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Wiring diagram - taG/pas w/ RMB Bicycles (2009+)

(Diagram is for representational purpose only. Your bicycle's wiring system may differ)

Rack Mount Battery (RMB w/ Controller-n-White Box, SLA Batteries) Bikes (2009 USA) WIRING DIAGRAM

Bikes with serial numbers that start with “DM”

WIRE HARNESS, SWITCH

SWITCH

WIRE HARNESS, BATTERY TERMINAL

BATTERY TERMINAL

Secondardy Battery Box

(optional)

CADENCE SENSOR

MOTOR

CONTROLLER

THROTTLE

CHARGER PORT

BATTERY CASE (Complete)

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

Summary of Contents for Ezip

Page 1: ......

Page 2: ...atest 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 traveled Terrain the smoother the terrain roadways vs fireroads etc the further the distance traveled Rider Weight the lighter the rid...

Page 3: ...RY ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE DO NOT RIDE AT NIGHT CPSC RECORDS SHOW THAT ABOUT 35 OF BICYCLE RELATED DEATHS OCCUR AFTER DARK AVOID RIDING IN WET CONDITIONS CPSC RECORDS SHOW THAT ABOUT 65 OF INJURIES HAPPEN TO CHILDREN UNDER 15 YEARS OF AGE RIDE ONLY WITH ADULT SUPERVISION HELMETS SAVE LIVES ...

Page 4: ...ns contact the experts at Currie Technologies directly by calling toll free 1 800 377 4532 Monday Friday 8 00 am 4 00 pm PST IMPORTANT Please activate your warranty by registering your new Currie product within 10 days of purchase by visiting our web site www currietech com and clicking the Register Your Product link PLEASE DO NOT RETURN THIS ITEM TO THE STORE For questions or assistance on assemb...

Page 5: ...aining and repairing your bicycle The bicycle you have purchased is a complex object We recommend that you consult a bicycle repair specialist if you have doubts or concerns as to your experience or ability to properly assemble repair or maintain your bicycle You will save time and the inconvenience of having to go back to the store if you choose to write or call us concerning missing parts servic...

Page 6: ..._____________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ ...

Page 7: ...on to the instructions blocked off and preceded by this symbol PART 1 Parts Identification and Tools 10 15 PART 2 Before You Ride 16 32 PART 3 Electrical Components 33 54 PART 4 Assembly 55 82 PART 5 Servicing 83 85 PART 6 Detailed Maintenance 86 111 PART 7 How Things Work 112 121 PART 8 Purchase Record 122 ...

Page 8: ...AS TMM Headset 94 Maintenance checklists 83 84 Motor See Currie Drive PAS 34 Pedals 61 97 98 Power switches Handlebar 46 Standard 45 Quick releases Front Wheel 64 65 Seatpost 62 63 Reflectors 23 24 106 Saddle See Seat seatpost Safety 20 21 25 27 Seat seatpost Assembly 60 61 Detailed maintenance 95 96 Quick release clamp See Quick release Shifters Assembly 58 Gears how to operate 28 30 Grip shifter...

Page 9: ...motor power in response to rider effort Trekking Enlightened Urban Cruiser Enlightened BATTERY SYSTEMS RMB Rack Mounted Battery with Sealed Lead Acid SLA cells Two SLA battery packs sit vertically in the rack Coastline Trailz Via Lento RTMB Rack Top Mounted Battery with Lithium Ion Li Ion cells A single Li Ion battery pack lies horizontally inside the rack Eco Ride Via Rapido Zuma STB Seat Tube Ba...

Page 10: ...ia Rapido Zuma Shifter Handlebar Throttle w PAS TAG selector Brake Lever Brake Control Cables Front Reflector Front Brake Fork Front Hub Spokes Stem Head Set Head Tube Power Switch Down Tube Seat Tube Bottom 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 b...

Page 11: ...trunks To see detailed 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 Handlebar Quick Release Handlebar Hinge Front Fender Rear Fender Frame Hinge Quick Release Controller Hub Motor Battery Pack Seat Post ...

Page 12: ...erfect for Commuting and City Riding TMM Sensor TMM models only Controller inside Hub Motor Battery Pack inside Control Box Charger Port To see detailed 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 ...

Page 13: ...ed 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 corresponding to your model See page 10 for common components ...

Page 14: ...14 Tricruiser Battery Charger port Fender front Fender rear Throttle Controller inside ...

Page 15: ...ent parts or have questions pertaining to assembly 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 workin...

Page 16: ...ntrol and fall Because any fall can result in serious injury or even death we do not repeat the warning of possible injury or death where ever the risk of falling is mentioned A SPECIAL NOTE FOR PARENTS It is a tragic fact that most bicycle accidents involve children As a parent or guardian you bear the responsibility for the activities and safety of your minor child Among these responsibilities a...

Page 17: ...y between types of bicycles and rider preference This makes straddling the frame when off the seat easier and safer in situations such as sudden traffic stops Women can use a men s style bicycle to determine the correct size women s model The following chart and diagram will help you make the correct choice Rider leg length refers to approximate pant inseam Approximate Rider Leg Length 61 69cm 24 ...

