Owner`s Manual

Transcript

OWNER’S MANUAL Important Safety and Product Information EVELO.COM WELCOME! TABLE OF CONTENTS Welcome! 3 Contact Information 3 Unboxing Your Evelo Electric Bicycle 4 Registration 5 Warranty 5 Battery Care and Maintenance 8 Assembly 10 Aries 11 Aurora 18 Luna 25 Orion 32 Riding Your EVELO Electric Bicycle 39 Maintenance 45 Troubleshooting 47 Congratulations on the purchase of your new, powerassisted electric bike from EVELO Electric Bicycles! This manual is designed to give you an understanding of the basic operation and maintenance of this bike. We believe that great customer service is part of your purchase, so please reach out to us if you ever need guidance or assistance. The latest version of this Owner’s Manual is always available at http://www.EVELO.com/ownersmanual.pdf. We suggest that you read this manual in its entirety before using your bicycle. Because Continuous Improvement is a key operational philosophy at EVELO Electric Bicycles, some images and descriptions in this manual may differ slightly from the bike you have. Riding a bicycle is an inherently dangerous activity, and it is your responsibility to ride safely and within your abilities. Proper assembly is vital to the safe operation of your bicycle, so seek professional assistance if you are unable to complete the assembly of your bicycle as outlined in this manual. Our bicycles have been tested and recommended for use by riders weighing 250 pounds (113 kilograms) or less. CONTACT INFORMATION Your enjoyment of — and satisfaction with — your new bike is important to us. For aftersales service, please contact us by email at [email protected] or call our toll-free tech support line at 1-877-991-7272. 2 EVELO.COM EVELO.COM 3 LET’S GET STARTED - UNBOXING REGISTERING YOUR NEW ELECTRIC BICYCLE NOTE : After unboxing, we recommend that you retain the original packaging for a short period of time and keep it as intact as possible. Please fill out the warranty form located on our website at http://www.evelo.com/warranty-and-returns/registration/ to register your bicycle. Since the bikes are heavy, take care in removing the bike from the box. Enlist the assistance of a second person if you intend to lift the bike up and out of the box. An alternative method is to lay the box on its side and slide the bike out. Registration is required before we can process a warranty claim. Registration is also a great security feature. Each bike has two unique serial numbers — one for the frame and the other for the motor — which the authorities can use to identify your bike if it is stolen. There are some plastic pieces used as protective packaging (e.g., a spacer placed between the front fork, an axle protector on the front wheel). These are not needed for assembly of the bicycle. The frame’s serial number is located on the head tube, just above the front fork. The motor’s serial number is on the top of the motor housing. Take your time cutting the zip ties used to hold the packaging to the bike. There are some similar-looking zip ties that are used to secure wires to the frame — do NOT cut ties that are holding wires in place. Locate and open the smaller box containing the charger prior to beginning assembly as some other smaller parts have been packed in that box. The battery lock key number is stamped on the key itself, and may be useful if replacement is required. Please take a moment to write your serial numbers here and keep a record in a safe place: MOTOR SERIAL NUMBER: ................................................................ FRAME SERIAL NUMBER: ................................................................ Included with your bike are the following: • EVELO Owner’s Manual • Display Panel Manual • 2 Keys • Left + Right Pedals • Front Fender and Mounting Bolt(s) • Charger Warranty Overview • Assembly Tool Kit Every EVELO Electric Bicycle comes with an 18-month warranty against manufacturing defects in materials or workmanship on its frame, battery, controller, and motor assembly. • Front Quick-Release Skewer 4 WARRANTY This warranty applies only to the original registered owner of the EVELO bicycle and is not transferable. This limited warranty does not apply to normal wear and tear, EVELO.COM EVELO.COM 5 malfunctions, or failures due to abuse, neglect, improper repair, improper maintenance, alteration, modification, accidents, or other improper use. It is important that you register your new bicycle within 30 days after purchase in order to activate the warranty. • Original Batteries – are warranted to be free from defects in material or workmanship for a period of 48 months from the date of purchase as follows: full replacement during the first 24 months, while replacements needed during months 25-48 are prorated as per the schedule listed on www.evelo.com Other Components – are warranted by the individual manufacturers as follows: • NuVinci® drivetrain – 24 months • Suspension forks – 24 months • Wheels – 24 months Terms of the Warranty For your reference, we’ve outlined the comprehensive terms of the warranty below: • Frame, Battery, Controller, and Motor Assembly — are warranted to be free from defects in material or workmanship for a period of 48 months from purchase. After any warranty period has elapsed, you may purchase spare and replacement parts by contacting us. • Replacement Batteries (if provided) — are warranted to be free from defects in material or workmanship for a period of six (6) months from purchase. • Other Components — are warranted by the individual manufacturers. Please note that while every effort is made to provide our customers with a superb shopping experience, issues sometimes can arise during shipping. If any parts of your bicycle have been damaged during shipping, EVELO will send a replacement part at our expense and will work with you or the bike shop of your choice to fix the issue at no cost to you. For warranty issues, EVELO will cover the cost of labor involved in handling the warranty service within a 30-day period after purchase. To receive this service, the customer needs to bring the bike to the authorized EVELO Full Service Dealer from which the bike was purchased. If the bicycle was purchased on the website, EVELO will help to arrange an appointment at a bike shop near the customer to investigate and resolve the issue. If a part or component is faulty, please contact us by email and provide a video or photo of the faulty part. After the 30-day free labor period for repairs, the customer will be responsible for labor costs associated with warranty replacements. For any parts under warranty that need to be replaced within the 48-month time frame, EVELO will cover the cost of freight to the customer. 