WARNINGLiveWire service manuals are intended for use by professional, qualified and experienced technicians. Attempting the procedures found within this manual without the proper training, tools and equipment could result in death or injury to you or others. This could also damage the motorcycle or cause the motorcycle to operate improperly. (12137a)
Safety is always the most important consideration when performing any job.
- Always have a complete understanding of the task.
- Use common sense.
- Use proper tools for the task.
- Protect yourself and bystanders by using Personal Protective Equipment (PPE) appropriate to the situation. The service procedures contained in this manual have been evaluated as a safe and effective method for servicing the motorcycle. LiveWire does not evaluate or advise technicians of every way in which a service procedure might be performed, or all possible hazardous consequences of every method, nor has it undertaken such a broad evaluation. Before using a tool or procedure not recommended by LiveWire, make sure that technician or rider safety will not be compromised.
Safety Messages
Statements in this manual preceded by the following words are of special significance.
DANGERDANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. (08704a)
WARNINGWARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a)
CAUTIONCAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a)
NOTICE
NOTICE indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140b)
NOTE
Refers to important information. It is recommended that you take special notice of these items.
These safety words may be accompanied by graphic symbols. The graphic symbols indicate potential safety hazards and avoidance actions to prevent a hazardous situation. The graphical symbols may be present in manuals, instructions, and on the motorcycle and/or Parts & Accessory product labels.
Refer to the appropriate section in this manual and/or Parts & Accessory instructions for additional safety information. See Safe Operating Rules or the tables in the Safety Symbols Definitions section in the owner's manual.
Customer Safety
WARNINGThe rider's safety depends upon proper motorcycle service and maintenance. If a procedure in this manual is not within your capabilities or you do not have the correct tools, have a LiveWire dealer perform the procedure. Improper service or maintenance could result in death or serious injury. (12136b)
Proper service and repair are important for the safe, reliable operation of all mechanical products. The service procedures recommended and described in this manual are effective methods for performing service operations and are essential to your customer's safety and the reliable, safe operation of your customer's motorcycle.
Personal Protection
WARNING- Always wear safety glasses or goggles when performing service or maintenance procedures. Flying objects or materials can cause serious eye injury or death.
- Wear protective gear that is appropriate to the situation. Helmets, gloves, boots and other protective clothing can prevent serious injury or death.
- Wear ear protection when loud noises are present. Loud noises can damage ears and cause hearing loss.
Tool Safety
Some of these service operations require the use of tools specially designed for the purpose. Follow the manufacturer's suggested usage and safety instructions. If using a tool other than that recommended by LiveWire, be sure that the tool is appropriate for the service or maintenance procedure and is being used in accordance with the tool's safety instructions.
Product Safety
WARNINGRead and follow warnings and directions on all products. Failure to follow warnings and directions can result in death or serious injury. (00470b)
- When reference is made to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted.
- Some referenced or recommended products contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm as indicated on the product label or at the point of purchase.
Hazardous Materials
WARNINGRead and follow warnings and directions on all products. Failure to follow warnings and directions can result in death or serious injury. (00470b)
- Keep hazardous products out of the reach of children.
- Many products (oils, lubricants, solvents, sealants and cleaners, etc.) can cause death or serious injury if inhaled, absorbed, injected, ingested or improperly contacted. If hazardous contact is made with a product, follow the instructions on the product label and, if necessary, contact poison control or a medical facility.
- Some products are flammable and/or explosive as indicated on the product label or at the point of purchase. Keep these products away from flame and intense heat.
- Some products are corrosive as indicated on the product label. Wear appropriate protective gear to prevent skin contact. Use service covers to prevent damage to cosmetic surfaces on the motorcycle.
- Some products contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm as indicated on the product label or at the point of purchase.
- For the purpose of shipping and handling, lithium ion batteries are considered hazardous materials. Refer to local regulations regarding special handling and packing requirements, shipping instructions, and for training requirements on hazardous materials.
