Vectrix VX-2 2011 User manual

VECTRIX VX-2 SERVICE MANUAL
www.vectrix.com
Version 1.0/May 2011
VECTRIX, LLC

VECTRIX VX-2 SERVICE MANUAL
CONTENTS
SECTION A: Tools
1 Tools Needed
SECTION B: Mechanical Parts
1 Front Fairing
2 Front Console Cover
3 Speedometer Cover
4 Front Vertical Panel Cover-Lower
5 Front Vertical Panel Cover-Upper
6 Center Step-Through Cover
7 Front Fender
8 Seat
9 Under Board
10 Rear Side Body Panels + Side Emblem Replacement
11 Rear Fender
12 Front Brake
13 Front Wheel
14 Foot Rest
15 Side Cover
16 Rear Brake
17 Rear Shock
18 Rear Suspension
19 Handlebar
SECTION C: Electrical Parts
1 Speedometer
2 Throttle
3 Brake Switch
4 Handlebar-Left Switch Assembly
5 Handlebar-Right Switch Assembly
6 Ignition Switch
7 Horn
8 Position Light/Headlamp Assembly Replacement
9 Front Turn Indicator Assembly
10 Side Stand Switch
11 Rear Light Assembly
12 License Plate Light Assembly
13 Rear Turn Indicator Assembly
14 Sevcon Motor Controller
15 Motor
16 Battery
17 Battery Charger
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VECTRIX VX-2 SERVICE MANUAL
SECTION D: Adjustments
1 Mirrors Adjustment
2 Front Headlamp/Position Light Adjustment
SECTION E: Troubleshooting
1 Speedometer Display & Controller LED Indication
2 Malfunctions
3 Check of Charger Function
SECTION F: Technical Information
1 Cable Assembly-Front Brake/Turn Indicators + BOM
2 Cable Assembly-Front Headlamp + BOM
3 Cable Assembly-Rear Brake/Indicators/Battery/Side Stand + BOM
4 Torque List
SECTION G: Unpacking/Prep
1 Unpacking Instructions
2 Prep Instructions
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VECTRIX VX-2 SERVICE MANUAL
SECTION A-1:
TOOLS NEEDED
For repairing and testing of the VX-2 scooter the following tools are needed:
Tools:
Description Specification Using for
Open wrench 5.5mm Converter
Open wrench/Turned Full-
contact (#S02445) 8mm Speedometer; Cover; Side stand; Horn
Open wrench 10mm Rear light; Front fender
Open wrench 12mm Rear shock, top; Main stand; Front brake
Open wrench 13mm Rear shock; Main stand; Front shock
Open wrench 14mm Front axle; Battery
Open wrench 16mm Front shock
Open wrench 17mm Side stand; Front axle; Battery
Open wrench 18mm Rear fork
Open wrench 19mm Rear fork
Open wrench 32mm Steering nut, top
Open wrench 45mm Steering nut, bottom
Special tool Motor nut
Torque wrench 0-20Nm
Torque wrench 10-100Nm
Spanner socket 12mm
Spanner socket 13mm
Spanner socket 14mm
Spanner socket 17mm
Allen key 2.5mm Accelerator
Allen key 4mm Plastic rear cover; Brake hose clamp; Motor
Allen key 5mm Balance weight; Controller
Allen key 6mm Front brake disc, Rear brake
Phillips screwdriver #1 Cover
Phillips screwdriver #2 Cover
Phillips screwdriver #3 Cover
Screwdriver, flat 4.5mm Front top cover
Security TORX Screwdriver TX10 Cover for electronic box
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VECTRIX VX-2 SERVICE MANUAL
SECTION B-1:
FRONT FAIRING
For safety put a plastic or other soft material onto the
fender
Unscrew the 6 Phillips screws 1 to 8 in order as seen on
the picture with a Phillips screwdriver PH2
Remark:
While loosening screws 7 and 8 hold the front cover
otherwise it drops down and could break!
87
1
5
4
6
3
2
Remark:
While loosening screws 7 and 8 hold the front cover
otherwise it drops down and could break!
Assemble all parts in the other direction
Remark: For assembling the cover please take care of the noses being in the right position
and no edge is standing out. Put in the screws slightly and if all screws and the
cover are in the correct positions tighten them.
See also the last picture on the next Section for the right position of the clamp
screw.
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VECTRIX VX-2 SERVICE MANUAL
Front Fairing Complete Removal
Preparations:
Disassemble Under Board see Section B-10
Disassemble Front Fender see Section B-8
Disassemble Front Wheel see Section B-14
Hold the front cover and loosen all the connectors of the
lamps
Assemble all parts in the other direction
Remark: For assembling the cover please take care of the noses being in the right position
and no edge is standing out. Put in the screws slightly and if all screws and the
cover are in the correct positions tighten them.
Please be sure the clamp nuts are on the right position
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VECTRIX VX-2 SERVICE MANUAL
SECTION B-2:
FRONT CONSOLE COVER
Preparations:
Disassemble the Front Fairing see Section B-1
Unscrew the two Phillips screws (left and right position)
with a Phillips screwdriver PH2
Slide in a flat screwdriver into the position as seen on the
picture. Hold the front cover by hand. Carefully turn the
screwdriver counter-clockwise [ccw] (left side) and
clockwise [cw] (right side) until the front cover snaps out.
