Dyson Bike User manual

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User Guide - The Hard Tail

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Contents
Page Item
______________________________________________________________
4 Acknowledgements and Foreword
5 Symbols and Users‟information and Responsibility
7 Components Description and Specification
9 Assembly Instruments
12 Mechanical Operation and Adjustment
17 Electric Operation and Adjustment
26 Safety
28 Maintenance and Care
32 Trouble shooting
33 Warranty
34 Maintenance Records

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Acknowledgments
This manual has been developed by Dyson Bikes and their supplier. The information contained in
this manual complies with relevantAustralian Standards at the time of printing.
Copyright 2014 Dyson Bikes. This manual may not be reproduced in part or whole without the
express and written permission of Dyson Bikes.
Foreword
Thank you for purchasing a Dyson e-bike, we are certain you will enjoy it for many years to come.
Please take the time to read this instruction manual thoroughly before assembly (if required), and
taking your first ride.
There are warnings throughout this manual and these will be highlighted with symbols or words as
detailed on the next page. Please ensure you follow these warning instructions, don‟t risk your
safety or that of others.
Failure to comply with these conditions may also affect your warranty and the long-term reliability of
your e-bike.
Your new e-bike is considered a vehicle and when ridden on public roads you must comply with all
local requirements. Laws vary in Australia from State to State - please refer to the relevant authority
in your State for more information.
YOU SHOULD READ THIS MANUAL
Your e-bike is an electrically power assisted cycle (EPAC),
which uses the same traffic
areas as cars, trucks and motorcycles. You need to know about certain legal and common
sense requirements for the safe and trouble free use of your e-bike.

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Symbols used
Important information for your safety is specially marked. Always follow these instructions to avoid
personal injury or e-bike damage.
WARNING
Warns of dangers to your health and implies potential risk of injury.
ATTENTION
Indicates a potential hazard to the equipment or other objects.
Failure to observe could result in voiding of warranty.
NOTE
Suggestions and information.
Users’ information and responsibility
To reduce the risk of serious personal injury, you should read the instructions in this manual
carefully.
This is an electrically power assisted cycle (EPAC or commonly referred to as an e-bike), with a 1:1
pedal assistance system, designed for urban commuting and short distance travel.
The e-bike is intended only for riding on paved roads and trails. Do not use it for off-road purposes.
Do not use it in water, for jumping, stunting or in competitive sports events.
During riding, you should note that the e-bike covers 5 meters per second at a medium speed of
about 18 kilometers per hour in fine dry weather conditions. Keep sufficient distance from other
road users to ensure you can stop safely in case of an emergency and always consider the current
weather and road conditions.
Pay attention to the traffic during your ride and keep both hands on the handlebars at all times.
There are warnings on the e-bike containing
safety instructions. Non-observance of these
instructions may cause injury, failure or damage!

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Do not use headphones in road traffic as it blocks other sounds and increases the risk of accidents.
Check the e-bike thoroughly against this manual to ensure correct function of components before
your first ride and rectify any issues before riding. The owner is then responsible for normal
maintenance of the e-bike.
Learn how to operate all standard and accessory equipment on the e-bike.
Ensure that anyone who uses the e-bike has been fully instructed in the operation of its mechanical
and electrical functions.
Your e-bike conforms to relevant Australian standards (AS NZS 1927-2010 Pedal bicycles - Safety
requirements and European Committee for Standardization EN 15194:2009+A1:2011 Cycles –
Electrically power assisted cycles –EPAC Bicycles). Please note other local regulations may apply.
Check our website www.dysonbikes.com.au for additional information or call 0497 357 117 if you
cannot find the answer to your question.

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Section-1 Component Description and Specification
An e-bike consists of various mechanical parts such as the frame, wheels, brake, handlebar, saddle
etc.
Please take the time to familiarise yourself with this terminology; it will make basic operation and
maintenance instructions easier to follow.
The e-bike serial number is engraved in the front of the head tube.
NOTE This diagram is for reference only, from time to time changes may be made in the interests of
product improvement.

