ARC FEATHER User manual

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LAST UPDATED: 3/08/2018 1
ARC FEATHER USER MANUAL
The complete guide on how to assemble, operate and maintain your
new electric bike.
ENGLISH

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We at Arc would like to thank you for your purchase. Your support is crucial to
helping us achieve excellence in the electric bicycle arena. Should you have any
quesons about your product that aren’t covered in this manual, please contact
us directly or speak to your local Arc dealer.
We hope that you love your new Arc Feather kit, and wish you a safe onward
journey.
Though we at Arc perform an extensive safety check prior to the dispatch of
each of our bikes and kits, we recommend that you go over each part of your
new kit with tools of your own, from me to me. Regular maintenance will
ensure the safe and smooth operaon of your kit well into the future.
MECHANICAL SAFETY CHECK
Prior to embarking on your maiden ride, we recommend taking a moment to
familiarise yourself with the performance controls outlined in this manual.
Ensure that there is adequate space in front of the bike before beginning your
rst ride and remember to wear a helmet at all mes. Compleng these few
tasks will ensure your rst ride, and every ride thereaer, is a safe one.
FIRST RIDE CHECK
THANK YOU!

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TABLE OF CONTENTS
EBike Components and Terminology........................................................4
Assembly..................................................................................................6
Unboxing...........................................................................................6
Inventory...........................................................................................7
Bicycle Preparaon ...........................................................................8
Motor..............................................................................................10
Baery ............................................................................................15
Handlebar .......................................................................................17
Pedal Assistance..............................................................................18
Wiring .............................................................................................21
Operaon...............................................................................................22
Baery Charging .............................................................................22
Display operaon…………………………………………..…See separate manual
Baery Informaon ...............................................................................23
Maintenance..........................................................................................26
Troubleshoong Tips..............................................................................27
Troubleshoong Table............................................................................28
Contact Us .............................................................................................29
Please note that this manual shows the rst version of the Arc Feather kit, so
some of the components in your kit may look slightly dierent. The installaon
instrucons however remain the same.

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This secon will help you understand the operaon of your new electric bicycle
and the common terms and components involved. If you are familiar with what
an electric bike is and how they operate, then feel free to skip over this secon.
Otherwise, we recommend that you familiarise yourself with these terms.
An electric bike consists of mulple electronic components that are powered
from the baery. The most common components of an electric bike are:
A) Electric Motor
B) Motor Controller
C) Baery
D) Handlebar Display
E) Throle (Oponal)
F) Pedal Assistance Sensor and Magnet Ring
G) Electric Brake Cut-os (E-brake cut-os) - not part of the Arc Feather kit
EBIKE COMPONENTS AND TERMINOLOGY

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A) Electric Motor
The muscle. This component applies rotaonal force to the wheels and propels
the bicycle forward. Motors can either be hub drive (in the wheel) or mid drive.
B) Motor Controller
The brain. This complex piece of electronics takes input from other components
and operates the motor. The motor controller is generally built into the frame
of the electric bicycle, but can be found aached to the motor or outer frame.
C) Baery
The heart. Without this component there will be no speedy take o or smooth
runs over hills. The baery of an electric bike is generally a Lithium Ion type
(though some are sll lead acid). They have baery management systems that
ensure the safe operaon and charging of the baery.
D) Handlebar Display
The ears and eyes. This component takes in input from the rider and
communicates it to the motor controller,. It can also use that informaon to
restrict the motor controller’s operaon. This device usually allows the rider to
change pedal assistance levels and check baery levels.
E) Throle (Oponal)
This device is controlled by the rider and is typically located on the handlebar.
When the rider uses the throle, it will propel the bike forward.
F) Pedal Assistance Sensor and Magnet Ring
Another input to the motor controller. This component detects the rotaon of
the pedals and alerts the motor controller. The motor controller then acvates
power to the motor based on the seng requested on the handlebar display.
G) Electric Brake Cut-os (E-brake cut-os)
Typically aached to the brakes or built in to the brakes, this component
detects the actuaon of the brakes and cuts power to the motor. This is an
added safety feature built into most electric bikes that use pedal assistance.