Assemble all parts in the other direction
Remark: For assembling the top cover, please take care the noses are in the right position
and no edge is standing out.
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VECTRIX VX-2 SERVICE MANUAL
SECTION B-3:
SPEEDOMETER COVER
Preparations:
Disassemble Front Fairing see Section B-1
Disassemble Front Console Cover see Section B-2
Open the connector from Speedometer
Unscrew the Phillips screw with Phillips screwdriver PH2
Unscrew the Phillips screw with Phillips screwdriver PH2
Remove the plastic part including Speedometer
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VECTRIX VX-2 SERVICE MANUAL
SECTION B-4:
FRONT VERTICAL PANEL COVER-LOWER
Unscrew the two Phillips screws (up and down position)
with a Phillips screwdriver PH2
Unscrew the two Phillips screws (right and left position)
with a Phillips screwdriver PH2
Slide a Phillips screwdriver PH2 into the hole and pull out
carefully the cover to the left. The fingers holding the cover
and pull backwards
Carefully push back the cover more and more
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Now remove the cover backwards
The four Phillips screws are M6x16mm
Assemble all parts in the other direction
Remark: For assembling the cover please take care of the noses being in the right position
and no edge is standing out. Put in the screws slightly and if all screws and the
cover are in the correct positions tighten them.
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VECTRIX VX-2 SERVICE MANUAL
SECTION B-5:
FRONT VERTICAL PANEL COVER-UPPER
Preparations:
Disassemble Front Fairing see Section B-1
Carefully move the cover of Key Switch out
Remove the cover of Key Switch
Side view of the inner backside cover
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VECTRIX VX-2 SERVICE MANUAL
Unscrew the two Phillips screws (left and right position)
with a Phillips screwdriver PH2
Remove the cover
Assemble all parts in the other direction
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VECTRIX VX-2 SERVICE MANUAL
SECTION B-6:
CENTER STEP-THROUGH COVER
Preparations:
Disassemble Seat see Section B-8
Unscrew the two Phillips screws (left and right position)
with a Phillips screwdriver PH2
Slightly press out left and right side of the cover so that
they can pass the metal holder
Carefully move the cover forward until the cover can easily
be taken out
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VECTRIX VX-2 SERVICE MANUAL
Side view of the inner backside cover
The two Phillips screws are M6 x 16mm
Assemble all parts in the other direction
Remark: For assembling the cover please take care of the noses being in the right position
and no edge is standing out. Put in the screws slightly and if all screws and the
cover are in the correct positions tighten them.
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VECTRIX VX-2 SERVICE MANUAL
SECTION B-7:
FRONT FENDER
Unscrew the four Phillips screws (left and right side) with a
Phillips screwdriver PH2
To unscrew the Phillips screw hold the inner nut with
8mm open wrench.
Assemble all parts in the other direction
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VECTRIX VX-2 SERVICE MANUAL
SECTION B-8:
SEAT
Unscrew the Phillips screw with a Phillips screwdriver PH2
Hold the seat during unscrewing the second Phillips screw
Remove the seat
The two Phillips screws are M6 x 16mm
Assemble all parts in the other direction
Test if the seat lock works smoothly
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VECTRIX VX-2 SERVICE MANUAL
SECTION B-9:
UNDER BOARD
Unscrew the two Phillips screws (left and right position)
with a Phillips screwdriver PH2
Unscrew the screw (Front position) with a 8mm wrench
1
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6
4
2
Unscrew the 6 Phillips screws in order as seen on the
picture with a Phillips screwdriver PH2
While loosening screws 5 and 6 hold the Under board
otherwise it drops down and could break! 5
3
Assemble all parts in the other direction
Remark:
When assembling the cover, please take care of the noses are in the right position and no edge
is outstanding. First, just slightly screw in the screws and if all screws and the cover are in the
correct position tighten the screws.
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VECTRIX VX-2 SERVICE MANUAL
SECTION B-10:
REAR SIDE BODY PANELS + SIDE EMBLEM REPLACEMENT
Unscrew the four Phillips screws (top left and right
position) with a Phillips screwdriver PH2
Unscrew the four Phillips screws (left and right position)
with a Phillips screwdriver PH2
Carefully pull out left and right side until the cover can
easily lift up
Remark: Be careful for the left side because there is
the seat lock
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The four Phillips screws for the top are plate screw 3.5 x
12mm
The four Phillips screws for the side are plate screw 3.2 x
12mm (black)
Assemble all parts in the other direction
Put in the screws slightly and if all screws and the cover are in the correct positions tighten
them.
Rear Side Panel Emblem/Nameplate Replacement
S-XC-S00329
Removal Procedure
1. Right side:
Remove the right rear & cheek panel. Refer to Rear & Cheek Panel Right Replacement in Body
Rear End.
Left side:
Remove the left rear & cheek panel. Refer to Rear Cheek Panel Left Replacement in Body Rear
End.
2. Remove the 2 screws (1) and remove the Emblem/Nameplate.
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VECTRIX VX-2 SERVICE MANUAL
Installation Procedure
1. Align the Emblem/Nameplate and install the 2 screws (1).
2. Right side:
Install the right rear & cheek panel. Refer to Rear & Cheek Panel Right Replacement in Body
Rear End.
3. Left side:
Install the left rear & cheek panel. Refer to Rear & Cheek Panel Left Replacement in Body Rear
End.
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