Onyx CTY2 User manual
BEEP!
BEEP!
3
YOU ARE NOW THE PROUD OWNER OF AN ONYX CTY2.
In this document we will cover the basic landscape and maintenance of the
CTY2.
We want to thank you for choosing ONYX as your new form of transportation
and recreational use. We welcome you to the ONYX riding community. We
hope you use this manual to provide for reference in the operation, inspection
and basic maintenance of your ONYX. We are constantly updating and refining
our product. Please to use this document to keep yourself up to speed for
many enjoyable miles to come.
Sincerely,
ONYX Motorbikes
WELCOME
onyxmotorbikes.com
310.800.2531
@onyxmotorbikes
@onyxmotorbikes
@onyxmotorbikes
ONYX Motorbikes Group
facebook.com/groups/
onyxmotorbikes
GET IN TOUCH
WARNING
Riding an electric bike is extremely dangerous. Use of this product can result in serious damage, injury,
or death. ONYX products function differently from conventional bicycles and are dangerous. To minimize
risk of serious injury, protective equipment should be worn at all times including a helmet. You are
responsible for your own safety. Use this product with extreme caution and at your own risk.
CONTENTS
8QUICK START GUIDE
LET’S GET READY TO RIDE!
CHECKING AND PREPARING THE BIKE FOR THE FIRST RIDE
BASIC BATTERY CHARGING PROCEDURE
USEFUL RIDING INFORMATION
14
SAFETY INFORMATION
GENERAL SAFETY INFORMATION
OPERATING SAFETY INFORMATION
IMPORTANT LABELS & WARNINGS
16
GENERAL INFORMATION
STANDARD CTY2 MODEL TECH SPECS
OPTIONAL EQUIPMENT SPECS
ACCESSORIES SPECS
TYPICAL CTY2 MODEL DISTANCE RANGE
28OPERATING CONTROLS
MODEL CTY2 FEATURES OVERVIEW
HEADLIGHT BRAKE LIGHT
PEDALS BATTERY COVER
BATTERY LOCATION REAR HUB
MOTOR
ELECTRONICS COMPARTMENT
HANDLEBAR CONTROL FEATURES OVERVIEW
LCD DASH DISPLAY OVERVIEW
SET CLOCK
RIGHT SIDE CONTROLS LEFT SIDE
CONTROLS
KEY-FOB BUTTON LAYOUT AND OPERATION OPTIONAL
ACCESSORY OVERVIEW
36OPERATING INSTRUCTIONS
GENERAL OPERATION
THROTTLE, BRAKING, PARKING
BATTERY OPERATION, CHARGING AND STORAGE
BATTERY OVERVIEW BATTERY COVER
REMOVAL
BATTERY REMOVAL + INSTALLATION BATTERY
CHARGING AND CHARGERS BATTERY
BALANCING
BATTERY STORAGE
BATTERY MAINTENANCE AND SAFETY TIPS
53MAINTENANCE
OWNER RESPONSIBILITIES
RECOMMENDED MAINTENANCE AND SERVICE SCHEDULE BASIC
CTY2 MODEL MAINTENANCE
CLEANING
BODY PARTS & SKINS SERVICE CHECK
YOUR NUTS & BOLTS CHECK YOUR
ELECTRICAL STUFF BRAKE SERVICE
WHEEL & TIRE SERVICE CHAIN &
FREEWHEEL LONG TERM
STORAGE
FASTENER LOCATION
TORQUE SPECS
57
TROUBLESHOOTING
CTY2 MODEL ELECTRIC MOTORBIKE PRECAUTIONS
COMMON TROUBLESHOOTING
ADDITIONAL TROUBLESHOOTING RESOURCES
7
CALIFORNIA PROPOSITION 65
WARNING: Operating, servicing, or maintaining a passenger vehicle or off-highway motor
vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates,
and lead, which are known to the State of California to cause cancer and birth defects or
other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the
engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or
wash your hands frequently when servicing your vehicle. For more information go to
www.P65Warnings.ca.gov/passenger-vehicle.
CALIFORNIA PERCHLORATE ADVISORY
WARNING: Certain components of this motorbike such as lithium batteries may contain perchlorate
material. Special handling may apply for service or end of life disposal. See www.dtsc.ca.gov.
QUICK START GUIDE
QUICK START GUIDE
CTY2 MODEL
8
LET’S GET READY TO RIDE
Okay you are super tempted to ride the bike, but
let’s get the bike fully charged and ready to ride
before you go ride off into the sunset. Your bike
should come nominally charged when shipped. If
you ride the bike uncharged you could cause
problems with operating the bike. So let’s get
started!
