Home

Service Document: User Manual G1 - Green

1. WARNING Extreme caution should be used when attempting to touch any part of the motor after it has been in continuous operation for more than five minutes Use the same caution you would use in the kitchen with hot pots or pans or boiling water We recommend that you do not attempt to touch the motor unless it has been switched off for at least five minutes On days when the ambient air temperature is above 25 degrees Celsius be extra careful with heat building up in the motor We do not recommend that you keep the motor on full power for more than 5 minutes continuously You should allow the motor 1 minute of zero power for every 5 minutes at full power 8 3 7 Maximising Your Motor s Performance and Reliability 8 3 7 1 Dos Pedal up hills and keep your speed in the power band of the motor This is about 8 12mph At this speed you will get maximum power from the motor If you are approaching a hill keep your speed above 8mph this will give you the best boost from the motor Allow the motor a minute or two for every 5 minutes of riding to cool down 8 3 7 2 Don ts When riding at temperatures above 25 degrees Celsius do not run the motor for more than 5 minutes continuously If you have run the motor for 5 minutes continuously you should stop running the motor for at least 1 minute before starting the motor again Generally EU mode will produce less heat and provide a higher range than USA mode Further to the a
2. WARNING Wet weather impairs traction braking and visibility both for the cyclist and for other vehicles sharing the road The risk of an accident is dramatically increased in wet conditions To make sure that you can slow down and stop safely in wet conditions ride more slowly and apply your brakes more gradually than you would under normal dry conditions 4 9 Tools Required For Maintenance No Tools Required for Assembly e Headset 40mm flat wrench 1 5mm Allen key e Stem height M4 Allen key e Handlebar stem if your model has a bolted stem to handlebar M4 Allen key e Fork quick release M6 Allen key e Front and rear brake callipers M6 Allen key e Controller M4 button Allen key e Seat clamp M5 Allen key Karbon Kinetics Limited All Rights Reserved 5 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Q e Bottom bracket collar M4 Allen key e PitstopWheel quick releases M4 Allen key e Rear hub bearings 2 14 mm flat wrenches e Front mudguard M4 button Allen key e Rear mudguard Phillips head screwdriver e Front and rear reflectors Phillips head screwdriver 4 10 Pre Ride Checklist You must be able to adhere to all items in the pre ride checklist below within 10 minutes prior to riding a Gocycle Unless you can answer yes to ALL of the questions in this section of the owner s manual do not attempt to operate yout Gocycle The consequence of operating your Gocycle without f
3. Karbon Kinetics Limited All Rights Reserved A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 2 GOCYCLE FRAME NUMBER Your Gocycle comes with a unique identifier called a frame number The frame number along with bar code and required safety standards codes is positioned on the Gocycle as shown below Frame number Safety standards coding Minimum leg height with standard seat post compact seat post available at PER T T BS 6102 1992 EE www gocycle com Karbon Kinetics Ltd EN 14764 2005 UK Reg No 4357956 Bar code brake type frame number and colour FBR front brake Is on right side FBL front brake is on left side Figure 2 1 Gocycle Frame 000301 Karbon Kinetics Limited All Rights Reserved 2 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 3 DISCLAIMER COPYRIGHTS AND TRADEMARKS 3 1 Disclaimer The specifications information and performance of the Gocycle and other products manufactured under license granted by Karbon Kinetics Limited and featured in this document may change without notice Since the use of this information and the conditions by which the products are used are beyond the control of Karbon Kinetics Limited it is the obligation of the buyer and or the rider to determine the correct and safe selection and settings and conditions of use of the products and to periodically check the products for secure and proper ope
4. WARRANTY The warranty applies only to a Gocycle purchased new from KKL or purchased new from a KKL approved reseller and coverage commences from the original date of purchase by the original end user owner Any warranty claim must be made through a KKL approved reseller or directly through KKL Before a claim can be processed the product must be registered with KKL through online registration at www gocycle com setvice Proof of purchase is required KKL warrants the magnesium frame and wheel components of each new Gocycle to be free from defects in material and workmanship for five years This does not include normal wear and tear Warranty coverage on all other components is one year Warranty does not cover improper assembly or improper user maintenance Wear items such as tyres tubes brake pads handlebar grips or cables are not covered under warranty The warranty does not cover normal wear and tear including corrosion rust hairline cracks in paint chips in paint water damage the results of fatigue and any damage failure or loss caused by accident misuse neglect abuse theft or failure to follow instructions or warnings in the Gocycle Owner s Manual Fatigue damage is a symptom of the frame ot component being worn out through normal use It is the owner s responsibility to inspect his her Gocycle in accordance with responsible practice and the recommendations outlined in the Gocycle Owner s Manual All warranty services must b
5. may not otherwise use reproduce store post broadcast transmit modify sell or make available to others or the public content from this material without the prior written approval of Karbon Kinetics Limited 3 3 Trademarks Gocycle PitstopWheel Cleandrive and Magflow are registered trademarks of Karbon Kinetics Limited Gocycle to Work EmpowerPack Vgonomic Adjustment Lockshock and Shocklock are trademarks of Karbon Kinetics Limited All trademarks and the Gocycle logo may not be used without the prior written approval of Karbon Kinetics Limited a United Kingdom Registered Company Number 4357956 Karbon Kinetics Limited All Rights Reserved 3 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 4 SAFETY 4 1 Intended Use Gocycle is an electric bicycle developed with responsible professional customers and their families and friends in mind The design and build contemplates commuting usage and or simple riding context in fair weather and at speeds relevant to safe and appropriate travel in an urban environment Where applicable the product has been tested to meet or exceed minimum requirements outlined in EN 14764 BS 6102 and North American Bicycle Standards and has CE certification on the battery pack charger and front motor fork electronics Abusive riding styles or inappropriate use will invalidate any warranty protection offered in this agreement The Gocycle including its
6. AFTER A RIDE Karbon Kinetics Limited All Rights Reserved 40 A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 8 THE THIRD BEST PRACTICE FOR YOUR BATTERY IS TO CHARGE IT FULLY AND THEN UNPLUG THE CONTROLLER YOU CAN THEN LEAVE THE BATTERY FOR UP TO ONE MONTH BEFORE FULLY RECHARGING IT 9 NEVER LEAVE YOUR BATTERY IN A DEPLETED OR PARTIALLY CHARGED STATE 10 WHEN IN DOUBT PUT THE BATTERY ON CHARGE AND LEAVE IT ON CHARGE Battery performance will vary from customer to customer and there is no practical qualification on what normal performance is and what is less than normal Generally if there is zero input power to the pedals you should get more than 35 minutes of run time at 15mph on level ground in EU mode and you should get more than 20 minutes of run time at 17mph on level ground with an 80kg rider and luggage in USA mode Substantially less than this run time may indicate that there is a fault with the battery Note at temperatures below 10 degrees Celsius performance of the battery may be lower than the minimums stated above This is considered normal for the NiMh chemistry of this battery pack WARNING If you hear multiple beeps from the controller every 2 to 3 minutes your battery pack is dangerously low on voltage and needs immediate charging This is the low voltage alarm alerting you that the battery is being damaged The controller records these low voltage alarms and recordings of exces
7. CANCIO eea A E EEE ES 6 5 Recommended Assembly Sequence sssesssrsrerrererrersrrsrrrrerrrrerrrrnrrnrerrrrerrererrersrrerne 8 Sek U E aa E OE E E sears 8 52 ICING the Handlebar SEM tesa aransennsducaensneciaceannsincsnaudtiatd aan IEAA Naia 8 Ba FIENNES eat POSE erare E A EE TE EAE atteteareet 12 54 Unfolding th Frae serceeewerrentaearetresianedieen crap eeasanvauteaewey aver in cotenves nia ents ECNIN Prarie 14 5 5 Fitting the Front Fork Assembly cccccecceceeceeseeeeeeeeeeeeeeeeesaueeeeeeeeeneeeeeesaeeaesetsnteenegs 17 5 6 Attaching the PHSLODW NCE s ceasanascarininsadOrsiwvadeenmnarseaniinnsatensinnedainad a a rasa 20 S AUN Ene Rear MUdguUa aara inter acanenenai suave enensnenmn 22 50 Attaching the Front Brake seeieaahecctuntet caiteiesaiacadsentetated divedetnaetnniaatetanchadwicnnclinmewindutneaiet a bdeernnedusdora s 24 6 Fitting the Front and Rear Reflectors ccccccscscsececeeueueueueeeeterererseeeeeaeeeeeaeavarauansas 26 oye SMP aos 6 ei no E he ne er 26 OZ Rear Re We O vicederunaivens oratiaasnon T E dui alien amnienvaginanaserieaneis 26 OS PONR ETO Gee een ent eet eee he ee E eer ere ne ee 27 7 Adjusting Seat and Handlebar Position ssesssreserrersrsrrrrnrrnrsrrrrerrnrsrrrrerrerrrrererrne 29 Dede a RO a a E E miatiaemantearaion uel er nteetanion es 29 T ANAE en EON aaa E E EN 30 7 3 Ha ndl bar Reach POSION scsi cdsirtensconianiasbantanitedtesiasanaudnsatatrndetevinseaniannneielanbdisiehcuasuet 34 7 4