6 EVELO.COM Limited Remedy: Unless otherwise provided, the sole remedy under the above warranty, or any implied warranty, is limited to the replacement of defective components and parts with those of equal or greater value at the sole discretion of EVELO. Unless this falls within the 30-day free labor repair period, the customer is responsible for labor costs associated with warranty replacements. In no event shall EVELO be responsible for direct, incidental or consequential damages, including, without limitation, damages for personal injury, property damage, or economic losses, whether based on contract, warranty, negligence, product liability, or any other theory. Some states do not allow the exclusion or limitation of damages, so the above limitation or exclusion may not apply to you. Exclusions: The above warranty, or any implied warranty, does not cover normal wear and tear. All warranties are void if the electric vehicle is used for other than normal activities, including, but not limited to, failing to follow the owner’s manual or using the electric vehicle for commercial activities or in competitive events, and training for such activities or events. EVELO makes no other warranties, express or implied. All implied warranties, including the warranties of merchantability and fitness for a particular purpose, are limited in duration to that of the express warranties stated above. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. EVELO.COM 7 BATTERY CARE & MAINTENANCE The battery provided with your EVELO Electric Bicycle is a high-quality unit that requires very little from the user in terms of care. However, a few things are worth noting with respect to any Lithium Ion battery. Battery Charging To maximize the lifespan of your battery, we suggest an initial conditioning charge of 12 hours. After that, connect it to the charger as needed. While there is no need to recharge the battery following short trips, we recommend not leaving a battery partially discharged — and especially not completely discharged — for extended periods of time. A typical charge takes 4-6 hours (longer in very cold temperatures) to complete. The battery will perform best if you do NOT leave it plugged in constantly, since charging / discharging keeps the electrons in the unit moving, which improves longevity. A note about the lock: it is a theft deterrent, NOT an electrical switch. Powering the bike on is accomplished with the controls on the handlebars. See your Display Manual for more information. Using Your Charger The charger that comes with your bike has internal controls that prevent overcharging of the battery. First, plug the charger into the battery. Then connect the wire connections at the charger block and make sure the cord is fully seated. Then plug it into a 120v AC outlet. The light on the charger should be RED, and that light will change to GREEN when the battery is fully charged. We do not recommend leaving the unit plugged in for extended periods of time. In addition, we do not recommend using the charger unit in poorly ventilated spaces such as closets or drawers, as it may overheat. Connect your battery to the charger as shown: Environmental Conditions Temperature extremes can affect your battery. Please keep it within the following temperature ranges, as suggested by the battery manufacturer. Charging: 32 degrees to 113 degrees F (0 degrees – 45 degrees C) Discharging and Storage: -4 degrees to 140 degrees F (-20 degrees to 60 degrees C) ARIES AURORA CHARGER CONNECTIONS Battery Storage If you store your battery for 30 days or longer, it is suggested that you keep it in a place that is within the above temperatures and give it a full 12-hour conditioning charge every 30 days. Removing the Battery From the Bike You can easily remove the battery from the bike if desired. First, unlock the battery. For the Aries/Aurora, simply lift the battery straight up — some friction is expected. For the Luna/Orion, slide the battery rearward — again, some friction is expected. LUNA ORION CHARGER CONNECTIONS 8 EVELO.COM EVELO.COM 9 ASSEMBLY OF YOUR EVELO ELECTRIC BICYCLE Overview ARIES The models in our line are very similar, but do have some differences, especially when it comes to assembly. NOTE : If you do not have the ability or skill to assemble the bicycle yourself, please take it to a local bike shop for professional assembly. MODEL You should have received an email containing an assembly video after you placed your order. Contact us if you would like that video re-sent. In addition, our Customer Service Team can help guide you through the process if needed. Tools to complete the job are included, and some of the smaller pieces are packed inside the charger box to prevent loss. Proper assembly is extremely important for the safe and smooth operation of your electric bicycle. Please read through the entire assembly instructions before beginning. Once again, if you do not feel comfortable assembling the bicycle yourself, please take it to a qualified bicycle mechanic. The following are assembly directions for each of the four EVELO models. Find and follow the specific directions for the model of electric bicycle you have purchased. 10 EVELO.COM EVELO.COM 11 ASSEMBLY ARIES STEP 2 : ATTACH FRONT FENDER 1. Locate the special threaded nut on the underside of the fork that has been installed at the factory. 2. Using the wrench and bolt provided, install the fender from the underside of the fork. STEP 1 : INSTALL FRONT WHEEL 1. The front wheel is attached to the bike with a quick-release type of skewer. After locating the skewer, remove the nut on the end opposite the lever, and slide one of the conical springs onto the skewer — wide-end first. 2. Once the spring is against the lever’s nut, slide the skewer through the axle so that the lever is on the same side as the brake disc. 3. 4. 5. Now slide the second spring onto the skewer — narrow-end first — then screw the nut partially back on. Place the wheel into the fork, taking care to make sure the disc goes into the brake caliper. STEP 3 : ATTACH HANDLEBARS 1. Remove the two bolts that hold the handlebar clamping bracket on. 2. While taking care to keep the wires and cables as straight as possible, place the center of the handlebars into the bracket and replace the bracket. 