EVT-168

TECHNICAL MANUAL

www.powabyke.com
© Copyright Powabyke Ltd. Bath UK 13/07/2006
Summary
I- Getting the scooter unpacked ...................................................................p 3
1- Unpacking the scooter....................................................................................p 4
2- Fitting the Left Front Signal Lamp .................................................................p 6
3- Fitting the Rear View Mirrors ........................................................................p 7
II- Parts replacement ...................................................................................p 8
1- Replacing the Batteries .................................................................................p 9
2- Replacing the Brake Sensors.........................................................................p 11
3- Replacing the Circuit Board .........................................................................p 13
4- Replacing the Covers.....................................................................................p 16
5- Replacing the Electric Motor........................................................................p 18
6- Replacing the Front Brake Cable .................................................................p 22
7- Replacing the Front Brake Linings ..............................................................p 24
8- Replacing the Fuses .......................................................................................p 26
9- Replacing the Headlamp Bulb ......................................................................p 32
10- Replacing the Rear Brake Linings ...............................................................p 33
11- Replacing the Throttle ..................................................................................p 35
III- Appendix ..............................................................................................p 37
1- Trouble Shooting and Repair..........................................................................p 38
2- Periodic Maintenance Table ...........................................................................p 41
3- Specifications.................................................................................................p 42

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Version 07/06 3
 1-Unpacking the scooter

Tools required :

• Scissors
• A 12mm spanner

Steps to follow :

1. Cut the 3 plastic straps. 3. Remove the main carton.

2. Remove the 2 cartons which are inside the main 4. Remove the protective bubble wrap of the scooter.
carton.

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5. Unscrew the bar which keeps the scooter on its
stand (use the 12mm spanner).
6. Remove the plastic protection which are located:
- on the headlamp and the tail lamp,
- on the reflectors (located on the side of the foot
stand),
- on the suspensions: front and rear,
- on the left handle bar and the throttle,
- on the seat.

Important: during the unpacking of the scooter, check you have:

- the 2 rear view mirrors which are packed in a white carton box located on the foot
stand of the scooter: 1 ,
- the battery charger which is packed in a brown carton box located on the right of
the rear wheel: 2 ,
- the key of the scooter tied on the handle-bar: 3 ,
- the Operation Manual located under the seat.

Time required : 30 minutes

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 2-Fitting the Left Front Signal Lamp

Tools required :

• Scissors
• A crosshead screwdriver

Steps to follow :

1. Cut the cable tie to remove the signal lamp from 3. Tighten the screw of the signal lamp.
the handle-bar.

2. Fit the tab of the signal lamp in the notch of the

lower part of the handle.

Time required : 10 minutes

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 3-Fitting the Rear View Mirrors

Tools required :

• A 14mm spanner

Steps to follow :

1. Tighten the rear view mirror in the hole on 3. Repeat these steps for the fitting of the second rear
handle bars. view mirror.

2. Tighten the locknut.

Time required : 15 minutes

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Version 07/06 8
 1-Replacing the Batteries

Tools required :

• A crosshead screwdriver
• A 10mm spanner

Steps to follow :

1. Remove the strap that retains the batteries. 3. Clutch the handles of the battery and remove it.

2. Disconnect the battery by pulling on the grey 4. Disconnect the + and – connectors of the battery:
connector which is located on the left side of the unscrew the 2 screws with the spanner and then with
scooter. the screwdriver.

5. Repeat for the others batteries.

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 To replace the batteries, reverse the procedure.
Important: check regularly the condition of the batteries and follow the manufacturers
instructions to charge them.

Time required : 15-30 minutes

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 2-Replacing the Brake Sensors

Tools required :

• Rear brake sensor: a flat screwdriver

• Front brake sensor: tweezers

Steps to follow :

1. With the flat screwdriver or the tweezers, press 2. Pull on the sensors cables whilst keeping pressure
the plastic tabs of the sensors. with the screwdriver or the tweezers to remove the
sensors from the handles.

