E-Bike | 36V | Specifications | E-Bike 36V Specifications

For future reference, please fill in the important information below.
Vehicle Identification Number (VIN#)
(Your VIN# can be found on the inward facing surface of the frame seat stay.)
Model Code (Printed on the end of your shipping carton.)
Dealer Name:
This manual contains important safety, performance and
maintenance information. Read the manual before taking
your first ride on your new E-Bike™, and keep the manual
handy for future reference.
1. About This Manual
Why Should You Read This Manual
Important Safety Information
Reporting Safety Defects
Inspection and Maintenance
Inspection and Maintenance Chart
2. Operational Instructions
Beep/LED Codes
Right Hand Controls
Left Hand Controls
On-Board Battery Charging
Care and Cleaning
3. Fit and Safety
Safety Equipment
Mechanical Safety Check
4. Riding Safely and Responsibly
The Basics
Rules of the Road
Wet Weather Riding
Night Riding
5. How Things Work
Wheel Quick Release
Removing and Installing Bolt-On Wheels
Seatpost Quick Release
Tires and Tubes
Bicycle Suspension
6. Service and Maintenance
Service and Maintenance Schedule
Getting Home When Something Breaks
Upgrading Your Bike and Equipment
About Your Dealer
inspect your E-Bike™. Many of the Warnings and Cautions
say "you may lose control and fall". Because any fall can
result in serious injury or even death, we do not repeat the
warning of possible injury or death whenever the risk of
falling is mentioned.
This manual was written to help you get the most
performance, comfort, enjoyment and safety when riding
your new E-Bike™. The manual describes specific care and
maintenance procedures that help protect your warranty and
ensure years of trouble free use. Please pay particular
attention to the section on battery charging and
Your E-Bike™ can provide many years of service, fun and
fitness - if you take responsibility for your own safety.
Understand the features of your E-Bike™ and become aware
of the challenges that you will meet on the road. There is
much that you can do to protect yourself while riding. We will
offer many recommendations and safety tips throughout this
manual. The following are those that we feel are most
It is important for you to understand your new E-Bike™, its
features and its operation, so you get maximum enjoyment
with maximum safety. By reading this manual before you go
out on your first ride, you'll know how to get the most from
your new E-Bike™.
Always Wear A Helmet!
Helmets significantly reduce the number and severity of head
injuries. Always wear a helmet that complies with your state
laws when riding the E-Bike™. Check with your local police
department for requirements in your community. Do not wear
loose fitting clothing that can become tangled in the moving
parts of the E-Bike™. Wear sturdy shoes and eye protection.
Also check your state laws concerning other protective gear
that may be required when riding the E-Bike™.
It is also important that your first ride on a new E-Bike™ is
taken in a controlled environment, away from cars, obstacles
and other cyclists.
Cycling can be a hazardous activity even under the best of
circumstances. Proper maintenance of your E-Bike™ is your
responsibility as it helps reduce the risk of injury. This
manual contains many "Warnings" and "Cautions"
concerning the consequences of failure to maintain or
Not wearing a helmet significantly increases the chance of
serious injury or death in a crash. Always wear a helmet, eye
protection and appropriate apparel when you ride.
Ride Within Your Limits!
Take it slow until you are familiar with the riding conditions
that you encounter. Be especially careful in wet conditions as
traction can be greatly reduced and brakes become less
effective. Never ride faster than conditions warrant or beyond
your riding abilities. Remember that alcohol, drugs, fatigue
and inattention can significantly reduce your ability to make
good judgements and ride safely.
Know your E-Bike™!
Your new E-Bike™ incorporates many features and functions
that have never been built into a bicycle before. Read this
manual thoroughly to understand how those features
enhance your riding pleasure and safety.
Keep Your E-Bike™ In Safe Condition
Follow the inspection and maintenance guidelines beginning
on page 3. Check critical safety equipment before each and
every ride.
Ride Defensively!
One of the most frequent cycling accidents occurs when the
driver of a parked car opens his door into a rider’s path.
Another common occurrence is when a car or another cyclist
moves suddenly into your path. Always be aware of other
vehicles around you. Do not assume that the driver or the
other cyclist sees you. Be prepared to take evasive action or
stop suddenly.
Know The Law
Cyclists are required to follow the rules of the road.
Additionally, some communities regulate the use of
motorized bicycles regarding minimum age requirements and
necessary equipment. Check with your local police
department for specific details.
Make Yourself Easy To See!
Make yourself more visible by wearing bright reflective
clothing. Keep your reflectors clean and properly aligned. Use
your head and tail lights in reduced lighting conditions. Signal
your intentions so that drivers and other cyclists can
anticipate your actions. Use your horn when needed to make
your presence known.
Offroad Riding
Offroad riding is not recommended because the E-Bike™
tires are for street use only. Dust and extreme impacts from
offroad riding can cause electrical system problems.
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you should
immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying EV Global
Motors Company.
For your safety and enjoyment, and to insure a long life for
your E-Bike™, inspect and maintain your E-Bike™ regularly.
Use the table below for guidance. It is very important that you
check certain systems and components
before each and every ride. The proper condition and
function of these systems is critically important for your
If NHTSA receives similar complaints, it may open an
investigation, and if it finds that a safety defect exists in a
group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer or EV Global
Motors Company.
Your E-Bike™ should be returned to your servicing dealer at
least once a year for a complete and thorough inspection and
tune up. If a problem arises that is not described below,
discontinue riding the E-Bike™ and return it to your servicing
dealer immediately. For more information about service and
maintenance, please refer to page 37.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 202-366-0123 in
Washington, DC area) or write to: NHTSA, U.S. Department
of Transportation, Washington, DC 20590. You can also
obtain other information about motor vehicle safety from the
Refer to
Component or Condition
Tire pressure (55-65 psi)
Tire wear/damage
Brake pad adjustment
Wheel quick release adjustment
Head/tail/brake lights
Mirror position
Controls and displays
Seat post quick release adjustment
Brake pad wear
Brake cable tension/wear
Spoke tension
Wheel true
Hub bearings
Chain lubrication
Derailleur adjustment
Battery and charger
Headset adjustment
Bottom bracket adjustment
All bolts, nuts, and mounting hardware
Inspect before
Clean and/or
every ride
*Every 5 to 10 rides depending on length and conditions of the ride.
if necessary
Please read and understand these instructions completely
before operating your E-Bike™ to prevent serious injury to
yourself and others, and to prevent damage to the bike.
• Do not break the warranty seal from the charger, and
do not attempt to repair this component. Always
contact an authorized E-Bike™ dealer for repair or
service of the charger.
• Always pedal assist your E-Bike™ when the pedalassist beep sounds.
• If the overheat warning beep sounds and the yellow
LED flashes, pedal your E-Bike™ until the good beep
sounds and the yellow LED stops flashing. Do not turn
the power knob OFF-ON repeatedly and attempt to
override the overheat protection function. This may
cause motor or controller damage and will void the
• Always recharge the battery pack immediately after
each use. Failure to do so within 72 hrs may damage
the battery.
• The charger can remain plugged-in for trickle-charge
purposes during long periods of storage.
• For storage periods over 3 months, the battery pack
should be checked and fully recharged every 3 months.
The three state-of-charge LEDs on the throttle controller
indicate battery state of charge. The E-Bike™ uses these
LEDs and three distinct beeps to alert you to particular
conditions. The following chart describes these signals and
their various meanings.
Good Beep
The system has been
checked and is
A problem exists in a
system or component
The system requests
pedal assist. Sounds
when on a steep hill
or when the motor or
controller approaches
an overheat condition.
Whenever the power
knob is turned ON, the
system performs a
series of checks. This
signal indicates that
the E-Bike™ is ON
and ready for
1 continous
beep sounds
for 1 second.
4 sets of 4 short
3 short beeps
every 16
Bad Beep
Pedal Assist
System ON
Good Beep
Throttle Fault This code occurs
whenever you turn the
power knob ON while
pressing the throttle or
if the throttle is faulty.
Turn the power OFF,
release the throttle,
and turn the power
knob to ON. If the
code persists, have
the throttle checked
by an authorized
E-Bike™ dealer.
The battery has
state-of100% to 80% of
run time remaining.
80% to 60% of
run time remaining.
60% to 40% of
run time remaining.
40% to 15% of
run time remaining.
Low Battery 15% to 5% of run
time remaining.
Very low
Less than 5% of run
time or 1 minute of
operation remaining.
Motor shut
The power to the
motor has been shut
off. You must pedal.
The state-ofcharge LEDs
flash together
3 times.
Bad Beep
All 3 state-ofcharge LEDs
flash continously until the fault
is cleared and
until the power
knob is turned
OFF then ON
Green LED on.
Green and
yellow LEDs on.
