.5 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 Brakes - Sys 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 Brakes - SR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.8 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.9 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.10 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . 17
3 Service Information
3.1 Component Reuse . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . 19
3.3 Application of Threadlocker . . . . . . . . . . . . . . . 19
3.4 Standard Torque Settings . . . . . . . . . . . . . . . . 19

UBCO TECHNICAL SERVICE MANUAL PAGE 3 OF 159
3.5 Use Of Cable Ties . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6 Brake Component Handling . . . . . . . . . . . . . . . 20
4 Service Checks, Adjustments and Processes
4.1 Sys 2 - Checking Brake Fluid Level . . . . . . . . . 22
4.2 Sys 2 - Bleeding / Replacing Brake fluid. . . . . 23
4.3 Sys 2 - Inspecting Brake Pads . . . . . . . . . . . . . 25
4.4 Sys 2 - Inspecting Brake discs . . . . . . . . . . . . . 26
4.5 SR - Checking Brake Fluid Level . . . . . . . . . . . 27
4.6 SR - Bleeding / Replacing Brake Fluid . . . . . . 28
4.7 SR - Adjusting Brake Calipers . . . . . . . . . . . . . 31
4.8 SR - Inspecting Front or Rear Brake Pads. . . 33
4.9 SR - Inspecting Brake Discs . . . . . . . . . . . . . . . 34
4.10 SR - Adjusting Lever Blades . . . . . . . . . . . . . . . 35
4.11 Adjusting Front Suspension Settings . . . . . . . 36
4.12 Adjusting Rear Suspension Settings. . . . . . . . 37
4.13 Recommended Suspension Settings . . . . . . . 39
4.14 Inspecting Tyres . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.15 Inspecting & Adjusting Wheels. . . . . . . . . . . . . 41
4.16 Adjusting Headlamp Beam. . . . . . . . . . . . . . . . 43
4.17 Charging the Battery. . . . . . . . . . . . . . . . . . . . . 45
5 Removal and Replacement Operations
5.1 Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.2 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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Sys 2 - Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Sys 2 - Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Sys 2 - Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Sys 2 - Brake Master Cylinder . . . . . . . . . . . . . . . . . . 58
Sys 2 - Front Brake Line . . . . . . . . . . . . . . . . . . . . . . .60
Sys 2 - Rear Brake Line . . . . . . . . . . . . . . . . . . . . . . . . 62
Sys 2 - Front Brake Set . . . . . . . . . . . . . . . . . . . . . . . . 64
Sys 2 - Rear Brake Set . . . . . . . . . . . . . . . . . . . . . . . . 66
SR - Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SR - Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
SR - Front or Rear Brake Caliper . . . . . . . . . . . . . . . 71
SR - Front or Rear Brake Master Cylinder . . . . . . . 73
SR - Front Brake Line . . . . . . . . . . . . . . . . . . . . . . . . . 75
SR - Rear Brake Line . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SR - Front Brake Set . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SR - Rear Brake Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.3 Steering and Suspension. . . . . . . . . . . . . . . . . . 83
Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Disassemble Front Fork . . . . . . . . . . . . . . . . . . . . . . . 86
Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Rear Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . .90
Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Steering Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Lever Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.4 Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Front Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Front Console Cover . . . . . . . . . . . . . . . . . . . . . . . . . 102
Front Console Rear Panel . . . . . . . . . . . . . . . . . . . . 104
Rear Console Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Rear Console Rear Panel . . . . . . . . . . . . . . . . . . . . .108
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Front Mudguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

UBCO TECHNICAL SERVICE MANUAL PAGE 5 OF 159
Swing Arm Mudguard . . . . . . . . . . . . . . . . . . . . . . . . 113
Rear Mudguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Kickstand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Footpegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Sys 2 - Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
SR - Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.5 Electronics and Controls . . . . . . . . . . . . . . . . . 122
KxH Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Battery Plug Harness . . . . . . . . . . . . . . . . . . . . . . . . 125
On Road Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Left Hand Switch Block . . . . . . . . . . . . . . . . . . . . . . 130
Throttle/Kill Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Front Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Rear Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Tailight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
VMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Front Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Rear Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.6 Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Motor Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Planetary Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Motor Bearings and Seals . . . . . . . . . . . . . . . . . . . . 158

