Reference for Electric Motorcycle / Scooter Assembly Process

This two-wheel electric motorcycle / scooter assembly process, aligned with top domestic manufacturers’ standards, follows a systematic workflow centered on the frame, adhering to “mechanics first, electronics second; inner parts first, outer parts later” principles. Starting with pre-assembly preparation (material sorting, tool calibration), it proceeds through 10 core stages: chassis pre-assembly, motor/transmission fitting, suspension installation, wheel/brake assembly, steering/control component mounting, electrical harness laying, battery/controller fitting, instrument/lighting setup, exterior part assembly, and final commissioning. Each step enforces strict quality checks—such as torque control (±5% error), dimensional accuracy (e.g., 0.3mm frame fixture tolerance), and functional testing (speed limit ≤25km/h, braking distance ≤4m at 20km/h). Post-assembly road tests and traceability coding ensure 100% compliance with national standards and product quality consistency.

Electric Motorcycle Assembly
Electric Scooter Assembly Process

Two-wheel Electric Scooter Assembly Process (Top Domestic Manufacturer Standard)

1

Pre-assembly Preparation StageMaterials/Equipment

Complete material sorting and tooling calibration according to work orders to prepare for assembly

  • Material sorting: SPS material distribution system sorts parts according to BOM, key parts (battery/motor) are scanned for traceability, AGV delivers to workstations
  • Part pre-processing: Apply lubricating grease to motor shafts/bearings, clean wire harness connectors, test battery voltage
  • Equipment calibration: Calibrate torque wrenches and detectors before shift, torque error ≤±5%; Level frame fixtures (error ＜0.3mm)
Quality Check Points: No damage or deformation of parts, complete tool calibration records, battery voltage meets calibrated value
2

Frame Loading and Chassis Pre-assemblyMechanical Foundation

Take the frame as the core carrier to complete the pre-assembly of basic chassis components

  • Hoist the frame to the positioning fixture and lock it to prevent assembly displacement
  • Install frame bottom nut seats, wire harness rubber sleeves, motor suspension brackets, battery compartment brackets
  • Pre-tighten bolts according to specified torque to ensure accurate installation benchmarks
Quality Check Points: No virtual welding/cracks in frame welding, no slipping in threaded holes, battery compartment size matches battery specifications
3

Motor and Transmission System AssemblyCore Power

Complete the assembly of core power components to ensure smooth transmission

  • Hub motor: Install into rear fork, tighten motor shaft nut (torque 45-50N·m), add phase line protective sleeve
  • Mid-mounted motor: Hoist to bracket, install chain/sprocket, adjust sag to 10-15mm, add anti-chain drop device
Quality Check Points: Motor rotates without jamming, no damage to phase line connectors, no interference of transmission parts
4

Suspension and Support Components AssemblyRunning System

Assemble shock absorption and support components to ensure driving stability

  • Front shock absorber: Insert into steering column connecting plate, tighten bolts (30-35N·m), adjust damping to factory value
  • Rear shock absorber: Connect frame and rear fork to ensure smooth expansion and contraction (single/double shock absorber adapted to models)
  • Install main/side stands, adjust angle to ensure stable parking, no jamming in rebound
Quality Check Points: No leakage of shock absorbers, no resistance in front and rear wheel swing, reliable support of stands
5

Wheel and Brake System AssemblySafety System

Complete wheel installation and brake system commissioning to ensure driving safety

  • Front wheel assembly: Install into front shock absorber, tighten axle nut (40-45N·m), install fender
  • Disc brake: Install caliper/brake disc (gap 0.1-0.2mm), drain air from oil pipe, firm hand feel
  • Drum brake: Adjust cable tightness, brake handle stroke in 1/3-1/2 range
  • Tire inflation: Front 2.0bar, rear 2.2bar (2.3-2.5bar for load-bearing models)
Quality Check Points: No wheel runout, sensitive brake response, no interference of oil pipes/cables
6

Steering and Control Components AssemblyControl System

Assemble steering and control components in accordance with ergonomic design

  • Install handlebars, handlebar switches, throttle grip, handle angle 15°-20°
  • Connect throttle Hall signal wire, adjust cable tightness to ensure smooth return
  • Install rearview mirrors, adjust field of view, tighten to prevent loosening
Quality Check Points: No jamming in steering, normal switch rebound, linear throttle stroke
7

Electrical System Main Harness LayingElectrical Foundation

Complete main harness laying and connection of core electrical connectors

  • Lay main harness according to wiring slot, fix with cable ties (spacing 20-30cm) to avoid friction/pulling
  • Connect motor phase lines (red/yellow/blue) with controller, tighten wiring terminals
  • Install fuse box/relay, fuse specification matches (e.g. 48V20Ah with 20A)
Quality Check Points: No distortion or extrusion of wire harness, locked connectors, correct fuse specifications
8

Battery and Controller AssemblyElectronic Control Core

Complete assembly of core electronic control components to ensure electrical matching

  • Battery installation: Put into battery compartment, connect positive pole first then negative pole, lock fixing strap to prevent displacement
  • Controller installation: Fix in controller box/frame, add waterproof sleeve, connect all connectors
  • Connect BMS wire harness to ensure normal communication
Quality Check Points: Normal battery voltage, firm controller fixation, waterproof connectors
9

Instrument and Lighting System AssemblyElectrical Accessories

Complete assembly of instrument and lighting system to ensure normal functions

  • Install instrument panel, test normal display of power/speed/fault code
  • Assemble headlight/turn signal/tail light, adjust headlight irradiation angle (height 0.8-1.0m at 10m)
  • Install horn and USB charging port, test stable power supply
Quality Check Points: Normal lighting of lamps, loud horn, stable power supply of USB interface
10

Exterior Parts AssemblyInterior & Exterior Trim

Complete assembly of interior and exterior trim parts to ensure appearance consistency

  • Pre-assembly: Foot pedals, seat lock, battery compartment cover, inner panel brackets
  • Final assembly: Side panels, front panel, rear skirt, fixed with buckles/bolts (plastic part torque 8-10N·m)
  • Install seat, paste nameplate/3C certification mark/warning signs
Quality Check Points: Uniform gap of exterior parts (＜0.5mm), no scratches or deformation, flat pasting of marks
11

Vehicle Commissioning and Off-line InspectionFinal Inspection

Complete vehicle function commissioning and compliance inspection to ensure factory qualification

  • Power-on self-test: No fault code on instrument, normal functions of lights/horn/brake power-off
  • Power test: Smooth rotation of rear wheel, sensitive brake power-off, calibrated speed limit ≤25km/h
  • Road test: Smooth acceleration, braking distance ≤4m (20km/h), no deviation
  • Final inspection and rectification: Full inspection of appearance/function/torque, rectify unqualified items offline
  • Cleaning and packaging: Clean the whole vehicle, add protection, scan code for warehousing and traceability
Quality Check Points: 100% normal functions, no abnormal noise or leakage, parameters meet national standards, complete traceability code generation

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