Front
brake
sensor

Rear
brake
sensor

3. Remove the metallic rings which are located on the

rubber protection boots of the sensor connections.

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4. Pull away the rubber protection boots to enable 5. Disconnect the electric cables of the sensors.
access to the electric cables.

Note 1: follow exactly the same procedure for the front brake sensor.
Note 2: you can execute the steps 3, 4 and 5 before 1 and 2. It is not necessary to carry out 1
and 2 steps if the fault is not the sensor but in the electric cables or connections.

To replace the brake sensors, reverse the procedure.

Time required : 10 minutes for one sensor

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 3-Replacing the Circuit Board

Tools required :

• A crosshead screwdriver
• A flat screwdriver
• A 14mm spanner

Steps to follow :

1. Remove the right hand rear cover of the scooter: 3. Detach the accelerator cable from the handle bar
refer to the “Replacing the Covers” procedure. twist grip: refer to the “Replacing the Throttle”
procedure.

2. Disconnect the batteries by separating the red

connector located on the frame of the scooter. 4. Unscrew the 14mm nut of the accelerator cable.

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5. Remove the 4 screws which attach the circuit 7. Remove the back plate.
board box to the scooter frame.

6. Remove the 12 screws from the back plate of the

circuit board box.

8. Push the spring loaded accelerator rod out until the

nipple is exposed and disconnect the cable.

9. Using a flat screwdriver, prise off the name plate

of the circuit board box.

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10. Unscrew the 6 screws to detach the printed 12. Remove the printed circuit board.
circuit board.

11. Unplug the electrical connections.

To replace, reverse the procedure.

Time required : around 1-1,5 hours

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 4-Replacing the Covers

Name of the different covers :

4
9

10
3

12

11

8
1

1. Front mudguard
2. White front cover
3. Light Blue/Orange/Purple/Dark Green/Silver front cover
4. “Fork T” cover
5. Foot plate
6. Exterior chest cover
7. Right side cover
8. Left side cover
9. Rear cover
10. Interior chest cover
11. Rear mudguard
12. Bib

Procedure to remove the covers:

It is not possible to remove each cover alone because they are joined together.
Nevertheless, the mudguards, the white front cover and the “Fork T” cover can be remove
alone.
Follow these steps to remove the others covers:

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Rear covers
1. Remove the exterior chest cover (6): 2 screws and 1 bolt (8mm spanner).
2. Unscrew the side covers (7) and (8): 4 screws for the left cover and 5 screws for the
right one.
3. Pull out of joint the side covers (7) and (8) from the rear cover (9).
4. Unscrew the rear cover (9): 4 screws (2 on each side).
5. Remove the carrier to separate the rear cover (9) from the scooter frame: 1 CHC screw
(6mm Allen key) and 1 bolt (10mm spanner).
Note: the steps 4. and 5. are interchangeable.
6. Remove the two covers from the scooter frame by pulling on the front of the interior
chest cover (10).
7. Separate the two covers.

Front covers
1. Remove the rubber protection of the foot plate (5).
2. Unscrew the foot plate (5): 4 bolts (10mm spanner).
3. Pull out of joint the foot plate (5) from the front cover (3): pull on the rear of the foot
plate (5) and rotate it toward to the front of the scooter until you can remove it.
4. Remove the front cover (3).

To replace the covers, reverse the procedure.

Time required: around 1-1,5 hours

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 5-Replacing the Electric Motor

Tools required :

• A crosshead screwdriver
• A flat screwdriver
• Two 30mm spanner
• Ramp or rear jack assembly
• A 4mm Allen key

Steps to follow :

1. Remove the protection cover of the electrcial 3. Unscrew the two 17mm nuts located on the two
cables (3 screws). sides of the wheel axle.

2. Remove the brake stirrup: refer to the “Replacing

the Rear Brake Linings” procedure.
4. To be able to remove easily, lift up the rear of the
scooter.

