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Currier Tech eZip Skyline Owner'S Manual Download Page 64

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Summary of Contents for eZip Skyline

Page 1: ...BK W IZ VIBE BK K6 IZ VIBE RD W K6 Izip E3 Path IZ PATH GY IZ PATH BL W IZ PATH M GY IZ PATH L GY Izip E3 Zuma IZ ZUMA BL IZ ZUMA RD W IZ ZUMA M BL IZ ZUMA L BL IZ ZUMA RD W Izip E3 Metro IZ MET GY IZ MET GY W IZ MET M GYBL IZ MET L GYBL IZ MET GYBL W Izip E3 Ultra IZ ULT BK IZ ULT M BK IZ ULT L BK IZ ULT BK W Izip Compact IZ COM WH Currie Technologies 9453 Owensmouth Avenue Chatsworth CA 91311 Ph...

Page 2: ...he rider pedals the further the distance traveled Continuous riding as opposed to frequent stopping and starting will yield the greatest range possible Elevation Gain the flatter the road the further the distance traveled Weather cold weather can adversely affect the battery capacity Wind traveling with a tailwind will increase distance traveled traveling into a headwind will decrease distance tra...

Page 3: ...ct Currie Technologies Customer Service Serial Number Location Bike Shown Upside Down Serial Number Currie Technologies 9453 Owensmouth Avenue Chatsworth CA 91311 Phone 818 734 8123 Fax 818 734 8199 www CurrieTech com Customer Service 800 377 4532 The following manual is only a guide to assist you and is not a complete or comprehensive manual of all aspects of maintaining and repairing your bicycl...

Page 4: ..._____________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ DIRECTORY Warning Important Take notice of this symbol throughout this manual and pay particular attention to the instructions blocked off and preceded by this symbol PART 1 Parts Identification...

Page 5: ... downtube E3Metro Trekking Enlightened Ultra Urban Cruiser Enlightened Via Urbano TERMINOLOGY PART 1 PARTS IDENTIFICATION INDEX Battery Care and information 42 43 Chargers 44 48 Gauge 35 Terminal covers 44 Brakes Explanation 116 117 Lever setup 72 Parts explosion linear pull 74 Setup disc Avid BB7 80 81 Setup disc Tektro 78 79 Setup linear pull 75 77 Cables cable housing 97 Care 33 34 Chain 106 10...

Page 6: ...om Bracket inside Rim Tire Chain Crank Arm Pedal Chain Stay Chain Tire Valve Top Tube Seat Seat Post Seatpost clamp Battery Rear Brake Seat Stay Freewheel Charger port Rear Reflector PAS Sensor behind chainring Hub Motor Rear Derailleur Folding Bicycles Super portable with easy folding design Perfect for camping fits in RV s boats and car trunks To see detailed spare parts diagrams for each bicycl...

Page 7: ...iled spare parts diagrams for each bicycle please visit www izipusa com and click on the page corresponding to your model See page 10 for common components RMB RACK mounted battery bICYCLES RMB rack Sealed Lead Acid Battery Currie Drive Motor PAS TAG Throttle PAS Sensor behind chainring To see detailed spare parts diagrams for each bicycle please visit www izipusa com and click on the page corresp...

Page 8: ...sembly of your bicycle call the service line direct at SERVICE AND TECHNICAL SUPPORT 1 800 377 4532 Monday Friday 8 00 a m 4 00 p m PST Typical Tools Required Phillips head screw driver 2 5mm 3mm 4mm 5mm 6mm 8mm Allen keys Adjustable wrench or a 8mm 9mm 10mm 13mm 14mm 15mm 17mm open box end wrenches A pair of pliers with cable cutting ability When working on your bicycle as instructed by this manu...

Page 9: ... child ride the bicycle Please make sure that your child always wears an ANSI ASTM SNELL approved bicycle helmet when riding CORRECT FRAME SIZE When selecting a new bicycle the correct choice of frame size is a very important safety consideration Most full sized bicycles come in a range of frame sizes These sizes usually refer to the distance between the center of the bottom bracket and the top of...

