Pony4 P4 Service manual
Pony4 - Operating and Service Manual
1 Introduction 3
1.1 Description 4
1.2 Variants, specifications and options 5
2 Delivery 7
2.1 Unpacking 7
2.2 First assembly and adjustments for rider 8
2.3 Front boom assembly 10
2.3.1 Front boom assembly Pinion or crankset without motor 10
2.3.2 Front boom assembly Long frame with Pinion and motor 12
2.3.3 Front boom assembly Long frame with Rohloff and motor 16
2.4 Basic check after assembly 20
3 Operation 23
3.1 Basics 23
3.2 Vehicle 23
3.3 Load carrying 28
4 Safety 30
4.1 General 30
4.2 Visibility 30
4.3 Rider position 30
4.4 Shoes with clipless and other system 30
4.5 Load securing 30
4.6 Pre ride check 31
4.7 Ride 31
4.8 After the ride 32
5 Service 32
5.1 In general 32
5.2 Brake-in period 32
5.3 Frame and Rails 33
5.4 Boom 33
5.5 Seat and seat brackets 33
5.6 Steering and geometry alignment 33
5.7 Brakes 37
5.8 Gears 38
5.9 Suspension 38
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1 Introduction
Dear Customer, First of all, we would like to thank you for choosing Pony4 (P4) to meet
your transportation needs. We hope you will be happy to ride any number of kilometers or miles
with our product to improve the environment on planet earth.
Our team believes that any human powered vehicle can be adapted to almost any
transportation need, and if it doesn't exist, it hasn't been developed yet.
In this manual we will go through all aspects of living with a P4 from delivery, initial
installation, alignment, safety, maintenance, and finally durability and warranty. Because this
process can be quite complex, we have marked the important parts with the word CAUTION: For a
better understanding, you will also find links to our video channel: Pony4bike in some cases.
If you are unsure about any details in our instructions or other things related to the P4,
please visit our website. We have a lot of useful information there combined with some video
tutorials and drawings.
For components and parts from other manufacturers (e.g. internal gear systems, brakes, etc.),
we recommend that you study those manufacturers' specific manuals. These manuals contain
specific procedures for assembly, disassembly and maintenance of these parts. Familiarize yourself
with them, as failure to follow these procedures may result in damage to the parts and limitation of
the warranty. Please note that some tasks can only be completely performed by the manufacturers
(for example, disassembly of the internal parts of Rohloff hub gears).
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1.1 Description
P4 is considered as a bicycle due to human power (and limited electric assist) in a lot of
countries. However, sometimes local rules may differ, so familiarise yourself with them and contact
the authorities on this matter. For some parts you will find great similarity with bicycles and
recumbents such as wheels, transmissions, drum brakes, seat, etc. Other parts will be completely
new for you, for example leaf springs, rear axle, etc. For these parts we will have a more detailed
review in the manual. Since each P4 bike is built to a specific order with optional extras, some parts
may vary from bike to bike.
Basic important P4 parts with terminology can be seen at followed scheme:
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Fig. 1. Pony4 basic scheme with terminology
1.2 Variants, specifications and options
We have developed three basic variants of the P4. All variants share the same principle of
frame construction and transmission. For light cargo applications there is a SHORT FRAME /
LIGHTWEIGHT version with one damper on the rear axle. For compact cargo with more weight,
we have a SHORT FRAME / HEAVY LOAD version with two dampers with optional steel springs
on the rear axle. And finally for bulkier and more heavy cargo we have the LONG FRAME /
HEAVY LOAD version with two dampers and optional steel springs on the rear axle.
Fig. 2. Pony4 LIGHTWEIGHT (left) and HEAVY LOAD (right) with Flat Cargo Platforms
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Fig. 3. Pony4 HEAVY LOAD Short -Cargo Box Low (L), Cargo Box High (R)
Fig. 4. Pony4 HEAVY LOAD Long with Cargo Box Low
Pony 4 is equipped with 90 mm front drum brakes with improved cooling. Rear axle is
without brakes. For transmissions, we offer Pinion gearboxes in two variants with one chain drive.
