American cycle company Current User manual

Electric Bike User Manual

FULLY CHARGE BATTERIES BEFORE FIRST USE - Batteries should be fully
charged immediately when they are received and immediately after each use for the recommended charge
times (see below).
Li-Ion (Lithium Ion) batteries 4-6 hours•
With proper care and maintenance your American Cycle Company® "Current" Electric Bicycle will provide ease of use and be
fun to ride. Below are points that will help you to maximize the enjoyment you get from your new hybrid electric bicycle.
FACTORS TO MAXIMIZE THE RANGE OF YOUR ELECTRIC BICYCLE
RIDER INPUT•- the more the rider pedals the further the distance traveled. Continuous riding, as opposed to
frequent stopping and starting, will yield the greatest range possible
ELEVATION GAIN•- the flatter the road the further the distance traveled
WEATHER•- cold weather can adversely affect the battery capacity
WIND•- traveling with a tailwind will increase distance traveled, traveling into a headwind will decrease distance
traveled
TERRAIN•- the smoother the terrain (roadways vs. fireroads, etc.) the further the distance traveled
RIDER WEIGHT•- the lighter the rider, resulting in less drain on the batteries, the further distance traveled
BICYCLE MAINTENANCE•- a properly maintained bicycle will yield the greatest range possible
TIRE PRESSURE•- properly inflated tires have less rolling resistance and will be easier to pedal
BATTERIES•- properly charged and maintained batteries will yield the greatest range possible. Batteries stored in
cold areas (below 50 degrees Fahrenheit / 10 degrees Celsius) will show reduced range. Never allow batteries to
freeze (below 32º Fahrenheit) as this will result in permanent damage to them. Batteries that have not been kept in
optimum condition will show reduced range and run time.
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01

CORRECT FITTING - MAKE
SURE YOUR HELMET COVERS
YOUR FOREHEAD.
INCORRECT FITTING. FOREHEAD
IS EXPOSED AND VULNERABLE
TO SERIOUS INJURY.
• ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE
YOUR BICYCLE.
• DO NOT RIDE AT NIGHT.
• CPSC RECORDS SHOW THAT ABOUT 35% OF BICYCLE
RELATED DEATHS OCCUR AFTER DARK.
• AVOID RIDING IN WET CONDITIONS.
• CPSC RECORDS SHOW THAT ABOUT 65% OF INJURIES
HAPPEN TO CHILDREN UNDER 15 YEARS OF AGE.
• RIDE ONLY WITH ADULT SUPERVISION
HELMETS
SAVE
LIVES!!!
02

www.americancycle.bike
The following manual is only a guide to assist you and is not a complete or comprehensive manual of all aspects of
maintaining and repairing your bicycle. The bicycle you have purchased is a complex object. We recommend that you
consult a bicycle repair specialist if you have doubts or concerns as to your experience or ability to properly assemble,
repair, or maintain your bicycle.
03

DIRECTORY
Warning / Important - Take notice of this symbol throughout this manual and pay
particular attention to the instructions blocked off and preceded by this symbol.
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PART 1 Before You Ride. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
PART 2 Bike Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-46
PART 3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47-74
PART 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75-79
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04
PART 2 Tools & Electronic Component Overview. . .. . . . . . . . . . . . . . . . .15-24

BEFORE YOU RIDE
ABOUT THIS MANUAL
It is important for you to understand your new bicycle. By reading this manual before you go out on your first ride, you’ll know
how to get better performance, comfort, and enjoyment from your new bicycle.
It is also important that your first ride on your new bicycle is taken in a controlled environment, away from cars, obstacles, and
other cyclists.
GENERAL WARNING
Bicycling can be a hazardous activity even under the best of circumstances. Proper maintenance of your bicycle 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 inspect your bicycle. 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.
A SPECIAL NOTE FOR PARENTS
It is a tragic fact that most bicycle accidents involve children. As a parent or guardian, you bear the responsibility for the
activities and safety of your minor child. Among these responsibilities are to make sure that the bicycle which your child is
riding is properly fitted to the child; that it is in good repair and safe operating condition; that you and your child have learned,
understand and obey not only the applicable local motor vehicle, bicycle, and traffic laws, but also the common sense rules of
safe and responsible bicycling. As a parent, you should read this manual before letting your child ride the bicycle. Please make
sure that your child always wears an ANSI, ASTM, SNELL approved bicycle helmet when riding.
05

