Owner’s Manual

Operation and Maintenance Instructions

Wisper 906xc Tourer

April 2010 1 st

edition

Revised August 2010

- 1 -

We strongly recommend that you read this entire manual before using your Wisper bike

Wisper Limited

User Guide

4

5

1

2

3

6

7

8

Introduction

Part 1 Caring for your Wisper bike and pre use checks

Before you set off for the first time

Before each use

Battery care

Recharging your battery

Water

Maintenance and adjustments

Technical specifications and performance

Simple trouble shooting

Part 2 Controls and Equipment

9

10

11

12

13

14

15

Battery on off and battery lock

The LCD functions

The lights

Pedelec mode and assist button

Throttle

Brakes

Handle bar stem

- 2 -

Page 3

Page 4

Page 5

Page 5

Page 6

Page 6

Page 6

Page 8

Page 9

Page 10

Page 10

Page 12

Page 12

Page 13

Page 13

Page 16

16

17

18

19

20

Warranty

The front connection box

Quick release saddle height adjustment

Rims and spokes

Chain and drive wheel

Rear hub

Service contacts

Page 16

Page 16

Page 17

Page 17

Page 17

Page 17

Page 19

Introduction

Thank for choosing a Wisper electric bicycle.

By making the decision to use an electric bike you are helping to safeguard our environment by saving our planet’s precious resources and reducing carbon pollution.

Before you use your Wisper bike it is important that you read this manual carefully.

If there is anything you do not understand completely please contact us.

Please observe traffic regulations, and don’t lend your bicycle to anyone who is unfamiliar with it. The bicycle can only legally be used on the road by a person aged

14 years or older.

We strongly advise you to always wear a cycle helmet when using your bicycle and if you are unfamiliar with cycling to attend a cycle proficiency course prior to using it. Your Wisper Works 905 range is not toy and should be considered a serious mode of transport.

As with all bicycles it is important that you stay within safe limits, if you feel as if you are traveling too quickly for the road conditions you probably are so slow down.

Test your brakes prior to using the bike every time you use it and remember the

- 3 -

bike will not stop as quickly in wet or icy conditions as it would on a dry road.

Before you use the bike for the first time you must make absolutely certain that it has been correctly built. You can do this by either taking it to your nearest cycle engineer or if you are proficient in cycle mechanics inspecting it yourself. In particular you must make sure that the pedals, saddle, handle bars and any self assembly items have been correctly fitted.

NEVER drink alcohol and ride your electric bike. The use of alcohol greatly reduces reflexes and limits your ability to ride safely. Even a very small amount of alcohol will limit your ability to be safe on the road.

Always wear an approved cycle helmet.

When you need to replace your battery please either dispose of it properly or preferably send it back to us or our distributors and we will make sure it is properly recycled.

Happy cycling!

Wisper Ltd

Part 1 Caring for your Wisper bike and checks

Although your Wisper bike has been thoroughly tested prior to delivery, it is very important that you check the bike thoroughly before its first use. Equally important are frequent and regular spot checks they will protect you and your Wisper bike.

Please read this manual carefully. Only once you understand all the functions of this electric bicycle should you attempt to use it.

Your Wisper bike has been transported in a strong seven layers corrugated carton, to save space it has been delivered with the front wheel, handlebars, seat post and seat, rear rack and pedals ready for assembly with the tool kit provided.

Your retailer may have assembled your bike for you if not you will find assembly instructions on the Wisper website www.wisperbikes.com

1 Before you set off for the first time

1.1 Check the handle bars and handle bar stem are properly tightened

- 4 -

2.4

2.5

2.6

2.7

Check brake functions

Check electronic functions

Check reflectors are in place and lights are working

Check your battery for any visible signs of damage

3 Battery care

3.1

charge

Before you use the battery for the first time it is best to give it a full deep for 12 hours. To fully condition your new battery give it complete deep charge, and discharge cycles for the first three charges. This is achieved by charging your battery for 12 hours and then using the bike until the battery is completely drained. After this “conditioning” process you can then charge and discharge the battery as and when you require for long or short periods.

3.2 If you are going to leave your battery uncharged for more than eight weeks it is best left half charged. You should then re charge it every four weeks for two hours to keep it in top condition.

3.3 Before setting off on any journey it is always better to have a fully charged battery.

3.4 Always remember that you use up to three times more power when setting off using the throttle. To preserve the life of each charge always set off using pedal assist.