Note: this operation is not obligatory but is really

advised to facilitate the extraction of the rear wheel
later.

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5. Using the flat screwdriver, remove the part located 6. Push on the wheel toward to the floor to separate
between the nut and the oscillating arm: prise the part the axle from the oscillating arm.
to remove it from the oscillating arm and then, with
your other hand, push it down.

7. Remove the wheel on the side.

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 Note: to open the electric motor, it is necessary to unplug the connectors at the circuit board
and to remove the sheath which is around the electrical cables before removing the Allen
screws located on the motor cover.

Location of the electric motor connector on the frame of Connectors of the electric motor
the scooter

Interior of the electric motor

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 To replace the rear wheel, reverse the procedure.

Time required : around 1,5-2 hours to dismantle just the rear wheel (dismantling of the
electric motor non-included)

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 6-Replacing the Front Brake Cable

Tools required :

• Pliers

Steps to follow :

1. Unscrew the tension brake adjustment nut. 3. Remove the cable from the brake drum.

2. Pull on the cable to remove the thread end from

the brake tab.

4. Remove the rubber protection located on the brake

lever.

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5. Remove the cable from the brake handle: pull on 6. Finally, remove the cable from the brake lever:
the cable to pass it in the opening located in the rotate the cable and then pull it down.
extension of the brake lever.

7. Using pliers, remove the lug located at the end of

the cable.

8. Pull on the cable to remove it from the sheath.

To replace the front brake cable, reverse the procedure.

Note: during the fitting of the new brake cable, grease it to enable easier relocation.

Time required : 15-30 minutes

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 7-Replacing the Front Brake Linings

Tools required :

• A 14mm spanner
• Two 17mm spanners
• A hammer
• A flat screwdriver
• Pliers

Steps to follow :

1. Unscrew the 14mm screw located on the anti- 3. Remove the screw to detach the anti-rotation
rotation bracket. bracket.

2. Using a hammer, tap the screw until the screw 4. Unscrew the front wheel axle: 17mm nut.
head is exposed on the other side.

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5. Stand the wheel upright and remove the front 7. Remove the brake drum from the wheel.
wheel axle with your other hand.

6. Support the forks of the scooter.

To replace the set, reverse the procedure.

Important: during the replacing of the brake drum in the wheel, check that there is enough
grease where the wheel axle pass. Always clean the contact surface between the brake linings
and the interior of the wheel (dust, foreign particles, ...).

Surfaces which need to be grease

Time required : between 45 minutes and 1 hour

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 8-Replacing the Fuses

The scooter has 3 fuses: 2 fuses of 15A and 1 fuse of 7.5A. The 2 fuses of 15 protect
the lighting circuit and the different handle controls. The 7.5A fuse protects the “general
circuit”: lighting circuit and the different handle controls plus the power circuit (electric
motor, battery).

Location of the fuses :

• On the front of the scooter: 1

• On the right side of the scooter: 2

• Inside the chest: 3

Tools required :

• Fuse 1 : 2 crosshead screwdriver

• Fuse 2 : a crosshead srewdriver and a 8mm spanner
• Fuse 3 : no tools required

Steps to follow :

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 Fuse 1

1. Remove the white front cover: refer to the 3. Open it and remove the fuse.
“Replacing the Covers” procedure.

2. Locate the fuse box.

Fuse 2

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1. Remove the exterior chest cover and the right 3. Unscrew the 3 screws that hold the box to the
side cover: refer to the “Replacing the Covers” scooter frame.
procedure.

4. Unscrew the 4 little screws that hold the dissipator

2. Disconnect the batteries by separating the red to the box.
connector located on the frame of the scooter.

5. Pull on the dissipator to remove it from the box.

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6. Locate the fuse on the printed circuit. 7. Remove the fuse.

Fuse 3

1. Open the chest of the scooter. 2. Remove the strap that retains the battery.

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3. Disconnect the battery by pulling on the grey 5. Locate the fuse box.
connector which is located on the left side of the
scooter.

