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E-Bike ® Service Manual 24V MODELS

1. Chapter Two SPECIFICATIONS Table 1 Mechanical Specifications Component Specification Headset Stack height 33 mm 1 30 in Dimensions 25 4 mm x 34 mm x 30 mm w seal Fork Type PU Allen key adjustable Steerer tube 1 1 8 in Travel 65 mm Stem 1 Std model 17 degrees 110 mm extension C amp T models 40 degrees 110 mm extension Stem 2 28 6 mm 25 4 mm x 150 mm with quill Handlebar Std model Rise 30 mm 10 degrees Width 620 mm Handle 200 mm Seat post Std model 300 mm x 30 0 mm O D Seat post spacer 100 mm x 30 1 mm ID x 34 9 mm O D Seat post suspension C amp T models 350 mm x 27 2 mm O D Seat post spacer 100 mm x 27 3 I D x 34 9 mm O D Tires Std amp C models 26 x 1 95 in black T model 26 x 1 95 in Skinwall black Rims 26 x 1 5 in 14G x 36H double wall Spokes Front 266 mm 14G stainless with brass nipples Rear 216 mm amp 219 mm 14G stainless with brass nipples Bottom bracket B B 127 mm cartridge Freewheel 14 28 T 7 speed Chainring 33 Chainring clearance 16 17 mm 0 63 0 67 in Crankarm 170 mm 6 7 in Chain 1 2 x 3 322 x 110 L 2 2 Chapter Two Table 2 Gear Ratios Chainring Freewheel Gear Inches Ratio 33T 14T 61 3 0 42 14
2. 2 Loosen the caliper pinch bolt B Figure 1 and free the brake cable inner wire from the pinch mechanism 3 Loosen the adjuster locknut at the brake lever 4 Turn the barrel adjuster and the adjuster locknut until their slots align with the slot in the brake lever body 5 Pull the cable housing from the adjusting barrel and slide the inner cable through the slots in the brake lever adjusting barrel and adjuster locknut Figure 2 6 Pull the brake lever toward the handlebar and disconnect the inner cable barrel Figure 3 from the cable anchor on the lever NOTE oo If the cable housing is not damaged the rear brake inner wire can be removed and replaced without removing the cable housing or the left side cover 5 2 Chapter Five 7 Remove the brake cable If you are replac ing the rear brake cable remove the left side cover and remove the cable from the rear inlet on the side cover Installation 1 At the brake lever align the slots in the brake lever barrel adjuster and the barrel lock nut 2 Pull the brake lever to the handlebar and fit the inner cable barrel into the cable anchor in the brake lever Figure 3 3 Slide the inner cable through the slots in the brake lever barrel adjuster and the barrel locknut Figure 2 4 Turn the barrel adjuster three full turns out from its fully in position Turn the barrel adjuster and locknut so their slots do not align with the slot in the b
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4. 6 Repeat for the left crank arm if necessary sure the left crank is 180 opposite the right crank arm CHAINRING Removal 1 Remove the right crank arm as described in this chapter 7 5 2 Examine the inboard side of the crank arm chainring Note that the chainring is mounted so the cutout with the tab aligns with the crank arm Figure 13 The chainring will have to be mounted in this position during installation 3 Remove the five chainring bolts and remove the chainring from the crank arm Installation 1 Fit the chainring onto the spider the crank arm spokes so the chainring mounting holes align with the threaded hole on the spider 2 Be sure the cutout with the tab Figure 13 aligns with the crank arm 3 Apply oil to the threads of the chainring bolts 4 Finger tighten all five chainring bolts and then torque the bolts to the specification in Table 4 Chainring Wobble Check When installing a new right crank arm or rein stalling a right crank arm with a new chainring you must install the crank arm in the position that produces the least amount of chainring wobble Perform the following to determine that position 1 Place a reference mark in one corner of the end of right spindle 2 Rotate the spindle so the reference mark is at 12 o clock 3 Fit the right crank arm onto the spindle so the arm points to 6 o clock 4 Strike the arm with a rubber mallet so the arm is secure
5. CAUTION Do not use solvent to clean the shifter housing and twist unit The solvent could attack the plastic in these parts 1 Clean the shifter housing and twist unit with soap and water Dry them thoroughly before proceeding 2 Preset the derailleur adjustment screws before installing the cable a Stand behind the E Bike and check the position of the derailleur The guide pulley should align with the outermost cog as shown in Figure 9 b If necessary adjust the outward limit by turning the H screw Tighten the H screw to adjust the guide pulley inward Loosen the H screw to adjust the derailleur out ward c Use your hand to move the derailleur to its innermost position d Hold the derailleur against the stop and check the guide pulley alignment e The guide pulley should align with the innermost cog as shown in Figure 10 If necessary adjust the inward limit by turning the L screw Tighten the L screw to move the derailleur outward Loosen the L screw to move the derailleur inward H Screw CAUTION 1 11 Lubricate the shifter and cable with Grip Shift Jonnisnot grease or petroleum jelly No other lubricant is suitable for the shifter 3 Thoroughly lubricate the shifter housing bar rel spring cable groove shifter housing clip and the twist unit with Grip Shift Jonnisnot grease or petroleum jelly 4 Feed the free end of the inner wire through the socket in the twis
6. battery pack is fully charged Remote Charging 1 Remove the battery pack from the E Bike 2 Set the battery pack on its side so the bat tery pack cover faces up and the handle is to the side 3 2 Chapter Three 3 Retrieve the charging cord from the com partment above the bottom bracket 4 Plug the female end of the charging cord into the receptacle on the battery charger WARNING The charger is equipped with a cooling fan If the cooling fan does not operate when the charging cord is plugged in and the red LED is on unplug the charger from the electrical out let immediately Determine why the fan is not operating before charging the battery pack Replace the charger if necessary 5 Plug the male end of the charging cord into a standard 110V 60 cycle electrical outlet The red LED on the charger and the cooling fan will automatically turn on The LED switches to green and the cooling fan turns off when the battery pack is fully charged REPLACING THE BATTERIES The battery pack contains two sealed lead acid batteries that are connected in series The following procedure describes how to remove and replace the two batteries CAUTION Always replace both batteries as a set Do not mix old batteries with new batteries and do not mix different brands of batteries WARNING Never use a battery that is cracked or broken Battery acid is highly corrosive and can cause severe burns if it comes in c
7. 25 mm 0 98 in 4 Turn the barrel adjuster as necessary to adjust clearance to within specification Turning the adjuster out tightens the inner wire turning the adjuster in loosens the wire When the brake lever is within specification tighten the adjuster locknut 5 Squeeze the caliper arms together and remove the cable guide from the bracket on the left caliper arm A Figure 1 The brake 5 4 Chapter Five lever free play is properly adjusted if the cable guide can be easily removed from the bracket 6 If you cannot easily release the cable guide from the bracket perform the following a Turn the adjusting barrel at the brake lever in clockwise one full turn Try to remove the cable guide again b If you still cannot release the cable guide turn the adjusting barrel in an additional turn c If the cable guide still does not release loosen the pinch bolt B Figure 1 and release 2 3 mm 0 079 0 118 in of inner wire from the pinch mechanism d Repeat the adjusting procedure BRAKE PAD The brake pads in the E Bike use a threaded stud curved washer system Figure 8 Convex and concave washers on each side of the brake caliper arm control how the pad is positioned against the wheel Removal NOTE Do not mix the parts during disassembly The convex and concave washers become mated through use and they must be reinstalled in the same position during assembly 1 Squeeze the
8. 33 33T 16T 53 6 0 48 16 33 33T 18T 47 7 0 55 18 33 33T 20T 42 9 0 61 20 33 33T 22T 39 0 0 67 22 33 24 83 28 33 33 24 35 8 0 73 24 33 33T 28T 30 6 0 85 28 33 Table 3 Electrical Specifications Component Specification Battery WP12 12 2 in series Type Deep discharge sealed AGM lead acid Capacity 12 volts 12 amp hours Charger Input 115 VAC 60 50 Hz 2 amps Output 24 VDC 3 amps Charger cord Length 1 2 m 4 ft Wire 18 AWG 2 wire with ground SPECIFICATIONS 23 Table 4 Torque Specifications Item kg cm Special Instructions Handlebar binder bolt 140 200 Apply Loctite Handlebar arm clamp bolts 140 200 Apply Loctite Stem binder bolt stem 2 quill bolt 180 250 Headset locknut 40 50 34 7 43 4 Accessory control clamp bolt 30 40 26 5 34 7 Throttle control clamp bolt 30 40 26 5 34 7 Controller mounting screw 15 130 Brake lever clamp bolt 30 40 26 5 34 7 Brake caliper pinch bolt 140 200 Apply Loctite Brake pad nut 63 6 85 2 Caliper pivot bolt 85 2 106 8 Apply Loctite Left side cover mounting screws 1 Apply Loctite Right side cover mounting screws Apply Loctite Battery terminal block mounting screw Battery compartment mounting screw Battery pack handle Battery cover screw Apply Loctite Charger board mounting screw Derailleur mounting bolt Derailleur pinch mechanism nut Shifter clamp bolt Mirror mounting screw Chain guard sc
9. Height Adjustment Handlebar Replacement Throttle Control Housing Accessory Control Housing Headset Chapter Five Brakes Brake Cable Replacement Brake Lever Brake Lever Free Play Adjustment Brake Pad Brake Pad Alignment Caliper Arm Disc Brake Chapter Six Shifter and Derailleur Shifter TUTTO Shifter Cable Derailleur Chapter Sever Chall and Crankset Chain Crank Arm Chainring Pedal Bottom Bracket Cartridge Chapter Eight Electrical Connector Gna Right Side Cover Left Side Cover Controller Quick Release Connector Motor Headlight Taillight Troubleshooting Electrical Schematic 141 2 1 3 1 4 1 5 1 6 1 7 1 8 1 1 1 Chapter One GENERAL INFORMATION BEEP LED CODES The E Bike beeps and flashes various codes to alert the rider to particular conditions The fol lowing chart lists the codes and describes their various functions Beep codes consist of a series of long and short beeps like Morse code A long beep is represented by a dash A short beep is rep resented by a dot 9 Meaning OK The battery pack is installed and properly connected GO Sounds at power knob ON The charge level The system is on and LEDs cycle twice ready to operate in sequence Pedal assist The system requests pedal assist Sounds when on a steep hill or when the motor has overheated Over heat 1 The motor is 000o overheated Followed by the pedal The syste
10. caliper arms together and dis connect the cable guide from the bracket A Figure 1 on the left caliper arm 2 Remove the brake pad nut from the pad stud F Figure 8 3 Remove the plain washer E Figure 8 the concave washer D Figure 8 and the convex washer C Figure 8 from the pad stud 4 Remove the brake pad from the caliper arm 5 Remove the convex B Figure 8 and con cave washers A Figure 8 from the brake pad Discard the old pad Do not mix the inboard and the outboard parts Installation Brake pads on the E Bike are not inter changeable The pads are marked left L and right R Be sure to install a left pad on a left caliper arm and a right pad on a right arm 1 Find the left L or right R marking on the new brake pad Be sure to install the cor rect pad onto the caliper arm 2 Install the inboard concave washer A Figure 8 onto the stud of the new brake pad The flat side of the washer must face the brake pad 3 Install the inboard convex washer B Figure 8 onto the pad stud so the convex side faces the concave washer 4 Fit the brake pad stud through the cutout in the caliper arm 5 Slide the convex washer C Figure 8 onto the pad stud so the convex side faces out 6 Install the concave washer D Figure 8 so the flat side of the washer faces out 7 Install the plain washer E Figure 8 8 Apply Loctite to the threads of the pad stud and install the brake p