3.5 Do not expose the bicycle or battery pack to fire, heat sources, acid or alkaline substances.

3.6 When leaving your bicycle during hot weather always leave in a shaded well ventilated area

3.7 For best results always recharge the battery at room temperature

3.8 Before unloading the battery make sure it is turned off at the key, then raise the saddle and unload the battery using the battery handle

3.9 If your battery is damaged or appears to be overheating for any reason immediately return it to your dealer for advice and a safety check

4 Recharging your battery

4.1 Make sure the charger is turned off and connect the charger to your battery.

Then turn on the charger. Red and yellow lamps on the charger indicate the battery is charging. When the yellow light turns green the battery is fully charged. Always turn off the charger and disconnect from the mains after charging. Always disconnect the charger from the mains before

- 6 -

disconnecting the charger from the battery. It is possible that the battery will take up to 12 hours to charge on the first three charges.

4.2 When charging the battery always do so in a well ventilated area.

4.3 Do not leave the charger connected to the mains when not in use.

5 Water

5.1

Your electric bicycle is rain and splash proof and can be used in all weathers.

5.2 The electrical components of the vehicle, such as motor, battery, and controller, must not be submerged in water.

6 Maintenance and adjustments

6.1 IMPORTANT! Do not attempt to open the casings of the battery, motor or controller. It could be dangerous and all warrantees will become void. If you experience a problem contact our service department or your dealer.

6.2 Wheel spokes should be adjusted after 300 miles riding. The handlebar stem and saddle seat post should never be raised beyond the maximum indicated by a safety line around the tubes. The recommended torque settings are as follows:

(A) Front motor axle nuts. 46 Nm

(B) Back axle nuts. 45 Nm

(C)Handlebar stem expander bolt. (18 to 20)Nm

(D)Seat pillar clamp nut/bolt. (5-8) Nm

(E)Seat clamp nuts. 24 Nm

(F) Gear shifter nuts. 4 Nm

(G) Rear carrier nuts. 8 Nm

(H) Mudguard bracket nuts 8 Nm

Other nut torque depends on the nut size. M4：2.5-4.0 Nm M5：4.0-6.0

Nm M6：6.0-7.5 Nm

6.3 Your bike has a low maintenance SHIMANO 8 speed Alfine gear box

6.4 The brake leavers should lock the wheels when compressed half way between their open position and touching the handle bars. When they need adjusting please follows the procedure in section 14

6.5 Warning: Handlebar hand grips or tube end plugs should be replaced if damaged, as bare tube ends have been known to cause injury.

6.6 Warning: Any replacement forks must have the same rake and same tube inner diameter as the originally fitted to the bicycle.

6.7 Disc brake pad wear and replacement. Remove the brake pads and check them for wear. If they have

- 7 -

worn to the point where the caliper piston pin-positioning hole goes all the way through, then they need to be replaced.

IMPORTANT braking distances increase on wet or icy roads.

6.8 Lubrication:

Every three months lubricate the chain with light oil

6.9 Recommended tools for proper maintenance:

Torque wrench with lbin or Nm graduations, 2, 4, 5, 6, 8 mm Allen wrenches

9, 10, 15, 17 and 19 mm open-end wrenches, 14 mm box end wrench

Socket wrench, 14, 15, and 19 mm socket. T25 Torx wrench

No. 1 and 2 Phillips head screwdriver Bicycle tube patch kit, tyre pump

7 Technical specifications & performance

Type

Performance

Assisted range

Wisper 906xc Tourer

(with 75kg 165lb rider)

8A up to 50km

14A up to 70km

Battery only

8Ah up to 38km

14Ah up to 50km

Maximum speed 25kph (15.5mph)

Weight with 14Ah battery 25.2kg max

Maximum load 130kg (240)

- 8 -

Battery specifications

Cell Type

Capacity

Nominal voltage

Advanced Environmental Lithium Polymer with BMS

8Ah or 14Ah

37V

Main Controller specifications

Low voltage safeguard 31.5V

Overload current safeguard 15A

Main hub motor specifications

Motor type

Rated power

Rated voltage

Hi speed brushless

Aus NZ 200W / Europe 250W / USA Canada 350W

36V

Charger

Lithium 115 to 230V 36V fan cooled

- 9 -

8 Simple Trouble shooting

Problem

Top speed too slow

Possible reasons

1. Low battery voltage

2. Handle bar control problem

3. Damage to motor driveline

Trouble shooting

1. Recharge battery fully

2. Call service

3. Call service

Power on but motor not working

Driving shorter distance per recharge

1. Battery not connected

2. Battery fuse blown

3. Motor connection damaged

4. Handle bar control problem

5. Brake cut out switch faulty

1. Tyre pressure too low

2. Undercharge or charger fault

3. Battery capacity loss or damage

4. Hill climbing, frequent stops, strong head winds, over loading

1. Re install battery

2. Replace lower fuse in battery

3. Call service

4. Call service

5. Call service

1. Check pressures

2. Recharge completely or have charger inspected

3. Replace battery

4. Use power assist and try and avoid throttle only

LCD diagnostics 02 flashes

03 flashes

04 flashes

05 flashes

07 flashes

08 flashes

09 flashes

Motor current is too high.