Yellow LED on.
Yellow and red
LEDs on.
Red LED on.
Bad Beep
Bad beep
The motor or controlBad beep
ler temperature
exceeds operating
temperature. The controller cuts the power
to the motor. You must
pedal until the temperature drops to operating
The motor or controller Good Beep
temperature has cooled to operating
temperature. You may
resume using the throttle.
Overheat and The motor or controller Bad beep
temperature exceeds
operating temperature
and the battery
state-of-charge is low.
Press the throttle lever (B, Figure 1) with your thumb to apply
power to the motor.
Yellow LED
Front Brake Lever
The front brake is activated by squeezing the right brake lever
(C, Figure 1). This is the opposite of a traditional bicycle.
The appropriate
LED turns on.
The yellow and
red LEDs flash
Power On/Off
• Turn the power knob (A, Figure 1) on the throttle
controller clockwise to the ON position.
• The
simultaneously three times and the good beep will
sound to indicate the system and controls are ready for
Battery Charge Level
The three state-of-charge LEDs (D, Figure 1) on the throttle
controller indicate the battery charge level.
• Green (or full) indicates the battery is 100% to 80%
• Green and yellow indicate the battery is 80% to 60%
• Yellow (or half) indicates the battery is 60% to 40%
• Yellow and red indicate the battery is 40% to 15%
• Red (or empty) indicates the battery is 15% to 5%
charged (low battery condition).
• Red LED flashes indicates the battery is less than 5%
charged (very low battery condition).
Performance or Economy Switch (P/E)
The Blue P /E switch (A, Figure 2) provides two different
power delivery characteristics. In the Performance or Pmode, your E-Bike™ has maximum hill climbing capability
and acceleration. Total range, however, is shorter because
power usage will be greater.
In the Economy or E-mode, your E-Bike™ has lower top
speed, lower hill climbing capability, and accelerates more
slowly. Total range is longer because power usage is less.
The motor automatically shuts off when the battery is below
a preset limit to help extend battery life. The red LED flashes
to signify the motor is off and the battery must be recharged.
Recharge the battery pack immediately after use. Failure to
do so within 72 hrs may damage the battery.
The right hand lever activates the front brake on the EBike™. This is the OPPOSITE of a traditional bicycle.
Horn Switch
Press the red horn button (B, Figure 2) to activate the horn.
If you turn the power knob ON while the headlight switch is
ON, there will be a 16 second delay before the headlight
turns on. This is normal.
Cruise Control
The green cruise control (C, Figure 2) button allows you to
set a constant throttle setting for throttle-free operation.
Twist Grip Gear Selector
By twisting this grip (E, Figure 2) while pedaling, you can
select any one of seven gears on the rear wheel. The grip is
labeled with the corresponding gear selection.
To set the cruise control, hold the throttle at a desired speed,
press the green cruise button, and then release your thumb
from the throttle lever. To cancel cruise control, pull either
brake lever, press the cruise button, press the horn button, or
turn the power knob OFF.
Rear View Mirror
Sit on your E-Bike™ and adjust the rear view mirror (F,
Figure 2) so that you can see behind you. It is intended to be
used for added safety but always be sure to look over your
shoulder for maximum viewing.
Headlight On/Off
The yellow headlight switch (D, Figure 2) activates the
headlight, taillight (running light) and the green LED on the
accessory controller.
Rear Brake Lever
The rear brake is activated by squeezing the left brake lever
(G, Figure 2). This is the opposite of a traditional bicycle.
Press the headlight switch to ON for headlight and taillight
operation. In the ON position, power consumption will
increase and total range will decrease. When the motor is
shut-off due to a low battery or overheat condition, the
headlight and taillight will continue to operate until the battery
is fully discharged if the power knob is ON. They will not
operate if the power knob is OFF. Recharge the battery
pack immediately after use. Failure to do so within 72 hrs
may damage the battery.
The left brake lever activates the rear brake on the E-Bike™.
It is the OPPOSITE of a traditional bicycle.
• Always recharge the battery pack immediately after
each use. Failure to do so within 72 hrs may damage the
• The charger can remain plugged-in for trickle-charge
purposes during long periods of storage.
• For storage periods over 3 months, the battery pack
should be checked and fully recharged every 3 months.
• A battery charger is located at the top of the battery
pack. The battery can be charged when the battery is
on-board the E-Bike™ or it can be removed for remote
On-Board Battery Charging
Perform the following to charge the battery while the battery
pack is installed in the E-Bike™.
1. Turn the power knob to the OFF position.
2. Turn the battery-compartment latches clockwise, and
open the door.
3. Retrieve the charging cord from the compartment above
the bottom bracket.
4. Plug the female end of the cord into the receptacle on
the battery charger as shown in Figure 3. Plug the male
end of the cord into a standard U.S. 110V/60 cycle wall
5.The red LED on the charger and cooling fan will
automatically turn on when in the charging mode.
6. The LED turns to green and the cooling fan turns off
when the battery pack is fully charged.
Keep the charger and battery pack away from water to
prevent electrical shock and shorting. The charger is
intended for indoor use only.
If the cooling fan does not operate when in the charging
mode (Red LED on), immediately unplug the charger from
the wall socket. Contact an authorized EVG dealer for advice.
Remote Battery Power Pack Charging
The battery pack can be removed for remote charging.
1. Turn the power knob to the OFF position.
2. Open the battery-compartment door.
3. Release the retainer gate latch.
The battery pack weighs over 20 pounds. Use both hands to
remove or install it. Reinstall the battery - pack by tilting the
bottom first.
4. Grasp the power-pack handle with one hand. Pull the
battery pack from the battery compartment while
supporting the bottom of the power pack with your free
hand as shown in Figure 4.
5. Set the power pack on a bench so the side with the fan
faces up and the handle is on the side.
6. Retrieve the charging cord located in the compartment
above the bottom bracket.
7. Plug the female end of the cord into the receptacle on
the side of the battery charger and the male end of the
cord into a standard U.S. 110V/60 cycle wall socket.
8. The red LED and cooling fan will automatically turn on
when in the charging mode.
Keep the charger and battery pack away from water to
prevent electrical shock an shorting. The charger is intended
for indoor use only.
Be sure the cooling fan vent is unrestricted or facing out
when charging the battery to prevent the charger from overheating. The cooling fan should always be on when the red
LED is on to prevent charger overheating.
9. Reinstall the battery pack, and close the retainer gate.
10. Close latch by lifting the latch ring with your left hand and
locating it on to the frame hook with your right hand.
11. Close the battery compartment door and turn latches
If your E-Bike™ does not fit properly, you may lose control
and fall. If your new E-Bike™ does not fit, ask your dealer to
exchange it before you ride it.
Make sure the E-Bike™ fits. A bike that is too big or too small
for the rider is harder to control and can be uncomfortable.
Remove the battery pack before washing your E-Bike™.
Keep the battery pack and charger away from water to
prevent electrical shock and damage to the charger or
Standover Height
The first check for correct size is standover height. Standover
height is the distance from the ground to the top of the top
tube at that point where your crotch would be if you were
straddling the E-Bike™ by standing half way between the
saddle and the handlebar stem.
Clean the E-Bike™ with a mild soap and a sponge. DO NOT
use a power hose or washer. Gently rinse with water. Avoid
spraying water directly onto the control switches, motor and
front hub bearings. Do not spray water inside the battery
compartment. Dry the frame mounted electrical connector in
the battery compartment before reinstalling the battery pack.
Use automotive wax to protect painted surfaces. Lubricate
the chain periodically to help prevent corrosion and minimize
FIG. 5
a. Up and down adjustment.
Your leg length determines the correct saddle height. The
saddle is at the correct height if you can just reach the
"down" pedal with one heel when you are seated on the
saddle and the crank arms are parallel to the seat tube. To
check for correct saddle height, perform the following:
1. Sit on the saddle, and place one heel on a pedal.
2. Rotate the crank until the pedal with your heel on it is in
the down position and the crank arm is parallel to the
seat tube.
3. You leg should be completely straight and just touching
the center of the pedal. If this is not the case, your
saddle height needs to be adjusted.
To check the standover height, straddle the E-Bike™ while
wearing the kind of shoes you will wear while riding. See
Figure 5. Bounce vigorously on your heels. Miminum
standover height clearance is one to two inches. If your
crotch touches the frame, the E-Bike™ is too big for you. Do
not even ride the E-Bike™ around the block.
Saddle position
Correct saddle adjustment is an important factor in getting
the most performance and comfort from your E-Bike™.
Your dealer will have positioned the saddle where experience
tells him most people find it comfortable. If you find the
saddle position is not comfortable, there are three
adjustments you canmake.(See Figure 6 to determine the
type of saddle attachment used on your E-Bike™.)