Page 18: ...st project from the frame beyond its Minimum Insertion or Maximum Extension mark If your seat post projects from the frame beyond these markings the seat post or frame may break which could cause you to lose control and fall Prior to your first ride be sure to tighten the seat clamp properly A loose seat clamp or seat post binder can cause damage to the bicycle or can cause you to lose control and...

Page 19: ...tube which could cause you to lose control and fall Failure to properly tighten the stem binder bolt the handlebar binder bolt or the bar end extension clamping bolts may compromise steering action which could cause you to lose control and fall Place the front wheel of the bicycle between your legs and attempt to twist the handlebar stem assembly using a reasonable amount of force If you can twist...

Page 20: ... or excessive wear Ensure rims run true and have no obvious wobbles or kinks Ensure all wheel spokes are tight and not broken Check that axle nuts are tight If your bicycle is fitted with quick release axles make sure locking levers are correctly tensioned and in the closed position 3 Steering Ensure handlebar and stem are correctly adjusted and tightened and allow proper steering Ensure that the ...

Page 21: ...to the handlebar shift and brake Ensure derailleurs shift levers and shift and brake cables are properly lubricated 8 Frame and Fork Check that the frame and fork are not bent or broken If either are bent or broken they should be replaced 9 Accessories Ensure that all reflectors are properly fitted and not obscured Ensure all other fittings on the bike are properly and securely fastened and functi...

Page 22: ...you ride and to comply with all applicable laws including properly equipping yourself and your bike as the law requires Reflectors are important safety devices which are designed as an integral part of your bicycle Federal regulations require every bicycle to be equipped with front rear wheel and pedal reflectors These reflectors are designed to pick up and reflect street lights and car lights in ...

Page 23: ...lector Bracket Assembly First insert one washer onto the hex bolt and insert hex bolt through the reflector bracket and then through the fork Next insert a second washer onto the bolt and thread a hex nut onto the bolt behind the fork Tighten bolts until snug making sure the reflector is in an upright position See diagram at the right Front Reflector Mount with Handlebar Bracket Assembly First att...

Page 24: ...mp screw to hold reflector assembly in place see the second diagram Finally adjust the reflector assembly in place and ensure that it is upright and facing away from the bike Seatstay Mount Reflector Bracket Assembly First insert one washer onto the hex bolt and insert hex bolt through the reflector bracket and then through the seatstay bridge Next insert a second washer onto the bolt and thread a...

Page 25: ... concealed driveways Be extra careful at intersections and when preparing to pass other vehicles Familiarize yourself with all the bicycle s features Practice gear shifts braking and the use of toe clips and straps if fitted If you are wearing loose pants use leg clips or elastic bands to prevent them from being caught in the chain or gears Wear proper riding attire and avoid wearing open toe shoe...

Page 26: ... lights Potholes and slippery surfaces such as line markings and train tracks all become more hazardous and more difficult to see when wet Night Riding IT IS RECOMMENDED TO NOT RIDE AT NIGHT Ride at night only if necessary Slow down and use familiar roads with street lighting if possible Ensure bicycle is equipped with a full set of correctly positioned and clean reflectors Use a properly function...

Page 27: ...Currie products are designed for riders age 13 or older To avoid accidents teach children good riding skills with an emphasis on safety from an early age Children should always be supervised by an adult 1 Always wear a properly fitted helmet 2 Do not play in driveways or the road 3 Do not ride on busy streets 4 Do not ride at night 5 Obey all the traffic laws especially stop signs and red lights 6...

Page 28: ...ated by the left shift lever and the rear derailleur by the right To operate you must be pedaling forward You can not shift derailleur gears when you are stopped or when pedaling backwards Before shifting ease up on your pedaling pressure For a smooth gear change when approaching a hill shift to a lower gear BEFORE your pedaling speed slows down too much When coming to a stop shift to a lower gear...

Page 29: ...ward you to engage a larger rear cog You can shift one gear at a time by moving the Grip Shift one click or through multiple gears by continued twisting To select a higher gear twist the left shifter forward or away from you to engage a smaller rear cog Single shifts can be achieved by twisting one click at a time and multiple shifts by larger twists Front Low Gear Rear Low Gear Front High Gear Re...

Page 30: ...e chain one cog continuing to push will move the chain over multiple cogs Pulling the smaller upper left shifter with your index finger moves the chain from a larger to a smaller chainwheel To select a higher gear pull the smaller upper right lever with your index finger to engage a smaller rear cog Pushing the larger lower left lever with your thumb will move the chain from a smaller to a larger ...

Page 31: ...uid Store your bicycle under shelter Avoid leaving it in the rain or exposed to corrosive materials Riding on the beach or in coastal areas exposes your bicycle to salt which is very corrosive Wash your bicycle frequently and wipe or spray all unpainted parts with an anti rust treatment Make sure wheel rims are dry so braking performance is not affected After rain dry your bicycle and apply anti r...