Motor cable connections may be loose.

Battery voltage is too low.

Brake lever cut out function problem.

Throttle faulty

Controller faulty.

Battery output voltage is too high.

- 10 -

Part 2 Controls and Equipment

In this section we will describe the functions and any specific maintenance needed on all the main controls and ancillary equipment.

9 Battery on off and battery lock

9.1 Your Wisper bike has one key. The key turns the battery on/off and locks the battery in the bike. Please keep a careful note of the key numbers as we cannot replace them without these numbers should they become mislaid.

9.2 The battery is connected to the electrical system of the bike automatically when you slide the battery into the frame. To turn on the bike electrical system, turn the key in the battery clockwise, to turn off the power turn the key anti clockwise.

9.3 When the battery has been turned on the bike is now ready for use. The

ON/OFF button on the handle bar display unit isolates the power from the bike. When the bike is “on” you will see the LCD display illuminated. When the ON/OFF button is pushed and the LCD shut down you have turned the bike “off”. When the bike is “off” you will not get any assistance from the battery and motor and the bike is effectively simply an unpowered push bike.

9.4 To lock the battery into the bike frame turn the key clockwise until the locking bolt engages with the frame. If you want to turn the battery power on, turn clockwise again. If you want to unlock the battery press the key and turn the key anti clockwise. (Refer the picture). See section 3 and 4 for battery care and advice on charging at the beginning of this manual.

9.5 The battery can be charged either on or off the bike.

9.6 To remove the battery turn off the power by turning the key to position

“Unlocking”, raise the seat post to its maximum height. Using the handle on top of the battery lift out the battery.

9.7 To replace the battery reverse the procedure for removing it.

10LCD display functions

10.1

The LCD display has the following functions (Refer to picture below).

A: Power ON/OFF button. For details see paragraph below.

B: Up (increase) adjusting button. For adjusting the pedal assistance strength and back light brightness.

- 11 -

C: Down (decrease) adjusting button.

D: Set. When pressed, you can set the back light of the LCD and the single trip distance. If you press it together with C button, you can set the bike’s tyre size.

E: This shows the instant power consumption. A longer bar indicates the motor output is higher.

F:

F: Battery capacity. Three bars indicate 80% capacity, two bars indicate

70%, one bar indicates 55% capacity, and half bar indicates 5% capacity left.

G: Instant speed figures.

H: Pedal assistance strength levels.

I: Total riding range.

10.2

When the ON/OFF button is pushed and the capacity indicator goes out you have turned the bike “off”. When the bike is “off” you will not get any assistance from the battery and motor and the bike is effectively an unpowered push bike. To turn the power back on so the pedelec and throttle work again simply press the ON/OFF button once, the capacity indicator will illuminate showing the power is on.

10.3

How to adjust functions:

10.3.1

How to adjust the pedal assistance. Refer 12.2, 12.3 and 12.4

paragraphs.

10.3.2

How to adjust the back light of the LCD. Press the “set” button once, you will see a light symbol added under the battery capacity indicator, then press the “up arrow” to turn the back light on. The more times you press the brighter back light you will get.

Refer to above picture.

- 12 -

10.3.3

How to read the single trip distance. Press the “set” button twice; you will see a symbol in the left side of the screen.

10.3.4 How to read the single trip riding time. Press the “set” button three times; you will see a clock symbol in the left side of the screen. This display does not provide the time of day – simply elapsed riding time.

11The LIGHTS

11.1

The front light is an automatic sensor light.

When you turn the power on, it checks the brightness of the surroundings. It will light when you ride the bike in low light conditions. It will turn off after 30 seconds when the ambient light increases.

11.2 The rear light is fitted with AAA batteries. You can turn the light switch on using the switch

(in the right hand side of the light). For your safety, please always turn it on in low light conditions!

