E-Bike 36V Service Manual Download

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M A N U A L

3 6 V M O D E L S

S E R V I C E

Summary of Contents for 36V

Page 1: ...M A N U A L 3 6 V M O D E L S S E R V I C E ...

Page 2: ...E Bike Service Manual 36V MODELS EV Global Motors Company 16201 Stagg Street Van Nuys CA 91406 Tel 818 756 0566 Fax 818 756 0563 www ebike com ...

Page 3: ...r by any means without the prior permission of EV Global Motors Company Although every precaution has been taken to assure this publication is complete and accurate EV Global assumes no liability for errors or omissions All informa tion contained in this publication is based on the latest information available at the time of publication and is sub ject to change without notice ...

Page 4: ...apter Four Handlebar and Controls 4 1 Handlebar Position Handlebar Height Adjustment Handlebar Replacement Throttle Control Right Side Accessory Control Left Side Headset Chapter Five Brakes 5 1 Brake Cable Replacement Brake Lever Brake Lever Free Play Adjustment Brake Pad Brake Pad Alignment Caliper Arm Modulator Brakes Disc Brake Chapter Six Shifter and Derailleur 6 1 Shifter Shifter Cable Derai...

Page 5: ...his code occurs when Bad beep All 3 state of ever you turn the power charge LEDs knob ON while pressing flash continuously the throttle or if the throttle until the fault is is faulty Turn the power cleared and until OFF release the throttle the power knob is and turn the power knob turned OFF then to ON If the code persists ON again have throttle checked by an authorized E Bike dealer Battery sta...

Page 6: ...erating temperature You LED turns on may resume using the throttle Overheat and low The motor temperature Bad beep The yellow and battery condition exceeds operating tempera red LEDs flash ture and the battery state of simultaneously charge is low 1 2 Model code Model prefix Year Description Color 1 Color 2 Color 3 B1 Bicycles 01 B136LE R L 3B1 2001 LE Candy Apply Radiant NA Red R Metallic Blue 01...

Page 7: ...other residue Apply a small amount of Loctite Excess compound could work its way down the threads and bond parts together The torque chart in Chapter Two includes Loctite recommendations for particular fasteners 1 3 TERMS Left and Right Most of the time left and right in this man ual refer to the rider s point of view when seat ed on the E Bike and facing forward The one exception to this rule inv...

Page 8: ... Tighten all bolts nuts and mounting X hardware Depending upon length of ride and riding conditions Inspect more frequently when riding in dusty or wet conditions SPECIAL TOOLS The following special tools are needed for servicing the E Bike Tool Part number Hex wrench set 4mm 5mm 6mm Park AWS 1 Hex wrench set Park AWS 11C Hex wrench set 2mm 5mm 3mm Park AWS 3 Fourth hand cable stretcher Park BT 2 ...

Page 9: ...s 110 mm extension LE model 40 degrees 110 mm extension Stem 2 28 6 mm x 25 4 mm x 150 mm with quill Handlebar LE model Rise 9 degrees Width 625 mm Handle 200 mm Center flat 100 mm SX PE models Rise 9 degrees Width 660 mm Handle 200 mm Center flat 100 mm Seatpost LE model 300 mm x 30 0 mm O D Seatpost spacer 100 mm x 30 1 mm ID x 34 9 mm O D Seatpost suspension SX PE models 350 mm x 27 2 mm O D Se...

Page 10: ... right 14G 14G stainless with brass nipples Bottom bracket B B 127 mm cartridge Freewheel 14 28 T 7 speed Chainring 38 T Chainring clearance 16 17 mm 0 63 0 67 in Crankarm 170 mm 6 7 in Chain 1 2 x 3 32 x 110 L Table 2 Gear Ratios Chainring Freewheel Gear Inches Ratio 38T 14T 70 6 0 37 14 38 38T 16T 61 8 0 42 16 38 38T 18T 54 9 0 47 18 38 38T 20T 49 4 0 53 20 38 38T 22T 44 9 0 58 22 38 38T 24T 41 ...

