KBO Tornado Step-Thru User manual

Owner's Manual
www.kbobike.com
Tornado Step-Thru

Content
Home Page
About Manual
Product Speci�ication
Product Structure
Assembly Instructions
Recommended Torque Values
Display Features
Routine Operation
Driving Range
Parking Storage and Transport
Basic Battery Charging Tips
Bicycle Care
Basic Troubleshooting
Warranty Info
Additional Warranty Terms
Warranty Card
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Home Page 1
Thank you for your purchase!
This manual contains details of the product, information on its operation and maintenance, and other helpful tips for owners. Read it carefully
and familiarize yourself with the KBO Tornado Step-Thru before using it to ensure safe use and prevent tragic accidents. Be sure to retain this
manual as your convenient KBO Tornado Step-Thru information source.
NOTICE: To prevent your KBO Tornado Step-Thru from being stolen and cannot be found, it is suggested that you record the Serial
Number of your bike(Near the left crank connection).

About Manual 2
All information in this manual should be carefully reviewed and if you have any questions you should contact KBO Bike immediately. The notes
contained within the manual and marked by this dialogue balloons symbol should also be given special care. Users should also pay special
attention to information marked in this manual beginning with NOTICE.
Because it is impossible to anticipate every situation or condition which can occur while riding, this manual makes no representations about
the safe use of bicycles under all conditions. There are risks associated with the use of any bicycle which cannot be predicted or avoided, and
which are the sole responsibility of the rider. You should keep this manual, along with any other documents that were included with your
bicycle, for future reference, however all content in this manual is subject to change or withdrawal without notice. Visit www.kbobike.com to
download the latest version. KBO Bike makes every effort to ensure the accuracy of its documentation and assumes no responsibility or liability
if any errors or inaccuracies appear within. Assembly and �irst adjustment of your KBO Bike require special tools and skills and it is
recommended that this should be done by a trained bicycle mechanic if possible.

Product Speci�ication 3
Battery
Derailleur
Speed
Pedal Assist
48V 13Ah Lithium Battery Front Fork Front Suspension Fork
500W Geared Motor Bike Frame 6061 Aluminum
LCD Display 160mm Brakes
6-speed 54.6V 2A
20 mph 6 Speed
Intelligent 5-level Pedal Assist Shimano
Twist Throttle 26’’x4’’ Tires
6 Hours 72 lbs
5'1" - 6'2" 92 lbs
Package
Dimensions
Package Weight
Model
Dimensions
61.5''x12.2''x33.1'' 75.4''x48.9''x27.6''
Brake
Charger
Freewheel
Shifter
Tires
Product Weight
Motor
Display
Throttle
Charging Time
Recommended
Rider Heights

Product Structure 4
Handle
On/Off
LCD Display
Shimano Shifter
Throttle
Brake Lever
LED Rear Light
Rear Rack
Saddle
Frame
Stem
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5
6
7
8
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10
11
Battery
LED Head Light
Front Fork
Front Brake
Tire
Pedal
Controller
Derailleur
Motor
Rear Brake
Crank Set
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14
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16
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22
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3
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5
6
910 11 12
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Assembly Instructions 5
NOTICE: The following assembly steps are only a general guide to assist in the assembly of your KBO Bike and is not a complete or
comprehensive manual of all aspects of assembly, maintenance and repair. We recommend you consult a certi�ied bike mechanic to
assist in the assembly, repair and maintenance of your bike. For detailed instructions, please view the KBO Tornado Step-Thru
assembly video found at www.kbobike.com.
Open the bike box, with the help of another person capable of safely lifting a heavy object, remove the ebike from the bike box, and fully remove
the packaging material protecting the bike frame and components. Keep the packaging materials in case you want to ship the bike. Remove the
small box from the bottom of the bike box and carefully set out the contents.
◆ Unpack the bike

◆ Install the handlebar:
Assembly Instructions 6
Orient the handlebar properly. The brake levers should face forward and the shifter should be on the right side. Trace the brake housing from
the left brake lever to the brake caliper and make sure the bundle of cables is not twisted. Remove the four screws from the stem, ensuring the
linear markings on the handlebars are centered and handlebars are adjusted to a comfortable position. Finally, tighten the screws with the
assembly tool.

Assembly Instructions 7
◆ Install the front wheel
Remove the plastic axle guards from the front wheel being sure not to touch the brake rotor set. Open the quick skewer and remove the
thumb nut and cone spring. Carefully lower the fork and ensure the brake rotor goes into the caliper.
Next align the dropouts with the axle of the wheel hub to make sure the fork dropouts are fully seated on the axle. Install the quick
skewer starting from the brake rotor side of the wheel and then push the quick release skewer through the hub. Keep two cone springs
pointed towards the wheel hub. Tighten the thumb nut until the quick release lever is held in line with the axle.
Use a 15mm wrench to tighten the bolts on both sides of the axle, and install the two thumb nuts by pressing them tightly.
Step 1:
Step 2:
Step 3:

◆ Install the headlight & front fender
Assembly Instructions 8
The headlight and front fender are both secured by a single bolt, so the front fender must be installed together with the headlight. If you prefer
not to have a front fender, you may install the headlight by itself.
Loosen the bolt on the fork brace. Align the bolt holes of both your front fender together with the hole on the fork brace, then reinsert
the bolt through all holes and tighten the bolt.
Pull one end of the fender brace until the loop at the end is centered in the bracket, reinsert the bolt through the loop at the end of the
brace, and tighten completely with a 4mm hex wrench and a 8mm bolt extractor holding the nut. Repeat on the other side.
Step 1:
Step 2:

Assembly Instructions 9
Make sure your pedals are installed on the correct side, as installing on the wrong side will damage the threads.
Indicators for the right pedal (R) and the left pedal (L) can be found at the bottom of the pedal threads. Start threading the pedal on by hand to
ensure the pedal is going in perfectly straight, rotating in the direction of the pointer shown on the crank. If it is not spinning smoothly, make
doubly sure that you have the correct left or right pedal. After initial hand-tightening, �inish tightening the pedals with a standard 15mm wrench.
◆Install the pedals
Open the seatpost quick release lever. Adjust the seatpost height by sliding the seatpost up or down to a height appropriate for your leg length
and preferred riding position. Do not extend the seatpost beyond the minimum insertion marking etched onto the seatpost.
◆Adjust the seat

Recommended Torque Values 10
Hardware Location
Handlebar
Stem
Saddle
Front Wheel
Rear Wheel
Rear Derailleur Cable Pinch
Hardware Location
Bottom Bracket Parts
Pedals
Disk Mounting Bolts
Disk Caliper Mount
Crank Bolts
Front Derailleur Clamp
Torque Required (Nm)
18-20
18-20
18-20
16-25
35-40
6
Torque Required (Nm)
35-55
35
6
10
40
7

Display Features 11
The image shows the various features and information displayed on the display.
BATTERY LEVEL INDICATOR (Current / Max / Average)
11
SPEED INDICATOR (Current / Max / Average)
2
ERROR CODE INDICATOR (In the Event of a Problem)
3
5 LEVELS OF ASSIST (0: No Assist. 5: Max Assist)
4
WALK MODE (On / Off)
5
BACKLIGHT INDICATOR (On / Off)
6
MULTI-FUNCTIONAL DISPLAY AREA:
DISTANCE INDICATOR
(Current Trip / System Mileage)
VOLTAGE OUTPUT INDICATOR
(Real-Time)
7
2
3
7
6
4
5
LCD DISPLAY

Routine Operation 12
◆ GETTING STARTED
1. The display pad is equipped with 3 buttons including “M”, “UP” and “DOWN”. The M button is the mode/switch button.
2. Press and hold the “M” button on the handlebar controls to turn on the display. Now, your ebike is ready to ride. To turn off, press and hold
“M” for 3 seconds.
3. Press the “M” button on the handlebar controls to switch the contents of the multi-functional display area.
4. The Level ebike offers pedal assist. When using pedal assist, an electric motor supplements the rider’s own effort. To use the pedal assist,
simply start pedaling, then tap the “UP” or “DOWN” arrows to increase or decrease the amount of pedal assist.
5. Press and hold the "DOWN" for 3 seconds to activate the push-assist function of the ebike.
Error Code
30
33
34
De�inition
Abnormal Communication
Abnormal Current
Throttle Fault
Error Code
35
36
37
De�inition
Motor Phase Problem
Motor Hall Defect
Brake Failed or Brake Applied While Turning On
NOTICE: When the error code is displayed, please promptly remove the fault. After the fault occurs, the electric bike will not be able to ride normally.

Driving Range 13
The range of your KBO Bike is the distance the bike will travel on a single full charge of the onboard battery pack. The range values in this
manual are estimates based on expected usage characteristics. Some of the factors which affect the range include changes in elevation, speed,
payload, and acceleration, number of starts and stops and ambient air temperatures. Tire pressure and terrain are also important variables to
consider.
We suggest that you select a lower pedal assist level when you �irst get your KBO Bike to get to know your bike and travel routes. Once you
become familiar with the range requirements of your travel routes, and the capabilities of your KBO Bike you can then adjust your riding
characteristics if you desire.
The following table provides general estimates and outlines various factors’ effective range and their combined estimated effects on range. This
table is meant to help owners understand the factors that can increase or decrease range, but KBO Bike makes no claims to the range that
individual users might obtain.
Best Practices for Extending Range and Battery Life
1. Do not climb hills steeper than 15% in grade.
2. Pedal to assist the motor when climbing hills and accelerating from a stop.
3. Avoid sudden starts and stops.
4. Accelerate slowly.

