Ultra motor A2B Metro Service Manual Download | Manualshive

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Copyright © 2009 by Ultra Motor USA, Inc

First Edition

August, 2009

All rights reserved. No part of this publication may be repro-

duced or transmitted in any form or by any means without the

prior permission of Ultra Motor USA, Inc.

Although every precaution has been taken to assure this publi-

cation is complete and accurate, Ultra Motor USA assumes no

liability for errors or omissions. All information contained in this

publication is based on the latest information available at the

time of publication and is subject to change without notice.

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Summary of Contents for A2B Metro

Page 1: ...TM A2B Metro Service Manual TM clean mobility technology A2B Metro Service Manual...

Page 2: ......

Page 3: ...A2B Metro Service Manual Ultra Motor USA 45 Broadway Street San Francisco CA 94111 Tel 415 693 3110 Fax 415 693 3121 www ultramotor com...

Page 4: ...eans without the prior permission of Ultra Motor USA Inc Although every precaution has been taken to assure this publi cation is complete and accurate Ultra Motor USA assumes no liability for errors o...

Page 5: ...e Cable Inner Wire Brake Caliper Brake Pad Replacement Brake Disc Chapter Four Shifter and Derailleur 4 1 Shifter Shifter Cable Inner Wire Derailleur Chapter Five Chain and Crankset 5 1 Chain Crank Ar...

Page 6: ......

Page 7: ...grease and other residue from the thread surfaces Apply a small amount of Loctite Excess compound could work its way down the threads and bond parts together Table 5 this chapter provides torque speci...

Page 8: ...rk AWS 3 Fourth hand cable stretcher Park BT 2 Chain checker Park CC 2C Chain breaker screw type Park CT 3 Crank wrench Park CCW 14R Cable and housing cutter Park CN 4C Gearclean brush Park GSC 1 32mm...

Page 9: ...th 670 mm 26 38 in Handlebar stem MJ Cycle ST 001 Seatpost Kalloy SP 600 Tires Kenda K1032 20 in x 3 0 in Rims Alex DX 32 Rim runout with or without tire Axial runout 1 mm 0 039 in Radial runout 1 mm...

Page 10: ...Table 3 Electrical Specifications Component Specification Battery 36 volt Type Lithium ion Capacity 11 4 amp hrs 422 watt hrs Charger High Power HP8204C 10s Input 115 230 VAC 60 50 Hz 1 5 0 9 A Outpu...

Page 11: ...30 Apply grease to bolt threads Derailleur anchor bolt 4 1 36 5 Derailleur mounting bolt 7 9 70 Front fender 3 26 5 Handlebar binder bolt 6 53 Apply grease to the bolt threads Handlebar stem clamp bol...

Page 12: ......

Page 13: ...throttle and the shifter relative to its handlebar grip If nec essary measure the gap between each item and its handlebar grip or make a drawing so these components can be reinstalled with the proper...

Page 14: ...nstall a grip spacer and handlebar grip onto each handlebar end e Position the throttle or shifter relative to its handlebar grip as noted during remov al Tighten their set screws f Slide each brake l...

Page 15: ...stem bolt can damage the headset bearings If the handlebar stem clamp bolt is not properly torqued the fork may not turn when the handlebar is turned 2 3 STEERING and FRONT SUSPENSION HANDLEBAR STEM R...

Page 16: ...m in place and in alignment with the front wheel a Tighten the handlebar stem bolt B Figure 4 until there is no play in the steer ing b Tighten the stem bolt an additional 120 degrees clockwise and th...

Page 17: ...evenly tighten the bolts Torque the caliper mounting bolts to the specification in Table 5 5 Install the handlebar this chapter 8 Visually inspect the seal B Figure 11 and the cone on the upper bearin...

Page 18: ......

Page 19: ...ar grip or make a drawing so these components can be reinstalled with the proper positioning and orientation Also note the orientation of the handlebar within the handlebar stem 2 Remove the battery f...

Page 20: ...guide the brake switch wire through the shroud into the frame cutout and through the frame downtube until the switch connec tor emerges from the battery compart ment 5 Install the battery Chapter Seve...

Page 21: ...r wire from the pinch mechanism c Pull the cable housing and inner wire from the caliper barrel adjuster 2 Remove the caliper mounting bolts A Figure 5 and slide the brake caliper B from the brake dis...

Page 22: ...brake disc bolts A Figure 8 to the specification in Table 5 Chapter Three 3 4 Installation 1 Carefully slide the brake caliper over the brake disc Seat the caliper against the inboard side of the moun...