CORRECT FRAME SIZE
When selecting a new bicycle, the correct choice of frame size is a very important safety consideration. Most full sized
bicycles come in a range of frame sizes. These sizes usually refer to the distance between the center of the bottom bracket
and the top of the frame seat tube.
For safe and comfortable riding there should be clearance of no less than 1 - 2 inches between
the groin area of the intended rider and the top tube of the bicycle frame, while the rider straddles the
bicycle with both feet flat on the ground.
The ideal clearance will vary between types of bicycles and rider preference. This makes straddling the frame when off
the seat easier and safer in situations such as sudden traffic stops. Women can use a men’s style bicycle to determine the
correct size women’s model.
The following chart and diagram will help you make the correct choice. Rider leg length refers to approximate pant inseam.
Approximate Rider Leg
Length
61-69cm / 24-27 inches
66-76cm / 26-30 inches
71-79cm / 28-31 inches
76-84cm / 30-33 inches
79-86cm / 31-34 inches
81-89cm / 32-35 Inches
86-94cm / 34-37 inches
Suggested Frame Size for
Racing/Touring Bicycle
-
-
50cm / 19.5 inches
55cm / 21.5 inches
57cm / 22.5 inches
60cm / 23.5 Inches
63cm / 25 inches
Suggested frame Size for
Mountain, Hybrid, Comfort,
or Cruiser Bicycle
37cm / 14.5 inches
43cm / 17 inches
45cm / 18 inches
50cm / 19.5 inches
52cm / 20.5 inches
53-56cm / 21-22 Inches
58-60cm / 23-23.5 inches
Frame Sizing Guide
1-2in.
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06

SAFETY CHECKLIST
Before every ride, it is important to carry out the following safety checks:
1. Brakes
Ensure front and rear brakes work properly.•Ensure brake shoe pads are not over worn and are correctly positioned in relation to the rims.•Ensure brake control cables are lubricated, correctly adjusted and display no obvious wear.•Ensure brake control levers are lubricated and tightly secured to the handlebar.•
2. Wheels and Tires
Ensure tires are inflated to within the recommended limit as displayed on the tire sidewall.•Ensure tires have tread and have no bulges or excessive wear.•Ensure rims run true and have no obvious wobbles or kinks.•Ensure all wheel spokes are tight and not broken.•Check that axle nuts are tight. If your bicycle is fitted with quick release axles, make sure locking levers are•correctly tensioned and in the closed position.
3. Steering
Ensure handlebar and stem are correctly adjusted and tightened, and allow proper steering.•Ensure that the handlebars are set correctly in relation to the forks and the direction of travel.•Check that the headset locking mechanism is properly adjusted and tightened.•If the bicycle is fitted with handlebar end extensions, ensure they are properly positioned and tightened.•
4. Chain
Ensure chain is oiled, clean and runs smoothly.•Extra care is required in wet or dusty conditions.•
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5. Bearings
Ensure all bearings are lubricated, run freely and display no excess movement, grinding or rattling.•Check headset, wheel bearings, pedal bearings and bottom bracket bearings.•
6. Cranks and Pedals
Ensure pedals are securely tightened to the cranks.•Ensure cranks are securely tightened to the axle and are not bent.•
7. Derailleurs
Check that front and rear mechanisms are adjusted and function properly.•Ensure shift and brake levers are attached to the handlebar, shift and brake.•Ensure derailleurs, shift levers and shift and brake cables are properly lubricated.•
8. Frame and Fork
Check that the frame and fork are not bent or broken.•If either are bent or broken, they should be replaced.•
9. Accessories
Ensure that all reflectors are properly fitted and not obscured.•Ensure all other fittings on the bike are properly and securely fastened, and functioning.•Ensure the rider is wearing a helmet.•
10. Motor Drive Assembly and Throttle
Ensure all motor drive components are correctly mounted and functioning properly.•
11. Battery Pack
Ensure the batteries are in good operation condition and kept fully charged.•
08

RIDING SAFELY
General Rules
When riding obey the same road laws as all other road vehicles, including giving way to pedestrians, and stopping
at red lights and stop signs.
For further information, contact the Road Traffic Authority, police department or Department of Motor Vehicles in
your State.
Ride predictably and in a straight line. Never ride against traffic.
Use correct hand signals to indicate turning or stopping.
Ride defensively. To other road users, you may be hard to see.
Concentrate on the path ahead. Avoid pot holes, gravel, wet road markings, oil, curbs, speed bumps, drain grates
and other obstacles.
Cross train tracks at a 90 degree angle or walk your bicycle across.
Expect the unexpected such as opening car doors or cars backing out of concealed driveways.
Be extra careful at intersections and when preparing to pass other vehicles.
Familiarize yourself with all the bicycle's features. Practice gear shifts, braking, and the use of toe clips and straps,
if fitted.
If you are wearing loose pants, use leg clips or elastic bands to prevent them from being caught in the chain or
gears. Wear proper riding attire and avoid wearing open toe shoes.
Don't carry packages or passengers that will interfere with your visibility or control of the bicycle. Don't use items
that may restrict your hearing.
Do not lock up the brakes. When braking, always apply the rear brake first, then the front. The front brake is more
powerful and if it is not correctly applied, you may lose control and fall.
Maintain a comfortable stopping distance from all other riders, vehicles and objects. Safe braking distances and
forces are subject to the prevailing weather conditions.
Use designated bicycle paths if possible.
09

