User manual and installation guide EN - EGO-KITS
Contents
1. Before you take off 1 Sit down on your bike 2 Connect the battery wire to the saddle plug and check the wire length 3 Only then turn on the main switch on the throttle You re ready to hit the trails EGO KITS USER MANUAL VERSION 1 0 EN LED Code Explanation Blinking RED System is on Normal operation EGO KITS USER MANUAL VERSION 1 0 EN q The LED flashes once at power on then keeps off for normal operation 1 2 for instance means it flashes once then flashes twice after 1 second The time between two flashes LED Code Explanation Solution LED Code Explanation Solution 12 ee Over voltage error 1 Battery voltage is higher than max operating voltage of the 2 4 eooo Throttle error at 1 Throttle signal is higher than configured dead zone at power on controller Please check the battery voltage and configuration power up 2 The fault will disappear if restart or release throttle 2 Over voltage at regeneration Controller will cut back or stop regeneration 599 Frequent reset It can be caused by over current bad motor bad ground wiring or so 3 Please note there could be 2 error with Overvoltage setting 1 3 eee Low voltage error 1 The controller will attempt to clear the fault code automatically 3 2 ee Internal reset Reset caused by over current high battery voltage or low after 5 s2. EGO KIT USER MANUAL 1200 WATT ADD ON ELECTRIC POWER KIT Before using the EGO Kit please read the entire user manual as it contains important information Each and every crash with the bicycle can lead to serious or even fatal injuries Depending on the for its proper usage and reduced user risk Damages resulting from not adhering to this user manual intensity of use the EGO Kit and all of its parts should be thoroughly inspected and maintained will void the warranty guarantee Proper maintenance of the bicycle as well as the EGO Kit is regularly Please contact your EGO Kit dealer for service arrangements essential as it reduces the risk of injury and or accidents with possible lethal consequences for the bicyclist or others Never ride alone in remote areas Be sure to tell a friend or family member where you are planning on going Ensure that the EGO Kit is properly mounted and functional before going on your first ride After installing the EGO Kit on your bike go for a test ride to check the bike and EGO Kit for proper function on a well known route without obstructions THE EGO KIT IS A RETROFIT PROPULSION DEVICE DESIGNED FOR WELL BUILT NONCARBON FIBER Before going for a ride the EGO Kit and bicycle to which the EGO Kit has been mounted both must MOUNTAIN BIKES be checked for any damage and proper function You must not put the bike and EGO Kit into service if you notice bent fractured or cracked parts on th
3. The largest power output and optimum efficiency is in the mid RPM range As with any motorized vehicle operating the bike at full throttle for extended periods of time will damage the materials used The EGO Kit is splash proof but not waterproof e Do not ride through puddles or streams neither the motor nor the controller must be submerged MAINTENANCE ADVICE The EGO Kit must be regularly maintained cleaned and inspected as moisture and dirt may accu mulate depending on the riding conditions We recommend that the EGO Kit is regularly cleaned dried and freshly lubricated in order to ascertain its proper function Do not store the bike outside or in the rain Have the chains checked regularly for elongation by a bicycle dealer of your choice EN Before beginning mounting or maintenance work on your EGO Kit ensure that the battery has been disconnected Never reach between the chain the chain ring or any other moving part while the bike is in operational readiness mode or in operation Do not burn yourself During and after use certain parts of the EGO Kit such as the motor heat up Never open the motor The motor may only be repaired and maintained by trained professionals In case of any signs of abnormal function stop using the kit immediately and contact EGO Kits support Never use batteries that were not supplied with the EGO Kit Using third party batteries can cause irrevocable damage to the
