eBike 36V User manual

MANUAL
36V MODELS
SERVICE

E-Bike®
Service Manual
36V MODELS
EV Global Motors Company
16201 Stagg Street
Van Nuys, CA 91406
Tel: [phone]
Fax: [phone]
www.ebike.com

Copyright © 2000 EV Global Motors Company
First Edition
October, 2000
LIT-82001-01-36
All rights reserved. No parts of this publication may be
reproduced or transmitted in any form or by any means
without the prior permission of EV Global Motors
Company.
Although every precaution has been taken to assure this
publication is complete and accurate, EV Global
assumes no liability for errors or omissions. All informa-
tion contained in this publication is based on the latest
information available at the time of publication and is sub-
ject to change without notice.

TABLE OF CONTENTS
Chapter One: General Information 1-1
Beep/LED Codes
Vehicle Identification Number
How to Read the Model Code
Terms
Lubricants
Threadlock
Recommended Maintenance Schedule
Special Tools
Chapter Two: Specifications 2-1
Mechanical Specifications
Gear Ratios
Electrical Specifications
Torque Specifications
Performance Specifications
Frame Specifications
Chapter Three: Battery Pack 3-1
Charging the Battery
Replacing the Battery
Replacing the Charger
Battery Pack Test
Chapter Four: Handlebar and Controls 4-1
Handlebar Position
Handlebar Height Adjustment
Handlebar Replacement
Throttle Control (Right Side)
Accessory Control (Left Side)
Headset
Chapter Five: Brakes 5-1
Brake Cable Replacement
Brake Lever
Brake Lever Free Play Adjustment
Brake Pad
Brake Pad Alignment
Caliper Arm
Modulator Brakes
Disc Brake
Chapter Six: Shifter and Derailleur 6-1
Shifter
Shifter Cable
Derailleur
Chapter Seven: Chain and Crankset 7-1
Chain
Crank Arm
Chainring
Pedal
Bottom-Bracket Cartridge
Chapter Eight: Electrical 8-1
Connector Identification
Right Side Cover
Left Side Cover
Controller
Quick-Release Connector
Motor
Headlight
Taillight
Troubleshooting
Electrical Schematic

Code Meaning Beep LEDs
Good beep The system has been 1 continuous beep
checked and is operational sounds for 1 second.
Bad Beep A problem exists in a 4 sets of 4 short
system or component. beeps
Pedal assist The system requests 3 short beeps every
pedal assist. Sounds 16 seconds
when on a steep hill or
when the motor or
controller approaches
an overheat condition.
System ON Whenever the power Good beep The state-of-
knob is turned ON, the charge LEDs
system performs a flashes
series of checks.This
signal indicates that the
E-Bike®is ON and ready
for operation.
Throttle Fault This code occurs when- Bad beep All 3 state-of-
ever you turn the power charge LEDs
knob ON while pressing flash continuously
the throttle or if the throttle until the fault is
is faulty. Turn the power cleared and until
OFF, release the throttle, the power knob is
and turn the power knob turned OFF then
to ON. If the code persists, ON again.
have throttle checked by
an authorized E-Bike®
dealer.
Battery state-of-charge The battery has 100% to None Green LED on.
80% of run time remaining.
Chapter One
GENERAL
INFORMATION
BEEP/LED CODES
The three state-of-charge LEDs on the throttle control indicate battery state of charge.The E-Bike®
uses these LEDs and three distinct beeps to alert you to particular conditions.The following chart
describes these signals and their various meanings.
1-1