3. Tighten the bolts evenly. 4. Loosen the two bolts that clamp the handlebar stem to the steer tube, and align the handlebars with the front wheel. 5. Firmly re-tighten the two bolts. Note: Do not loosen the bolt located in the top-center of the metal cap. With the axle fully seated into the fork dropouts (the slots that accept the axle), and the lever in the OPEN position, turn the nut to adjust the clamping pressure, and swing the lever rearward to the CLOSED position, where you will feel noticeable resistance. The lever should leave a slight impression in your hand, and the lever should be parallel to the center-line of the bike when adjusted properly. FIG 1A. QUICK RELEASE SKEWER FIG 1B. BRAKE ARCH CRITICAL : If the wheel is oriented correctly, the brake arch (the painted portion of the fork that bridges the two fork legs) of the front fork should be rotated FORWARD, as in the photo. You can now lower the kickstand to keep the bike upright for the remainder of the assembly. 12 FIG 2. FENDER BOLT ARIES MODEL ARIES MODEL 13 STEP 4 : INSTALL HEADLIGHT 1. Attach the headlight to the front fender bracket, taking care to run the wires as cleanly as possible. 2. Remove the single bolt from the light, keeping the nut in place. 3. Install the light on the bracket located on the front fender, insert the bolt, and tighten securely. FIG 6. HEADLIGHT ATTACHMENT STEP 5 : CHECK BRAKE INSTALLATION 1. Follow each brake cable, starting at the brake lever. Make sure that the brake housing (the sheathing that the cable runs through) is fully seated into the cylindrical hole at the brake lever, as shown in Fig. 8 on the next page. Fig. 9 shows a dislodged housing, which occasionally occurs during shipping and handling. 2. Check the housing at the brake caliper end as well — it also should be seated into the hole in the brake. 3. Repeat for the other brake. STEP 6: INSTALL PEDALS Keep in mind that the left and right pedals are threaded differently, and it is crucial that they are installed on the correct side of the bicycle. For this reason, they are marked “L” and “R” with stickers at the factory. 1. Locate the right-side pedal (marked with an “R”). 2. Thread the “R” pedal clockwise onto the drive-side crank (side of the bike with gears). 3. Tighten the “R” pedal clockwise with a 15 mm wrench or the wrench provided. 4. Locate the left-side pedal (marked with an “L”). 5. Thread the “L” pedal COUNTER-CLOCKWISE* onto the non-drive-side crank (side of the bike without gears). 6. Tighten the “L” pedal COUNTER-CLOCKWISE with a 15 mm wrench or the wrench provided. *NOTE : The left and right pedals are not interchangeable. The left (“L”) pedal and crank are REVERSE-THREADED so that the pedal will not come loose while riding. To TIGHTEN the left pedal, turn COUNTER-CLOCKWISE. To LOOSEN it, turn CLOCKWISE. STEP 7 : INSTALL & CONNECT BATTERY 1. Once the battery has been fully charged (see section “Battery Care and Maintenance” on Page 8), simply lower it straight down into the frame. Fully push the large, three-pronged plug on the right side of the bicycle into the socket in the battery. FIG 10. BATTERY SOCKET FIG 8. CORRECT BRAKE HOUSING 14 FIG 9. INCORRECT HOUSING ARIES MODEL ARIES MODEL 15 2. Using your key, lock the battery — this will help stabilize it when riding and also provide some anti-theft security. The lock is located on the left side of the battery case. 2. Raise or lower the stem to the desired angle. 3. Finish by re-tightening the bolt located underneath the handlebars (the one indicated by the arrow in the photo above). 4. Depending on how much you moved the stem, you may want to rotate the handlebars themselves, especially if you need to correct the angle of the brake levers. Just loosen the two bolts that clamp the handlebar, rotate it to the desired position, and re-tighten the bolts. (This is described in the above section, “Attach Handlebars.”) 5. Double-check all bolts to make sure they are tight. FIG 11. KEY LOCK FIT ADJUSTMENTS ARIES Many parts of your new EVELO Electric Bicycle can be customized for a personalized fit. Seat Adjustment The seat is easily adjusted up or down by flipping the quick-release lever that clamps the post into the bike. Note that there is a “minimum insertion line” stamped on the seat post that must be adhered to for safety’s sake. (If you need your seat to be higher than permitted with the stock seat post, please contact us.) Front Shock Please consult the manual provided by the manufacturer. Rear Shock To make the ride firmer and lower the frame slightly, grasp the barrel of the shock and rotate in the direction of the Orange arrow (shown in Fig. 13) to compress the internal spring. Alternatively, rotate in the direction of the Blue arrow to relax the spring, which will increase the “travel” of the shock and soften the ride, raising the frame slightly. If your Aries is equipped with an Air Shock, firmness is adjusted through the use of a special pump by adjusting air pressure in the shock. The Valve is located under the cap shown below. Please consult your shock manual for more information. The seat can also be moved forward and backward by loosening the single bolt on the underside of the seat. Since it slides on its rails, there is no need to remove the bolt — just loosen it, adjust, and firmly re-tighten. Loosening this bolt also lets you change the angle of the seat up or down a bit. Again, be sure to re-tighten it firmly if you loosen it to change the seat position in any way. FIG 13. REAR SHOCK ADJUST Tire Inflation The tires have a range of recommended inflation of 40-65 psi. This range is also indicated on the sidewall of the tire. Lower pressure will give a softer ride. A higher pressure will provide a firmer ride, but will give the best range per battery charge. 16 ARIES MODEL ARIES MODEL 17 ASSEMBLY AURORA STEP 1 : INSTALL FRONT WHEEL AURORA MODEL 1. The front wheel is attached to the bike with a quick-release type of skewer. After locating the skewer, remove the nut on the end opposite the lever, and slide one of the conical springs onto the skewer — wide-end first. 2. Once the spring is against the lever’s nut, slide the skewer through the axle so that the lever is on the same side as the brake disc. 3. Now slide the second spring onto the skewer — narrow-end first — then screw the nut partially back on. 4. Place the wheel into the fork, taking care to make sure the disc goes into the brake caliper. 