Razor MX500/MX650 Front Fork Replacement Instructions
Part #: W15128190023
Required Tools: (Not included)
- A. 4 mm Allen wrench
- B. 5 mm Allen wrench
- C. 6 mm Allen wrench
- D. 10 mm wrench
- E. 16 mm wrench
- F. 17 mm wrench
- G. Cutting pliers
- H. Phillips screwdriver
WARNING
CAUTION: To avoid potential shock or other injury, turn power switch OFF and disconnect charger before performing any assembly or maintenance procedures. Failure to follow these steps in the correct order may cause irreparable damage.
Step 1
Remove the two (2) Allen bolts under the seat using a 5 mm Allen wrench and a 10 mm wrench to hold the nut from the bottom and then remove the fairing away from the unit.
[Diagram Description: Underside of the scooter seat area showing bolts to be removed and the fairing.]
Step 2
Remove the two (2) Allen bolts under the seat using a 5 mm Allen wrench and a 10 mm wrench to hold the nut from the bottom and then remove the fairing away from the unit.
[Diagram Description: Similar to Step 1, illustrating the removal of bolts and fairing.]
Step 3
Remove the four (4) Phillips screws that hold the battery cover, two (2) at the bottom and two (2) at the front. Also remove the two (2) 4 mm Allen bolts on the top of the battery cover.
[Diagram Description: Battery cover shown with circled locations of Phillips screws and 4 mm Allen bolts.]
Step 4
Follow the brake lever and throttle wires and disconnect them from the control module. Cut the zip tie and remove the cable wrap. Set cable wrap aside. Gently pull the wires through the hole in the number plate.
[Diagram Description: Scooter wiring harness, showing wires being disconnected from a control module and routed through a hole in the number plate.]
Step 5
Using a 6 mm Allen wrench, loosen and remove the four (4) bolts from the handlebar clamps. Using a Phillips screwdriver, remove the screw from the front of the number plate.
[Diagram Description: Handlebar area showing clamps and bolts, and the front of the number plate with a screw.]
Step 6
Using a 5 mm Allen wrench and a 10 mm wrench, remove the locknut and bolt that holds the number plate and fender onto the fork and remove.
[Diagram Description: Front fork area showing the number plate and fender attached by a bolt and locknut.]
Step 7
Using a pair of cutting pliers, carefully pinch the silver end cap at the end of the brake cable and remove. Set end cap aside. Using a 5 mm Allen wrench, loosen the anchor bolt just enough to allow you to pull the brake cable out from the brake caliper.
[Diagram Description: Close-up of the brake caliper and cable, showing the end cap and anchor bolt.]
Step 8
Using a 6 mm Allen wrench and a 17 mm wrench, remove the steering bolt. With a 16 mm wrench, loosen up and remove the bolts from the fork and remove the fork.
[Diagram Description: Fork assembly showing the steering bolt, fork bolts, and the fork being detached.]
Step 9
Reverse the procedures:
- Reinstall the fork and steering bolt.
- Reattach the silver end cap and retighten the brake cable.
- Reattach the fender and number plate.
- Reattach handlebar clamps.
- Reattach cable wrap and push through hole in number plate.
- Reattach battery cover and fairing.
Attention: Charge battery for 12 hours before using.
Need Help?
Visit our website at www.razor.com or call toll-free at 866-467-2967 Monday - Friday 8:00 AM - 5:00 PM PST.