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General
Wheel size
26 inches
Dimension LxWxH
1660x235x850 mm
Tyre Pressure range
280 –460 kPa
Valve type
Schraeder
Dimension (packing) LxWxH
1840x255x980 mm
Net Weight (battery included)
22 kg
Range on one full charge
Approx. 60~70 km*
Max. load of carrier (if fitted)
25 kg
Permissible total weight
120 kg
Max. speed (with assistance)
25 km/h
Technical specification of the battery
Battery type
Sony - Li（NiCoMn）O2
Capacity
316.8WH –8.8AH
Nominal voltage
36V
Charging voltage
42V
Max charging current
1830 mA
Discharge current
15000 mA
Operating temperature of discharging
-20 ~ 40℃
Operating temperature of charging mode
0 ~ 45 ℃
Technical specifications of the motor
Motor type
Brushless geared hub motor
Power
250 W
Voltage
36 V
Max. torque
4.5~15 Nm
Max. rotational speed
274 RPM
Control system
Cadence sensor in bottom bracket
Technical specifications of the controller and the charger
Undervoltage protection
29±0.5 V
Overload protection
12±0.5A
Charging mode
3-step “Intelligent”
Charging current
Approx. 1.8 A
Display
By LED red / green
Weight
550 g
Charging time
Approx. 5 hours (2.5 hours, up to 80%)^
*The range on a full charge is affected by many external factors, such as the weight of the rider, the terrain and
winds.
^ Depending on the depth of battery discharge this time may be longer or shorter.

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Section 2 - Assembly Instructions
If you have purchased your new e-bike online and had it delivered, you will need to carry out some
minor assembly before your e-bike can be ridden. If you have purchased an assembled e-bike
please continue reading from Section 3 on page 12.
Please follow these instructions carefully to ensure your new e-bike is correctly assembled for safe
operation.
If you are unsure of anything and require further assistance please call Dyson Bikes on
0497 357 117 and we will be happy to talk you through the procedure.
Alternately you may wish to have your e-bike assembled by a trained e-bike mechanic.
Step 1.
Remove e-bike from outer carton and remove packaging material from frame taking care not to
mark or scratch your new e-bike.
Step 2.
Locate included tools, namely 3, 4, 5, 6-mm Allen Keys and 8, 10, 13, 15-mm spanners.
Step 3.
To fit the handlebar to your e-bike, remove the small black rubber cap and hex bolt with the 5mm
Allen Key, then remove the ring spacers and set aside, (refer images on the following page). Please
take care that the controls will not interfere with the correct operation of other components, or
cables.
Now fit two thin rings followed by the head stem, then the last thin ring to the top of the fork. Take
the black cap and hex bolt previously removed and refit. Check that the lower bearing is seated
correctly and tighten, (taking care not to over tighten) it is right when the handlebars turn freely and
there is no free play. Check by holding the front brake on and moving the bike back and forth.
Check for correct alignment of the front wheel in relation to the handlebars, they should be at right
angles. Now tighten the two locking hex bolts to 7~10NM, take care not to over tighten.

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More information regarding handlebar adjustment can be found on page 14.
Step 4.
Locate pedals and use 15-mm spanner to attach to crank arms
as shown in the image shown here.
Note that the pedals are marked „L‟ for left and „R‟ for right. The
Left pedal has a left hand thread and needs to be tightened in
an anti-clockwise direction; the right hand pedal tightens in a
regular clockwise direction.
Screw into the crank carefully using your fingers, then tighten
firmly with the 15-mm spanner. We recommend a torque
wrench be used to tighten to ≥35Nm.

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Step 5.
Charging the battery. The battery is held into the
frame with a keyed lock, two keys are supplied
with your e-bike.
We highly recommend that you keep one key in a
safe and secure location in the event the main key
is lost.
Locate the battery charger and plug into a regular
240-Volt wall socket, the other small plug can then
be inserted into the battery as shown below. The
LED light on the charger will glow red to indicate
charging is in progress.
Charging can take place with the battery in the frame, or you can remove and charge separately.
Once fully charged the LED indicator light on the Charger will be green.
Make sure the battery is fully charged before the first ride and charge again for at least 6-hours
after.
Further notes on battery care can be found under Section 4.2 Battery and Charger.
Step 6.
Your e-bike is now assembled, but it is not quite ready for the first ride. Please continue to read
through this manual paying particular attention to Section 3 ensuring that all bolts screws etc. are
firmly tightened to the recommended specification.