5. With the axle fully seated into the fork dropouts (the slots that accept the axle), and the lever in the OPEN position, turn the nut to adjust the clamping pressure, and swing the lever rearward to the CLOSED position, where you will feel noticeable resistance. The lever should leave a slight impression in your hand, and the lever should be parallel to the center-line of the bike when adjusted properly. FIG 1A. QUICK RELEASE SKEWER FIG 1B. BRAKE ARCH CRITICAL : If the wheel is oriented correctly, the brake arch (the painted portion of the fork that bridges the two fork legs) of the front fork should be rotated FORWARD, as in the photo. You can now lower the kickstand to keep the bike upright for the remainder of the assembly. 18 AURORA MODEL AURORA MODEL 19 STEP 2 : ATTACH FRONT FENDER STEP 4 : INSTALL HEADLIGHT 1. Locate the special threaded nut on the underside of the fork that has been installed at the factory. 1. Attach the headlight to the front fender bracket, taking care to run the wires as cleanly as possible. 2. Remove the single bolt from the light, keeping the nut in place. 2. Using the wrench and bolt provided, install the fender from the underside of the fork. 3. Install the light on the bracket located on the front fender, insert the bolt, and tighten securely. FIG 2. FENDER BOLT STEP 3 : ATTACH HANDLEBARS 1. Remove the bolts that hold the handlebar clamping bracket on. 2. While taking care to keep the wires and cables as straight as possible, place the center of the handlebars into the bracket and replace the forward portion of the bracket. 3. Tighten the bolts evenly so there is equal space at the front and rear of the bracket. Firmly tighten both of the bolts. FIG 6. HEADLIGHT ATTACHMENT FIG 3. CLAMPING BRACKET 4. 5. STEP 5 : CHECK BRAKE INSTALLATION 1. Loosen the two bolts that clamp the handlebar stem to the steer tube, and align the handlebars with the front wheel. Follow each brake cable, starting at the brake lever. Make sure that the brake housing (the sheathing that the cable runs through) is fully seated into the cylindrical hole at the brake lever, as shown in Fig. 8 on Page 22. Fig. 9 shows a dislodged housing, which occasionally occurs during shipping and handling. Firmly re-tighten the two bolts. Note: Do not loosen the bolt located in the top-center of the metal cap. 2. Check the housing at the brake caliper end as well — it also should be seated into the hole in the brake. 3. Repeat for the other brake. FIG 5. STEM CLAMP BOLTS 20 AURORA MODEL AURORA MODEL 21 2. FIG 8. CORRECT BRAKE HOUSING Using your key, lock the battery — this will help stabilize it when riding and also provide some anti-theft security. The lock is located on the left side of the battery case. FIG 9. INCORRECT HOUSING FIG 11. KEY LOCK STEP 6: INSTALL PEDALS Keep in mind that the left and right pedals are threaded differently, and it is crucial that they are installed on the correct side of the bicycle. For this reason, they are marked “L” and “R” with stickers at the factory. 1. Locate the right-side pedal (marked with an “R”). 2. Thread the “R” pedal clockwise onto the drive-side crank (side of the bike with gears). 3. Tighten the “R” pedal clockwise with a 15 mm wrench or the wrench provided. 4. Locate the left-side pedal (marked with an “L”). 5. Thread the “L” pedal COUNTER-CLOCKWISE* onto the non-drive-side crank (side of the bike without gears). 6. Tighten the “L” pedal COUNTER-CLOCKWISE with a 15 mm wrench or the wrench provided. *NOTE : The left and right pedals are not interchangeable. The left (“L”) pedal and crank are REVERSE-THREADED so that the pedal will not come loose while riding. To TIGHTEN the left pedal, turn COUNTER-CLOCKWISE. To LOOSEN it, turn CLOCKWISE. STEP 8 : INSTALL & CONNECT BATTERY 1. 22 Once the battery has been fully charged (see section “Battery Care and Maintenance” on Page 8), simply lower it straight down into the frame. Fully push the large, three-pronged plug on the right side of the bicycle into the socket in the battery. FIT ADJUSTMENTS AURORA Many parts of your new EVELO Electric Bicycle can be customized for a personalized fit. Seat Adjustment The seat is easily adjusted up or down by flipping the quick-release lever that clamps the post into the bike. Note that there is a “minimum insertion line” stamped on the seat post that must be adhered to for safety’s sake. (If you need your seat to be higher than permitted with the stock seat post, please contact us.) The seat can also be moved forward and backward by loosening the single bolt on the underside of the seat. Since it slides on its rails, there is no need to remove the bolt — just loosen it, adjust, and firmly re-tighten. Loosening this bolt also lets you change the angle of the seat up or down a bit. Again, be sure to re-tighten it firmly if you loosen it to change the seat position in any way. FIG 10. BATTERY SOCKET AURORA MODEL AURORA MODEL 23 Front Shock Fork lock out on Aurora: There is a blue knob located on the top of the right fork leg. This is a lock out switch that disables fork travel in situations where you want rigid fork performance and do not need the impact absorption of an active fork. Simply turn it toward the locked icon to lock it, and rotate it the other direction toward the unlock icon to restore normal fork operation. LUNA MODEL Please consult the manual provided by the manufacturer for additional information. Tire Inflation The tires have a range of recommended inflation range of 40-65 psi. This range is also indicated on the sidewall of the tire. Lower pressure will give a softer ride. A higher pressure will provide a firmer ride, but will give the best range per battery charge. 24 AURORA MODEL AURORA MODEL 25 ASSEMBLY LUNA STEP 1 : INSTALL FRONT WHEEL 1. To install the front wheel, you first need to determine the right and left sides of the front wheel. The easiest way to accomplish this is to find the small magnet located on one of the spokes, and orient the wheel so that the magnet is on the same side as the black sensor attached to the fork. This will ensure you have correctly oriented the wheel as to left and right. 2. The front wheel is attached to the bike with a quick-release type of skewer. After locating the skewer, remove the nut on the end opposite the lever, and slide one of the conical springs onto the skewer — wide-end first. 3. Once the spring is against the lever’s nut, slide the skewer through the axle so that the lever is on the left side of the wheel. 