Page 32: ...oss Don t cover the bicycle with plastic as sweating will result which may cause rusting Please notice that your bicycle warranty does not cover paint damage except as outlined in the warranty section of this manual rust corrosion dry rot or theft Security It is advisable that the following steps be taken to prepare for and help prevent possible theft 1 Maintain a record of the bicycle s serial nu...

Page 33: ... of LEDs or show the Yellow or even Red LED When the throttle is disengaged i e no power to the motor due to the bicycle being stationary or coasting the LEDs on the throttle will indicate the voltage of the battery pack The voltage of the battery pack will rise when no load is on the motor The best indication of how much battery life is remaining is to check the throttle LEDs after reaching cruis...

Page 34: ...the way the battery gauge measures charge the indicator lights may fluctuate while riding based on the motor s current load The best indication of remaining battery life is to check the battery level gauge LEDs after reaching cruising speed on a smooth ﬂat straight road This will allow the battery voltage to stabilize and will give a much more accurate reading The button controls motor assist powe...

Page 35: ...e 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 The best indication of remaining battery life is to check the battery level gauge LEDs after reaching cruising speed on a smooth ﬂat stra...

Page 36: ...riding without the motor assisting you Once you have twisted the throttle all the way the motor will accelerate you to its full speed of about 18 20mph 28 32 km h PAS Pedal Assist Electric bicycles with this system have a throttle that is only active when the pedals are in a forward motion A sensor ring on the bottom bracket spindle rotates and a sensor reads this rotation Begin by first riding as...

Page 37: ...37 ...

Page 38: ...ne full hour after the charger indicator light turns green Never charge batteries for longer than 24 hours SLA and Li Ion batteries do not have a memory Partial discharge charge cycles will not harm the batteries capacity or performance The rated output capacity of a battery is measured at 77 F 25 C Any variation in this temperature will alter the performance of the battery and shorten its expecte...

Page 39: ...nce This involves three complete discharges and three complete recharges After this initial break in cycle the batteries will have maximum possible performance and less line voltage fluctuations under load Q Is it normal that the batteries get warm when recharging A Yes it is normal that the batteries will become warm to the touch during the recharging process This is because the increase of inter...

Page 40: ...ith 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 the battery to make contact with terminals ...

Page 41: ...e them in an open area and do not lay anything on the charger unit while charging Although you cannot over charge the batteries using the Currie Smart Charger we recommend that you do not leave the charger plugged in for more than 24 hours If your charger shows a solid green light after charging for a short period of time your battery may have been only partially dis charged short ride or this may...

Page 42: ...tion as there are different chargers for different battery chemistries 3 Once the battery reaches full charge the light will return to solid green however you will need to refer to the sticker on the charger for actual status light indication 4 When charging is complete unplug the charger from the wall before removing it from the charger port Charge for the full time If the battery still has not c...

Page 43: ...will permanently damage the charger and or electrical components on the hybrid electric bicycle 1 Select the proper voltage for your country 115V for North American 230V for most of Asia and Europe Voltage Selector Switch Connect power cord to charger then plug power 1 cord into wall outlet Power Switch turn to OFF position Be sure the charger s power switch is turned OFF red 2 light should be off...

Page 44: ...n 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 void your warranty If the orange light flashes when the charger is plugged into t...

Page 45: ...B 2009 On the controller box Via Urbano RTMB 2010 Be sure to turn the switch off whenever you are not using the bicycle or when charging the bicycle STB Bicycles RMB Bicycles 2008 RTMB Bicycles 2009 Via Urbano Three Position Power Switch Three Position Power Switches Bikes with dual rack mounted battery packs RMB are equipped with a three position power switch This switch has two ON positions that...

Page 46: ...ndlebar Power Button RMB RTMB 2010 Two Position Power Switch Control Box Power Button TMM Key Lock Power Switches Certain models ex HG1000 Tricruiser are equipped with a key lock power switch This feature provides added security allowing only the person with the key to turn the power on or off This key lock switch has the same function as a standard power switch Control Box Power Button RMB Two Po...

Page 47: ...pack to access STB Series 2011 24V 40A glass type fuse On the battery pack externally accessible STB Series 36V 40A glass type fuse On the battery pack externally accessible Enlightened Series Li Ion 30A blade type fuse 5A blade type fuse inside the bottom end of the downtube remove downtube cap to access In the event of an overload the fuse will pop and need to be replaced In this instance replac...

Page 48: ...s 2008 USA WIRING DIAGRAM BATTERY CASE Complete BATTERY BATTERY FUSE SWITCH ON OFF FULL HALF LOW THROTTLE BRAKE LEVER LEFT BRAKE LEVER RIGHT WIRE HARNESS ADAPTER DM E 250C WHEEL REAR W HUB MOTOR L N E WIRE HARNESS BATTERY PORT CONNECTOR IN USE CONTROLLER For updated and new wiring diagrams please visit www currietech com or call our customer service line at 1 800 377 4532 ...