Page 10: ... of the seat can be altered in relation to the seat post Refer to page 66 on how to adjust the seat clamp Maximum Height Minimum Insertion Mark Should not be visible Arms not over extended Handlebar stem height about the same as seat height Pedal at bottom position Handlebar Height Maximum comfort is usually obtained when the handlebar height is equal to or slightly higher than the height of the s...

Page 11: ...ge carrier Note that bicycle handling steering and stopping distance may be different when the racks are carying weight Ensure that any luggage is securely fitted to the bicycle rack per the manufacturer s instructions and that no hanging straps can get caught in the wheels Be sure reflectors or lights attached to your bicycle are not obscured by your rack or attachments Distribute luggage evenly ...

Page 12: ...ightened If the bicycle is fitted with handlebar end extensions ensure they are properly positioned and tightened 4 Chain Ensure chain is oiled clean and runs smoothly Extra care is required in wet or dusty conditions 5 Bearings Ensure all bearings are lubricated run freely and display no excess movement grinding or rattling Check headset wheel bearings pedal bearings and bottom bracket bearings 6...

Page 13: ...ose Reflectors Your bicycle is supplied with one front white one rear red two wheel white and four pedal orange reflectors These are an important safety and legal requirements and should remain securely fitted and in good clean condition at all times Periodically inspect all reflectors brackets and mounting hardware for signs of wear or damage Replace immediately if damage is found Some bicycles w...

Page 14: ...dicate turning or stopping Ride defensively To other road users you may be hard to see Concentrate on the path ahead Avoid pot holes gravel wet road markings oil curbs speed bumps drain grates and other obstacles Cross train tracks at a 90 degree angle or walk your bicycle across Expect the unexpected such as opening car doors or cars backing out of concealed driveways Be extra careful at intersec...

Page 15: ...o maintain pedaling speed If you reach the lowest gear and are struggling stand up on your pedals You will then obtain more power from each pedal revolution On the descent use the high gears to avoid rapid pedaling Do not exceed a comfortable speed maintain control and take additional care Cornering Technique Brake slightly before cornering and prepare to lean your body into the corner Maintain th...

Page 16: ... you hear a slight rubbing noise from the front or rear gears some adjustments may be necessary Gently adjust the appropriate shifter using the barrel adjusters until the noise goes away For optimal performance and extended chain life it is recommended that you avoid using the extreme combinations of gear positions Refer to diagram on page 31 for extended periods It is recommended that a trained b...

Page 17: ... wiring and connectors to ensure there is no damage and the connectors have good continuity For painted frames dust the surface and remove any loose dirt with a dry cloth To clean wipe with a damp cloth soaked in a mild detergent mixture Dry with a cloth and polish with car or furniture wax Use soap and water to clean plastic parts and rubber tires Chrome plated bikes should be wiped over with a r...

Page 18: ...a high quality bicycle lock that will resist hack saws and bolt cutters Always lock your bicycle to an immovable object if it is left unattended ELECTRONIC COMPONENTS Battery Gauge When the throttle or sensor is engaged powering the motor and the bicycle is in motion the LEDs on the battery gauge on the throttle or separate unit indicate instantaneous line voltage as measured at the battery termin...

Page 19: ... five indications of battery level When the battery is depleted to the point of automatic shutoff the lowest gauge light will blink indicating the need to recharge immediately Of course the bicycle can still be ridden with the system turned off Due to the way the battery gauge measures charge the indicator lights may fluctuate while riding based on the motor s current load This behavior does not ap...

Page 20: ...decreases overall range The system defaults to assist level 2 at startup Regardless of the mode setting the The amount of pedal pressure and the amount of motor assist are proportional harder pedaling will result in the motor providing more assistance The throttle acts as a boost once the bike is rolling and overrides the pedal sensor when applied TAG Mode In TAG mode the pedal sensor E3Metro or p...

Page 21: ...e pedals are in motion you can slowly twist the throttle towards you to activate the full motor power PAS TAG throttle switch The type of system enables the rider to select between the PAS and TAG modes via the toggle switch left in PAS right in TAG Note When using the TAG mode you will use more battery power and thus shorten range of the bicycle TAG Throttle Power and PAS TAG selector toggle swit...