- Consumers are responsible for recycling or proper disposal of used batteries. Dispose in accordance with methods that meet or exceed all state and federal environmental laws.
- Never mix lithium-ion battery cores with lead acid cores.
Coolant
- Coolant contains toxic chemicals which could cause death or serious injuries if ingested. Do not induce vomiting. Call a physician immediately.
- Irritation to skin or eyes can occur from vapors or direct contact. Flush thoroughly with water if contact is made.
- Use in a well-ventilated area.
Hydraulic Brake Fluid
WARNINGContact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
- If inhaled: Keep calm, remove to fresh air, seek medical attention.
- If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
- If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
- If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Contact Poison Control. Immediate medical attention required.
- See Safety Data Sheet (SDS) for more details available at sds.livewire.com
WARNINGDOT 4 brake fluid absorbs moisture from the atmosphere over time, changing the properties of the fluid. Check brake fluid moisture content at every service interval or annually (whichever comes first). Flush and replace the brake fluid every two years, or sooner if moisture content is 3% or greater. Failure to flush and replace fluid can adversely affect braking, which could result in death or serious injury. (06304b)
To ensure the brake system is performing to design, check the moisture content of the brake fluid at every service interval or at least annually using a DOT 4 brake fluid moisture tester (part number HD-48497-A or equivalent) following the instructions included with the tool. Flush DOT 4 fluid every 2 years or sooner if the brake system fluid test shows moisture content is 3% or greater.
LiveWire recommends using Harley-Davidson Platinum Label DOT 4 Brake Fluid because of its superior moisture and corrosion inhibiting properties.
Electrical Systems
WARNINGImproper service or maintenance of the electrical system can cause damage to the electrical system. This may result in component failure. In certain situations, a component failure during operation could lead to a loss of control, which could result in death or serious injury. (00637b)
- Always use replacement fuses that are of the specified type and amperage rating.
- Do NOT pull on electrical wires. Pulling on electrical wires may damage wire conductivity.
- Route wires and harnesses properly to prevent chafing, stripping, pinching, crimping or cutting wires. Damaged wires can cause short circuits and component damage or failure.
- Do NOT overload the vehicle's charging system. If the electrical accessories consume more electrical current than the charging system can produce, the battery may be discharged and cause damage to the motorcycle's electrical system.
- Do NOT exceed the maximum amperage rating of the fuse or circuit breaker protecting a modified circuit.
- Avoid directly heating electrical system components other than the connectors on which heat shrink work is being performed.
BATTERIES
The main components of the charging system are the Rechargeable Energy Storage System (RESS), the On Board Charger (OBC), the 12 V Lithium-Ion Battery and the Electric Vehicle Supply Equipment (EVSE). High-voltage components are connected by high-voltage cables which are colored orange for easy identification.
High Voltage
The high voltage used by these vehicles is dangerous and can cause personal injury, severe burns, electric shock and even fatal injury unless appropriate precautions are taken. High voltage cable or wiring has an orange covering. Do not probe, cut or damage high voltage cables or wiring.
Do not disassemble, remove or replace high-voltage components, covers or guards. Always have the high voltage system serviced by qualified technicians.
Low Voltage
In addition to the high voltage system, the vehicle also has a low voltage electrical system. The low voltage system provides the energy needed to control and enable the high voltage system.
Rechargeable Energy Storage System (RESS)
DANGERThis vehicle contains a high voltage Rechargeable Energy Storage System (RESS). An improperly handled or damaged RESS can cause electrical shock and/or fire, which will result in death or serious injury.
- RESS must only be serviced by a qualified technician using proper Personal Protective Equipment (PPE).
- Do not touch RESS connecter terminals with fingers, tools, jewelry, or other metal objects.
- Do not disconnect, disassemble, or use RESS for other than its intended use.
- Improper charging, impact or exposure to fire can damage the RESS.
- A damaged RESS can leak electrolyte and/or generate flammable gas.