Page 49: ...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 BATTERY WIRE HARNESS BATTERY CASE FUSE BRAKE LEVER LEFT Wiring Diagram TAG PAS w RMB Bicycles 2008 Diagram is for 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 se...

Page 50: ...start with DM WIRE HARNESS SWITCH SWITCH WIRE HARNESS BATTERY TERMINAL WIRE HARNESS BATTERY TERMINAL BATTERY TERMINAL BATTERY TERMINAL Secondardy Battery Box optional CADENCE SENSOR MOTOR CONTROLLER THROTTLE 1 2 3 CHARGER PORT 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...

Page 51: ... PROGRAMMING PORT BRAKE LEVER LEFT BRAKE LEVER RIGHT for european production TMM SERVICE PORT Wiring Diagram TMM Bicycles Diagram is for 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 ...

Page 52: ...ter Note PAS TAG switch connection which is not used on the RTMB bikes Note TAG jumper for system testing only This item is not included with bike available as part of service kit part TL WR 007 RIGHT for european production BRAKE LEVER LEFT THROTTLE CONTROLLER Wiring Diagram Rack Top Mount Battery RTMB 2009 Diagram is for representational purpose only Your bicycle s wiring system may differ For u...

Page 53: ...3 CHARGER PORT BATTERY CASE Complete BATTERY BATTERY WIRE HARNESS BATTERY CASE FUSE CADENCE SENSOR THROTTLE FULL HALF LOW JUNCTION BOX WIRE HARNESS WHEEL w BRUSHLESS HUB MOTOR ON OFF PAS TAG HANDLEBAR CONTROLS BRAKE LEVER LEFT BRAKE LEVER Right WIRE HARNESS SWITCH SWITCH CONTROLLER Wiring Diagram TAG PAS w RMB Bicycles 2010 with hub motor Diagram is for representational purpose only Your bicycle s...

Page 54: ... BRUSHLESS HUB MOTOR 1 2 3 3 0 5 BATTERY RTMB BATTERY TERMINAL WIRE HARNESS For updated and new wiring diagrams please visit www currietech com or call our customer service line at 1 800 377 4532 Wiring Diagram Rack Top Mount Battery RTMB 2010 with hub motor Diagram is for representational purpose only Your bicycle s wiring system may differ ...

Page 55: ...rials until assembly is complete to insure that no required parts are accidentally discarded Note Your bicycle may be equipped with different style components than the ones illustrated We recommend that you consult a bicycle specialist if you have doubts or concerns as to your experience or ability to properly assembly repair or maintain your bicycle Assembly Guides Individual assembly guides for ...

Page 56: ...be of the bicycle Ensure that the Minimum Insertion Line is below the top nut of the headset 4 Align the stem and handlebar so it is in line with the front wheel 5 Tighten the Stem Bolt with the 6mm allen wrench Reinsert the Stem Plug into the stem 6 Check the headset for smooth rotation and that the top nut is secured tightly 7 Loosen the 6mm Binder Bolt and rotate the handlebar so the levers are...

Page 57: ...e stem to the steerer tube Handlebar Installation 1 Remove the stem cap bolts and stem cap 2 Insert handlebar into the stem cap 3 Tighten the stem cap bolts equally Note the distance between the stem and stem cap A should be equal on the top and bottom of the stem cap Installed by factory Compression Bolt Top Cap Stem Clamp Bolts Spacer Headset Wedge Bearing Race Bearing Dust Cover Bearing Retaine...

Page 58: ... it should be checked before operating your bicycle Figure 1 Handlebar with Grip Shifter Figure 2 Top mounted thumb shifter Failure to properly tighten clamping bolts may cause sudden movement of the component resulting in loss of steering control 1 Shifter binder bolt 2 5mm Allen key Brake lever binder bolt tighten from top side 5mm Allen key 2 Shifter binder bolt 4mm Allen key ...

Page 59: ...stable and are very difficult to disassemble If service is needed on a suspension fork consult a professional bicycle repair technician Do not attempt to disassemble a suspension fork yourself Consult a professional bicycle repair technician If your bike is equipped with a suspension fork check that the fork compresses and rebounds smoothly To do this place the fork dropouts against the ground pus...

Page 60: ...it may be necessary in some cases Partially tighten the seat fixing bolt then insert the seat assembly into the frame of the bicycle and adjust the seat to the proper height The seat post must be inserted to at least the Minimum Insertion line Move the quick release lever to the closed position You should feel considerable resistance while moving the lever If not re open and tighten the lever then...

Page 61: ...aches to the other crank arm and has a left hand counter clockwise thread It is very important that you check the crank set for correct adjustment and tightness before riding your bicycle New cranks may become loose with initial use refer to pages 99 101 for proper crank set adjustment and maintenance Once the pedals have been installed remove the dust caps from the center of each crank arm Tighte...

Page 62: ...ng with an improperly adjusted wheel quick release can allow the wheel to wobble or fall off the bicycle which can cause serious injury or death Therefore it is essential that you 1 Ask your dealer or a local bike shop to help you make sure you know how to install and remove your wheels safely 2 Understand and apply the correct technique for clamping your wheel in place with a quick release 3 Each...

