Bion x Ebike Manual

eBike Instruction Guide for Leaders

The Control Console

Removing the console

• Turn it off and then release the console by pushing the release lever on the console mount

• Slide the console out of the console mount

• Stow the console in the guest’s trunk bag for safe keeping

Inserting the console

• Slide the console into the console mount on the handlebar

• Make sure that the console engages securely. When inserted correctly, you will hear a “click”

Control Console Operations

Inserting or Removing the Battery

The battery key is attached the 15mm wrench located in the side pocket of the eBike trunk bag as well as in the van tool kits

Removing the battery

1. Turn off the BionX propulsion system via the console

2. Lightly press on the battery release arm, insert the key and turn clockwise

3. The lock cylinder will pop out, freeing the battery release arm

4. Remove the battery by opening the release arm

5. Slide the battery upwards on the rail

6. Lift the battery to remove

Inserting the battery

1. Place the battery onto the docking station

2. Slide the battery down the rail gently towards the connector

3. The release arm will begin to move to the closed position as the battery slides towards the connector

4. When the release arm is almost closed, hold it in place and simultaneously push in the lock cylinder –you will hear a “click” when the lock cylinder

is properly closed

Handling and Charging the Battery

Make sure that the battery is no longer connected to the power supply or charger once the charging is complete. Leaving the batteries plugged in for long

periods is not good for them. Overnight is fine, but don’t leave them plugged in for a week at the storage unit. Charging should be complete in about 4 to

5.5 hours. You are provided with a charger for every battery so you can charge several at once. These chargers draw minimal amounts of power so there is

little chance of tripping a breaker with several plugged in.

The battery does not need to be completely drained before charging. Go ahead and charge the battery after every ride, preferably when the state-of-charge

button display shows less than 50% (yellow light when you hit the button).

When the battery is really low it will signal that a recharge is needed by beeping. Please be sure to plug it in as soon as you can if you hear this beeping.

Power supply

1. Connect the power supply and the battery by inserting the charge connector into the TOUCH PORT

2. Connect the power supply to a wall plug

3. The battery TOUCH PORT (LED ring around the charge connector) lights up red upon insertion and then turns to amber during the charging process

4. When fully charged, the color of the LED ring changes to green. The battery charging process is then complete

Checking the Battery power/charge:

• Swipe your finger slowly over the TOUCH PORT

• Battery LED light will illuminate

• Allow ten (10) seconds before checking state-of-charge again

Assist Mode / Generate Mode

In Assist Mode, the rider is given four levels of assistance, marked by the graduated boxes on the right side of the Console:

There is also a Generation Mode which generates power back into the battery. The four levels within the Generation Mode are marked by the graduated

boxes on the left side of the console. In Generation Mode the rider will feel added resistance which may be beneficial on long downhill sections of a

ride, slowing the rider in addition to normal brake use.

Bicycle Mode provides zero assistance and zero resistance. On low battery power, or in the appropriate riding situation where neither assistance nor power

generation are required, it is recommended to use Bicycle Mode rather than turning off the system. This will allow for the rider to keep track of speed and

distance as well as enter Brake Generation mode while braking.

Assist and Generate mode selection is done with the + and –keys on the right hand side of the console. Generate/Assist level is indicated within the filled

boxes on either side of the Console.

Removing and Installing the Rear Wheel

A 15mm Wrench is found in the side pocket of the eBike trunk bag as well as the van tool kits

Removing the rear wheel

1. IMPORTANT NOTE: Make sure that the system is turned off via the console (skipping this step can damage the entire system)!

2. Remove the neoprene wrap on the chainstay

3. Disconnect the two cable connections that lead to the motor

4. Loosen the axle nut on the rear wheel using a 15mm wrench (found in the eBike trunk bag or van tool kit)

5. Slide the rear wheel downwards, out of the dropout

Installing the rear wheel

1. Guide the rear wheel axle into the dropouts. Ensure that the torque reaction collar is aligned so that it fits into the left dropout. Make sure the axle is

inserted all the way into the dropouts

2. Tighten the axle nuts to 40Nm (30lb-ft) (= VERY TIGHT!). This torque is essential for the correct function of the propulsion system.

3. IMPORTANT NOTE: use the torque wrench in the van tool kit to make sure you have tightened the nuts enough. If the van tool kit is not

accessible during a roadside tire repair, be sure to check the torque when you have access to the wrench back at the hotel.

4. Place the larger neoprene cover over the plug-in connections, and the smaller neoprene cover closer to the disc/motor to prevent the cables from

contacting any moving portions of the motor.

Racking an Electric Bicycle

1. Turn of the power on the console, remove the console and place it in the trunk bag, roll the console mount forward so it is not damaged by the tray.

2. Remove the battery.

3. Remove the rear wheel.

4. Remove the trunk bag.

5. Tray and rack the bike as normal.

eBikes & Weather

In case of severe inclement weather, the motor and console should be protected from the elements (tarped) and not left on the van overnight. The battery

is the one item you want to protect the most from rain. It is certainly weather proof, but you should avoid leaving it out in the rain when the bike is not

being ridden.

Troubleshooting

The system does not turn on

Check the battery and make sure that it is charged. The battery must be correctly inserted onto the docking station and the lock must be completely closed.

Also check that all connectors of the wiring harness are properly engaged, and the console is inserted properly.

The system can be turned on but there is no assist

Check that the cables running from the battery to the motor are properly connected (with the system turned off). Turn the system on.

The system is continuously in Generate mode

When the propulsion system is continuously in Generate mode and cannot be switched back to assist mode by pushing the key, the problem most likely

lies with the brake switch that is located under the brake lever. If the sensor has fallen out, it can easily be reinserted to get the guest riding again. Slide the

sensor so that the end of the sensor rests under the magnet on the bottom side of the brake lever (see the troubleshooting video on Mainstreet for more

information).

The motor is not as powerful after a repair or service

Tighten the nuts of the rear axle to the specified torque (40Nm/30lb-ft); check that the axle slot is facing in the direction of 6 o’clock. A torque wrench that

you can use to ensure the wheel is tight enough is in the van tool kit.

The battery state-of-charge display on the console does not show “full” after a complete charging procedure

Make sure that you have followed all of the instructions for the charging procedure. Let the battery cool off for a few hours and charge it again. If the