Untitled - Powabyke
Contents
1. POWATRYK BUILD MANUAL I W e Innovator www powabyke com Copyright Powabyke Ltd Bath UK 14 07 2006 Assembly Manual of the Tryke Tools required e 8mm spanner e 6mm Allen key e 10mm spanner x2 e Cross head screwdriver e 13mm spanner x2 e Chain link extractor tool e 14mm spanner e Hot air gun e 18mm spanner e Pliers e 22mm spanner e Side cutters e 2 5mm Allen key e Rubber mallet Consumables e 22 medium cable ties e 6 small cable ties e 15m nylon strapping and clips x5 e Large labels Preliminary notes Ensure you assemble on a board or similar surface to prevent scratching of paint work Two size trikes 24 and 20 Two boxes of parts for each trike Parts list gt Chain guard x1 gt Seat x1 gt Handle bars Nexus gear hub and cable set x1 or derailleur gt Rear mudguards x2 gt Front mudguard x1 gt Rear Wheels with tubes and tyres x2 gt Front tyre inner tube and rim protector x1 gt Battery housing pack xl gt Main frame with front forks chain crank and rear hub assembly x1 gt Back axle x1 gt Rear Basket x1 Parts Pack A gt Seat post xl gt Pedals x2 L amp R gt Nut covers for rear wheels x2 Version 07 06 2 gt Small rear chain x1 gt Front brake cable pack with anti rotation device x1 Rear basket stays x2 gt Front light box white x1 gt Handle bar grip x1 gt Anti Rotation Bracket gt Nuts and bolt2. Attach gear assembly onto nut with 10mm bolt Test gear change movement in 2 gear indicator on rear assembly should be between the lines Electric Parts 1 Attach keys to handle bars 2 Connect controller to bracket on front of handle bars lug between the two washers fig 37 and tighten 8mm Note Ensure key hole faces rider Version 07 06 11 3 Attach throttle to handle bar loosened grub screw 2 5mm hex but do not remove because impossible to re insert When throttle is in position tighten grub screw fig 38 With three small cable ties attach cable to handle bar and under controller fig 39 Note don t insert completely the throttle on the handle bar leave a small looseness between the end of the handle bar and the throttle otherwise throttle will not operate smoothly 4 Keeping electrical cables separate from gear and brake cables fig 40 connect white connector to front hub cable Ease heat shrink sleeve over connector and use hot gun to shrink sleeve fig 41 attach small cable ties above and below connector Use two cable ties to attach cable to forks and feed into frame clips fig 42 Version 07 06 12 5 Starting from rear thread main power cable from basket under frame in clips with other cable s leaving enough cable to attach plug to battery and secure with cable ties Excess cable should be at the front to facilitate turning Cable tie 2 or 3 to make neat fig 43 Remove all cabl
3. e tie ends 6 Four stickers should be placed on front stem fig 44 middle stem under seat post fig 45 chain guard fig 46 and rear axle frame fig 47 Version 07 06 13 7 Road Test by inserting test battery and check motor brakes and gears check for mudguards or chain rubbing 1 Place trike onto palleted box base 2 Attach three packing straps as photos _ 3 Insert accessories front and rear light bell battery charger and user manual 1n rear basket 4 Fit cardboard sides and top and secure with two straps 5 Label both long edges of box with Size Colour and Serial No Version 07 06 14
4. et is to rear of bike fig 19 Ensure that bolt heads are to the inside of the cage and that the largest washers are under the bolt heads 11 Assemble rear basket and fix with 2 cable ties per corner and side next to L shaped lugs 16 cable ties altogether fig 20 Fit rear basket to top of battery cage with rear basket stays fig 21 site basket so that seat can be raised and lowered freely Note during the fitting of the basket do not tighten too much cable ties before you have completely assemble the basket Otherwise it will be very hard to fit the last side of the basket 12 Insert battery inside battery cage Remove rubber protections which are located either Version 07 06 7 13 Remove plastic bolt cover fig 23 and unscrew 6mm hex bolt Insert stem into frame and tighten 6mm hex bolt fig 24 Replace plastic bolt cover Note respect the minimum penetration level of the stem indication engraved on the stem fig 25 14 Attach front mudguard removing plastic protection Secure to bolt through frame and screw side stays to brackets with attached screws Push down on guard before tightening fig 26 Version 07 06 8 15 Fit pedals using special spanner fig 27 Check which one is the right and the left pedal before to fit them indication engraved on end of pedals Note thread of left pedal is reversed left pitch D 16 Attach chain guard to lugs screws supplied on frame locate fro