4. Keep distance EGO KITS USER MANUAL VERSION 1 0 EN Before attaching the battery wire remove the saddle 6 1 Route the battery wire along the saddle post Ensure that the wire is not exposed to friction or tension 6 2 Using cable ties attach the wire to both saddle rails After mounting the wire must not slip but the cable ties must not damage the wire insulation either We recommend using two cable ties in the front of the saddle One tie clamps the wire to the left rail the other to the right rail Use a third cable tie to attach the wire to either rail near the back of the saddle 6 3 Attach the wire to the saddle post in such a manner that the saddle can still be adjusted without obstruction or difficulty The plug shown in the illustration on the right may have a different look e TOOL BOX 3x cable ties 5 mm Allen wrench to remove saddle g EGO KITS USER MANUAL VERSION 1 0 EN Before putting on the backpack ensure that the wire is properly routed 7 1 Decide if the wire should be routed along your left or right hip 7 2 Have the wire come out of the backpack as close as possible to the bottom of the backpack and attached to the hip belt to run it between your legs to the saddle plug Adjust the length so that the bike can be ridden standing up CAUTION when riding in the seated position do NOT let the wire loop drape over your knee which could cause interference when pedaling
5. Economic Area EEA The device conforms to CE and fulfills the required European guidelines The symbol showing an arrow pointing inside a house stands for utilization within an enclosed space Using the device outside could cause damage to the device The crossed out garbage can symbol signifies a selective waste disposal process for electric and electronic waste This means that this product has to be handled in a specific way when being recycled or taken apart in order to keep the environmental impact at a minimum Improper disposal may result in environmental or health related risks The symbol depicting an exclamation mark inside a triangle cautions to use special care in handling use or operation Please read the user manual carefully This symbol warns of misuse which could result in damage to persons property or the environment The symbol showing a lightning bolt inside a triangle is used if your health could be jeopardized such as by electric shock Do not open the device The symbol depicting the letter i inside a book located inside a circle advises to read the user manual carefully and to understand it The symbol ATE OK on the charging unit means that this device has passed automated tests The symbol HI POT OK on the charging unit means that this device has undergone a high voltage serial test ensuring that no high voltage can jump from the primary to the secondary circuit EGO KITS USER MANUAL VERSI
6. Set chain ring 22T 36T 42T Freewheel assembly with EGO Adapter Plate 4 X10 mm short chain ring bolts silver 4x12 mm long chain ring bolts black 4 x spacers black Motor chain Motor freewheel sprocket cover 3 x sleeves 1x low profile nut 4 x M6 bolts BATTERY PACK WITH BACKPACK AND CHARGING STATIO 48 V 12 5 Ah Li Mn Battery Backpack Ergon BA1 2 Ah charging station 10 Ah charging station optional equipment CONTROLLER Controller unit Mounting plate Throttle EGO KITS USER MANUAL VERSION 1 0 EN REQUIRED TOOLS 12 In order to mount the EGO Kit keep the following tools handy You can order the correct ISIS bottom bracket tool on our website e e Allen wrenches 2 5mm 3mm Crank remover v Torx driver 4mm 5mm SO Open end wrenches 8mm 10mm Box cutter VA v 4 Pliers Wire cutters f v Ratchet S v Cable ties X approx 5 pieces ISIS bottom bracket tool special accessory EGO KITS USER MANUAL VERSION 1 0 EN In order to mount the main carrier to the bottom bracket tube of the bicycle frame two different types of adapters are designed to provide the necessary spacing distance sleeve or spacer yellow in the diagram on the left side Depending on the width of the bottom bracket tube select the appropriate position TOP VIEW ON EGO BRACKET FR BRACKET DH BRACKET ISCG with different spacers spacer positions Bikes that do not feature ISCG attachment points can
7. addition travelling with the EGO Kit on the roof of a car or behind the car in the rain simulates a pressure washer Please make sure that if you must transport your bike in this fashion that the controller motor and throttle and covered with some protection such as a plastic bag EGO KITS USER MANUAL VERSION 1 0 Can keep pedaling after the battery has been drained Yes Because of the motor freewheel device there is no resistance when using the bike without motor support Your bike stays a bike Can keep the pedals stationary while under full throttle power Yes There is no crank sensor governing the amount of motor power to the rear wheel Acceleration comes only from twisting the throttle and of course your own physical power Furthermore due to the crank freewheel device the pedals do not move when the motor is used allowing you to fully concentrate on your uphill ride Can ride using any gear ratio selection of my choice In general yes However the EGO Kit is delivered with what we believe to be optimum gear ratio already mounted A tested and true combination of the motor sprocket motor chain ring and drive chain ring which delivers equally great results between power and top speed This is supplied with your EGO Kit ANY MORE QUESTIONS Just get in touch Easy going support ego kits com EN Motor is not turning Check the on off switch on the throttle to make sure it s in the ON position Ch