8. Figure 5 18 Karbon Kinetics Limited All Rights Reserved Unfold swing arm Pull out Lockshock pin and align plunger and Lockshock body Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Press down HARD here Figure 5 19 Holes are not yet aligned keep pushing down swing arm Figure 5 20 CORRECT Figure 5 21 Karbon Kinetics Limited All Rights Reserved 16 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Q Ready to install wheels front fork assembly Figure 5 22 5 5 Fitting the Front Fork Assembly Fit front fork assembly onto steerer Quick release lever is in open position Pull out fork lock pin Figure 5 24 Karbon Kinetics Limited All Rights Reserved 17 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Release fork lock pin Figure 5 25 Pull up in this direction Before you close the quick release pull up on the front fork assembly to check that the fork lock pin is fully engaged You should not be able to pull the front fork assembly off the steerer tube if the fork lock pin is correctly engaged YOU MUST PERFORM THI S TEST BEFORE CLOSI NG THE QUI CK RELEASE IF THE FORK CAN BE PULLED OFF THE STEERER DO NOT RI DE THE GOCYCLE Notice quick release is open Close quick release over fork lock pin as shown Figure 5 27 P
9. adjust the pannier clips to fit snugly between the vinyl end caps on the pannier rod This is Fea necessary to stop the pannier shifting side to side when riding Adjust the pannier to fit snugly against the vinyl end caps Figure 8 38 Karbon Kinetics Limited All Rights Reserved 53 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Do not carry more than 5kg of luggage in the front pannier but you also should never exceed the maximum allowable weight of rider clothing and luggage including the pannier itself of 100kg Figure 8 39 8 10 Fitting the Rear Luggage Arm F Rear luggage arm and mudguard Figure 8 40 Remove rear mudguard nut Remove bolts and mudguard Remove these two a nut bolts Torx head 25 amp Figure 8 41 Karbon Kinetics Limited All Rights Reserved 54 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Position over shock 7 threaded screw Position luggage arm over shock threaded screw and align with two Cleandrive bolt holes Ey a ay _ ow Align with these cn holes S Figure 8 42 Insert and tighten M6 captive nut with M6 Allen key as shown 5Nm torque Figure 8 43 Insert and tighten special bolts supplied with rear luggage arm as shown 5Nm torque Figure 8 44 Karbon Kinetics Limited All Rights Reserved 55 Gocycle Owner s Manual Ver
10. associated KKL products is intended as a power assisted bicycle for sensible use by physically competent consumers If you have any concerns or doubts about your use or enjoyment of such a product due to illness or recovery from treatment for illness you should consult your doctor regarding the suitability of the product for you in the light of any medical condition under consideration or treatment by such experts In the event that you are the user of an implanted medical device such as a pacemaker or defibrillator you agree to seek appropriate advice from the manufacturer of such device prior to the usage of KKL products 4 2 Maximum Design Limit Rider and Luggage Not to Exceed 100kg 220lbs WARNING This product has been designed with a maximum weight limit of 100kg 220lbs for the rider clothing and all luggage Do not exceed this weight limit at any time Riding or even sitting on the Gocycle while stationary with weight exceeding this limit will void all warranties and cause the product to be unsafe for operation 4 3 Limited Life Span WARNING Bicycles have a limited life span for safe operation As with all mechanical components bicycles components are subject to wear and high stresses Different materials and components may react to wear or stress fatigue in different ways If the design life of a component has been exceeded it may suddenly fail possibly causing injuries to the rider or even death Any form of crack scra
11. battery pack from the frame dry it with a dry cloth and charge it separately from the Gocycle To charge the Gocycle ensure that the main lead voltage on the charger is set to the mains voltage in your country 240V or 110V Ensure that you have the correct power cord or an adapter to meet the mains plug requirements in your country In some cases you may need to purchase a standard power cable such as that used on a computer sold at a computer supply store 1 Ensure that the charger is switched off 0 or zero 2 Plug the charger into the mains supply 3 Plug the charge lead into the socket at the rear of the battery pack 4 Turn on the charger 1 or one All three lights will turn on for 1 2 seconds and then the red light and yellow light will turn to solid indicating that the batteries are charging Depending on the state of charge of the batteries the charge cycle time could vary from 30 minutes to 4 hours 5 When charging is complete a green light will show solid a flashing green light indicates the charge cycle is nearly complete 6 FOR BEST PERFORMANCE AND LONG LIFE OF THE BATTERY YOU SHOULD PLACE THE BATTERY ON CHARGE IMMEDIATELY AFTER ANY RIDING AND LEAVE IT CHARGING CONTINUOUSLY 24 HOURS PER DAY THIS IS APPROXIMATELY THE EQUIVALENT OF LEAVING A 40 WATT LIGHT BULB ON FOR 1 HOUR PER DAY 7 THE NEXT BEST PRACTICE FOR YOUR BATTERY IS TO CHARGE IT FULLY AT LEAST ONCE PER WEEK AND ALWAYS IMMEDIATELY
12. here Check under the head tube junction for fatigue cracking and around the cable tube area Figure 9 5 9 3 Adjusting the Shifting The Gocycle has three speeds that may require adjustment from time to time as the shifting cable stretches To adjust the shifting mechanism 1 Turn the barrel adjuster clockwise until it is turned in all the way 2 Shift into Ist gear 3 Ona flat surface and not in the presence of moving traffic pedal gently and then turn the gear shifter into 2nd gear Did you feel a difference in the pedal resistance or hear the change in the sound of the rear gear clicking If no go to step 4 If yes then continue pedalling gently and shift into 3rd gear Did you again feel and hear a difference in the pedal resistance or the sound of the rear gear clicking If no go to step 4 If yes you have adjusted the shifting correctly 4 Stop the Gocycle and turn the barrel adjuster out one half turn Go to Step 2 Karbon Kinetics Limited All Rights Reserved 67 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Adjust the shifting using this inline barrel adjuster Figure 9 6 9 4 Adjusting the Brakes There are two types of adjustment for the brake pads initial setup and minor adjustment 9 4 1 General Overview Gocycle s brakes are a floating rotor mechanical calliper design The calliper is actuated by a wire cable that connects to the brake levers
13. will be greater than normal by as much as three times Until you are totally confident of the distance required to stop from any speed do not ride on a public road or in the presence of moving traffic Brake barrel amp adjuster is Adjusting the moving inner brake pad requires turning these two parts Lock nut Figure 9 7 Moving inner brake pad lt To adjust the fixed outer brake pad turn this part O 4 Fixed outer brake pad b iicn Figure 9 8 Karbon Kinetics Limited All Rights Reserved 70 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 9 9 Pre Ride Checklist 17 g Moving inner brake pad n a is k a a 3 Fixed outer brake pad Figure 9 10 Karbon Kinetics Limited All Rights Reserved Q Distance B should never be zero For example you should never be able to make the brake lever touch the handlebar when using full braking force To adjust the fixed outer brake pad turn this part 7 A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 9 5 Adding Brake Ferrules to Compensate for Cable Stretch Over time the brake cables will stretch In addition to this the brake pads can wear out The combination of both of these occurrences may result in the brake lever being pulled to the point that it touches the handlebar AND the brake barrel adjuster is turned out to the p
14. 0301 003300 Oe SOR Ba iassacvapisietoinc E A sietooredantoiedice rae ieuresanaisucuctiiaee etausetenaees 61 oa AT CA tape anaemia a rrnnenta sun E A 63 Maintenance and AdjUStMeNts cccccececeeseeeceteeeeeeeeeereeeeaeeeestateeaeseeeteeeeaeaesetenees 65 9 1 Waterand Cleaning acecasatus neniadanouenetinncmpnertene EEE EEE TEE ERAT NEEE R aa 65 9 2 Checking for Cracking and Fatigue Failures cccccsccsececceeeeeeeeeeeeeeseeeeeeeeeeeneeesaetaees 65 2o Ad EOS SAN cen r E E E 67 9 4 Adj sting the BKC Since rca contienagnenerasamiinhiwanininarensdaniae se n EE r Esra T Neri ea 68 9 5 Adding Brake Ferrules to Compensate for Cable Stretch cccecsecseceeseeeeeeeeeseeeeeeess 72 9 6 Replacing the Brake Pads cccccecceccecseceeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeseeaeeeeeesantaes 75 9 7 Adjusting the Bottom BIACK Cl iinecrsniinsnesadivratatnirasoriapovessniiaareniime aia drdenaneord eon 80 98 AdU TME FILO VCS saucers taninexvaradaweetunddunaias eta an eeE up NN 81 ae sense acc oe eatin ee ate erate one eee eeeeecanennes 82 DA S EROON eaer EA E EEEE 83 9 11 Adjusting the Headset cccccccecseceeseeeeeeeeeeeeeeeeeee eee esses eee eeeeeeeeeeeeeetaeeeeeeeauteeeesaetegss 84 9 12 Adjusting the Bearings on the Rear HUD cccccecseceeseeeeeeeeeeeeeeeeeseeeeeeeeeeeaeeeeretaeteeas 85 Karbon Kinetics Limited All Rights Reserved A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300
