Beyond SelfPoweredBike MA01 User manual

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SelfPoweredBike MA01
Repair & Maintenance Manual
BEYOND MOTOR TECHNOLOGIES, INC

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CONTENTS
1. Preface...................................................................................................................................................... 4
2. Safety Instructions................................................................................................................................. 4
3. List of Tools for Maintenance ........................................................................................................... 4
4. Common Issues and Troubleshooting........................................................................................... 5
4.1 Battery Not Charging ........................................................................................................... 5
4.1.1 Check Power Connection：......................................................................................... 5
4.1.2 Check Battery Connection：....................................................................................... 5
4.1.3 Check Charger Malfunction：..................................................................................... 5
4.1.4 Contact Customer Support：...................................................................................... 5
4.2 Power Assist System Failure............................................................................................... 6
4.2.1 No Response from Power Assist System:................................................................ 6
4.2.2 Weak or Unstable Power Assist:................................................................................. 6
4.2.3 Noise from the Power Assist System: ....................................................................... 6
4.3 Brake Failure .............................................................................................................................. 6
4.3.1 Inspect the Brake System:............................................................................................. 7
4.3.2 Check Brake System Adjustments:............................................................................. 7
4.3.3 Inspect Brake System Components:.......................................................................... 7
4.3.3 Lubricate the Brake System:......................................................................................... 7
4.4 Gear Shifting Adjustment Issues ......................................................................................... 7
4.4.1 Slow or Delayed Gear Shifting: ................................................................................... 8
4.4.2 Skipping or Slipping Gears:.......................................................................................... 8
4.4.3 Chain Rubbing or Noise:............................................................................................... 8
4.4.4 Inconsistent Shifting Across Gears:............................................................................ 8
5. Maintenance and Care Guide........................................................................................................... 8
5.1 Regular Inspection:.................................................................................................................. 9
5.2 Cleaning and Lubrication: ..................................................................................................... 9
5.3 Battery Care: .............................................................................................................................. 9
5.4 Brake Adjustment:.................................................................................................................... 9
5.5 Regular Maintenance:............................................................................................................. 9
6. Component Replacement and Adjustment................................................................................10

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6.1 Chain Replacement and Adjustment............................................................................... 10
6.1.1 Chain Replacement:...................................................................................................... 10
6.1.2 Chain Adjustment:......................................................................................................... 10
6.2 Brake Pad Replacement and Adjustment.......................................................................11
6.2.1 Brake Pad Adjustment: ................................................................................................11
6.2.2 Brake Pad Replacement: .............................................................................................11
6.3 Gear Adjustment and Replacement.................................................................................12
6.3.1 Gear Adjustment:...........................................................................................................12
6.3.2 Gear Replacement:........................................................................................................12
6.4 Pedal Replacement................................................................................................................13
Preparation:......................................................................................................................................13
Removal of Old Pedals: ................................................................................................................13
Installation of New Pedals: ..........................................................................................................13
Test and Final Adjustments: ........................................................................................................13
6.5 Tire Replacement and Inflation .........................................................................................14
6.5.1 Tire Replacement:..........................................................................................................14
6.5.2 Tire Inflation: ...................................................................................................................14
6.6 Headlight and Taillight Replacement ..............................................................................15
Headlight Replacement:...............................................................................................................15
Taillight Replacement:...................................................................................................................15
7. Riding Techniques and Safety Tips ............................................................................................... 16
7.1 Helmet and Protective Gear: ..............................................................................................16
7.2 Riding Posture and Balance:...............................................................................................16
7.3 Braking and Stopping:..........................................................................................................16
7.4Turning and Cornering:........................................................................................................16
7.5 Obey Traffic Laws and Regulations:.................................................................................16
7.6 Awareness and Visibility:......................................................................................................17
7.7 Maintenance and Inspections: ...........................................................................................17
7.8 Weather Conditions: .............................................................................................................17
7.9 Ride Responsibly: ...................................................................................................................17

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1. Preface
In this maintenance manual, you will find detailed information about the repair and
maintenance of electric-assist bicycles. Please read and follow the instructions in this manual
carefully to ensure that your bicycle operates safely and in good working condition.
2. Safety Instructions
Before performing any maintenance or servicing work, please make sure to adhere to the
following safety instructions:
➢Ensure that the bicycle is parked on a flat and stable surface.
➢Use appropriate personal protective equipment, such as gloves and safety goggles.
➢Turn off the electric-assist system and remove the battery.
➢Before making any adjustments or replacing components, ensure that the bicycle is
completely stationary and secure the frame on a stand.
3. List of Tools for Maintenance
➢Set of wrenches (different sizes)
➢Allen wrenches
➢Screwdrivers (different types and sizes)
➢Nut wrench
➢Chain lock
➢Bicycle pump
➢Pliers
➢Lubricating oil
➢Cleaning agent
➢Gloves and safety goggles