PRE-RIDE SAFETY CHECK
Before every ride, it is the owner responsibility to check
and maintain your vehicle according to the schedule
below unless service is needed otherwise:
Check the Headlight, Tail Light, & Any Other Installed
Lighting for Proper Operation
Check Tire Rotation – Should Spin Smooth & Straight
Check Tire Pressure (32 psi F&R)
Check Front & Rear Brake Operation
Check Battery Charge Level
Check & Torque Fork, Axle, Handlebar, and Suspension
Nuts and bolts (see General Information > CTY2
Torque Specifications, page 27)
Whether you are a seasoned cyclist or new to the
electric motorbike scene, riding an ONYX CTY2 is
an awesome experience every time and
everywhere you get to ride one. Pedaling your heart
out is great exercise and gets the blood flowing for
sure, but being able to twist the throttle to give you
power whenever you need it gives you a rush and
a thrill like nothing else! However, there are some
general riding considerations to understand and
keep in mind your CTY2 that will keep you and
others around you safe and happy.
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QUICK START GUIDE
9
PREPARING FOR THE FIRST RIDE
Wear properly fitting protective gear including at minimum:
full-face helmet, gloves, long pants, long sleeve bright
colored shirt, full-toed shoes, and a reflective vest. Do not
wear loose fitting pants or shoes that can get caught in the
chain, pedals, or wheels. Additional items that can make
your riding experience safer, better, and more comfortable
can include sunglasses (that will fit and work with your
helmet) and a jacket. Be careful wearing anything that can
limit your flexibility, mobility, or vision.
If your locale does not require you to obtain and maintain a
valid motorcycle/moped driver’s license, ONYX strongly
recommends that you do so anyway. In addition to learning
more about and being tested on knowing the rules of the
road for safety reasons, having a moped/motorcycle
driver/rider license will help put any law enforcement agent
at ease in case they question your ride or ability to ride…
Additionally, even if your locale does not require you to
complete any formal training, ONYX strongly recommends
that you take a moped or motorcycle riding course for
proper training, especially if you are new to motorbikes in
general. Contact your State or local Department of Motor
Vehicles or law enforcement agency for any
recommendations or suggestions on training programs or
courses. These courses will often count as partial or full
credit for obtaining your motorcycle/moped driver’s license!
Be sure to attend to the following before your first ride:
Be sure to switch on headlight at low visibility. When
your bike is on there will always be a running light
halo on.
Obey all traffic regulations.
Use hand signals when turning or changing lanes.
Please respect property of others and ride carefully.
Keep your feet on the pedals at all times. Keep the
pedals level, especially on turns.
After reaching maximum speed, reduce the throttle
opening to 3/4. While the reduction in speed will hardly
be noticeable, energy consumption nonetheless will be
considerably reduced.
Remember that regenerative (regen) braking is very
strong and can sometimes slow the bike to a stop alone
but it can be unreliable especially at a full battery
charge. So always use the regen brake feature with
caution.
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QUICK START GUIDE
10 BASIC BATTERY + CHARGING GUIDE
Getting the maximum performance out of the Onyx CTY2 requires taking great care of its battery.
For detailed battery and charging information see OPERATING INSTRUCTIONS, BATTERY OPERATION, page 44.
CHARGING THE BATTERY
Your Onyx CTY2 will include a 5 amp charger
and a 23ah 60v battery.
1. Remove the seal cover from the charging
port located at the bottom right of the
battery carriage
2. Align the plug to the charging port. Note:
Charging port will only go in one way.
3. Once charging plug has been inserted, turn
the connector counter clockwise.
4. To ensure proper charging, the yellow tab
must fall into place. You will hear a click
once it’s in place. CONSTANT VOLTAGE CHARGING
When the Standard 5 Amp Onyx CTY2
charger light turns green that means 97%
(69.2 volts) of the charge is complete. The
remaining 3% to charge to 100% (71.4 volts)
takes 95 more minutes after the charger light
turns green. This last 3% is called “constant
voltage” and is done through trickle charging.
It is okay to charge the Onyx CTY2 to
97% (69.2 volts) (charger light turns
green) and go for a ride. Charging to
100% is not necessary every time.
CTY2 MODEL
QUICK START GUIDE
11
PRO
TIP
+ Riding faster consumes more battery.
+ Become familiar with how many miles away your destination is going to be.
+ Keep your battery charge levels above 20 percent which is 57 volts on the display voltmeter.
+ How well the battery is taken care of directly impacts the CTY2’s performance, battery sag and top speed.