8. be retrofitted with an EGO ISCG Simulation Disk Please contact EGO Kits for further details i DOWNTUBENY n 1 EGO BRACKET SIZE BOTTOM V BRACKET ISCG 05 Standard 68 n 5 8 9 e N BSA threaded bottom bracket Vd CHAINSTAYS V V RIGHT EGO KITS USER MANUAL VERSION 1 0 EN 2 1 Controller mounted below the bottom bracket Delivered option bracket 86 101 short 2 2 Controller mounted below the down tube in front of the motor Delivered option bracket 86 101 long 23 Controller inside the frame triangle NOTE if you want to mount the controller like on 2 3 cut or break off the protruding piece of carrier sheet metal along the perforation and smooth out the resulting sharp edges with a file TOOL BOX 4 mm Allen wrench 8 mm 10 mm open end wrench EGO KITS USER MANUAL VERSION 1 0 2 3 EN Before you can begin mounting your EGO Kit the existing crank system and bottom bracket must be removed 3 1 Unbolt the clamps from the down tube 3 2 Using three bolts loosely attach the main carrier to the ISCG attachment points WITHOUT ISCG Mount the ISCG adapter to the right hand side 33 On the left side of the frame bolt a single bottom bracket jacket into the frame thereby loosely fastening the distance sleeve t
9. or near combustible materials even when charging Ensure that the charging station and battery are not covered up as the charging process generates heat e g do not charge the battery in the backpack e If the device has been moved from a cold to a warm room do not immediately put it into operation The resulting condensation may cause operational problems or damage e f at any point in time it is assumed that the device cannot be operated without danger if the battery or charging station shows visible signs of damage if the device is non functional it is to be taken out of service and must be secured in such a manner that it cannot be put into service again Do not operate the charging station battery unsupervised Turn off the charging station before unplugging it from the wall outlet when ending the charging cycle or if the battery is fully charged EN MAIN BRACKET bracket 86 long distance sleeve bracket 86 short distance sleeve bracket 101 long distance sleeve bracket 101 short distance sleeve 68 73 mm bottom bracket with crank bearing sleeve 83 mm bottom bracket with crank bearing sleeve Upper and lower clamp 2 x 10 mm chain ring sleeves ISCG simulation ring optional equipment DH chain guide optional equipment MOTOR DRIVE SYSTEM Motor with freewheel sprocket 13T ZA Right and left side crank Motor mount 2 x bolts 4 x M6 nuts DH Set chain ring 34T 42T Motor chain tensioner FR
10. system and may have life threatening results explosion fire The EGO kit will put additional strain to your existing bicycle components drivetrain and we recommend replacing your bike with a new chain and cassette prior to installing the EGO Kit EGO KITS USER MANUAL VERSION 1 0 The crank system was specifically developed for use with the EGO Kit and should not be used for other purposes Vehicles retrofitted with the EGO Kit are not street legal Abide by country specific laws and regulations governing the use of e bikes The EGO Kit is not meant to be used in competitive events For safety reasons the motor is equipped with an overheating safety device If this device should shut the system off do not disconnect the battery but wait until the system has reached normal temperatures again and the throttle can be operated again The temperature of the battery increases when in use After using the battery it should be allowed to cool down before recharging EN GENERAL INFORMATION In order to extend the life expectancy of the battery and avoid accidents we ask for your own interest that you adhere to the following safety precautions The main cause of battery related accidents is improper handling such as incorrect charge setting overheating or mechanical damage to the battery due to a crash No liability can be assumed for personal and or property and or consequential damages due to handling of the b