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Section 3 - Mechanical Operation and Adjustment
3.1 Fitting your e-bike for a safe ride
To ride safely and comfortably your e-bike and its equipment must be matched properly to the size
and skills of the rider.An e-bike that is too big or too small for the rider is hard to control and can be
uncomfortable. If your e-bike does not fit properly, you may lose control and fall.
3.2 Controls, position and adjustment
The brake and shifting levers on your e-bike are positioned in a way that they work best for most
riders. The angle of the shifting lever can be adjusted by loosening the hex bolts securing them to
the handlebars. Once adjusted, retighten securing hex bolts, ensuring the controls will not interfere
with the correct operation of other components or cables.
3.3 Brakes
Pulling either brake level will immediately cut out the electric motor, this is a safety feature of your
e-bike. Make sure that your hands can reach and squeeze the brake levers comfortably.
Due to normal brake pad wear or cable stretch you
may need to adjust the brakes from time to time.
To adjust you can make minor adjustments with
the thumb wheels (marked A) on the brake caliper
as shown.
If required, the cable may need to be adjusted by
loosening the attachment (marked B) and pulling
the cable through. It is recommended that a
trained e-bike technician perform this operation.
The brake pads should be adjusted in such a way
that they are parallel to the disc rotor and have a
lateral clearance of approximately 1 mm with the rotor. Two hex bolts securing the brake caliper to
either the front fork or frame make this adjustment. It is recommended that a trained e-bike
technician perform this adjustment.
Front wheel brake lever must be mounted on the RIGHT
hand
side; rear brake lever on the LEFT hand side.

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The brakes of the front and rear wheel can be applied independently, or simultaneously.
Keep the disc rotors and brake pads clean and free of lubricants, waxes or polishes.
WARNING
The e-bike is equipped with a front disc brake and it can achieve a very high braking force.
In sharp turns, on sandy or slippery roads, wet asphalt and icy paths; apply the front brake carefully,
so that the front wheel will not slip.
Please brake with care and caution. Locked wheels have a lower braking effect and can lead to
slipping and falling. In principle, do not brake while turning, instead do it beforehand. Braking in a
turn/curve increases the risk of slipping.
NOTE We do advise that you practice „worst case‟ heavy braking in a clear location, where you
won‟t injure yourself or others.
3.4 Saddle position
To ride comfortably and pedal efficiently, it's very important to have the saddle at the correct height.
Your leg length determines the correct saddle position. The saddle is at the correct height for you
when, while seated on the saddle, your knee is slightly bent when the crank is at the maximum
down stroke (pedal is closest to the ground).
To adjust the saddle height, loosen the seat post clamp
(marked A) by unlocking the quick release, and moving
the seat post up or down as required while ensuring it is
within the minimum and maximum range as marked on
the seat post. Make sure the saddle is parallel to the top
frame tube. Lock the quick release tight enough so that
you cannot twist the saddle out of alignment. Do not
overtighten. By adjusting the nut on the quick-release
lever, the clamping force can be regulated.
The saddle can be tilted and also adjusted in the
longitudinal direction for best fit. This may be adjusted
by loosening the hex screw located under the saddle. Adjust to the desired position then tighten.

