| Description | Part Number | Qty. |
|---|---|---|
| DIGITAL TECHNICIAN II | HD-48650 | 1 |
| 1. | Hover RESS two inches above EVPT. | |
| 2. | Install RESS to EVPT. See Electric Vehicle Powertrain (EVPT) → POWERTRAIN. | |
| 3. | Connect main harness Battery Disconnect Unit (BDU) connector to RESS. See Electrical → MAIN WIRE HARNESS. | |
| 4. | NOTE Make sure assembly is properly balanced and supported. | |
| 5. | Install EVPT high-voltage connector. See Electric Vehicle Powertrain (EVPT) → POWERTRAIN. | |
| 6. | Rotate battery charger and cooling system assembly toward RESS. | |
| 7. | Install radiator mounting tab screws. See Cooling System → RADIATOR. | |
| 8. | Secure coolant hoses with p-clamps to front of RESS. See Cooling System → COOLANT HOSES. | |
| 9. | Rotate steering head toward RESS. | |
| 10. | Install AC in-line filter. See High-Voltage System → AC OBC IN-LINE FILTER. | |
| 11. | Install right frame. See Chassis → FRAME. a. Loosely install frame to steering head long screws. b. Loosely install frame to steering head short screws. c. Install frame to RESS screws. Do not tighten. | |
| 12. | Route and attach main harness to top, left side and rear of the RESS. See Electrical → MAIN WIRE HARNESS. a. Top: BCM, BCM power, fuse, diagnostic link, antenna and charger. b. Left-side (upper main harness bracket): Headlamp, fork lock, hand control modules, and turn signal lamps. c. Rear: Lower main harness bracket. | |
| 13. | Install OBC. See High-Voltage System → ONBOARD CHARGER (OBC). a. Connect battery charger connectors. | |
| 14. | Install left frame. See Chassis → FRAME. a. Make sure main wire harness is properly routed and installed. See Electrical → MAIN WIRE HARNESS. NOTE Main wire harness can get pinched or frame will be difficult to align and install, if not properly installed. b. Loosely install frame to steering head nuts. c. Loosely install frame to steering short screws. d. Install frame to RESS screws. Do not tighten. | |
| 15. | Tighten left and right frame hardware in sequence. a. Tighten frame to steering head nuts. Do not torque. b. Tighten frame to steering head short screws. Do not torque. c. Tighten frame screws. Do not torque. d. Loosen frame to steering head nuts 90 degrees. e. Loosen remaining frame screws 90 degrees. | |
| 16. | Connect front wire harness. See Electrical → FRONT WIRE HARNESS. | |
| 17. | Connect twist grip sensor connector. See Electrical → TWIST GRIP SENSOR (TGS). | |
| 18. | Connect jiffy stand connector. See Electrical → JIFFY STAND SENSOR (JSS). | |
| 19. | Connect front WSS connector. See Electrical → FRONT WHEEL SPEED SENSOR (WSS). | |
| 20. | Route and install coolant drain hose to filler neck. See Cooling System → COOLANT HOSES. | |
| 21. | Connect TCU. See Electrical → TELEMETRY CONTROL UNIT (TCU). | |
| 22. | Install antenna. See Electrical → SECURITY SYSTEM ANTENNA. | |
| 23. | Install IMU. See Electrical → INERTIAL MEASUREMENT UNIT (IMU). | |
| 24. | Attach ABS module and brake lines to RESS. a. Move caliper, master cylinder, ABS module and brake lines into position. b. Attach brake lines to brackets, cable straps and clamps. See Chassis → BRAKE LINES. c. Attach ABS module to housing. See Chassis → ABS MODULE. d. Install ABS cover. | |
| 25. | Install left frame grounds: See Electrical → MAIN WIRE HARNESS. a. Upper front: Two on left side of frame. b. Lower rear: One on left side of inner frame. | |
| 26. | Attach front brake line manifold to under steering head. See Brake Line: Front Caliper to ABS Module in Chassis → BRAKE LINES. | |
| 27. | Install EVPT breather. See Electric Vehicle Powertrain (EVPT) → BREATHER ASSEMBLY. | |
| 28. | Install rear half of motorcycle to RESS. a. Move rear half of motorcycle to RESS. b. Install rear fork pivot shaft and idler sprocket. See Chassis → REAR FORK. c. Loosen rear fork pivot shaft 90 degrees. | |
| 29. | Tighten frame assembly hardware in sequence: a. Tighten frame to steering head nuts. See Chassis → FRAME. b. Tighten rear fork pivot shaft. See Remove and Install Idler Sprocket within Electric Vehicle Powertrain (EVPT) → TENSIONER PULLEY AND IDLER SPROCKET. c. Tighten remaining frame screws. See Chassis → FRAME. | |
| 30. | Attach rear brake caliper. See Chassis → REAR BRAKE CALIPER. | |
| 31. | Install P-clamp from rear caliper brake line to ABS module. See Chassis → BRAKE LINES. | |
| 32. | Connect connectors: a. Rear WSS. See Electrical → REAR WHEEL SPEED SENSOR (WSS). b. Rear wire harness. See Electrical → REAR WIRE HARNESS. | |
| 33. | Connect rear shock absorber to housing. a. Install front screw to rear shock absorber. See Chassis → REAR SHOCK ABSORBER. | |
| 34. | Install tensioner. See Electric Vehicle Powertrain (EVPT) → TENSIONER PULLEY AND IDLER SPROCKET. | |
| 35. | Install lower belt guard. See Chassis → BELT GUARDS. | |
| 36. | Install primary cover. See Electric Vehicle Powertrain (EVPT) → PRIMARY COVER. | |
| 37. | Install high-voltage cable cover. See Electric Vehicle Powertrain (EVPT) → HIGH-VOLTAGE CABLE COVER. | |
| 38. | Install sensor to jiffy stand. See Electrical → JIFFY STAND SENSOR (JSS). | |
| 39. | Install left and right footrest brackets. See Chassis → RIDER FOOTRESTS. | |
| 40. | Attach rear master cylinder to footrest. See Chassis → REAR BRAKE MASTER CYLINDER. | |
| 41. | Install front cover. See Electric Vehicle Powertrain (EVPT) → FRONT COVER. | |
| 42. | Install upper, middle and lower side covers. See Chassis → SIDE COVERS. | |
| 43. | Install fairing. See Chassis → FAIRING. | |
| 44. | Install tail section. See Chassis → TAIL SECTION. | |
| 45. | Install power receptacle assembly. See High-Voltage System → POWER RECEPTACLE (VEHICLE INLET). | |
| 46. | Install BCM. See Electrical → BODY CONTROL MODULE (BCM). | |
| 47. | Install skid plate. a. Remove special tool baseplate. b. Install skid plate. See Electric Vehicle Powertrain (EVPT) → SKID PLATE. | |
| 48. | Connect negative battery cable. See Maintenance → INSPECT BATTERY. | |
| 49. | Activate electrical system. See Electrical → POWER DISCONNECT. | |
| 50. | Install rear cover. See Chassis → REAR COVER. | |
| 51. | Install top cover. See Chassis → TOP COVER. | |
| 52. | Check and update software using special tool. Special Tool: DIGITAL TECHNICIAN II (HD-48650) | |
| 53. | Marry battery to vehicle using special tool. Special Tool: DIGITAL TECHNICIAN II (HD-48650) |