Please follow these basic parking, storage and transport tips to ensure your bike is well cared for on and off the road.
When pushing the vehicle manually, turn off the power to avoid accidental acceleration from the motor.
It is recommended to park indoors.
Switch the power off, and any lights to conserve battery. Remove the key from the bike and ensure the battery is locked to the frame or
removed and brought with you for security.
In public places, your KBO Bike must be parked in accordance with local rules and regulations.
If you must park outdoors in rain, or wet conditions you should only leave your KBO Bike outside for a few hours and proceed to park the
bike in a dry location afterwards to allow all the systems to dry out. Much like a regular bike, use in wet conditions mandates a more regular
maintenance schedule to ensure your bike does not become rusty, corroded and to ensure all systems are always working safely.
Do not park, store, or transport your KBO Bike on a rack that is not designed for the size and weight of the bike.
Locking up your bike is recommended to ensure your bike is secure and the chance of theft is reduced. KBO Bike makes no claims or
recommendations on the proper lock hardware or procedures to secure your bike, but we do recommend you take the appropriate
precautions to keep your KBO Bike safe from theft.
When storing your bike or carrying your bike on a rack for transport, you can remove the battery pack to reduce the weight of the bike and
make lifting and loading easier.
Parking Storage and Transport 14
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Basic Battery Charging Tips 15
NOTICE: The battery pack can take longer to charge when fully depleted and when the battery is new. As your battery ages you
might also experience increased charging times, but this is only expected after 3-5 years of regular use. If your battery does not seem
to be charging normally, and taking longer to charge than expected, please discontinue charging and contact KBO Bike immediately.
The battery should be recharged after each use. There is no memory effect, so you can charge the battery after short rides without damage.
The battery can be recharged on or off the bike.
Remove the battery by turning the key and then pulling the battery forward and up until the battery detaches from the mating receptacle.
The charger will automatically stop charging when the battery pack is full.
Always charge in dry locations and indoors away from direct sunlight, dirt or debris.
Do not cover up the charger when plugged in or charging, it air cools and needs to be left in an open space. Do not charge with the charger in
the inverted position which can inhibit cooling and reduce the charger’s life.
Check the charger cables, charger and battery for damage before beginning each charge.
The light on the charger will turn green when charging is complete and stay red while the battery charges. Ensure the light faces upward
when charging
Charging Time
When the input and output plugs of the charger are connected properly, and the battery is not fully charged, the red charging indicator light
should illuminate, showing that the battery is charging. The time that the battery takes to fully charge the battery is dependent on various
factors including distance traveled, riding characteristics, terrain, payload, and battery age.
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Bicycle Care 16
To ensure safe riding conditions you must ensure your bike is properly maintained. You should follow these basic guidelines and see your
certi�ied bicycle mechanic at regular intervals to ensure your bike is safe for use.
Properly maintain batteries by keeping them fully charged when not in use.
Never immerse the bike or any components in water as the electrical system may be damaged.
Periodically check wiring and connectors to ensure there is no damage and the connectors are secure.
To clean, wipe the frame with a damp cloth soaked in a mild non-corrosive detergent mixture. Dry with a cloth.
Store under shelter; avoid leaving it in the rain or exposed to corrosive materials. If exposed to rain, dry your bicycle afterwards and apply
anti-rust treatment to chain and other unpainted steel surfaces.
Riding on the beach or in coastal areas exposes your bicycle to salt which is very corrosive. Wash your bicycle frequently and wipe or spray
all unpainted parts with anti-rust treatment. Damage from corrosion is not covered under warranty so special care should be given to
extend the life of your bike when used in coastal areas or areas with salty air or water.
If the hub and bottom bracket bearings have been submerged in water, they should be taken out and re-greased. This will prevent
accelerated bearing deterioration.
If the paint has become scratched or chipped in the metal, use touch up paint to prevent rust. Clear nail polish can also be used as a
preventative measure.
Regularly clean and lubricate all moving parts, tighten components and adjust as required.
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Basic Troubleshooting 17
It doesn’t work
Irregular acceleration and/or
reduced top speed
When powered on the motor
does not respond
Reduced range
The battery won’t charge
Wheel or motor makes strange
noises
Safety Check Basic Steps Most Common Solutions
1. Insuf�icient battery power
2. Faulty connections
3. Battery not fully seated in tray
4. Improper turn on sequence
5. Brakes are applied
1. Insuf�icient battery power
2. Loose or damaged throttle
1. Loose wiring
2. Loose or damaged throttle
3. Loose or damaged motor plug wire
4. Damaged motor
1. Low tire pressure
2. Low or faulty battery
3. Driving with too many hills, headwind, braking, and/or excessive load
4. Battery discharged for long period of time without regular charges, aged or damaged
5. Brakes rubbing
1. Charger not well connected
2. Charger damaged
3. Battery damaged
4. Wiring damaged
1. Damaged motor bearings
2. Damaged wheel spokes or rim
3. Damaged motor wiring
1. Charge the battery pack
2. Clean and repair connectors
3. Install battery correctly
4. Turn on bike with proper sequence
5. Disengage brakes
1. Charge or replace battery
2. Replace throttle
1. Repair and or reconnect
2. Tighten or replace
3. Secure or replace
4. Repair or replace
1. Adjust tire pressure
2. Check connections or charge battery
3. Assist with pedals or adjust route
4. Replace the battery
1. Adjust the connections
2. Replace
3. Replace
4. Repair or replace
1. Replace
2. Repair or replace
3. Repair or replace motor