Page 11: ...attery cover screw 20 30 17 4 26 5 Apply Loctite Charger board mounting screw 10 8 6 Derailleur mounting bolt 84 70 Derailleur pinch mechanism nut 42 36 5 Shifter clamp bolt 30 40 26 5 34 7 Mirror mounting screw 30 40 26 5 34 7 Chain guard screws 15 13 0 Apply Loctite Left bottom bracket cover screws 20 30 17 4 26 5 Apply Loctite Crank arm mounting bolt 200 250 14 4 18 1 Apply grease to the bolt t...

Page 12: ...eed 17 5 mph 36 volts in P Performance mode 12 5 mph 36 volts in E Economy mode Maximum grade Over 12 with a 200 lb rider plus load Acceleration 0 10 mph in 3 seconds with a 200 lb rider Range Over 20 miles with moderate pedal assist Over 15 miles with no pedaling under good conditions Over a 25 increase in the range in the E Economy mode 200 pound rider with tires inflated to 60 psi no wind 2 4 ...

Page 13: ... over 3 months the battery pack should be checked and fully charged every 3 months Optimal storage temperature is 32 86 F 0 30 C Long term storage outside this temperature range will result in acceler ated battery discharge which could lead to battery damage Always pedal assist your E Bike when the pedal assist beep sounds If the overheat warning beep sounds and the yellow LED flashes pedal your E...

Page 14: ...is not operating before charging the battery pack Replace the charger if necessary 4 Plug the female end of the charging cord into the receptacle on the battery charger NOTE When a battery is new the LED may rapidly flicker instead of turning to green This is not a problem The battery is fully charged and can be used The flicking will cease after several use recharge cycles 5 Plug the male end of ...

Page 15: ...or moves remove the mounting screw and reinstall the lead with two washers on top of the eyelet 5 Repeat steps 3 and 4 and connect the blue negative lead to the negative battery terminal 3 Remove the mounting screw and discon nect the blue negative lead from the negative battery terminal Be sure to remove the washer 4 Repeat the above procedure and discon nect the red positive lead from the positi...

Page 16: ...e charger and discon nect the three electrical connectors from the charger board 4 Remove the screw that secures the charg er board to the bracket B Figure 4 5 Remove the three charger board mounting screws Figure 5 and remove the charger board Do not lose the spacer A Figure 6 from each mounting stud Installation 1 Be sure the insulator B Figure 6 is in place in the battery pack 2 If removed inst...

Page 17: ...ndle to pull the battery pack from the compartment Be sure to support the bot tom of the battery pack with your free hand Installation 1 Set the lower end of the battery pack into the battery compartment and tilt the battery into place 2 Close the gate over the battery and secure the gate latch 3 Close the battery compartment door and turn the latches counterclockwise BATTERY PACK TEST Charger ope...

Page 18: ...e battery stand for one hour 3 Remove the cover from the battery pack 4 Connect a digital voltmeter s positive test probe to the positive battery terminal and connect the voltmeter s negative test probe to the battery negative terminal as shown in Figure 7 5 Note the reading on the voltmeter 6 The reading should be 36 5 volts or greater If the reading is less than 36 5 volts the bat tery is faulty...

Page 19: ...t parallels the floor See Figure 2 for LE models Figure 3 for PE SX models 3 Be sure the knurled portion of the handle bar is centered within the handlebar binder 4 Tighten the handlebar binder bolts to the torque specification in Table 4 HANDLEBAR HEIGHT ADJUSTMENT 1 Loosen the stem binder bolt three or four turns counterclockwise A Figure 4 If the bolt rises from the steering stem strike the bol...