Page 23: ...e from the cable end A Figure 2 4 Loosen the anchor bolt B Figure 2 and release the cable inner wire from the from the derailleur pinch mechanism SHIFTER Removal 1 Note the position of the shifter rel...

Page 24: ...the socket Figure 7 5 Insert the wire through the barrel adjust er and seat the wire in the cable groove Figure 8 5 Remove the cable housing and inner wire from the derailleur barrel adjuster C Figur...

Page 25: ...quired to perform this procedure 1 Check the cable attachment to the derailleur pinch mechanism a Check the position of the inner wire in the pinch mechanism The wire should fol low the groove in the...

Page 26: ...o its fully in position and then back out the adjuster three full turns 3 Turn the shifter barrel adjuster C Figure 1 to its fully in position and then back it out one full turn NOTE Do not pull the i...

Page 27: ...ailleur stop tab presses against the stop tab on the hanger 6 Torque the derailleur mounting bolt D Figure 2 to the specification in Table 5 Derailleur Installation 1 Lubricate the derailleur as descr...

Page 28: ......

Page 29: ...Rotate the tool s dial so the pegs press against the inside of the chain rollers 3 The number opposite the V notch on the dial indicates the chain s condition a 0 1 the chain is in good condition b 1...

Page 30: ...compressed air Removal A chain breaker Park CT 3 is needed for removing and installing the chain 1 Shift the derailleur and move the chain to the smallest cog high gear Note how the chain passes over...

Page 31: ...he tool handle and drive the rivet until it is centered within the link The dis tance from the outer side plate to the end of the rivet should be the same on each side of the chain Figure 7 Lubricatio...

Page 32: ...arm if any spoke is cracked or shows signs of damage 3 Turn out and remove the crank arm bolt 4 Inspect the position of the spindle end It should be recessed within the crank arm square hole The crank...

Page 33: ...nd then install the left crank arm so it is oriented 180 degrees from the right arm 1 When installing a new right crank arm or a new chainring check chainring wobble as described in this chapter 2 Use...

Page 34: ...Its adapter ring threads into the left side of the bottom bracket 6 Rotate the crank arm and note the amount of wobble in the chainring 7 Remove the crank arm from the spindle 8 Rotate the spindle so...

Page 35: ...pter ring into the left side of the bottom bracket shell 5 Install the bottom bracket cartridge tool and torque the bottom bracket adapter ring to the specification in Table 5 The adapter ring on this...

Page 36: ......

Page 37: ...and its spacers 6 Visually inspect the spring A Figure 3 for cracks or signs of fatigue If necessary remove the adjusting ring B from the shock absorber and remove the spring 7 Inspect the shock housi...

Page 38: ...motor wires to the swingarm REAR FENDER Removal Installation 1 Remove the rear wheel as described in this chapter 2 Remove the fender stay bolt D Figure 5 from each side of the swingarm 3 Remove the...

Page 39: ...Figure 2 and torque the bolt to the specification in Table 5 d Apply Loctite 242 to the threads of the rear shock absorber bolt Figure 1 and torque the bolt to the specification in Table 5 e Make sur...

Page 40: ......

Page 41: ...ctor G Throttle connector 4 pin H State of charge connector 3 pin I Grommet CONNECTOR IDENTIFICATION Figure 1 identifies the connectors found within the battery compartment which is inside frame downt...

Page 42: ...ed in the A2B Metro BATTERY CAP Removal 1 Remove the right crank arm as described in Chapter Five 2 Remove the battery cap screws A Figure 2 from each side and remove the cap B from the frame downtube...

Page 43: ...y as described in this chapter 3 Slide the switch module A Figure 3 into the position noted during removal and press the wiring B into the battery com partment 4 Install the battery cap this chapter K...

Page 44: ...y is faulty if a click is not heard Replace the switch module Charger Port Test 1 Remove the battery cap this chapter 2 Disconnect the halves of the 2 pin char ger port connector D Figure 1 for the ma...

Page 45: ...ontinuity by performing the following a Connect one ohmmeter test probe to the red wire in port side of the charger port connector and connect the other test probe to the terminal No 1 on the port Con...

Page 46: ...Chapter Seven 7 6...

Page 47: ......

Page 48: ...www ultramotor com Ultra Motor USA 45 Broadway Street San Francisco CA 94111 Tel 415 693 3110 Fax 415 693 3121...

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