11. disconnected unless instructed otherwise A The battery does not beep OK when you secure the battery in the battery compart ment 1 Turn the headlight on If the light turns on the battery and the connection are fine Proceed to step 3 2 If the headlight does not turn on push the bottom of the battery into the battery compart ment with your hand The problem is solved if the E Bike beeps 3 If the headlight does not come on check the battery voltage Recharge the battery if neces sary 4 Replace the controller B The system beeps GO when the power knob is turned ON but the motor does not operate 1 Check the operation of the brake sensors by operating each brake lever The brake light should turn on when a brake lever is pulled The brake light should also turn off when a brake lever is released If the brake light oper ates properly when each brake lever is pulled and released proceed to step 5 2 Check the brake sensor connectors at the controller board A amp B Figure 1 Be sure each connector securely engages its mate in the board 3 Operate each brake lever again If the brake light operates properly when each brake lever is pulled and released reset the unit by turning the power knob ON and then OFF Turn the power knob ON and check the operation of the motor If the motor does not operate pro ceed to step 5 8 8 Chapter Eight 4 If the brake light does not operate properly when
12. is out side the specification replace the con troller NOTE EMEN The QR connector A Figure 7 is red and blue in some models but red and black in oth ers 8 Check the connections at the QR connector a Open the QR housing on the left chain stay A Figure 6 b Check QR connector A Figure 7 and the temperature sensor connector B Figure 7 The connector from the motor must securely engage its mate from the harness If the connector is loose press it together c Install the battery turn the power knob ON and operate the throttle If the motor operates the connection was the prob lem Close the QR housing If necessary secure the housing to the left chain stay with a cable tie 9 Check the voltage at the QR connection a Disconnect the QR connector at the QR housing A Figure 7 b Connect the probes of a voltmeter to the red and blue terminals on the har ness side of the connection c Turn the power knob ON and operate the throttle There should be 24 volts at the harness side of the connector when the throttle is operated If the voltage is with in specification replace the motor If not replace the wiring between the QR con nector and the controller C The unit does not beep GO when the power knob is turned ON 1 Charge the battery Turn the power knob ON If the system beeps GO the problem is resolved 2 Check the operation of the power switch a Turn the power knob OFF
13. of the brake cable inner wire through the pinch mechanism b Tighten the brake caliper pinch bolt B Figure 5 to the specification in Table 4 c Squeeze the arms of the rear brake caliper together and connect the cable guide to the bracket on the left caliper arm A Figure 5 d If necessary adjust the brakes CONTROLLER Removal 1 Be sure the power knob is OFF and remove the battery from the battery compartment 2 Remove the right side cover from the E 3 Disconnect all the connectors A F Figure 1 from the controller board On early production models the blue ground wire is secured to the controller heat sink by the rear controller mounting screw B Figure 4 On later production models this wire is secured by a separate ground screw that mounts to the heat sink just above the rear controller mounting screw B Figure 4 4 On later production models remove the ground screw and disconnect the blue ground wire from the heat sink 5 Hold the controller in place and remove the three controller mounting screws A B amp C Figure 4 When removing the rear controller mounting screw B Figure 4 note the two stepped washers that sit on either side of the hole in the heat sink They must be reinstalled in the same positions during assembly 6 Lift the controller from the E bike M discon nect the four connectors G J Figure 1 from behind the controller and then remove the contro
14. pad is closer to the rim than the other rotate the pad around the shoe stud to adjust tangent alignment Pad Height 1 Look at each pad from the side and note where the pad engages the brake surface of the rim Figure 12 2 To adjust the height move the brake stud up or down in the caliper slot Adjust height so the pad presses against the top of the rim without interfering with the tire The top of the pad should be 1 mm 0 04 in below the top of the rim 3 If pad height cannot be adjusted without affecting vertical alignment correctly set the pad height 4 Torque the pad mounting nut to the specifi cation in Table 4 5 If removed reconnect the cable guide to the bracket in the left caliper arm CALIPER ARM Removal 1 Squeeze the caliper arms together and dis connect the cable guide from the bracket on the left caliper arm A Figure 1 2 Loosen and unthread the caliper pivot bolt A Figure 4 3 Remove the caliper arm Do not lose the washer that sits behind the caliper pivot bolt 4 Inspect the caliper mounting boss in the frame a Be sure the threads of the caliper mount ing boss are clean b The mating surface caliper mounting boss should also be clean Dress the area with emery cloth if necessary c Inspect the caliper mounting boss for cracks or other signs of wear Installation 1 Check that the washer is in place on the caliper arm pivot bolt Figure 13 2 Apply Loctite 2
15. rider s point of view when seat ed on the E Bike M and facing forward The one exception to this rule involves the brake calipers Left and right on the calipers refers to a technician s point of view when standing in front of the E Bike and looking directly at the front brake caliper or when standing behind the E Bike and looking directly at the rear brake caliper Brake Type Battery Color V V brake 1 C D Disk brake 00 Lead Acid ML Metallic Blue CR Metallic Cranberry Red BK Black RD Rally Red NOTE CAUTION and WARNING The terms NOTE CAUTION and WARN ING have specific meaning in this manual A NOTE provides additional information to make a procedure easier or clearer A CAUTION emphasizes precautions that must be taken to avoid damage to your tools or to the E Bike A WARNING alerts you to a situation where negligence could lead to injury or death Take WARNINGS seriously Failure to heed a WARNING could result in serious personal injury or death LUBRICANTS Grease The bearings and other mechanical com ponents in the E Bike operate at relatively low temperatures so most automotive greases are inappropriate for use on the E Bike Always use grease made specifically for a bicycle such as grease from Bullshot Campagnolo Finish Line Pedros Phil Wood and Shimano Cil Always use oils made specifically for bicy cle use Bicycle oils need to be thin enough to penetrate
16. side of the bottom bracket shell Figure 17 NOTE The main body of the cartridge has left hand threads Turn the cartridge clockwise to remove it 4 Install the bottom bracket cartridge tool onto the main body of the cartridge and remove the cartridge from the right side of the bottom bracket Installation NOTE The bottom bracket cartridge has very fine threads that are easily damaged Check the threads in the bottom bracket shell before installation Dress or tap the threads as neces sary 1 Apply grease to the threads of the cartridge main body NOTE The main body uses left hand threads 2 Carefully threads the cartridge into the right side of the bottom bracket shell Turn the main body counterclockwise until the cartridge is snug in the bottom bracket shell 3 Apply grease to the threads of the adapter ring 4 Carefully thread the adapter ring into the left side of the bottom bracket shell 5 Fit the bottom bracket cartridge tool onto the adapter ring and torque the ring to the specifi cation in Table 4 Figure 17 6 Install the left bottom bracket cover Figure 16 Apply Loctite red to the threads of the bottom bracket cover screws and torque the screws the specification in Table 4 Chapter Eight ELECTRICAL CONNECTOR IDENTIFICATION Horn board All electrical components the E Bike are connected to the controller which is mounted between the side covers Refer
17. the V notch on the dial a 0 1 indicates the chain is in good condi tion b 1 2 indicates the chain is moderately worn c 2 3 indicates the chain is approaching the wear limit d 3 or more indicates the chain is worn beyond the wear limit Checking Chain Length 1 Secure the E bike in the stand so the E is at an angle it would be in if it were upright on level ground 2 Shift the derailleur so the chain rides on the outermost cog 3 Examine angle formed by a line through the center of the two derailleur pulleys and the ground or floor a The chain length is perfect if this line is perpendicular 90 degrees to the ground Figure 1 b Chain length is acceptable if the tension pulley is 1 75 in or less forward or rear ward of the guide pulley Examine the chain a The chain is too long if it sags in the upper chain run as shown in Figure 2 b The chain is too long if the chain contacts itself or any part of the derailleur after the chain leaves the tensioner pulley Figure 3 7 2 Chapter Seven Excessive contact 5 Shift the derailleur so the chain rides on the innermost cog 6 Examine the chain as it passes through the derailleur a If the chain passes through the derailleur without bending twice the chain is too short See Figure 4 Insufficient Bend Removal A chain breaker Park CT 3 is required for removing and installing the chain 1 Shift the chain to the outermo
18. the derailleur rearward so the out most cog engages the upper chain run 4 Lift the wheel rearward and up into the axle slots in the dropouts Be sure the outmost cog remains engaged with the top chain run 5 When the wheel is properly installed the washer and nut will be outboard of the dropout Figure 9 6 If removed loosely reinstall the axle nuts and washers Be sure the textured side of the washers faces inward toward the hub 7 Finger tighten the axle nuts 8 Secure the motor torque arm to the frame seat stay Apply Loctite 242 blue to the threads of the mounting bolt and tighten the nut securely Figure 8 9 Assemble the QR housing as described above 10 Reconnect the rear brake cable to the bracket on the left caliper arm A Figure 5 11 Center the wheel between the chain and seat stays Move the axle as necessary within the dropout so the wheel is centered This is critical Take the time to assure that the wheel is properly centered between the chain stays and between the seat stays 12 Also operate the brake to assure that the rim is centered between the brake pads 13 Once the wheel is centered torque the axle nuts to the specification in Table 4 8 6 Chapter Eight HEADLIGHT Disassembly 1 Unscrew the bezel A Figure 10 from the headlight housing 2 Remove the bezel and lens B Figure 10 3 Remove the headlight reflector A Figure 11 from the housing 4 Loosen the set screw
19. the lower cable port C Figure 6 until the O ring rests against the QR housing ELECTRICAL 7 Fit the seal B Figure 6 over the upper cable port until its rolled end rests against the QR housing 8 Use a cable tie to secure the QR housing to the left chain stay MOTOR Removal The motor is an integral part of the rear hub Removing the motor consists of discon necting the motor at the motor junction and then removing the rear wheel The procedure is described below 1 Shift the chain to the outermost rear cog on the freewheel 2 Squeeze the top of rear brake arms togeth er and free the rear brake cable from the bracket on the left arm A Figure 5 3 Disconnect the motor from the controller by disassembling the QR housing as described above 4 Remove the hardware that secures the motor torque arm to the left chain stay Figure 8 5 Remove the axle cover from each end of the axle 6 Remove the axle nut and washer on each side of the hub If necessary hold one nut tight while you break the other loose 7 Rotate the derailleur clockwise rearward around its mounting bolt and lower the wheel from the frame until the rear cogs clear the derailleur 8 Remove the wheel from the left side of the 8 5 Installation 1 Apply grease to the axle threads 2 From the left side of the E Bike M position the wheel so the outmost cog is between the upper and lower chain runs 3 Rotate
20. the top tube Secure it in place so it will remain out of the way Do not severely bend or kink the cable Installation 1 Slide the shifter housing onto the left end of the handlebar Figure 3 2 Gently route the shifter cable over and behind the headlight as you slide the shifter housing against the brake lever body 6 2 Chapter Six 3 Slide the shim onto the handlebar Install the handlebar grip so the grip end is flush with the handlebar end 4 Slide the shifter body against the grip shim 5 Rotate the shifter body so the barrel adjuster is below the brake lever Tighten the shifter clamp bolt to the specification in Table 4 6 Check the operation of the brake lever Reposition the shifter body as necessary 7 Secure the shift cable to the front brake cable with the S hook Figure 1 Be sure the rear brake cable is position behind the S hook 8 Fit the mirror housing into the handlebar end Figure 2 Tighten the mirror mounting screw to the specification in Table 4 SHIFTER CABLE Removal NOTE Before removing the shifter cable note how the cable is routed along the frame The new cable will have to be routed along the same path 1 Operate the shifter and move the chain to the outermost cog 2 Remove the right side cover from the E Bike 3 Note how the shifter cable is routed along the top tube and the right seat stay The cable will have to be rerouted along the same path 4 At the d