Code Meaning Beep LEDs
Battery state-of-charge 80% to 60% of run time None Green and yellow
remaining LEDs on.
60% to 40% of run time None Yellow LED on.
remaining.
40% to 15% of run time None Yellow and red
remaining. LEDs on.
Low battery 15% to 5% of run time None Red LED on.
remaining.
Very low battery Less than 5% of run Bad beep Red LED flashes
operation remaining.
Motor shut off The powerto the motor has Bad beep Red LED flashes
been shut off.You must pedal
Overheat condition The motor or controller tem- Bad beep Yellow LED flashes
perature exceeds operating
temperature.The controller
cuts power to the motor.
You must pedal until the
temperature drops to
operating temperature.
Operating temperature The motor has cooled to Good beep The appropriate
operating temperature.You LED turns on
may resume using the
throttle.
Overheat and low- The motor temperature Bad beep The yellow and
battery condition exceeds operating tempera- red LEDs flash
ture and the battery state-of- simultaneously.
charge is low.
1-2
Model code Model prefix Year Description Color 1 Color 2 Color 3
B1 Bicycles
01-B136LE – R, L 3B1 2001 LE Candy Apply Radiant NA
Red (R) Metallic Blue
01-B136SX – B 3B1 2001 SX Satin Black NA NA
(B)
01-B136PE – B 3B1 2001 PE Black (B) NA NA
VEHICLE IDENTIFICATION NUMBER
The 17-digit vehicle identification number (VIN) is printed on a label that is affixed to the inside
face of the right frame seat stay. This label also contains the gross-vehicle weight rating and recom-
mended tire inflation pressure.
HOW TO READ THE MODEL CODE
ModelYear 01 - B1 36 SX - R
Product Line
& Category Power System Model Color
B1 = Bicycle, 24 = 24 Volts Base = B R = Reds
Conventional 36 = 36Volts Comfort = C L = Blues
Touring = T B = Blacks
LE, PE, SX

OilAlways use oils made specifically for bicy-
cle use. Bicycle oils need to be thin enough to
penetrate tight places, they should be durable
so they can withstand exposure to the ele-
ments, and they must resist the accumulation
of dirt.
Suitable oils for the E-Bike®include Alsop,
Bullshot, Campagnolo, Finish Line, Lube Wax,
Phil Wood Tenacous Oil, Pedros, Superlube,
and Triflow.
Motor oil, WD40, 3-in-1 Oil, sewing
machine oil, gun oil, and other common oils
are not suitable and should not be used.
In general, applying oil from a drip applica-
tor is superior to using aerosols. Aerosols
promote over-lubrication, which leads to
excessive accumulation of dirt. Apply oil spar-
ingly. Apply enough oil to do the job, but not so
much that it starts to drip from the component.
After applying any oil, wipe off the excess.
THREADLOCK
A threadlocking compound should be used
on most fasteners on the E-Bike®.
Threadlocking compound prevents loosening
caused by vibration and helps seal out mois-
ture.
Loctite 242 (blue) or equivalent is recom-
mended for threadlocking applications. Loctite
242 is a medium-strength threadlocking com-
pound that permits disassembly with common
hand tools.
Before applying Loctite to threads, clean
the thread surface of oil, grease, and other
residue. Apply a small amount of Loctite.
Excess compound could work its way down
the threads and bond parts together. The
torque chart in Chapter Two includes Loctite
recommendations for particular fasteners.
1-3
TERMS
Left and Right
Most of the time, left and right in this man-
ual refer to the rider’s point of view when seat-
ed on the E-Bike®and facing forward.The one
exception to this rule involves the brake
calipers. Left and right on the calipers refers to
a technician’s point of view when standing in
front of the E-Bike®and looking directly at the
front brake caliper or when standing behind the
E-Bike®and looking directly at the rear brake-
caliper.
NOTE, CAUTION and WARNING
The terms NOTE, CAUTION and WARN-
ING have specific meaning in this manual. A
NOTE provides additional information to make
a procedure easier or clearer.
A CAUTION emphasizes precautions that
must be taken to avoid damage to your tools or
to the E-Bike®.
A WARNING alerts you to a situation where
negligence could lead to injury or death. Take
WARNINGS seriously. Failure to heed a
WARNING could result in serious personal
injury or death.
LUBRICANTS
Grease
The bearings and other mechanical com-
ponents in the E-Bike®operate at relatively low
temperatures so most automotive greases are
inappropriate for use on the E-Bike®.Always
use grease made specifically for a bicycle,
such as grease from Bullshot, Campagnolo,
Finish Line, Pedros, Phil Wood, and Shimano.

