Currie tech IZIP EXPRESS User manual

9453 Owensmouth Avenue | Chatsworth, CA 91311
Phone [phone] | Fax [phone]
www.CurrieTech.com
Customer Service [phone]
IZIP EXPRESS OWNER’S MANUAL

2
Table of ConTenTs
Introduction 3
Personal care from Currie Technologies .................................................................................................................. 3
Safety ....................................................................................................................................................................... 3
Parts and features .................................................................................................................................................... 4-5
Operation 6
Charging your battery ............................................................................................................................................... 6-7
Battery installation .................................................................................................................................................... 8-9
System on/off ........................................................................................................................................................... 10
Motor assist levels .................................................................................................................................................... 11
Battery indicator levels ............................................................................................................................................. 12
Lighting system ........................................................................................................................................................ 13
How to ride for best performance ............................................................................................................................. 13
How to get the most range from your Express ......................................................................................................... 14
Rider Adjustment 15
Seatpost height and suspension .............................................................................................................................. 15
Handlebar height ...................................................................................................................................................... 16
Fork lockout .............................................................................................................................................................. 16
Accessories and upgrades ....................................................................................................................................... 17
Mechanical Detail 18
Cadence sensor ........................................................................................................................................................18
Motor ........................................................................................................................................................................ 18
Evo-Drive™ hub ....................................................................................................................................................... 18
Battery Care 19
Long-term storage .................................................................................................................................................... 19
Service and Diagnostic 20
Belt tension adjustment ............................................................................................................................................ 20-21
Fuses ........................................................................................................................................................................ 22
Troubleshooting chart ............................................................................................................................................... 23
Warranty ................................................................................................................................................................ 24-25
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Personal care from Currie Technologies
Congratulations on your purchase! Our service department is dedicated to your satisfaction with our products. For
any questions regarding performance, assembly, operation, parts or returns, contact our customer and technical
service line directly by calling toll-free: 1-800-377-4352
Monday - Friday 8:00am - 4:00pm (PST)
Safety
The Express is unlike any electric bike on the market, and special care
should be taken when getting to know it. Because the bike quickly
and easily reaches high speeds, your rst ride should be in an area
without trafc or other hazards. Try familiarizing yourself with the
bike’s handling at a low assist level—see the “Motor assist levels”
section of this manual for more information—and read the “How
to ride for best performance” and “How to get the most range
from your Express” sections of this manual before attempting
any long or hazardous rides.
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INTRODUCTION
4
Parts and features
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10
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5
6
12
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1Custom rear rack
2Suspension seatpost with adjustable preload
3Threadless stem with adjustable angle
4Tail light (see “Lighting System” section)
5Currie Evo-Drive™ planetary dual input differential rear hub with belted transfer pulley
6Motor drive belt (Gates GT3 1150-5MGT)
7Motor housing
8Power button (top of battery)
9Assist level adjustment buttons (arrow shape, top of battery)
10 Battery and controller (inside)
11 Battery pack locking lever & pin
12 Headlight (see “Lighting System” section)
13 Cadence sensor (behind crank on opposite side)

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Charging your battery
Please charge your battery before riding your Express for the rst time. Battery charge time is
6-8 hours when the battery is completely empty, but “top off” charges will be signicantly shorter.
Please refer to the “Battery care and information” section of this manual for more information on
extending the working life of your battery.
The Express battery can be charged either on or off the bike.
1. Before using your charger for the rst time,
make sure the red switch shown is set to
115V (USA and Canada). Other countries
may have other line voltage. Wrong selection
may damage or ruin the battery, so be
careful! This kind of damage is not covered
by warranty.
OPERATION
6
115

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The ve lights around the power button indicate charging progress when
the battery is plugged in. During charging, the lights cycle individually
from left to right. In between these cycles, 1-5 of the indicators light up
steadily; this shows the current battery level. A single light means the
battery is 0~20% charged, ve lights correspond to between 80 and
100%. When the battery is fully charged, all ve lights will be steadily
illuminated.
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115
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2. With the charger switch in the OFF position, plug the charger into a wall socket.
3. Plug the other end of the charger into your Express battery, then ip the charger switch to the
ON position.
Set to 115 (USA and Canada)

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Battery installation
1. Standing on the left side of the Express, insert the
mushroom-shaped head of the battery locking pin into the
hole in the battery handle.
2. Pivot the battery so it is parallel with the bike inside the
frame triangle, letting the weight of the battery rest on the
bike frame.
3. Push the battery rearward into the motor plate as far
back as it is able to go. By looking between the motor plate
and the battery, you should be able to see if the battery is
fully connected.
Locking pin
Push