4. Rotate the fork so the brake is toward the front of the bike. 6. Release the front brake by squeezing the brake arms, and lift the bent tube holding the cable out of its cradle (indicated by the arrow in Fig. 1B). 7. You can now lower the kickstand to keep the bike upright for the remainder of the assembly. STEP 2 : ATTACH FRONT FENDER & HEADLIGHT FIG 1A. QUICK RELEASE SKEWER 1. Loosen and remove the pre-attached bolt that goes through the brake arch. 2. Slide the fender into position, placing the silver tab that extends upward behind the brake arch. 3. Bring the headlight into position in front of the brake arch, and screw the bolt into it, threading it in from the front. Add the 5 washers to fill the space as shown. 4. Insert the bolt through the brake arch, through the fender tab and tighten the nut. Holding the bolt from the front side with an Allen wrench while tightening the nut is helpful. FIG 1B. RELEASE LUNA BRAKE Now slide the second spring onto the skewer — narrow-end first — then screw the nut partially back on. 5. CRITICAL : If the wheel is oriented correctly, the brake arch (the painted portion of the fork that bridges the two fork legs) of the front fork should be rotated FORWARD, as in Fig. 1C. 5. Remove the two Phillips screws near the front axle. Bring the black plastic tabs on the end of the wire struts up and bolt them in place using the screws. Repeat for each side. FIG 1C. BRAKE ARCH With the axle fully seated into the fork dropouts (the slots that accept the axle), and the lever in the OPEN position, turn the nut to adjust the clamping pressure, and swing the lever rearward to the CLOSED position, where you will feel noticeable resistance. The lever should leave a slight impression in your hand, and the lever should be parallel to the center-line of the bike when adjusted properly. 26 LUNA MODEL LUNA MODEL 27 STEP 3 : ATTACH HANDLEBARS 1. Place the black cap over the large silver nuts and use the wire clip to capture the wires. FIG 8. CORRECT BRAKE HOUSING FIG 9. INCORRECT HOUSING STEP 4 : CHECK BRAKE INSTALLATION 1. 2. Insert the end of the stem into the black cap, taking care to insert past the minimum insertion line marked on the stem. 3. Follow each brake cable, starting at the brake lever. Make sure that the brake housing (the sheathing that the cable runs through) is fully seated into the cylindrical hole at the brake lever (as shown in Fig. 8). Fig. 9 shows a dislodged housing, which occasionally occurs during shipping and handling. FIG 10. INSTALL BRAKE CABLE 2. Now that the front wheel is on, squeeze the brake arms together near the rim, and replace the cable back into the cradle you removed it from earlier. 3. Test that the brakes move inward when you squeeze the left brake lever. Firmly tighten the bolt as shown. This pulls the small wedge now inside the bike up snug to secure the handlebar assembly. 4. The bolt shown in Fig. 6 can be loosened to adjust the position of the handlebars. Be sure to tighten securely after adjustment. STEP 5 : INSTALL PEDALS Keep in mind that the left and right pedals are threaded differently, and it is crucial that they are installed on the correct side of the bicycle. For this reason, they are marked “L” and “R” with stickers at the factory. FIG 5. LUNA WEDGE BOLT 28 1. Locate the right-side pedal (marked with an “R”). 2. Thread the “R” pedal clockwise onto the drive-side crank (side of the bike with gears). 3. Tighten the “R” pedal clockwise with a 15 mm wrench or the wrench provided. 4. Locate the left-side pedal (marked with an “L”). FIG 6. LUNA MODEL LUNA MODEL 29 5. Thread the “L” pedal COUNTER-CLOCKWISE* onto the non-drive-side crank (side of the bike without gears). 6. Tighten the “L” pedal COUNTER-CLOCKWISE with a 15 mm wrench or the wrench provided. *NOTE : The left and right pedals are not interchangeable. The left (“L”) pedal and crank are REVERSE-THREADED so that the pedal will not come loose while riding. To TIGHTEN the left pedal, turn COUNTER-CLOCKWISE. To LOOSEN it, turn CLOCKWISE. STEP 6 : INSTALL SEAT 1. Simply slide the seat into the seat-tube on the bike, and tighten the clamp to secure it. 2. If necessary, open the lever, tighten the nut a few turns, and re-clamp the lever to get it properly tight. Note that there is a “minimum insertion line” marked on the post that must be adhered to for safety’s sake. STEP 7 : INSTALL & CONNECT BATTERY 1. 2. Once the battery has been fully charged (see section “Battery Care and Maintenance” on Page 8), simply slide it into the rack from the back. Using your key, lock the battery — this will help stabilize it when riding and also provide some anti-theft security. The lock is located on the left side of the battery case. FIT ADJUSTMENTS LUNA Many parts of your new EVELO Electric Bicycle can be customized for a personalized fit. Seat Adjustment The seat is easily adjusted up or down by flipping the quick-release lever that clamps the post into the bike. Note that there is a “minimum insertion line” stamped on the seat post that must be adhered to for safety’s sake. (If you need your seat to be higher than permitted with the stock seat post, please contact us.) The seat can also be moved forward and backward by loosening the single bolt on the underside of the seat. Since it slides on its rails, there is no need to remove the bolt — just loosen it, adjust, and firmly re-tighten. Loosening this bolt also lets you change the angle of the seat up or down a bit. Again, be sure to re-tighten it firmly if you loosen it to change the seat position in any way. Stem Adjustment To adjust the handlebars to a customized height, lift the clamping lever (as you did during assembly) to access the silver pivot bolt. Loosen that bolt, adjust the height, and retighten the bolt. Reposition the handlebars and lower the clamping lever. FIG 11. KEY LOCK Front Shock Please consult the manual provided by the manufacturer. Tire Inflation The tires have a range of recommended inflation of 40-65 psi. This range is also indicated on the sidewall of the tire. Lower pressure will give a softer ride. A higher pressure will provide a firmer ride, but will give the best range per battery charge. 30 LUNA MODEL LUNA MODEL 31 ASSEMBLY ORION STEP 1 : INSTALL FRONT WHEEL ORION MODEL 1. To install the front wheel, you first need to determine the right and left sides of the front wheel. The easiest way to accomplish this is to find the small magnet located on one of the spokes, and orient the wheel so that the magnet is on the same side as the black sensor attached to the fork. This will ensure you have correctly oriented the wheel as to left and right. 