11. ON 1 0 This symbol shows the maximum ambient temperature safe for the use of the device marked A device marked with the symbol showing a crossed out lit match should be kept away from open flames or sources of ignition The RoHS 2002 95 EC Compliant Symbol indicates that the labeled devices adheres to the minimum levels for toxic components as required by EU Guideline 2002 95 EC EN We are continuously and diligently working on ensuring the quality and accuracy of all of the information provided in this booklet All work you perform on your bike is at your own risk When in doubt please contact us or take your bike to a specialist We do not warrant and cannot be held liable for the contents of this manual If you have questions doubts or suggestions please contact us immediately ANY MORE QUESTIONS Just get in touch Easy going support ego kits com With the exception of the express written duties in accordance with our warranty declaration EGO Kits and eRide and their suppliers and distributors are not liable for any direct indirect special accidental or subsequent damages unless otherwise demanded by local laws and regulations eRide Industries GmbH Munich Germany 11 Nov 2011 EGO KITS USER MANUAL VERSION 1 0 EN This user manual may not be copied or distributed either in whole or in part No changes are permitted Changes omissions errors including but not limited to typographical and prod
12. Y COPYRIGHT 10 11 12 13 19 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 EN Nothing satisfies the EGO more than DIY work Even so for the most relaxed DIY atmosphere we recommend aside from your favorite tunes that you enlist the help of a buddy for mounting the EGO Kit The EGO Kit is delivered pre assembled and with some experience can be mounted in about an hour If you only have basic knowledge it might take two hours ORIENTATION The bottom is not the top but where is the right hand side When in motion the direction of travel is what counts The same goes for when working on your bike thus the front is the front the back is the back and right and left are always the same as if you were riding your bike AREAS OF OPERATION For Downhill and Freeride Terrain In enclosed and secured areas n off road areas In approved areas check with your local authorities MODES OF OPERATION Normal pedaling WITHOUT motor support Normal pedaling WITH motor support Motor support with individual control using the throttle PROPER CLOTHING Before you take off there are a few essentials we wanted to mention Do not wear shoes with loose or dangling laces They should be properly secured Do not wear loose fitting pants only tight fitting bike shorts or pants in order to avoid getting caught in the chain Do wear fitting protective gear helmet protectors such as a back protec
13. all batteries and rechargeable batteries will eventually discharge even when not in use Self discharge is dependent on the ambient temperature and the higher the tem perature the quicker the self discharge Ideal temperatures for storing your battery are between 10 C 50 F and 25 C 77 F What is a total discharge and is it dangerous for the battery When a total discharge occurs the polarities of the cells of the battery with the lowest capacities get reversed Just a single total discharge may destroy a battery Furthermore a total discharge will diminish the capacity of the battery What happens if overcharge the battery Overcharging the battery will result in diminished capacity and damage to the battery After fully charging your battery the EGO Kit charging station will automatically switch to maintenance charging avoiding an overcharged battery The fan will also switch off at this time However the battery should be disconnected from the charging station as soon as feasibly possible after the battery has been fully charged EGO KITS USER MANUAL VERSION 1 0 What is the memory effect and how can avoid it The memory effect is mostly observed among Nickel Cadmium batteries and may diminish the capacity of the battery This happens most frequently when recharging a battery that was not completely discharged before The memory effect does not affect Lithium Manganese batteries such as supplied with your EGO Kit How
14. attery outside of its intended purpose or ignoring of the safety precautions EGO KITS USER MANUAL VERSION 1 0 CHARGING THE BATTERY Before connecting your charging station to a power outlet please ensure that the country you are in has the proper voltage for your charging station If your charging station is not rated for the country you are in please get in touch with us immediately CONNECTING THE BATTERY TO THE CHARGING STATION 1 Connect the battery to the charging station first 2 then connect the charging station to a wall socket 3 finally switch on the charger Only use an original EGO Kit charging station for charging the battery Using a non EGO Kit charging station may cause damage and will void the warranty CHARGING STATION LED DISPLAY The charging station is equipped with two differently colored LED s to indicate the charging state LED 1 RED POWER ON LED 2 RED battery being charged LED 2 GREEN charging cycle complete CHARGING TIMES for discharged battery 2Ah charging station 5h 80 7h 1009 o 10Ah charging station 1h 80 1 5h 100 optional equipment available separately EN STORING THE BATTERY Store the battery halfway charged 3 illuminated LEDs on the battery display in a dry place at room temperature never below 5 C 41 F protected from direct sunlight Check plugs regularly for moisture corrosion or other damage Store and transport the battery on