Page 20: ...1 Fit the handlebar into place in the binder on the handlebar arm Be sure the knurled portion of the handlebar is centered in the binder 2 Fit the handlebar clamp into place around the handlebar 3 Apply Loctite 242 blue to the threads of the handlebar binder bolts and install the bolts finger tight 4 Position the handlebar as described in this chapter and tighten the handlebar binder bolts to the ...

Page 21: ... you install the brake lever body 6 Finger tighten the clamp bolt to hold brake body in place Use the S hook to secure the front brake cable to the shifter cable C Figure 1 7 Roll the right handlebar grip onto the han dlebar until the grip is flush with the end of the handlebar 8 Slide the brake lever body against the han dlebar grip Position the brake lever as described in Chapter Five and torque...

Page 22: ...sen the clamp bolt on the brake lever body Figure 12 and remove the body from the handlebar Guide the brake cable around the headlight LE or SX models or the battery holder PE models as your remove the lever body Lay the lever body over the frame top tube so it is out of the way 11 Loosen the clamp bolt on the accessory control Slide the control off the handlebar On the LE and SX models pull its w...

Page 23: ...pe so it can be easily reset to the correct height during assem bly 2 Break the stem binder bolt loose A Figure 4 3 Remove the front wheel 4 Disconnect the brake cable from the front brake lever by performing the following a Loosen the adjuster locknut A Figure 13 at the brake lever Turn the adjusting barrel B Figure 13 and the locknut until their slots align with the slot in the brake lever body ...

Page 24: ...moving the forks The bearing may come out with the fork crown race or it could remain behind in the head tube 14 Carefully lower the forks from the head tube 15 Remove the lower bearing A Figure 19 Note how the bearing is oriented the closed side of the retainer facing up toward lower head tube race The bearing will have to be installed in this position during assembly 16 Remove the rubber seal B ...

Page 25: ...slot in the column B Figure 21 13 Install the washer and thread the headset locknut onto the fork column 14 Torque the headset locknut to the specifi cation in Table 4 15 On PE and SX models install the upper fork bridge by performing the following a Insert the collar into the center hole in the upper fork bridge Be sure to install the collar into the bottom of the fork bridge b Carefully slide ea...

Page 26: ...n this chapter and tighten the handlebar binder bolts to the torque specification in Table 4 20 Check the height of the stem and torque the stem binder bolt to the specifications in Table 4 21 Connect the brake cable to the anchor C Figure 13 on the brake lever Align the slots in the adjusting barrel and adjuster locknut with the slot in the brake body Slide the inner wire through the aligned slot...

Page 27: ...re 1 and free the brake cable inner wire from the pinch mechanism 3 Loosen the adjuster locknut at the brake lever 4 Turn the adjusting barrel and the adjuster locknut until their slots align with the slot in the brake lever body 5 Pull the cable housing from the adjusting barrel and slide the inner cable through the slots in the brake lever adjusting barrel and adjuster locknut Figure 2 6 Pull th...

Page 28: ...uster locknut Figure 2 4 Turn the adjusting barrel three full turns out from its fully in position Turn the adjusting bar rel and locknut so their slots do not align with the slot in the brake lever 5 If necessary align the brake pads as described in this chapter 6 Route the cable to the caliper If you are replacing a rear brake cable route the cable through the rear cable inlet in the left side c...

Page 29: ... is completely seated in the bracket 7A When installing the right brake lever install the handlebar grip so it is flush with the han dlebar end 7B When installing the left brake lever install the shifter onto the handlebar as described in Chapter Six 8 Set the brake lever to a 25 35 angle by per forming the following a Set the E Bike in an upright position on a level surface b Slide the brake leve...

Page 30: ...LIGNMENT Brake efficiency is affected by four parame ters toe vertical angle tangent and height Toe alignment determines how the brake pad face sits against the brake surface of the rim When properly adjusted a pad s trailing end the end facing the front should reach the rim before the leading end Figure 9 Vertical alignment sets the position of the pad s vertical Chapter Five 5 4 inner wire turni...

