Special Tools
| Description | Part Number | Qty. |
|---|---|---|
| DIGITAL TECHNICIAN II | HD-48650 | 1 |
| 1. | Figure 2 Install two chains and a strap attach them in the same manner as removal. | |
| 2. | Lift the Rechargeable Energy Storage System (RESS) (7). | |
| 3. | Install the Power Electronics Unit (PEU) (9) and make electrical connections. See High-Voltage System → POWER ELECTRONICS UNIT (PEU). | |
| 4. | Place a fat jack on the lift behind the front wheel. | |
| 5. | Figure 2 Lift the RESS, with the aid of a second person push the RESS forward to attain the proper orientation for installation, and over the fat jack. | |
| 6. | With the RESS held forward, extend the jack up under the PEU to securely support the weight of the RESS. | |
| 7. | Adjust the height of the hoist to align the RESS mounting holes to the steering head assembly (11). | |
| 8. | Install washers and screws (12). Tighten. Torque: 40–44 N·m (30–32 ft-lbs) Steering head screws | |
| 9. | Remove hoist (2), ratchet strap (10), bolts (6) and chains (5). | |
| 10. | Release front brake. | |
| 11. | Figure 1 Install seat bracket tab (2) and screws (1). Tighten. Torque: 5–7 N·m (44–62 in-lbs) Ground screw | |
| 12. | Install Inertial Measurement Unit (IMU). See Electrical → INERTIAL MEASUREMENT UNIT (IMU). | |
| 13. | Install front electrical caddy. See Electrical → FRONT ELECTRICAL CADDY. | |
| 14. | Install electric motor. See Electric Vehicle Powertrain (EVPT) → ELECTRIC MOTOR. | |
| 15. | Connect low voltage PEU connections and install cover. | |
| 16. | Connect electric motor to coolant pump hose and battery charger to electric motor coolant hose. See Cooling System → COOLANT HOSES. | |
| 17. | Attach Anti-lock Braking System (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. | |
| 18. | Install tail section. See Chassis → TAIL SECTION. | |
| 19. | Install rear harness and secure grounds. See Electrical → REAR WIRE HARNESS. | |
| 20. | Route harness and rear brake assembly the right side of the bike. | |
| 21. | Route rear brake reservoir over the shock guard. | |
| 22. | Install rear fork assembly. See Chassis → REAR BRAKE MASTER CYLINDER. | |
| 23. | Install right rider footrest and brake master. See Chassis → RIDER FOOTRESTS. | |
| 24. | Install rear caliper. See Chassis → REAR BRAKE CALIPER. | |
| 25. | Make LPM electrical connections. | |
| 26. | Connect onboard charger (PEU) LV and HV connections. See High-Voltage System → POWER ELECTRONICS UNIT (PEU). | |
| 27. | Install jiffy stand. See Chassis → JIFFY STAND. | |
| 28. | Lower bike to place weight on rear wheel and adjust drive belt. See Maintenance → INSPECT AND ADJUST DRIVE BELT AND SPROCKETS. | |
| 29. | Remove fat jack from under PEU. | |
| 30. | Install battery. See Maintenance → INSPECT BATTERY. Voltage: 12 V | |
| 31. | Fill and bleed cooling system. See Cooling System → COOLANT. | |
| 32. | Install bottom pan. See Chassis → BOTTOM PAN. | |
| 33. | Install left side foot control. See Chassis → RIDER FOOTRESTS. | |
| 34. | Install splash guard. See Chassis → SPLASH GUARD. | |
| 35. | Install rear cover. Remove rear cover. See Chassis → REAR COVER. | |
| 36. | Install belt guards. See Chassis → BELT GUARDS. | |
| 37. | Install top cover. See Chassis → TOP COVER. | |
| 38. | Check and update software using Digital Technician II (DT II). Special Tool: DIGITAL TECHNICIAN II (HD-48650) | |
| 39. | Marry battery to vehicle using DT II. Special Tool: DIGITAL TECHNICIAN II (HD-48650) | |
| 40. | Install right side foot cover. | |
| 41. | Install seat. See Chassis → SEAT. |
| 1 | Screws (2) |
| 2 | Seat bracket tab |
Figure 1. Seat Bracket Tab
| 1 | Arm |
| 2 | Hoist |
| 3 | Hole |
| 4 | Washer |
| 5 | Chains and L-brackets |
| 6 | Bolts (2) |
| 7 | RESS |
| 8 | Screws (4) |
| 9 | PEU |
| 10 | Ratchet strap |
| 11 | Steering head assembly |
| 12 | Screws (4) |
Figure 2. RESS Assembly