Dillenger Hunter BBS 2016 User manual

HUNTER
User Manual
This manual describes how to safely complete nal assembly
and includes tips for use and maintenance
English
Dillenger Hunter BBS 2016 Dillenger Hunter Hub Drive Dillenger Hunter BBS 2015
This manual covers the assembly of:

2
SAFETY
PLEASE NOTE
Mechanical Safety Check:
Routinely check the condition of your bike. Make sure no fasteners have come loose. Perform
a visual inspection of the whole bicycle before every ride. Make sure tyres are correctly inated
within the range given on the tyre sidewall. Check your brakes for proper operation.
Your First Ride:
Be sure to pick an area away from cars, other cyclists, obstacles or other hazards to become
familiar with the controls, features and performance of your new electric bike.
We highly recommend the purchase of the Dillenger electric bike repair
toolkit. It will make your setup and ongoing maintenance much easier.
This can be purchased online.
Thank you for purchasing your new Dillenger electric bike! We know you’ll love it, and with some
care it should last for a very long time. Please read through this manual carefully before
beginning nal assembly.
THANK YOU

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ITEM CHECK LIST
Each electric bike is assembled under the most strict quality control standards. Upon
completion, each electric bike is test ridden by a technician inside the assembly factory to
check that every function and adjustment on the bike is perfect.
Item Check list:
• Electric bike with front wheel and handlebars
• Charger box (this may container other important parts)
• Pedals (left and right) please note the left and right pedals are not identical
• Any loose boxes may container other parts, such as a light (if where a light is provided or
purchase) so please check all packaging thoroughly
• BBS shield and xings

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CONTENTS
THANK YOU 2
SAFETY 2
ITEM CHECK LIST 3
SUMMARY OF FINAL SETUP 5
UNBOXING 6
MAIN PARTS 7
ASSEMBLY 10
FRONT WHEEL 10
HANDLEBARS 14
PEDALS 17
SEAT 18
BBS SHIELD INSTALLATION 19
BATTERY OPERATION 24
LCD OPERATION 26
IMPORTANT POINTS 27
CHARGING 28
MAINTENANCE 29
TROUBLE SHOOTING 30
CONTACT US 33
Your Dillenger bike is fully assembled in our factory and tested to our high standards.
To t into an appropriately sized shipping carton to comply with the various courier
networks, some basic parts of the bike are temporarily removed. This is so that the bike
can t into the shipping carton safely, and so that we can adequately package each part of
the bike so that it is delivered in perfect condition.
These simple instruction will show you how to perform the nal setup. Your bike may
arrive in a more assembled state than what is shown here. These are the steps required
for most customers (packaging and nal assembly can vary by country).
In summary, these are the main steps.
Step 1, Unpacking/Unboxing
Step 2, Identify the pieces that require nal assembly
Step 3, Front wheel fastening
Step 4, Handlebar alignment
Step 5, Left and right side pedals
Step 6, Seat
Step 7, BBS Shield Installation
Tools required:
Allen keys (5 and 6mm)
These are provided and can be found in the charger box.
Other equipment not provided:
Bike pump (or service station car tyre pump)
3mm allen key, 11mm spanner (or shifter) for the BBS Shield

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Your Dillenger bike is fully assembled in our factory and tested to our high standards.
To t into an appropriately sized shipping carton to comply with the various courier
networks, some basic parts of the bike are temporarily removed. This is so that the bike
can t into the shipping carton safely, and so that we can adequately package each part of
the bike so that it is delivered in perfect condition.
These simple instruction will show you how to perform the nal setup. Your bike may
arrive in a more assembled state than what is shown here. These are the steps required
for most customers (packaging and nal assembly can vary by country).
In summary, these are the main steps.
Step 1, Unpacking/Unboxing
Step 2, Identify the pieces that require nal assembly
Step 3, Front wheel fastening
Step 4, Handlebar alignment
Step 5, Left and right side pedals
Step 6, Seat
Step 7, BBS Shield Installation
Tools required:
Allen keys (5 and 6mm)
These are provided and can be found in the charger box.
Other equipment not provided:
Bike pump (or service station car tyre pump)
3mm allen key, 11mm spanner (or shifter) for the BBS Shield
SUMMARY OF FINAL SETUP

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Unboxing your Dillenger will be very exciting, but it’s important to take care when
unboxing the bike as it’s possible to accidentally damage the bike or misplace crucial
parts. It’s also much easier to unbox the bike with someone to help you.
Remove the protective packaging from the bike carefully with a pair of scissors or a box
cutter. Make sure you don’t misplace any components in the lose packaging (there can be
quite a lot of protective packaging used).
A stand is shown in this photo for staging purposes only, it is not included with the bike.
After you’ve taken your Dillenger out of it’s shipping carton, you should have these parts:
1. The complete bike
2. Front wheel
UNBOXING

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MAIN PARTS
After you’ve taken your Dillenger out of it’s shipping carton, you should have these parts:
1. The complete bike
2. Front wheel

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5. Pedals (these can be in the same box as the charger, or fastened to the bike separately)
3. handlebars (attached by the wiring)
4. Charger
6. BBS Shield and Fixings
Please note your keys will be securely fastened to the frame or handlebars of your bike.
Make sure you do not lose these as they are coded and a replacement set can only be
tted in a Dillenger factory.

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5. Pedals (these can be in the same box as the charger, or fastened to the bike separately)
6. BBS Shield and Fixings
Please note your keys will be securely fastened to the frame or handlebars of your bike.
Make sure you do not lose these as they are coded and a replacement set can only be
tted in a Dillenger factory.