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4. Common Issues and Troubleshooting
4.1 Battery Not Charging
If your electric-assist bicycle battery is not charging, you can try the following steps for
troubleshooting:
4.1.1 Check Power Connection：
➢Ensure that the power socket is functioning properly by trying to connect other devices
to verify its functionality.
➢Check the connection of the battery charger's plug and socket to ensure they are secure
and not loose or detached.
4.1.2 Check Battery Connection：
➢Ensure that the battery is securely connected to the bicycle. Check the battery connectors
and interfaces for cleanliness and ensure they are free from rust or damage.
➢If there are issues with the connection, try reconnecting the battery and ensure that the
plug is inserted in the correct position.
4.1.3 Check Charger Malfunction：
➢If you have ruled out issues with the power source and battery connection, it is possible
that the charger itself is experiencing a malfunction.
➢Try using another charger (compatible with your electric-assist bicycle) to charge the
battery and observe if it charges properly.
➢If another charger works correctly, then your original charger may require repair or
replacement.
4.1.4 Contact Customer Support：
If you have followed the above steps and are still unable to resolve the issue of the battery
not charging, we recommend contacting the customer support.
Provide them with detailed information about the problem and follow their advice for further
troubleshooting steps.
Remember to always ensure that the power to the electric-assist bicycle is turned off and the
battery is disconnected before performing any repairs or troubleshooting to avoid the risk of
electric shock. If you are unsure about repairing the battery or charger, seek assistance from
a professional technician.

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4.2 Power Assist System Failure
If the power assist system of your electric-assist bicycle fails, it can affect the bike's
performance and riding experience. Here are some common power assist system failure
scenarios and their possible solutions:
4.2.1 No Response from Power Assist System:
➢Firstly, ensure that the power assist system is turned on and in proper working condition.
Check the battery level and ensure a secure battery connection.
➢If everything appears normal, but the power assist system still doesn't respond, check if
any error codes or warning messages are displayed on the power assist system controller
or display. Refer to the user manual for troubleshooting solutions.
4.2.2 Weak or Unstable Power Assist:
➢If you experience weak or unstable power assist, ensure that the battery has sufficient
charge. Check if the battery needs charging or replacement.
➢Review the settings and adjustments of the power assist system. Some electric-assist
bicycles may have different assist modes and levels, so ensure that you have selected the
appropriate mode and level.
4.2.3 Noise from the Power Assist System:
➢If abnormal noises are coming from the power assist system, start by checking the
drivetrain for proper functioning. Inspect components such as gears, chain, and
derailleur for any adjustments or replacements needed.
➢Verify that the motor and power assist system connections are secure and free from
loose screws or interfaces.
Please note that before performing any repairs or troubleshooting, always ensure that the
power to the electric-assist bicycle is turned off and the battery is disconnected to avoid the
risk of electric shock. If you are uncertain about repairing the power assist system, seek
assistance from a professional technician.
4.3 Brake Failure
If the brakes on your electric-assist bicycle fail, it can lead to dangerous situations. Brake
failure can compromise your riding safety and control. It is crucial to take the following steps
to troubleshoot brake failure issues:

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4.3.1 Inspect the Brake System:
➢First, check if the brake levers are operating correctly, ensuring that they can be fully
squeezed to engage the brakes.
➢Observe the brake cables for any signs of significant wear, breakage, or detachment. If
any issues are detected, replace the brake cables immediately.
➢Check the brake pads for excessive wear, and replace them promptly if needed.
4.3.2 Check Brake System Adjustments:
➢Ensure that the brake system is properly adjusted. Check the tension of the brake cables
and adjust them as necessary.
➢Verify that the brake pads make even contact with the wheel's surface. If uneven, make
the appropriate adjustments.
4.3.3 Inspect Brake System Components:
➢Check if the brake cables are binding or caught on any other components, ensuring that
they can move freely.
➢Inspect the brake calipers for looseness or damage. If any looseness or damage is present,
perform the necessary adjustments or replacements.
4.3.3 Lubricate the Brake System:
➢Apply appropriate brake lubricant to the moving parts of the brake system, such as the
brake levers and calipers.
If you still encounter brake failure issues after performing the above checks and adjustments,
it is strongly recommended to cease riding immediately and contact the customer support
department or the manufacturer's support team. Brake system failure may require the
intervention of a professional technician for further inspection and repair.
4.4 Gear Shifting Adjustment Issues
When it comes to gear shifting adjustment on an electric-assist bicycle, several common
issues may arise. It's important to address these problems promptly to ensure smooth and
accurate gear shifting. Below are some common gear shifting adjustment issues and their
potential solutions:

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4.4.1 Slow or Delayed Gear Shifting:
➢Check the gear cables for any signs of wear, fraying, or corrosion. Replace them if
necessary.
➢Adjust the cable tension to ensure proper shifting response.
➢Inspect the derailleur for any misalignment or damage that may impede gear shifting.
Make necessary adjustments or repairs.
4.4.2 Skipping or Slipping Gears:
➢Ensure the derailleur hanger is properly aligned. Misalignment can cause gears to skip
or slip.
➢Check the condition of the cassette or freewheel. Worn teeth or a damaged cassette may
require replacement.
➢Adjust the derailleur limit screws to ensure precise gear engagement.
4.4.3 Chain Rubbing or Noise:
➢Verify that the front and rear derailleurs are properly aligned with the chainrings and
cassette/freewheel.
➢Adjust the derailleur position to eliminate chain rub against adjacent gears.
➢Inspect the chain for wear and replace if necessary.
4.4.4 Inconsistent Shifting Across Gears:
➢Check the gear indexing by shifting through all gears and ensuring smooth transitions.
➢Fine-tune the cable tension using barrel adjusters for precise gear shifting across the
range.
➢Inspect and clean the gear cables and housing to eliminate any friction or resistance.
If you encounter persistent gear shifting adjustment issues despite attempting these solutions,
it is recommended to seek assistance from a professional bike mechanic or contact the
customer support team of the electric-assist bicycle manufacturer. They will provide expert
guidance and further assistance to resolve the gear shifting problems effectively.
5. Maintenance and Care Guide
In this maintenance and care guide, you will find detailed information on how to properly
maintain and care for your electric-assist bicycle. Please read and follow the instructions in
this guide carefully to ensure that your bike operates safely and effectively.

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5.1 Regular Inspection:
➢Before each ride, inspect the overall condition of the bicycle, including the frame,
handlebars, brakes, tires, and lights. Look for any signs of damage or wear that may
require attention or replacement.
➢Check the tire pressure and ensure it is within the recommended range. Inflate or deflate
the tires as necessary.
➢Examine the brake pads for wear and ensure they make proper contact with the braking
surface. Replace worn brake pads promptly.
➢Inspect the chain for any signs of dirt, rust, or excessive wear. Clean and lubricate the
chain regularly.
5.2 Cleaning and Lubrication:
➢Clean the bicycle regularly using a mild detergent and water. Pay attention to areas that
accumulate dirt and debris, such as the chain, gears, and brake assemblies.
➢After cleaning, thoroughly dry the bike to prevent moisture-related issues, such as rust
formation.
➢Lubricate the moving parts of the bicycle, including the chain, derailleur, and brake levers,
using a suitable lubricant. Wipe off any excess lubricant to avoid attracting dirt.
5.3Battery Care:
➢Follow the manufacturer's instructions for charging and storing the battery. Avoid
overcharging or exposing the battery to extreme temperatures.
➢Periodically inspect the battery connections for any signs of corrosion or loose
connections. Clean and tighten them as necessary.
➢If the battery is removable, store it in a cool and dry place when not in use.
5.4 Brake Adjustment:
➢Regularly check the brake performance and adjust the brake pads if needed. Ensure that
the brakes engage smoothly and provide sufficient stopping power.
➢If you are unsure about brake adjustment or experience persistent issues, consult a
professional bike mechanic for assistance.
5.5 Regular Maintenance:
➢Schedule regular maintenance at a qualified bike shop to ensure that your electric-assist
bicycle is properly serviced. This may include tasks such as wheel truing, gear adjustment,
and bearing lubrication.

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Always prioritize your safety when performing maintenance or repairs on your electric-assist
bicycle. If you are unsure about any aspect of maintenance, consult the user manual or seek
assistance from a knowledgeable bike technician.
6. Component Replacement and Adjustment
6.1 Chain Replacement and Adjustment
The chain on your electric-assist bicycle may require occasional replacement or adjustment
to ensure smooth and efficient gear shifting. Here are the steps to follow for chain
replacement and adjustment:
6.1.1 Chain Replacement:
➢Determine if your chain needs replacement by checking for signs of excessive wear, such
as elongation, rust, or stiff links. If the chain shows significant wear, it is recommended
to replace it.
➢To replace the chain, first, shift the gears to the smallest chainring and smallest rear cog.
This relieves tension on the chain and makes it easier to remove.
➢Use a chain tool or quick link pliers to break the chain at any link. Carefully remove the
old chain from the bicycle.
➢Install the new chain by threading it through the derailleur pulleys and around the
chainrings and rear cogs. Ensure proper alignment and engagement with the teeth.
➢Reconnect the chain by using a chain connector or joining pin according to the
manufacturer's instructions.
➢Check the chain tension and adjust it if necessary. The chain should have a slight amount
of sag but should not be too loose or too tight.
6.1.2 Chain Adjustment:
➢If your chain is skipping gears, not shifting smoothly, or causing excessive noise, it may
require adjustment.
➢Start by shifting the gears to the smallest chainring and smallest rear cog.
➢Use the barrel adjuster on the rear derailleur to fine-tune the shifting. Turn the adjuster
clockwise to move the derailleur towards the larger cogs and counterclockwise to move
it towards the smaller cogs.
➢Test the shifting by smoothly pedaling through all the gears. Make additional
adjustments if necessary until the chain shifts cleanly and accurately.
➢If the chain still does not shift properly, it may be necessary to adjust the limit screws on
the derailleur or seek assistance from a professional bike mechanic.