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Handlebar grips or tube-end plugs should be replaced if
damaged. Unprotected tube-ends can cause injury.
WARNING An incorrectly tightened quick release lever may come loose and rotate downward
during the ride. This may lead to serious falls.
The quick release lever will require sufficient pressure to close that the heel of the hand is needed
to move it. In this way, the friction is strong enough. The quick release shall be tight enough so that
it requires you to provide a degree of force to unlock it.
Under no circumstances should the seat post project from the frame beyond its 'Minimum Insertion'
or 'Maximum Extension' mark.
3.5 Handlebar position
The handlebar height is correct when the stem is on the same plane as the top surface of the
saddle or slightly higher. The height can be adjusted by moving the rings above or below the head
stem, refer pages 9-10.
To adjust remove the top hex bolt and black cap, then loosen the two locking hex bolts. Taking care
not to excessively bend control cables remove head stem and position rings to desired height and
refit top hex bolt and cap, tighten. Tighten locking hex bolts to 7~10NM while ensuring correct
alignment of handlebars is maintained.
3.6 Changing Gears
Located on the right hand handlebar is the control for the 9 speed gear system. The current gear is
indicated in the display with „1‟ being the lowest and „9‟ the highest. Use the lower gears for climbing
inclines or riding slowly. Note in the lower gears the crank will turn more in relation to the road
speed, this will cause the e-bike controller to provide greater assistance.
With experience you will learn the best gear to use in conjunction with the PAS level to maintain the
desired road speed.
To change down a gear, press the rear lever forward one „click‟ and to change to a higher gear,
press the front lever backward. Continue to pedal forward during this operation.
WARNING Do not pedal backwards whilst changing gears, the chain may fall off!

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3.7 Tyres
Ensure tyres are correctly inflated. Under inflated tyres can lead to punctures or damage to rims.
In addition to standard manual air pumping, the tyres can be inflated with air compressor devices
like those found at service stations.
We recommend a tyre pressure for front and rear at 420 kPa, (equivalent to approximately 60 PSI
or 4.1 Bar). This is a higher pressure within the acceptable range, higher pressures decrease the
rolling resistance making it easier to pedal and putting less load on the electric motor therefore
increasing the available range of a battery charge.
WARNING When pumping up tyres with an air compressor device (for example at service
stations) please note that due to the small volume of the tubes, the tyres will inflate quickly.
Do not over or under inflate. Keep within a range of 280 - 460 kPa (40 –65 PSI or 2.8 –4.6 Bar).
3.8 Cranks
The cranks will loosen gradually over time. Check regularly if the cranks are tightened properly.
Force the cranks from one side, and there should be no slack between it and the bottom bracket.
There should also be no slack between the bottom bracket and the axle, and the crank can rotate
easily. Check the bottom bracket regularly by moving the crank back and forth from one side.
If you find that the cranks or the bottom bracket is loose, go to an experienced repairer for
rectification. The cranks are tightened to max. 35 Nm.
3.9 Pedals
Check regularly that the pedals are firmly secured to the cranks.
Note that the pedals are marked „L‟ for Left and „R‟ for Right. The Left pedal has a left hand thread
and needs to be tightened in an anti-clockwise direction; the Right pedal tightens in a regular
clockwise direction.
Tighten firmly with a 15-mm spanner. We recommend a torque wrench be used to tighten to
≥35Nm.

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3.10 Spokes
A tight fit of the spokes is important for impact-free running of the wheels. Loose spokes should be
retightened as soon as possible.
A broken spoke/s and their opposite spokes must be replaced immediately and the wheel trued
thoroughly. If necessary, rebuild the wheel.
Broken spokes and an out of balance wheel can often result from improper tensioning of spokes.
It is recommended that a trained e-bike technician replaces, tightens or eases spokes.
3.11 Forks
The forks can be set to the locked position by a level located on the top right hand leg.
In the event that the front forks need to be replaced it is critical that they are replaced with a
component of the same specification. Forks of a different size may cause your e-bike to become
unsafe.
3.12 Kick Stand
If fitted, ensure the kick stand is folded down completely when parking. Make sure it is folded back
up before riding.