BATTERY SAG
Become familiar with the amount of battery sag full throttle
causes in eco mode, normal mode, and sport mode. Sag
is described as the amount of electricity drawn depending
on how much throttle is given. On a colder day it is not
uncommon at full throttle for the voltage sag to be 7 volts
and on warmer days for it to be between 4 volts to 5 volts.
Each mode limits the amount of sag.
Eco mode will help prevent cut offs by reducing battery
sag.
The amount of throttle given directly controls the
amount of battery sag.
BATTERY CUT OFF
When the amount of battery sag falls below 51
volts with a 23ah battery, the Onyx CTY2 will turn
off.
Cut off occurs because the battery management
is protecting the batteries from damage. If it
completely cuts out your battery will reset within 10
seconds. You will need your key fob to unlock the
bike.
One way to prevent the Onyx CTY2 with 23ah
battery from completely cutting off is to immediately
activate regenerative braking by using your rear
brake.
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QUICK START GUIDE
12
Research and understand your local laws and
classifications where you live as well as where
you intend to ride!
ONYX Motorbikes recommends that you register
and insure your CTY2 in one way or another if
you want to and IF YOU NEED TO. Please consult
your local laws.
Respect the environment, and tread lightly. Don’t
tear up or ride off of designated roads and trails. It
is cool to blaze your own trail sometimes, but
make sure it is OK to do so without damaging the
local vegetation or animal population!
Be aware of your surroundings. Remember that
e-bikes are quiet. Be aware of joggers, people
pushing strollers, and other cyclists that may be on
or near the paths and lanes that you may be using.
BEFORE YOU RIDE...
USEFUL RIDING INFORMATION
Consider installing some or all of the following
items as they can help or enhance your riding
experience, safety and visibility on the public roads
with other drivers:
+ Rearview Mirrors
+ Front and/or Rear Wheel Fender(s)
+ License Plate (with a light to illuminate the plate)
+ Front & Rear Side Reflectors
Visit onyxmotorbikes.com to purchase some of the
available accessories.
Whether you are a seasoned cyclist or new to the
electric bike scene, riding an ONYX CTY2 is an
awesome experience every time and everywhere
you get to ride one.
CTY2 MODEL
QUICK START GUIDE
LEFT TURN STOP
RIGHT TURN
13
HAND SIGNALS
GENERAL SAFETY INFORMATION
The high performance CTY2 should be treated with
extreme caution. Proper safety gear, including a
regionally approved helmet, eye protection, riding
boots, gloves, and protective clothing should be
worn while riding to reduce the risk of potential
injury.
Never permit a guest to ride your electric motorbike
without proper instruction. Never use alcohol or
mind-altering drugs before operating your CTY2.
The owner assumes all responsibility while
operating their CTY2. The seller assumes no
liability for misuse or operator negligence.
Prior to each use the rider must check everything
in the “Pre-Ride Safety Check” section of the
Quick Start Guide.
Modifications and additional loads may affect your
bikes performance, handling, range and operation.
Use caution.
SAFETY INFORMATION
OPERATING SAFETY
INFORMATION
Your safety depends in part on the good mechanical
condition of the CTY2. Be sure to follow the
maintenance schedule and adjustment
requirements contained in this manual. Be sure you
understand the importance of checking all items
thoroughly before riding and abiding by the local,
state, and federal laws.
IMPORTANT LABELS &
WARNINGS
Read all additional warnings and product
instructions in this owner’s manual, as well as
safety labels, before operating your CTY2.
(see BATTERY SAFETY TIPS, page 44)
CTY2 MODEL
SAFETY INFORMATION
14
SAFETY INFORMATION
15
IDENTIFICATION NUMBER LOCATIONS
FRAME NUMBER LOCATION
The frame number is etched
underneath the rear seat down
tube.
MOTOR SERIAL NUMBER
LOCATION
The motor number can be found
on the pedal chain side etched on
the hub motor side cover plate.
The motor number starts after the
ONYX.
FOB CODE
The fob code is found on your key
fob.
GENERAL INFORMATION
16 GENERAL INFORMATION
STANDARD CTY2 MODEL TECH SPECS
ONYX Motorbikes reserves the right to make changes to the product information contained on this site at any time
without notice, including with respect to equipment, specifications, models, colors, and materials.
GENERAL VEHICLE INFORMATION
ITEM SPECIFICATION
Drivetrain 100% Electric Direct-Drive Rear Hub Powertrain
Transmission Clutchless Shiftless Direct Drive Rear Hub Motor
Drive Modes ECO1 = Economy NRM = Normal SPT = Sport
Motor Power (continuous) 500W (governed)1750W (limited) 1500W (limited)
Riding Range 60 miles140 miles 20 miles
Top Speed (limited) Approx. 15 mph1Approx. 20 mph Approx. 40 mph (max.)