Page 31: ...the pad or by using a spacer Both methods are described below Manual Method 1 Loosen the pad mounting nut just enough so the pad can be manipulated by hand 2 Adjust the brake cable so the face of the pad almost touches the rim 3 Manually set the toe by pulling the leading edge of the pad rear edge away from the rim while pressing the trailing edge front edge to the rim 4 Tighten the pad mounting n...

Page 32: ... to the top of the rim should be the same at each end of the pad Figure 11 2 If one end of the pad is closer to the rim than the other rotate the pad around the shoe stud to adjust tangent alignment Pad Height 1 Look at each pad from the side and note where the pad engages the brake surface of the rim Figure 12 2 To adjust the height move the brake stud up or down in the caliper slot Adjust height...

Page 33: ... too high c If necessary balance the caliper arms by turning the spring tension adjuster B Figure 4 on either arm 10 Adjust the brake lever free play as described in this chapter MODULATOR BRAKES The rear brakes on PE and SX models are equipped with modulator brakes The spring activated arms on these brakes rapidly apply and release the brakes to inhibit wheel lockup To adjust the brake cable free...

Page 34: ...describes brake pad adjustment on this disc brake 1 Hold the adjuster A Figure 17 with an Allen wrench and loosen the adjuster locknut B Figure 17 2 Spin the wheel and turn the adjuster clock wise until the brake pads barely scrape against the brake disc 3 Back out the adjuster 1 2 turn counter clockwise 4 Hold the adjuster with an Allen wrench and tighten the locknut B Figure 17 securely 5 Set th...

Page 35: ...ifter housing 4 Loosen the shifter clamp bolt and slide the shifter housing from the handlebar Figure 3 Guide the shifter cable around the headlight as you remove the shifter housing 5 If you are not servicing the shifter or the cable lay the shifter over the top tube Secure it in place so it will remain out of the way Do not severely bend or kink the cable Installation 1 Slide the shifter housing...

Page 36: ...erate the shifter and move the chain to the outermost cog 2 Remove the right side cover from the E Bike 3 Note how the shifter cable is routed along the top tube and the right seat stay The cable will have to be rerouted along the same path 4 At the derailleur remove the end cap A Figure 4 from the end of the inner wire 5 Loosen the pinch mechanism nut B Figure 4 Pull the shifter cable from the de...

Page 37: ...position of the derailleur The guide pulley should align with the outermost cog as shown in Figure 9 b If necessary adjust the outward limit by turning the H screw Tighten the H screw to adjust the guide pulley inward Loosen the H screw to adjust the derailleur out ward c Use your hand to move the derailleur to its innermost position d Hold the derailleur against the stop and check the guide pulle...

Page 38: ...nlet in the right side cover and along the top tube 12 Slide the tube B Figure 5 over the free end of the inner wire and up to the cable hous ing 13 Fit the inner wire through the two housing stops on the right seat stay A Figure 5 Be sure the ferrule from the upper cable housing fits into the upper housing stop and that the tube is secure between both housing stops 14 Lubricate the lower cable ho...

Page 39: ... its inward limit The B screw adjusts the distance between the bottom of the cogset and the derailleur s guide pulley A fourth hand tool Park Tool BT 2 is required to perform this procedure 1 Check the cable attachment to the derailleur pinch mechanism a Inspect the position of the inner wire in the pinch mechanism The innerwire should follow the groove in the pinch plate and the tab on the pinch ...

Page 40: ...ation in Table 4 6 6 3 Set the derailleur s outward limit by perform ing the following a Shift the derailleur so the chain is on the outermost cog b Stand behind the E Bike and check the position of the derailleur The guide pulley should align with the outermost cog as shown in Figure 9 c If necessary adjust the outward limit by turning the H screw Tighten the H screw to adjust the guide pulley in...

