Miami Sun EV-3 Assembly & Owners Manual Download

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*This Trike Should Be Assembled By A Qualified Bicycle Mechanic

Revised 3-99

Trike Assembly* & Owners Manual

Contents

Page

Warranty

Introduction

Precautions

4-5

Getting Started

Recharging

6-7

Parts List

Torque Specifications

8-14

Assembly

15-16 Optional Equipment

Motor Maintenance

Specifications

ev3man99.qxd 6/22/99 1:20 PM Page 1

Summary of Contents for EV-3

Page 1: ...3 99 Trike Assembly Owners Manual Contents Page 2 Warranty 3 Introduction 4 Precautions 4 5 Getting Started 5 Recharging 6 7 Parts List 8 Torque Specifications 8 14 Assembly 15 16 Optional Equipment 17 Motor Maintenance 18 Specifications ev3man99 qxd 6 22 99 1 20 PM Page 1 ...

Page 2: ...s from the date of purchase Bending of frame and any other components along with industrial and or commercial use are excluded from this warranty Bending is abuse and not covered 2 The Electric Motor excluding brushes is warranted to be free from defects in materials and workmanship for 1 year from date of purchase 3 The fork rear unit and other components excluding tires tubes cables and brake sh...

Page 3: ...d to avoid danger ALWAYS WEAR A BICYCLE HELMET We recommend buying your helmet from a dealer that can fit and instruct you on the correct way to wear a helmet Protecting your head is your primary safety responsibility Always wear a CPSC ANZI ASTM or SNELL approved bicycle helmet CPSC is the federal standard and all helmets must comply by 1999 CHECKLIST BEFORE RIDING Check your tires for proper air...

Page 4: ...Avoid riding on rainy days since you don t have the same control handling and stopping power as on a dry day When making a turn or stopping use hand signals to show your intent To signal use your left arm while maintaining control of the throt tle with your right Always ride with the flow of traffic never against traffic The rear basket is only intended for light storage DO NOT EVER PUT A CHILD PE...

Page 5: ...overed and dry area The battery case can be removed by unhooking the holding strap disconnecting the control cable and bringing in the battery to connect to the charger If the motor is used for a long time and overheats it will shut off It can be started again after it cools off The same thing applies to the charger if it gets too hot it will shut off and restart when cooled down If the battery ch...

Page 6: ...Parts List Description 1 30 2 44 43 42 41 40 39 38 37 36 35 33 31 29 28 27 26 25 24 23 22 21 20 19a 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 19 26 26c 26b 25a 25a 26 3a 12 35 6 ev3man99 qxd 6 22 99 1 21 PM Page 6 ...

Page 7: ...6702181 Basket fittings 2 6702180 Basket trike white vinyl coated 3 67142 Battery assembly 36v 3 67148 Battery case w o batteries 3a 67149 Battery charger 4 6702146 Brake cable 890 X 760 mm Blk Frt 5 1427 Brake cable rear black 6 6702145 Brake lever w lock left front 7 67152 Brake lever w lock right rear 8 13395 Brake shoe front cantilever white 9 6702290 Brake unit front Cantilever w locking leve...

Page 8: ...s are inside the frame Fig 1 D Make sure that axle flange on unit is to the right side of unit and frame Also unit must be installed with support bars up so that the basket can rest on them Fig 1 Torque Specifications Axle nut front 180 to 240 inch pounds Brake front cantilever pinch bolt 36 to 48 inch pounds Brake lever bolt 24 to 36 inch pounds Brake rear drum cable pinch nut 48 to 72 inch pound...

Page 9: ...rn chainwheel and see if chain runs smoothly with no binding or excessive noise If not loosen bolts move unit slightly forward Tighten bolts and check chain function again E Make sure the chain runs straight and true with the chainwheel F If chain now runs O K tighten all four carriage bolts A B securely taking care that the unit does not shift Torque 300 to 400 in lbs G Now install chainguard usi...

Page 10: ...C Replace safety washers and install axle cover bracket A on side that has the wires Fig 5 D Thread on axle nuts center wheel and tighten Torque 180 to 240 in lbs E Connect wires B and install axle cover with two metal screws to the cover bracket A Please note to take extra care in connecting the male and female plugs B on the wire and be sure that the parts are well seated F Warning Do not ride w...

Page 11: ...eel on left side This wheel is the idler First slip on the spacer then the wheel followed by a washer and the locking nut until it touches the bearing Now back off nut 1 8 of a turn Again Do Not Over Tighten Leave Some Play C VERY IMPORTANT It is critical for the protection of the bearings that you inform your customer that the idler wheel requires a slight amount of play in order to prevent beari...

Page 12: ...tall grips C Slide brake lever back as close as possible to grip on handlebar Turn lever to desired angle and tight en securely Torque 24 to 36 in lbs D Install brake arms by inserting the end of the spring into the middle hole on the fork stud and tighten arm E Insert the cable end nipple into slot on brake lever F Insert the cable into link wire G Set link wire end fitting into hook side of brak...

Page 13: ...orque 200 to 300 in lbs F Tighten seat brace carriage bolts Fig 15 on frame securely Torque 300 to 400 in lbs G Tighten seat brace clips Fig 15 securely H Warning The seat post minimum insert mark must be inside the seat tube Step 9 Attaching Throttle and Band Brake To Right Hand Side Of Handlebar A Loosen screw and slide brake lever to end do not tighten screw yet Fig 12 B Slide throttle control ...

Page 14: ...Install Battery Pack A Place the battery pack into its steel bracket and attach the safety strap Fig 17 Step 13 How To Attach Reflectors A Attach the white reflector to the reflector bracket on fork Fig 18 B Attach the red reflector to the reflector bracket on rear of basket Fig 19 C Attach the wheel reflectors opposite valve stems on the spokes Fig 20 Step 14 Check Tire Inflation Inflate tires pe...

Page 15: ...3 A Place CB or 3 spd C B hub unit into special frame conversion slot brackets located on top of rear bottom frame stays attach nuts Fig 22 Step 7 A Attach fixed sprocket onto rear trike axle See Fig 4B pg 9 and step 8 pg 11 You are now ready to attach the rear unit to the trike Step 4 A Attach chain 84 Links to chainwheel and outer CB or 3 spd C B sprocket and connect connecting link Step 5 A Pul...

Page 16: ...l axle key and tighten set screw 2 Slowly pull unit towards end of trike until chain slack is taken up 3 Tighten the two small carriage bolts 4 Turn chainwheel and see if chain runs smoothly with no binding or excessive noise If not loosen bolts move unit slightly forward Tighten bolts and check chain function again 5 If chain now runs O K tighten all four carriage bolts securely taking care that ...

Page 17: ... axle nuts washers and retaining clips 2 Loosen brake and remove front wheel assembly 3 Remove the 6 hex head screws A locknut and snapring from wire side of hub Fig 25 4 Carefully remove cover plate to expose brush housings Fig 26 5 Carefully remove black brush housing caps and remove old brushes B Fig 27 6 Reinstall new set of brushes Fig 28 Always replace both brushes at the same time to promot...

Page 18: ...laceable fuses Security Key switch Parking brakes Safety Motor engages only after pedaling Automatic low speed cutoff Spring loaded twist grip throttle Automatic shut down if not in use Low charge indicator Front and rear hand brakes with parking locks W eight capacity 250 lbs passenger and cargo Color Electric blue Options 3 speed coaster brake system and coaster brake system Speed and distance a...

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Miami Sun EV-3, Assembly & Owners Manual

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