15. battery This would increase the risk of a fire The temperature of the battery must not exceed 60 C 140 F ensure proper cooling and ventilation The battery should not be subjected to strong vibrations or friction The battery should not be subjected to excessive moisture Use the battery only for and in conjunction with the EGO Kit motor Before connecting or disconnecting the battery to from the EGO Kit the main switch on the throttle must be turned off Check that all functions are working properly before taking off Ensure that all plugs are connected properly Loose plug connections may cause damage due to electric sparks e n case the battery housing the wire connections or the plugs are damaged contact EGO Kits Support immediately Liquids may leak from the battery if handled inappropriately Avoid eye and skin contact How ever if you do get in contact with the liquid rinse the affected parts with plenty of water and consult a physician immediately Charge the battery only with the EGO Kits charging station Do not connect discharged batteries to the motor Recharge the battery immediately after use after letting it cool down or before putting it into storage If the battery is not at least halfway charged before going into storage for longer periods of time a deep discharge could damage the cells Recharging the battery is not possible if the battery is excessively warm A temperature safety devi
16. ce will prevent this Letthe battery cool down to room temperature after use Do not charge while still warm EGO KITS USER MANUAL VERSION 1 0 CHARGING STATION Using your auditory visual and touch senses ensure that the cooling fan of the charging station is working properly during operation For safety and product registration reasons CE you must not tamper with the charging station The charging stations are calibrated to work with your specific EGO Kits battery f you have questions or doubts about the function safety or how to connect the device please con tact a specialist or return the charging station to us after contacting us first The charging station must not become wet or moist thus it should only be used inside Verify if the power outlet to which you wish to connect the charging station can handle the current the charging station will require Also verify that the wall outlet is equipped with a failsafe device or properly fused RCD GFCI device Only charge one battery on any given circuit at a time Keep the charging station away from high temperatures gt 40 C 104 F low temperatures lt 0 C 32 F direct sunlight dust and dirt Always ensure that the plugs are properly connected Loose connections may cause damage Leave a minimum distance of 20 cm 8 between the charging station the battery and other objects Never place the battery on a combustible surface e g carpet
17. do dispose of my EGO Kit battery Please check your local battery recycling laws Do not throw batteries away with your household trash Does the battery have a fuse Yes the battery is equipped with a built in fuse which only EGO Kits can replace Please contact EGO Kits support for assistance EN Is it ok to mount a chain guide Yes The EGO Kit adapter is equipped with a support for an optional EGO compatible chain guide Chain guide for dual chain ring bottom Chain guide for single chain ring top and bottom Is the electric motor difficult to maintain No brushless motor is virtually maintenance free As usual keeping the chain and sprocket properly lubricated has its advantages The transmission lubricant in the planetary gearbox should be checked regularly by a service professional What s the point of putting the battery in the backpack This solution keeps the weight of the bike low thus leaving the handling of the bike as it should be for downhill and freeride rides nimble and active How is the level of power controlled By using the throttle It s mounted on the right arm of the handlebar and is approx 3 cm 134 wide and looks similar to a grip shift gear changer EGO KITS USER MANUAL VERSION 1 0 Is the battery recharged while braking Cool idea but no Unfortunately in reality such a system would be too heavy and thus compromise the ride characteristics of your bike The resulting recuperatio