12 Pedelec mode and ASSIST mode

12.1

When you first ride your 906xc you will notice that after one turn of the pedals the motor will start working, assisting you ride the bike by adding power to the front wheel. This is the standard or pedelec mode. To continue using the pedelec mode you must keep turning the pedals. If you stop the motor will stop and the bike will slow to a halt. If you start pedaling again after one turn the motor will start again.

12.2

You will find the ASSIST level shows on the LCD display. You can adjust the assistance strength by pressing the up or down arrow. There are 6 levels of assistance（

40%/50%/60%/70%/90%/100%

.

12.3

70%, 90% and 100% mode are generally used when you need a greater amount of assistance from the motor. 60% mode is used when you do not need the instant power of 90% or 100%. 40% and 50% are used in high traffic situations or poor conditions such as ice and snow when 70%, 90% and 100% power could be dangerous.

- 13 -

12.4

Power consumption. When you increase the assistance, you will find the battery range is reduced

- 14 -

13Throttle

13.1

The throttle can be used independently to the pedelec mode but the operation will vary depending on the country where the bike is supplied.

Bikes are set up to be legal in the region in which they are supplied and will either provide full power (100%) or power up to 4 mph (6kph) (walkalong mode) independently of the pedelec.

13.2

The independent use of the throttle, when available, will enable you to use the throttle without pedaling.

13.3

The use of the throttle in pedelec mode is legal in most countries. Throttle in pedelec mode enables you to turn up the power to the motor as long as you are pedaling the bike, if you stop pedaling the motor will stop too. If you have the pedelec mode set too Low, you can increase the assistance from the motor from 40% to 100% of available power simply but turning the throttle towards you.

IMPORTANT Make sure your throttle grip and the grip on the left hand side of your handlebars are always intact, in good condition and on the bike. Uncovered handlebar tubes can be very dangerous in case of a collision.

14Brakes

14.1

Front: Disc Rear: Disc

14.2

The brakes on your Wisper bike are fitted with cut outs which are required by law. This means that when you pull on either the back or front brake lever the motor immediately stops working.

14.3

Full details of how to adjust and maintain your brakes are as follows:

Once a month, inspect brake pads for wear. If the grooves in the braking surface are less than 1.0mm deep replace the pads.

Front disc:

Mechanical disc brakes offer several advantages over traditional rim brakes better braking in wet, muddy or other adverse conditions, less braking power fade over extended downhill braking and the ability to continue braking even if your rim becomes bent or distorted.

14.3.1.

To adjust the pads and caliper:

14.3.1.1.

Use a 3mm Allen wrench to adjust the stationary caliper adjusting bolt at the back (hub side) of the caliper. Adjust the

- 15 -

bolt so that there is 0.3mm clearance between the stationary

(hub side) pad and the rotor.

14.3.1.2.

Adjust the cable tension to the desired modulation by tightening/loosing the tension modulation adjuster bolt on the caliper with a 5mm Allen wrench

14.3.1.3.

Adjust the cable adjuster bolt on the caliper So that there is

0.3mm clearance between the outside pad and the rotor. Turn this bolt in a clockwise direction to provide more clearance, and anti-clockwise for less clearance.

14.3.2.

Removing and installing pads.

Caution: The pads and rotor must be kept clean and free from oil or grease based contamination. If the pads become contaminated you must discard them and replace them with a new set. A contaminated rotor should be cleaned with brake cleaning solvent and dried.

14.3.2.1.

Unscrew the caliper’s two screws fixed in front fork. Pads can be removed by releasing the pin which goes through the pads and then maneuvering pads out of rotor slot. Straighten the pin or replace with a new item if damaged.

14.3.2.2.

Holding the pad end-tab, insert it into caliper slot with its metal backing towards the piston. Make sure the hole in the metal backing goes over the piston pins. When correctly inserted, the pad will be held in place magnetically, repeat the procedure for the other pad. Refit the caliper following the reverse procedure.

- 16 -

Rear disc:

14.3.3. Adjust the pads and caliper

14.3.3.1.

Use a 3mm Allen wrench to adjust the stationary caliper adjusting bolt at the back (hub side) of the caliper. Adjust the bolt so that there is 0.3mm clearance between the stationary (hub side) pad and the rotor.

14.3.3.2.

Adjust the spring tension to the desired modulation by tightening/loosing the tension modulation adjuster bolt on the caliper with 5mm Allen wrench

14.3.3.3.

Use a 3mm Allen wrench (Refer picture) to adjust the left side caliper’s pad 0.3mm clearance between the rotor.

14.3.4. Removing and installing pads.

14.3.4.1.

Unscrew the two caliper screws fixed in the rear fork.