To adjust the saddle height, loosen the quick release
(Figure 7) and move the seat post up or down as required.
Make sure that the saddle is parallel to the top tube of the EBike™, and retighten the quick release so that you cannot
twist the saddle out of alignment. Check the adjustment as
described above. Under no circumstances should the seat
post project from the frame beyond its "Minimum Insertion"
or "Maximum Extension" mark (Figure 7).
FIG. 6
FIG. 7
If your seat post projects from the frame beyond the
Minimum Insertion or Maximum Extension mark (see Figure
7) the seat post may break, which could cause you to lose
control and fall.
After any saddle adjustment, be sure to tighten the saddle
adjusting mechanism properly before riding. A loose saddle
clamp or seat post binder can cause damage to the seat
post, or can cause you to lose control and fall. A correctly
tightened saddle adjusting mechanism will allow no saddle
movement in any direction. Periodically check to make sure
that the saddle adjusting mechanism is properly tightened.
b. Front and back adjustment
Loosen the saddle clamping mechanism (see Figure 6) and
slide the saddle back or forward on its rails. Start with the
saddle clamped in about the middle, and adjust it forward or
back until you find the position which is most comfortable for
you. Retighten the saddle clamping mechanism as tight as
you can.
If, in spite of carefully adjusting the saddle height, tilt, and
fore-and-aft position, your saddle is still uncomfortable, you
may need a different saddle design. Saddles, like people,
come in many different shapes, sizes, and resilience. Your
dealer can help you select a saddle which, when correctly
adjusted for your body and riding style, will be comfortable.
c. Saddle tilt adjustment
Most people prefer a horizontal saddle; but some riders
prefer to have the saddle nose tilted slightly up or down. You
can adjust saddle tilt by loosening the saddle clamping
mechanism, tilting the saddle to the desired position, and
retightening the saddle clamping mechanism tight enough so
that you cannot move or jiggle the saddle.
Extended riding with a saddle which is incorrectly adjusted or
which does not support your pelvic area correctly can cause
short-term or long-term injury to nerves and blood vessels. If
your saddle causes you pain or numbness, adjust the saddle
position and your riding position. If pain or numbness persist,
talk to your dealer about fitting a different saddle to your EBike™.
Very small changes in saddle position can have a substantial
effect on performance and comfort. Consequently, whenever
you make a change to your saddle position, make only one
directional change at a time, and make the changes in small
increments until you have found the position at which you are
most comfortable.
2. Turn the side-to-side adjuster (A, Figure 7) in or out to
adjust the amount of side-to-side play at the saddle tip.
d. Suspension Seatpost Adjustment
On models equipped with a suspension seatpost, the preload
and saddle side-to-side can be adjusted to suit your
Handlebar height and angle
On the E-Bike™, you can raise or lower your handlebars a bit
by adjusting stem height. Loosen the stem binder (Figure 9)
bolt by turning it counterclockwise three or four full turns. If
the bolt rises but the stem doesn't, get a piece of wood or a
soft mallet and give the bolt a good whack to release the
wedge. Adjust the stem position as desired, align stem with
the tire, and retighten the binder bolt tight enough so that you
cannot twist the stem and handlebars out of alignment. Under
no circumstances should the stem be retightened with its
minimum insertion mark or maximum extension mark visible.
Check to make sure that the handlebars rotate freely in both
directions without the brake cables catching or binding on
1. To adjust the preload, perform the following:
a. Release the QR release and remove the seatpost
from the frame.
b. Use a 6 mm Allen wrench to turn the preload adjuster
at the bottom of the suspension seatpost. See Figure 8.
Turning the adjuster clockwise increase the
preload, which stiffens the suspension. Turning the
adjuster counterclockwise decreases the preload,
which softens the suspension.
c. Insert the seatpost into the frame, and adjust the seat
height as described above.
FIG. 8
You can change the angle of the handlebar or bar end
extensions by loosening their binder bolt, rotating the bar or
extension to the desired angle, recentering it and retightening
the binder bolt tight enough so that the bars or extensions
cannot move in relation to each other and the stem.
Changing stem height can affect the tension of the front
brake cable, locking the front brake or creating sufficient
cable slack to make the front brake inoperable. If the front
brake pads move in towards the wheel rim or out away from
the wheel rim when you change stem height, take your EBike™ to your dealer for correct brake adjustment before
riding it.
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 E-Bike™
between your legs and attempt to twist the handlebar/stem
assembly. If you can twist the stem in relation to the front
wheel, turn the handlebars in relation to the stem, or turn the
bar end extensions in relation to the handlebar, tighten the
The stem's minimum insertion mark must not be visible
above the top of the headset (see Figure 9). If the stem is
extended beyond the minimum insertion mark, the stem may
damage the fork's steerer tube or break, which could cause
you to lose control and fall.
Control position adjustments: The brake and shifting controls
on your E-Bike™ are positioned where they work best for
most people. The angle of the controls and their position on
the handlebars can be changed. Ask your dealer to show you
how, or to make the adjustments for you.
FIG. 9
Eye protection
Any kind of riding involves airborne dirt, dust and bugs, so it's
a good idea always to ride with protective eyewear -- tinted
when the sun is bright, clear when it's not. Most E-Bike™
shops carry protective fashion eyewear, some with
interchangeable lens systems.
Many states require specific safety devices. It is your
responsibility to familiarize yourself with the laws of the state
where you ride and to comply with all applicable laws,
including properly equipping yourself and your E-Bike™ as
the law requires.
The mechanical safety check is a simple, sixty-second check
you should perform whenever you’re about to get on the EBike™.
Do not remove the reflectors or lights from your E-Bike™.They are
an integral part of the safety system on the E-Bike™.
Removing the reflectors or lights may reduce your visibility to
others using the roadway. Being struck by other vehicles
often results in serious injury or death. Remember, reflectors
are not a substitute for lights. Always ensure your E-Bike™
with is equipped with all state and locally mandated lights.
Nuts, bolts & straps
Lift the front wheel off the ground by two or three inches, and
then let it bounce on the ground. Does anything sound, feel
or look loose? Do a quick visual and tactile inspection of the
whole E-Bike™. Any loose parts or accessories? If so,
secure them. If you're not sure, ask someone with experience
to check these items.
Some higher performance models come equipped with
pedals that have sharp and potentially dangerous surfaces.
These surfaces are designed to add safety by increasing
adhesion between the rider's shoe and the pedal. If you
install these high-performance pedals on your E-Bike™, you
must take extra care to avoid serious injury from the pedals'
sharp surfaces. Based on your riding style or skill level, you
may prefer a less aggressive pedal design. Your dealer can
show you a number of options and make suitable
Tires & Wheels
Tires correctly inflated? Check by putting one hand on the
saddle, one on the intersection of the handlebars and stem,
then bouncing your weight on the E-Bike™ while looking at
tire deflection. Compare what you see with how it looks when
you know the tires are correctly inflated. Adjust the tire
pressure if necessary.
Tires in good shape? Spin each wheel slowly and look for
cuts in the tread and sidewall. Replace damaged tires before
riding the E-Bike™.
Wheels true? Spin each wheel and check for brake clearance
and side-to-side wobble. If a wheel wobbles from side to side
or hits the brake pads, take the E-Bike™ to a qualified bike
shop to have the wheel trued.
Wheels must be true for the brakes to work effectively. Wheel
truing is a skill which requires special tools and experience.
Do not attempt to true a wheel unless you have the
knowledge and tools needed to do the job correctly.
FIG. 10
Squeeze the brake levers. Does the cable guide on the brake
cable securely engage the quick release bracket on the left
caliper arm? (Figure 10) Are the brake pads contacting the
wheel rim within an inch of brake lever movement? Can you
apply full braking force at the levers without having them
touch the handlebar? If not, your brakes need adjustment. Do
not ride the E-Bike™ until the brakes are properly adjusted.
See Chapter 5 for details.
Riding with improperly adjusted brakes or worn brake pads is
dangerous and can result in serious injury or death.
Quick Releases
Are the front wheel and seat post quick releases properly
adjusted and in the locked position? Adjust the quick release
mechanism as necessary. See Chapter 5 for details.
Riding with an improperly adjusted wheel quick release can
cause the wheel to wobble or disengage from the E-Bike™,
which can cause damage to the E-Bike™ and serious injury
or death.
Like any sport, bicycling involves risk of injury and damage.
By choosing to ride an E-Bike™, you assume the
responsibility for that risk. Not the people who sold you the EBike™. Not the people who made it. Not the people who
distribute it. Not the people who manage or maintain the
roads or trails you ride on. You. So you need to know -- and
to practice -- the rules of safe and responsible riding.
