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Levo Retailer Technical Guide
Troubleshooting & Diagnosis Guide -
Function Issues
Diagnose Motor Harness & Plug Connections Using Substitute Components
To diagnose motor harness and plug connections, you must remove the left crankarm and left side motor cover. You must also have
spare components, that are known to be in working order, to determine by process of elimination which connections are malfunctioning.
Some connection issues can be repaired by hand, other issues require harness replacement.
Component to
Check
What to Look for Additional Checks/Information
Harness Is there any external damage to the motor
connector?
External damage from previous maintenance/service or
when initially assembled can cause internal damage in the
connector.
Are any of the pins in the motor connector
bent, uneven, or damaged?
If the internal connectors are slightly bent they can be
carefully bent back into place. If they are folded, broken, or
shorter than the others the harness should be replaced.
Is it difficult to reach the battery terminal with
the harness?
Check the position of the harness anchor and move it if
possible. If the harness anchor cannot be adjusted without
placing more stress on the motor connector, measure the
length between plugs. If the distance is 165 mm, replace
the harness with a 180 mm length version.
Does a replacement harness address the
issue?
Speed Sensor Is there any external damage to the speed
sensor connector?
If the plastic plug housing is cracked or damaged, replace
the entire sensor.
Are either of the pins in the speed sensor
connector bent, uneven, or damaged?
If the pins are slightly bent, they may be carefully bent back
into place. Otherwise the speed sensor should be replaced.
Does a replacement speed sensor address
the issue?
Motor Is there any external damage to the
connector housing on the motor?
Look for external damage to the plastic connector housing.
Damage can keep the plugs from full engagement.
Do any of the internal terminals appear to be
damaged or more open than the others?
Female terminals inside the motor connector housing can
be carefully compressed with a sharp pick.
Are any of the blind plugs missing? Ask about service/warranty history. The blind plugs are
included on new bikes but not on replacement motors. Use
in wet conditions without the blind plugs can allow water
entry.
Is there evidence of burning/melting on any
of the blind plugs?
The HMI blind plug has jumpers and a capacitor and is
necessary on the Levo. It is keyed internally to fit in only
one direction but can be forced into place the wrong way.
This can cause the capacitor to burn out and can also
cause internal damage to the motor.
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