Page 41: ...Rotate the tool s dial so the pegs press against the inside of the chain rollers 3 Read the number opposite the V notch on the dial a 0 1 indicates the chain is in good condi tion b 1 2 indicates the chain is moderately worn c 2 3 indicates the chain is approaching the wear limit d 3 or more indicates the chain is worn beyond the wear limit Checking Chain Length 1 Secure the E Bike in the stand so...

Page 42: ... centered on the chain rivet 4 Turn the tool handle until the driving pin just touches the rivet NOTE The rivet should be pressed the minimum dis tance necessary to separate the chain and no more Do not drive the rivet completely from the inner plate on the inboard side of the chain The chain can be separated once the rivet extends 0 5 to 1 0 mm into the inside of the inner chain plate See Figure ...

Page 43: ... NOTE Do not apply excessive amounts of oil to the chain Excessive lubrication promotes the accumulation of dirt which accelerates chain wear CAUTION Use oil designed for bicycles Automotive and household oils are unsuitable for the E Bike chain 1 Oil the contact areas between the inner and outer side plates on each link A Figure 7 as well as the contact areas between the inner side plates and eac...

Page 44: ... the crank wrench handle with your fingers Figure 10 CAUTION If the crank wrench body starts to rotate or if the body appears to pull from the crank arm when you tighten the crank wrench remove the crank wrench body and identify the prob lem The crank wrench threads may be dam aged Correct the problem before proceeding 7 Turn the crank wrench handle clockwise and press the crank arm off the spindl...

Page 45: ...ap the crank arm onto the spindle with a plastic mallet 4 Apply grease to the crank arm mounting bolt 5 Install the crank arm mounting bolt and torque it to the specification in Table 4 6 Repeat for the left crank arm if necessary Be sure the left crank arm is 180 opposite the right crank arm CHAINRING Removal 1 Remove the right crank arm as described in this chapter 2 Examine the inboard side of ...

Page 46: ...l forward normal pedaling motion and remove the pedal 5 Repeat this procedure for the opposite pedal Installation 1 Inspect the threads of the pedal stud Install the pedal with the right hand thread onto the right side of the E Bike Install the pedal with the left hand threads onto the left side 2 Grease the threads of the pedal stud 3 Thread the left pedal onto the left crank arm Tighten the peda...

Page 47: ...at are easily damaged Check the threads in the bottom bracket shell before installation Dress or tap the threads as neces sary 1 Apply grease to the threads of the cartridge main body NOTE The main body uses left hand threads 2 Carefully thread the cartridge into the right side of the bottom bracket shell Turn the main body counterclockwise until the cartridge is snug in the bottom bracket shell 3...

Page 48: ... from the left side cover Pull the cable inlet cover forward and around the head tube until the tabs clear the left side cover Installation 1 If removed install the cable inlet cover into the left side cover Slide the tabs of the cover A Figure 2 onto the tongues of the side cover Gently push cable inlet cover so it fol lows the side cover contour around the head tube and rests in place in the lef...

Page 49: ...eft side cover 2 Pivot the side cover into place Carefully fit the battery compartment door between the front wheel and the forward down tube and fit the side cover onto the left side of the E Bike Be sure all electrical wires and cables fit into the cable inlet at the front of the left side cover 3 Install the three battery compartment screws Figure 3 finger tight 4 Apply Loctite 242 blue to the ...

Page 50: ...e con troller board Label each connector before removal so it can be easily identified during assembly If the headlight or horn connector are attached to the wrong terminal the devices will not operate FIG 5 4 Disconnect connectors B C D E F G and H from the controller board See Figure 1 5 Remove the two mounting screws A Figure 6 and lift the terminal block B Figure 6 from the frame CAUTION The r...

Page 51: ...to the seat stay Be sure the QR connector wires are secured in the lower and upper retainers Figure 9 on the seat stay The wires must be clear of the wheel 5 Gently pull the left side cover from the frame and route the power leads between the side cover and the frame Figure 11 6 Secure each power lead onto its post on the terminal block Be sure the red power lead B Figure 7 is connected to the lef...