Page 63: ...tpost out of alignment with the frame the seatpost clamp needs to be adjusted Holding the quick release lever in the OPEN position with one hand tighten the tension adjusting nut with your other hand about 1 2 turn clockwise 5 Attempt to swing the lever into the CLOSED position If the lever cannot be pushed all the way to the CLOSED position figure b return the lever to the OPEN position then turn...

Page 64: ... If your bicycle has a disc brake insert the skewer starting on the side with the brake rotor Replace the spring and tension adjusting nut fig a 2 If your bicycle has rim brakes disengage them to increase the clearance between the tire and brake pads 3 Install the wheel into the dropouts making sure the quick release lever is on the left side of the bicycle 4 Holding the quick release lever in the...

Page 65: ... turn then try again 6 If the lever cannot be pushed all the way to a position parallel to the fork blade return the lever to the OPEN position Then turn the tension adjusting nut counterclockwise one quarter turn and try tightening the lever again 7 Re engage the brake to restore correct brake pad to rim clearance spin the wheel to make sure that it is centered in the frame and clears the brake p...

Page 66: ...ly 2 Place wheel into fork dropouts 3 Install retaining washers with raised lip pointed towards the fork and insert into the small hole of the fork blade NOTE Some bikes may have step retaining washers in place of the retaining washer shown in dotted box If so install the step retaining washer raised portion sliding in to the fork dropouts 4 Install axle nut and tighten Make sure the wheel is cent...

Page 67: ...is very important to ensure the connections are made properly Rear Wheel Bolt on 1 Make sure the brakes are loose enough to allow the wheel to pass through the brake pads easily 2 Place the wheel into the frame dropouts 3 Slide a washer onto each side of the axle 4 Install axle nuts and tighten Make sure the wheel is centered in the frame This may be easiest with the bike turned upside down 5 Spin...

Page 68: ...s For more information on brake adjustment and maintenance refer to pages 70 77 Brake Lever Setup All Brake Types Squeeze the brake lever and place the nipple of the brake cable into the lever s cable end holder then release the lever Line up the slots in the barrel adjustor and lock nut with the slot on top of the brake body Pull the cable housing into place in the barrel adjustor then turn the b...

Page 69: ...69 ...

Page 70: ...70 Boot Cable Fixing Bolt Washers Link Fixing Bolt Shoe Fixing Nut Washer B Washer B Washer A Washer Spring Tension Adjustment Screw A Washer Linear Pull Brakes Brake Shoes Brake Noodle ...

Page 71: ...rake 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 adjust it more easily with the brake lever barrel adjustor see photo on page 61 5 If the brake pads...

Page 72: ... paper as a shim between the rim and the rear half the pad to set the gap 2 Depress the brake lever about 10 times as far as the grip to check that everything is operating correctly and that the shoe clearance is correct before riding the bike This also serves to pre stretch the cable and seat brake components If cable slack develops after pumping the brakes repeat step 4 or adjust the brake lever...

Page 73: ...t apply the brakes while trying to push the bike forward to make sure they will stop the bicycle Never ride a bicycle that is not functioning properly Do not lock up brakes Sudden or excessive application of the front brake may pitch the rider over the handlebars causing serious injury or death When braking always apply the rear brake first then the front Never ride your bicycle if the brake pads ...

Page 74: ...n re installing them 2 Make sure the two bolts securing the caliper adaptor bracket to the fork are tight 3 Thread the brake cable through the caliper 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 Caliper Mounting Bolts 4 Caliper Adaptor Bracket Bolts Cable Fixing Bolt 2 3 1 Caliper Barrel Adjustor ...

Page 75: ...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 wear in process The disc brake should be cleaned before the first ride using rubbing alcohol NEVER use oil or similar products to clean your disc brake system Avoid touching the rotor disc ...

Page 76: ... when re installing them 2 Make sure the two bolts securing the caliper adaptor bracket to the fork are tight 3 Install the wheel making sure the brake rotor fits into the slot in the caliper 4 Turn the two pad adjustment knobs counter clockwise fully Adaptor Bracket Bolts Tighten 2 Brake Rotor attached to wheel 3 4 1 Turn Fully Inner pad adjusting knob Outer pad adjusting knob Turn Fully ...

Page 77: ...imately 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 rotor gap 6 Squeeze lever to test caliper brake Adjust lever modulation setting by moving pads inward or outward from rotor by using both pad adjusting knobs To maintain the 2 1 ratio turn the fixed pad adjusting kno...

Page 78: ... achieved is done quietly and without hesitation If necessary use the barrel adjuster to fine tune the cable tension by turning it the direction you want the chain to go For example turning clockwise will loosen the cable tension and move the chain away from the wheel while turning counter clockwise will tighten cable tension and direct the chain towards the wheel Guide Pulley Cable Barrel Adjuste...