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This secon will help you complete the inial setup of your electric bike kit. This
informaon will likely only be required if you purchased your bicycle kit online
or from a venue separate to our retail stores, though it may be helpful for new
users too.
ASSEMBLY
The moment of unboxing of your new electric bike kit is an excing me and,
while we wouldn't ever want to take that from you, we do urge cauon during
the unboxing process. Enthusiascally cung into the box with a cardboard
knife or pair of scissors may lead to unintended scratches or damage to your
new kit before you've even had a chance to use it and nobody wants that.
We recommend having a partner on hand to help you remove the bicycle from
its packaging as doing it by yourself can be a dicult process. Your bike may be
quite heavy, and making it a two-person job ensures you'll be able to get it out
of the box without the risk of injury to yourself or your bike.
Carefully remove all packaging and wrapping from each secon of the bicycle
frame, always being mindful not to damage any part of the bike or its
components with any tools you may use.
ASSEMBLY—UNBOXING

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This is what the inside of the carton is likely to look like. The motor on the right
side, baery in the middle le, charger boom le and the other parts and
accessories in the top le box.
TOOLS REQUIRED:
• Spanner set or shiing spanner
• Set of Allen keys
• Pair of side cuers/scissors
• Tyre levers (may not be required)
• Addional zip es (oponal)
• Strong adhesive (oponal)
ASSEMBLY—INVENTORY

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This secon will detail some of the basic steps you should undertake to prepare
your bicycle for conversion.
ASSEMBLY—BICYCLE PREPERATION
The rst thing you should do is nd a suitable space in which to conduct the
installaon. If you don’t have a nice so surface to ip the bike over onto, or
don’t have a bike maintenance stand, then we recommend using some of the
foam packaging in the kit to prevent any unintended damage to your bike.
As in the photographs above, ip the bike over in preparaon for removing the
front wheel motor mounng. In the case of the bike pictured, the front wheel
was quick release making it very easy to remove without tools. You may require
a spanner or shier to remove the front wheel, depending on the construcon
of your bicycle.

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Once the wheel has been removed, check if your bicycle has a front disk brake.
If so, you will need to remove the disk brake for mounng onto the front motor.
ASSEMBLY—BICYCLE PREPERATION
Some disk brakes may require specialist tools to remove, though most will only
require a standard 5mm Allen key. Once you have removed the disk brake,
place it aside for the next step.
Unless you purchased a new tyre and tube to go with the motor, you will also
need to remove the current wheel’s tube and tyre for relocaon to the hub
motor from the conversion kit. Deate the tyre and remove the tyre and tube.
This can usually be done by hand, though it may require some tyre levers to
help get the job done. You should avoid using tyre levers if you can as they can
lead to a higher likelihood of tyre puncture. Just start on the side opposite to
the tube’s valve, removing the tyre from the rim and work your way around
unl the tyre is completely removed.

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Now that the bicycle has been prepared, the motor can be mounted on the
bicycle.
ASSEMBLY—FRONT MOTOR
Remove the motor from its packaging if you have not done so already. At this
point you can remount the tyre and tube, making sure you get the direcon
right. This is typically marked on the side of tyre tube. The motor has a cable
coming out of the right side which may help you get the correct direcon.
If you have removed a disk brake in the previous secon, you should remount it
on the motor now. To do this, you can remove the Allen key bolts from the
motor as shown above. The motor has a plasc spacer in the posion of the
disk brake as a placeholder. Remove this and mount the disk brake in posion.
Be sure to ghten the bolts evenly all the way round.

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Now to mount the motor into the front forks.
ASSEMBLY—FRONT MOTOR
Familiarise yourself with the washers and their posions. Ensure that the
torque washers (which are the washers with a notch) are both on the same way
on the axle.
Line the torque washers up with the axle slots. As you can see in the
photograph on the right, the torque washer will not t in the axle slot with the
current washer conguraon. We will need to remove the internal washer from
the setup so that the torque washer is the only washer present on that side.
This secon is dierent for every bike and will require some common sense to
complete the install.

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Another observable issue is that the calliper is ever-so-slightly rubbing against
the disk.
ASSEMBLY—FRONT MOTOR
To solve this, we recommend loosening the brake calliper before readjusng
the washer posions so that the axle will correctly slot into the front dropouts.
As you can see from the pictures above, the motor has been mounted into the
front forks with enough clearance for the disk brake and the motor. The motor
can now spin in the drop outs without rubbing on the disk brake calliper or the
frame in any way.

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With the motor sloed in the front forks and able to rotate without running
afoul of the frame or brakes, the nal stage of assembly can begin.
ASSEMBLY—FRONT MOTOR
Insert washers on the axle on both sides to completely ll out the secon so
the axle nut will have a nice at surface to ghten up to. Once the washers are
in place ghten the nuts up with a spanner/shier.
Ensure that your brake calliper is ghtened up again. You have now completed
the front motor installaon. The bicycle can be ipped back to its vercal
posion for the remainder of the installaon process. Ensure that the tyres are
properly inated before ipping over.