15. 03300 Using a screwdriver twist the brake pad from here to here so that the tab is visible Figure 9 24 T Figure 9 25 Remove the pad with pliers Figure 9 26 Karbon Kinetics Limited All Rights Reserved Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 9 27 Figure 9 28 Figure 9 29 Karbon Kinetics Limited All Rights Reserved Insert the new pad by reversing the previous steps Q 77 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Re fit and tighten the brake calliper backplate to 8 10Nm torque Figure 9 30 9 7 Adjusting the Bottom Bracket It is unlikely that any adjustment of the bottom bracket should be required However if there is a knocking or clicking sound that coincides with each pedal stroke then adjustment may be required To adjust the bottom bracket collar 1 Loosen the M4 lock bolt as shown 2 With a wooden mallet gently tap on the drive side crank arm as shown Gently tap on the drive side crank as shown Use a rubber mallet or a cloth to SSN prevent damage to the crank Tap gently in this direction D a S D EN arm and bolt Figure 9 31 Karbon Kinetics Limited All Rights Reserved 80 3 9 8 Figure 9 32 A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Turn the two bottom bracket lock collars in the direction shown as tightly a
16. Adjusting the Handlebar Stem Quick Release Tension ssssssssserernrrsrerrrerrrrersrerrsrens 35 7 5 Quick Fold Handlebar POSItiON cccccceececceceeeeeeeeeeeeeeeeeeeeseeeeeeeeseeeeeeeeeeeetaeresanennnegs 36 S PUOC CCC S50 HCG en a EEE T N ON 37 81 Emp wer PACK BaltEly srren nne isn e EEN A EATEN EE ETE ET 37 8 2 Empower Pack Charging ssessssrersssrrrrrrrrrrrrnrnrrrrrrrrrrrrrrrrrrrrrrrrrrrrerrrrrrrrrrrrrrrrrrrrrne 40 8 3 Empower Pack Operation ccccceccecsecseceeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeereeaesaeteseeseteeseeantaees 42 84 Attaching the MUdOUArdS sssssisririridsnsdati einni ena A 44 Bro JLIGMIEVEIONE PEO ad e E E EE 45 86 Antithert BOIS TOF PIGEOPWNECE sosisini iann e EAA AE 45 oF DNO KO a EEE E A naan 46 8 8 Front and Rear Safety Lights sssssrsrrrnrrrrrrnrnrnrrrrrnrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrne 47 8 9 Front Pannier Rod cccecseceeceeneeeeeeeeeeeeeeeeeeeeeeeee eee eeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeaeneeeeeantgees 51 8 10 Fitting the Rear Luggage ArM esesersrersrersrernrrrnrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrne 54 8 11 Fitting the Heavy Duty Kickstand s sssssnsnrnsnrrrrsrsrersrererererrrsrersrnrsrerererererererererererns 57 8 12 Fitting Ortlieb Luggage ccccceeeseesesssseeseeeeeeceeeeceueceececcececeetenetstseeueuvavuneeeeeeeeeeenenegs 58 Karbon Kinetics Limited All Rights Reserved Gocycle Owner s Manual Version 2 2 Frame Numbers 00
17. All Rights Reserved 30 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 n Before riding check that stem lock pin at rear of handlebar stem is secure Stem lock pin Figure 7 7 To adjust handlebar stem height loosen stem pinch bolt Figure 7 8 Remove safety circlip Figure 7 9 Karbon Kinetics Limited All Rights Reserved J Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Remove safety pin from rear of stem Figure 7 10 Adjust height of stem Figure 7 11 Reinsert pin at rear of stem Figure 7 12 Karbon Kinetics Limited All Rights Reserved 32 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Q Check that pin is fully inserted Figure 7 13 Replace safety circlip Figure 7 14 Do not loosen or tighten from this side Retighten stem pinch bolt Figure 7 15 Karbon Kinetics Limited All Rights Reserved oo Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 7 3 Handlebar Reach Position Three hole positions are available to set the forward and backward position of the handlebars Adjusting handlebar reach Figure 7 16 Step 1 Open the rear quick release lever Step 2 Loosen the quick release lever nut Figure 7 17 Pull out rear quick release lever Figure 7 18 Karbon Kinetics Limited All Rights
18. Gocycle Owner s Manual Version 2 2 for Gocycle Frame Numbers 000301 through 003300 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 TABLE OF CONTENTS WANS OF COMIN ar E E E ean anita eed iad TL EEE ec enes ute serene E E A E EE A EE E E 1 2 Gocycle Frame NUMDELS cccceccecececeeeee ee ee ee eee ee ee eens eee esse ete ea SS EAE EE EEA SEES EE SESSA SEES SHEE ES 2 3 Disclaimer Copyrights and Trademarks cccccceceeeeseceeeeeeeeeeeeeeeaeeeeeteeeeeeaeeeteeeeneaas 3 A SANO e E E E EA E EAE E A E N 3 SL LOAA NON E a E E E E A E E T E E 3 so TOONE e E E E E E 3 A O E te nes ete ts tes E E ae eee enn ede nea ate 4 Ad Intended USC ster succtccnvaces dt inne a A ET TE 4 4 2 Maximum Design Limit Rider and Luggage Not to Exceed 100kg 220Ibs 0068 4 Ao HME Sa anea e E EN E E 4 4 4 Attaching the Front and Rear ReflectOMs ccccccecseceeceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeaereetesaetegs 4 4 5 Fit Front and Rear Lights if Riding in Low Light Conditions essssssrsrsrersrererererererersrn 5 4 6 Wear a Helmet ccccccccecseceeceeseteeeeeeeeeeeeeeeeeeeeeeeee esse eeeeeeeeeaeeaeeeeeeesereeeesautaereeaenentegs 5 4 7 No Hands Riding ssssssssesenssnnnnnsnnnnnnnonoronsnnnnnnunnanonennanenensnnnnnnnanenansnsnnnnnnnnnnnnananennnn 5 Aco NCW ANNT RIO ees E 5 4 9 Tools Required For Maintenance No Tools Required for Assembly cecceceeceeeeeeeeees 5 ATO PEROS
19. Gocycle is travelling at a speed above 2mph When starting out from a stop or after 30 seconds of not pedalling you will need to pedal a minimum of 6 revolutions before the motor will function To start the motor simply press and hold the red power button down If the Gocycle is moving above 2mph AND the pedals are moving AND the pedals have moved more than 6 revolutions the motor will start Power from the motor will increase as your speed increases to about 12 13mph At this point the power will decrease with increasing speed of the Gocycle up to 15mph when the motor will shut off completely Pedalling above 15mph will not allow you to have any power from the motor This is in accordance with EU regulations NOTE If you require different power performance for specialised racing or tuning you can purchase the Gocycle Chip Tuning Software 8 3 3 USA Mode In USA mode the pedals do not have to revolve to activate power Power will be available at speeds above 2mph and will start to decline at speeds around 17mph assuming level smooth pavement depending on the weight and size of the rider and the tyre pressure 8 3 4 Resetting the Controller From time to time the controller may require rebooting much like a PC If it appears that the controller is not functioning correctly perform the following reboot sequence e To reset to EU mode for customers operating Gocycle within the EU With the Gocycle at a stop such as with the br
20. Reserved 34 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Move handlebar to desired hole position Figure 7 19 7 4 Adjusting the Handlebar Stem Quick Release Tension Re fit rear quick release lever and nut Tighten nut by hand until lever is 80 Figure 7 20 degrees open then F close the lever Figure 7 21 Karbon Kinetics Limited All Rights Reserved 35 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Q 7 5 Quick Fold Handlebar Position Quick fold on handlebars for space efficient storage Figure 7 22 Notice gap here rotate handlebar 90 degrees and close quick release Figure 7 23 Karbon Kinetics Limited All Rights Reserved 36 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 8 FITTING THE ACCESSORIES 8 1 Empower Pack Battery E Installing the battery pack Figure 8 1 Insert battery case Figure 8 2 Karbon Kinetics Limited All Rights Reserved 37 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Notice hole for screw Figure 8 3 To secure battery in frame tighten the battery knob by turning it clockwise Figure 8 4 Karbon Kinetics Limited All Rights Reserved 38 A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 When you plug the controller leads into the battery pack inside the frame you wi
21. When the brake lever on the handlebar is pulled the wire cable activates a mechanism that pushes ONLY one moving inner side brake pad towards the disk rotor When this occurs the disk rotor will move sideways or float until it is pushed against the fixed outer side brake pad Depending on the force used at the brake lever the disk rotor will be slowed down or even stopped from rotating as the pressure between the moving inner and fixed outer brake pads increases Adjusting the brakes to give the right performance is a combination of adjusting the moving inner brake pad position adjusted at the brake lever on the handlebars and the fixed outer brake pad position adjusted at the brake calliper See the images at the end of this section for descriptions of key parts and adjustments Initial Setup 1 We recommend that you turn the Gocycle upside down and rest it on the seat and handlebar to perform this setup 2 Loosen the brake barrel adjuster lock nut 3 Turn in the brake lever barrel adjuster to the position shown all the way tn 4 Turn out stationary brake pad adjuster as shown 5 Spin wheel by hand Did you hear any rubbing of the moving inner brake pad against the disk rotor If yes proceed to step 6 If no turn out brake lever barrel adjuster one full turn and go to step 5 6 Turn out the brake lever barrel adjuster one half turn and then tighten the lock nut You have now set the position of the moving in