21. tight places they should be durable so they can withstand exposure to the ele ments and they must resist the accumulation of dirt Suitable oils for the E bike include Alsop Bullshot Campagnolo Finish Line Lube Wax Phil Wood Tenacous Oil Pedros Superlube and Triflow Motor oil WD40 3 in 1 Oil sewing machine oil gun oil and other common oils are not suitable and should not be used In general applying oil from a drip applica RECOMMENDED MAINTENANCE SCHEDULE Component or Condition Inspect before every ride promote over lubrication which leads to excessive accumulation of dirt Apply oil spar ingly Apply enough oil to do the job but not so much that it starts to drip from the component After applying any oil wipe off the excess THREADLOCK A threadlocking compound should be used on most fasteners on the Threadlocking compound prevents loosening caused by vibration and helps seal out mois ture Loctite 242 blue or equivalent is recom mended for threadlocking applications Loctite 242 is a medium strength threadlocking com pound that permits disassembly with common hand tools Before applying Loctite to threads clean the thread surface of oil grease and other residue Apply a small amount of Loctite Excess compound could work its way down the threads and bond parts together The torque chart in Chapter Two includes Loctite recommendations for particular fasteners Inspect ev
22. to Figure 1 Except for the brake sensor connec tors which are interchangeable each compo nent s connector is mated It can only be con nected to its proper place in the E Bike Controller Board Connectors A T Brake sensone O O SS BY Brake sensor right C 6 o edigh 222202 D J megwBmkign oO Behind Controller Connectors f Motor temperature sensor 2 black wires 2 pin Horn Board Connectors E e Number Component Function Controller yellow and white wires pin Horn and white wires 2pin Power red and black wires from 2 pin battery terminal block 8 2 Chapter Eight RIGHT SIDE COVER Removal 1 Open the door to the battery compartment 2 Remove the three rubber plugs from the right side cover holes Note that the small plug goes in the lower hole 3 Remove the three side cover screws The screw from the lower hole is smaller than the two upper screws It will have to be reinstalled in the same location 4 Lift the side cover from the E Bike 5 If necessary remove the cable inlet cover from the left side cover Pull the cable inlet cover forward and around the head tube until the tabs clear the left side cover Figure 2 Installation 1 If removed install the cable inlet cover into the left side cover Slide the tabs of the inlet cover onto the tongues of the side c
23. 42 blue to the threads of the caliper pivot bolt 3 Align the pin on the caliper bushing with the indexing hole in the caliper mount boss Figure 14 BRAKES 4 Thread the caliper pivot bolt into the caliper mounting boss As you tighten the pivot bolt be sure the pin engages then indexing hole in the boss 5 Torque the caliper pivot bolt to the specifica tion in Table 4 6 Align the brake pads as described in this chapter 7 Squeeze the caliper arms together and con nect the cable guide to the bracket on the left caliper arm A Figure 1 8 Secure the inner wire in the brake caliper pinch mechanism by performing the following a Feed the brake cable inner wire through the slot in the pinch mechanism b Use the fourth hand cable stretcher Park Tool BT 2 to pull the inner wire until the combined clearance between each brake pad and the rim equals 2 mm 0 08 in c Tighten the pinch bolt B Figure 1 to the specification in Table 4 d Crimp a new end cap onto the end of the inner wire 9 Depress and release the brake lever several times and check the caliper arm balance a The brake pads should contact the rim at the same time when the brakes are applied b The gap between each pad and the rim should equal 1 mm 0 04 in when the brake lever is released CAUTION Do not set the caliper arm spring tension too high C If necessary balance the caliper arms by turning the spring tension
24. 8 Fit the cover onto the battery pack Be sure no wire is pinched beneath the cover 9 Apply Loctite 242 blue to the threads of the two cover screws and secure the cover in place REPLACING THE CHARGER Removal WARNING SS Make sure the charger is not plugged in during service 1 Remove the batteries from the battery pack 2 Remove the three charger cover screws that secure the cover to the vent A Figure 4 3 Lift the cover from the charger and discon nect the three electrical connectors from the charger board 4 Remove the screw that secures the charg er board to the bracket B Figure 4 5 Remove the three charger board mounting screws Figure 5 and remove the charger board Do not lose the spacer A Figure 6 from each mounting stud 3 3 Installation 1 Be sure the insulator B Figure 6 is in place in the battery pack 2 If removed install the spacer A Figure 6 onto each mounting stud in the battery pack 3 Set the charger board into place on the mounting studs Secure the board in place with the charger board mounting screws and wash er Figure 5 FIG 6 4 Secure the board to the bracket with the mounting screw B Figure 4 5 Plug the connectors from the cover into their mates in the charger board 6 Fit the cover in place over the charger board Be sure the two charger wires are not pinched under the cover 7 Secure the cover in place with the three charger cover s
25. B Figure 11 and remove the bulb socket from the headlight reflector Assembly 1 Slide the socket into the headlight reflector and secure the socket in place with the set screw B Figure 11 2 Fit the reflector A Figure 11 into the head light housing Be sure the cutouts in the reflec tor engage the tabs in the housing 3 Install the lens B Figure 10 so the cutouts engage the tabs in the headlight housing 4 Screw the bezel A Figure 10 in place Do not over tighten the plastic threads Headlight Bulb Replacement 1 Disassemble the headlight as described above in this chapter 2 Squeeze the bulb socket contacts together and unhook the bulb from the headlight socket 3 Hook a new bulb onto the socket contacts Be sure there are good connections between the bulb hooks and socket contacts 4 Fit the socket into the headlight reflector and secure the socket in place with the set screw 5 Assemble the headlight as described above Headlight Adjustment Adjust the headlight according to Department of Motor Vehicle regulations in your state 1 Set the E Bike on a level surface approxi mately 25 feet from a wall 2 Have a friend sit on the bike and hold it ver tically Be sure the tires are inflated to the proper inflation pressure when adjusting the headlight 3 Draw a horizontal line on the wall that is 35 inches above the floor ground 4 Turns the headlight on 5 The main beam of li
26. Charging NOTE The charger must be operational for this test to be valid Perform the charger output test before performing this test 1 Charge the battery as described in this chapter 2 Unplug the charger and let the battery stand for one hour 3 Remove the cover from the battery pack 4 Connect voltmeters positive test probe to the positive battery terminal and connect the voltmeter s negative test probe to the battery negative terminal as shown in Figure 7 5 Note the reading on the voltmeter 6 The reading should be 12 5 volts or greater If the reading is less than 12 5 volts the bat tery is faulty and should be replaced Chapter Four HANDLEBAR and CONTROLS HANDLEBAR POSITION NOTE 042 The handlebar may be adjusted to suit the riders preference The following procedure describes how to set the handlebar to the stock position 1 Loosen the handlebar binder bolts A Figure 1 2 Position the handlebar so the ends point down slightly The handlebar grips should form a 10 20 angle with a line that parallels the floor See Figure 2 3 Be sure the knurled portion of the handlebar is centered within the handlebar binder 4 Tighten the handlebar binder bolts to the torque specification in Table 4 HANDLEBAR HEIGHT ADJUSTMENT 1 Loosen the stem binder bolt three or four turns counterclockwise A Figure 3 If the bolt rises from the steering stem strike t
27. Figure 14 FIG 14 74 5 Set the seal in place on the fork crown race Be sure the seal is oriented in the same direction you noted during removal 6 Apply grease to the threads of the fork col umn 7 Fit the fork column up into the head tube 8 Thread the adjustable race A Figure 15 onto the fork column 9 Let the forks drop down so the forks are sup ported by the adjustable race 10 Turn the adjustable race until the forks are drawn up into the head tube 11 Inspect the position of each cone relative to its race Each cone should be in the position you noted during removal 12 Fit the headlight bracket and washer on the fork column Be sure their notches engage the slot in the column B Figure 15 13 Thread the headset locknut onto the fork column 14 Install the wheel onto the forks Torque the headset locknut to the specification in Table 4 15 Check the headset free play by performing the following NOTE 4 Do not check for headset free play by grasping the bottom of the forks Normal movement in the suspension could be misinterpreted as bearing free play a Grasp the fork crown with one hand the upper stanchions above the fork boots and grasp the lower fork tube with the other b Try to move the forks back and forth You should not notice any play in the head set c If free play is noticed adjust the headset by tightening the adjustable race d If looseness cannot be elimina
28. JA MANUAL 24 MODELS bike E Bike Service Manual 24V MODELS EV Global Motors Company 10900 Wilshire Boulevard Suite 310 Los Angeles CA 90024 Tel 310 208 7076 Fax 310 208 2444 www ebike com Copyright 2000 EV Global Motors Company Second Edition September 2000 LIT 82001 00 00 All rights reserved No parts of this publication may be reproduced or transmitted in any form or by any means without the prior permission of EV Global Motors Company Although every precaution has been taken to assure this publication is complete and accurate EV Global assumes no liability for errors or omissions All informa tion contained in this publication is based on the latest information available at the time of publication and is sub ject to change without notice TABLE OF CONTENTS Chapter One General Information BOopLEDHCOdeg Terms Vehicle Identification Number Key number Model Code How to Read the Model Code Terms Lubricants Threadlock Recommended Maintenance Schedule Special Tools Chapter Two Specifications Mechanisal amp pacintaliang eese eee Gear Ratios Electrical Specifications Torque Specifications Performance Specifications Frame Specifications Chapter Three Battery eomm Charging the Batteries Replacing the Batteries Replacing the Charger Battery Pack Chapter Four Handlebar and Controls Handlebar Position Handlebar
29. UICK RELEASE QR CONNECTOR The QR connector is the electrical connec tion where the motor connects to the controller The QR connector sits inside the QR housing which is affixed to the left chain stay A Figure 6 Chapter Eight QR Housing Disassembly 1 Roll the seal off the upper cable port B Figure 6 on the housing 2 Roll the O ring off the lower cable port C Figure 6 on the housing 3 Release the latch and open the housing 4 Disconnect the QR connector A Figure 7 This is a red and blue connector on some mod els red and black on others 5 Disconnect the temperature sensor connec tor B Figure 7 QR Housing Assembly 1 Connect the temperature sensor connector from the controller to its mate from the motor 2 Connect the QR connector from the con troller to its mate from the motor 3 Fit the QR connector into place in the QR housing Be sure the connection engages the locating dot in the housing 4 Fit the temperature sensor connector into the housing 5 Route the motor and controller wires out the respective ports in the housing 6 Close the housing lid and secure the latch Be sure the motor and controller wires are not pinched in the housing or the cable ports when you close the lid CAUTION ___ The O ring and seal must properly installed on the upper and lower cable ports They help keep water out of the QR housing 6 Roll the O ring up the motor wire and over