UBCO TECHNICAL SERVICE MANUAL PAGE 6 OF 159
1 GENERAL INFORMATION

UBCO TECHNICAL SERVICE MANUAL PAGE 7 OF 159
1.1 GENERAL INFORMATION AND DISCLAIMERS
Please read this disclaimer carefully before using the technical repair manual. By
accessing and utilizing this manual, you acknowledge and agree to the following
terms and conditions:
1. USE AT YOUR OWN RISK: This technical repair manual is provided for informa-
tional and educational purposes only. The information contained herein is
intended for skilled technicians and professionals who have the necessary
tools, equipment, and expertise to safely and accurately perform the repairs
described. The use of this manual is entirely at your own risk, and the manual's
publisher, authors, and contributors shall not be held liable for any damages or
losses arising from its use.
2. PROFESSIONAL GUIDANCE: This manual is not a substitute for professional
advice, diagnosis, or repair services. It is essential to consult with an UBCO
certified technician or manufacturer-approved service personnel when dealing
with complex technical repairs or maintenance tasks. The manual is meant to
complement, not replace, professional expertise.
3. APPLICABILITY: The procedures and instructions in this manual are generic in
nature and may not be suitable for all devices, equipment, or situations.
Always refer to UBCO documentation or guidelines for device-specific repair
instructions and specifications where available.
4. SAFETY PRECAUTIONS: Motorcycle repairs can be dangerous and may involve
exposure to electrical hazards, moving parts, and other potential risks. Prior to
attempting any repair, please ensure that you are adequately trained and
equipped with the necessary safety gear. Follow all safety warnings provided
by the manufacturer as well as industry health and safety guidelines.
5. WARRANTY IMPLICATIONS: Attempting repairs on a product covered by a war-
ranty or service agreement may void such coverage. Always check UBCO’s
warranty terms and conditions before undertaking any repair work.
6. COPYRIGHT AND INTELLECTUAL PROPERTY: This technical repair manual is
protected by copyright law. You may use it for personal, non-commercial pur-
poses only. Reproduction, distribution, or modification of the manual's con-
tent for commercial use is prohibited without prior written consent from the
copyright holder.
7. ACCURACY AND UPDATES: The information within this manual may become
outdated over time due to evolving technology and product changes. The
authors and publisher do not guarantee the accuracy, reliability, or complete-
ness of the information. It is the user’s responsibility to verify and cross-refer-
ence the information.

UBCO TECHNICAL SERVICE MANUAL PAGE 8 OF 159
8. LIMITATION OF LIABILITY: In no event shall the manual's publisher, authors, or
contributors be liable for any direct, indirect, special, punitive, incidental, or
consequential damages arising from the use of this manual or any informa-
tion contained within.
By using this technical repair manual, you agree to abide by these terms and con-
ditions. If you do not agree to these terms, do not continue to use this manual.
Your use of this manual constitutes your acceptance of these disclaimers and
limitations.
1.2 BIKE IDENTIFICATION
UBCO ADV and WRK bikes are manufactured with a Vehicle Identification Num-
ber (VIN) and Product Identification Number (PIN) respectively. This identifier is
located on the right hand side of the head tube of the frame.
VIN / PIN Location

UBCO TECHNICAL SERVICE MANUAL PAGE 9 OF 159
1.3 BRAKE SYSTEM IDENTIFICATION
The UBCO 2x2 Gen 5 is available with different braking systems.
These are referred to as- “SR” or “SYS 2”
Where there are variations in processes due to these different brake systems,
clear instructions for each system are provided.
These brake systems can be easily identified by component comparison with the
below images.
SR

UBCO TECHNICAL SERVICE MANUAL PAGE 10 OF 159
SYSTEM 2

UBCO TECHNICAL SERVICE MANUAL PAGE 11 OF 159
1.4 REQUIRED TOOLS AND CONSUMABLES
The following basic hand tools are required for carrying out the processes defined
within this manual.
ALLEN KEYS
• 2mm
• 2.5mm
• 3mm
• 4mm
• 5mm
• 6mm
• 7mm
• 8mm
ALLEN KEY SOCKETS
• 2.5mm
• 3mm
• 4mm
• 5mm
• 6mm
• 7mm
• 8mm
TORX KEYS
• T20
• T25
• T30
TORX SOCKETS
• T20
• T25
• T30
SCREWDRIVERS
• #1 Philips
• #2 Philips
• 5mm Flat
SOCKETS
• 8mm Crows Foot
• 10mm
• 17mm
• 21mm
SPANNERS
• 7mm
• 8mm
• 10mm
• 13mm
• 14mm
• 17mm
• 36mm