RECOMMENDED MAINTENANCE SCHEDULE
Component or Condition Inspect before every ride Inspect every 5 to 10 rides*
Brake pad adjustment X
Wheel quick release adjustment X
Tire pressure X
Tire wear/damage X
Head/tail/brake light operation X
Mirror position X
Controls and display X
Seatpost quick release adjustment X
Brake pad wear X
Brake cable tension/wear XX
Spoke tension X
Wheel true X
Hub bearings adjustment X
Hub bearing lubrication X
Chain lubrication X
Derailleur adjustment X
Reflectors X
Battery and charger X
Headset adjustment X
Bottom bracket adjustment X
Tighten all bolts, nuts, and mounting X
hardware
* Depending upon length of ride and riding conditions. Inspect more frequently when riding in dusty or wet
conditions.
SPECIAL TOOLS
The following special tools are needed for servicing the E-Bike®.
Tool Part number
Hex wrench set: 4mm, 5mm, 6mm Park AWS-1
Hex wrench set Park AWS-11C
Hex wrench set: 2mm, 5mm, 3mm Park AWS-3
Fourth hand cable stretcher Park BT-2
Chain checker Park CC-2C
Chain breaker (screw type) Park CT-3
Crank wrench Park CCW-14R
Cable and housing cutter Park CN-4C
Gearclean brush Park GSC-1
32mm & 36mm head wrench Park HCW-15
Pedal wrench Park PW-3
Spoke wrench (black) Park SW-0
Spoke wrench (red) Park SW-2
Tire lever set Park TL-1C
Freewheel tool Park Tool FR-1
Bottom-bracket-cartridge tool Park Tool BBT-2
1-4

Table 1: Mechanical Specifications
Component Specification
Headset
Stack height 33 mm (1.30 in.)
Dimensions 25.4 mm x 34 mm x 30 mm w/seal
Forks (LE)
Type Polyurethane Allen key adjustable
Steerer tube 1-1/8 in.
Travel 65 mm
Triple Forks (SX/PE)
Type Nitro DH
Steerer tube 1-1/8 in.
Travel 75 mm
Stem 1
PE model 17 degrees, 110 mm extension
SX model 15 degrees, 110 mm extension
LE model 40 degrees, 110 mm extension
Stem 2 28.6 mm x 25.4 mm x 150 mm with quill
Handlebar
LE model
Rise 9 degrees
Width 625 mm
Handle 200 mm
Center flat 100 mm
SX/PE models
Rise 9 degrees
Width 660 mm
Handle 200 mm
Center flat 100 mm
Seatpost
LE model 300 mm x 30.0 mm O.D.
Seatpost spacer 100 mm x 30.1 mm ID x 34.9 mm O.D.
Seatpost, suspension
SX/PE models 350 mm x 27.2 mm O.D.
Seatpost spacer 100 mm x 27.3 I.D. x 34.9 mm O.D.
Tires
LE model 26 x 1.95 in., black w/ reflective stripe, puncture
resistant
Chapter Two
SPECIFICATIONS
2-1

SX model 26 x 1.95 in., CSK, puncture resistant
PE model 26 x 1.95 in., black with reflective stripe, puncture
resistant
Rims
DH-17
Front 26 x 1.5 in., 14G x 32H, double wall
Rear 26 x 1.5 in., 14G x 36H, double wall
G3000
Front 26 x 1.5 in., 14G x 32H, double wall
Rear 26 x 1.5 in., 14G x 36H, double wall
Spokes, front
DH-17 rim 266 mm, 14G stainless with brass nipples
G3000 rim 254 mm left, 255 mm right, 14G stainless with
brass nipples
Spokes, rear
DH-17 rim 216 mm left, 216 mm right, 14G stainless with
brass nipples
G3000 rim 210 mm left, 209 mm right 14G 14G stainless with
brass nipples
Bottom bracket (B/B) 127 mm cartridge
Freewheel 14-28 T, 7-speed
Chainring 38 T
Chainring clearance 16~17 mm (0.63~0.67 in.)
Crankarm 170 mm (6.7 in.)
Chain 1/2 x 3/32 x 110 L
Table 2: Gear Ratios
Chainring Freewheel Gear Inches Ratio
38T 14T 70.6 0.37 (14/38)
38T 16T 61.8 0.42 (16/38)
38T 18T 54.9 0.47 (18/38)
38T 20T 49.4 0.53 (20/38)
38T 22T 44.9 0.58 (22/38)
38T 24T 41.2 0.63 (24/38)
38T 28T 35.3 0.74 (28/38)
Table 3: Electrical Specifications
Component Specification
Battery (WP8-36E) Single block
Type Deep discharge, sealed AGM lead-acid
Capacity 36 volts, 8 amp hours.
Charger
Input 115 VAC, 60/50 Hz, 1 amp
Output 36 VDC, 2 amps
Charger cord
Length 1.8 m (6 ft.)
Wire 18 AWG, 2-wire with ground
Chapter Two
2-2