30. a brake lever is pulled and released or if the brake light is always on a brake sensor has failed Replace the brake lever body with the defective sensor 5 Check the throttle control connector F Figure 1 Be sure the connector is securely connected to the controller 6 Check the resistance of the throttle a Turn the power knob OFF and remove the battery from the battery compartment b Disconnect the throttle control connector F Figure 1 from the controller board c Measure the resistance between the black and red terminals in the connector when the throttle is not applied and when it is fully applied Throttle resistance black to red terminals No throttle 10K x 1K ohms Full throttle 10K x ohms d Check the resistance between black and brown terminals when the throttle is not applied and when it is fully applied Throttle resistance black to brown terminals No throttle 500 500 ohms Full throttle 5000 500 ohms e If any resistance is outside of the speci fied range replace the throttle control 7 Check the output of the controller by per forming the following a Attach the positive probe of the voltmeter to the positive battery terminal G Figure 1 on the controller b Connect the negative probe to the heat sink on the controller c Turn the power knob ON The voltage should read zero Operate the throttle and watch the meter The voltage should jump to 24 volts If either reading
31. ad nut F Figure 8 Tighten the nut to the torque specification in Table 4 9 Align the brake pads as described in this chapter BRAKE PAD ALIGNMENT Brake efficiency is affected by four parame ters toe vertical angle tangent and height Toe alignment determines how the brake pad face sits against the brake surface of the rim When properly adjusted a pad s trailing end the end facing the front should reach the rim before the leading end Figure 9 Vertical alignment sets the position of the pad s vertical plane relative to the brake sur face of the rim Figure 10 The pad s vertical plane should parallel the vertical plane of the brake surface of the rim BRAKES Front FIG 9 Poor vertical alignment Good vertical alignment Tangent alignment sets the position of the horizontal axis of the pad relative to the wheel rim The distance between the top of the wheel rim and the top of the pad should be the same at each end of the pad Figure 11 Good tangent Poor tangent E Height adjustment locates the brake pad in the rim brake surface When height is properly adjusted the pad will press as near to the top of the rim as possible without interfering with the tire Figure 12 Pad alignment procedure is described below Good height Too high Lp Toe vertical alignment tangent and height must be set whenever the brake pads caliper arms or wheels are replac
32. adjuster B Figure 4 on either arm 10 Adjust the brake lever free play as described in this chapter DISC BRAKE Brake Pad Clearance Adjustment 1 Hold the adjuster A Figure 15 with Allen wrench and loosen the adjuster locknut B Figure 15 2 Spin the wheel and turn the adjuster clock wise until the brake pads barely scrape against the brake disc 3 Back out the adjuster 1 2 turn counterclock wise 4 Hold the adjuster with an Allen wrench and tighten the locknut B Figure 15 securely 5 Set the pads by sharply apply the brakes four or five times A slight amount of pad scraping is normal especially with new brakes or new brake pads 6 Spin the wheel and check for brake pad disc scraping Repeat the adjustment procedure if scraping is noted Chapter Six SHIFTER and DERAILLEUR SHIFTER 2 Loosen the mounting screw in the mirror housing and remove the mirror from the end of Removal the handlebar Figure 2 3 Remove the handlebar grip from the left end 1 Remove the shift cable from the S hook of the handlebar Do not lose the shim between Figure 1 that holds the cable to the front the grip and the shifter housing brake cable 4 Loosen the shifter clamp bolt and slide the shifter housing from the handlebar Figure 3 Guide the shifter cable around the headlight as you remove the shifter housing 5 If you are not servicing the shifter or the cable lay the shifter over
33. and remove the battery from the battery compart ment b Disconnect the throttle control con nector F Figure 1 from the controller board c Connect an ohmmeter to the red and orange terminals in the throttle con trol connector d Check the continuity when the power knob is OFF and when it is ON There should be no continuity when the switch is OFF There should be continuity when the switch is ON Replace the throttle control if it fails either continuity test ELECTRICAL 3 Check the temperature sensor connection behind the controller Figure 1 Be sure the connector is secure Install the battery and turn the power knob ON If the system beeps GO you have corrected the problem 4 Check the temperature sensor connection in the QR housing a Open the QR housing and check that the temperature sensor connector is secure B Figure 7 b Check system operation by turning the power knob OFF and then ON If the system beep GO you have corrected the problem 5 Check the temperature sensor by perform ing the following a Disconnect the temperature sensor con nector B Figure 7 in the QR housing b Connect a jumper across the terminals in the harness side of the connector The 24 gauge black wires c Turn the switch ON The temperature sensor is bad if the unit beeps GO d If the system does not beep GO perform this test at the temperature sensor con nector on the controller 1 Figure 1 Jump th
34. andlebar grip from the handle bar 2 If removing the left brake lever perform the following a Loosen the mounting screw and remove the mirror from the left end of the han dlebar Figure 5 b Loosen the set screw on the shifter and remove the shifter from the handlebar Lay the shifter over the handlebar so it is out of the way BRAKES 3 Squeeze the caliper arms together and dis connect the cable guide from the bracket on the left caliper arm A Figure 1 4 Loosen the adjuster locknut at the brake lever 5 Turn the barrel adjuster and the adjuster locknut until their slots align with the slot in the brake lever body 6 Pull the inner cable from the adjusting bar rel and slide the inner cable through the slots in the brake lever adjusting barrel and adjuster locknut Figure 2 7 Disconnect the cable end from the cable anchor in the brake lever Figure 3 8 Loosen the brake lever clamp bolt Figure 6 and slide the brake lever body from the han dlebar 5 3 the handlebar grip so it is flush with the han dlebar end 7B When installing the left brake lever install the shifter onto the handlebar as described in Chapter Six 8 Set the brake lever to a 25 35 angle by per forming the following a Set the E Bike in an upright position on a level surface b Slide the brake lever body against the shifter left brake lever or against the handlebar grip right brake lever c Rotate th
35. ar Guide the brake cable around the headlight as your remove the lever body Lay the lever body over the frame top tube so it is out of the way 11 Loosen the set bolt on the accessory con trol Slide the housing off the handlebar Pull its wire free of the headlight bracket Installation 1 Slide the accessory control onto the left handlebar 2 Feed the connector end of the accessory control wire through the cutout in the headlight bracket Figure 7 3 Feed the wire around the head tube through the cable inlet in the left side cover and plug the connector into position E Figure 4 on the controller panel 4 Slide the rear brake lever body onto the left handlebar Take care to guide the rear brake cable around the headlight 5 Slide the shifter body onto the left handlebar Guide the shifter cable around the headlight 6 Slide the shim onto the handlebar Twist the handlebar grip onto the handlebar until the grip is flush with the handlebar end 7 Slide the shifter against the handlebar grip shim 8 Position the shifter body as described in Chapter Six and tighten the shifter body clamp bolt to the torque specification in Table 4 9 Slide the brake lever body against the shifter Position the brake lever as described in Chapter Five and torque the brake lever clamp bolt to the specification in Table 4 10 Fit the mirror mount into the handlebar end Figure 8 Position the mirror and tighten the mirror moun
36. arm for cracks or other signs of wear Pay particular attention to the area around the mounting holes at either end of the crank arm Replace the crank arm if it is worn 4 Inspect the spider arms the crank arm spokes on the right crank arm Replace the crank arm if any spider arm is cracked or shows other signs of damage Installation When installing both crank arms install the right crank arm first and then install the left crank arm so it is oriented 180 from the right arm 1 If you are installing a new right crank arm or a new chainring check chainring wobble as described below 2 Clean the flats of the spindle with acetone or alcohol 3A If you are reinstalling the old crank arm fit the crank arm onto the spindle so the mark you made on the crank arm aligns with the mark on the spindle end Figure 9 Tap the crank arm onto the spindle with a plastic mallet 3B If installing a new right crank arm and or new chainring perform the following a Rotate the spindle so the reference mark from the chainring wobble test is at the position that produced the least amount of wobble b Fit the chainring into the chain c Rotate the derailleur forward and fit the crank arm onto the spindle so that the arm is at 6 o clock d Tap the crank arm onto the spindle with a plastic mallet 4 Apply grease to the crank arm mounting bolt 5 Install the crank arm mounting bolt and torque it to the specification in Table 4
37. as described in this chapter and tighten the handlebar binder bolts to the torque specification in Table 4 5 Install the throttle control as described in this chapter 6 Install the accessory control as described in this chapter THROTTLE CONTROL RIGHT SIDE Removal 1 Remove the battery from the battery com partment 2 Remove the right side cover from the E 3 Pull the cable inlet cover around the head tube and remove the cable inlet cover from the left side cover 4 Disconnect the throttle control connector F Figure 4 from the controller board Note how the throttle control wire is routed through the frame The new wire will have to be rerouted along the same path Horn board Controller board 5 Pull the wire so the connector passes through the frame and emerges at the cable inlet in the left side cover Figure 5 HANDLEBAR and CONTROLS 43 6 Twist and remove the right handlebar grip from the handlebar 7 Disconnect the front brake cable from the 5 C Figure 1 Note how the front brake cable is routed around the headlight It will have to be routed along the same path during assembly 8 Loosen the right brake lever clamp bolt and slide the brake lever body from the right handlebar Guide the front brake cable around the headlight as you remove the brake lever 9 Lay the brake lever over the frame top tube so it is out of the way Do not severely bend
38. crews A Figure 4 8 Reinstall the batteries and the battery pack cover 3 4 Removal 1 Turn the power knob OFF 2 Open the battery compartment door 3 Release the gate latch and open the bat tery gate 4 Use the handle to pull the battery pack from the compartment Be sure to support the bot tom of the battery pack with your free hand Installation 1 Set the lower end of the battery pack into the battery compartment and tilt the battery into place NOTE The E Bike beeps the OK __ _ _ when ever the battery pack is reinstalled and good contact exists between the battery pack and terminal block in the E Bike 2 Close the gate over the battery and secure the gate latch 3 Close the battery compartment door and turn the latches counterclockwise BATTERY PACK TEST Charger operation test 1 Plug the female end of the charging cord into the port on the charger 2 Plug the male end into a 110 volt outlet 3 Watch the battery charger LED and perform the indicated procedure a If the battery charger LED does not illu minate the charger is faulty and should be replaced Unplug the charging cord and check the battery voltage before charging as described below b If the battery charger LED turns to red and the cooling fan is not operating the charger is faulty and should be replaced Unplug the charger and ch
39. d Press the horn button and measure the voltage If the voltage is 24 volts DC replace the horn If the voltage is not 24 volts DC proceed to step 5 5 Check the voltage at the horn board power connector a Disconnect the horn board power con nector N Figure 1 from the horn board 0 gt The red and black leads from connector N con nect directly to the battery Power is applied to this connector whenever the battery is in the battery compartment b Install the battery into the battery com partment c Check the voltage at the red and black terminals on the connector d If the voltage is 24 volts DC proceed to step 6 If the voltage is not 24 volts DC replace the horn board power connector and wires 6 Check the voltage from the controller to the horn board a Disconnect connector L Figure 1 from the horn board b Connect a voltmeter to the white and yellow terminals of connector L c Install the battery if you have not already done so d Press the button and check the voltage If the voltage reads 24 volts DC replace the horn board F The taillight does not turn on when the headlight switch is ON 1 Turn on the headlight switch and check the operation of the taillight Press the horn button and check the operation of the horn If the horn headlight and taillight do not operate check the three amp fuse F3 in the schematic inside the controller a Remove the con