UBCO TECHNICAL SERVICE MANUAL PAGE 12 OF 159
The following workshop equipment is required for carrying out the processes
defined within this manual.
ITEM
• Micrometer
• Tyre Pressure Gauge
• Tread Depth Gauge
• Spoke Wrench
• Short Legged Bearing Puller
• External Circlip Pliers
• Flush Cutters
• Dial Gauge
• Breaker Bar
• Socket Driver
• Hammer
• Punch
• Rubber Hammer
• Heat Gun
• Brake Pad Spacer
Note - Impact drivers should not be used at any point within the assembly or dis-
assembly of components on the UBCO bike.
The following consumables are required for carrying out the processes defined
within this manual.
LUBRICANTS
• Silicone Grease
• ROCOL FOODLUBE Premier 1, EP1
• Red Rubber Grease
ADHESIVES
• Loctite 243
• Loctite 273
FLUIDS
• DOT 4 - Brake Fluid
• Mineral Oil - Brake Fluid
• Isopropyl Alcohol
OTHER
• Cloth - Lint Free
• Cloth - Cleaning

UBCO TECHNICAL SERVICE MANUAL PAGE 13 OF 159
1.5 BIKE ORIENTATION
Throughout this manual the bike orientation is to referred to from the rider posi-
tion. For example, the right hand side refers to the right hand side of the vehicle
when you are seated, facing the handlebars.
Front
Right
Top

UBCO TECHNICAL SERVICE MANUAL PAGE 14 OF 159
2 MODEL SPECIFICATIONS

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2.1 MODEL NAMING
Model. . . . . . . . . . . . . . . . . . . . . . . . . UBCO 2x2 ADV Gen 5 (2020 to Present)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UBCO 2x2 WRK Gen 5 (2020 to Present)
2.2 DIMENSIONS
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1820mm
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820mm
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040mm
Seat Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815mm
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1215mm
2.3 MASS
Chassis Mass (No Battery)
Vehicle Mass (2.1kWh Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66kg
Vehicle Mass (3.1kWh Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71kg
Battery Mass (2.1kWh Battery). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13kg
Battery Mass (3.1kWh Battery). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18kg
Maximum Payload (including Rider) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150kg
2.4 FRONT AND REAR WHEEL
Rim Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminium
Spoke Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Gauge
Rim Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17” x 1.85”
Trueness Deflection Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2mm
2.5 TYRES
Tyre Rim Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17” x 1.85”
Tyre Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17” x 2.75”
Tyre Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubed
Tyre Intended Use Type . . . . . . . . . . . . . . . . . . . . . .On Road, Mixed, Off Road1
1.ON ROAD AND MIXED ARE ROAD LEGAL, OFF ROAD IS NOT UNLESS DOT RATED TYRE FITTED.

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Minimum Tread Depth (On Road) . . . . . . . . . . . . . Refer to local authorities
Recommended Tyre Pressure (On Road). . . . . . . . 207kPa / 30psi / 2.06 bar
Tyre Grip Limit (Mixed) . . . . . . . . . . . . . . . . . . . . . . . Refer to local authorities
Recommended Tyre Pressure (Mixed) . . . . . . . . . . 207kPa / 30psi / 2.06 bar
Tyre Grip Limit (Off Road) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3mm
Recommended Tyre Pressure (Off Road) . . . . . . . . 172kPa / 25psi / 1.72 bar
2.6 BRAKES - SYS 2
Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Disc Brake
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand Lever
Front Brake Disc Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240mm
Front Brake Disc Standard Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7mm
Rear Brake Disc Minimum Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4mm
Front Brake Disc Runout Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5mm
Rear Brake Disc Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240mm
Rear Brake Disc Standard Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7mm
Rear Brake Disc Minimum Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4mm
Rear Brake Disc Runout Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5mm
Brake Pad Thickness (Friction Material Only) . . . . . . . . . . . . . . . . . . . . 3.2mm
Brake Pad Thickness Limit (Friction Material Only . . . . . . . . . . . . . . . .0.5mm
Recommended Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOT 4
2.7 BRAKES - SR
Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Disc Brake
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand Lever
Front Brake Disc Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200mm
Front Brake Disc Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.0mm
Front Brake Disc Thickness Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8mm
Front Brake Disc Runout Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5mm
Rear Brake Disc Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200mm
Rear Brake Disc Standard Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.0mm
Rear Brake Disc Minimum Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8mm
Rear Brake Disc Runout Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5mm