Table 4:Torque Specifications
Item kg-cm in.-lb. ft.-lb. Special Instructions
Handlebar-binder bolt 140~200 - 10~15 Apply Loctite
Handlebar-arm clamp bolts 140~200 - 10~15 Apply Loctite
Stem-binder bolt (stem-2 quill bolt) 180~250 - 13~18
Headset locknut 40~50 34.7~43.4
Accessory control clamp bolt 30~40 26.5~34.7 -
Throttle control clamp bolt 30~40 26.5~34.7 -
Controller mounting screw 15 13.0 -
Brake-lever clamp bolt 30~40 26.5~34.7 -
Brake-caliper pinch bolt 140~200 - 10~15 Apply Loctite
Brake-pad nut 63.6~85.2 53~71 -
Caliper pivot bolt 85.2~106.8 71~89 - Apply Loctite
Left-side-cover mounting screws 10 8.6 - Apply Loctite
Right-side-cover mounting screws 10 8.6 - Apply Loctite
Battery-terminal-block mounting screw 10 8.3 -
Battery compartment mounting screw 10 8.3 -
Battery pack handle 15 13.0 -
Battery cover screw 20~30 17.4~26.5 Apply Loctite
Charger-board mounting screw 10 8.6 -
Derailleur mounting bolt 84 70 -
Derailleur pinch-mechanism nut 42 36.5 -
Shifter clamp bolt 30~40 26.5~34.7 -
Mirror-mounting screw 30~40 26.5~34.7 -
Chain guard screws 15 13.0 - Apply Loctite
Left bottom-bracket cover screws 20~30 17.4~26.5 - Apply Loctite
Crank-arm mounting bolt 200~250 - 14.4~18.1 Apply grease to the bolt
threads
Pedal 30~50 26.5~43.4 - Apply grease to the stud
threads
Bottom-bracket cartridge adapter ring 300~400 - 21.7~28.9 Apply grease to the threads
Chainring bolt 350~450 - 25~32 Apply oil to the bolt threads
Motor torque arm 15 13.0 - Apply Loctite
Headlight mount 15 13.0 -
Taillight mounting nut 20 17.4
Horn mounting nut 15 13.0 -
Cord access cover 5 4.2 -
Frame mounted connector 10 8.6 - Apply Loctite
Front fender 15 13.0 -
Rear fender 15 13.0 -
Front fork clamp bolt
Triple Fork (SX/PE) 100 89 -
Forks (LE) 100 89 -
Fork slider bottom bolt
Triple Fork (SX/PE) 70 62 -
Forks (LE) 70 62 -
SPECIFICATIONS 2-3

Frame Specifications
Frame Size (Center to top)
419 cm (16.5 in.)
Wheel Base 1062.3 mm (41.8 in.)
RC 431.5 mm
(17.0 in.)
72˚
Head Tube
163 mm (6.4 in.)
Table 5: Performance Specifications*
Item Specification
Top speed 17.5 mph @ 36 volts in “P” Performance mode.
12.5 mph @ 36 volts in “E” Economy mode.
Maximum grade Over 12% with a 200 lb. rider plus load.
Acceleration 0~10 mph in 3 seconds with a 200 lb. rider.
Range Over 20 miles with moderate pedal assist.
Over 15 miles with no pedaling under good conditions.
Over a 25% increase in the range in the “E” Economy
mode
*200-pound rider with tires inflated to 60 psi, no wind
2-4