DANGERA damaged Rechargeable Energy Storage System (RESS) can leak electrolyte. Contact with electrolyte will cause serious chemical burns or blindness.
- Always wear proper Personal Protective Equipment (PPE) while handling RESS.
- If electrolyte comes in contact with eyes, skin, or clothing, rinse affected area with clean water and seek medical attention immediately.
- See Safety Data Sheet (SDS) for more details available at sds.livewire.com.
DANGERAlways assume a damaged vehicle's High Voltage (HV) system is charged and energized! Wear appropriate Personal Protective Equipment (PPE), including a self-contained breathing apparatus (SCBA). Failure to wear PPE can result electric shock, burns and/or exposure to toxic materials which will lead to death or serious injury.
- Damage to a high voltage battery may result in immediate or delayed release of toxic/flammable gasses and/or fire.
- Exposed HV components, wires, and batteries present high voltage shock hazards.
- Venting of vapors/gasses from HV batteries may be toxic and/or flammable.
WARNINGMisused or abused lithium-ion batteries can get hot, explode or ignite, or potentially release gas, smoke or liquid. Always follow battery safety precautions. Misuse or abuse of lithium-ion batteries could result in death or serious injury. (07729b)
Safety is a primary consideration with EV drive systems because of their high voltage characteristics. Only trained HV personnel should attempt to repair or service electric vehicles.
Ensure all safety equipment required by federal, state and local law is installed and in good operating condition.
12 V Lithium-Ion Battery
- Do not use battery if it gives off an odor, generates heat, releases gas, smoke or liquid, becomes discolored, or deformed or appears abnormal in any way. If the battery is in use or being recharged, disconnect it from the motorcycle or charger immediately and discontinue use. Wear a protective face shield, rubberized gloves, respiratory protection and protective clothing when handling a damaged battery to prevent exposure to internal battery contents.
- Never attempt to open or disassemble a battery. If accidental contact with internal battery contents occurs, wash the affected skin area and contact a doctor for medical assistance.
- Do not pierce the battery case with a nail or other sharp objects, do not break it open, do not crush.
- Do not place the battery in a microwave oven or pressurized container.
- Do not immerse the battery in water.
- Do not strike, throw or subject the battery to severe physical shock.
- Do not press the indicator button on the battery longer than a few seconds.
- Keep out of reach of children and pets.
In the Event of Contact with Internal Battery Contents
WARNINGContact with internal battery contents can have serious health effects. Wear protective face shield, rubberized gloves, respiratory protection, and protective clothing when handling damaged batteries. Failure to wear proper protective gear while handling a damaged battery could result in death or serious injury.
See Safety Data Sheet (SDS) for more details available at sds.livewire.com (12209b)
General information: The following first aid measures are required only in case of exposure to internal battery contents after damage of the external battery casing.
Table 1. Battery Electrolyte Antidote
Physical Location | Procedure |
|---|---|
After Inhalation |
|
After Contact with Skin |
|
After Contact with Eyes |
|
After Ingestion |
|
CHARGING
Charging time depends on the begining State of Charge (SOC) and the target state of charge.
- The RESS keeps the 12 V Lithium-Ion battery charged.
- Level 1 (AC Slow Charge) charging with the EVSE requires a dedicated, properly grounded 120 VAC single phase outlet protected by a 15 amp circuit breaker.
- Level 2 AC charging stations provide a high power AC current to the electric vehicle’s charge port, which is converted to DC through the PEU which then charges the RESS. The motorcycle charging port in some markets provides primary EVSE theft resistance feature via an inlet lock pin commanded by the PEU.
Electric Vehicle Supply Equipment (EVSE), Level 1 Charging
The EVSE is also commonly referred to as the vehicle charging cord. The EVSE includes the connection to the outlet, the cable and the connection to the motorcycle.
- The supplied EVSE is intended only for this motorcycle.
- Do not use EVSE if there is any cracking or damage to the unit, the EVSE cable or the connector. Do not attempt to repair. Replace EVSE if damaged.