Wet Weather
IT IS RECOMMENDED TO NOT RIDE IN WET WEATHER This hybrid electric bicycle is not
meant for use in the water (damp roads, puddles, rain, streams, etc.). Never immerse this
product in water as the electrical system may be damaged.
In wet weather you need to take extra care.•Brake earlier, you will take up to 6 times longer distance to stop.•Decrease your riding speed, avoid sudden braking and take corners with additional caution.•Be more visible on the road.•Wear reflective clothing and use safety lights.•Potholes and slippery surfaces such as line markings and train tracks all become more•hazardous and more difficult to see when wet.
Night Riding
IT IS RECOMMENDED TO NOT RIDE AT NIGHT
Ensure bicycle is equipped with a full set of correctly positioned and clean reflectors.•Refer to page 1 and 101 of this manual.•Use a properly functioning lighting set comprising of a white front lamp and a red rear lamp.•If using battery powered lights, make sure batteries are well charged.•Some rear lights available have a flashing mechanism which enhances visibility.•Wear reflective and light colored clothing.•Ride at night only if necessary. Slow down and use familiar roads with street lighting, if possible.•
Pedaling Technique
Position the ball of your foot on the center of the pedal.•When pedaling, ensure your knees are parallel to the bicycle frame.•To absorb shock, keep your elbows slightly bent.•Learn to operate the gears properly. (Refer to pages 26-28)•
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10

Hill Technique
Gear down before a climb and continue gearing down as required to maintain pedaling speed.•If you reach the lowest gear and are struggling, stand up on your pedals. You will then obtain more power from•each pedal revolution.
On the descent, use the high gears to avoid rapid pedaling.•Do not exceed a comfortable speed; maintain control and take additional care.•
Cornering Technique
Brake slightly before cornering and prepare to lean your body into the corner. Maintain the inside pedal at the 12 o'clock
position and slightly point the inside knee in the direction you are turning. Keep the other leg straight, don't pedal through
fast or tight corners. While going through the turn, keep your eyes parallel to the horizon and look as far ahead of you
as possible.
Please refer to pages 128-130 for braking techniques and pages 130-133 for gear shifting techniques.
Rules for Children
To avoid accidents, teach children good riding skills with an emphasis on safety from an early age. Children should always be
supervised by an adult.
Always wear a properly fitted helmet.1. Do not play in driveways or the road.2. Do not ride on busy streets.3. Do not ride at night.4. Obey all the traffic laws, especially stop signs and red lights.5. Be aware of other road vehicles behind and nearby.6. Before entering a street: Stop, look right, left, and right again for traffic. If there's no traffic, proceed into the roadway.7. If riding downhill, be extra careful. Slow down using the brakes and maintain control of the steering.8. Never take your hands off the handlebars, or your feet off the pedals when riding downhill.9.
The Consumer Protection Safety Commission advises that the riding of small wheel diameter bicycles at
excessive speeds can lead to instability and is not recommended. Children should be made aware of all
possible riding hazards and correct riding behavior before they take to the streets. Do not leave it up to
trial and error.
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11