Page 52: ...ts Be sure the outmost cog remains engaged with the top chain run 5 When the wheel is properly installed the washer and nut sit outside of the dropout Figure 14 This self sealing connector A Figure 12 mounted on the inside of the left seat stay Disconnecting 1 Clip the cable tie B Figure 12 that secures the QR connector to the left seat stay 2 Unlatch the lock on the QR connector 3 Disconnect the ...

Page 53: ...ve the bezel rubber gasket and the lens from the housing Do not lose the rubber gasket B Figure 15 It may come out with the bezel or the lens 3 Gently pull the reflector from the headlight housing 4 Disconnect the black wire A Figure 16 from the spade terminal on the reflector housing 5 Disconnect the white wire B Figure 16 from the blue electrical lead from the headlight bulb and remove the refle...

Page 54: ... Adjust the headlight according to Department of Motor Vehicle regulations in your state 1 Set the E Bike on a level surface approxi mately 25 feet from a wall 2 Have a friend sit on the bike and hold it ver tically Be sure the tires are inflated to the prop er inflation pressure when adjusting the head light 3 Draw a horizontal line on the wall that is 35 inches above the floor ground 4 Turns the...

Page 55: ...oller fuse test 4 Perform the power knob test 5 If all of the above components work proper ly replace the controller B The controller fuse is blown NOTE The controller fuse blows whenever there is a failure in either the headlight horn or taillight circuit Do not simply replace a controller fuse without solving the problem The new fuse will also be blown Perform the following tests cor rect the pr...

Page 56: ...aner 2 Reinstall the battery pack into the E Bike Push the bottom of the battery pack into the battery compartment with your hand and turn the power knob ON The problem is solved if the E Bike beeps GO and the LEDs flash 3 Measure the voltage between the controller fuse and the brake sensor 2 terminal by per forming the following a Disconnect a brake sensor connector D or E Figure 1 from its termi...

Page 57: ...oller fuse blows whenever there is a failure in either the headlight horn or taillight circuit Do not simply replace a controller fuse without solving the problem The new fuse will also be blown 1 Remove the battery pack from the E Bike and turn the power knob to ON 2 Visually inspect the fuse on the controller Replace the fuse and perform troubleshooting procedure B if the fuse appears blown 3 Ch...

Page 58: ...check the continuity across pins 3 and 4 in the connector The throttle control should have continuity when power knob is ON It should not have continuity when power knob OFF The throttle control is faulty if it does not pass both tests replace it QR connector test 1 Inspect the cable on both sides of the con nector Be sure the cable does not rub against the wheel 2 Disconnect the QR connector 3 Pl...

Page 59: ...3 1 2 3 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 1 2 HORN LEFT TAIL LAMP RIGHT BRAKE LEFT BRAKE RIGHT POWER RED POWER BLACK RED MOTOR BROWN MOTOR 1 2 3 1 2 3 1 2 3 4 1 2 1 2 HEADLIGHT HORN TAIL LAMP BRAKE LEFT BRAKE RIGHT 8 12 Wiring Diagram ...

Page 60: ...AKE SWITCH TAILLIGHT HORN HEADLIGHT 1 2 3 4 5 6 1 2 3 4 5 6 7 HORN SWITCH CRUISE SWITCH ECONOMY SWITCH HEAD LIGHT LED HEAD LAMP SWITCH ACCESSORY CONTROL LEFT THROTTLE CONTROL RIGHT THROTTLE POWER KNOB GREEN LED AMBER LED RED LED ...

Page 61: ...EV Global Motors Company 16201 Stagg Street Van Nuys CA 91406 www ebike com 818 756 0566 tel 818 756 0563 fax P N LIT 82001 01 36 a Lee Iacocca Enterprise ...

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