40. d then back out the adjuster three full turns 3 Turn the shifter barrel adjuster to its fully in position and then back out the adjuster one full turn NOTE gt Do not pull the inner wire so much that the derailleur begins to move 4 Use a fourth hand tool to pull the slack out of the inner wire 5 Torque the pinch mechanism nut to the specification in Table 4 Check that the inner wire 15 still positioned within the pinch mecha nism groove Derailleur Installation 1 Lubricate the derailleur as described above 2 Align the mounting bolt with the hole in the hanger 3 Rotate the derailleur clockwise so the stop tab on the derailleur mounting plate or the end of the B screw is forward clockwise of the stop tab on the derailleur hanger 4 Thread the mounting bolt into the hanger but do not completely secure the bolt at this time 5 Rotate the derailleur counterclockwise until the derailleur stop tab presses against the stop tab on the hanger 6 Tight the mounting bolt to the torque specifi cation in Table 4 Chapter Seven CHAIN and CRANKSET CHAIN Inspection The chain inspection tool Part Tool CC 2C is required for this service 1 Install the chain inspection tool onto the chain according to the manufacturer s instruc tions Be sure both of the tool s pegs are inside a chain link 2 Rotate the tool s dial so the pegs press against the inside of the chain rollers 3 Read the number opposite
41. derailleur as described in this chapter 22 Set the cable tension as described in this chapter DERAILLEUR Derailleur Lubrication Apply lubricant to the following points on the derailleur See Figure 15 1 Each edge of the pulley wheel dust cap 2 Both ends of each pivot on the parallelo gram 3 Threads of the mounting bolt 4 Threads of the barrel adjuster 5 Threads of the pinch mechanism Mounting bolt Tension pulley Derailleur Adjustment Three screws the H L and B screws are used to adjust the derailleur The H screw sets the outward limit of the derailleurs movement The L screw sets its inward limit The B screw adjusts the distance between the bottom of the cogset and the derailleur s guide pulley A fourth hand tool Park Tool BT 2 is required to perform this procedure 1 Check the cable attachment to the derailleur pinch mechanism a Inspect the position of the inner wire in the pinch mechanism The innerwire should follow the groove in the pinch plate and the tab on the pinch plate should be on the outboard side of the cable when you look directly at the pinch mechanism stud Figure 14 b Loosen the pinch mechanism nut Use the forth tool to pull the slack from the inner wire c Torque the pinch mechanism nut to the specification in Table 4 d Check that the inner cable is still con tained within the groove in the pinch mechanism plate 2 Set the derailleur as close as poss
42. derailleur so it is under the outermost cog CHAIN and CRANKSET 73 2 Take the non riveted end of the chain and feed it under and around the rear of the tension pulley on the derailleur Following the derailleur cage route the chain up the front and over the top of the guide pulley Once the chain emerges from the derailleur cage route it under and around the outermost cog 3 Next route the chain around the chainring 4 Move the chain so the two free ends meet at the middle of the lower chain run 5 Join the two ends together by slipping the end of the inner plate under the rivet protrud ing inward from the outer plate 6 Fit the chain tool onto the chain Pay atten tion to the following a If the tool has two cradles fit the chain over the cradle furthest away from the tool handle b Be sure the rollers are fully seated on the tool cradle c Turn the tool handle so the drive pin is centered on the rivet d Check that the side plates are properly aligned 7 Turn the tool handle and drive the rivet through the chain until the rivet is centered within the link The rivet is properly installed when an equal amount of rivet protrudes from the outside of each outer side plate Figure 6 Lubrication NOTE Do not apply excessive amounts of oil to the chain Excessive lubrication promotes the accumulation of dirt which accelerates chain wear CAUTION gt gt gt Use oil desi
43. e E Bike will not be used for more than one week remove the battery pack from the E and store it in a cool dry place The controller uses a small amount of power when ever the battery pack is installed in the E Bike Consequently the batteries slowly dis charge whenever the battery pack is in place even if the power knob is OFF To prevent total battery discharge during extended periods of non use remove the battery pack and store it in a cool dry place A stored battery should be recharged at least every three months to help maintain performance and quality On board Charging 1 Be sure the power knob is turned OFF 2 Turn the battery compartment latches clockwise and open the door 3 Retrieve the charging cord from the com partment above the bottom bracket 4 Plug the female end of the charging cord into the receptacle on the battery charger Figure 1 WARNING 1 1 The charger is equipped with a cooling fan If the cooling fan does not operate when the charging cord is plugged in and the red LED is on unplug the charger from the electrical out let immediately Determine why the fan is not operating before charging the battery pack Replace the charger if necessary 5 Plug the male end of the charging cord into a standard 110V 60 cycle electrical outlet The red LED on the charger and the cooling fan will automatically turn on The LED switches to green and the cooling fan turns off when the
44. e brake lever so it is forms a 25 35 angle with a line that parallels the floor Figure 7 d Tighten the brake lever clamp bolt to the torque specification in Table 4 Installation 1 Fita new brake lever body onto the handle bar and slide the brake lever body against the throttle control 2 Turn the barrel adjuster and the adjuster locknut until their slots align with the slot in the brake lever body 3 Connect the end of the brake cable inner wire to cable anchor in the brake lever Figure 3 4 Slide the inner cable through the slots in the brake lever adjuster barrel and adjuster locknut Figure 2 Fit the cable into barrel adjuster 5 Turn the barrel adjuster and adjuster lock nut so their slots do not align with the slot in the brake lever 6 Squeeze the caliper arms together and fit the cable guide into the bracket on the left caliper arm A Figure 1 Be sure the guide end is completely seated in the bracket 7A When installing the right brake lever install 9 Adjust the brake lever free play as described in this chapter BRAKE LEVER FREE PLAY ADJUSTMENT 1 Pull the brake lever to simulate a panic stop and then release the brake lever Repeat this at least ten times This assures that all components are properly installed and seated 2 Pull the brake lever until the brake pads just touch the rim 3 Measure the clearance between the brake lever and the handlebar grip This distance should be
45. e clamp bolt 10 Reinstall the right side cover ACCESSORY CONTROL LEFT SIDE Removal 1 Remove the battery from the battery com partment 2 Remove the right side cover from the E BikeTM 3 Pull the cable inlet cover around the head tube and remove the cable inlet cover from the left side cover 4 Disconnect the accessory control connec tor E Figure 4 from the controller board Note how the accessory control wire is routed through the frame The new wire will have to be rerouted along the same path 5 Pull the wire so the connector passes through the frame and emerges at cable inlet in the left side cover Figure 5 44 Chapter Four 6 Loosen the mirror mounting bolt Figure 8 and remove the mirror from the handlebar end 7 Twist the left handlebar grip from the han dlebar Do not lose the shim that sits between the handlebar grip and the shifter body 8 Disconnect the shifter cable from the S hook C Figure 1 Note how the cable is rout ed around the headlight It will have to be rout ed along the same path during assembly 9 Loosen the shifter clamp bolt and slide the shifter body from the handlebar Figure 9 Guide the shifter cable around the headlight as you remove the shifter Lay the shifter over the frame top tube so it is out of the way Do not severely bend or kink the cable 10 Loosen the clamp bolt on the brake lever body Figure 10 and remove the body from the handleb
46. e connector If the system beeps GO the problem is in the wire Replace it If the system does not beep GO replace the controller D The headlight does not operate when the switch is turned on 1 Turn on the headlight switch and check the operation of the taillight Press the horn button and check the operation of the horn If the horn headlight and taillight do not operate check the three amp fuse F3 in the schematic inside the controller a Remove the controller open the con troller lid and inspect the fuse LED b If the LED is on replace the three amp fuse F3 c If the LED is not on check the fuse F1 on the controller fuse module If you find a 16 amp fuse replace it with a 25 amp fuse If you find a blown 25 amp fuse replace the controller 2 Check the power by operating the horn If it does not sound charge the battery and retest the horn If the horn sounds continue with step 3 8 9 3 Check the headlight bulb Replace the bulb if itis burned out 4 Check the headlight connector C Figure 1 5 Check the continuity of the headlight switch a Turn the power knob OFF and remove the battery from the battery compart ment b Disconnect the accessory control con nector E Figure 1 from the controller board c Connect an ohmmeter between the blue and white terminals in the connector d Check the continuity when the headlight switch is turned OFF and turned ON e There should be no con
47. eck the battery voltage before charg ing as described below c If the battery charger LED turns red and the cooling fan operates perform the charger output test described below d If the battery charger LED turns green perform the charger output test described below Charger Output Test 1 Remove the cover from the battery pack 2 Connect a voltmeter s positive test probe to the positive battery terminal and con nect the voltmeter s negative test probe to the battery negative terminal as shown in Figure 7 Note the reading on the voltmeter 3 With the voltmeter still connected as described in step 2 plug the charger into a 110 volt outlet Note the reading on the volt meter 4 Compare the two readings a If the reading is higher when the charger is plugged in the charger is operating properly Perform the battery voltage test before charging b If the two readings are the same the charger has failed and should be replaced Battery Voltage Test Before Charging 1 Let the battery stand for one hour 2 Remove the cover from the battery pack 3 Connect a voltmeter s positive test probe to the positive battery terminal and con nect the voltmeters negative test probe to the battery negative terminal as shown in Figure 7 4 Note the reading on the voltmeter 5 If the reading is less than 12 volts the bat tery is faulty and should be replaced Battery Voltage Test After
48. ed Toe and Vertical Alignment Toe can be set by manually manipulating the pad or by using a spacer Both methods are described below Manual Method 1 Loosen the pad mounting nut just enough so the pad can be manipulated by hand 2 Adjust the brake cable so the face of the pad almost touches the rim 3 Manually set the toe by pulling the leading edge of the pad rear side away from the rim while pressing the trailing edge front side to the rim 4 Tighten the pad mounting nut enough to hold the pad in position 5 Visually inspect the pad for vertical angle alignment If necessary manipulate the pad so the pad face parallels the surface of the rim Figure 10 Spacer Method 1 Loosen the pad mounting nut just enough so the pad can be manipulated by hand 2 Put a spacer between the leading edge rear edge of the pad and the rim 3 Adjust the brake cable so the face of the trailing edge front edge of the pad touches the rim 4 Tighten the pad mounting nut enough to hold the pad in position 5 6 Chapter Five 5 Visually inspect the pad for vertical angle alignment If necessary manipulate the pad so the face of the pad parallels the rim Figure 10 Tangent Alignment 1 Look at each pad from the side and note the position of the top of the pad relative to the rim The distance from the top of the pad to the top of the rim should be the same at each end of the pad Figure 11 2 If one end of the
