V2 Key Lock - Service and Install

For VoltBike models:

Elegant V2, Bravo V2, Yukon V2,

Venture, Outback V2, Elite, Mariner V2, Urban V2

Tools/ Parts required:

Number 1 Phillips screwdriver

T30 Torx tool

Introduction

The VoltBike V2 bikes use a new modern frame design that allows the battery and the key lock to be out of sight and integrated into the downtube of the frame. This design uses four variations of a new key lock depending on which V2 model of bike. Like any key lock, they are subject to wear from repeated use and the unfortunate possibility of lost or broken keys. The key is only required to remove the battery from the bike frame for V2 models and is not required to turn on or operate the bike. Typically, the key needs to be turned to the unlock position, and then the battery or frame lever turned to fully release and remove the battery. This allows the rider to remove the battery for charging or storage or viewing the LED indicator.

Keep your second spare key safe in a separate location. If your key is lost or broken, you can note the three-digit code on the key lock. Under some circumstances a spare key can be sourced or cut with this code. Different keys from one bike to another are not compatible and will not allow you to remove the battery from the bike. Bent keys are best to be straightened by carefully flattening them in a bench vice.

V2 Key Lock Types

V2 Venture

V2 Mariner, V2 Urban

Note: Aluminum mounting bracket not shown. Yukon Elite key lock not shown

V2 Yukon, V2 Bravo, V2 Elegant ,V2 Outback

Troubleshooting – Inserting and Removing the battery

Typically, the key needs to be turned to the unlock position, and then the battery or frame lever turned to fully release and remove the battery. This allows the rider to remove the battery for charging or storage or viewing the LED indicator.

Note: For some models the latch or lever may be part of the battery, frame, or key lock.

For sticky key or locks: Occasionally an alignment issue or a binding key lock mechanism may affect how easily the battery can be installed or removed from the bike frame. A high-quality thin lubricant (Tri-flow) can be used on the key surface, inside the key slot, and on the battery and frame’s locking mechanism and latches. The frame's mounting bolts, or battery latch may need to be loosened and re-aligned slightly to ensure smooth fit and release.

New Key Lock Installation

Note: There may be minor variations to installation procedure depending on the bike model.

In case of a damaged lock, broken or lost keys, the frame’s lock mechanism may need to be removed from the frame and a completely new key lock, or a new tumbler installed. First remove the battery and hold the power button on till the screen flashes to ensure the controller is fully discharged.

If the release lever is connected through the bike frame, (Venture) use a small Phillips screwdriver to remove the small bolt and release lever. For other models the release lever is part of the battery.  A black plastic cable cover that sits between the upper lock and lower battery mount should be removed if present.

Next: use a T30 Torx tool to remove the two (or three) countersunk bolts that locate and fasten the aluminum mounting bracket or lock inside the downtube.

Once the aluminum mounting bracket and plastic key lock have been uninstalled from the frame, the four small screws that hold the lock to the aluminum bracket can be bracket.

Replacing the tumbler

Under some circumstances a new lock will not be required, just a new tumbler and matching key can be replaced. Once the key lock unit has been removed from the bike frame, a Phillips screwdriver can be used to carefully remove the tumbler from the plastic housing.

Ensure the small plates of the new tumbler are in place, insert and turn the key to the correct position to slide the tumbler into the plastic housing. Check the new key action is working correctly and move the orange locking pin before re-installing the small bolt on the backside. The V2 models: Yukon, Mariner, Bravo, Elegant, Outback, and Urban all use the same style of tumbler.               

Reinstalling the key lock in the frame

Carefully position the new key lock up inside the frame with the key slot centered in the frames side hole. Visually align the two threaded mounting holes with the countersunk holes in the downtube. Use a T30 Torx tool to carefully thread each bolt part way while checking the alignment and that the lock is seated correctly.

Final Check

Before tightening the bolts to a hard stop, insert the battery to confirm the alignment, and test the key lock by installing and removing it a few times. Once the action seems good the bolts can be tightened firmly in the frame. Approx. torque is 5-6 N*m. Ensure the battery is secure and locked in the frame before test riding the bike. Failure to follow this warning may result in personal injury or death, and/or loss of property!

Re-check bolts after 12 hours of riding time.

Countersunk bolts: M6 x 12mm