CHARGING THE BATTERIES
The E-Bike®includes a charger that is an
integral part of the battery pack. Batteries can
be charged when the battery pack is on-board
the E-Bike®or when the battery pack is
removed for remote charging.
To assure maximum battery life, always
fully charge the battery after each ride. The
battery will be damaged if it is allowed to total-
ly discharge.To prevent total battery discharge
during extended periods of non-use, remove
the battery pack and store it in a cool, dry
place. Optimal storage temperature is 32-86˚ F
(0-30˚ C). Long-term storage outside this tem-
perature range will result in accelerated battery
discharge, which could lead to battery damage.
A stored battery should be recharged at least
every three months to help maintain a full
charge, maximum capacity, and maximum cycle
life.
IMPORTANT NOTICES
•Always charge the battery pack immedi-
atelly after each use. Failure to do so
within 72 hours may damage the battery.
• The charger can remain plugged-in for
trickle-charge purposes for up to 72
hours.
• For storage periods over 3 months, the
battery pack should be checked and
fully charged every 3 months.
• Optimal storage temperature is 32-86˚ F
(0-30˚ C). Long-term storage outside this
temperature range will result in acceler-
ated battery discharge which,could lead
to battery damage.
• Always pedal assist your E-Bike®when
the pedal-assist beep sounds.
• If the overheat warning beep sounds
and the yellow LED flashes, pedal your
E-Bike®until the good beep sounds
and the yellow LED stops flashing. Do
not turn the power knob from OFF to ON
repeatedly in an effort to override the
overheat protection function. This may
cause motor or controller damage,and it
will void the warranty.
On-board Charging
1. Be sure the power knob is turned OFF.
2. Turn the battery-compartment latches
clockwise, and open the door.
3. Retrieve the charging cord from the com-
partment above the bottom bracket.
WARNING
The charger is equipped with a cooling fan. If
the cooling fan does not operate when the LED
is red, unplug the charger from the electrical
outlet immediately. Determine why the fan is
not operating before charging the battery pack.
Replace the charger if necessary.
4. Plug the female end of the charging cord
into the receptacle on the battery charger
(Figure 1).
Chapter Three
BATTERY PACK
3-1

NOTE
When a battery is new, the LED may rapidly
flicker instead of turning to green.This is not a
problem. The battery is fully charged and can
be used. The flicking will cease after several
use/recharge cycles.
5. Plug the male end of the charging cord into
a standard 110V/60 cycle electrical outlet.The
charger LED turns red and the cooling fan
automatically turns on. The LED switches to
green and the cooling fan turns off when the
battery pack is fully charged.
If the LED switches to flashing orange,
unplug the charger immediately. Check for an
intermittent connection in the charging cord, at
the battery terminals, or in the battery-to-
charger connections. If there are no intermit-
tent connections, replace the battery.
If the LED does not illuminate, unplug the
charger immediately. Replace the charger.
If the charger operates (the LED turns red
and the fan operates), but the charger does not
turn off after four hours, unplug the charger
immediately. Perform the charger test
described later in this chapter. If the charger is
faulty, replace it. If the charger is working,
replace the battery.
Remote Charging
1. Remove the battery pack from the E-Bike®.
2. Set the battery pack on its side so the bat-
tery-pack cover faces up and the handle is to
the side.
3. Retrieve the charging cord from the com-
partment above the bottom bracket.
WARNING
The charger is equipped with a cooling fan. If
the cooling fan does not operate when the LED
is red, unplug the charger from the electrical
outlet immediately. Determine why the fan is
not operating before charging the battery pack.
Replace the charger if necessary.
4. Plug the female end of the charging cord
into the receptacle on the battery charger.
NOTE
When a battery is new, the LED may rapidly
flicker instead of turning to green.This is not a
problem. The battery is fully charged and can
be used. The flicking will cease after several
use/recharge cycles.
5. Plug the male end of the charging cord into
a standard 110V/60 cycle electrical outlet.The
charger LED turns red and the cooling fan
automatically turns on. The LED switches to
green and the cooling fan turns off when the
battery pack is fully charged.
If the LED switches to flashing orange,
unplug the charger immediately. Check for an
intermittent connection in the charging cord, at
the battery terminals, or in the battery-to-
charger connections. If there are no intermit-
tent connections, replace the battery.
If the LED does not illuminate, unplug the
charger immediately. Replace the charger.
If the charger operates (the LED turns red
and the fan operates), but the charger does not
turn off after four hours, unplug the charger
immediately. Perform the charger test
described later in this chapter. If the charger is
faulty, replace it. If the charger is working,
replace the battery.
REPLACING THE BATTERY
The battery pack contains a sealed lead-
acid battery.The following procedure describes
how to remove and replace the battery.
WARNING
Never use a battery that is cracked or broken.
Battery acid is highly corrosive and can cause-
severe burns if it comes in contact with your
eyes or skin.
Removal
1. Remove the battery pack from the E-Bike®.
2. Remove the two cover screws from the bat-
tery pack, and remove the cover.
Chapter Three
FIG. 1
3-2

