WARNING!- If You don’t have suffcient mechanical knowledge, experience and proper tools, we strongly recommend, that You have these operations done by Your selling dealer or at Your local motorcycle service center! Making mistake during the disassembly or assembly of the electric system will void the warranty and may cause a hazardous situation, resulting in fire, severe injury or death and damage to property.
- For safety reasons it is strongly recommended to leave the battery discharged before handling any component of the motorcycle's electrical system!
- Do not let the battery to stay fully discharged for longer than neccessary, as it may have a negative impact on its capacity. Charge the battery after each ride.
Table of contents:- Unproper charging procedure and/or frequency
- Using the motorcycle at temperatures out of recommended range
- Faulty charger, charge port or battery
1. Unproper charging procedure and/or frequency
CAUTION!- Some charge ports have rotatable cap - rotate it to open the charge port. Other charge ports have a rubber cover - unplug the cover to open the charger port.
- Be sure to use the correct charger. Lead-Acid and Li-Ion versions of Start/Trial/Cross (MY2024 and newer) use the same charge port, but the charging curve and voltage is specific for each battery.
- New battery needs several discharging and charging cycles to reach its full capacity.
- If the charger is plugged into the motorcycle with the charger switched OFF, a potential inward rush of electrical current from the motorcycle’s battery may damage the charger.
- Optimum charging and storage temperature is 50 - 77 °F (10 - 25 °C). Do NOT charge the battery, if the temperature is out of this range. Too low or high temperature may permanently damage the battery.
Follow these steps to charge the motorcycle:- Ensure, that the magnetic kill switch is in OFF position (magnet NOT attached).
- Connect the charger to an electrical outlet. The LED on the charger will glow blue (Lead-Acid battery charger) or green (Li-Ion battery charger).
- Connect the charger to the charge port on the motorcycle. The LED on the charger will glow red (Lead-Acid battery charger) or yellow (Li-Ion battery charger).
- When charging is finished, the LED on the charger will glow green.
Frequency and duration of battery charing:- The Lead-Acid battery in Start consists of 2 batteries, each with 12 V nominal voltage (above 14 V fully charged), connected in series. The Lead-Acid battery in Trial/Cross consists of 3 batteries, each with 12 V nominal voltage (above 14 V fully charged), connected in series. The Li-Ion battery consists of 1 battery, enclosed in a metal box. Every KUBERG battery for Start/Trial/Cross has a rubber surface from below to prevent abrasion between the frame and a battery and to minimize the risk of formatting an impact cracks.
- Charging time may vary depending on the battery type, supplied battery charger, state of charge, ambient and battery temperature and state of health of the battery.
- The Li-Ion battery has an advanced battery management system (BMS), which monitors each cell voltage, currents, temperatures etc.
- The Lead-Acid battery in Trial/Cross can be upgraded to Li-ion battery.
Lead-Acid battery charging:
- Fully charge the battery before the first ride.
- Fully charge the battery after each ride.
- Fully charge the battery after every 60 days of storage.
Li-Ion battery charging:- Fully charge the battery before the first ride.
- Fully charge the battery after each ride.
- Fully charge the battery every 90 days of storage.
2. Using the motorcycle at temperatures out of recommended range
Recommended operating temperatures:- 41 - 95 °F (5 - 35 °C) for Lead-Acid battery
- 32 - 95 °F (0 - 35°C) for Li-Ion battery
Recommended storage and charging temperatures: Very cold weather is hard on the motorcycle’s electrical system and may cause, that the battery charge won’t last as long as at temperatures around 20 °C. Furthermore a Lead-Acid battery is more influenced by low temperature than a Li-Ion battery.
3. Faulty charger, charge port or battery
Follow these steps to check the function of each part:
Required tools:- hex wrench #3
- hex wrench #4
- hex wrench #5
- hex wrench #6
- Torx wrench #T25
- multimeter
- brush
- technical alcohol
- compressed air source with moisture separator
- Make sure, that the magnetic kill switch is in OFF position (magnet NOT attached).
- Place the motorcycle on a solid and level surface of a mounting stand, so that both wheels are on the ground.