18. e EGO Kit or the bicycle or if one or more of the initially delivered parts are missing TERMS AND CONDITIONS AND WARRANTY please refer to http www ego kits com en support agb EGO KITS USER MANUAL VERSION 1 0 EN SHOW RESPECT WHEN USING THE EGO KIT Adhere to all local laws and regulations governing the use of electrified bicycles on and off road EGO KITS USER MANUAL VERSION 1 0 SHOW RESPECT FOR NATURE f possible use paved paths to avoid uphill erosion Look out for pedestrians and other users Respect the trails and Tread Lightly AGE APPROPRIATE OPERATION Bicycles with powerful electric motors and or batteries are not toys Please ensure age appropriate operation We recommend the EGO Kit for adult use only Previous knowledge and experience with the operation of electrified motors and motorcycles is an advantage EN CONSUMER SAFETY QI Ey deo p Show Respect When Using the EGO Kit Show Respectfor Nature sess Age appropriate Operation GENERAL TIPS FOR USING THE EGO KIT OMG MAHON MR Areasof operation i EE Fev ea aul Modes of operation ro co ec erento nene needed Proper clothing Ie potter ce e e ai erred RD ta unde Reduced life expectancy Operating safety D
19. e a complete connection ensure that the battery wire is routed properly along the backpack and that unobstructed operation of the bike is ensured Ideally it is routed along the abdominal strap of the backpack via the groin area to the saddle page 19 before turning on the system be sure that the throttle can be twisted freely without friction The throttle is supposed to auto reset into its original position page 17 select the proper gear for taking off from standstill depending on the terrain incline terrain properties etc ensure that the chains are properly lubricated check the chains regularly for proper tension check electrical wires and plugs for damage EGO KITS USER MANUAL VERSION 1 0 PROPER USE Select the appropriate gear for taking off You should be able to power the bike yourself in the gear you select Start with pedaling yourself then twist the throttle SLOWLY for the appropriate dosage of power Avoid gears where the chain would be running in an extremely offset position e g large chain ring in both front and back For going uphill use the small chain ring in lower gears Change gears without motor power use only your own pedaling power After gears have been changed you may carefully resume acceleration with the throttle Do not change gears while the motor is powering the bike This will lead to excessive wear on chain and chain rings possibly even chain failure
20. eck the saddle plug to the battery for a snug connection Charge the battery never store the battery in a discharged state Check wires including insulation for damage Contact EGO Kits if needed Check for LED error codes on the controller Battery is not charging Check the connections Redo the connections in the proper order Battery Charging Station wall outlet on switch Battery temperature too high let the battery cool down and try again Charging station getting hot Some elevated temperature is normal Check the fan to make sure it can move freely without dis assembly EGO KITS USER MANUAL VERSION 1 0 Battery getting warm This is normal Depending on the current being drawn the battery will generate heat The battery management system inside the battery will ensure that the temperature generation remains within safe levels CAUTION A warm battery should be allowed to cool down before attempting to recharge it Throttle sticking Check to see if it can move freely f needed move the handlebar grip a little away from the throttle Ensure that the throttle display is not pushed up by the brake lever clamp Chain derailing Check chain tension and chain run Motor sprocket and motor chain ring must be properly aligned Chain must not hang loosely EN gt PD The symbol signifies freely marketable industrial products in the European
21. econds if battery voltage returns to normal supply voltage It is normal if occurs occasionally E 2 Check the battery voltage 9 3 Charge battery if necessary 3 3 eee Throttle short or 1 Check whether the throttle is short or open up P open circuit when 2 When the throttle is normal restart will clear the error 3 14 e eeee Over temperature 1 The controller temperature is over 90 The controller will cut using 1 4v hall 5 warning back current in the case Stop or reduce output to ensure the sensor throttle temperature fall 2 Improve heat sink or airflow 3 4 eee coco Throttle isn t zero The controller won t change drive direction if throttle isn t zero 5 when try to Also it won t change direction at high speed The controller will E 21 e Motor fails to start Motor hasn t reached 25 electrical RPM after 2 seconds from change direction wait throttle and speed close to zero before change direction starting Most likely the hall or phase wiring problem 5 4 000 Over voltage at The controller won t drive motor if detect overvoltage at power 9 25210 Internal voltage 1 Check if the B and PWR voltage are correct refer to startup or up It will cut back regen current or stop regen at overvoltage 5 fault B or RTN Could be PWR voltage low regeneration You may set max voltage threshold with GUI 5 2 Please check load 5V supply Could be high load z on 5V Incorrect pot wiring can load it heavi