22. ads In the event that the brake lever can be depressed to make contact with the handlebar grip and the barrel adjusters on the lever and the stationary pads are turned clockwise completely the brake pads will need to be replaced To replace the brake pads 1 Remove the wheel 2 Turn out the stationary pad adjuster until it is flush with the surface B and turn out the brake lever adjuster 3 Unscrew the two M6 bolts using an Allen key wrench to hold the M6 bolts front brake only stationary 4 Remove the stationary brake pad and replace it with a new pad 5 Using gloves or a cloth to protect your fingers from being cut on the disk rotor pull the disk rotor away from the moving pad and calliper 6 Using needle nose pliers grab the tap of the moving brake pad and pull it out from the calliper housing 7 While holding the disk rotor away from the calliper housing insert a new brake pad into the moving calliper side 8 Replace the stationary brake calliper and tighten the 2 M6 bolts to 6 8Nm torque Hold the 2 M6 captive nuts front fork only while tightening 9 Go to initial setup to adjust pads Note e Over time and in some cases the brake cables can become stretched to the point that even with new brake pads the braking performance is unsafe e Inthe event that more than 8mm of length of dimension B is required to prevent the brake lever from touching the handlebar grip you will require a Brake Barre
23. ake held on press and hold the red power button for 7 to 10 seconds until you hear 1 beep then release the button immediately e To reset to USA mode for customers operating Gocycle with the United States With the Gocycle at a stop such as with the brake held on press and hold the red power button for about 20 to 50 seconds until you hear 2 beeps then release the button immediately WARNING Operating the Gocycle in USA mode is not legal on public roads within the EU Operating in USA mode within the EU is only legal on private property such as a racing track Karbon Kinetics Limited All Rights Reserved 42 A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 8 3 5 Sleep Mode In order to conserve battery discharge the controller will go into sleep mode after 20 minutes if no movement of button wheels or pedals is detected Upon any detection of movement in wheels pedals or pressing of the button the controller will wake up and beep depending on the mode of operation i e 1 beep for EU mode 2 beeps for USA mode This beeping will confirm that the controller is functioning correctly 8 3 6 Heat Gocycle s motor is extremely compact and lightweight While the benefits of this design are apparent certain drawbacks exist specifically the motor can get hot Gocyvcle s motor will get hot under normal running similar to the exhaust pipe or engine of a motorcycle or moped y a g pip g y p
24. alf turn Repeat the squeezing of the brake lever and check distance B again Repeat turning out one half turn of the brake lever barrel adjuster until the brake lever cannot be made to touch the handlebar Then tighten the brake lever barrel adjuster lock nut 12 Check that the wheel rotates freely by spinning it with your hand You should be able to spin it a minimum of 2 revolutions 13 Repeat steps 1 to 12 for the front of rear brake as well 14 Now you ate ready to test the brakes Minor Adjustment 1 From time to time and under normal braking the brake pads will wear down This will result in more and more distance that the brake lever will have to be pulled in order to brake the Gocycles to a stop Once the brake lever can be made to touch the handlebar with substantial force minor adjustment of the brake pad positions should be made 2 Each brake pad the moving inner and the fixed outer pads should be moved closer to the disk rotor by equal amounts 3 To make a minor adjustment loosen the lock nut and turn out the brake lever barrel adjuster counter clockwise one half turn Retighten the lock nut Then turn in the fixed outer brake pad adjuster one half turn clockwise 4 Spin the wheel by hand It should rotate freely If the brake pads are rubbing you may need to reposition the inner and outer brake pads by one quarter of a turn 5 Check that the brake lever cannot be made to touch the handlebar with substantial f
25. ant national safety body or a reputable cycle dealer on what the minimum recommended lighting requirements are in your particular country or region For reference Gocycle has a 34 9mm diameter seat post for the rear light strap You can fit the front light to the handlebar or the vertical stem tube also 34 9mm diameter if required We recommend that you choose a light with a variable length strap mounting system We recommend the following safety and tail light accessories for the Gocycle available for purchase at www gocycle com e Front safety light CatEye HL LD130 e Rear light reflector CatEye TL LD500 Ensure that rear lights reflectors are not obstructed by the rider s clothing 4 6 Wear a Helmet WARNING Never ride a bicycle without wearing an approved helmet Serious brain damage can occur If you fall off a bicycle and you are not wearing a helmet Be smart and wear a helmet when riding 4 7 No Hands Riding WARNING Never ride a bicycle without both hands holding and in control of the handlebar and steering Riding without both hands holding the handlebar can cause a bicycle to become unstable and result in serious injury or even death 4 8 Wet Weather Riding Under wet conditions the stopping power of your brakes as well as the brakes of other vehicles sharing the road is dramatically reduced and your tyres will not grip nearly as well This make it harder to control speed and easier to lose control
26. atter of compromise and feel If in doubt consult KKL for advice Retighten the outer lock nut Note after tightening the outer lock nut the hub may need re adjusting due to the nature of the tightening process You may need to repeat this process until you have the desired freeness of rotation and minimal lateral play at the rim 87
27. bove it is illegal to operate Gocycle in USA mode while riding on EU public roads However EU mode is legal for operating an electric bicycle in the USA public streets Karbon Kinetics Limited All Rights Reserved 43 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 8 4 Attaching the Mudguards 8 4 1 Front 1 Using an M4 Allen key tighten the two bolts and lock washers as shown in Figure 8 11 below BUT DO NOT TIGHTEN ALL THE WAY 2 Fit the wheel 3 Look at the wheel and align the mudguard visually so that it is on centreline with the tyre 4 Remove the wheel 5 Tighten the two bolts to 3Nm torque 8 4 2 Rear 1 Tighten the two bolts with a Phillips screwdriver as shown in Figure 8 12 below BUT DO NOT TIGHTEN ALL THE WAY 2 Fit the mudguard 3 Fit the rear wheel 4 Look at the wheel and align the mudguard visually so that it is on centreline with the tyre 5 Remove the wheel 6 Tighten the two bolts to 3Nm torque Attaching the front mudguard use M4 Allen key Figure 8 11 Karbon Kinetics Limited All Rights Reserved 44 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Q Adjusting the alignment of the rear mudguard use a Phillips head screwdriver to tighten the two screws once you have aligned the rear mudguard with the rear tyre Figure 8 12 8 5 Lightweight Display Stand Tighten to 5Nm torque Fitting the lig
28. d f UNSAFE TO RIDE One quick release is not fully closed Figure 5 35 Pull here To remove PitstopWheel first open quick release levers Figure 5 36 Karbon Kinetics Limited All Rights Reserved 21 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Strike rim here to remove wheel Remove PitstopWheel hip J Hold quick E IN a in fully open position Figure 5 37 5 7 Fitting the Rear Mudguard hiir aiy Bey a A FEF iA MI liaere a estais EMAL So gE LO 000 Fit rear mudguard Figure 5 38 Ve a QG6 SCP ON Cex 3 sooz ralrl N3 ae nen Z66L ZOL9 SB L0 000 Tighten knob Figure 5 39 Karbon Kinetics Limited All Rights Reserved 22 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 5 40 Turn Gocycle right side up Figure 5 41 Insert Lockshock pin This may take high force to insert Rotating it while inserting can help Press down on the seat with your body weight to compress the suspension while you insert the pin Figure 5 42 Karbon Kinetics Limited All Rights Reserved 2a Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 5 8 Attaching the Front Brake Figure 5 43 Figure 5 44 Lift up brake calliper lever a p f A r Pa s ii lt _ Hook cable end Talwele a 1 lt gt calliper leve
29. d mild liquid soap First wipe down all areas with a damp towel then wipe dry with a dry towel e To clean the rim and tyre remove the PitstopWheel soak the rim and tyre in a bucket of soapy water and then dry with a towel WARNING Never spray the Gocycle with a hose or high pressure cleaning system Never use polishes waxes or solvents to clean your Gocycle 9 2 Checking for Cracking and Fatigue Failures A bicycle will not last forever It is a mechanical item that under normal riding will be stressed and eventually the parts will fatigue cracks will develop and it will become unsafe to ride The number of miles of riding a bicycle will endure cannot be predicted since there are many variables that affect product life including e Rider weight e Riding style e Tyre pressure and type e Roughness of the road e Whether or not the bicycle has been crashed or damaged in transit e Whether or not the bicycle has been ridden over large bumps such as potholes or curbs e The amount and weight of luggage carried e The speed at which it has travelled e Whether it has been subject to abuse or vandalism e Time of exposure to ultraviolet radiation from the sun e Storage conditions such as ambient temperature and moisture levels Responsible safe riding and regular maintenance such as within the guidelines of this manual should afford many thousands of miles of operation of the Gocycle Nevertheless you must inspect the Gocycle eve