(Figure 3) sits in the bottom of the case (the
end with the capacitor). Be sure the battery is
properly seated in the battery case.
NOTE
Perform the following when connecting a bullet
connector.
a. Press the male and female connector
halves together.
b. Roll the seal over the connector.
2A. On batteries with an external thermal
switch, refer to Figure 2 and perform the fol-
lowing:
a. Remove the thermal switch from the old
battery and install it on the new one.
b. Connect the bullet connector on one red
wire from the thermal switch to the red
wire from the charger.
c. Connect the bullet connector on the sec-
ond red wire from the thermal switch to
the red wire from the battery.
d. Connect the bullet connector on the
black charger-to-battery wire.
2B. On batteries without an external thermal
switch, connect the bullet connectors on the
red charger-to-battery wire and connect the
bullet connectors on the black charger-to-bat-
tery wire.
3. Connect the red positive lead to the positive
(+) battery terminal.Place the washer on top of
the lead’s eyelet, and tighten the mounting
screw securely.
4. Check the connection by trying to rotate the
lead’s connector around the mounting screw. If
the connector moves, remove the mounting
screw and reinstall the lead with two washers
on top of the eyelet.
5. Repeat steps 3 and 4, and connect the blue
negative lead to the negative (-) battery terminal.
3. Remove the mounting screw, and discon-
nect the blue negative lead from the negative (-)
battery terminal. Be sure to remove the washer.
4. Repeat the above procedure and discon-
nect the red positive lead from the positive (+)
battery terminal.
NOTE
Perform the following when disconnecting a
bullet connector.
a. Pull back the seal to expose the bullet
connector.
b. Pull the male and female halves of the
connector and separate the connector.
5A. On batteries with an external thermal
switch, disconnect the bullet connectors on the
two red wires from the thermal switch and dis-
connect the bullet connector on the black
charger-to-battery wire. See Figure 2.
5B. On batteries without an external thermal
switch, disconnect the bullet connector on the
red charger-to-battery wire and the connector
on the black charger-to-battery wire.
6. Invert the battery pack, and remove the bat-
tery.
NOTE
Contact your state or local agency for informa-
tion on proper battery disposal.
7. Properly dispose of the old batteries.
Installation
1. Gently lower the battery into the battery
case so the end with the terminals
FIG. 3
3-3
FIG. 2
Black
Blue
Red
Red
Fuse
Capacitor
Bullet Connector
Bullet Connector
Thermal Switch
BATTERY PACK