5. nd all spoke ends covered fig 8 Fit tyre inner tube and inflate to 40psi Version 07 06 4 6 Fit Rear Wheels for the right rear wheel locate the 3 pins on axle into the holes on wheel fig 9 Tighten nuts 22mm Tap on plastic nut covers fig 10 Note do not tighten too much nuts because otherwise you will damage wheels bearings 7 Working right way up with electrical connector to near side left if sitting on bike Remove the black angle bracket on the axle nut near side fig 12 13 and undo the rubber protection cap fig 14 Fit front wheel to forks between washers on near side only Remove one washer on off side axle ensure good fit on axle fig 15 16 Line up Front wheel with forks Note to fit front wheel to forks before to assemble it lightly widen the forks by pulling apart while offering the wheel into position Version 07 06 5 8 Fit anti rotation device to right side front axle with bracket around fork 10mm fig 17 Tighten nuts on axle both sides before tightening bracket 18mm Replace rubber protection cap and fit the black angle bracket onto the axle nut left side Tighten all front nuts Check alignment of front wheel 9 Fit Rear mudguards with 10mm spanners Retain plastic covering for protection fig 18 Note finger tight only as mudguards need to be moveable for packing Version 07 06 6 10 Fit battery cage to frame with 13mm bolts 1n pack ensure that the rotation of the bask
6. nt screw first and check chain can run free without rubbing Adjust if necessary 17 Adjust the angle position of the seat and then fit seat post to seat and locate into frame 14mm 18 Attach front brake cable to lever Adjust brake blocks 8mm bolts to contact rim only not tyre fig 28 and pass cable through L shaped cable guide inserted into bracket fit rubber gaiter and secure wire through cable clamp 10mm fig 29 Finish cable ends with clamped on aluminium caps Version 07 06 9 19 Attach rear brake cable to lever fig 31 and thread through frame clips to rear brake cable clamp Insert rear brake spring and then pull cable taught and tighten 10mm Finish cable ends with clamped on aluminium caps fig 32 Note put the tryke upright on these rear wheels to proceed 20 Select gear 5 and thread gear cable through frame clips Attach gear cable to frame with 2 cable ties fig 33 Secure wire through cable clamp 10mm and finish cable ends with clamped on aluminium caps fig 34 Test Gear change movement and ajust it if necessary by turning the adjustment nut located at the end of the cable at the derailleur side Note put the tryke upright on these rear wheels to proceed Version 07 06 10 20bis If Hub gear Select gear 1 and thread gear cable through frame clips pass gear assembly between chain and frame fig 35 Insert Gear spring in gear shaft and make sure chamfer is outward fig 36
7. s pack gt Motorised front wheel x1 gt Battery Charger xl gt Electric wiring loom throttle keys and control box pack x1 gt Spare brake lever x1 not used gt Stickers x4 cables ties and spare heat shrinks pack x1 Assembly instructions Mechanical Parts 1 Unpack and check all parts against Parts list Please note serial number under bike frame for use later 2 Check that all the gears good work push on the derailleur and with your other hand run chain by turning pedals fig 1 2 3 If gears not operate smoothly adjust them by acting on the adjustment screw of the derailleur U gt Fig 2 x 4 pe e lt A a A 14 A Ne lt a X Version 07 06 3 3 Fit back axle to frame slide axle inside frame fig 4 locating four bolts into the slots fig 5 Don t tighten nuts for the moment Note four locating holes for the battery cage should be uppermost 4 Fit small rear chain and adjust it first of all ensure cogs are lined up Then using chain link tool to insert pin into link from one side until proud fig 6 After that swap link over and push pin back a little to allow free movement of link fig 7 Finally tighten the chain do not overtighten leave around 1cm loose check alignment and tighten all nuts on rear assembly 14mm Note extra link may be required on 20 model 5 Assemble front wheel fit wheel rim protector ensure valve holes are aligned a
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