Remove the clip (Refer 14.3.3.1

picture), and then unscrew the bolt shown in picture. Then maneuver the pads out of the rotor slot.

14.3.4.2.

Holding the pad end-tab, insert it into caliper slot with its metal backing towards the piston. Make sure the hole in the metal

- 17 -

backing goes over the piston pins. When correctly inserted, the pad will be held in place magnetically, repeat the procedure for the other pad. Refit the caliper following the reverse steps above.

Warning: If you are unsure about any part of the installation process you should seek advice from a Wisper service center or qualified mechanic.

15 Handle bar stem

15.1

Your bike has been fitted with an adjustable handlebar stem that allows you to change the position of the bar to find the most comfortable riding position.

15.2

The stem and handle bars need to be fitted before you use the bike.

15.3

To fit, insert the stem into the front tube at least to the position of the

“Minimum insertion” mark.

15.4

Tighten the quill bolt and fix stem.

15.5

Adjust stem to preferred angle and tighten the side BOLT

15.6

Test the bars to make certain they are tight and do not rotate. If they are not tight enough, repeat until the handle bars are tight and safe.

16 The front connection box

16.1

The front connection box allows for the easy removal for repair or replacement of any of the electronic components on the handle bars.

17 Quick release saddle height adjustment

17.1

Your Wisper bike has been fitted with a quick release saddle post collar to facilitate the movement of the saddle to remove the battery or to change the riding position.

17.2

It is important that the nut on the collar is tightened so the post will be

- 18 -

gripped firmly when the lever is closed. Make this adjustment with the quick release lever in the open position.

17.3

Adjust the seat to the correct height and close the lever. When you sit on the saddle there should be no vertical movement at all in the saddle post.

IMPORTANT never raise the saddle past the point where the maximum marks on the saddle post are visible above the quick release collar

18 Rims and spokes

18.1

It is essential to get your spokes checked and tightened after 300 miles.

This is a free service provided by your supplier. If this service has not been undertaken at the correct time this may cause damage to the wheels and spokes that will not covered under our guarantee.

19Chain and drive wheel

20.1

The chain and drive wheel are made from rust proof materials.

20.2

Lightly oil with bicycle chain with oil at least once a month.

20Gear hub

21.1

Your Wisper bike is fitted with the premium quality 8 speed SHIMANO

Alfine gear box. You can adjust it by the rapid fire shift lever even when the bike is stationary. Under normal conditions no maintenance is required.

Warranty

Repair or replacement of components

IMPORTANT To validate this Warranty the retail customer must register the bike at www.wisperbikes/mywarranty within 14 days of purchase.

Only use this product in accordance with this user manual. We offer a limited warranty of on the following items.

- 19 -

6

7

8

9

1

2

3

4

5

The main frame

Gears, bearings, motor shell, hub motor, front forks

Handle bar controls, brakes (excluding brake shoes and pads)

Controller and Charger

Battery casing, battery leak, battery capacity step-down by more than

25%

Paintwork (excluding deliberate or accidental damage)

Front and rear axle, bottom bracket and chain wheel

Plating and paint, on wheel rims, rack and kickstand

Other cases that render the bike unsafe to use.

Six years

Two years

One year

Two years

Two year

Two years

One year

Six months

By negotiation

1. If the product has a quality fault within 15 days of delivery the part will be repaired or replaced or in exceptional circumstances we may replace the whole vehicle.

2. The period of assurance shall commence from the day delivery was made to the retail customer, or from the day the retail customer collected the bike from the retailer.

3. To validate this Warranty the retail customer must register his / her bike at www.wisperbikes/mywarranty within 14 days of purchase.

Exceptions to Limited Warranties

1. Damage resulting from misuse, not maintaining the vehicle or not following the guidelines within this user guide

2. Accidental or deliberate damage

3. Damage due to private repair or alteration by user or unauthorised service centre.

4. Failure to produce invoice or proof of purchase.

5. Spare parts and components worn in normal use.

6. Failure to register your bike at www.wisperbikes/mywarranty within 14 days of purchase.

It is essential to get your spokes checked and tightened after 300 miles. This is a free service provided by your supplier. If this service has not been undertaken at the correct time this may cause damage to the wheels and spokes that will not covered under our guarantee.

- 20 -

Service through

Your retailer or

Wisper Ltd

10 Oakenbrow

Sway

Hants

SO41 6DY

Tele:01590 681553

Mobile:07977 185830 [email protected]

www.wisperbikes.com

Copyright April 2010 Wisper Ltd

- 21 -