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Brake Pad Thickness (Friction Material Only . . . . . . . . . . . . . . . . . . . . . . .2mm
Brake Pad Thickness Limit (Friction Material Only . . . . . . . . . . . . . . . .0.5mm
Recommended Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOT 4
2.8 FRONT SUSPENSION
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Telescopic Fork
Spring / Shock Absorber Type . . . . . . . . . . . . . . . Coil Spring / Gas Damper
Fork Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130mm
2.9 REAR SUSPENSION
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swingarm Linkage
Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Spring / Shock Absorber Type . . . . . . . . . . . . . . . . .Coil Spring / Oil Damper
Fork Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120mm
2.10 CHASSIS SPECIFICATIONS
Frame Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubular Aluminium
Caster Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26°
Trail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.7mm

UBCO TECHNICAL SERVICE MANUAL PAGE 18 OF 159
3 SERVICE INFORMATION
WAITING FOR UBCO

UBCO TECHNICAL SERVICE MANUAL PAGE 19 OF 159
3.1 COMPONENT REUSE
When carrying out procedures within this manual the guidance is to re use com-
ponents. It should be noted that components like washers, circlips, o-rings and
fasteners are easily damaged and should be replaced if signs of wear or tear are
present.
3.2 CLEANING PROCEDURES
When a fastener (new or old) is to be used within a procedure outlined within this
manual, it first requires cleaning. To clean a fastener follow the below process;
Prepare the threads using an appropriate aqueous or solvent based cleaner.
Wipe the threads ensuring no corrosion inhibitor, dirt or debris remains.
If there is any stubborn debris use a fine wire brush to agitate, remove and then
prepare the threads with an appropriate cleaner.
Assess the thread for signs of wear and tear and replace with new if required.
3.3 APPLICATION OF THREADLOCKER
This procedure should be followed for every use of threadlocker within this man-
ual. Ideally refer to the manufacturers specifications for the application of
threadlocker. If these are unavailable follow the below process;
1. Prepare the threads using an appropriate aqueous or solvent based cleaner.
Wipe the threads ensuring no corrosion inhibitor, dirt or debris remains.
2. Allow the threads to dry after cleaning ensuring no trace of the cleaners used
in the first stage remains.
3. Apply a few drops of threadlocker to the section of the bolt where the nut will
sit.
4. Slowly fit the nut onto the bolt allowing the threadlocker to spread evenly.
5. Allow the threadlocker to cure for 24 hours. During this time movement of the
assembly should be kept to a minimum. In cases where this is not possible, an
accelerator may be used. Refer to the manufacturers specifications for pro-
cess.
3.4 STANDARD TORQUE SETTINGS
This chart specifies tightening torques for standard metric ISO fasteners with a
standard ISO thread pitch. Tightening torque specifications for special compo-
nents or assemblies are provided for each chapter of this manual. To avoid warp-
age, tighten multi-fastener assemblies in a crisscross pattern and progressive
stages until the specified tightening torque is reached. Unless otherwise speci-

UBCO TECHNICAL SERVICE MANUAL PAGE 20 OF 159
fied, tightening torque specifications require clean, dry threads. Components
should be at room temperature.
3.5 USE OF CABLE TIES
Wherever used Cable Ties should be trimmed with no sharp edges. Where possi-
ble Cable Ties should be placed so that the final trimmed edge is least likely to
come into contact with the user during normal use of the Bike.
3.6 BRAKE COMPONENT HANDLING
When handling brake pads and discs ensure that the active surfaces of the com-
ponents do not come in contact with contaminants. Do not allow the brake pad
surface or portion of brake disc that comes into contact with the brake pad to
touch anything other than a clean, lint free cloth. If the brake pads or discs do
become contaminated, attempt to clean with Isopropyl alcohol and discard if
unsuccessful.
TABLE 1: STANDARD TORQUE SETTINGS
TORQUE SETTING FOR
FASTENER GRADE (NM)
FASTENER 8.8 10.9 12.9
M3 1.2 2 2.4
M4 3.0 4 5
M5 6 8.5 10
M6 10.5 15 18
M8 25 35 42
M10 50 71 85