30. e performed by a Gocycle Service Centre Warranty service includes the costs of parts and labour but does not include the cost of shipment packaging or transportation to or from a Gocycle Service Centre KKL will endeavour to complete the warranty service within 10 working days from the time of recorded receipt of the item s at a Gocycle Service Centre to the time of the item s being ready for dispatch or collection from the Gocycle Service Centre KKL will have the option of either repair or replacement at no charge for a defective product or repayment of an amount equal to the purchase price of the product In the event KKL elects to replace a defective frame a new frame of equal or greater value will be provided The new frame may not be the exact model purchased If you elect to repair a defective product yourself or use the services of a KKL reseller or any other party other than the Gocycle Service Centre or if you use a replacement part not supplied by KKL KKL will not be liable for any damage failure or loss caused by the use of such unauthorized service or parts and the warranty will be void Disassembling any part of the Gocycle beyond that which is shown in the Gocycle Owner s Manual will void the warranty of that item and any other affected items KKL reserves the right to determine what components are affected by such disassembling Prior to KKL dispatching any replacement item the affected frame number must be provided to KKL
31. ease lever Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 5 9 Figure 5 10 Pre Ride Checklist 17 b Karbon Kinetics Limited All Rights Reserved UNSAFE TO RIDE There is more than 1mm gap between the stem adjuster and the headset collar This means that the lock pin has not engaged into the hole in the steerer UNSAFE TO RIDE Notice that the lock pin has not engaged in the steerer CORRECT Quick release levers closed Lock pin fully engaged Less than 1mm gap Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 5 3 Fitting the Seat Post Insert seat post assembly Figure 5 11 Tighten knob Figure 5 12 Karbon Kinetics Limited All Rights Reserved 12 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 5 13 Flip the Gocycle over and stand it on the handlebar and seat Figure 5 14 Karbon Kinetics Limited All Rights Reserved 13 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Q 5 4 Unfolding the Frame Pull fold lock pin to release Spring spring Figure 5 15 Open frame Figure 5 16 Karbon Kinetics Limited All Rights Reserved 14 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 5 17 Plunger r o k n gt ag i F A j 4 F i _ ol h Lockshock oE Lockshock body
32. ers 000301 003300 Fit bracket as shown Figure 8 27 Figure 8 28 Fit safety light to bracket as shown me Figure 8 29 Karbon Kinetics Limited All Rights Reserved 50 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 8 9 Front Pannier Rod T a F J en A N 7 stem pinch bolt Figure 8 30 Notice the rod does not have the end cover fitted Figure 8 31 Figure 8 32 Karbon Kinetics Limited All Rights Reserved Q First loosen the handlebar stem pinch bolt Slide pannier rod through stem hole as shown Centre the pannier rod 5 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 7 Y Ii gt Push the end caps on to both ends ii Figure 8 33 Tighten stem pinch bolt Figure 8 34 Figure 8 35 Karbon Kinetics Limited All Rights Reserved Q Push the vinyl end caps on to both ends Tighten stem pinch bolt Correct fit can take some effort The end caps must be fitted on both ends completely as shown 52 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 If the end caps are not pushed on all the way as shown at left the pannier could fall off while the Gocycle is moving which could cause serious injury Incorrect fit Keep pushing on the end cap Figure 8 36 Fit the pannier Figure 8 37 You may need to
33. eserved 63 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Close the zipper while case is on Its side then rotate the case onto its four caster wheels Figure 8 60 Karbon Kinetics Limited All Rights Reserved 64 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 9 MAINTENANCE AND ADJUSTMENTS 9 1 Water and Cleaning We do not recommend that you ride your Gocycle in heavy rain or store it in damp or wet areas Please read section 4 8 for safety recommendations under wet road conditions If you do find yourself riding while it is raining we recommend that you use the motor Using the motor will allow heat to build up in the motor and the electronics which will evaporate the water from these moisture sensitive components Use caution when you use the motor on wet roads as the roads will be slippery and the motor may cause the front wheel to spin Water and moisture reduce the life of products such as bicycles through rust and or corrosion Leaving water and moisture on the Gocycle could also result in premature failure of the electronics battery or motor system Here are some best practice recommendations e If your Gocycle has water on it we recommend that you wipe it dry as soon as possible with a towel e The less you expose Gocycle to moisture or water the longer it will last e If you wish to clean the Gocycle we recommend that you use a damp towel or cloth an
34. htweight display stand Figure 8 13 8 6 Antitheft Bolts for Pitstop Wheel L Antitheft screws for the Ti PitstopWheel can be fitted in three places These can be J d ordered from www gocycle com Figure 8 14 Karbon Kinetics Limited All Rights Reserved 45 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 v 8 7 Shocklock Fitting the lock into the Lockshock Figure 8 15 Figure 8 16 Figure 8 17 Karbon Kinetics Limited All Rights Reserved 46 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Fit the cable through wheels if wheels do not have antitheft screws fitted Figure 8 18 8 8 Front and Rear Safety Lights Fit rear light Figure 8 19 Figure 8 20 Karbon Kinetics Limited All Rights Reserved 47 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Q Tighten strap Figure 8 21 Attach rear light Figure 8 22 Figure 8 23 Karbon Kinetics Limited All Rights Reserved 48 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 8 24 Ensure that rear light reflector is not obstructed by the rider s clothing Figure 8 25 To fit front safety light first slide rubber gaiter upwards Figure 8 26 Karbon Kinetics Limited All Rights Reserved 49 Q Gocycle Owner s Manual Version 2 2 Frame Numb
35. irst answering yes to ALL of the questions in this section is serious injury or even death Be safe and responsible and do not ride your Gocycle unless you can answer yes to ALL of the questions in this section 1 2 10 11 12 13 Karbon Kinetics Limited All Rights Reserved I have read this owner s manual completely I understand this owner s manual and the instructions contained in it and I understand that serious injury or even death may occur if I do not carry out the instructions in this owner s manual with at least average competence When in doubt I will seek clarification on the instructions and warnings from the manufacturer The weight of my luggage clothing and person is not more than 100kg 2201b combined in total I have never been injured to the extent that I have received compensation for my injuries from a manufacturer or retailer or designer of a bicycle component or a complete bicycle or electric powered two wheeled vehicle If you answered NO to question 4 you may be more prone to injury from riding a two wheeled vehicle than the average person or you may have an unsafe or abusive riding style that imparts higher than normal stresses onto the bicycle that can cause premature and unexpected failure DO NOT UNDER ANY CIRCUMSTANCES RIDE THE GOCYCLE SERIOUS INJURY OR EVEN DEATH MAY RESULT I understand that Gocycle is an electric powered bicycle and may require new and different skills to ride
36. it safely If you are unsure of the new and different skills required for safe riding of an electric powered bicycle you should not ride this product and should consult an electric bicycle specialist in order to gain the necessary skills to ride this type of product I have a valid automobile driving license in the country state or region in which I will operate the Gocycle I confirm that the Gocycle has not been involved in a collision of any kind or has been subject to abusive riding such as being ridden into up or off a curb I understand that riding a bicycle on paved streets in the presence of cars trucks or motorcycles is potentially life threatening dangerous and could result in serious injury or death I always ride wearing an approved helmet and eye protection I have fitted the Gocycle with approved front and rear reflectors for the country of operation and if light is poor I have fitted the Gocycle with approved front and rear lights I have checked that my clothing such as a jacket does not cover the lights or reflectors while I am riding I have ridden a bicycle competently and safely within the last six months I have not sustained injuries that required professional medical attention as a result of riding a bicycle A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 14 My senses of sight sound speech judgment and reaction time are not impaired in any way such as but not limited to the inf