6. Open it and remove the fuse.

4. Remove the second battery using the same

procedure.

To replace the fuses, reverse the procedure.

Important: check that the new fuse is the same that the old one (written on the head of the
fuse: resistance in ampere).
Time required :

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 • Fuse 1 : 15 minutes
• Fuse 2 : 30-45 minutes
• Fuse 3 : 15 minutes

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 9-Replacing the Headlamp Bulb

Tools required :

• A crosshead screwdriver

Steps to follow :

1. Remove the screw located under the headlamp. 3. Separate the 2 parts of the headlamp.

4. Push and then turn the ring to remove the part

where the bulb is fitted.

2. Remove the crown located around the headlamp:

remove it by pulling towards you.

5. Remove the bulb: push on the bulb and then turn it

until you can remove it.

To replace the headlamp bulb, reverse the procedure.

Time required : 15-30 minutes

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 10-Replacing the Rear Brake Linings

Tools required :

• A 12mm
• A 6mm Allen key
• A flat screwdriver or tweezers

Steps to follow :

1. Unscrew the 12mm black head screw. 3. Unscrew the Allen screw.

2. Unscrew the other 12mm screw (gold color). 4. Hold the brake stirrup and pull upwards to remove
it from the brake disk.

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5. Rotate the part where the brake linings are fitted. 6. To remove the brake linings, place the screwdriver
under them and then lever out. Or you can pull on the
brake linings, if loose enough.

To replace the rear brake linings and refit the brake stirrup, reverse the procedure.
Important: during the fitting of the brake stirrup, check that you have 3 washers behind each
of the 2 screw which assure the liaison between the stirrup and the oscillating arm. If not you
could probably seriously damage the brake disk.
Furthermore, remove any dust on the brake stirrup before refitting.

washers

Time required : 30 minutes

Time required: 30 minutes

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 11-Replacing the Throttle

Tools required :

• A crosshead screwdriver
• Small pliers
• Replacing the cable: wire cutters

Steps to follow :

1. Unscrew the 2 screws located on the handle. 3. Remove the accelerator cable from its notch in the
handle: turn the cable to remove it from the guide,
then pull on the cable to remove the lug from the
notch.

2. Separate the assembly

4. Unscrew the screw which holds a small tab to
remove the cable from the « half body » of the
assembly.

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5. Finally, pull on the cable to remove it from the
body of the assembly.

To replace the throttle, reverse the procedure.

Important: during the replacing of the throttle, check that the throttle operates smoothly,
otherwise grease the handle-bar.

Note: to replace the accelerator cable, it is necessary to disconnect the cable at the circuit
board: refer to the “Replacing the Circuit Board” procedure. Furthermore, to remove the cable
from his sheath, it’s necessary to cut one end (handle side: lug / circuit board side: ball).

Time required : 30 minutes just to replace the throttle (accelerator cable non-included)

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Version 07/06 37

Conditions
Display Panel indicator light is working, but
bike will not go when twist throttle.
Display Panel indicator light is not working or
no starting beep sound when you turn the
switch to the “ON” position.
The first red light blinking (1)
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1-Trouble Shooting and Repair (1)
Inspect
1. The power will cut off when brake is
applied
2. Brake switch breakdown
3. Check Controller cable is fixed
4. Check Motor cable is fixed
5. Motor breakdown.
6. Controller breakdown
1. Key switch breakdown
2. Check main switch cable is fixed
3. Hase the fuse blown?
4. Serious insufficient energy left
5. Controller breakdown
6. Display panel breakdown
7. The starting beeper breakdown
8. Check the battery connector is fixed
1. Serious insufficient energy left
2. The battery is aged or useless
Repair
1. Release the brake and then gently twisting
throttle
2. ~ 6. See our agent
1. 2. See your agent
3. Remove the fuse and replace
4. Recharge battery
5. ~ 7. See your agent
8. Fixed the battery connector
1. Recharge battery immediately
2. Replace the battery
38