Page 22: ...them in the garbage Check www call2recycle org for more information on free battery dropoff locations Storage When storing your batteries for a long period of time longer than two months Charge your batteries every 90 days to avoid capacity loss Batteries slowly self discharge when left unused for a long period of time if the battery cells are allowed to reach a critically low voltage their lifesp...

Page 23: ...damage is found stop using the affected part until the it can be repaired or replaced Battery Terminal Covers Bicycles with Rack Mounted Batteries are equipped with battery terminal cover s see photo These protect the battery terminals from debris and water when the terminal is not in use i e when the battery is removed from the bike These battery terminal covers need to be removed in order for th...

Page 24: ...ticker on the charger for actual status light indication 2 Insert the plug XLR 2v1h DC or 3v into the charger port on the bike being sure the charger plug is fully seated in the charger port The light should be solid red or blinking green to indicate charging however you will need to refer to the sticker on the charger for actual status light indication as there are different chargers for differen...

Page 25: ...ht should come on indicating the charger has power The orange light should then come on indicating that the charger is charging the battery When the light changes from orange to green the battery is full and the charger has completed charging the battery Use only Currie Authorized Li Ion chargers with bicycles equipped with Li Ion batteries Using any other charger will damage the batteries and voi...

Page 26: ...itch located behind the rear reflector on the backside of the rack The left or right switch position selects a corresponding battery and does not need to be changed again unless a different battery source is desired Fuses All Currie Technologies Hybrid Electric Bicycles are equipped with fuses The fuse may be located depending on the model of bike in the following locations CX Series 40A glass typ...

Page 27: ...r call our customer service line at 1 800 377 4532 Rack Mount Battery RMB w SLA Batteries Bikes 2008 USA WIRING DIAGRAM WIRE HARNESS SWITCH SWITCH WIRE HARNESS BATTERY PORT WIRE HARNESS BATTERY PORT BATTERY PORT BATTERY PORT Secondardy Battery Box optional ASSIST CONVERTER a k a WHITE BOX 1 1 ASSIST SENSOR a k a BLACK BOX MOTOR CONTROLLER THROTTLE 1 2 3 CHARGER PORT BATTERY CASE Complete BATTERY B...

Page 28: ...ORT BATTERY CASE Complete BATTERY BATTERY WIRE HARNESS BATTERY CASE FUSE BRAKE LEVER LEFT TAG PAS full half empty For updated and new wiring diagrams please visit www currietech com or call our customer service line at 1 800 377 4532 ENLIGHTENED TMM WIRING DIAGRAM rev3 CONTROLLER 5 30 1 2 3 CHARGER PORT WHEEL w HUB MOTOR BATTERY TMM4 SENSOR TMM METER BOX PROGRAMMING PORT BRAKE LEVER LEFT BRAKE LEV...

Page 29: ...or representational purpose only Your bicycle s wiring system may differ For updated and new wiring diagrams please visit www currietech com or call our customer service line at 1 800 377 4532 For updated and new wiring diagrams please visit www currietech com or call our customer service line at 1 800 377 4532 WIRE HARNESS BATTERY TERMINAL BATTERY TERMINAL BATTERY TERMINAL Secondardy Battery Box ...

Page 30: ...ve wrapping from the bicycle Inspect the bicycle and all accessories and parts for possible shortages It is recommended that the threads and all moving parts in the parts package be lubricated prior to installation Do not discard packing materials until assembly is complete to insure that no required parts are accidentally discarded Note Your bicycle may be equipped with different style components...

Page 31: ...e the handlebar does not rotate in the stem WARNING MINIMUM INSERTION LINE MUST BE HIDDEN WITHIN THE HEADTUBE OF THE BICYCLE Stem and Handlebars Threadless Aheadset Stem Installation Should be assembled on the bike already 1 Insert the compression bolt through the top cap and the stem Begin threading into the star nut 2 Tighten compression bolt so it removes all play from the fork but allows the f...