37. ither way before inserting the upper seat tube assembly into the lower seat tube assembly and testing the tightness of the seat height adjusting lever It is not possible to prevent all rotation of the seat WARNING Do not over tighten the black washer If the seat height adjuster lever feels too tight do not force it Loosen the black washer as described above Karbon Kinetics Limited All Rights Reserved 83 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 9 36 Do not allow rubber bush to be exposed as shown Figure 9 37 9 11 Adjusting the Headset Q Turn black washer clockwise one eighth of a turn between adjustments to tighten seat lever operation Do not store the upper seat post in the lower seat post in the tightened position with the rubber bush exposed as shown The rubber bush will deform over time and it will not be possible to slide the seat post freely The headset should be tightened to the point where the handlebars do not flop freely when the Gocycle is lifted off the ground and tilted to the side Karbon Kinetics Limited All Rights Reserved 84 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Adjusting the headset Loosen the set screw Figure 9 38 Use a 40mm flat wrench to loosen or tighten Figure 9 39 9 12 Adjusting the Bearings on the Rear Hub It is unlikely that you will need t
38. l Extender KKL ID 124 This part can be obtained directly from Karbon Kinetics Limited e To install the brake barrel extender turn the brake lever barrel in all the way e Ensure that the fixed outer brake pad adjuster is turned out all the way e Pull the brake housing black cable out of the lever barrel adjuster and insert the brake barrel extender e Proceed to section 9 4 for initial brake setup WARNING If the brake levers can be pulled to the point of touching the handlebar grip do not ride the Gocycle The brakes are not safe and will require adjustment as outlined in section 9 4 Karbon Kinetics Limited All Rights Reserved 75 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Loosen the calliper backplate bolts Note that the rear calliper backplate does not have an inner bolt Figure 9 19 Figure 9 20 Lift out the worn brake pad Figure 9 21 Karbon Kinetics Limited All Rights Reserved 76 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 m o Figure 9 22 To remove the moving brake pad insert a screwdriver or Allen key between the disk rotor and the calliper housing The disk rotor is a floating rotor design will lift away from the pad when you apply a parting action to the screwdriver Figure 9 23 Karbon Kinetics Limited All Rights Reserved Ti Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 0
39. l also carry general luggage using bungee cords and the four holes located in the rear deck Karbon Kinetics Limited All Rights Reserved 58 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Karbon Kinetics Limited All Rights Reserved Align these tabs Push here to release Ortlieb Office Bag 2 Ortlieb Office Bag 2 Q 57 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Push down and click Ortlieb Office Bag 2 Figure 8 52 Ortlieb Bike Box 2 Figure 8 53 Karbon Kinetics Limited All Rights Reserved 60 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 8 13 Soft Bag Pack the Gocycle into the foam cradle Figure 8 54 Place the cradle into the soft bag Figure 8 55 Karbon Kinetics Limited All Rights Reserved 61 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 8 56 d Figure 8 57 Karbon Kinetics Limited All Rights Reserved Zip up and go Q 62 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 8 14 Hard Case WARNING This hard case is not suitable for air travel The Gocycle will likely be damaged as a result of improper or abusive baggage handling Figure 8 58 Place cradle into hard case as shown Figure 8 59 Karbon Kinetics Limited All Rights R
40. ll hear one beep EU mode or two beeps USA mode This means the controller is functioning correctly Rounded edge of Plug in controller by inserting plug toward front upwards into outlet rounded edge of plug towards front Figure 8 5 Rounded edge of plug toward front NOTI CE ROUND EDGE OF PLUG IS TOWARDS THE RUBBER DUST BOOT ON FRONT STEERER AND FLAT EDGE OF PLUG POI NTS TOWARDS THE REAR NCORRECT POSITION OF PLUG WILL CAUSE MOTOR TO MALFUNCTION Figure 8 6 Controller should be plugged in with no more than 1mm gap between frame body and plug Figure 8 7 Karbon Kinetics Limited All Rights Reserved 39 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Plug not inserted fully Will not function During normal riding the plug should never disconnect by itself If this happens you have not pushed it in all the Way Figure 8 8 8 2 Empower Pack Charging You can charge the battery while it is inside the frame and with the controller plugged in WARNING Never charge the battery if the Gocycle has been ridden in heavy rain and has water droplets on the frame Never charge the Gocycle while it is exposed to rain for example when it Is outside in the rain You should wait until the water has completely evaporated from all surfaces before charging If you must charge the battery and cannot wait until the Gocycle is completely dry then you should remove the
41. luence of alcohol or drugs 15 Itis not raining to the extent that standing water or puddles are visible on the road 16 There is no chance of ice being on the roads 17 I have checked and can confirm all of the following points a b Karbon Kinetics Limited All Rights Reserved All six wheel quick release levers are in the closed position as shown in Figure 5 34 The safety lock pin for the handlebar stem adjuster is fully engaged in the steerer tube and you have confirmed this by performing the procedure described in Figure 5 6 and the quick release levers are fully closed as shown in Figure 5 10 The safety lock pin for the fork is fully engaged and you have confirmed this by performing the procedure described in Figure 5 26 and the quick release lever is fully closed as shown in Figure 5 27 The handlebar stem height safety lock pin and circlip are fully engaged as shown in Figure 7 6 and the screw that fixes the upper and lower handlebar stems is tightened to a minimum of 6Nm torque The tyres are inflated with air at a pressure of 20 60psi but not more than the maximum pressure rated on the tyre sidewall I have checked which brake lever operates the front wheel brake and which brake lever operates the rear wheel brake The brake levers cannot be made to touch the handlebar as shown in Figure 9 9 I do not feel any loose joints or connections on the Gocycle Gocycle Owner s Manual Version 2 2 Frame N
42. ner brake pad The key is to have this moving inner brake pad as close to the rotor as possible without having it touch the rotor NOTE If the moving inner brake pad is new it may not be possible to adjust it so that it does not rub on the rotor This is not a dangerous situation and Karbon Kinetics Limited All Rights Reserved 68 A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 simply means that the pad must be worn down through normal braking before it will not drag on the rotor Losses due to brake pads dragging on the rotor are very small 7 Now it is time to set the position of the fixed outer brake pad Turn in the fixed outer brake pad adjuster as shown until you cannot turn it any further At this point you should not be able to rotate the wheel by hand 8 Now turn the fixed outer brake pad adjuster one half turn out counter clockwise 9 Spin the wheel by hand It should spin freely and you should not hear any rubbing noise from the pads touching the disk rotor NOTE some noise may always exist if the pad is new 10 Squeeze the brake lever with heavy force and confirm that there is a minimum of 10mm distance between the handlebar grip and the brake lever at the point closest to the handlebar 11 If the distance B is less than 10mm or the brake lever can be made to touch the handlebar loosen the brake lever lock nut and turn the brake lever barrel adjuster out counter clockwise one h
43. o adjust the bearings on the rear hub However in the event that the rear wheel develops play more than 1mm at the rim or it feels heavy to pedal Le the hub is too tight you may need to tighten the bearing cone To check if this needs to be done turn the Gocycle upside down Using gentle pressure move the wheel at the rim side to side Some flex in the wheel is normal but if you feel that the wheel is loose you will need to adjust the bearing cone as shown below Karbon Kinetics Limited All Rights Reserved 85 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Remove dust cover Figure 9 40 Adjusting the rear hub gear bearing cups Figure 9 41 Use 2 14mm s Second tighten wrenches s x the inner adjuster nut 7 m m Adjusting the rear hub gear bearing cups First loosen the lock nut Figure 9 42 Karbon Kinetics Limited All Rights Reserved 86 O Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 9 43 Use 2 14mm wrenches Hold the inner nut stationary a Retighten the outer lock nut Figure 9 44 Karbon Kinetics Limited All Rights Reserved Between adjustments check that the rear hub rotates in the freewheel direction The bearing cup nuts should be tightened until the wheel does not have more than 1mm of free play at the rim and the wheel is able to rotate freely This is a m