Conditions
The second yellow light blinking (2)
The third green light blinking while driving
(3)
The fourth green light blinking (4)
The OH indicator blinking
Charging indicator is not on
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1-Trouble Shooting and Repair (2)
Inspect Repair
1. Insufficient energy left 1. Recharge the battery (The power cut off
while driving, please switch the power to
“OFF” position, and wait for several minutes
then restart. You may still drive a short
distance.)
1. Over current 1. Switch the power to “OFF” position, and
wait for few seconds to restart
2. Controller breakdown
2. See your agent
Throttle stuck 1. See your agent
Twist throttle and let go before the panel
2. Switch the power to “OFF” position, and
indicator stops blinking or the starting beep
wait for few seconds to restart
sound stops
3. See your agent
2. Controller breakdown
1. Over heat 1. Switch the power to “OFF” position, and
wait for several minutes then restart
2. Controller breakdown
2. See your agent
1. Are the outlet and inlet plugs secure? 1. Pull out and insert again or change outlet
2. Check the fuse is fixed 2. Press the fuse button
39
 Instrument Panel
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 2-Periodic Maintenance Table
A: Inspection C: Clean R: Replace T: Tighten
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Mileage (KM) 400 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 More
1. Brush A
A. Motor
2. Bearing A
B. Controller A A
C. Battery A A A A

REPEAT ITEM 2-13

D. Charger A A A A
1. Pressure A A A A A A A A A A A A
2. Tire A A A
E. Safety
3. Brakes A A A A A A A A A A A A A
4. Brakes Linings A A A
F. Lamp, Horn A A A A A A A A A A A A A
G. Screws T T T T T T T T T T T T T
H. Turning, Transmission A A C A C
Directions for the Inspetcions:
Points to check
1. Tire: pressure, gaps, cuts, damaged
2. Brakes: gaps of left and right brakes are normal (1-2cm is normal), Sufficient brake fluid
3. Lamps: Direction Lamps, Brake Lamps, Head Lamp
4. Turning Bar: Operating smoothly
5. Motor: Operating smoothly, No particular noise
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 3-Specifications (1)
BRAND EVT FRAME UNDER BONE
MODEL EVT-168 TYPE DIRETC DRIVEN
TXS
LENGTH 165 cm GEAR RATIO DIRETC DRIVEN
DIMENSION

WIDTH 74 cm TYPE SEALED LEAD ACID

HEIGHT 109 cm DIMENSION (mm) 197(L)x165(W)x170(H)
AXLE LENGHT 121 cm BATTERY WEIGHT 15kg x 4
FRONT 43 kg VOLUME 12V/50AH x 4
HYDRAULIC SHOCK
UNLOAD

REAR 85 kg FRONT
ABSORBER
WEIGHT

SUSPENSION
SPRING SHOCK
TOTAL 128 kg REAR
ABSORBER
TIRE FRONT 30PSI
RIDERS/WEIGHT 1P (75 kg)
PRESSURE REAR 36PSI
MAX. SPEED E/35km/h P/45km/h F 3.00-10,6pr
SPEC

TIRE SIZE & PAIRS (p.r)

CLIMBING 23.8km/h at 8° Slope/lp R 3.00-10,6pr
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 3-Specifications (2)
TYPE 48V BRUSHED FRONT DRUM BRAKE
BRAKE
MOTOR

CONTROLLER PWM REAR DISK BRAKE

MAX .H.P 3.0hp 80 km/h
SPEEDO METER
MAX.R.P.M. 755rpm 50 mph
HI 12V/35W
CHARGING TIME 5 hrs (up to 90%) FRONT (HI, LO)
CHARGER

LO 12V/35W
POWER 500W LAMPS PLATE LAMP 12V/5W
INPUT AC110V/220V BRAKE LAMP 12V/21W
OUTPUT 48V DIRECTION LAMP 12V/10W x 4
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