Page 79: ...djusters to fine tune the cable tension The barrel adjuster for the front derailleur is located on the front shifter where the cable comes out of the shifter Clockwise will loosen the cable tension and direct the chain closer to the frame while counter clockwise will tighten the cable tension and direct the chain away from the frame Do not ride a bicycle that is not shifting properly Overlooking p...

Page 80: ... the cage to the bicycle using the Allen bolts provided Some bikes come equipped with a saddle bag or frame bag The saddle bag installs under the seat with the zipper facing the rear wheel Undo the straps that wrap around the bag thread them through the rails underneath the seat and secure around the bag The smaller strap wraps around the seat post Frame bags install at the apex of the top and sea...

Page 81: ...fender bracket holes line up with those in the frame Attach the fender by using two screws to directly mount the fender onto the frame The mounts are located below the seat post and near the rear of the crank Tighten all screws until snug 2 10mm Bolt and Screw System First remove the rear wheel Place the fender assembly between the stays making sure the fender bracket holes line up with those in t...

Page 82: ... are attached and all quick releases nuts and bolts have been tightened securely Correct maintenance of your bicycle will ensure many years of happy riding Service your bicycle regularly by referring to the relevant sections of this manual OR take it to a professional bicycle shop Remember Always wear a helmet and obey all traffic laws Never inflate a tire beyond the maximum pres sure marked on th...

Page 83: ...ot over lubricate remove excess lubricant to prevent dirt build up Never use a degreaser to lubricate your chain WD 40 PART 5 SERVICING Frequency Component Lubricant How to Lubricate Weekly Chain Chain Lube or Light Oil Brush On or Squirt Derailleur Pulleys Chain Lube or Light Oil Brush On or Squirt Derailleurs Oil Oil Can Brake Calipers Oil 3 drops from oil can Brake Levers Oil 2 drops from oil c...

Page 84: ...1 83 Monthly Inspect wires Inspect connectors Lubrication as per schedule 1 83 Check derailleur adjustment 78 79 Check brake adjustment 68 77 Check brake and gear cable adjustment 93 Check tire wear and pressure 87 89 116 117 Check wheels are true and spokes tight 86 Check hub head set and crank bearings for looseness 89 949 99 101 Check pedals are tight 97 Check handlebars and stem are tight 90 9...

Page 85: ...wdriver 6 Standard Phillips head screwdriver 7 Standard slip joint pliers 8 Tire pump 9 Tube repair kit 10 Tire levers Travel Tools 1 Spare Tube 2 Patch kit 3 Pump 4 Tire levers 5 Multi tool 6 Change phone call Frequency Task Page Reference Check all points as per monthly service 83 Check and replace brake pads if required 70 77 Check chain for excess play or wear 102 103 Yearly Lubrication as per...

Page 86: ... are not straight they will need to be adjusted This is quite difficult and is best left to a bicycle repair specialist Broken or loose spokes Check that all spokes are tight and that none are missing or damaged Caution Such damage can result in severe instability and possibly an accident if not corrected Again spoke repairs are best handled by a bicycle repair specialist Loose hub bearings Lift e...

Page 87: ... before you fully inflate the tire Tread Check that the tread shows no signs of excessive wear or flat spots and that there are no cuts or other damage Caution Excessively worn or damaged tires should be replaced Valves Make sure valve caps are fitted and that valves are free from dirt A slow leak caused by the entry of the dirt can lead to a flat tire and possibly a dangerous situation Recommende...

Page 88: ...e tire completely and inspect for a nail glass etc and remove if located Also inspect the inside of the rim to ensure there are no protruding spokes rust or other potential causes Replace the rim tape which covers the spoke ends if damaged 8 Remount one side of the tire onto the rim 9 Using a hand pump inflate the tube just enough to give it some shape 10 Place the valve stem through the hole in t...

Page 89: ... adjusted Hub Bearing Adjustment When checked the hub bearings of either wheel will require adjustment if there is any more than slight side play 1 Check to make sure neither locknut is loose 2 To adjust remove wheel from bicycle and loosen the locknut on one side of the hub while holding the bearing cone on the same side with a flat open end wrench 3 Rotate the adjusting cone as needed to elimina...

Page 90: ...the wedge that will be inserted into the frame The height of the handlebar can be adjusted to suit your comfort preference If the stem is removed from the steering column you will notice a mark about 65mm up from the bottom with the words max height or minimum insertion Never ride a bicycle if the stem has been raised so that the max height minimum insertion line can be seen Handlebar Clamp Bolts ...

Page 91: ...r of personal comfort For MTB bicycles the bar should be approximately horizontal with the ends pointing back and slightly up On MTB and racing style bicycles the handlebar is usually tightened in the stem by a single allen key bolt or hexagonal bolt On beach cruiser style bicycles there may be four clamping bolts Please note that if you need to replace the fork on your bicycle at any time please ...

Page 92: ...ent the grip from interfering with Grip Shift rotation 5 Slide handlebar grip over handlebar Thread the cable inner wire through cable housings and frame and attach to derailleur Make sure that the cable is in the V groove at the derailleur attachment bolt If trimming the cable housing is necessary be sure to replace the housing end cap 6 Adjust indexing 7 Slide rear Grip Shift over right side of ...