2. The front wheel is attached to the bike with a quick-release type of skewer. After locating the skewer, remove the nut on the end opposite the lever, and slide one of the conical springs onto the skewer — wide-end first. 3. Once the spring is against the lever’s nut, slide the skewer through the axle so that the lever is on the left side of the wheel. 4. Now slide the second spring onto the skewer — narrow-end first — then screw the nut partially back on. 5. Rotate the fork so the brake is toward the front of the bike. 6. Release the front brake by squeezing the brake arms, and lift the bent tube holding the cable out of its cradle (indicated by the arrow in Fig. 1B). 7. With the axle fully seated into the fork dropouts (the slots that accept the axle), and the lever in the OPEN position, turn the nut to adjust the clamping pressure, and swing the lever rearward to the CLOSED position, where you will feel noticeable resistance. The lever should leave a slight impression in your hand, and the lever should be parallel to the center-line of the bike when adjusted properly. FIG 1A. QUICK RELEASE SKEWER 32 ORION MODEL ORION MODEL FIG 1B. RELEASE ORION BRAKE 33 STEP 3 : ATTACH FRONT FENDER & HEADLIGHT CRITICAL : If the wheel is oriented correctly, the brake arch (the painted portion of the fork that bridges the two fork legs) of the front fork should be rotated FORWARD, as in Fig. 1C. You can now lower the kickstand to keep the bike upright for the remainder of the assembly. FIG 1C. BRAKE ARCH STEP 2 : ATTACH HANDLEBARS 1. Remove the bolts that hold the handlebar clamping bracket on. 2. While taking care to keep the wires and cables as straight as possible, place the center of the handlebars into the bracket and replace the forward portion of the bracket. 3. Tighten the bolts evenly so there is equal space at the front and rear of the bracket. 1. Loosen and remove the pre-attached bolt that goes through the brake arch. 2. Slide the fender into position, placing the silver tab that extends upward behind the brake arch. 3. Re-insert the bolt from the front of the headlight, threading it in. Place 5 washers onto the bolt to fill the gap in the headlight bracket. 4. Slide the bolt through the brake arch and tab on the fender. 5. Tighten the nut onto the bolt. Holding the bolt from the front with an Allen wrench will be helpful. 6. Remove the two Phillips screws near the front axle. Bring the black plastic tabs on the end of the wire struts up and bolt them in place using the screws. Repeat for each side. FIG 5. LOWER ORION FENDER STEP 4 : CHECK BRAKE INSTALLATION 1. FIG 3. BARS IN CAMPING BRACKET 5. Loosen the two bolts that clamp the handlebar stem to the steer tube, and align the handlebars with the front wheel. 6. Firmly re-tighten the two bolts. Note: Do not loosen the bolt located in the top-center of the metal cap. Follow each brake cable, starting at the brake lever. Make sure that the brake housing (the sheathing that the cable runs through) is fully seated into the cylindrical hole at the brake lever (as shown in Fig. 6). Fig. 7 shows a dislodged housing, which occasionally occurs during shipping and handling. FIG 6. CORRECT BRAKE HOUSING FIG 7. INCORRECT HOUSING FIG 4. STEM CLAMP BOLTS 34 ORION MODEL ORION MODEL 35 2. 3. STEP 7 : INSTALL & CONNECT BATTERY Now that the front wheel is on, squeeze the brake arms together near the rim, and replace the cable back into the cradle you removed it from earlier. Test that the brakes move inward when you squeeze the left brake lever. FIG 8. INSTALL BRAKE CABLE STEP 5 : INSTALL PEDALS Keep in mind that the left and right pedals are threaded differently, and it is crucial that they are installed on the correct side of the bicycle. For this reason, they are marked “L” and “R” with stickers at the factory. 1. Locate the right-side pedal (marked with an “R”). 2. Thread the “R” pedal clockwise onto the drive-side crank (side of the bike with gears). 3. Tighten the “R” pedal clockwise with a 15 mm wrench or the wrench provided. 4. Locate the left-side pedal (marked with an “L”). 5. Thread the “L” pedal COUNTER-CLOCKWISE* onto the non-drive-side crank (side of the bike without gears). 6. Tighten the “L” pedal COUNTER-CLOCKWISE with a 15 mm wrench or the wrench provided. *NOTE : The left and right pedals are not interchangeable. The left (“L”) pedal and crank are REVERSE-THREADED so that the pedal will not come loose while riding. To TIGHTEN the left pedal, turn COUNTER-CLOCKWISE. To LOOSEN it, turn CLOCKWISE. STEP 6 : INSTALL SEAT 1. Simply slide the seat into the seat-tube on the bike, and tighten the clamp to secure it. 2. If necessary, open the lever, tighten the nut a few turns, and re-clamp the lever to get it properly tight. Note that there is a “minimum insertion line” marked on the post that must be adhered to for safety’s sake. 36 ORION MODEL 1. Once the battery has been fully charged (see section “Battery Care and Maintenance” on Page 8), simply slide it into the rack from the back. 2. Using your key, lock the battery — this will help stabilize it when riding and also provide some anti-theft security. The lock is located on the left side of the battery case. FIT ADJUSTMENTS FIG 9. KEY LOCK ORION Many parts of your new EVELO Electric Bicycle can be customized for a personalized fit. Seat Adjustment The seat is easily adjusted up or down by flipping the quick-release lever that clamps the post into the bike. Note that there is a “minimum insertion line” stamped on the seat post that must be adhered to for safety’s sake. (If you need your seat to be higher than permitted with the stock seat post, please contact us.) The seat can also be moved forward and backward by loosening the single bolt on the underside of the seat. Since it slides on its rails, there is no need to remove the bolt — just loosen it, adjust, and firmly re-tighten. Loosening this bolt also lets you change the angle of the seat up or down a bit. Again, be sure to re-tighten it firmly if you loosen it to change the seat position in any way. ORION MODEL 37 RIDING YOUR EVELO ELECTRIC BICYCLE PRE-RIDE CHECKLIST Front Shock Carry out this pre-ride checklist before EVERY RIDE! Please consult the manual provided by the manufacturer. Tire Inflation The recommended inflation range for the tires is indicated on the tire sidewall (50-75 psi). Lower pressure will give a softer ride. A higher pressure will provide a firmer ride, but will give the best range per battery charge. Make sure the tires are properly inflated. All bicycle tires gradually lose air over time, and this can affect handling, range, and punctureresistance. Are the “Quick Release” levers on the front wheel and seat tight? Check both wheels for broken spokes. If you find any, seek service before riding the bike. Are the handlebars tight? If there is any noticeable movement, tighten properly before riding. Visually inspect your tires for cuts, embedded glass, or other signs of possible failure. Make sure that the pedals are screwed in tightly, as damage is possible if they come loose. Are the brakes working properly? Squeeze the levers before riding to ensure they apply the brakes, and then test them at a very low speed. Turn on the pedal-assist and while riding at a very low speed, make sure the motor turns off when either brake lever is squeezed. 