BICYCLE CARE
Basic Maintenance
The following procedures will help you maintain your hybrid electric bicycle for years of enjoyable riding.
Properly maintain the batteries by keeping them fully charged when not in use.
Do not ride your hybrid electrical bicycle in the water (damp roads, puddles, rain, streams, etc.) and never immerse it in water
as the electrical system may be damaged.
Periodically check the wiring and connectors to ensure there is no damage and the connectors had good continuity.
For painted frames, dust the surface and remove any loose dirt with a dry cloth. To clean, wipe with a damp cloth soaked in
a mild detergent mixture. Dry with a cloth and polish with car or furniture wax. Use soap and water to clean plastic parts and
rubber tires. Chrome plated bikes should be wiped over with a rust preventative fluid.
Store your bicycle under shelter. Avoid leaving it in the rain or exposed to corrosive materials.
Riding on the beach or in coastal areas exposes your bicycle to salt which is very corrosive. Wash your bicycle frequently
and wipe or spray all unpainted parts with an anti-rust treatment. Make sure wheel rims are dry so braking performance is not
affected. After rain, dry your bicycle and apply anti-rust treatment.
If the hub and bottom bracket bearings of your bicycle have been submerged in water, they should be taken out and
re-greased. This will prevent accelerated bearing deterioration.
If paint has become scratched or chipped to the metal, use touch up paint to prevent rust. Clear nail polish can also be used as
a preventative measure.
Regularly clean and lubricate all moving parts, tighten components and make adjustments as required. (Refer to Parts
5 and 6 of this manual for further details).
The use of alloy components and BED, SATIN and TITANIUM surface treatments minimizes the number of places
where rust can surface.
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Storage
Keep your bicycle in a dry location away from the weather and the sun.
Direct sunlight may cause paint to fade or rubber and plastic parts to
crack. Before storing your bicycle for a long period of time, clean and
lubricate all components and wax the frame. Deflate the tires to half
pressure and hang the bicycle off the ground. Don't cover with plastic as
"sweating” will result which may cause rusting. Please notice that your
bicycle warranty does not cover paint damage, rust, corrosion, dry rot or
theft.
Security
It is advisable that the following steps be taken to prepare for and help
prevent possible theft.
Maintain a record of the bicycle’s serial number, generally1. located on the frame underneath the bottom bracket or on the
head tube.
Register the bicycle with the local police.2. Invest in a high quality bicycle lock that will resist hack saws3. and bolt cutters. Always lock your bicycle to an immovable
object if it is left unattended.
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Helmets
It is strongly advised that a properly fitting, ANSI or SNELL approved,
bicycle safety helmet be worn at all times when riding your bicycle. In
addition, if you are carrying a passenger in a child safety seat, they
must also be wearing a helmet.
The correct helmet should:
- be comfortable
- be lightweight
- have good ventilation
- fit correctly
- cover forehead
Always wear a properly fitted helmet which covers the forehead when riding a bicycle. 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
bike as the law requires. Reflectors are important safety devices which are designed as an integral part
of your bicycle. Federal regulations require every bicycle to be equipped with front, rear, wheel, and
pedal reflectors. These reflectors are designed to pick up and reflect street lights and car lights in a
way that helps you to be seen and recognized as a moving bicyclist. Check reflectors and their
mounting brackets regularly to make sure they are clean, straight, unbroken and securely mounted.
Have your dealer replace damaged reflectors and straighten or tighten any that are bent or loose.
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Your new bicycle was partially assembled in the factory and then partially disassembled for shipping. You may
have purchased the bicycle already fully assembled and ready to ride OR in the shipping carton in the partially
disassembled form. The following instructions will enable you to prepare your bicycle for years of enjoyable
cycling. For more details on inspection, lubrication, maintenance and adjustment of any area please refer to the
relevant sections in this manual. If you have questions about your ability to properly assemble this unit, please
consult a qualified bicycle service specialist before riding.
Tools Included:
•Phillips head screw driver
•5mm &6mm Allen keys
•13mm/15mm open end wrench
•A pair of pliers with cable cutting ability
To avoid injury, this product must be properly assembled before use. If your bicycle was
obtained assembled, we strongly recommend that you review the complete assembly
instructions and perform checks specified in this manual before riding.
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Tools Suggested (optional):
Adjustable wrench or a 10mm open end wrench
•
•Scissors
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ELECTRONIC COMPONENTS
The line voltage will fluctuate depending on the instantaneous load
that the motor is under. For example, when starting out from a dead
stop, or going up a steep hill, the motor will be under a high load nd
may show a reduced number of LED's .
Pedal Assist Control Unit
with Battery Gauge
Pedal Assist Control Unit/Battery Gauge
This unit is featured on the Enlightened series of bicycles. Not only
does it act like a battery gauge but it also enables the rider to vary
the level of support from Low to High (1 LED = least amount of
power assistance, 3LED's = maximum amount of power
assistance).
Press the "+" button to increase the amount of power assistance