Handlebar and saddle alignment
Are the saddle and handlebar stem correctly parallel to the
top tube of the E-Bike™. Are the binder bolts tight enough so
that you cannot twist them out of alignment?
Handlebar ends
Are the handlebar grips secure and in good condition? If not,
replace them. Are the handlebar ends and extensions
plugged? If not, plug them before you ride.
1. Always perform the mechanical safety check described
above before you get on a E-Bike™.
2. Always wear a helmet which complies with your state
laws when riding the E-Bike™. Check with your local
police department for requirements in your community.
3. Keep body parts and other objects away from the sharp
teeth of chainring, the moving chain, the turning pedals
and cranks, and the spinning wheels of your E-Bike™.
4. Always wear shoes that will stay on your feet and will
grip the pedals. Never ride barefoot or when wearing
5. Be thoroughly familiar with the controls of your EBike™.
Loose or damaged handlebar grips or extensions can cause
you to lose control and fall. Unplugged handlebars or
extensions can act like a cookie cutter on your body and can
cause serious injury in an otherwise minor accident.
6. Wear bright, visible clothing that is not so loose that it
can catch on moving parts of the E-Bike™ or be
snagged by objects at the side of the road or trail.
7. Do not jump with your E-Bike™. Jumping an E-Bike™
can be fun; but it puts incredible stress on everything
from your spokes to your pedals. Perhaps most
vulnerable to jumping-related damage is your front fork.
Riders who insist on jumping an E-Bike™ risk serious
damage to the E-Bike™ as well as to themselves.
8. Think about your speed, and keep your speed at a level
which is consistent with conditions. Always keep in
mind that there is a direct relationship between speed
and control, and between speed and component stress
Parked car doors opening in front of you.
Pedestrians stepping out in front of you.
Children playing near the road.
Pot holes, sewer grating, railroad tracks, expansion
joints, road or sidewalk construction, debris and other
obstructions that could cause you to swerve into traffic,
catch your wheel or otherwise cause you to lose control
and have an accident.
• The many other hazards and distractions which can
occur on an E-Bike™ ride.
4. Use hand signals for turning and stopping. Learn the local
vehicle code for the correct signals.
5. Never ride with headphones. They mask traffic sounds and
emergency vehicle sirens, and they distract you from
concentrating on what's going on around you. Their wires can
also tangle in the moving parts of the E-Bike™, causing you
to lose control.
6. Never carry a passenger.
7. Never carry anything which obstructs your vision or your
complete control of the E-Bike™, or which could become
entangled in the moving parts of the E-Bike™.
8. Never hitch a ride by holding onto another vehicle.
9. Never perform stunts, wheelies or jumps. They can cause
you injury and damage your E-Bike™.
10. Do not weave through traffic or make any moves that may
surprise people with whom you are sharing the road.
11. Observe and yield the right of way.
1. You are sharing the road with others -- motorists,
pedestrians and other cyclists. Respect their rights, and
be tolerant if they infringe on yours.
2. Ride defensively. Assume that the people with whom you
are sharing the road are so absorbed with what they are
doing and where they are going that they are oblivious to you.
3. Look ahead of where you're going, and be ready to avoid:
• Vehicles slowing or turning in front of you, entering the
road or your lane ahead of you, or coming up behind
12. Never ride your E-Bike™ while under the influence of
alcohol or drugs.
13. If possible, avoid riding in bad weather, when visibility is
obscured, or when extremely tired. Each of these conditions
increases the risk of accident.
other times of poor visibility. If you must ride under these
conditions, check and be sure you comply with all local laws
about night riding. Follow the rules of the road even more
carefully, and you must take the following additional
Before riding at dusk or at night, take the following steps to
make yourself more visible:
• Make sure that your E-Bike™ is equipped with correctly
positioned and securely mounted reflectors.
• Be sure the headlight and taillight are operational.
• Wear light colored, reflective clothing and accessories,
such as a reflective vest, reflective arm and leg bands,
reflective stripes on your helmet, flashing lights ... any
reflective device or light source that moves will help you
get the attention of approaching motorists, pedestrians
and other traffic.
• Make sure your clothing or anything you may be
carrying on the E-Bike™ does not obstruct a reflector or
Wet weather impairs traction, braking and visibility, both for
the rider and for other vehicles sharing the road. The risk of
accident is dramatically increased in wet conditions.
Under wet conditions, the stopping power of your brakes (as
well as the brakes of other vehicles sharing the road) is
dramatically reduced and your tires do not grip nearly as well.
This makes it harder to control speed and easier to lose
control. To make sure that you can slow down and stop safely
in wet conditions, ride more slowly and apply your brakes
earlier and more gradually than you would under normal, dry
While riding at dusk or at night:
• Ride slowly.
• Avoid areas of heavy traffic, dark areas, and roads with
speed limits over 35 mph.
• Avoid road hazards.
• If possible, ride on routes already familiar to you.
Even if you have excellent night vision, many of the people
with whom you share the road do not. A rider is very difficult
for motorists and pedestrians to see at dusk, at night, or at
nature, it is critical that you understand how it works and how
to use it properly.
It's important to your performance, enjoyment and safety to
understand how things work on your E-Bike™. Even if you
are an experienced cyclist, be sure to read -- and to
understand -- this section of the manual. If you have even the
slightest doubt as to whether you understand something, talk
to your dealer.
While it looks like a long bolt with a lever on one end and a
nut on the other, the wheel quick release uses a cam action
to clamp the E-Bike™ wheel in place (see Figure 11).
Wheel Quick Release
Riding with an improperly adjusted wheel quick release can
allow the wheel to wobble or disengage from the E-Bike™,
causing damage to the E-Bike™ and serious injury or death
to the rider. Therefore, it is essential that you:
1. Ask your dealer 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 time, before you ride the E-Bike™, check that the
wheel is securely clamped.
The wheel quick release, which was invented in the 1930s,
allows quick, easy wheel removal without the need for tools.
It has become standard equipment on most recreational,
sports and competition bicycles. Because of its adjustable
Holding the nut with one hand and turning the lever like a
wing nut with the other hand until everything is as tight as you
can get it will not clamp the wheel safely in the dropouts. The
full force of the cam action is needed to clamp the wheel
Adjusting the quick release mechanism
The wheel hub is clamped in place by the force of the quick
release cam pushing against one dropout and pulling the
tension adjusting nut against the other dropout.The amount
of clamping force is controlled by the tension adjusting nut.
Turning the tension adjusting nut clockwise while keeping the
cam lever from rotating increases clamping force. Turning the
nut 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.
Secondary retention devices fall into two basic categories:
• The clip-on type is an accessory part which the
manufacturer adds to the front wheel hub or front fork.
• The integral type is molded, cast or machined into the
outer faces of the front fork dropouts.
Once the quick release is installed in the hub axle by the
manufacturer or the dealer, it never needs to be removed
unless the hub itself requires servicing. If the hub requires
servicing, consult your dealer.
Removing or disabling the secondary retention device is
extremely dangerous and may lead to serious injury or death.
It also may void the warranty.
Front Wheel Secondary Retention Devices
Removing a Quick Release Front Wheel
1. Open up the brake pads as described below in this
2. Rotate the wheel’s quick release lever from the locked or
CLOSED position to the OPEN position (Figure 12).
3. Loosen the tension adjusting nut about six full turns to
release the secondary retention device.
4. Lift the handlebar so the front wheel is off the ground.
5. Tap the top of the wheel with the palm of your hand to
knock the wheel out of the front forks.
Your E-Bike™ has front forks which utilize an integral-type
secondary wheel retention device to keep the wheel from
disengaging if the quick release is incorrectly adjusted.
Secondary retention devices are not a substitute for correct
quick release adjustment.
Secondary retention devices are not a substitute for correct
quick release adjustment. Failure to properly adjust the quick
release mechanism can cause the wheel to wobble or
disengage, which could cause you to loose control and fall,
resulting in serious injury or death.
If you can fully close the quick release without wrapping your
fingers around the fork blade for leverage and if the lever
does not leave a clear imprint in the palm of your hand, the
tension is insufficient. Open the lever, turn the tension
adjusting nut clockwise a quarter turn, and then try again.
Installing a Quick Release Front Wheel
1. Rotate the quick-release lever so that it curves away from
the wheel (Figure 12). This is the OPEN position.
2. With the steering fork facing forward, insert the wheel
between the fork blades so that the axle seats firmly at the
top of the fork dropouts (the slots at the tip of the fork blades).
The quick-release lever should be on the left side of the EBike™ (Figure 12).
5. 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.
6. Close the brake pads. Spin the wheel to make sure that it
is centered in the frame and clears the brake pads.
Removing a Bolt-On Rear Wheel
1. Open the rear brake pads.
2. Shift the rear derailleur to high gear (the smallest rear
3. With a 15 mm box wrench or a six-inch adjustable wrench,
loosen the two axle nuts (Figure 13).