44. oint where distance C is more than 6 5mm as shown in Figure 9 11 In the event that is occurs you must fit a brake ferrule to reset the braking system as shown in the following figures If the brake adjuster is more than 6 5mm out and the lever can be made to touch the handlebar then you must fit a brake ferrule as shown in the following figures Figure 9 11 Locate the brake ferrules from the small parts bag ferrules Figure 9 12 Karbon Kinetics Limited All Rights Reserved 72 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Align the slots Figure 9 13 Figure 9 14 F F Brake ferrule sm b Figure 9 15 Karbon Kinetics Limited All Rights Reserved Turn the brake barrel adjuster in all the way and align it with the brake barrel lock collar as shown Pull out the brake cable housing as shown Insert the brake ferrule in line and onto the cable as shown 73 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 9 16 Figure 9 17 Figure 9 18 Karbon Kinetics Limited All Rights Reserved Push the brake cable housing into the ferrule as shown Now push the ferrule into the brake barrel adjuster as shown Complete Now adjust the brakes as described in section 9 4 74 A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 9 6 Replacing the Brake P
45. orce NOTE There may be some initial drag or contact of the brake pads with the disk rotor especially after fitting new brake pads or if the Gocycle is new A running in period may be necessary for the brake pads to wear down a bit to allow the wheel to rotate freely and without any drag from the pads NOTE Brake lever feel is a matter of personal preference Some riders prefer sharp braking 1 e a small movement of the lever applies the brakes immediately Others prefer more gradual braking so that severe stopping power only comes when the lever is close to the handlebars In general you should adjust the brakes so that you feel safe and confident when you brake HOWEVER as a rule of thumb you should always have enough braking force to skid the rear tyre while seated in a normal position AND you should have enough braking power to lift the reat wheel from the ground when seated normally and applying only the front brake If you are unsure of how to Karbon Kinetics Limited All Rights Reserved 69 A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 check this we suggest you ask an experienced and qualified bicycle rider such as a mechanic at a bicycle shop to check that your brakes have enough power to safely stop WARNING Use caution during this running in period as the braking performance will be reduced from normal and heavy force will be required to bring the Gocycle to a stop Stopping distances
46. r hook Figure 5 45 Karbon Kinetics Limited All Rights Reserved Insert fork plug Attach front brake cable Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 yu fe P ra rd Figure 5 46 Karbon Kinetics Limited All Rights Reserved Q 25 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Q 6 FITTING THE FRONT AND REAR REFLECTORS 6 1 Small Parts Bag Rear reflector bracket and rubber tube shim P Bracket screw n Front reflector bracket amp rubber tube shim H Bracket cee screw Rear reflector RED Front reflector WHITE Figure 6 1 6 2 Rear Reflector Attach rear bracket as shown to seat post Figure 6 2 Attach rear reflector to bracket as shown Figure 6 3 Karbon Kinetics Limited All Rights Reserved 26 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Rear reflector position Ensure that the reflector is not obstructed by the rider s clothing Adjust this screw to ensure reflector face is perpendicular to the ground Figure 6 4 6 3 Front Reflector Attach front bracket as shown to vertical handlebar stem tube Figure 6 5 Attach front reflector to bracket as shown Figure 6 6 Karbon Kinetics Limited All Rights Reserved 27 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Adj
47. ration To the extent that the law permits any liability which may be incurred as a result of the use or future use of a product manufactured or sold under license granted by Karbon Kinetics Limited is limited to the cost of repairing or replacing the failed product or component at the discretion of Karbon Kinetics Limited either within or outside of warranty periods and does not extend to any loss or damage which may be caused as a consequence of misuse or failure of the products Damages to the product other property or any persons are the responsibility of the buyer By purchasing this product supplied by or manufactured under license granted by Karbon Kinetics Limited you are stating that you have read this disclaimer and agree to hold Karbon Kinetics Limited its owner s and any of its employees or directors free from all liabilities and agree that you are using and operating the product at your own risk and that no warrantees or guarantees are made by Karbon Kinetics Limited expressed or implied on performance or operation 3 2 Copyright Notice Copyright Karbon Kinetics Limited All rights reserved This material provided by Karbon Kinetics Limited is the property of Karbon Kinetics Limited and is protected by copytight trademark and other intellectual property laws You may view this material and print this material only for personal use provided that you maintain all copyright trademark and other proprietary rights or notices You
48. re Ride Checklist 17 c Karbon Kinetics Limited All Rights Reserved 18 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Open quick release rh to 90 degrees Adjust the fork quick release tension Insert M6 Allen key Figure 5 28 Tighten internal nut until tension is felt when quick release is 90 degrees y Adjust the fork quick release tension from the closed position Figure 5 29 UNSAFE TO RIDE Notice that the fork is not engaged with the fork lock pin i eot Fork lock pin is not seated into fork a a i D p i T rA s oi a a te ia say Ho Aaa Ta ah u i Figure 5 30 Karbon Kinetics Limited All Rights Reserved 19 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 5 31 5 6 Attaching the PitstooWheel z P Figure 5 32 r Press here and in direction of arrow Figure 5 33 Karbon Kinetics Limited All Rights Reserved UNSAFE TO RIDE Notice that the fork is not engaged with the fork lock pin Fork lock pin is not engaged in fork The quick releases are shown in fully open position Close quick releases Note safe direction and position to close quick releases 20 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Quick releases are shown in fully closed position Not fully close
49. ructions in the road Smooth riding styles are generally proven to be the most efficient and fastest with the bonus of giving your machinery the longest life span Karbon Kinetics Limited All Rights Reserved 82 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Tyre pressure should not be less than 20psi on the front and 40psi on the rear When changing a tyre always use plastic tyre irons Never use a metal tyre iron as you will damage the rim Note the correct direction of the tread of the Gocycle tyre in relation to the wheels see figure below In the event that you wish to use a lower performance tyre with increased puncture resistance you can use any BMX sized tyre 406x40 47 from 1 75 to 2 We recommend the Vredestein Moree tyre as an alternative to the Gocycle performance tyre WARNING When the centreline grooves in the tyre have worn down it may be dangerous to continue to ride on the tyre and in this event we recommend that you replace the tyre Note orientation of tyre tread Centreline Z Fitting the tyres and tyre tread orientation Figure 9 35 9 10 Seat Rotation In the event that the seat twists side to side during riding you can increase the tension in the seat height adjustment lever as follows Turn the black washer clockwise to tighten and counter clockwise to loosen the seat height adjuster lever Do not turn the washer more than one eighth of a turn e
50. ry 500 miles to see if any of the components have cracks and need replacing To do this clean the Gocycle thoroughly with a damp cloth Wipe away all dust or dirt Look carefully at all the components under good lighting Examples of cracking are shown in the figures below If a crack is more than 3mm long do not ride the Gocycle and immediately contact the Gocycle Service Centre Under normal conditions items under warranty will be replaced Karbon Kinetics Limited All Rights Reserved 65 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 O Pay particular attention to the areas where the spokes join the rims of the wheels Failure to inspect the Gocycle thoroughly may have serious consequences and could result in serious bodily injury or even death t Fatigue crack This wheel is not safe to ride Figure 9 1 4 7 2 gt B D Fatigue crack This frame is not safe to ride Figure 9 2 Check for cracking here Figure 9 3 Karbon Kinetics Limited All Rights Reserved Check for fatigue cracks where the spokes join the rim of the wheel Check for fatigue cracking around the seat tube frame joint Check the head tube junction for fatigue cracking 66 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Check for Check the head tube cracking here j i junction for fatigue cracking Figure 9 4 Check for cracking