22. er sa ere Re Ree er xu ix baa pun se donde E m Mainteriarice advice rne pub nd SPECIFIC WARNINGS WHEN USING THE EGO KIT IMPORTANT INFORMATION FOR USING THE EGO POWER BATTERY Gensralinformatlol c cuerpo nano Pin tune tte rae en naa Charging the battery Connecting the battery to the charging station Charging station LED display Charging LIMES ERE Reo oi Pb Ea Storing the battery uen et oet e Rev Feo e in case of fire MM EGO KITS USER MANUAL VERSION 1 0 IMPORTANT INFORMATION REGARDING THE RECHARGEABLE BATTERY CHARGING STATION THE EGO KIT REQUIRED TOOLS MOUNTING THE EGO KIT 1 1 Preparing the bottom bracket ISCG adapter Controller position 1 255 1122 rc Den quen Mounting the EGO Kit to the frame Mounting the chain and attaching the crank Mounting the throttle riore rere REP Yer e ee AR e e Re FR RH na Routing the wire around the saddle Connecting the battery Y EE tre ER R aas THROTTLE LED CODES CONTROLLER LED CODES FAQ RECHARGEABLE BATTERY FAQ OPERATION TROUBLESHOOTING EXPLANATION OF IMPORTANT GRAPHIC SYMBOLS LIMITATIONS OF LIABILIT
23. lts need to be loosened The motor can now be moved along the longitudinal axis to tension the chain and along the cross axis to allign the chainrings Avoid overdrawn chain tension or loose fitment p TG IB ee Sm TOOL BOX 5mm 2mm Allen wrench 8mm 10 mm open end wrenches 25 OQ EGO KITS USER MANUAL VERSION 1 0 EN Before you begin mounting the throttle the right hand handle bar grip needs to be removed 5 1 Slide the throttle loosely over the handlebar display facing upwards 5 4 5 2 Ensure that the brake and gear shift levers are in such position as to not cause any obstruction nor cause them to be obstructed in order to ensure their proper function E g one arrangement would be from the center to the outside brake lever gear shift lever throttle Brake lever and gear shift lever may have to switch positions 53 Boltthe throttle to the handlebar The wire must not interfere within the full range of motion of the handlebar 5 4 Using a saw or box cutter shorten the original grip by about 1 3 and reattach to the handlebar CAUTION in order to avoid throttle movement being obstructed it is extremely important that you keep a distance of 1 2 mm between the throttle and the handle bar grip TOOL BOX 2 5 mm 3 mm Allen wrenches
24. ly 4 2 ecco oo Hall sensor 1 Most likely caused by incorrect hall wiring 3 The controller is damaged Please contact EGO Kits signal error wrong pin or loose wire 2 Intermittent or damaged hall sensor 8 2 3 eee Over temperature 1 controller temperature is over 100 C 3 Double check hall angle setting 60 degree or 120 degree Controller stops driving in the case 2 Stop driving and wait for temperature fall 4 3 ooo Motor over 1 The motor temperature higher than configured max temperature g The controller will restart if temperature drops below 80 C temperature Controller will shutdown and wait for motor temperature drops S 2 Can change the temperature setting with configuration program EGO KITS USER MANUAL VERSION 1 0 EN What is the best way to store my rechargeable batteries Rechargeable batteries should be stored at least halfway charged at room temperature and a rela tive humidity of 509 o EGO Kit batteries should be recharged on a monthly basis as every battery discharges itself if not used This may cause permanent damage The battery is not fully charged when delivered thus it needs to be fully charged before its first use What is self discharge Self discharge occurs on its own and is dependent on ambient temperature It is a chemical reac tion process which takes place on the battery s electrodes when it is not connected to an electrical consumer This means that
25. ly in fireproof containers Riding with the EGO Kit is the only exception and the battery should of course be placed in the backpack during this time When not in use the battery voltage must be checked every four weeks and if needed be recharged In case the battery was not stored properly or if a deep discharge has occurred take the battery to your dealer immediately The battery has been designed with a special function to save battery cells that have been severely drained NEVER OPEN THE BATTERY EGO KITS USER MANUAL VERSION 1 0 IN CASE OF FIRE Using Lithium batteries battery packs outside their intended purpose may result in the cells exploding and or catching fire If for any reason a charging station or battery fire occurs BATTERY Batteries and charging devices are not toys and must be kept away from children Batteries must never be shorted out taken apart or thrown into fire This may result in fire or explosion Before each charging cycle inspect the battery pack for damage Adamaged battery must not be charged or put into operation Never place the battery on a combustible surface e g carpet or near combustible materials Ensure proper ventilation during the charging process When attaching the battery to the charging station ensure proper polarity and voltage If the battery poles are crossed both the battery and the charging station will be damaged Do not overcharge the