WARNINGTo avoid risk of fire or electric shock, only use the supplied EVSE when charging motorcycle. Fire or electric shock could result in death or serious injury.
- Do not use EVSE with an extension cord.
- Charge the motorcycle in a well-ventilated area.
- Make sure connectors are fully inserted into the outlet and motorcycle.
- Do not allow charging equipment to be immersed in water or liquids.
- Do not put fingers, jewelry or other metal objects in charging socket.
- Use a dedicated, properly grounded, AC outlet protected by a circuit breaker.
- Observe charging for several minutes before leaving the motorcycle unattended to ensure the vehicle is charging as expected.
On Board Charger (OBC)
WARNINGRisk of electric shock or burn. Do not touch with fingers, jewelry or other metal objects. Only to be serviced by a qualified technician. Failure to follow instructions can result in death or serious injury. (08804b)
The EVSE connects to the vehicle inlet/charge receptacle which supplies charging power to the OBC.
- If motorcycle is not equipped with a battery tender connector, then remove battery from motorcycle prior to charging. See Maintenance → INSPECT BATTERY.
- Do not recharge battery if voltage is below 8 V to prevent hazardous situations. Charging a deep discharged battery can cause release of smoke, gas and liquids.
- To prevent damage to the battery, the charging voltage should NEVER be higher than 14.4 V.
- Do not overcharge. In case of overcharging, a degassing event with smoke generation could occur.
- Do not connect the battery directly to an AC outlet.
- Only charge or discharge the battery in a well-ventilated area.
- Always use a lithium-ion battery specific battery charger to charge the lithium-ion battery, ensure charging voltage is between 14.2 V and 14.4 V.
When charging 12 V Lithium-Ion Battery:
ELECTRIC VEHICLE CRASH OR DAMAGE
DANGERThis vehicle contains a high voltage Rechargeable Energy Storage System (RESS). An improperly handled or damaged RESS can cause electrical shock and/or fire, which will result in death or serious injury.
- RESS must only be serviced by a qualified technician using proper Personal Protective Equipment (PPE).
- Do not touch RESS connecter terminals with fingers, tools, jewelry, or other metal objects.
- Do not disconnect, disassemble, or use RESS for other than its intended use.
- Improper charging, impact or exposure to fire can damage the RESS.
- A damaged RESS can leak electrolyte and/or generate flammable gas.
DANGERA damaged Rechargeable Energy Storage System (RESS) can leak electrolyte. Contact with electrolyte will cause serious chemical burns or blindness.
- Always wear proper Personal Protective Equipment (PPE) while handling RESS.
- If electrolyte comes in contact with eyes, skin, or clothing, rinse affected area with clean water and seek medical attention immediately.
- See Safety Data Sheet (SDS) for more details available at sds.livewire.com.
WARNINGMisused or abused lithium-ion batteries can get hot, explode or ignite, or potentially release gas, smoke or liquid. Always follow battery safety precautions. Misuse or abuse of lithium-ion batteries could result in death or serious injury. (07729b)
In the event of a crash, always handle as though the electric vehicle's high voltage system is charged and powered up. Stay clear of the motorcycle and contact an emergency response team to evaluate the vehicle. Damage to a high voltage battery may result in immediate or delayed release of toxic/flamable gases and/or fire.
In the Event of Contact with Internal Battery Contents
WARNINGContact with internal battery contents can have serious health effects. Wear protective face shield, rubberized gloves, respiratory protection, and protective clothing when handling damaged batteries. Failure to wear proper protective gear while handling a damaged battery could result in death or serious injury.
See Safety Data Sheet (SDS) for more details available at sds.livewire.com (12209b)
General information: The following first aid measures are required only in case of exposure to internal battery contents after damage of the external battery casing.
Table 2. Battery Electrolyte Antidote
Physical Location | Procedure |
|---|---|
After Inhalation |
|
After Contact with Skin |
|
After Contact with Eyes |
|
After Ingestion |
|