38 ORION MODEL ORION EVELO.COM MODEL 39 YOUR FIRST RIDE Initially, we recommend you take a ride on the bike with the motor turned off. The bike handles differently than traditional bikes you may be used to riding, so it may take a little getting used to. A ride or two without the motor engaged will help you adjust to the differences from a traditional bike, making for an easier transition when you do engage the electric assist. When you first use the bike with the motor on, please familiarize yourself with the functions and performance of your bike by riding at slower speeds on flat ground in a safe area. Make sure you are comfortable with the bike in these conditions before increasing speed or riding in more difficult conditions such as bumpy or hilly ground, in traffic, or in less-than-ideal weather. 1. Select an area in which to ride that allows you to reach a moderate speed safely. 2. Accelerate to a moderate speed and apply the brakes evenly, slowing the bike to a walking pace. Do NOT come to a complete stop. Repeat this acceleration and braking sequence 20 times. Braking power will increase during this process. 3. Next, accelerate to a slightly higher speed and apply the brakes, slowing to a walking pace. Again, do not come to a complete stop. Repeat this sequence 10 times. 4. Allow the brakes to fully cool before riding again. After you complete this “embedding” process, the brakes should operate at full power without noise. PEDAL-ASSIST, THROTTLE & STOPPING QUICK-START GUIDE TO OPERATING THE DISPLAY Full instructions for your display panel are in your Display Panel Manual, but some of the most basic functions are listed here for your convenience. • To turn the bike on and off, press and hold the MODE button for about 2 seconds. NOTE: 500w Luna and Orion models have an additional power switch on the right side of the battery. Press the "line side" of the switch down before pressing MODE. • To turn the lights on and off, first turn on the bike, then press and hold the MODE button and the UP ARROW button together for about 2 seconds. • To energize the USB port (located on the left edge of the panel), press and hold the MODE button, the UP ARROW and the DOWN ARROW. Any device connected to this USB port should be mounted to the handlebars, not placed anywhere on the rider as that creates an unsafe situation. Multiple levels of power assist are provided by the motor. The level of assist provided at any given time can be adjusted using the display panel on the handlebars. A sensor at the crank activates the motor when the pedals have travelled about half of a turn of the crank. The motor continues to run at the pre-selected level as long as the crank continues to turn as the rider pedals. When first using the power-assist mode, we recommend you start off with a low level of assist until you get used to the power function and the bike in general. The throttle is a twist control built into the left handle grip. When the bike is powered on, twisting the throttle provides power to the motor even when the rider is not pedaling. The throttle is also used for immediate power from a dead stop in the event you don’t want to wait for the half turn of the crank to activate the pedal assist. The throttle over-rides the pedal assist setting. Brake cut-off switches are built into the brake levers so that power to the motor is turned off when either brake is applied. This is a safety feature. A NOTE ABOUT DISC BRAKES If your bike is equipped with disc brakes, you can prevent brake squeal by properly “embedding” the brakes. It is important to do this when the brake pads are new. 40 EVELO.COM EVELO.COM 41 ACHIEVING THE BEST PERFORMANCE FROM YOUR EVELO ELECTRIC BICYCLE THE MID-DRIVE MOTOR One of the nicest features of your new bicycle is its mid-drive motor. This design allows the motor, as well as the rider, to take advantage of gear changes in the shifting system, improving efficiency. To get the most out of the mid-drive motor, you need to shift the gears. Select models are available with the NuVinci® “Harmony” automatic shifting system. Only models so equipped shift automatically. Harmony owners can disregard the remainder of this section. In general, when starting from a dead stop, you should be in a low gear. With Shimano 8-Speed or Nexus-equipped bikes, this means number 1 or 2. On NuVinci®-equipped bikes, the orange cyclist on the shifter should appear to be riding up a hill. As the bike gains speed, progressively shift up through the gears. For the Shimano 8-Speed, this means 3, 4, 5, etc. With the Nexus, shift to 2 and then 3. For the NuVinci®, twist the grip so that the orange hill gradually flattens out. As the bike gains speed, progressively shift up through the gears. For the Shimano 8-Speed, this means 3,4,5, etc. With the Nexus, shift to 2 and then 3. For the NuVinci®, twist the grip so that the orange hill gradually flattens out. If you encounter a hill, shift back down into lower gears. You should also shift to lower gears as you approach a stop, so you are already in the proper gear when you start again. 