4. Remove the motor torque arm bolt from the left side seat
stay above the drop out.
5. Disconnect the motor QR-connector and temperaturesensor connector in the QR housing on the inside of the left
seat stay above the motor torque arm bolt.
3. Hold the quick-release lever in the OPEN position with
your right hand, and tighten the tension adjusting nut with
your left hand until it is finger tight against the fork dropout
(Figure 12).
4. While pushing the wheel firmly to the top of the fork
dropouts, and at the same time centering the wheel rim in the
fork, rotate the quick-release lever upwards and push it into
the CLOSED position (Figure 12). The lever should be
parallel to the fork blade and curved toward the wheel.
6. Push the rear derailleur back into position.
7. Reconnect the motor QR- and temperature-sensor
connectors and close the QR housing.
8. Close the brake. Spin the wheel to make sure that it is
centered in the frame and clears the brake pads.
Seatpost Quick Release
Most E-Bike™s are equipped with quick-release seatpost
binders. The seatpost quick-release binder works exactly like
the wheel quick release While a quick release looks like a
bolt with a lever on one end and a nut on the other, the quick
release uses a cam action to firmly clamp the seat post (see
Figure 7).
6. Lift the rear wheel off the ground a few inches and pull the
derailleur body back with your right hand.
7. With the derailleur still pulled back, push the wheel forward
and down until it comes out of the rear dropouts.
Riding with an improperly tightened seat post can allow the
saddle to turn or move and cause you to lose control and fall.
Installing a Bolt-On Rear Wheel
1. Shift the rear derailleur to its outermost position and pull
the derailleur body back with your right hand.
2. Put the chain on to the smallest sprocket.
3. Insert the wheel into the frame dropouts and pull it all the
way into the dropouts. The axle nut washers should be on the
outside of the dropouts, between the frame and the axle nut.
4. Reinstall the motor torque arm and bolt.
5. Tighten the axle nuts as tightly as you can, using a six-inch
adjustable wrench or a 15 mm box wrench (Figure 13).
1. Ask your dealer to help you make sure you know how to
correctly clamp your seat post.
2. Understand and apply the correct technique for clamping
your seat post quick release.
3. Before you ride the E-Bike™, first check that the seatpost
is securely clamped.
Adjusting the quick release mechanism
The action of the quick release cam squeezes the seat collar
around the seat post to hold the seat post securely in place.
The amount of clamping force is controlled by the tension
adjusting nut. Turning the tension adjusting nut clockwise
while keeping the cam lever from rotating increases clamping
force. Turning the nut counterclockwise while keeping the
cam lever from rotating reduces clamping force. Less than
half a turn of the adjusting nut can make the difference
between safe clamping force and unsafe clamping force.
How Brakes Work
It's important to your safety that you instinctively know which
brake lever controls which brake. On your E-Bike™. the right
brake lever controls the front brake. The left brake lever
controls the rear brake.
The braking action of a E-Bike™ is a function of the friction
between the brake surfaces -- usually the brake pads and the
wheel rim. To make sure that you have maximum friction
available, keep your wheel rims and brake pads clean and
free of lubricants, waxes or polishes.
Holding the nut with one hand and turning the lever like a
wing nut with the other hand until everything is as tight as you
can get it will not clamp the seatpost safely. The full force of
the cam action is needed to clamp the seatpost securely.
Make sure that your hands can reach and squeeze the brake
levers comfortably. If your hands are too small to operate the
levers comfortably, consult your dealer before riding the EBike™. You may need a different brake lever design.
For most effective braking, use both brakes and apply them
Brakes are designed to control your speed, not just to stop
the E-Bike™. Maximum braking force for each wheel occurs
at the point just before the wheel locks up (stops rotating) and
starts to skid. Once the tire skids, you actually lose most of
your stopping force and all directional control. You need to
practice slowing and stopping smoothly without locking up a
wheel. The technique is called progressive brake modulation.
Instead of jerking the brake lever to the position where you
think you will generate appropriate braking force, squeeze
Sudden or excessive application of the front brake may pitch
the rider over the handlebars, causing serious injury or
the lever, progressively increasing the braking force. If you
feel the wheel begin to lock up, release pressure just a little
to keep the wheel rotating just short of lockup. It is important
to develop a feel for the amount of brake lever pressure
required for each wheel at different speeds and on different
surfaces. To better understand this, experiment a little by
walking your E-Bike™ and applying different amounts of
pressure to each brake lever until the wheel locks.
increase front braking force. This is even more important on
steep descents, because descending shifts weight forward.
The keys to effective speed control and safe stopping are
controlling wheel lockup and weight transfer. Practice braking
and weight transfer techniques where there is no traffic or
other hazards and distractions.
Everything changes when you ride on loose surfaces or in
wet weather. Tire adhesion is reduced, so the wheels have
less cornering and braking traction and can lock up with less
brake force. Moisture or dirt on the brake pads reduces their
ability to grip. The way to maintain control on loose or wet
surfaces is to go more slowly to begin with.
Some E-Bike™ brakes, such as disc brakes, are extremely
powerful.You should take extra care in becoming familiar with
these brakes and exercise particular care when using them.
When you apply one or both brakes, the E-Bike™ begins to
slow, but your body wants to continue at the speed at which
it 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 rear of
the E-Bike™, to transfer weight back onto the rear wheel. At
the same time, you need to both decrease rear braking and
Brake Release
The brake pads of the V-brakes can be quickly opened so the
pads can clear the tire when the wheel is removed or
installed. To open the front or rear brake pads, perform the
1. Squeeze the caliper arms together.
2. Disconnect the cable guide on the brake cable from the
quick release bracket on the left caliper arm (A, Figure 14).
1. Pull the brake lever to simulate a panic stop, and then
release the brake lever. Repeat this at least ten times. This
assures that all components are properly seated.
2. Pull the brake lever until the brake pads just touch the rim.
3. Measure the clearance between the brake lever and the
handlebar grip. This distance should be 25 mm (0.98 in.).
4. Loosen the adjuster locknut, and turn the barrel adjuster
(Figure 15) as necessary to adjust clearance to within
specification. (Turning the adjuster out tightens the inner wire;
turning the adjuster in loosens the wire.) When the brake
lever is within specification, tighten the adjuster locknut.
5. Squeeze the caliper arms together, and remove the cable
guide from the quick release bracket on the left caliper arm
(A, Figure 14). The brake lever free play is properly adjusted
if the cable guide can be easily removed from the bracket.
6. If you cannot easily release the cable guide from the
bracket, perform the following:
a. Turn the adjusting barrel at the brake lever in
(clockwise) one full turn. Try to remove the cable
guide again.
b. If you still cannot release the cable guide, turn the
adjusting barrel in an additional turn.
c. If the cable guide still does not release, loosen the
pinch bolt (B, Figure 14) and release 2-3 mm (0.0790.118 in.) of inner wire from the pinch mechanism.
d. Tighten the pinch bolt, and repeat the adjusting
Once the wheel is reinstalled, close the brake pads by
performing the following:
1. Squeeze the caliper arms together.
2. Connect the cable guide to the bracket on the left caliper
arm (A,Figure 14).
Brake Cable Free Play Adjustment (V-Brakes)
If either brake lever fails the mechanical safety check, restore
brake lever travel by adjusting the brake lever free play as
described below.
Brake Cable Free Play Adjustment (Disc Brake
5. If you cannot adjust the free play to specification at the
brake lever adjuster, tighten the adjuster locknut and perform
the following:
a. Loosen the adjuster locknut (A, Figure 16) at the
caliper, and turn the barrel adjuster (B, Figure 16) as
necessary to adjust clearance within specification.
Tighten the adjuster locknut.
1. Pull the brake lever to simulate a panic stop, and then
release the brake lever. Repeat this at least ten times. This
assures that all components are properly seated.
2. Pull the brake lever until the brake pads just touch the rim.
3. Measure the clearance between the brake lever and the
handlebar grip. This distance should be 25 mm (0.98 in.).
4. Loosen the adjuster locknut, and turn the barrel adjuster
(Figure 15) as necessary to adjust clearance to within
specification. (Turning the adjuster out tightens the inner wire;
turning the adjuster in loosens the wire.) When the brake
lever is within specification, tighten the adjuster locknut.
Rear Modulation Adjustment
Rear modulation brakes are equipped with an adjuster that
increases or decreases the amount of modulation. Turning
the modulation adjuster (Figure 17) clockwise increases
the brake pressure and stopping ability. Turning the adjuster
adjuster counterclockwise decreases the brake pressure and
stopping ability.
Your seven-speed E-Bike™ uses a derailleur drivetrain,
which consists of.