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Section 4 - Electric operation and adjustment
This section covers using the display panel and other e-bike specific functions.
4.1 General information
The Pedal Assistance System, (PAS) is dependent on the pedaling frequency and will end when
you stop pedaling (motor stops in about 2 seconds), more assistance is provided when you pedal
faster (such as when in a lower gear).
The assistance will decrease when your riding speed goes up and will completely end at about
25km/h (this is a legal requirement for operating the e-bike on public roads).
Applying either the front of rear brake level will cut out PAS.
You can adjust and/or completely turn off the assistance at any time, and ride your e-bike as an
ordinary bicycle.
We recommend you disable the assistance in hard rain, in sandy terrain and in heavy traffic.
If you have to wheel the e-bike, switch off the control panel in case the motor might suddenly start
due to an unintended crank rotation.
Always keep the control panel off when the e-bike is not in use.
WARNING Never turn on the motor in heavy traffic or crowds!
4.2 Battery and Charger
The battery of your Dyson e-bike is Lithium–ion and some care is needed to maintain the battery‟s
peak performance.
The battery features a self-contained charge indicator, press the small blue button on the topside to
display the current state of charge, red only is low, red and three blue LED‟s is full.
Only use the supplied charger to charge the battery. If lost or damaged replace only with a genuine
Dyson charger.

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The charger is a computer-controlled system with many monitoring and control functions. The
charger stops charging when the battery is fully charged. The battery cannot be overcharged
however; we recommend that the battery be connected to the charger only when the e-bike will be
used in the near future. The included charger must only be used for charging genuine Dyson
batteries.
The LED on the charger indicates the current operating status.
Charging cycle and LED indicators for lithium ion Battery
LED COLOR
MODE
Red
Charging
Green
Charging finished; Charger stops working
If the charging is abnormal
Check if the power outlet is OK.
Check if the contact to connectors is right.
If it is still not possible to charge, please contact Dyson Bikes for advice on how to rectify.
The battery may be charged while mounted to the e-bike, or may be removed and charged
separately.
To remove the battery use one of the supplied keys in the lock situated on the top of the frame near
the head. Turn to open with one hand and use the other to remove by placing two fingers in the slot
on the underside near the lock. Use care, as the battery is heavy!
To refit the battery align the bottom of the battery with the frame and carefully push the top of the
battery into the frame. A „click‟ will be heard from the locking mechanism once positioned correctly.
When the battery is removed from the e-bike it is advisable to keep the power switch in the „OFF‟
position to remove the risk of accidentally shorting the battery terminals.
NOTE Two keys are supplied with your e-bike; store one in a safe place in case the other is lost.
To charge the battery plug the charger into a regular 240-Volt wall socket, the other small plug can
then be inserted into the battery by lifting the small flap next to the battery power switch. The LED
light on the charger will glow red to indicate charging in progress.

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Once fully charged the LED indicator light on the
Charger will be green.
Make sure the battery is fully charged before the first
ride and charge again for at least 6 hours after.
Switch on the main power switch located on the battery
when using the e-bike and off again when the bike is not
in use.
The position of the battery power switch does not affect
charging.
To maximize the battery life, the following instructions should be followed:
The charger will not work efficiently if the battery stays below 0° C or above +40° C. Ideally,
keep the battery at room temperature (approx. 20° C) during charging.
Remove charger once charged; do not leave on charge for extended periods.
Charge in a dry place.
Recharge every 2 months if unused.
Before re-using the battery after long periods, charge the battery fully.
Keep the battery as close to normal room temperature as possible by parking the bike out of
the sun on hot days and not leaving in hot cars or sheds. If necessary remove the battery
from the bike.
WARNING Failure to comply can lead to absolute discharge of the battery. A completely
discharged battery is not covered by warranty.
NOTE Self-discharge will occur over time, this is a normal characteristic of batteries. This is due to
chemical processes in the gas-tight cells, state of charge and environmental conditions
(temperature, humidity).

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4.3 Control panel
4.3.1 Display indication
The display indicates the key functions of the e-bike such as battery charge status and PAS level.
The control panel is operated by
the three buttons located on the
small pad on the left hand side of
the handlebars.
For your e-bike to function, the
main power switch on the battery
must be in the ON position.
4.3.2 Settings and configuration
Your e-bike is set to the correct settings before delivery and no adjustment is required for normal
operation, but it is possible to make adjustments. See the following for advice on how to make
changes.
4.3.3 Entering setting mode
Ensure the battery mounted power switch is in the „I‟ position.
Press the centre „MODE‟ button for 1.5 seconds to turn on the display.
After switching the display on, immediately press both „UP‟ and „DOWN‟ buttons
simultaneously for 2.5 seconds.
The display then enters into setting mode and the first parameter flashes.