42 EVELO.COM RANGE Travelling as far as possible on a single battery charge is dependent upon many variables. Some ways to maximize range include: • Contribute by pedaling; • Select the lower pedal-assist settings; • Use higher inflation pressures for your tires; • Ride at moderate speeds (higher speeds bring greater wind resistance, putting a greater load on the motor); and • Avoid riding in stop-and-go traffic. In many ways, considerations similar to those one takes to improve gas mileage for a car are likely to be helpful in increasing the range of your new electric bike. Different riders in different conditions can expect different performance. For example, a 130-pound rider who is pedaling on flat terrain will go significantly farther on a single battery charge than a 230-pound rider on hilly terrain who is not pedaling. This is why distance–per-charges are estimated in such a broad range (such as 20-40 miles). RIDING IN THE RAIN EVELO Electric Bicycles are designed so that you can operate them in rainy weather. Factory-level design elements keep the electrical components wellprotected and nearly all the electrical connections are located within the frame. However, if you do choose to ride in the rain, be aware that necessary braking distances can be increased significantly, and keep in mind that the road surface can be slick. Use caution in wet conditions — even if it is not actively raining. Although rain and wet weather is acceptable use, we do recommend that you avoid circumstances where your bike will be immersed in water, such as riding EVELO.COM 43 through a deep stream. The bike is water-resistant, but not waterproof. After riding in the rain, disconnect the battery and air-dry the electrical connection points to avoid corrosion. We also recommend that you dry your bike with a soft towel if you have been riding in the rain. OF YOUR EVELO ELECTRIC BICYCLE As with any mechanical device or machine, you will get longer life and better performance from your electric bicycle if you adhere to a basic maintenance schedule. SAFETY TIPS We recommend the following safety-related procedures: In addition to the items in the “Pre-Ride Checklist” section, we recommend the following: • Wear a helmet. • Ride in control at all times. • Use lights and reflective gear in low light situations. • Inspect your bike often — especially the brakes. • Seek maintenance if there are any notable changes in bike performance. • Know and observe the rules of the road before cycling. Bike users must follow all road rules. • Ride defensively. To motorists, pedestrians, or even other cyclists, you are not as visible as you might think. Always watch for hazardous situations, and be ready to stop or take evasive action at all times. With the assistance of the electric motor, you may be travelling faster than drivers expect — beware of cars pulling out in front of you, reversing out of driveways, or car doors opening unexpectedly, and other such hazards. • Avoid road hazards. Watch for and avoid potholes, drain grates, railroad tracks, loose road material, and other hazards which could cause your wheels to slip, fly up to hit you or your bike, or cause you to fall. • Use both the front and the rear brakes together for best performance. Using ONLY the rear brake will significantly increase your stopping distance. 44 MAINTENANCE EVELO.COM • Tires — Check tire pressure weekly. All bike tires lose air naturally over time. • Chain — Lubricate the chain whenever it appears dry, and also every 200-400 miles depending on conditions. If you often ride in wet conditions, lubricate the chain more often. Always wipe off excess lubrication, as it tends to attract dirt. • Cables — Each month, visually inspect cable ends for fraying and replace if it is present. Replace all cables and housings annually. • Nuts and bolts — Check all nuts and bolts each month for tightness. • Cleaning — Clean the bike whenever excess dirt is apparent. Avoid high-pressure washing, especially near the motor, at places where wires enter/exit the frame, or of the battery and wheel/crank bearings. • Wheels — Check for straightness on a monthly basis, and more often if you have experienced a rough ride or sudden impact. Have the wheels serviced if there is notable side-to-side wobble. EVELO.COM 45 • Brakes — Inspect your brakes at least once per month. If a brake lever can be squeezed all the way to the handlebar grip, there is a basic adjustment (see below) that can be made. If this adjustment does not work, and your brakes are worn, either take the bike to a local bike shop for professional service, or contact EVELO for additional instructions. • First, loosen the adjustment barrel by unscrewing it so there is a slight gap between it and the actual lever mount. • Then, unscrew the adjustment barrel a turn or so. This has the effect of lengthening the cable housing and pulling on the cable a bit. • Test by squeezing the lever, then lifting the tire off the ground and spinning it. Ideally, you should be able to adjust it so the lever won’t reach the handlebar grip when pulled hard, yet the wheel spins freely without resistance when the brake is released. • When you find the proper adjustment, re-tighten the lock ring to hold the barrel in this new position. TROUBLESHOOTING If you experience difficulty with your EVELO Electric Bicycle, consult the following list. If you do not find the problem on this list, contact our Customer Service Team, and we will work with you to identify the source of the problem and help with a solution. Symptom Likely Cause Action No power at display Loose battery connections Check and secure connection between bike and battery Range seems low Battery not fully charged / gearing not being utilized Consult other sections of this manual: “Using your Charger” and “Achieving the Best Performance From Your EVELO Electric Bicycle” Error code 25 when bike is turned on Brake levers are being squeezed during initial system initialization. Make sure the brake levers are not being squeezed when first pressing the MODE button Battery won’t Charge Charger not connected / battery connected to bike while fully discharged Consult “Using Your Charger” section of this manual / remove battery from bike before connecting charger. Intermittent loss of electrical power Battery connection is poor Lock battery to hold in place more securely. On Aries/Aurora, make sure plug is fully seated in its socket. Brake light won’t work Bike not equipped with brake light function. Due to engineering limitations, 500 watt versions of the Aries and Aurora do not have brake light functionality. Speed and distance won’t display Magnet and Sensor not aligned Make sure the magnet on the spoke of the front wheel passes within 1/8” of the LOWER TIP of the speed sensor on the front right fork. BRAKE LEVER ADJUSTMENT • 46 Tune-Up — We recommend a full-service tune-up annually by a professional bicycle mechanic. EVELO.COM EVELO.COM 47 Questions? Get In Touch: Email: [email protected] Call: 877-991-7272 EVELO.COM 4th ( Edition)