49. erailleur remove the end cap A Figure 4 from the end of the inner wire 5 Loosen the pinch mechanism nut B Figure 4 Pull the shifter cable from the derailleur pinch mechanism and out of the barrel adjuster 6 Slide the lower cable housing C Figure 4 off the inner wire Do not lose the ferrule from either end of the lower cable housing 7 Release the inner wire from the two hous ing stops on the right seat stay A Figure 5 8 Slide the tube B Figure 5 that sits between the two housing stops off the inner wire 9 Pull the shifter cable from the cable inlet in the right side cover 10 Slide the upper cable housing from the inner wire Figure 6 Do not lose the ferrule from either end of the upper cable housing SHIFTER and DERAILLEUR 6 3 11 Remove the shifter from the handlebar as described in this chapter 12 Gently pry the cover plate from the inside face of the shifter housing Figure 7 13 Pull the twist unit from the shifter housing Slide the shifter housing down the inner wire and remove it 14 Push the inner wire into the twister unit until the barrel end of the inner wire emerges from the socket in the twister unit Figure 8 15 Pull the inner wire from the twister unit NOTE The shifter inner wire can be removed and replaced without removing the cable housings Installation A fourth hand tool Park Tool BT 2 is required to perform this procedure
50. ery 5 to 10 rides Brake pad adjustment Wheel quick release adjustment Tire pressure Tire wear damage Head tail brake light operation Mirror position Controls and display Seat post quick release adjustment Brake pad wear Brake cable tension wear Spoke tension Wheel true Hub bearings adjustment Hub bearing lubrication Chain lubrication Derailleur adjustment Reflectors Battery and charger Headset adjustment Bottom bracket adjustment Tighten all bolts nuts and mounting hardware gt lt gt lt gt lt gt lt gt lt DK gt lt gt lt lt Depending upon length of ride and riding conditions Inspect more frequently when riding in dusty or wet conditions 1 4 SPECIAL TOOLS The following special tools are needed for servicing the E Bike Tool Part number Hex wrench set 4mm 5mm 6mm Park AWS 1 Hex wrench set Park AWS 11C Hex wrench set 2mm 5mm 3mm Park AWS 3 Fourth hand cable stretcher Park BT 2 Chain checker Park CC 2C Chain breaker screw type Park 3 Crank wrench Park CCW 14R Cable and housing cutter Park CN 4C Gearclean brush Park GSC 1 32mm amp 36mm head wrench Park HCW 15 Pedal wrench Park PW 3 Spoke wrench black Park SW 0 Spoke wrench red Park SW 2 Tire lever set Park TL 1C Freewheel tool Park Tool FR 1 Bottom bracket cartridge tool Park Tool BBT 2
51. ether black and white and check the continuity across the black and white terminals in the headlight connector C Figure 1 If there is no continuity replace the headlight wire E The horn does not sound when the but ton is pressed 1 Turn on the headlight switch and check the operation of the taillight Press the horn button and check the operation of the horn If the horn headlight and taillight do not operate check the three amp fuse F3 in the schematic inside the controller a Remove the controller open the con troller lid and inspect the fuse LED b If the LED is on replace the three amp fuse F3 c If the LED is not on check the fuse F1 on the controller fuse module If you find a 16 amp fuse replace it with a 25 amp fuse If you find a blown 25 amp fuse replace the controller 2 Check the power supply by turning on the headlight If the light does not operate charge the battery 3 Check the horn switch by performing the fol lowing a Turn the headlight on The headlight indicator should light b Press the horn switch If the indicator light goes off the horn switch is okay If the indicator does not go off replace the accessory control 4 Check the voltage at the horn a Remove the left side cover b Disconnect the spade connectors from the back of the horn c Connect a voltmeter s positive lead to the red terminal Connect the voltmeter s negative lead to the white terminal
52. fits into the upper housing stop and that the tube is secure between both housing stops 14 Lubricate the lower cable housing with oil Be sure a ferrule is in place on each end of the lower cable housing and install the inner wire through the lower cable housing C Figure 4 Fit the upper ferrule into the seat in the lower housing stop 15 Feed the inner wire through the barrel adjuster on the derailleur and through the pinch mechanism The lower housing ferrule should be seated in the barrel adjuster and the inner wire should be properly routed through the pinch mechanism 16 Finger tighten the pinch mechanism nut so the inner wire is held securely in the pinch plate groove and check the following a The inner wire should follow the goove in the pinch plate b When looking directly at the pinch mech anism stud the tab on the pinch plate should be on the outboard side of the inner wire Figure 14 SHIFTER and DERAILLEUR 6 5 Correct Incorrect Pinch plate 17 Loosen the pinch mechanism nut and use the fourth hand tool to pull the slack from the inner wire 18 Torque the pinch mechanism nut B Figure 4 to the specification in Table 4 Check that the inner cable is still contained within the groove in the pinch mechanism plate 19 Fit an end cap A Figure 4 over the end of the inner wire and crimp it onto the wire 20 Install the shifter onto the left handlebar as described in this chapter 21 Adjust the
53. ght should be centered on the horizontal line That is there should be an equal amount of light above and below the line If necessary adjust the headlight by per forming the following a Loosen the headlight locknut Figure 12 behind the headlight housing b Tilt the headlight housing up or down until the beam is centered on the hori zontal line c Tighten the locknut Torque the headlight locknut to the specification in Table 4 ELECTRICAL TAILLIGHT Replacement The LEDs in the taillight cannot be replaced If the taillight LEDs burn out install a new taillight assembly 1 Be sure the power knob is OFF and remove the battery from the compartment 2 Disconnect the taillight brake light connector under the seat Figure 13 3 Remove the two taillight mounting nuts Figure 14 and remove the taillight assembly from the seat bracket 4 Fit a new taillight assembly in place and secure it with the two taillight mounting nuts Torque the nuts to the specification in Table 4 5 Connect the taillight brake light connector Figure 13 TROUBLESHOOTING General instructions Find the symptom that describes the condition you are trying to correct Follow that trou bleshooting procedure step by step until the problem is corrected Perform the trou bleshooting procedures in the indicated order unless instructed to proceed to another step Before moving on to a next step reconnect any part that had been
54. gned for bicycles Automotive and household oils are unsuitable for the E Bike chain 1 Oil the contact areas between the inner and outer side plates on each link A Figure 7 as well as the contact areas between the inner side plates and each end of the rollers B Figure 7 2 If the chain is installed on the E Bike M back pedal for 30 seconds If the chain is not installed wiggle the chain for 30 seconds This helps the lubricant penetrate the crevices in the chain 3 Use a clean cloth to wipe excess lubricant from the chain CRANK ARM Removal A cotterless crank wrench Park Tool CCW 14R is required for this service 1 If the pedal will also be serviced remove the pedal from the crank arm 2 Measure the clearance between the outside face of the chainring and the right chain stay a Check the clearance on the rear side of the chainring b Check the chainring clearance at sever al places and write down the smallest value c Compare this value to the specification in Table 1 d The chainring and or chain stay is dam aged if the measurement is not within the specified range 3 Loosen and remove the crank arm mount ing bolt Figure 8 7 4 Chapter Seven 4 Inspect the position of the spindle end The end of the spindle should be recessed within the crank arm square hole If the spindle end is flush with the surface of the crank arm square hole the crank arm is excessively worn and must be re
55. he bolt with a plastic mallet to force the stem wedge down 42 Chapter Four CAUTION The Minimum Insert mark on the handlebar stem must not sit above the top of the headset 2 Raise or lower the stem within the head tube until the handlebar is at the desired height 3 Rotate the handlebar from side to side and align the handlebar with the wheel or fork dropouts 4 Tighten the stem binder bolt to the torque specification in Table 4 HANDLEBAR REPLACEMENT Removal 1 Note how the brake cables shifter cable and electrical wires are routed around the headlight They will have to be rerouted along the same path during installation 2 Remove the following components from the right handlebar a The handlebar grip b The brake lever housing c The throttle control and throttle stop 3 Remove the following from the left handlebar a The mirror b The handlebar grip c The shifter d The brake lever housing e The accessory control 4 Remove the two handlebar binder bolts A Figure 1 5 Remove the handlebar clamp B Figure 1 and the handlebar Installation 1 Fit the handlebar into place in the binder on the handlebar arm Be sure the knurled portion of the handlebar is centered in the binder 2 Fit the handlebar clamp into place around the handlebar 3 Apply Loctite 242 blue to the threads of the handlebar binder bolts and install the bolts finger tight 4 Position the handlebar
56. ible to the cogset by performing the following a Shift the chain to the innermost cog b Completely loosen the B screw c Back pedal and check for bouncing at the guide pulley Figure 16 The B screw is too loose if bouncing is noticed d Tighten the B screw one turn and repeat the bounce check 6 6 3 Set the derailleur s outward limit by perform ing the following a Shift the derailleur so the chain is on the outermost cog b Stand behind the E Bike and check the position of the derailleur The guide pulley should align with the outer most cog as shown in Figure 9 If necessary adjust the outward limit by turning the H screw Tighten the H screw to adjust the guide pulley inward Loosen the H screw to adjust the derailleur outward 4 Set the derailleur s inward limit by perform ing the following a Shift the derailleur so the chain rests on the innermost cog b Stand behind the E Bike M and check the position of the derailleur The guide pulley should align with the innermost cog as shown in Figure 10 C If necessary adjust the inward limit by turning the L screw Tighten the L screw to move the derailleur outward Loosen the L screw to move the derailleur inward Setting Cable Tension A fourth hand tool Park Tool 2 is required to perform this procedure 1 Loosen the nut on the derailleur pinch mech anism 2 Turn the derailleur barrel adjuster to its full in position an
57. ller Installation 1 Apply Loctite 242 blue to the threads of the controller mounting screws 2 Attach the following connectors to their mates on the back of the controller a The red power connector G Figure 1 8 4 b The black power connector H Figure 1 c The motor connector Figure 1 d The horn board connector J Figure 1 3 Fit the controller into place in the E Bike and install the three controller mounting screws A B amp C Figure 4 Finger tighten the screws at this point When installing the rear mounting screw B Figure 4 be sure a stepped washer fits into each side of the mounting hole on the heat sink 4A On early production models be sure the blue motor ground wire from the motor harness is installed under the rear controller mounting screw B Figure 4 4B On later production models use the ground screw to secure the blue ground wire to the controller heat sink This screw mounts to the threaded hole above the rear controller mounting screw B Figure 4 5 Torque the three controller mounting screws to the specification in Table 4 6 Connect the following connectors to their mates on the controller board a Brake sensor connectors A and B Figure 1 b Headlight connector C Figure 1 Taillight orake light connector D Figure 1 d Accessory control connector E Figure 1 e Throttle control connector F Figure 1 7 Install the right side cover Q