Page 32: ...ension fork check that the fork compresses and rebounds smoothly To do this place the fork dropouts against the ground push and release the handle bar The fork will generally compress 1 2 and rebound quickly Most elastomer type forks will gradually soften with use Steerer Tube Crown Brake Boss Blade Drop out 1 Steerer Tube Brake Boss Fork Blade Drop out Brake Bridge Crown 2 Shifters Tighten the bo...

Page 33: ...uick releases for more detailed instructions Adjust the seat to be centered in the clamp and generally level with the ground then re tighten the clamp nuts evenly before riding Avoid riding the bike with a loose saddle Micro Adjustable Seatpost Loosen the seat fixing bolt then slide the seat into the clamp The two seat rails should fit into the corresponding channels in the clamp There is usually ...

Page 34: ...rely clamped Adjusting a quick release seatpost clamp In a seatpost quick release system the seatpost is clamped in place by the force of the quick release cam pushing against one side of the clamp and pulling the tension adjusting nut by way of the skewer against the other The amount of clamping force is controlled by the tension adjusting nut Turning the tension adjusting nut clockwise while kee...

Page 35: ...nsion adjusting nut clockwise while keeping the cam lever from rotating increases clamping force turning it counterclockwise while keeping the cam lever from rotating reduces clamping force Less than half a turn of the tension adjusting nut can make the difference between safe clamping force and unsafe clamping force 1 Remove the tension adjusting nut and one of the small springs then slide the qu...

Page 36: ...d replace if necessary When reinstalling it is very important to ensure the connections are made properly Rear Wheel Bolt on Installation 1 If the bicycle has rim brakes make sure the brakes are loose enough to allow the wheel to pass through the brake pads easily For disc brakes no adjustment is required 2 Place the wheel into the frame dropouts 3 Slide a washer onto each side of the axle 4 Insta...

Page 37: ...al or debris and clean the pads with a wire brush or pick if necessary Worn rims can cause brake or wheel failure resulting in a fall Your bike may be equipped with rim wear indicator Check the decals on the rim to confirm if there is instruction on checking wear Brakes Determine which type of brake your bike is equipped with and refer to the appropriate assembly instructions For more information ...

Page 38: ...for wider 26 wheels 2 While holding the shoe against the rim tighten the shoe fixing nut The brake shoe should be centered vertically on the rim 3 Thread the brake cable through the brake noodle and boot 4 Set the clearance between the brake shoes and the rim to 1mm on each side and tighten the cable fixing bolt This distance does not need to be set exactly at the brake arm as you can finely adjus...

Page 39: ... should be adjusted so they are 1 mm to 2 mm away from the rim when the brakes are not applied Brake pads should be centered on the rim and toed in so the rear portion of each brake pad is about 0 5 1 0 mm farther from the rim than the front portion of the brake pad Do not ride the bicycle until the brakes are functioning properly To test apply the brakes while trying to push the bike forward to m...

Page 40: ...per as shown and secure it with the cable fixing bolt 4 Loosen the two caliper mounting bolts enough to allow the brake caliper to float freely Disc brakes require breaking in Ride and use the brakes gently for about 13 miles before using the brakes in downhill conditions for sudden stops or any other serious braking Please be aware that your brake system will change in performance throughout the ...

Page 41: ...ead the brake cable through the caliper as shown and secure it with the cable fixing bolt Do not allow the caliper arm to move upward while securing the bolt 5 Set pad clearance Loosen outer pad adjusting knob approximately 1 4 turn counter clockwise Loosen inner pad adjusting knob approximately 1 2 turn counter clockwise Inner pad fixed pad to rotor gap should appear larger than the outer pad to ...

Page 42: ...usting Screw Cable Anchor Bolt Derailleur Cage High Adjusting Screw Chainguide clearance of 1 3mm Derailleur Although the front and rear derailleurs are initially adjusted at the factory you will need to inspect and readjust both before riding the bicycle Rear Derailleur Begin by shifting the rear shifter to largest number indicated loosen the cable from the rear derailleur cable anchor bolt and p...