6. Fit the cover onto the battery pack. Be sure
no wire is pinched beneath the cover.
7. Apply Loctite 242 (blue) to the threads of
the two cover screws, and secure the cover in
place.
REPLACING THE CHARGER
Two types of chargers are used on these
models: an IC charger and a non-IC charger.
To determine which type of charger you have,
look at the model number on the charger
cover. An IC charger has the letters “IC” at the
end of the model number. A non-IC charger
does not.
A non-IC charger must be installed in a bat-
tery pack with an external thermal switch. An
IC charger can be installed with or without an
external thermal switch.
Removal
WARNING
Make sure the charger is not plugged in dur-
ing service.
1. Remove the battery from the battery pack.
2. Remove the three charger-cover screws
that secure the cover to the vent (A, Figure
4).
3. Lift the cover from the charger, and discon-
nect the three electrical connectors from the
charger board.
4. Remove the screw that secures the charg-
er board to the bracket (B, Figure 4).
5. Remove the three charger-board mounting
screws (Figure 5), and remove the charger
board. Do not lose the spacer (A, Figure 6)
from each mounting stud.
Installation
1. Be sure the insulator (B, Figure 6) is in
place in the battery pack.
2. If removed, install the spacer (A, Figure 6)
onto each mounting stud in the battery pack.
3. Set the charger board into place on the
mounting studs.Secure the board in place with
the charger-board mounting screws and wash-
er (Figure 5).
4. Secure the board to the bracket with the
mounting screw (B, Figure 4).
5. Plug the connectors from the cover into
their mates in the charger board.
6. Fit the cover in place over the charger
board. Be sure the two charger wires are not
pinched under the cover.
7. Secure the cover in place with the three
charger-cover screws (A, Figure 4).
8. Reinstall the battery and the battery-pack
cover.
3-4
FIG. 6
A
A
A
A
B
FIG. 5
FIG. 4
A
A
A
B
Chapter Three

If there are no intermittent connections,
replace the battery.
Charger Output Test
1. Remove the cover from the battery pack.
2. Connect a digital voltmeter’s positive (+)
test probe to the positive (+) battery terminal,
and connect the voltmeter’s negative (-) test
probe to the battery negative (-) terminal as
shown in Figure 7. Note the reading on the
voltmeter.
3. With the voltmeter still connected as
described in step 2, plug the charger into a
110V/60 cycle outlet. Note the reading on the
voltmeter.
4. Compare the two readings.
a. If the reading is higher when the charger
is plugged in, the charger is operating
properly.Perform the battery voltage test
(before charging).
b. If the two readings are the same, the
charger has failed and should be
replaced.
Battery Voltage Test, Before Charging
1. Let the battery stand for one hour.
2. Remove the cover from the battery pack.
3.Connect a digital voltmeter’s positive (+) test
probe to the positive (+) battery terminal, and
connect the voltmeter’s negative (-) test probe
to the battery negative (-) terminal as shown in
Figure 7.
4. Note the reading on the voltmeter.
5.If the reading is less than 31.5 volts, perform
the battery voltage test (after charging).
BATTERY PACK
Removal
1. Turn the power knob OFF.
2. Open the battery compartment door.
3. Release the gate latch, and open the bat-
tery gate.
4. Use the handle to pull the battery pack from
the compartment. Be sure to support the bot-
tom of the battery pack with your free hand.
Installation
1. Set the lower end of the battery pack into
the battery compartment, and tilt the battery
into place.
2. Close the gate over the battery, and secure
the gate latch.
3. Close the battery compartment door, and
turn the latches counterclockwise.
BATTERY PACK TEST
Charger operation test
1. Plug the female end of the charging cord
into the port on the charger.
2. Plug the male end into a 110V60 cycle out-
let
3. Watch the battery charger LED and per-
form the indicated procedure.
a. If the battery charger LED does not illu-
minate, the charger is faulty and should
be replaced. Unplug the charging cord,
and check the battery voltage (before
charging) as described below.
b. If the battery charger LED turns to red
and the cooling fan is not operating, the
charger is faulty and should be replaced.
Unplug the charger, and check the bat-
tery voltage (before charging) as
described below.
c. If the battery charger LED turns red and
the cooling fan operates, perform the
charger output test described below.
d If the battery charger LED turns green,
perform the charger output test
described below.
e. If the LED switches to flashing orange,
unplug the charger immediately. Check
for an intermittent connection in the
charging cord, at the battery terminals,
or in the battery-to-charger connections.
3-5
36.5
FIG. 7
Black
Thermal
Switch
Red
Blue
Capacitor
Fuse
Bullet
Connector
Bullet
Connector
Red
BATTERY PACK