Pedal Assist Full-Function, but Passive-Assist (not pedelec)
Battery Type Single Removable 60V Lithium-Ion Battery Pack
Anti-Theft Protection Anti-Theft Power Lock + Multi-Function Remote Alarm Key Fob
Front Fork/Suspension Design Heavy-Duty Motorcycle Style Forged Aluminum Fork
Rear Suspension Swingarm with Double 300mm Adjustable Coilover Shock Absorber
Brakes Front Hydraulic & Rear Mechanical Disc Brakes with Binary Power Regeneration
Tires 17” Diameter x 3.00” Wide
CTY2 MODEL
GENERAL INFORMATION
17
Headlight Powerful Harley-Style 3-Element LED Bright White Projector Headlight with Halo Ring
Running Light
Tail Light Bright Red LED Brake Tail Light with Running Light
Frame Automotive Grade Steel Tube Chassis and Strong Battery Holder Tray Chassis
Display LED Backlit Multi-Function Speedometer, Clock, Odometer, Battery “Gas” Gauge, Battery
Voltage Reading
Basic Dimensions Compact 67” Long x 40” Tall x 27.5” Wide
GVWR - Gross
Vehicle Weight
Restriction
506 lbs. (229 kg)
Total Curb “Wet” Weight (with battery) 145 lbs. (65. kg)
Maximum (Payload) Carrying Capacity (including
rider, installed accessories, and gear)
300 lbs. (136 kg)
Total “Dry” Weight (without Battery) 131 lbs. (59 kg)
Front Axle Weight Distribution 64 lbs. (29.2 kg); 41%
Rear Axle Weight Distribution 92 lbs. (41.8 kg); 59%
ITEM SPECIFICATION
Charge Capacity 23 Ah
Battery Weight 15lbs (6kg)
Battery Dimensions 11.75” long x 3.730” wide x 6.688” tall
Battery Cell Components 21700 4500mAh
Battery Cells Customized 17S Lithium battery pack
Voltage Cut Off The BMS is programmed to cut off at 72.5 volts to 47.6 volts.
Recommended Voltage Charge Rate Recommended voltage charge and discharge range is between 71.4 volts and 51
volts
BATTERY INFORMATION (Battery Cell information, see OPERATING INSTRUCTIONS, BATTERY OPERATION, page 44)
GENERAL INFORMATION
ELECTRONICS INFORMATION
18 ITEM SPECIFICATION
LCD Dash Display Bright Multi-Function LCD Display in Streamlined Housing with Current Speed, Charge Level Indicator,
Odometer, Trip Odometer, Voltage Reading
LCD Dashboard Drive Mode Indicator (ECO, NRM, SPT), Headlight Indicator, Left/Right Turn Indicator (optional
function)
Front Headlight Multi-Function LED Headlight, LED Ring Running Light (always on), 3-Element High Power LED
Rear Tail Light Red LED Tail Light with Brake Light
Throttle Half-Grip Twist Throttle with Kill Switch and Mode Select Switch
Battery Nominal Voltage - Output 60 VDC
Battery Case Dimensions 12.25” x 7.125” x 3.5” (310 mm x 180 mm x 90mm)
Battery Weight 15 lbs. (6 kg)
Operating Voltage Range 50-71.4 VDC
Maximum Charge Voltage 71.4 Volts +/- 2%
Battery Capacity 23 Amp-hour / 1,446 Watt-hour (1.4kWh)
Rated Current 55 Amps (constant current, discharge)
Peak Current ~70 Amps
Typical / Max Charge Current 5 Amps – Recommended Standard / 10 Amp Maximum
Battery Cell Type High-Quality 3.7V Lithium Ion - NCM (Nickel Cobalt Manganese Oxide Based) 21700 Cells
ONYX Battery Pack Configuration 17S5P
Battery Pack Cell Matching & Grouping
Tolerances
Cell Capacity Gap = +/- 30 mah; Cell Voltage Gap = +/- 5 mV; Cell Internal Resistance Gap = +/- 3
mOhm
ONYX Battery Management System (BMS) Integrated Battery Battery Management System (BMS manages safe and efficient charging and
balancing of each and all battery cells as a system to maintain battery life and performance)
ONYX Battery BMS Management Scheme The BMS has an overcharge voltage protection function that detects and protects single cells in ad-
dition to serial groupings that will cut off charging to 4.25 V +/- 50 mV (recover at 4.15 V +/- 50 mV).
The over-discharge cutoff is 2.8 V +/-80 mV (recover at 2.85 V +/- 150 mV). Also each cell incorpo-
rates PTC and CID protections. PTC (Positive Thermal Coefficient) provides external short condition
cell protection, and CID (Current Interrupt Device) provides overcharge condition cell protection.