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FRONT WHEEL
Start by loosening the 4 bolts at the bottom of the fork in order to remove the through
axle. You will have to remove this axle to mount the front wheel and then the axle can be
inserted and fastened.
Prior to assembling the front wheel, we suggest removing the front brake caliper. It’s not
essential but it does make it a lot easier. Once you’ve removed the caliper from the front
fork, you can insert the wheel into the forks as shown below. It can be quite a tight t, this
is intentional. You will have to maneuver wheel and forks where needed so you can line
up the through-axle with the center.
This stage shows the through axle almost in position:
Once in place, tighten the through axle with the specialized nut provided:
ASSEMBLY

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This stage shows the through axle almost in position:
Once in place, tighten the through axle with the specialized nut provided:

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Secure the through axle in place by tightening the 4 bolts that were loosened to remove
the through axle:
Remove the packing shim/spacer from the caliper and re-attached as shown. If you
tighten the caliper almost 100%, then engage the front brake lever, this will align the
caliper and then you can tighten completely.

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Remove the packing shim/spacer from the caliper and re-attached as shown. If you
tighten the caliper almost 100%, then engage the front brake lever, this will align the
caliper and then you can tighten completely.

14
HANDLEBARS
The handlebars will be connected by the cables and wires, all that’s required for nal
setup is to mount the handlebar stem onto the head tube as shown here:
You can remove a number of the black spacer rings on the head tube, leaving 2. These 2
can be placed in any arrangement. In these photos we have the handlebars in the highest
position, with 2 spacers under the stem. Make sure none of the cables are twisted or
too tight (you may have the handlebars twisted). Tighten as shown here, making sure
the handlebars are aligned to the front wheel. This step fastens the stem down onto the
headtube to remove any vertical play:
Stem and handlebars are now in position on the headtube.

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Stem and handlebars are now in position on the headtube.

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Fasten the stem onto the headtube. Tighten each side evenly. This is the nal step in
fastening the handlebars correctly.
All bicycles (electric bikes included) have left and right side pedals. Make sure you identify
each one. This image shows how to identify each pedal. You can see the ‘R’ written on this
pedal, denoting this is the right side pedal, to be used on the right side of the bike (if you
were sitting on the bike).
The right side pedal mounts to the right side crank (if you were sitting on the bike) and
left side pedal on the left crank. The right side pedal is a right hand thread, it will tighten
by turning clockwise (normal). The left side pedal is a left hand thread and will tighten
by turning anticlockwise (opposite normal). It is essential not to confuse which pedal is
used where and not to cross thread the pedal. If it feels too tight, you might have made a
mistake.
The pedals are designed this way so that the act of pedaling (while riding) does not loosen
the pedals over time.

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PEDALS
All bicycles (electric bikes included) have left and right side pedals. Make sure you identify
each one. This image shows how to identify each pedal. You can see the ‘R’ written on this
pedal, denoting this is the right side pedal, to be used on the right side of the bike (if you
were sitting on the bike).
The right side pedal mounts to the right side crank (if you were sitting on the bike) and
left side pedal on the left crank. The right side pedal is a right hand thread, it will tighten
by turning clockwise (normal). The left side pedal is a left hand thread and will tighten
by turning anticlockwise (opposite normal). It is essential not to confuse which pedal is
used where and not to cross thread the pedal. If it feels too tight, you might have made a
mistake.
The pedals are designed this way so that the act of pedaling (while riding) does not loosen
the pedals over time.

New for 2016, we have designed a shield for the BBS motor to help protect the motor
from the elements. Follow these steps to properly assemble and install the shield. If you
have a Hunter with Hub Drive you can skip this step.
First you must remove the bolt from the BBS motor as shown in the photos below.
The next step is to place all the washers, spacers and the mounting plate on the main bolt
in the correct order. The order is two big washers rst, then the plastic spacer, another
big washer, the mounting plate, a small washer and nally the nut. This is shown in the
photos below. This order is not 100% necessary, but recommended as it worked well for
us.
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SEAT
This is the easy part. Simply insert your seat to the desired height (about hip height) as
shown:

BBS SHIELD INSTALLATION
New for 2016, we have designed a shield for the BBS motor to help protect the motor
from the elements. Follow these steps to properly assemble and install the shield. If you
have a Hunter with Hub Drive you can skip this step.
First you must remove the bolt from the BBS motor as shown in the photos below.
The next step is to place all the washers, spacers and the mounting plate on the main bolt
in the correct order. The order is two big washers rst, then the plastic spacer, another
big washer, the mounting plate, a small washer and nally the nut. This is shown in the
photos below. This order is not 100% necessary, but recommended as it worked well for
us.
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BBS SHIELD INSTALLATION CONTINUED...
Now you should insert the BBS shield in between the two big washers as shown the the
photos below.
After this you must position the assembly so that it will mount to your bike easily. Make
sure the nut is tightened at the end of the cutout of the mounting plate and that the
angled part of the mounting plate is facing up. The correct position of the mounting plate
is shown in the rst photo below.
You must also ensure that the mounting assembly is tightened at the bottom of the cutout
in the BBS shield. This is shown in the second photo below.
Next, you can put two washers on the smaller bolt shown in the rst photo below. Insert
this bolt into the angled part of the mounting plate as shown in the second photo below.
Two more washers should now be added to the bolt as shown in the third photo below.
Now you should insert the skinniest bolt (shown in photo 4).
Place the skinny bolt in the BBS shield and the put the washer followed b the long space
onto the bolt.
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