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There are a lot of important steps and consider while mounng the front
wheel. Let’s take a moment to summarise the front motor assembly:
• Install tyre and tube
• Install disk brake rotor (if required)
• Check that washer posions are similar on both sides
• Aempt to insert the motor into the drop outs.
• If the motor does not t inially, check what it is fouling on (disc brake,
washer posion or frame)
• If the motor is fouling because of the washer posion, adjust washer
posions to create more or less space as required to t the motor.
• If the motor is fouling because of the disk brake posion, adjust the brake
calliper to create more space as required.
• If the motor is fouling on a part of the bicycle frame, you may be doing
something incorrectly or the bicycle may simply be incompable with this
kit. Please contact support right away for assistance.
• Once the motor has been mounted on the forks, secure the motor by
ghtening down the axle nuts. Ensure that washers are placed on the axle
before ghtening the axle nuts.
Take each step slowly and ensure that it ts before moving onto the next step.
The motor will rarely have to be forced into posion and, if mounted correctly,
should be rotang without rubbing on any part of the frame. Each bicycle is
slightly dierent to convert and will require some common sense to complete.
If you get stuck at any point or your are concerned you’ve made a mistake,
please contact support at once.
ASSEMBLY—FRONT MOTOR SUMMARY

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This part explains how to connect the baery and install it onto the handlebars.
ASSEMBLY—BATTERY
Remove the baery from its packaging. This a small bag that holds the baery
and the motor controller. As in the image in the upper right, the bag has ve
plugs. On the le side is the motor plug and the charger plug. On the right is
the display (green), throle (yellow) the pedal assistance (yellow). There are 3
straps that are available for mounng the pouch onto the handlebars.
Before mounng the baery onto the handlebars, it is likely that the baery is
physically disconnected inside the pouch for safe transport. Locate the two
plugs and connect them with the arrows poinng towards each other. If yours
look dierent than the photo above, make sure you connect red to red and
black to black. Once these are connected, you can reinsert the baery and
motor controller back into the pouch.

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ASSEMBLY—BATTERY
There are 3 straps for mounng the pouch onto the handlebars — two that are
vercal straps designed to run directly around the handlebars as shown in the
top right image, and a single horizontal strap that can then be wrapped around
a part of the handlebar stem.
You have now completed the installaon of the baery onto the handlebars.

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As there are only two components that require installing on the handlebars,
this stage of the installaon is quite simple.
To install the thumb throle, remove one side of the handlebar components
(like your grip and brake lever) and slide the thumb throle into the posion
that is most suitable for you. There is a small Allen key on the boom side of
the throle that ghtens the device to the handlebars once you nd a posion
you're happy with. Ensure that the place washer is inserted as well. This
prevents the thumb throle from geng stuck on other components. Connect
the yellow plug to the matching plug from the handlebar bag.
To install the display, loosen the screw in the clamp, clamp the display onto the
handlebars, and ghten the screw back up. Connect the green plug to the
matching plug from the handlebar bag.
ASSEMBLY—HANDLEBAR COMPONENTS

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This secon will explain how to install your pedal assistance sensor to the
bicycle.
ASSEMBLY—PEDAL ASSISTANCE
Pictured above is the pedal assistance sensor (PAS) and the magnet wheel. The
magnet wheel will aach around the boom bracket crank sha.
If your boom bracket crank sha looks similar to the one in the lower le
picture, then it is likely your bike will be directly compable with this type of
pedal assistance sensor. The magnet wheel can be split in half so that you do
not have to remove the crank arm from the bicycle (which would require
specialised tools). One side of the magnet wheel is marked as the working side
and is completely at. This side will face the bike.

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ASSEMBLY—PEDAL ASSISTANCE
Clip the two halves of the pedal assistance sensor around the crank sha as
shown, with the working side facing the bicycle. Then aach the metal circlip
around the magnet wheel, securing it in place. This magnet wheel should
rotate with the pedals when the pedal cranks are rotated.
Now to t the PAS. The PAS can mounted anywhere on the frame so that the
sensor lines up with the magnets on the magnet wheel. In this case, the best t
for the PAS was on the diagonal down tube pictured in the lower le photo.
This posioning may vary from bike-to-bike.

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To mount the PAS, apply a single zip e around the top secon of the PAS unit.
This will allow you to parally test operaon before mounng it more
permanently. The sensor should be no further than 5mm away from the
magnet wheel and not have a large angle.
ASSEMBLY—PEDAL ASSISTANCE
Now that the PAS is ed, when the system is turned on the and the pedals are
turned, the motor will acvate. You will noce that the light on the PAS will
ash when the system is operang. If this is not ashing you may need to adjust
the sensor’s locaon/angle so that the sensor is very close to the magnet
wheel.