26. n of energy would be way too little to warrant the device How many chain rings can mount Three chain rings have been mounted to the crank One motor chain ring and two drive chain rings to transfer power to the rear wheel A separating disc is located between the motor chain ring and drive chain rings to ensure proper propulsion We discourage installing a third drive chain ring as there is not enough space to safely utilize that many chain rings Generally freeride bikes are not equipped with more than two drive chain rings Downhill use with a chain guard calls for the use of only a single drive chain gear EN How does the motor weight affect the handling of the bike It s neutral Because we put it near the center of gravity of the bike the handling remains as agile and nimble as possible This was the main goal behind the development of the EGO Kit Does mounting the EGO Kit reduce ground clearance No At least not for most bikes The lowest point on any bike is the chain ring Unusual down tube designs may influence the position of the motor though Can ride in the rain with an electric motor Sunshine is way better than rain however you don t want to skimp on fun just because it s raining Splash water is not a problem Do not use pressure washers for cleaning as this will void the warranty Avoid riding through creeks or rivers If riding in the rain make sure to cover the throttle A plastic bag works well In
27. o the frame CAUTION the main carrier should butt up to the down tube highest possible position for the motor Run the wire inside the main carrier being careful not to pinch the wire e TOOL BOX Two 5 mm Allen wrenches X20 Torx driver g EGO KITS USER MANUAL VERSION 1 0 3 4 Press the clamps together and attach to the appropriate holes 3 5 Insert bottom bracket from the right hand side and bolt it in left hand thread 3 6 Tighten the left side bottom bracket jacket and the ISCG CAUTION route the throttle wire inside the clamps Be careful not to pinch them EN 4 1 Drape the motor chain over the outer chain ring Drape the pedaling chain over the inner chain 4 3 The chain tension is set in a correct manner if you are able to move the chain for 1 cm between ring while pulling the rear gear change arm forward and securing it or have a friend keep it chainring and motor sprocket like shown in the illustration below in place Slide the crank system onto the bottom bracket and render the bottom bracket bolts When tightening the bolts again approx 10 Nm 7 38 lb ft be sure that the chain immovable is straight and parallel to the bike frame do not mount the motor crookedly 4 2 Check the chain run and adjust if needed In order to set up the motor position properly and thus allowing for an ideal chain run and optimal tension the four bolts that connect the motor mount to the main carrier 4 screw bo
28. tor gloves etc are a prerequisite to minimize risk EGO KITS USER MANUAL VERSION 1 0 CLEANING Do not use pressure washers for cleaning Use a sponge and brush instead Use only commercially available soap and water Do not use chemical or corrosive solvents REDUCED LIFE EXPECTANCY The life expectancy of the EGO Kit is reduced if itis used more often than average the terrain you ride in is less even than the average terrain you carry heavy loads you put more stress on its components than the average rider you put too much strain on the electrical components you ignore warnings or error codes of the EGO Kit the EGO Kit is installed and or maintained improperly e the EGO Kit is subjected to harsher than average environments corrosive mud salty air salted roadways etc the EGO Kit is damaged due to a crash jump or other abuse The more of these factors apply the shorter the life span of the EGO Kit Due to the large number of factors we are unable to be more specific on the expected life expectancy EN OPERATING SAFETY Before each ride check that all bolts and screws are properly tightened check that the motor chain has the proper tension page 16 get on the bike first then connect the battery before connecting the battery ensure that the system is turned off ON OFF switch on the throttle when connecting the battery plug to the saddle plug ensur
29. uction errors accepted EGO KITS USER MANUAL VERSION 1 0 EN
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