- Connect the charger to an electrical outlet. The LED on the charger will glow blue (Lead-Acid battery charger) or green (Li-Ion battery charger). If the charger have no visible LED indication, even if it has a LED, then it is probably faulty.
- (Only for Start/Trial/Cross): Measure the charger output voltage – it should be approx. 44.5 V for Lead-Acid battery charger and approx. 42 V for Li-Ion battery charger. If the charger has very different output voltage (difference greater than 1.5 V), or the output voltage is measurable only when its connector is in specific position, the charger or its connector may be faulty.
- Connect the charger to the charge port on the motorcycle. The LED on the charger will glow red (Lead-Acid battery charger) or yellow (Li-Ion battery charger). If the LED colour does NOT change after connecting, the charge port may be either disconnected from the battery, or it may be faulty (skip step #6 and see below).
- Charge the battery to 100%, then disconnect the charger from the motorcycle and note the current time. When charging is finished, the LED on the charger will glow green. If the charging process will not finish even after 12 hours, the charger or battery may be faulty.
Follow these steps to uncover the motorcycle battery and charge port:
- (Only for Ranger): Using the hex wrench #3 loosen and remove the 2 bolts holding the inspection lid (from below the frame, just above front fender) and remove the inspection lid from the motorcycle.
- (Only for Ranger): Using the hex wrench #3 loosen and remove 3 bolts from the left frame cover (above battery) and put the cover aside.
- (Only for FreeRider): Using the hex wrench #5 loosen and remove the bolt holding the upper controller cover (just by the steering stem) and remove the cover from the motorcycle.
- (Only for FreeRider): Using the hex wrench #4 loosen and remove the lower one of the 2 bolts, that are located on the front metal cover of the battery.
- (Only for FreeRider): Using the hex wrench #6 loosen and remove the bolt on the left side of the seat section frame.
- (Only for FreeRider): Grasp the seat section frame with both hands and gently pull it to lift it up and slightly backwards.
- (Only for Challenger): Using the hex wrench #3 loosen and remove 2 bolts on the right side panel and gently slide this panel up to remove it.
- (Only for Cross/X-Force): Using the hex wrench #6 loosen and remove the underseat bolt, located on the underside of the upper plastic bodywork (above the rear wheel), slide the seat forward and remove it from the motorcycle.
- (Only for Cross/X-Force): Using the Torx wrench #T25 loosen and remove the upper 4 bolts from the left and right plastic bodywork (2 on the left side + 2 on the right side).
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- (Only for Start/Trial/Cross/X-Force): Remove the upper plastic bodywork by gentle pull up.
- (Only for Start/Trial/Cross/X-Force): Using the Torx wrench #T25 loosen and remove the 4 additional bolts from the left and right plastic bodywork (2 on the left side + 2 on the right side) and with a light frame tilt on the mounting stand remove both plastic bodyworks.
NOTE:
The Lead-Acid battery of Start/Trial/Cross consists of 3 batteries, each with 12 V nominal voltage (above 14 V fully charged), connected in series. Every KUBERG battery for Start/Trial/Cross has a rubber surface from below to prevent abrasion between the frame and a battery and to minimize the risk of formatting an impact cracks. The Li-Ion battery for all other KUBERG motorcycles consist of 1 battery, enclosed in a metal box.
- If You were able to charge the battery, wait 1 hour from the moment of disconnecting the charger from the motorcycle, then measure the DC voltage of the battery:
(Only for Lead-Acid version): Do NOT disconnect any cable and measure the voltage directly on each battery. If the voltage of any battery is below 12 V, consider battery exchange. Optionally You can use a charger with recovery mode to charge each battery separately. When changing batteries, do NOT mix old batteries with new ones! (see knowledgebase article "Battery removal and installation")
(Only for Li-Ion version of Trial/Cross): Disconnect the main red battery connectors and measure the battery voltage directly on battery poles. If the voltage is below 34 V, consider battery exchange. (see knowledgebase article "Battery removal and installation")
(Only for Ranger/Challenger/FreeRider/X-Force): Disconnect the main red and black battery connectors, turn the kill switch ON and measure the battery voltage directly on battery poles and in the charge port pins. If the voltage is below 42 V, consider battery exchange (see knowledgebase article "Battery removal and installation"). If the voltage difference measured on the battery connectors and in the charge port is greater than 0.7 V, please contact Your selling dealer or the KUBERG Customer Service.