Page 43: ...ector Reflector Water bottle and cage Rear Fender The rear fender is mounted at the seatstay brace There are two ways in which to mount your rear fender The first is the screw mounting system see figure 3 and the second is the 10mm bolt and screw system see figure 4 Identify the mounting system used on your bicycle and follow the given instructions for that particular type of mounting system 1 Scr...

Page 44: ...rious damage or injury Correct routine maintenance of your new bike will ensure smooth running Longer lasting components Safer riding Lower running costs Every time you ride your bicycle its condition changes The more you ride the more frequently maintenance will be required We recommend you spend a little time on regular maintenance tasks The following schedules are a useful guide and by referrin...

Page 45: ...ick wipe down with damp cloth Weekly Lubrication as per schedule 1 87 Monthly Inspect wires Inspect connectors Lubrication as per schedule 1 87 Check derailleur adjustment 81 83 Check brake adjustment 72 81 Check brake and gear cable adjustment 97 Check tire wear and pressure 91 93 120 121 Check wheels are true and spokes tight 70 Check hub head set and crank bearings for looseness 93 98 103 105 C...

Page 46: ... important that wheels are kept in top condition Properly maintaining your bicycle s wheels will help braking performance and stability when riding Be aware of the following potential problems Dirty or greasy rims Caution These can render your brakes ineffective Do not clean them with oily or greasy materials When cleaning use a clean rag or wash with soapy water rinse and air dry Don t ride while...

Page 47: ...ge the rim and tire 4 Remove the tube leaving the tire on the rim 5 Locate the leaks and patch using a tube repair kit carefully following the instructions or replace the tube Note Ensure that the replacement tube size matches the size stated on the tire sidewall and that the valve is the correct type for your bicycle 6 Match the position of the leak in the tube with the tire to locate the possibl...

Page 48: ...ndlebar Assembly Grip Handlebar Stem Bolt Handlebar Stem Stem Bolt Wedge Make sure handlebars and fork are facing forward Note curved rake of fork faces forward HANDLEBARS AND STEM Stem The stem fits into the steering column and is held firmly by the action of a binder bolt and expander wedge which when tightened binds with the inside of the fork steerer tube When removing the stem loosen the stem...

Page 49: ...e lever to accommodate Grip Shift and handlebar grip 2 Rotate assembly until cable exits beneath brake lever with adequate clearance for brake lever movement 3 Firmly tighten recessed clamp screw Installation torque should be 20 in lbs 4 Slide the two 7 8 plastic washers over handlebar The washers prevent the grip from interfering with Grip Shift rotation 5 Slide handlebar grip over handlebar Thre...

Page 50: ...hile standing over the frame top tube with both feet on the ground apply the front brake firmly and rock the bicycle back and forth if you detect any looseness in the headset it will need adjustment Check that the headset is not over tight by slowly rotating the fork to the right and left If the fork tends to stick or bind at any point the bearings are too tight Note If your bike is equipped with ...

Page 51: ...eat and trying to turn it sideways If it moves you will need to further tighten the binder bolt Note Remember that the minimum insertion mark must remain inside the frame assembly DRIVETRAIN The drivetrain of a bicycle refers to all parts that transmit power to the rear wheel including the pedals chain chainwheel crank set and freewheel PEDALS Pedals are available in a variety of shapes sizes and ...

Page 52: ...nto the inside bearings and this should be done every six months If the pedal is the type that can be fully disassembled then the bearings should be removed cleaned and greased every six to twelve months Because of the wide variety of pedal types and their internal complexity disassembly procedures are beyond the scope of this manual and further assistance should be sought from a specialist Attach...

Page 53: ...ten the lockring taking care not to alter the cup adjustment To disassemble 1 Remove the cranks from the axle 2 Remove the left side lockring by turning it counter clockwise 3 Remove the adjusting cup by turning it counter clockwise 4 Remove the left ball retainer and slide the axle out of the frame to the left 5 Remove the right side fixed cup by turning it counter clockwise and remove the right ...