58. ly seated on the spindle 7 6 Chapter Seven 5 Set your hand against the frame down tube with the end of your forefinger touching the inside of the chainring Figure 14 6 Rotate the crank arm and note the amount of wobble in the chainring 7 Remove the crank arm by striking the arm with the rubber mallet 8 Rotate the spindle so the reference mark is now at 3 o clock and repeat steps 3 7 9 Rotate the spindle so the reference mark is at 6 o clock and repeat steps 3 7 10 Rotate the spindle so the reference mark is at 9 o clock and repeat steps 3 7 11 Note the position that produces the least amount of chainring wobble Install the crank arm with the reference mark in that position PEDAL The pedal on the right side has right hand threads The pedal on the left side has left hand threads Keep this in mind when remov ing and installing pedals onto the crank arms Removal 1 Rotate the crank so the arm with the pedal being removed points towards the rear of the 2 Place a wrench onto the pedal flats so the shaft of the wrench is horizontal and pointing forward 3 Break the pedal loose 4 While facing the crank hold the pedal with one hand and the wrench with the other Rotate the pedal forward normal pedaling motion and remove the pedal 5 Repeat this procedure for the opposite pedal Installation 1 Inspect the ends of the pedal stud Each pedal is identified by an L
59. m will disable the assist code motor within 3 5 every 8 seconds seconds Over heat 2 Sounds at power knob ON if the motor has been disabled System refusal An error has been detected The system will not operate Battery state of Indicates the battery Green 100 60 charge state of charge within 3 Yellow 60 20 seconds of power knob ON Red 20 0 Low battery The system will shut Charge level LEDs down within 3 to 5 cycle continuously seconds in sequence 1 2 VEHICLE IDENTIFICATION NUMBER The 17 digit vehicle identification number VIN is printed on a label that is affixed to the inside face of the right frame seat stay KEY NUMBER The 4 digit key number is stamped on the upper portion of the key shaft MODEL CODE Model code Model prefix Description Color 1 Color 2 This label also contains the gross vehicle weight rating and recommended tire inflation pressure B1 Bicycles 99 B124BV00 BK RD 1B1 Black BK Red RD 99 B124CV00 BK RD 2B1 Comfort Black BK Rally Red RD 99 B124TV00 ML CR 2B1 HOW TO READ THE MODEL CODE Metallic Metallic Blue ML Cranberry CR Model Year 99 B1 24 CV 00 BK Product Line amp Category Power System dint B1 Bicycle 24 24 Volts Base Conventional Touring T TERMS Left and Right Most of the time left and right in this man ual refer to the
60. o suspend the side cover form the seat 8B If the side cover must be completely removed perform the following a Squeeze the arms of the rear brake caliper together and disconnect the rear brake cable guide from the bracket on the left caliper arm A Figure 5 b Loosen the brake cable pinch bolt B Figure 5 and release the inner cable end from the pinch mechanism c Carefully pull the brake cable from the rear inlet in the left side cover Installation 1 If removed route the rear brake cable through the rear inlet in the left side cover 2 Pivot the side cover into place Carefully fit the battery compartment door between the front wheel and the forward down tube and fit the side cover onto the left side of the E Be sure all electrical wires and cables fit into the cable inlet at the front of the left side cover 3 Install the three battery compartment screws Figure 3 finger tight 4 Apply Loctite 242 blue to the threads of each left side cover mounting screw install each screw finger tight 5 Install the upper right controller mounting screw A Figure 4 along with the washer Apply Loctite 242 blue to the threads of the screw and finger tighten the screw 6 Torque the controller mounting screw and the three side cover mounting screws to the specifications in Table 4 8 3 7 If the brake cable was disconnected from the rear brake perform the following a Feed the end
61. ontact with your eyes or skin Removal 1 Remove the battery pack from the E Bike 2 Remove the two cover screws from the bat tery pack and remove the cover 3 Disconnect and remove the blue intercon nect wire that connects the two batteries to each other in series Note the fuse on the inter connect cable Figure 2 4 Disconnect the battery pack leads black and red from the spade connectors on each battery 5 Invert the battery case Tap the case against the bench or floor to dislodge the batteries from the battery pack 6 Remove each battery and its damper strap Figure 3 Interconnect Wire Bullet Connector NOTE Contact your state or local agency for informa tion on proper battery disposal 7 Properly dispose of the old batteries Installation 1 Wrap the damper strap around the first bat tery Figure 3 2 Set the battery into the compartment so the end with the spade connectors faces the charger Press the battery into the compart ment until it bottoms 3 Repeat for the second battery 4 Inspect the fuse on the blue interconnect wire Replace the fuse as necessary 5 Connect the blue interconnect wire to the upper battery s positive terminal and to the lower battery s negative terminal 6 Connect the red lead from the battery pack to the positive terminal on the lower battery 7 Connect the black lead from the battery pack to the negative terminal on the upper bat tery
62. or R stamped on the stud 2 Grease the threads of the pedal stud 3 Thread the left pedal onto the left crank arm Tighten the pedal stud as far as possible by hand 4 Face the pedal and fit a wrench onto the pedal flats Hold the pedal with one hand and hold the wrench with the other Figure 15 5 Rotate the crank arm rearward opposite the direction of normal pedal rotation until the pedal is snug 6 Tighten the pedal to the torque specification in Table 4 CAUTION 1 Metal burrs are often created when the pedal is tightened against the crank arm Use a rag to wipe up excess grease so you will not have to deburr your finger 7 Use a rag to wipe excess grease from the crank arm 8 Repeat this procedure for the right pedal BOTTOM BRACKET CARTRIDGE The E Bike uses a Chinhaur CH52 73 bottom bracket cartridge This cartridge threads into the right side of the bottom brack et Its adapter ring threads into the left side of the bottom bracket The adapter ring on this cartridge has stan dard right hand threads The main body how ever has left hand threads CHAIN and CRANKSET 7 7 A bottom bracket cartridge tool Park Tool BBT 2 is required for removing and installing the bottom bracket cartridge Removal 1 Remove both crank arms 2 Remove the left bottom bracket cover Figure 16 3 Install the bottom bracket cartridge tool onto the adapter ring and remove the ring from the left
63. or kink the cable 10 Loosen the set bolt on the throttle control 11 Slide the throttle control and throttle stop off the handlebar Pull its wire free of the head light bracket Installation 1 Fit the throttle stop onto the bottom of the throttle control Figure 6 2 Slide the throttle control and the throttle stop onto the right handlebar 3 Feed the connector end of the throttle con trol wire through the cutout in the headlight bracket Figure 7 4 Feed the cable around the head tube through the cable inlet in the left side cover and plug the connector into position F Figure 4 on the controller panel 5 Slide the right brake lever body onto the right handlebar Guide the front brake cable around the headlight as you install the brake lever body 6 Finger tighten the clamp bolt to hold brake body in place Use the S hook to secure the front brake cable to the shifter cable C Figure 1 7 Twist the right handlebar grip onto the han dlebar until the grip is flush with the end of the handlebar 8 Slide the brake lever body against the han dlebar grip Position the brake lever as described in Chapter Five and torque the clamp bolt to the specification in Table 4 9 Slide the throttle control throttle stop assembly against the brake lever Rotate the throttle control so the LEDs point to the rider s eyes Tighten the clamp bolt so there is enough friction to hold it in place Do not over tighten th
64. over Figure 2 Gently push the cable inlet cover so it follows the side cover contour around the head tube and rests in place in the left side cover 2 Fit the right side cover into place on the E Bike Be sure no cables or wires are pinched between the side cover and the frame 3 Apply Loctite 242 blue to the threads of the side cover mounting screws 4 Install the screws Be sure the short screw is installed in the lower hole Torque the side cover mounting screws to the specification in Table 4 5 Close and secure the battery compartment door LEFT SIDE COVER Removal 1 Be sure the power knob is OFF and remove the battery from the battery compartment 2 Remove the right side cover from the E 3 Remove the cable inlet cover from the left side cover 4 Remove the three battery compartment screws Figure 3 at the front of the battery compartment 5 Remove the upper right controller screw A Figure 4 Do not lose the washer behind this screw 6 Remove the three left side cover screws One is located behind the controller D Figure 4 one is behind the steering head and the third is above the bottom bracket 7 Carefully pivot the right side cover away from the E Bike until the battery compart ment passes between the front wheel and for ward down tube ELECTRICAL 8A If you do not need to completely remove the left side cover form the E Bike use a wire or bungee cord t
65. placed 5 If you intend to reinstall the crank arm mark one corner of the spindle end and a corre sponding mark on the crank arm Figure 9 The marks will facilitate assembly 6 Carefully thread the crank wrench onto the crank arm Finger tighten the wrench until it bottoms in the crank arm and then snug it in place with an adjustable wrench When prop erly installed you should be able to turn the crank wrench handle with your fingers Figure 10 CAUTION If the crank wrench body starts to rotate or if the body appears to pull from the crank arm when you tighten the crank wrench remove the crank wrench body and identify the prob lem The crank wrench threads may be dam aged Correct the problem before proceeding 7 Turn the crank wrench handle clockwise and press the crank arm off the spindle 8 If you are removing the right arm remove the chainring from the chain and suspend the chain from the frame with a bungee cord Inspection 1 Inspect the spindle flats for signs of a loose or worn crank arm The crank arm marks on the spindle flats should not extent along the entire surface of the flat Figure 11 If they do the crank arm is worn and must be replaced Replace FIG 12 CHAIN and CRANKSET 2 Inspect the square hole in the crank arm Figure 12 The flats of the hole should be straight and even Replace the crank arm if its square hole shows signs of wear or damage 3 Inspect the crank
66. rake lever 5 If necessary align the brake pads as described in this chapter 6 Route the cable to the caliper If you are replacing a rear brake cable route the cable through the rear cable inlet in the left side cover 7 Fit the cable guide into the bracket on the left caliper arm A Figure 1 8 Squeeze the caliper arms together and connect the cable guide to the bracket on the left caliper arm 9 Secure the inner wire in the brake caliper pinch mechanism by performing the following a Feed the brake cable inner wire through the slot in the pinch mechanism b Use the fourth hand cable stretcher Park Tool BT 2 to pull the inner wire until the combined clearance between each brake pad and the rim equals 2 mm 0 08 in c Tighten the pinch bolt B Figure 1 to the specification in Table 4 d Crimp a new end cap onto the end of the inner wire 10 Depress and release the brake lever sever al times and check the caliper arm balance a The brake pads should contact the rim at the same time when the brakes are applied b The gap between each pad and the rim should equal 1 mm 0 04 in when the brake lever is released CAUTION Do not set the caliper arm spring tension too high C If necessary balance the caliper arms by turning the spring tension adjuster B Figure 4 on either arm 11 Adjust the brake lever free play as described in this chapter BRAKE LEVER Removal 1 Remove the h
67. rews Apply Loctite Left bottom bracket cover screws 17 4 26 5 Apply Loctite Crank arm mounting bolt 200 250 14 4 18 1 Apply grease to the bolt threads Pedal 30 50 26 5 43 4 Apply grease to the stud threads Bottom bracket cartridge adapter ring 300 400 21 7 28 9 Apply grease to the threads Chainring bolt 350 450 25 32 Apply oil to the bolt threads Motor torque arm Apply Loctite Headlight mount 1 Taillight mounting nut Horn mounting nut Cord access cover Frame mounted connector 1 Apply Loctite Front fender Rear fender Table 5 Performance Specifications Item Specification Top speed 13 5 14 0 mph Range E mode flat no wind 18 20 miles Maximum gradeability 1196 grade 6 mph Acceleration 0 10 mph in 5 3 seconds 200 pound rider with tires inflated to 60 psi 2 4 Frame Specifications Head Tube 163 mm 6 4 in Frame Size Center to top 419 cm 16 5 in RC 431 5 mm 17 0 in Wheel Base 1062 3 mm 41 8 in Chapter Three BATTERY PACK CHARGING THE BATTERIES The E Bike includes a charger that is integral part of the battery pack Batteries can be charged when the battery pack is on board the E bike or when the battery pack is removed for remote charging To assure maximum battery life always fully recharge the battery after each ride If th