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4. Close the battery locking lever to secure the battery
pack. If the lever does not have sufcient tension to hold the
battery tightly, you can adjust its preload by nger-tightening
the mushroom-head at the top of the locking pin.
5. Use the small lock near the battery handle to secure the
battery, if desired. This is simply a security measure and is
not essential to hold the battery in place.
Close
Turn to adjust

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System on/off
Turn the Express on by pressing the round button on the top of the battery pack. To power off,
simply hold the same button for about three seconds.
The system defaults to medium power
assist, indicated by three ashing lights
during the startup sequence.
About three seconds after pressing
the power button, when the indicator
lights stop blinking, the bike is
ready to ride. In their default state,
these lights show approximate
remaining battery power. Five
lights indicate a full charge; a
single blinking light means the
battery is almost empty and that
emergency shut-off is imminent.

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Motor assist levels
Selectable with the up & down arrows on the battery pack
-1
Lights-only
mode. Motor
is disabled,
but front and
rear lights stay
powered
0
Eco mode.
Motor is limited
to very low
speed. Useful
for extremely
long trips or
as a “survival
mode” with
depleted battery
power.
1
Super economy
mode; Longest
range, at
normal pedaling
cadence
2
Economy mode;
long range at
normal cadence
3
Startup default;
medium range
and at normal
cadence
4
Express mode;
Full power at
normal pedaling
cadence, lower
range.
5
‘Easy mode”;
Lowest range,
maximum
power, even
at very low
pedaling
cadence.
%
≤100
%%%% ≤80
≤60
≤40
≤20
%
~0

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Battery indicator levels
%
≤100
%%%% ≤80
≤60
≤40
≤20
%
~0
One blinking
indicator light. The
battery is almost
empty. The system
will soon power
down to prevent
battery cell dam-
age
One solid indicator
light. The battery
has about 20%
or less charge
remaining.
Two solid indicator
lights. The battery
has about 40%
or less charge
remaining.
Three solid
indicator lights.
The battery has
about 60% or less
charge remaining.
Four solid indicator
lights. The battery
has about 80%
or less charge
remaining.
Five solid indicator
lights. The battery
is close to fully
charged.
Displayed around the On/Off button during normal riding

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How to ride for best performance
Because the cadence sensor regulates motor power based on the pedaling speed of the rider, you
should maintain a reasonably high pedaling cadence to get a signicant level of motor assist and
to use the system to its fullest potential. Ideally, you should pedal at around 60-90 RPM for the best
experience both physically (fast pedaling increases physical tness, all other things being equal)
and electrically (the system is tuned to provide progressively more assist with increased RPM).
Faster pedaling gives more boost. At level 5 full power boost is reached at a lower pedaling
cadence than level 4 does, and so on.
As with all electric vehicles, overall range and performance will be greatly affected by factors such
as rider weight (and luggage), terrain, headwinds, and riding style. Lighter weight and atter terrain
will yield the most range, while heavier riders or abnormally hilly terrain may cause range to drop
below the normal expectation.
Lighting system
The Express is equipped with front and rear lights that are automatically triggered by an ambient
light sensor located in the battery pack. Even when riding without motor assist, the lights can be
turned on by setting the assist level to its lowest “-1” lights-only mode (see the “Motor assist levels”
section for more information).

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How to get the most range from your Express
To increase your battery range as much as possible, please consider the following advice:
• Try not to ride against strong headwinds
• Don’t ride with more weight (like luggage) than is necessary for a given situation
• Coast down hills instead of running the motor
• Conserve power by using a lower boost setting (such as 1 or 2)
• The Express is great at climbing hills, but consider a atter route for very long rides
• Riding in conditions that force many starts and stops (such as city trafc) draws more power
from the batteries, because more energy is required to accelerate from a full stop than to
maintain a constant speed. Consider taking routes that have long, uninterrupted stretches of
riding whenever possible.
• Keep your Express properly maintained. Lube the chain, inate the tires to the pressure
indicated on the sidewall, and have your local bike shop make sure the drivetrain and brakes
are properly adjusted and maintained regularly.
• All batteries are affected by temperature changes; extreme cold or heat can negatively affect
battery capacity and thus range.

