UBCO 2x2 ADV Gen 5 Operating manual
Technical
Service Manual
Version 1.0
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October
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UBCO TECHNICAL SERVICE MANUAL PAGE 2 OF 159
TABLE OF CONTENTS
1 General Information
1.1 General Information And Disclaimers . . . . . . . 7
1.2 Bike Identification. . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Brake System Identification. . . . . . . . . . . . . . . . 9
1.4 Required Tools and Consumables . . . . . . . . . . . 11
1.5 Bike Orientation . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Model Specifications
2.1 Model Naming . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Front and Rear Wheel . . . . . . . . . . . . . . . . . . . . 15
2.5 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6 Brakes - Sys 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 Brakes - SR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.8 Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.9 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.10 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . 17
3 Service Information
3.1 Component Reuse . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . 19
3.3 Application of Threadlocker . . . . . . . . . . . . . . . 19
3.4 Standard Torque Settings . . . . . . . . . . . . . . . . 19
UBCO TECHNICAL SERVICE MANUAL PAGE 3 OF 159
3.5 Use Of Cable Ties . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6 Brake Component Handling . . . . . . . . . . . . . . . 20
4 Service Checks, Adjustments and Processes
4.1 Sys 2 - Checking Brake Fluid Level . . . . . . . . . 22
4.2 Sys 2 - Bleeding / Replacing Brake fluid. . . . . 23
4.3 Sys 2 - Inspecting Brake Pads . . . . . . . . . . . . . 25
4.4 Sys 2 - Inspecting Brake discs . . . . . . . . . . . . . 26
4.5 SR - Checking Brake Fluid Level . . . . . . . . . . . 27
4.6 SR - Bleeding / Replacing Brake Fluid . . . . . . 28
4.7 SR - Adjusting Brake Calipers . . . . . . . . . . . . . 31
4.8 SR - Inspecting Front or Rear Brake Pads. . . 33
4.9 SR - Inspecting Brake Discs . . . . . . . . . . . . . . . 34
4.10 SR - Adjusting Lever Blades . . . . . . . . . . . . . . . 35
4.11 Adjusting Front Suspension Settings . . . . . . . 36
4.12 Adjusting Rear Suspension Settings. . . . . . . . 37
4.13 Recommended Suspension Settings . . . . . . . 39
4.14 Inspecting Tyres . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.15 Inspecting & Adjusting Wheels. . . . . . . . . . . . . 41
4.16 Adjusting Headlamp Beam. . . . . . . . . . . . . . . . 43
4.17 Charging the Battery. . . . . . . . . . . . . . . . . . . . . 45
5 Removal and Replacement Operations
5.1 Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.2 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
UBCO TECHNICAL SERVICE MANUAL PAGE 4 OF 159
Sys 2 - Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Sys 2 - Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Sys 2 - Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Sys 2 - Brake Master Cylinder . . . . . . . . . . . . . . . . . . 58
Sys 2 - Front Brake Line . . . . . . . . . . . . . . . . . . . . . . .60
Sys 2 - Rear Brake Line . . . . . . . . . . . . . . . . . . . . . . . . 62
Sys 2 - Front Brake Set . . . . . . . . . . . . . . . . . . . . . . . . 64
Sys 2 - Rear Brake Set . . . . . . . . . . . . . . . . . . . . . . . . 66
SR - Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SR - Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
SR - Front or Rear Brake Caliper . . . . . . . . . . . . . . . 71
SR - Front or Rear Brake Master Cylinder . . . . . . . 73
SR - Front Brake Line . . . . . . . . . . . . . . . . . . . . . . . . . 75
SR - Rear Brake Line . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SR - Front Brake Set . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SR - Rear Brake Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.3 Steering and Suspension. . . . . . . . . . . . . . . . . . 83
Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Disassemble Front Fork . . . . . . . . . . . . . . . . . . . . . . . 86
Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Rear Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . .90
Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Steering Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Lever Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.4 Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Front Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Front Console Cover . . . . . . . . . . . . . . . . . . . . . . . . . 102
Front Console Rear Panel . . . . . . . . . . . . . . . . . . . . 104
Rear Console Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Rear Console Rear Panel . . . . . . . . . . . . . . . . . . . . .108
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Front Mudguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
UBCO TECHNICAL SERVICE MANUAL PAGE 5 OF 159
Swing Arm Mudguard . . . . . . . . . . . . . . . . . . . . . . . . 113
Rear Mudguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Kickstand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Footpegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Sys 2 - Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