Battery Voltage Test, After Charging
NOTE
The charger must be operational for this test to
be valid.Perform the charger output test before
performing this test.
1. Charge the battery as described in this
chapter.
2. Unplug the charger, and let the battery
stand for one hour.
3. Remove the cover from the battery pack.
4. Connect a digital voltmeter’s positive (+)
test probe to the positive (+) battery terminal,
and connect the voltmeter’s negative (-) test
probe to the battery negative (-) terminal as
shown in Figure 7.
5. Note the reading on the voltmeter.
6. The reading should be 36.5 volts or greater.
If the reading is less than 36.5 volts, the bat-
tery is faulty and should be replaced.
Chapter Three
3-6

HANDLEBAR POSITION
NOTE
The handlebar may be adjusted to suit the
rider’s preference. The following procedure
describes how to set the handlebar to the stock
position.
1. Loosen the handlebar-binder bolts (A,
Figure 1).
2. Rotate the handlebar so the ends point
down slightly.The handlebar grip should form a
10-20˚angle with a line that parallels the floor.
See Figure 2 for LE models; Figure 3 for PE &
SX models.
3. Be sure the knurled portion of the handle-
bar is centered within the handlebar binder.
4. Tighten the handlebar-binder bolts to the
torque specification in Table 4.
HANDLEBAR HEIGHT ADJUSTMENT
1. Loosen the stem-binder bolt three or four
turns counterclockwise (A, Figure 4).If the bolt
rises from the steering stem, strike the bolt with
a plastic mallet to force the stem wedge down.
FIG.1
FIG. 2
FIG. 3
4-1
Chapter Four
HANDLEBAR
and CONTROLS
A
C
B
A10 ~ 20˚
10 ~ 20˚

WARNING
The "Minimum Insert" mark on the handlebar
stem must not sit above the top of the headset.
2. Raise or lower the stem within the fork col-
umn until the handlebar is at the desired
height.
3. Rotate the handlebar from side to side, and
align the handlebar with the wheel or fork
dropouts.
4. Tighten the stem-binder bolt to the torque
specification in Table 4.
HANDLEBAR REPLACEMENT
Removal
1. Note how the brake cables, shifter cable,
and electrical wires are routed around the
headlight. On PE and SX models, note how
they are routed past the fork tubes. All wires
and cables will have to be rerouted along their
original paths during installation.
2. Remove the following components from the
right handlebar:
a.The handlebar grip.
b. The brake-lever housing
c.The throttle control and throttle stop.
3. Remove the following from the left handle-
bar:
a.The mirror.
b. The handlebar grip
c.The shifter.
d.The brake-lever housing.
e.The accessory control.
4. Remove the two handlebar-binder bolts (A,
Figure 1).
5. Remove the handlebar clamp (B, Figure 1).
Installation
1. Fit the handlebar into place in the binder on
the handlebar arm.Be sure the knurled portion
of the handlebar is centered in the binder.
2. Fit the handlebar clamp into place around
the handlebar.
3. Apply Loctite 242 (blue) to the threads of
the handlebar-binder bolts, and install the bolts
finger tight.
4. Position the handlebar as described in this
chapter, and tighten the handlebar-binder bolts
to the torque specification in Table 4.
5. Install the throttle control as described in
this chapter.
6. Install the accessory control as described
in this chapter.
THROTTLE CONTROL (RIGHT SIDE)
Removal
1. Remove the battery from the battery com-
partment.
2. Remove the right side cover from the E-
Bike®.
3. Pull the cable inlet cover around the head
tube, and remove the cable inlet cover from the
left side cover.
4. Disconnect the throttle control connector
(C, Figure 5) from the controller lead. Note
how the throttle control wire is routed through
the frame.The new wire will have to be rerout-
ed along the same path.
5. Pull the wire so the connector passes
through the frame and emerges at the cable
inlet in the left side cover (Figure 6).
6. Roll and remove the right handlebar grip off
the handlebar.
FIG. 4
C
D
E
F
HG
AB
Controller
FIG. 5
Chapter Four
4-2
B
A
B