Page 93: ...e needed to operate the brakes or shifters Before every ride check that there are no kinks or frays in the cables and housing Also check that the housing is seated properly into each cable stop of the bicycle It is recommended that the cables and housing are replaced at least every riding season to prolong the life of your bike Do not ride a bicycle that is not operating properly kink fray good ca...

Page 94: ... If your bike is equipped with a threadless headset please see a qualified specialist for repairs and adjustments Adjustment Loosen the headset top locknut or remove it completely along with the reflector bracket if fitted Turn the adjusting cup clockwise until finger tight Replace the lock washer or reflector bracket and re tighten the lock nut using a suitable wrench Note Do not over tighten or ...

Page 95: ... minimum insertion To avoid damage to either the seat post the frame or possibly the rider the minimum insertion mark must be inside the frame Lubrication Remove the seat post from the frame and wipe off any grease rust or dirt Then apply a thin film of new grease to the part that will be inserted into the frame Re insert adjust and tighten the seat post in the frame Seat Fixing Bolt Micro Adjusta...

Page 96: ... the clamping mechanism There are two types of seat clamps commonly in use The most common employs a steel clamp with hexagonal nuts on either side to tighten The other type known as a micro adjustable clamp uses a single vertically mounted Allen head fixing bolt to tighten After fixing the seat to the desired position on the post adjust the height to the required level and tighten the binder bolt...

Page 97: ... them safely Inspection Pedals should be inspected every month taking note of the following areas Check correct tightness into the crank arms If pedals are allowed to become loose they will not only be dangerous but will also cause irreparable damage to the cranks Check that pedal bearings are properly adjusted Move the pedals up and down and right to left and also rotate them by hand If you detec...

Page 98: ...d are not interchangeable Never force a pedal into the incorrect crank arm The right pedal which attaches to the chainwheel side is marked R on the end of the axle and screws in with a clockwise thread The left pedal which attaches to the other crank arm is marked L on the axle and screws in with a counter clockwise thread Insert the correct pedal into the crank arm and begin to turn the thread wi...

Page 99: ...properly adjusted Remove the chain and try to move the cranks from side to side with your hands The cranks should not move on the axle and there should be only very slight movement in the bottom bracket Next spin the cranks If they don t spin freely without grinding noise then adjustment or lubrication will be needed Also check that there are no broken teeth on the chainrings and wipe off excess d...

Page 100: ...urning it counter clockwise and remove the right ball retainer Clean and inspect all bearing surfaces and ball retainers and replace any damaged parts Pack the ball bearing retainers with grease then re assemble in reverse of the above procedure Standard Crank Removal To remove cotterless cranks use the following procedure Note that a special tool will be required 1 Remove the dust cap with a coin...

Page 101: ... cap 2 Tap the crank arm lightly with a mallet 3 Re tighten the flange nuts and refit the dust caps New cranks may become loose with initial use Perform the following task after several hours of riding and repeat it two or three times after further use Cranks should then remain tight Tighten the flange nut Replace the dust cap Position the crank on the axle Lightly tap the crank onto the axle Scre...

Page 102: ... if it stretches breaks or causes inefficient gear shifting Make sure that there are no stiff links they must all move freely Lubrication The chain bicycle and motor drive should be lubricated with light oil at least every month or after use in wet muddy or dusty conditions Take care to wipe off excess oil and not to get oil on the tires or rim braking surfaces ...

Page 103: ... be pried off of the master link with a screwdriver To replace feed the chain around the chainwheel and rear sprocket fit the master link into the rollers into each end of the chain position the master link side plate and slip on the U shaped snap on plate Make sure the open end of the U shaped plate is trailing as the link approaches the chainwheel when pedaling forward Derailleur geared bicycles...

Page 104: ...axle nut 5 Slide the motor with the motor plate forward or backward to adjust the drive chain tension to allow only about 5mm of vertical slack 3 16 6 Tighten the 17mm inner axle nut 7 Tighten the 15mm outer axle nut 8 Tighten the 5mm motor plate mounting bolts 9 Tighten clockwise the outer adjusting nut and loosen counter clockwise the inner adjusting nut clamping the chainstay tension bracket Mo...

Page 105: ...xcess FREEWHEEL Inspection Like the chain the freewheel must be kept clean and well lubricated If the chain has become worn and needs replacing then it is likely that the freewheel will also have become worn and should also be replaced Take the chain off the freewheel and rotate it with your hand If you hear a grinding noise or the freewheel stops suddenly after spinning it it may need adjustment ...

Page 106: ...rement and should remain securely fitted and in good clean conditions at all times Periodically inspect all reflectors brackets and mounting hardware for signs of wear or damage Replace immediately if damage is found Please see pages 23 24 for more information Wear reflective clothing when riding Attach a light to your bike if you ride at night Reflectors Reflectors ...