51. s alarm readings could void the warranty To charge the battery pack open the charger jack cover Figure 8 9 Plug in the charger and switch it on The charge Is complete when the green light is solid Green light flashing is nearly charged Full charge takes about 3 5 hours Figure 8 10 Karbon Kinetics Limited All Rights Reserved 4 A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 8 3 Empower Pack Operation 8 3 1 Gocycle Motor Philosophy Gocycle s electric motor is designed to boost performance in terms of getting you from point A to point B more i y g p g ay p p quickly and with less effort On demand power comes when you press the red button next to the left brake lever on the handlebar and hold it down When you release the button you cut the power We do not recommend you hold the button down while applying the brakes you will cut the power as you slow the Gocycle under braking and you will cut power completely when your speed falls below 2mph In EU mode the motor will not start unless you are travelling faster than 2mph and only after you have pedalled more than 6 revolutions In USA mode the motor will not start unless you are travelling faster than 2mph The Gocycle is supplied with the legal operating mode EU or USA of the country in which you purchased the Gocycle 8 3 2 EU Mode In EU mode the motor will not function unless the pedals are turning AND the
52. s you can by hand Do not use pliers to tighten this collar as this will overstress the pedal crank bearings To adjust the Unscrew the two collars until hand tight le bottom bracket Then tighten the outer Cae eA GA VOO first loosen the collar set screw to se bolt shown then 3Nm poke adjust the collars z then retighten 5 bolt Turn the pedals backward to test that they are not unusually hard to turn If they are unusually hard to turn then you have over tightened the lock collar and should loosen it slightly Tighten the M4 lock bolt to 2 3Nm Adjusting the Pitstop Wheel All three quick release levers should have equal pressure to close and open In the event that the levers have different pressure or for example one lever feels loose you may need to adjust the tension in the levers To adjust the PitstopWheel 1 Remove the red rubber grommets 2 Use an M4 Allen key and WHILE HOLDING THE QUICK RELEASE LEVER IN THE CLOSED POSITION tighten the stud to 3 4Nm You will need to tighten all of the studs at least two times since the tightness of one stud may affect the next We recommend that you tighten in a clockwise direction and through 720 degrees 1 e 2 times for each stud WARNING Never tighten more than 3 4Nm as Serious injury or death could result 3 Replace the red grommets Karbon Kinetics Limited All Rights Reserved 81 Q Gocycle Owner s Manual Version 2 2 Frame N
53. sion 2 2 Frame Numbers 000301 003300 Figure 8 45 Karbon Kinetics Limited All Rights Reserved O Rear luggage arm fitted correctly Although the design rating of this luggage arm is 25kg maximum load we do not recommend that you exceed more than a 15kg load When riding with any rear luggage attached the riding characteristics including stability braking distances cornering feeling of safety can be severely different and you should adopt a cautious riding style until you are confident of the handling of the Gocycle with rear luggage 56 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 8 11 Fitting the Heavy Duty Kickstand gt H M Heavy duty kickstand Remove lightweight display stand if fitted Figure 8 46 Tighten to 10Nm torque Figure 8 47 Figure 8 48 Karbon Kinetics Limited All Rights Reserved Q Fit bolt through rear luggage arm as shown Separate frame to allow access to tightening bolt Kickstand in the up position 57 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Figure 8 49 Q Kickstand in the down position 8 12 Fitting Ortlieb Luggage Ortlieb is a registered trademark of ORTLIEB Sportartikel GmbH See www ortlieb com The rear luggage arm will suit the following Ortlieb products Office Bag 2 Shuttle Bike Bike Box 2 Bike Box 3 The rear luggage arm wil
54. tch or change of colouring in highly stressed areas indicates that the life of the component has been reached and it should be replaced before any further use Any unusual or abusive riding style such as jumping or excessive speed and braking can accelerate wear and fatigue of components to the point where premature and sudden without warning failure of the component may occur See section 9 2 for parts of the Gocycle that require visual inspection from time to time 4 4 Attaching the Front and Rear Reflectors WARNING Never ride a bicycle without fitted front and rear reflectors that meet or exceed the national standards of the territory in which it is being ridden In most countries riding a bicycle without front and rear reflectors is illegal Gocycle is shipped with front and rear reflectors in the small parts bag Locate these reflectors and the mounting accessories and attach them as shown in Section 6 Karbon Kinetics Limited All Rights Reserved 4 A Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 4 5 Fit Front and Rear Lights if Riding in Low Light Conditions WARNING Never ride a bicycle in low light conditions such as when 1 automobile driver in 20 would consider it appropriate to have headlights on without front and rear lights fitted and on illuminated that meet or exceed the national standards of the territory in which it is being ridden We recommend that you consult the relev
55. umbers 000301 003300 5 RECOMMENDED ASSEMBLY SEQUENCE 5 1 Unpacking Steerer Handlebar stem assembly Figure 5 1 5 2 Fitting the Handlebar Stem n AANA Figure 5 2 Karbon Kinetics Limited All Rights Reserved Q Start with main frame assembly as shown Fit the handlebar stem assembly to the steerer Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Front quick release lever must be open Notice notch in steerer to align the two parts and the lock pin Figure 5 3 UNSAFE TO RIDE Avoid twisting the cables when assembling the handlebar stem Figure 5 4 Pull lock pin Figure 5 5 Karbon Kinetics Limited All Rights Reserved 9 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Pull up in this direction Notice quick release IS Open Figure 5 6 Pre Ride Checklist 17 b Figure 5 7 Karbon Kinetics Limited All Rights Reserved Q Before you close the quick release pull up on the handlebar stem assembly to check that the lock pin is fully engaged You should not be able to pull the handlebar stem assembly off the steerer tube if the lock pin is correctly engaged YOU MUST PERFORM THI S TEST BEFORE CLOSI NG THE QUI CK RELEASE IF THE HANDLEBAR STEM ASSEMBLY CAN BE PULLED OFF THE STEERER DO NOT RIDE THE GOCYCLE Release lock pin and close quick rel
56. umbers 000301 003300 Remove the red dust grommets Figure 9 33 While holding the quick release lever closed tighten the quick release lever adjuster stud to 3 4Nm torque Continue to adjust all 3 studs twice over progressing through 720 degrees so that relative tightness is equalized between all three levers Figure 9 34 99 Tyres Gocycle comes fitted with specialised and high performance tyres designed to give the lowest rolling resistance possible We do not recommend that you use lower quality tyres than those supplied with Gocycle We recommend that you operate Gocycle with 25 30 psi on the front tyre and 50 60psi on the rear This will give the best balance of low rolling resistance and comfort We do not recommend that you inflate the tyres to more than 60psi Higher inflation pressures will reduce comfort and the life of the rim and tyre WARNING Inflating the front tyre to more than 30psi places high shock loads into the motor drive clutch while using the power on acceleration or over rough roads We strongly recommend that if you are running higher than 30psi front tyre pressure or you are above 85kg in weight that you adopt a smooth riding power style J ust like in a car as you would not drop the clutch on rough roads while the engine is revving high or accelerate rapidly on very rough roads we recommend that you release the power button when going over potholes or soeed bumps or similar obst
57. ust this screw to ensure reflector face is perpendicular to the ground Rear reflector RED Figure 6 8 Karbon Kinetics Limited All Rights Reserved Front reflector WHITE i Eaa B q y h ba Ba MF nr f F j i r F Q Front reflector position Front and rear reflector angles should be adjusted so that the reflector face is perpendicular to the ground 28 Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 7 ADJUSTING SEAT AND HANDLEBAR POSITION 7 1 Seat Height Turn lever in direction shown to open Figure 7 1 Figure 7 2 Do not raise seat post higher than minimum insertion depth mark on seat post Figure 7 3 Karbon Kinetics Limited All Rights Reserved Q Adjusting seat height Adjust seat up or down 29 Q Gocycle Owner s Manual Version 2 2 Frame Numbers 000301 003300 Close lever to secure seat m post Turn lever in direction shown to secure Figure 7 4 Maximum seat height should allow you to comfortably touch the ground with both feet while you are seated on the saddle Note If you would like to adjust the seat height for optimum pedalling efficiency consult the Internet for articles on this subject Figure 7 5 7 2 Handlebar Stem Height Circli _ MUST Be ET TED Before riding check that circlip at front of handlebar stem Is secure Figure 7 6 Karbon Kinetics Limited

Service Document: User Manual G1 - Green

Contents

Download Pdf Manuals

Related Search

Related Contents