(Note that this will also decrease the range of the bicycle because
more battery power is being used).
Press the "-" to decrease the amount of the power assistance (Note
that this will also increase the range of the bicycle because less
battery power is being used).
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Throttles
Throttles are equipped on some models of electric bicycles. Throttles
operate by rotating the throttle towards the rider much like a
motorcycle. They generally are the inner half of the right side handlebar
grip. The more you twist the throttle, the faster the motor system will
propel the bicycle.
Twist and Go Throttle
Before you begin riding, turn the main power switch on, then start
riding as you would ride any regular, non motor assisted bicycle. After
you have begun to ride, slowly twist the throttle towards you. The
more you twist the throttle, the more motor power will be applied to the
wheels. You may feel the pedals get a “lighter” feel than riding without
the motor assisting you. Once you have twisted the throttle all the
way, the motor will accelerate you to its full speed of approximately
20mph (24 km/h).
PAS (Pedal Assist System)
Using the Pedal Assist function allows the rider to have the bike match
their pedaling power at three levels of support (Low, Medium, High),
High giving you the most assistance. Once you start pedaling, a torque
sensor picks up your movement and power integrates seamlessly while
you ride. Just pedal and go. Once you use the brakes or quit pedaling,
the power is deactivated and you need to pedal again (lightly) to re-
activate pedal assistance.
PAS / TAG throttle switch
It is possible to be in Pedal Assist Mode and use the Throttle for an
extra boost, However, this will significantly drain battery power. Note:
When only using the Throttle mode you will use more battery power in
general and thus shorten range of the bicycle per charge.
Throttle
Pedal Assist
Support Levels
(1-3)
Battery Gauge
Pedal
Assist
ON/OFF
Light
ON/OFF
Button
Pedal Assist
Control Unit
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Electric Bikes with Seat Tube
Mounted Battery (STB) Packs
- Remove the power cable from
the charger port.
Taking Care of Your Batteries
Proper maintenance of the batteries will maximize their lifespan and available ride time.
American Cycle Company® warrants your new batteries from the date of purchase but only if
properly cared for. Refer to the limited warranty for details.
•American Cycle Company uses Li-Ion (Lithium Ion) batteries in all of our electric bicycles.
These are very user friendly types of batteries when cared for properly
Batteries should be fully charged immediately when they are received for the•recommended charge times. FULLY CHARGE BATTERIES BEFORE FIRST USE.
Below are the recommended charge times for each type of batteries.
Li-Ion (Lithium Ion) batteries 4-6 hours•
•Charge batteries at least every 90 days until normal use is resumed.
Always store bicycle with fully charged batteries.•
Never charge the batteries for more than 24 hours.•
Always disconnect the charger from the wall outlet and bicycle when charging is•complete (as indicated by the status on the charger) before storing the bicycle.
Do not store batteries below 50º Fahrenheit and never allow batteries to freeze•
(below 32º Fahrenheit).
•Bikes are equipped with a 5 minute sleep mode. If no activity is detected after 5 minutes
the bike will go into stasis mode to conserve the batteries. To restart, cycle the power
switch Off then On. Bikes are not to be stored in the 5 minute sleep mode.
•Always be sure to turn the bike “OFF” when not in use via the Ignition/Battery Lock. If
you have left the power on or your product has not been charged for a long period of
time, the batteries may reach a stage at which it will no longer hold a charge.
Be friendly to the environment! Be sure to recycle your old batteries at a local battery•recycling center. Do not throw them in the garbage!
Frequent “stops and starts” will drain a battery more quickly than sustained, long-term•use
•Even with proper care, rechargeable batteries do not last forever. Average battery life
depends on use and conditions.
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Battery FAQ's
Q: Do I need to charge the batteries before using them?
A: Yes, you should charge the batteries fully before first using them.
Q: Do I need to "break-in" my batteries?
A: Yes, the batteries used in the American Cycle Company Electric Bicycles will need to have a “break-in” cycle consisting of ~
three dis-charge/charge cycles before they will reach optimum performance. This involves three complete discharges and three
complete recharges. After this initial “break-in” cycle the batteries will have maximum possible performance and less line
voltage fluctuations under load.
Q: How long will the batteries hold their charge?
A: All batteries will self-discharge when not in use. The self-discharging rate depends on the temperature at which they are
stored. Excessively cold or hot storage temperatures will drain the batteries faster than normal. Ideally the batteries should be
stored at room temperature.
Q: Why should I recharge my batteries at least every 90 days when I am not using them?
A: Batteries naturally lose their charge over time. To keep the batteries in optimal condition and extend their life, it is recom-
mended that a top-off recharge be performed at least every 90 days.
Q: What happens if I leave the power switch on longer than 5 minutes?
A: American Cycle Company bikes are equipped with a 5 minute shut-off mode. If no activity is detected after 5 minutes the
bike will turn itself off to protect the batteries. To restart, cycle the power switch (OFF then ON). If you have left the power
switch on or your product has not been charged for a long period of time, the batteries may reach a stage at which it will no
longer hold a charge.
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