Page 54: ...ke sure the open end of the U shaped plate is trailing as the link approaches the chainwheel when pedaling forward Derailleur geared bicycles use narrower chains and require a special tool to fit and remove chain links or to change the length To remove fit the rivet tool so that the punch pin is centered over any one of the chain rivets Push the rivet almost all the way out then back out the punch...

Page 55: ...ope of this manual and you should consult a specialist Currie Drive Chain Tension Adjustment 1 Loosen do not remove the 5mm motor plate mounting bolt 2 Loosen counter clockwise the 10mm outer tension adjusting nut then tighten clockwise the 10mm inner tension adjusting nut to unclamp the chainstay tension bracket 3 Loosen the 15mm outer axle nut 4 Using a cone wrench loosen the 17mm thin inner axl...

Page 56: ...properly Excessively worn chipped chainring or freewheel sprocket teeth Chain worn stretched Stiff link in chain Non compatible chain chainring freewheel Chainring out of true Chainring loose Chainring teeth bent or broken Rear or front derailleur side to side travel out of adjustment Stiff chain link Loose pedal axle bearings Loose bottom bracket axle bearings Bent bottom bracket or pedal axle Lo...

Page 57: ... replace cables Adjust brake levers Center brakes Replace blocks Correct block toe in Clean blocks and rim Tighten mounting bolts True wheel or take to a bike shop for repair Tighten bolts Center brakes and or adjust brake block toe in Tighten headset Replace axle True wheel Adjust hub bearings Adjust headset Replace bearings Adjust QR mechanism Remedy Align wheels correctly Adjust tighten headset...

Page 58: ... runs at full speed without pedaling Faulty TMM sensor Enlightened Series Replace TMM sensor and retest Faulty throttle Replace throttle and retest Faulty controller Replace controller and retest Bicycle RMB or STB Series works in TAG mode but not in PAS mode Sensor and sensor ring not aligned Realigned so gap between sensor and sensor ring is 1 2mm Faulty White Box Replace White Box and retest Ba...

Page 59: ...rt on the brake shoes reduces their ability to grip The way to maintain control on loose or wet surfaces is to go more slowly to begin with 2 Adjusting your brakes If either brake lever on your bike fails the Mechanical Safety Check you can restore brake lever travel by turning the brake cable adjusting barrel counterclockwise then lock the adjustment in by turning the barrel s lock nut clockwise ...

Page 60: ...est front combination is for the greatest speed It is not necessary to shift gears in sequence Instead find the starting gear which is right for your level of ability a gear which is hard enough for quick acceleration but easy enough to let you start from a stop without wobbling and experiment with upshifting and downshifting to get a feel for the different gear combinations At first practice shif...

Page 61: ...system manufacturer s instructions and recommendations and always check for changes in the handling and braking characteristics of the bicycle after a suspension adjustment by taking a careful test ride in a hazard free area Tires and Tubes 1 Tires Bicycle tires are available in many designs and specifications ranging from general purpose designs to tires designed to perform best under very specif...

Page 62: ...lways proceed cautiously in areas where you are not familiar with the terrain If you exceed your limitations serious injury or death could occur Addt l SAFETY INSTRUCTIONS Do not allow hands feet hair body parts clothing or similar articles to come in contact with moving parts wheels or drivetrain while the motor is running Make sure that the areas that the bicycle is to be used in are safe and su...

Page 63: ... Shift lever area Front derailleur cable pinch 44 60 5 0 6 8 Front derailleur clamp mount 44 60 5 0 6 8 Rear derailleur cable pinch bolt 35 45 4 0 5 1 Rear derailleur mounting bolt 70 86 7 9 9 7 Shift lever MTB thumb type 22 26 2 5 2 9 Shift lever SRAM grip shift type 17 1 9 BICYCLE TORQUE VALUES Component Recommended Torque Value in lb Nm Rack area Bicycle rack to frame 6mm bolts 88 5 10 Wheel ar...

Page 64: ...__________________________________ Address ______________________________________________________ Date Purchased ________________ Place of Purchase ______________ Model Brand Information ______________________________________ Wheel Size _____________________ Color __________________________ Serial Number ___________________ Serial Number Location PART 8 PURCHASE RECORD WARRANTY ...

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