Page 107: ...out of adjustment Stiff chain link Loose pedal axle bearings Loose bottom bracket axle bearings Bent bottom bracket or pedal axle Loose crankset Pedal bearings too tight Bottom bracket bearings too tight Chain fouling derailleurs Derailleur jockey wheels dirty binding Remedy Lubricate tighten replace cables Adjust derailleurs Adjust indexing Replace chainring sprockets and chain Replace chain Lubr...

Page 108: ...ose Bulge in the rim or rim out of true Brake mounting bolts loose Brakes out of adjustment Fork loose in head tube Axle broken Wheel out of true Hub comes loose Headset binding Hub bearings collapsed QR mechanism loose Remedy Lubricate If problem persists replace freewheel Replace brake blocks Clean blocks and rim Clean adjust replace cables Adjust brake levers Center brakes Replace blocks Correc...

Page 109: ...emove sharp object embedded in tire Correct tire pressure File down spoke Problem Steering not accurate Frequent punctures Possible Cause Wheels not aligned in frame Headset loose or binding Front forks or frame bent Inner tube old or faulty Tire tread casing worn Tire unsuited to rim Tire not checked after previous puncture Tire pressure too low Spoke protruding into rim ...

Page 110: ... recommended time Damaged planetary gears Replace hub motor wheel No power when the switch is turned ON Blown fuse Replace fuse Loose connectors Check all connectors Broke wire Inspect all wires for damage Faulty switch Replace switch and retest Faulty controller Replace controller and retest Bicycle operates OK but battery gauge does not light up Loose connectors Check throttle and or battery gau...

Page 111: ... clean battery terminals Throttle on bicycles so equipped does not spring back to neutral position Grip jammed against throttle Reposition grip so gap between it and the throttle is 1 2mm Faulty throttle Replace throttle Bicycle has intermittent power Loose connectors Check all connectors Loose fuse Check fuse connector Damaged wires Inspect all wires Charger shows a full charge in an unusually sh...

Page 112: ...ght brake lever controlling the rear brake and the left lever controlling the front brake The braking action of a bicycle is a function of the friction between the brake surfaces usually the brake shoes and the wheel rim To make sure that you have maximum friction available keep your wheel rims and brake shoes clean and free of lubricants waxes or polishes Make sure that your hands can reach and s...

Page 113: ...t was going This causes a transfer of weight to the front wheel or under heavy braking around the front wheel hub which could send you flying over the handlebars A wheel with more weight on it will accept greater brake pressure before lockup a wheel with less weight will lock up with less brake pressure So as you apply brakes and your weight shifts forward you need to shift your body toward the re...

Page 114: ...derailleur drivetrain If your bicycle has a derailleur drivetrain the gear changing mechanism will consist of A rear sprocket cluster called a freewheel or freewheel cassette A rear derailleur Usually a front derailleur One or two shifters One or two control cables One two or three front sprockets called chainrings A drive chain The number of possible gear combinations speeds is the product of mul...

Page 115: ...l cranks The larger sprockets produce lower gear ratios Using them requires less pedaling effort but takes you a shorter distance with each pedal crank revolution Moving the chain from a smaller sprocket of the gear cluster to a larger sprocket results in a downshift Moving the chain from a larger sprocket to a smaller sprocket results in an upshift In order for the derailleur to disengage the cha...

Page 116: ...a large volume of air very rapidly and will raise the pressure in your tire very rapidly To avoid over inflation when using a gas station air hose put air into your tire in short spaced bursts Tire pressure is given either as maximum pressure or as a pressure range How a tire performs under different terrain or weather conditions depends largely on tire pressure Inflating the tire to near its maxi...

Page 117: ... and push down on the valve stem to free it up Then push the pump head on to the valve head and inflate To inflate a Presta valve with a gas station air hose you ll need a Presta adapter available at your bike shop which screws on to the valve stem once you ve freed up the valve The adapter fits the end of the air hose fitting Close the valve after inflation To let air out of a Presta valve open u...

Page 118: ...suspension system safely before trying any downhill or very fast mountain biking Suspension can increase the handling capabilities and comfort of your bicycle This enhanced capability may allow you to ride faster but you must not confuse the enhanced capabilities of the bicycle with your own capabilities as a rider Increasing your skill will take time and practice Proceed carefully until you are s...

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Page 120: ...lamp bolts 120 144 13 6 16 3 Crankset Bottom Bracket Pedal area Chainring bolt aluminum 44 88 5 0 9 9 Chainring bolt steel 70 95 7 9 10 7 Crank bolts 305 391 34 5 44 2 Pedal into crank 307 350 34 7 39 5 Derailleur 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 ...

Page 121: ...0 390 29 4 44 1 Brakes Brake cable pinch bolt linear pull 53 69 6 0 7 8 Brake caliper linear pull to frame fork 45 60 5 1 6 8 Brake lever MTB type 53 69 6 0 7 8 Brake pad to caliper 50 70 5 6 7 9 Disc brake caliper mount 60 90 6 8 10 2 Disc rotor to hub 35 55 4 0 6 2 BICYCLE TORQUE VALUES CTD ...

Page 122: ..._________________________________ 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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