• A rear sprocket cluster, called a freewheel or cogset
• A rear derailleur
• One shifter
• One control cable
• One front sprocket called a chainring
• A drive chain
There are many different types of shifter mechanisms, each
preferred for specific applications because of its ergonomic,
performance and price characteristics. The designers of your
E-Bike™ have selected the twist-type shifter design which
will give the best results on your E-Bike™.
To shift to a higher gear, twist the shifter forward or
counterclockwise while pedaling forward. To shift to a lower
gear, twist the shifter rearward or clockwise. See Figure 18.
Small changes in the modulation adjustment can have a
significant effect upon brake pressure and stopping ability.
Whenever you adjust the modulation, adjust each caliper in
1/4 turn increments and test the brakes. Always adjust each
side of the brakes equally. If you increase the modulation on
the left caliper by 1/4 turn, you should also increase the
modulation on the right caliper by an equal amount.
A downshift is a shift to a lower or slower gear, one which is
easier to pedal. An upshift is a shift to a higher or faster gear,
one which harder to pedal gear. For example, you can
downshift to a lower gear to make pedaling easier on a hill.
On the otherhand, you may upshift to a higher gear when you
wish to go faster.
FIG. 18
changing gear drive ratio. The smaller sprockets on the gear
cluster produce higher gear ratios. Pedaling in the higher
gears requires greater pedaling effort, but takes you a greater
distance with each revolution of the pedal crank. 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 chain from
one sprocket and move it on to another, the chain must be
moving forward (i.e. the rider must be pedaling forward).
Whether upshifting or downshifting the E-Bike™, the
derailleur system requires that the drive chain be moving
forward and be under at least some tension. A derailleur will
shift only if you are pedaling forward.
Never move the shifter while pedaling backward, nor pedal
backwards after having moved the shifter. This could jam the
chain and cause serious damage to the E-Bike™.
Three screws, the H-, L-, and B-screws, are used to adjust
the derailleur. The H-screw sets the outward limit of the
derailleur’s movement. The L-screw sets its inward limit. The
B-screw adjusts the distance between the bottom of the
cogset and the derailleur’s guide pulley.
Never shift a misadjusted derailleur onto the largest or the
smallest sprocket. The chain could jam, causing you to lose
control and fall.
A fourth–hand tool (Park Tool BT-2) is required to perform this
1. Check the cable attachment to the derailleur pinch
a. Inspect the position of the inner wire in the pinchmechanism. The inner wire should follow the groove
Derailleur Adjustment
The function of the rear derailleur is to move the drive chain
from one gear to another on the rear gear cluster, thereby
in the pinch plate, and the tab on the pinch plate
should be inboard of the cable when you look
directly at the pinch-mechanism stud (Figure 19).
FIG. 20
b. Loosen the pinch-mechanism nut. Use the forthhand tool to pull the slack from the inner wire.
c. Torque the pinch-mechanism nut securely. Torque
the nut to 42 kg-cm (36.5 in.-lb.).
d. Check that the inner cable is still contained within
the groove in the pinch-mechanism plate.
2. Set the derailleur as close as possible to the cogset by
performing the following.
a. Shift the chain to the innermost cog.
b. Completely loosen the B-screw (Figure 20).
c. Back-pedal, and check for bouncing at the guide
pulley (Figure 21). The B-screw is too loose if
bouncing is noticed.
FIG. 21
d. Tighten the B-screw one turn, and repeat the
bounce check.
3. Set the derailleur’s outward limit by performing the
a. Shift the derailleur so the chain is on the outermost
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 22.
4. Set the derailleur’s inward limit by performing the
a. Shift the derailleur so the chain rests on the
innermost cog.
b. Stand behind the E-Bike, and check the position of
the derailleur. The guide pulley should align with the
innermost cog as shown in Figure 23.
c. If necessary, adjust the inward limit by turning the Lscrew. Tighten the L-screw to move the derailleur
outward. Loosen the L-screw to move the derailleur
Bicycle tires are available in many designs and
specifications, ranging from general-purpose designs to tires
designed to perform best under very specific weather or
terrain conditions. Your E-Bike™ has been equipped with
tires which the manufacturer felt were the best balance of
performance and value for the use for which the E-Bike™
was intended. If, once you've gained experience with your
new E-Bike™, you feel that a different tire might better suit
your riding needs, your dealer can help you select the most
appropriate design.
FIG. 22
FIG. 23
c. 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 outward.
The size, pressure rating, and other information appear on
the sidewall of the tire (Figure. 24). The part of this inform-
ation which is most important to you is tire pressure. EV
Global recommends that the tires be inflated to 55-65 psi.
Note that best performance is achieved when tires are
inflated to 60-65 psi. These recommendations apply only to
the OEM tires that were originally installed on your E-Bike™.
If you use another tire, follow the inflation-pressure
recommendations marked on the tire sidewall.
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 upon tire pressure.
Inflating the tire to near its maximum recommended pressure
gives the lowest rolling resistance; but also produces the
harshest ride. High pressures work best on smooth, dry
Very low pressures, at the bottom of the recommended
pressure range, give the best performance on smooth, slick
terrain such as hard-packed clay, and on deep, loose
surfaces such as deep, dry sand.
FIG. 24
Never inflate a tire beyond the maximum pressure marked on
the tire's sidewall. Exceeding the recommended maximum
pressure may blow the tire off the rim, which could cause
damage to the E-Bike™ and injury to the rider and
Tire pressure that is too low for your weight and the riding
conditions can cause a puncture of the tube by allowing the
tire to deform sufficiently to pinch the inner tube between the
rim and the riding surface.
Pencil type automotive tire gauges and gas station air hose
pressure settings are generally inaccurate and should not be
depended on for consistent, accurate pressure. Instead, use
a good quality dial gauge.
The best way to inflate a E-Bike™ tire to the correct pressure
is with a bike pump. Your dealer can help you select an
appropriate pump.
Gas station air hoses move a large volume of air very rapidly
and will raise the pressure in your tire very rapidly. To avoid
overinflation when using a gas station air hose, put air into
your tire in short, spaced burst.
Ask your dealer to recommend the best tire pressure for the
kind of riding you will most often do, and have the dealer
inflate your tires to that pressure. Then, check inflation as
described so you'll know how correctly inflated tires should
look and feel. Some tires may need to be brought up to
pressure every week or two.
Some special high-performance tires have unidirectional
treads. Their tread pattern is designed to work better in one
direction than in the other. The sidewall marking of a
unidirectional tire will have an arrow showing the correct
rotation direction. If you use unidirectional tires on your EBike™, be sure that they are mounted to rotate in the correct
FIG. 25
Tire Valves
The tire valve allows air to enter the tire's inner tube under
pressure, but doesn't let it back out unless you want it to.
There are primarily two kinds of bicycle tube valves used in
the United States: the Schraeder Valve and the Presta Valve.
The bicycle pump you use must have the fitting appropriate
to the valve stems on your tire.
There are many different types of suspension systems --- too
many to deal with individually in this manual. Ask your dealer
to provide you with the appropriate adjustment and
maintenance instructions for the suspension on your EBike™.
The E-Bike™ OEM tires use a Schraeder valve (Figure 25),
which is like the valve on a car tire. To inflate a Schraeder
valve tube, remove the valve cap and push the air hose or
pump fitting onto the end of the valve stem. To let air out of a
Schraeder valve, depress the pin in the end of the valve stem
with the end of a key or other appropriate object.
Failure to check and properly adjust the suspension system
may result in suspension malfunction, which may cause you
to lose control and fall.
Changing suspension adjustment can change the handling
and braking characteristics of your E-Bike™. Never change
suspension adjustment unless you are thoroughly familiar
with the suspension system manufacturer's instructions and
recommendations, and always check for changes in the
handling and braking characteristics of the E-Bike™ after a
suspension adjustment by taking a careful test ride in a
hazard-free area.
rider. Increasing your skill will take time and practice. Proceed
carefully until you are sure you are competent to handle the
full capabilities of your E-Bike™.
Suspension Adjustment
Two types of forks are used on the E-Bike™: the Zokes 65
mm forks and the Nitro DH forks. The preload can be
adjusted on both types of forks. The adjustment procedure is
described below. You will need a 4 mm Allen wrench to turn
the adjusters on the Zokes 65 mm forks. The Nitro DH forks
are equipped with hand adjusters.
Not all models can be safely retrofitted with some types of
suspension systems. Before retrofitting an E-Bike™ with any
suspension, check with the E-Bike™ manufacturer to make
sure that what you want to do is compatible with the E-Bike™
Turning an adjuster clockwise stiffens the suspension.
Turning it counterclockwise softens the suspension.
1. Remove the cap from the top of each fork leg.
2. Set the preload in each fork tube to the minimum setting
by turning each adjuster counterclockwise until it stops.