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Rider adjustment
Seatpost height and suspension
The Express has several features included to allow the rider to adjust his or her bike for maximum
comfort and to suit their riding style.
The Express’ suspension seatpost is designed to be adjusted based on
individual preference. To raise or lower the seatpost, as on any bike, simply
open the quick release mechanism securing it, then move the saddle up or
down until the most comfortable position is found.
To adjust the stiffness of the suspension mechanism, remove the post from
the bike, then use a 6mm Allen wrench to turn the preload adjustment plate
clockwise or counter-clockwise to stiffen or soften the suspension system. The
plate is located inside the main seatpost tube (normally hidden inside the bike),
and is accessed from the bottom.
Soft
Firm
rider adjustment
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Handlebar height
The Express is equipped with an adjustable-angle stem, which can be used to raise or lower the
handlebars based on rider preference. To adjust the stem, rst loosen the cap on its right side using
a 5mm Allen wrench. Once the cap bolt has been loosened a few turns, push the left-side cap
into the stem, disengaging the mechanism. The stem angle can now be changed. Once you are
satised with the new position, simply tighten the right-side cap bolt to the torque value printed on
the cap. Fork lockout
The front fork has a lockout mechanism that allows the rider
to switch on-the-y between rigid and
suspension modes. The rigid “lock”
mode is best when climbing hard hills
or riding on smooth, easy terrain; the
lack of suspension travel in this case
means that less of the rider’s pedaling
effort is lost to fork compression.
Switch to “open” mode to allow full
suspension travel when riding on bumpy or uneven surfaces,
or when you desire the softest ride irrespective of terrain.
Loosen
Push

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Accessories & upgrades
The Express can be tted with comparable aftermarket parts and accessories in almost all areas,
with a few exceptions:
• The rear wheel cannot be replaced, unless the new wheel uses a Currie Evo-Drive™ hub
• A square-taper bottom bracket must be used for proper cadence sensor operation
• Be sure any changes you make to not interfere with the belt drive system
Additional/replacement battery packs are available from Currie, as are other unique Express
replacement parts. Because almost all parts on the Express are standard bicycle equipment, most
parts can be ordered from a bike shop and/or upgraded to suit individual preferences.

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Cadence sensor
Motor
Inside the motor box is a brushed DC
motor, capable of producing 750 watts of
power and very high torque, thanks in part
to its rare-earth Neodymium magnets. The
motor is bolted to a movable plate that
facilitates belt tension adjustments.
The Evo-Drive™ cadence sensor measures the rider’s pedaling speed, translating it into an
electrical signal that is read by the motor controller. Inside the sensor, a large sprocket is driven by
the rotation of the bicycle’s crank. This sprocket is connected with a belt to the spindle of a small
electric motor, which acts as a generator, outputting voltage that directly corresponds to the rider’s
pedaling cadence.
Evo-Drive™ hub
The Currie exclusive Evo-Drive™ rear hub
uses a proprietary & patented planetary
differential to combine human effort
with electric assistance. The hub uses a
standard freehub body, compatible with
Shimano or SRAM 9-speed cassettes.
Cadence sensor, cover removed
mechanical detail
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Battery care and information
Long-term battery storage
All batteries have a nite life cycle, and will eventually lose storage capacity below a useful level.
In order to keep your batteries running for as long as possible you should follow these care instruc-
tions closely.
• Avoid storing your batteries in extreme temperatures, whether hot or cold. Batteries are best
kept in a cool, dry place
• Lithium-Ion batteries do not have a “memory,” and actually prefer frequent, partial discharge/
charge cycles rather than fewer full deep cycles.
• Your Express batteries have an effective life of about 600-700 full charge/discharge cycles.
Small “top off” charges count fractionally towards a single full cycle.
• Generally, as the batteries age they will lose about 13% of their total capacity per year. This will
manifest itself in a corresponding range decrease.
• Li-Ion batteries are recyclable at the end of their life; please dispose of your batteries according
to local laws.
When storing your Express batteries for a long period of time (longer than two months):
• Charge the battery to about 50% (three indicator lights), then recharge every 60 days as needed
to maintain this level. Allowing your batteries to sit for longer than two months in a discharged
state could lead to permanent capacity loss.
• Ideally, batteries should be stored between 32° and 80° F. Avoid long periods of extreme heat
(104°F or higher)
• Store the batteries in dry, low-humidity conditions. Do not allow the battery to accumulate con-
densation such as dew, as this could cause shorting or corrosion.
battery care
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?Service and diagnostic
Belt tension adjustment
In this section you will nd basic maintenance, diagnostic, and troubleshooting information. For
questions, problems or service not discussed in this manual, or for parts ordering, please call Currie
technical and customer service at 1-800-377-4532.
Although the tension of the main drive belt is set at the
factory, over time the belt may stretch a small amount.
Generally, this stretching is indicated by a grinding noise from
the motor pulley wheel as the belt skips under load. While this
will not cause damage to the drivetrain, the belt could fall off
the hub pulley and cause a fall if not re-tensioned properly.
1. Pull the drive belt off of the hub pulley wheel by prying it
from above with your ngers.
2. Remove the ve bolts holding the black plastic motor
housing to the Express, then detach both sides of the
housing. In order to remove the right-side housing
completely, you will need to carefully slide the small circuit
board out of its slot as shown.
Slide
1
2
service & diagnostic
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