SR - Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.5 Electronics and Controls . . . . . . . . . . . . . . . . . 122
KxH Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Battery Plug Harness . . . . . . . . . . . . . . . . . . . . . . . . 125
On Road Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Left Hand Switch Block . . . . . . . . . . . . . . . . . . . . . . 130
Throttle/Kill Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Front Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Rear Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Tailight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
VMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Front Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Rear Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.6 Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Motor Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Planetary Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Motor Bearings and Seals . . . . . . . . . . . . . . . . . . . . 158
UBCO TECHNICAL SERVICE MANUAL PAGE 6 OF 159
1 GENERAL INFORMATION
UBCO TECHNICAL SERVICE MANUAL PAGE 7 OF 159
1.1 GENERAL INFORMATION AND DISCLAIMERS
Please read this disclaimer carefully before using the technical repair manual. By
accessing and utilizing this manual, you acknowledge and agree to the following
terms and conditions:
1. USE AT YOUR OWN RISK: This technical repair manual is provided for informa-
tional and educational purposes only. The information contained herein is
intended for skilled technicians and professionals who have the necessary
tools, equipment, and expertise to safely and accurately perform the repairs
described. The use of this manual is entirely at your own risk, and the manual's
publisher, authors, and contributors shall not be held liable for any damages or
losses arising from its use.
2. PROFESSIONAL GUIDANCE: This manual is not a substitute for professional
advice, diagnosis, or repair services. It is essential to consult with an UBCO
certified technician or manufacturer-approved service personnel when dealing
with complex technical repairs or maintenance tasks. The manual is meant to
complement, not replace, professional expertise.
3. APPLICABILITY: The procedures and instructions in this manual are generic in
nature and may not be suitable for all devices, equipment, or situations.
Always refer to UBCO documentation or guidelines for device-specific repair
instructions and specifications where available.
4. SAFETY PRECAUTIONS: Motorcycle repairs can be dangerous and may involve
exposure to electrical hazards, moving parts, and other potential risks. Prior to
attempting any repair, please ensure that you are adequately trained and
equipped with the necessary safety gear. Follow all safety warnings provided
by the manufacturer as well as industry health and safety guidelines.
5. WARRANTY IMPLICATIONS: Attempting repairs on a product covered by a war-
ranty or service agreement may void such coverage. Always check UBCO’s
warranty terms and conditions before undertaking any repair work.
6. COPYRIGHT AND INTELLECTUAL PROPERTY: This technical repair manual is
protected by copyright law. You may use it for personal, non-commercial pur-
poses only. Reproduction, distribution, or modification of the manual's con-
tent for commercial use is prohibited without prior written consent from the
copyright holder.
7. ACCURACY AND UPDATES: The information within this manual may become
outdated over time due to evolving technology and product changes. The
authors and publisher do not guarantee the accuracy, reliability, or complete-
ness of the information. It is the user’s responsibility to verify and cross-refer-
ence the information.
UBCO TECHNICAL SERVICE MANUAL PAGE 8 OF 159
8. LIMITATION OF LIABILITY: In no event shall the manual's publisher, authors, or
contributors be liable for any direct, indirect, special, punitive, incidental, or
consequential damages arising from the use of this manual or any informa-
tion contained within.
By using this technical repair manual, you agree to abide by these terms and con-
ditions. If you do not agree to these terms, do not continue to use this manual.
Your use of this manual constitutes your acceptance of these disclaimers and
limitations.
1.2 BIKE IDENTIFICATION
UBCO ADV and WRK bikes are manufactured with a Vehicle Identification Num-
ber (VIN) and Product Identification Number (PIN) respectively. This identifier is
located on the right hand side of the head tube of the frame.
VIN / PIN Location
UBCO TECHNICAL SERVICE MANUAL PAGE 9 OF 159
1.3 BRAKE SYSTEM IDENTIFICATION
The UBCO 2x2 Gen 5 is available with different braking systems.
These are referred to as- “SR” or “SYS 2”
Where there are variations in processes due to these different brake systems,
clear instructions for each system are provided.
These brake systems can be easily identified by component comparison with the
below images.
SR
UBCO TECHNICAL SERVICE MANUAL PAGE 10 OF 159
SYSTEM 2
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