3. If you need to, use a marker to place indexing marks on
the adjuster and on the fork tube on each fork leg. Be sure
the mark on the fork tube aligns with the mark on the
4. Turn the adjuster in each leg 1/4-turn clockwise. Check the
setting by pressing down on the handlebars. Note how the
suspension feels.
5. Repeat this procedure – turning each adjuster in 1/4-turn
increments and checking the suspension – until the desired
preload is obtained.
If your E-Bike™ has suspension, the increased speed you
may develop also increases your risk. When braking, the
front of a suspended E-Bike™ dips. You could lose control
and fall if your skill is not up to handling this system. Get to
know how to handle your suspension system safely.
Suspension can increase the handling capabilities and
comfort of your E-Bike™. This enhanced capability may allow
you to ride faster; but you must not confuse the enhanced
capabilities of the E-Bike™ with your own capabilities as a
6. Install the cap onto each fork leg.
7. Compress the forks several times to ensure they function
Many E-Bike™ service and repair tasks require special
knowledge and tools. Do not begin any adjustments or
service on your E-Bike™ if you have the slightest doubt
about your ability to properly complete them. Improper
adjustment or service may result in damage to the E-Bike™
or in an accident which can cause serious injury or death.
Technological advances have made the E-Bike™ and EBike™ components more complex than ever before, and the
pace of innovation is increasing. This on-going evolution
makes it impossible for this manual to provide all the
information required to properly repair and/or maintain your
E-Bike™. In order to help minimize the chances of an
accident and possible injury, it is critical that you have any
repair or maintenance which is not specifically described in
this manual performed by your dealer.
Equally important is that your individual maintenance
requirements will be determined by everything from your
riding style to geographic location. Consult your dealer for
help in determining your maintenance requirements. How
much of your E-Bike™ service and maintenance you can do
yourself depends upon your level of skill and experience, and
on whether you have the special tools required.
If you want to learn to do major service and repair work on
your E-Bike™, you have four options:
1. Order an E-Bike™ service manual from your dealer.
2. Ask your dealer whether copies of the manufacturer’s
installation and service instructions for the components on
your E-Bike™ are available.
3. Ask your dealer to recommend a book on E-Bike™ repair.
4. Ask your dealer about the availability of E-Bike™ repair
courses in your area. Regardless of which option you select,
we recommend that you ask your dealer to check the quality
of your work the first time you work on something and before
you ride the E-Bike™, just to make sure that you did
everything correctly. Since that will require the time of a
mechanic, there may be a modest charge for this service.
Before every ride:
• Perform the mechanical safety check described in
Chapter Three.
Some service and maintenance can and should be
performed by the owner, and require no special tools or
knowledge beyond what is presented in this manual.
After every long or hard ride; if the E-Bike™ has been
exposed to water or grit; or at least every 100 miles:
• Clean the E-Bike™.
• Lightly oil the chain, freewheel cogs and rear
derailleur pulley bushings. Wipe off excess oil.
Lubrication is a function of climate. Talk to your
recommended lubrication frequency for your area.
The following are examples of the type of service you should
perform yourself. All other service, maintenance and repair
should be performed in a properly equipped facility by a
qualified E-Bike™ mechanic using the correct tools and
procedures specified by the manufacturer.
Break-in Period
Your E-Bike™ will last longer and work better if you break it
in before riding it hard. Control cables and wheel spokes may
stretch or seat when a new E-Bike™ is first used and may
require readjustment by your dealer. Your mechanical safety
check (Chapter Three) will help you identify some things that
need readjustment. But even if everything seems fine to you,
it’s best to take your E-Bike™ back to the dealer for a
checkup. Dealers typically suggest you bring the E-Bike™ in
for a 30 day checkup. Another way to judge when it’s time for
the first checkup is to bring the E-Bike™ in after 10 to 15
hours of use. But if you think something is wrong with the EBike™, take it to your dealer before riding it again.
After every long or hard ride or after every 10 to 20 hours
of riding:
• Squeeze the front brake and rock the E-Bike™
forward and back. Does everything feel solid? If you
feel a clunk with each forward or backward
movement of the E-Bike™, you probably have a
loose headset. Have your dealer check it.
• Lift the front wheel off the ground and swing it from
side to side. Feel smooth? If you feel any binding or
roughness in the steering, you may have a tight
headset. Have your dealer check it.
• Make sure all bolts, nuts and mounting hardware are
• Grab one pedal and rock it toward and away from
the centerline of the E-Bike™; then do the same with
the other pedal. Does the bottom bracket feel loose?
If so, have your dealer check it.
• Take a look at the brake pads. Starting to look worn or not
hitting the wheel rim squarely? Time to have the
dealer adjust or replace them.
• Carefully check the control cables and cable housings.
Any rust? Kinks? Fraying? If so, have your dealer
replace them.
• Squeeze each adjoining pair of spokes on either side of
each wheel between your thumb and index finger. Do
they all feel about the same? If any feel loose, have your
dealer check the wheel runout and spoke tension.
• Check the frame, particularly in the area around all tube
joints, the handlebars, the stem, and the seatpost for
any deep scratches, cracks or discoloration. These are
signs of stress-caused fatigue and indicate that a part is
at the end of its useful life and needs to be replaced.
• Check to make sure that all parts and accessories are
still secure. Tighten any which are not.
Like any mechanical device, an E-Bike™ and its components
are subject to wear and stress. Different materials and
mechanisms wear at different rates and have different life
cycles. If a component’s life cycle is exceeded, the
component can suddenly and catastrophically fail, causing
serious injury or death to the rider. Scratches, cracks, fraying
and discoloration are signs of stress-caused fatigue and
indicate that a part is at the end of its useful life and needs to
be replaced.
As required:
• If either brake lever fails the mechanical saftey check,
adjust the brake lever free play as described in Chapter
Five. If the lever free play cannot be adjusted within
specification, have the brakes checked by your dealer.
• If the chain will not shift smoothly and quietly from gear
to gear, the derailleur is out of adjustment. The cause
may be as simple as cable stretch, in which case you
can compensate by turning the shifter or derailleur
cable adjusting barrel counterclockwise 1/2 turn. Try
shifting again. If 1/2 turn to a full turn of the cable
adjusting barrel does not cure the problem, see your
Every 50 hours of riding:
• Take your E-Bike™ to your dealer for a complete
Carefully check the outside and inside of the tire for the
cause of the puncture and remove the cause if it is still there.
If the tire is cut, line the inside of the tire in the area of the cut
with something handy -- tape, a spare patch, a piece of inner
tube, a dollar bill -- whatever will keep the cut from pinching
the inner tube.
Unless you're going for a short ride in the neighborhood, or
you can walk home or call someone to pick you up if
something breaks, you should never go for a E-Bike™ ride
without the following emergency equipment:
• 4mm, 5mm and 6mm Allen wrenches, used to tighten
various clamping bolts that may loosen
• Patch kit and a spare inner tube
• Tire levers
• Tire pump or cartridge inflator with correct head to fit
your tire valves (see Chapter Five).
• Some kind of identification (so people know who you
are in case of accident).
• A couple of dollars in cash (for a candy bar, cool drink
or emergency phone call).
Either patch the tube (follow the instructions in your patch
kit), or use a new one. Reinstall the tire and tube. Slip one tire
bead over the rim. Insert the tube valve through its hole in the
rim. Feed the tube carefully into the cavity of the tire. Inflate
the tube just enough to give it some shape. Starting at the
valve stem use your thumbs to seat the tire bead inside the
rim. Work your way around both side of the wheel until the
entire bead is seated in the rim. Be careful not to pinch the
tube between the tire bead and the wheel rim. If you have
trouble getting the last few inches of bead over the edge of
the rim with thumb pressure, use a tire lever and be careful
not to pinch the tube.
Flat Tire
If you get a flat tire, remove the wheel as described in
Chapter Five. Depress the tire valve to let all the air out of the
tube. Remove one bead of the tire from the rim by grasping
the tire at a point opposite the valve stem with both hands
and lifting and peeling one side of the tire off the rim. If the
bead is on too tight for you to unseat it with your hands, use
tire levers to lift the bead carefully over the tire rim. Push the
valve stem through the wheel rim. Remove the inner tube.
If you use a screwdriver or any tool other than a tire lever, you
are likely to puncture the tube.
Check to make sure the tire is evenly seated around both
sides of the rim and that the tube is inside the tire beads.
Push the valve stem into the tire to make sure that its base is
seated within the tire's beads. Inflate the tube slowly to the
recommended pressure, all the while checking to make sure
that the tire beads stay seated in the rim. Replace the valve
cap, and install the wheel onto the E-Bike™.
against a brake pad, try turning the brake cable adjusting
barrel(s) clockwise to slacken the cable and open up the
brakes. If the wheel still won't turn, open the brake's quick
release and secure any loose cable as best you can. Walk the
E-Bike™, or if you must, ride it with extreme caution,
because you now have only one working brake.