CTY2 MODEL
GENERAL INFORMATION
19
Battery Load Connector Heavy-Duty Anti Spark QS8
Battery Charge Cable Connector Type XT-90 with Externally Accessible PowerCon Charge Port
Battery (Charge Cycle) Life Rated for 800 Charge Cycles
Battery Charger – Standard Charge Separate External 71.4 VDC Output, Fixed Output 5 Amp Smart Charger, 110 VAC and 230 VAC Power
Cord
Battery Charger Output 5 Amps @ 71.4 VDC (recommended; standard rate charger)
Battery Charger Charge Cable Connector
Type
PowerCon (male)
Battery Charger Charge Cable Connector
Pinout
Male - L = DC+ (positive); N = DC- (negative)
Typical Battery Charge Time – Empty to Full 80% Charge = 2.5 Hours
100% Charge = 4.5 Hours
Motor Controller Type Electronic Sine Wave
System & Motor Speed Controller Features High-Efficiency 60V, 1500W (max.) Sinusoidal Wave Brushless DC (BLDC) Waterproof Motor Control-
ler with: Regenerative Power Support During Braking; Hardware Over-Current and Over-Voltage
Protection; LED Fault Code; Thermal and Current Cutback Plus Low Voltage Battery Protection
Shutdown; Rugged Waterproof Aluminum Housing for Maximum Heat Dissipation; Blue-tooth (Android
Support)
Motor Type 4T Turn Count Brushless DC (BLDC) Permanent Magnet 1500W Electric High Power Spoke Rear Hub
Motor with 3 Hall Sensors
Max. Motor Peak Torque 133.5 ft-lb (181N-m)
Motor Rated Power 750W (nominal in ECO Mode) up to 1500W (maximum)
Motor Environmental Protection IP54
Motor Temperature Protection Thermic Probe (sense to prevent overheating)
Anti-Theft Protection Devices Audible Motion-Activated Alarm with Bike Activation/Deactivation Control and Power Button Fob
(set of 2 fobs provided); Uniquely Cut Key Lock for Battery Cover (set of 2 keys provided)
Anti-Theft Alarm dB Level 120 dB
Anti-Theft Alarm Frequency 433 MHz
Anti-Theft Alarm Fob Battery Type CR2032
Wiring Complete Insulated and Wrapped Wiring Harness with Water-Resistant Connectors
GENERAL INFORMATION
MECHANICAL INFORMATION (continued)
20 ITEM SPECIFICATION
Frame Automated Robot-Formed and Welded Tubular and Plate Steel Construction
Fork Heavy-Duty ONYX-Designed Non-Adjustable Motorcycle Fork with Steel Fork Brace
Fork Spring Stiffness Heavy-Duty ONYX-Designed Non-Adjustable Motorcycle Fork with Steel Fork Brace
Fork Suspension Travel 3” (80 mm)
Battery Cover Material 5 Ply Laminated Mahogany Plywood with Brown Stain
Headtube Length 5.7” (145mm)
Handlebar 7/8” DIA Tubular Steel 27.5” (700 mm) Wide 22mm outer diameter
Handlebar Rise 2” (51 mm)
Dropout Width – Front 4.25” (108 mm)
Dropout Width – Rear 5.75” (150 mm)
Brake System Type – Front Single-Piston Hydraulic 220 mm DIA Hydraulic Disc Brake
Brake Operation – Front Right Hand
Front Brake Type Single-Piston Hydraulic 220 mm DIA Hydraulic Disc Brake with Braided Stainless Steel Brake Hose
Front Brake Rotor Disc Cross-Drilled Slots 220 mm DIA x 5 mm THK
Front Brake Fluid Type DOT-3
Front Brake Caliper Style ZUMA50 BWS YW50 Front Left
Front Brake Pad Type Material Semi-Metallic; Powerful Initial Bite with Long Life and Thermal Stability Up to 1100 °F
Front Brake Pad Style Yamaha Zuma 50 02-11, 49mm (61mm w/tabs) x 27mm x 4 mm THK
(NOTE: Replacement must match shape and configuration.)
Brake System Type – Rear Dual Piston Line-Pulled Hydraulic 205mm DIA 6-Bolt (Pitch Circle Diameter = 44 mm) Drilled Disc
Brake; Regenerative Braking Energy Recovery System
Brake Operation – Rear Left Hand
Rear Brake Type High-Strength Aluminum Alloy Material HB-100 Single Piston Line-Pulled Hydraulic Disc Brake
CTY2 MODEL
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