- Disconnect the charge port and clean it properly with a brush, technical alcohol and pressurized air.
NOTE:
Start/Trial/Cross (MY2023 and older) had a switch included in the charge port. If the charger is plugged in, the inner switch is disconnected and the motorcycle is unable to turn ON using the kill switch. If the charger is NOT plugged in, the inner switch is connected, so the motorcycle can be turned ON by the kill switch. If this switch is damaged, the charger is unable to charge the battery, or the motorcycle can NOT be turned ON, or both. The switch function can be temporarily disabled and bypassed by connecting the 2 cables mentioned below.
- (Only for Start/Trial/Cross MY2023 and older): Disconnect the charger from the electrical outlet and keep it this way for the next step.
- (Only for Start/Trial/Cross MY2023 and older): Use a multimeter with the circuit check function. The correct function of the charge port is:
Without the charger connected to the charge port: middle and right pin on the output connector = open circuit
With the charger connected to the charge port: middle and right pin on the output connector = closed circuit
Reinstall the charge port when finished.
Follow these steps to reassemble the motorcycle:
- (Only for Ranger): Reinstall the inspection lid and it 2 bolts, holding the inspection lid on the frame, and using the hex wrench #3 tighten them (5 - 6 Nm).(Only for Ranger): Reinstall the left frame cover with its 3 bolts and using the hex wrench #3 tighten them (5 - 6 Nm).
- (Only for FreeRider): Reinstall the upper controller cover and its bolt and using the hex wrench #5 tighten it (5 - 6 Nm).(Only for FreeRider): Reinstall the seat section frame by slowly sliding its front tube onto the mating piece on the main frame of the motorcycle and at the same time align the bolt holes of the seat section frame with the corresponding threads on the main frame. During this process be very careful to the main power cables - they must NOT deform in any way.
- (Only for FreeRider): Reinstall the bolt to the seat section frame and using the hex wrench #6 tighten it (18 - 20 Nm). You can make this process easier by inserting the hex wrench #6 from the right side of the motorcycle through all the holes and then by pushing the wrench out with the bolt itself.
- (Only for FreeRider): Reinstall the lower one of the 2 bolts, that are located on the front metal cover of the battery, and using the hex wrench #4 tighten it (5 - 6 Nm).
- (Only for Challenger): Reinstall the right side panel and its 2 bolts and using the hex wrench #3 tighten it (5 - 6 Nm).
- (Only for Start/Trial/Cross/X-Force): With a light frame tilt on the mounting stand reinstall the left plastic bodywork and using the Torx wrench #T25 install and tighten the 2 lower bolts (5 - 6 Nm).
- (Only for Start/Trial/Cross/X-Force): Repeat the same step with the right plastic bodywork.
- (Only for Start/Trial/Cross/X-Force): Reinstall the upper plastic bodywork, align its 2 left holes with the holes on the frame and on the left side bodywork, reinstall 2 bolts and using the Torx wrench #T25 tighten them (5 - 6 Nm).
- (Only for Start/Trial/Cross/X-Force): Repeat the same step on the right side.
- (Only for Cross/X-Force): Install the seat by sliding it backward on the bolt, located close to the Torque & Speed control button, and align the hole in the seat and the upper plastic bodywork with its corresponding hole on the frame just above the rear wheel.
- (Only for Cross/X-Force): Install the seat bolt and tighten it using the hex wrench #6 (18 - 20 Nm).
- Double check, that all bolts and nuts are properly tightened.
If Your motorcycle is under warranty, please register it on our website, if You have not already done so:
https://www.kuberg.com/en/bike-registration
If the problem persists, please contact Your dealer or KUBERG customer service (support@kuberg.com). For the fastest possible resolution please send:- VIN of Your motorcycle (it is stamped on the right side of the steering column).
- Detailed information on actions taken so far, a few photos and preferably a video.