Riding your E-Bike™ with a flat or under-inflated tire can
seriously damage the tire, tube and E-Bike™, and can cause
you to lose control and fall.
If You Crash
A crash can put extraordinary stress on E-Bike™
components, causing them to fatigue prematurely.
Components suffering from stress fatigue can fail suddenly
and catastrophically, causing loss of control, serious injury or
Broken Spoke
A wheel with a loose or broken spoke is much weaker than a
fully tensioned wheel. If you break a spoke while on a ride,
you will have to ride home much more slowly and carefully
because the weakened wheel could break additional spokes
and become useless.
First, check yourself for injuries, and take care of them as
best you can. Seek medical help if necessary. Next, check
your E-Bike™ for damage, and fix what you can. When you
get home, carefully perform the checks described in Chapter
Three, and check for any other damaged parts. All bent,
scored or discolored parts are suspect and should be
A broken spoke seriously weakens the wheel and may cause
it to wobble, striking the brakes or the frame. Riding with a
broken spoke can cause you to lose control and fall.
Twist the broken spoke around the spoke next to it to keep it
from flopping around and getting caught between the wheel
and the frame. Spin the wheel to see if the rim clears the
brake pads. If the wheel will not turn because it is rubbing
If you have any doubt about the condition of the E-Bike™ or
any of its parts, take it to your dealer for a thorough check.
likely to be comfortable for most buyers of that particular
model. But that doesn’t mean it’s going to be the most
comfortable shape for you. That’s why your dealer stocks
saddles which offer a variety of shapes, padding, covering
materials and prices. If the saddle on your new E-Bike™ is
uncomfortable, ask your dealer to suggest an alternative.
The variety of components and accessories available to
enhance the comfort, performance and appearance of your
E-Bike™ is almost endless. Your dealer can help you select
those that will work best for the kind of riding you do.
Even if you are an experienced rider, read, and understand,
the instructions that accompany the products you purchase
for your E-Bike™. If you have the slightest doubt as to their
suitability or about your ability to install them correctly, ask
your dealer for help.
If you’re planning to spend an hour or more at a time on your
E-Bike™, get a pair of cycling gloves. Their padded palms
help keep your hands from getting numb from the vibration of
the handlebars (the numbness, called carpal tunnel
syndrome, can become quite painful if not taken care of), and
they’ll provide some abrasion protection for your hands if you
Failure to install and operate any component or accessory
properly can result in serious damage to the E-Bike™, and
serious injury or death to the rider.
Cycling shorts and cycling jerseys are both performance and
comfort accessories. There are two kinds of cycling shorts:
the traditional skin-tight Lycra shorts and loose-fit cycling
shorts. Both are designed to reduce friction and chafing. The
washable pad in the crotch of the shorts both cushions and
protects against chafing. Wear them without underwear to
avoid the undergarment’s bunching up and chafing. Also
available are undergarments designed to reduce chafing
when worn with regular street clothes. The jerseys have
pockets in the back, so that the things you carry don’t bang
around when you ride. Many are made of special materials
with properties that improve riding comfort and performance.
Comfort and Convenience Accessories
Once the E-Bike™ fit (frame size, saddle position and angle,
stem length and rise) is correct, the saddle becomes the
single most important comfort accessory.
The comfort of a E-Bike™ saddle depends much more on
how the saddle shape relates to the rider’s body than on the
thickness or material of the padding. Bicycle manufacturers
select a saddle shape based on their best guess of what’s
It’s important to drink plenty of liquids before and during
exercise. A water bottle is an essential companion on a
longer ride.
fully compatible with the rest of the components on
yourE-Bike™. Your dealer can help you determine
component compatibility and resolve compatibility conflicts.
Some basic tools are also useful. The minimum tool kit you
will need to make adjustments, perform maintenance and
handle emergency repairs should include:
• A set of Allen wrenches in 2mm, 4mm, 5mm and 6mm
• A set of tire levers
• A 6-inch adjustable wrench
• A No. 1 Phillips screwdriver and a 1/4 inch flat blade
• A tire pump
• A tire patching kit and a spare tire tube
Another popular way to improve the performance of a EBike™ is to substitute lighter weight racing components.
Lighter wheels, tires, handlebars and so on can enhance the
performance of your E-Bike™; but you must always keep in
mind that light weight racing components are not intended to
have the life expectancy of their heavier counterparts, and
you must therefore exercise extra care in checking for signs
of stress fatigue.
Suspension forks are also a popular component upgrade.
Before installing a suspension fork on a non-suspension EBike™ or installing a fork with different travel or geometry
characteristics, you must make sure that the frame is
designed to take the change in geometry and the changes in
stress characteristics which the change in fork can cause.
Such stresses can result in sudden, catastrophic frame
failure, which can cause serious injury or death.
Performance Upgrades
Changing the components on your E-Bike™ may void the
warranty. To avoid voiding your warranty, check with your
dealer before changing the components on your E-Bike™.
Disc brakes are becoming a more common performance
upgrade. Most front suspension forks are designed to accept
a disc brake, and can take the added stresses at the brake
mounting points. Be sure that the fork you are using is
designed to accept disc brakes. Otherwise, such stresses
The most popular way to improve the performance of a EBike™ is to substitute higher priced drivetrain or brake
components. Before attempting to upgrade your drivetrain or
brakes, make sure that the components you plan to install are
can result in sudden, catastrophic frame failure, which can
cause serious injury or death.
But your dealer's staff can't make decisions for you; nor can
they assume responsibility for your lack of knowledge,
experience, skill or common sense. They can explain to you
how something works, or what part or accessory will meet
your special needs, but they cannot know your questions or
your needs unless you tell them.
Your dealer has many other comfort and performance
accessories that can increase your cycling enjoyment.
If you have a problem with your E-Bike™ or your riding, talk
to your dealer. Make sure that the dealer understands your
problem or question, and make sure that you really
understand the answers.
Your dealer is there to help you get the E-Bike™ and
accessories which are most appropriate for the kind of riding
that you intend to do and to help you maintain your
equipment so that you can get the maximum enjoyment from
it. Your E-Bike™ shop's staff has the knowledge, tools and
experience to give you reliable advice and competent
service. Your dealer carries the products of a variety of
manufacturers so that you can have the choices which best
meet your needs and your budget.
Please contact EV Global Motors at:
800-871-4545 toll-free
818-756-0563 fax
www.evglobal.com or www.ebike.com
1. Performance Specifications:
Top Speed:
Maximum Grade:
-12V, 35 watt, 6000 candlepower, H-3 Halogen
(LE & SX models only) automotive bulb with 45 degree spread angle.
-36 volt, LED array brake and running lights.
-24 volt, 105bd maximum output.
-17.5 mph @ 36 volts, in "P" Performance
-12.5 mph @ 36 volts, in "E" Economy Mode
-12% with a 200 lb. rider plus load
-Over 20 miles with moderate pedal assist
-Over 15 miles with no pedaling, under good
-Over a 25% increase in range in the "E"
Economy Mode.
-0-10 mph in less than 3 seconds with a 200
pound rider.
3. Mechanical Specifications:
Gear Ratio
2. Electrical Specifications:
Battery Life:
-36 Volt, 8-amp hour, Rechargeable, Deep
discharge, Sealed AGM Lead-acid
-Over 250 recharge cycle-life (70% maximum
capacity at termination of useful life)
-Input – 115V VAC, 60/50 Hz, 2 amps
-Output – 36VDC, 1.6 amps
-Trickle charge capability
-Recharge time:
25% - approx. 1 hour
50% - approx. 2 hours
75% - approx. 3 hours
95% - approx. 4 hours
100% - approx. 4.5 hours
-36V Hub, Brushed
-Rated Output, Continuous Power 500 watts
-Digital logic integrated electrical system
management, waterproof.
Crank Arms
Inflation pressure
Bottom Bracket
Zokes Forks
Nitro DH Triple Forks
-170mm (6.7 inches)
-1/2 x 3/32 x 110 L
-26 x 1.95 inch
-55-65 psi (best performance @ 60-65 psi)
-26 x 1.5 inch, double wall
-Rear-36H, 14 gauge stainless spokes
-Front-32H, 14 gauge stainless spokes
-127 mm cartridge
-65 mm travel (LE models)
-75 mm travel (SX and PE models)
EV Global Motors Company
16201 Stagg Street
Van Nuys, CA 91406
818-756-0566 tel / 818-756-0563 fax
P/N: LIT-51000-00-00
Download PDF