68. ring A Figure 13 Note how the bearing is oriented the closed side of the retainer facing up toward lower head tube race The bearing will have to be installed in this position during assembly 13 Remove the rubber seal B Figure 13 from the fork crown race Note how the seal is oriented It will have to be installed in this posi tion during assembly 14 Remove the upper bearing from the head tube Note how the bearing is oriented the closed side of the retainer facing down toward the upper head tube race The bearing will have to be installed in this position during assembly bracket from the fork column 10 Support the forks and remove the adjustable race from the fork column NOTE The bearing must be reinstalled with the prop er orientation during assembly Look for the lower bearing when removing the forks The bearing may come out with the fork crown race or it could remain behind in the head tube Assembly 1 Clean the bearings head tube races fork crown race and adjustable race with solvent 2 Lightly coat the upper head tube race and the lower head tube race with grease A 1 mm bead in each race should be sufficient 3 Pack the bearings with grease 4 6 OOI gt The grease in the lower head tube race should hold the bearing in place during assembly 4 Press each bearing into the grease in the head tube Be sure the closed side of each bearing faces the race in the head tube
69. ry from the battery compartment b Disconnect the taillight brake light con nector Figure 13 under the seat c Disconnect the taillight brake light con nector D Figure 1 from the controller board d Place a jumper across the brown and black terminals in the connector at the controller end of the wire e Connect an ohmmeter to the brown and black terminals at the taillight brake light end of the wire and check the continuity of the wire f If there is no continuity replace the tail light brake light to controller wire G The brake light does not operate 1 Turn on the headlight switch and check the operation of the taillight Press the horn button and check the operation of the horn If the horn headlight and taillight do not operate check the three amp fuse F3 in the schematic inside the controller a Remove the controller open the con troller lid and inspect the fuse LED b If the LED is on replace the three amp fuse F3 c If the LED is not on check the fuse F1 on the controller fuse module If you find a 16 amp fuse replace it with a 25 amp fuse If you find a blown 25 amp fuse replace the controller 2 Turn the headlight on to check the power If the light does not operate charge the battery 3 Check the brake sensor connectors A and B Figure 1 at the controller board Each should be secure 4 Check the output from the brake sensor a Disconnect one of the brake sensor connector
70. s from the controller b Connect an ohmmeter to the terminals in the connector c Operate the brake lever for that side and check the continuity d There should be continuity when the brake lever is applied but no continuity when the lever is released e Replace the brake lever body if the brake sensor fails either of these tests Proceed to step 6 if the brake sensor passes both tests 5 Perform this test on the other brake sensor 6 Check the voltage at the taillight brake light connector a Disconnect the taillight brake light con nector Figure 13 under the seat b Install the battery into the battery com partment if you have not already done SO c Connect a voltmeter to the black and yellow terminals on the controller side of the connector d Operate a brake lever and check the voltage at the connector If the voltage is 24 volts DC replace the taillight brake light assembly WAVIIONI ALOHA 9D1V310NI 308YHD JWH SOLVJIONT TNS AN311vB 43 104 230410922 C1N0N3 1HOIS 33v AS 1MOTMDIS 51041 02 avB83ln0NvH IHOIS CIRO 1331 32v as wows AS HITO AS AS 7051407 3510952 AS MO IVDIDNI 1HD1 QY3H S10aLNGD av83710NYH 1431 1H9I Q v3H 1 093 gt 15015 32N88 570 1 02 NY8300NYH 18013 anenar 3 MYG3TONNH 1333 22 GavOa LINIAIID NaOH Wiring Diagram 173110 3333386 033
71. st cog 2 Inspect the driving pin of the chain breaker Replace the tool if the pin is not straight CAUTION Some chain breakers have two cradles The cradle furthest from the guide pin is for remov ing installing the chain The cradle closest to the guide pin is for adjusting a tight link Be sure to use the correct cradle for the task 3 Fit the chain breaker onto a link in the chain s lower run Be sure the chain rollers are fully seated in the tool s cradle and that the driving pin is centered on the chain rivet 4 Turn the tool handle until the driving pin just touches the rivet NOTE 23 The rivet should be pressed the minimum dis tance necessary to separate the chain and no more Do not drive the rivet completely from the inner plate on the inboard side of the chain The chain can be separated once the rivet extends 0 5 to 1 0 mm into the inside of the inner chain plate See Figure 5 5 Turn the tool handle five full turns but no more 6 Remove the tool from the chain 7 Flex the chain laterally and separate the chain 8 Remove the chain from the E Bike Cleaning 1 Immerse the chain in solvent 2 Use a stiff brush to clean the both sides of the chain 3 Use the brush carefully when cleaning the rollers Take special care to see that the rollers are completely clean 4 Rinse the chain in clean solvent 5 Dry the chain with compressed air Installation 1 If necessary move the
72. t unit until the barrel end of the wire is seated in the socket Figure 11 6 4 Chapter Six 5 Feed the inner wire along the cable groove Figure 12 in the shifter housing and out through the barrel adjuster FIG 12 6 Fit the twist unit into the shifter housing Pull firmly on the inner wire while pressing the twist unit into the shifter housing Be sure the end of the twist unit engages the clip in the shifter housing Figure 13 7 Check that the cable is still seated in the groove in the shifter housing and install the cover plate Figure 7 8 Check the operation of the shifter Pull the inner wire while you operate the shifter The inner wire should move in and out and the shifter should click along its detents 9 Slip the shifter onto the handlebar 10 Lubricate the upper cable housing with oil and slide the inner wire through the upper cable housing Be sure the inner wire passes through the ferrule at each end of the cable Slide the upper cable along the inner wire until the ferrule is seated inside the barrel adjuster at the shifter housing 11 Route the shift cable around the headlight through the cable inlet in the right side cover and along the top tube 12 Slide the tube B Figure 5 over the free end of the inner wire and up to the cable hous ing 13 Fit the inner wire through the two housing stops on the right seat stay A Figure 5 Be sure the ferrule from the upper cable housing
73. ted with out the bearings becoming excessively tight the headset must be overhauled 16 Reinstall the stem into the fork column Set the stem to the height you noted during disas sembly Torque the stem binder bolt to the specification in Table 4 17 Slide the handlebar assembly onto the stem Be sure the top of the arm is below the stem crown 18 Tighten the handlebar arm clamp bolts to the specification in Table 4 19 Check for tight bearings by performing the following a Turn the handlebars from side to side The forks should turn smoothly with no binding The bearings are too tight if you feel jerky incremental movement instead of a smooth fluid motion b Lift the E Bike by the top frame tube and watch the front wheel It should freely rotate to one side or the other The bearings are too tight if the wheel does not fall to one side when you lift the E If necessary adjust the headset by loos ening the adjustable race Chapter Five BRAKES V BRAKES NOTE When working on the brake calipers and pads the terms left and right refer to the techni cian s point of view when standing in front of the E Bike and looking at the front brake caliper or when standing behind the E Bike and looking at the rear brake caliper BRAKE CABLE REPLACEMENT Removal 1 Squeeze the caliper arms together and dis connect the cable guide from the bracket on the left caliper arm A Figure 1
74. ting bolt to the torque specification in Table 4 11 Slide the accessory control against the brake lever Rotate the accessory control on the handlebar to the same relative position as the throttle control housing Tighten the clamp bolt so there is enough friction to hold it in place Do not over tighten the clamp bolt 12 Use the S hook to secure the shifter cable to the front brake cable C Figure 1 HANDLEBAR and CONTROLS 45 13 Reinstall the cable inlet cover and right side cover HEADSET A 36 mm spanner Park Tool HCW 15 is required for servicing the headset Disassembly 1 Remove the front wheel 2 Mark the stem height with tape so it can be easily reset to the correct height during assem bly 3 Break the stem binder bolt A Figure 3 loose while the handlebar arm assembly is still attached to the stem 4 Loosen the handlebar arm clamp bolts B Figure 3 and remove the handlebar arm assembly from the stem 5 Use a bungee cord or wire to suspend the handlebar assembly from the frame 6 Remove the stem from the fork column 7 Visually inspect the position of cone in the adjustable race and in the fork crown Note how far the cone protrudes from its respective cup Figure 11 This will help during assem bly 8 Remove the headset locknut with the Park 36 mm wrench Figure 12 9 Remove the washer and the headlight 11 Carefully lower the forks from the head tube 12 Remove the lower bea
75. tinuity when the headlight switch is OFF There should be continuity when the headlight switch is ON Replace the accessory control if it fails either of these tests 6 Check the voltage at the bulb socket a Reinstall the battery b Remove the bulb socket from the head light reflector c Connect a voltmeter s positive lead to the socket contact with the black wire Connect the voltmeter s negative lead to the socket contact with the white wire d Turn the headlight switch ON and mea sure the voltage between the contacts Voltage should read 24 volts DC If the voltage reading is 24 VDC replace the bulb or the socket If the voltage is not 24 volts DC proceed to step 7 7 Check the voltage at the headlight wire a Be sure the headlight switch is OFF b Disconnect the headlight socket wires from the two leads from the headlight wire c Turn the headlight switch ON and check voltage between the white and black leads of the headlight wire Voltage should read 24 volts DC If voltage is 24 VDC replace the bulb socket If the volt age is not 24 VDC proceed to step 8 8 Check the continuity of the headlight wire a Be sure the power knob is OFF and remove the battery from the battery compartment b Disconnect the headlight connector C Figure 1 from the controller board c Remove the headlight reflector as described in this chapter 8 10 Chapter Eight d Twist the ends of the headlight wire tog
76. troller open the con troller lid and inspect the fuse LED b If the LED is on replace the three amp fuse F3 c If the LED is not on check the fuse F1 on the controller fuse module If you find a 16 amp fuse replace it with a 25 amp fuse If you find a blown 25 amp fuse replace the controller 2 Press the horn button to check power flow If the horn sounds continue If not charge the battery 3 Check the taillight brake light connector D Figure 1 at the controller board Be sure it is securely connected to the board 4 Check the taillight switch by performing the following a Turn the headlight switch on and check the headlight LED 8 11 ELECTRICAL b If the LED turns on the switch is fine If it does not operate replace the acces sory control 5 Check the voltage at the taillight brake light connector a Disconnect the taillight brake light con nector Figure 13 under the seat b Install the battery into the battery com partment if you have not already done so c Connect a voltmeter to the brown and black terminals on the controller side of the connector d Turn the headlight switch ON and check the voltage at the connector If the volt age is 24 volts DC replace the tail light brake light assembly If the voltage is not 24 volts DC proceed to step 6 6 Check the continuity of the controller to tail light brake light wire a Be sure the power knob is off and remove the batte

E-Bike ® Service Manual 24V MODELS

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E-Bike &reg; Service Manual 24V MODELS

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E-Bike ® Service Manual 24V MODELS