Second option is the Rohloff hub in the middle position with two chains. E-assist, a pedelec system,
is offered in several variants. Simple version, combined with Pinion, is mounted in the front of front
leaf springs with 250 W motor and 30 Nm or 45 Nm torque levels . For heavy cargo and more hilly
terrain a mid-drive motor located in cranks together with Rohloff is better suited.
You will find detailed variants and parameters description on Fig.5. Complete options list can be
found in order form at followed link:
https://www.pony4.bike/wp-content/uploads/2021/02/PONY4-ORDER-FORM.pdf
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Fig. 5. Pony4 variants and basic parameters
2 Delivery
All Pony4 bikes can be ordered directly from us or through our dealers. In the case of direct
sales, each bike is packed in an oversized cardboard box and is assembled with the exception of the
seat, boom (in the case of long frames) and specific accessories (mudguards, etc.). Handlebars are
attached and folded. We use recycled materials for packaging of disassembled parts and spare parts
to avoid possible damage. These boxes are usually hot-glued to the outer box to prevent movement.
To avoid having to wrap the outer carton during shipping, we use empty cartons inside to fill the
empty space. Check all boxes inside the packaging for parts before discarding them when
unpacking.
2.1 Unpacking
Unpacking is simple. First cut the outer straps, then cut the tape on the top to open the box.
Remove the seat which is usually fixed with zip ties to the wheel and handlebars. Check for other
parts possibly attached to P4. After that it is better to lift the P4 from the box. Then inside of the big
box there will be smaller paper boxes with other parts including extra options (usually manual,
boom with chainset, mudguards, etc.). LONG FRAME P4 versions have a pedal frame (boom) with
cranks and chainset removed from frame. Boom with the option of Pinion gearbox is packed inside
front leaf springs due to connection of shifting cables. Some parts are fragile when not mounted so
handle them with care (for example composite mudguards).
Unpacking can be seen in the first part of this tutorial video:
PONY4 - unpack and prepare for your first ride
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2.2 First assembly and adjustments for rider
First assembly is rather easy and intuitive if you follow this order: Seat, Handlebars, Pedal
frame, Chain, Brakes, Mirrors.
Seat is attached to the frame in two places. Seat lower area is resting on a conic shaped silentblock.
Fig. 6. Seat adjustment movements
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Fig. 7. Seat adjustment - upper mount
Fig. 8. Seat adjustment - lower mount, attached on the seat for transport (L)
different positions of the seat in the rails (R)
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Fig. 9. Seat adjustment - lower mount fixation
2.3 Front boom assembly
Pedal frame (boom) is already installed, in a short frame variant, and set to your specified
leg-length. This variant requires only minor adjustments due to human body variations. In case of a
long frame variant, your pedal frame is taken out of the frame for transport. Carefully install the
pedal frame inside the front part of the frame. Do not clean the front boom. We use special paste to
increase friction. Same is used for front boom assembly with crankset.
2.3.1 Front boom assembly Pinion or Crankset
Due to Pinion shifting cables, boom assembly is placed inside of front leaf springs for transport.
Carefully unpack assembly. Be sure that the main stainless-steel clamp on the frame is not tightened. Do not
clean the front boom, we use special friction paste! Be sure that the right handlebar is directing horizontally
backwards.Boom installation needs all slack of shifting cables.
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Fig. 10. Sliding the boom inside the frame
Place the boom inside the frame and slide it with force inside the frame. Adjust the boom to your desired leg
length position and align the bottom bracket axis to be horizontal. Tighten stainless-steel clamps temporarily.
Next step is to assemble the chain tensioner with the tube holder in place.
Fig. 11. Chain tensioner installed
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Last step is to put the chain carefully on the sprocket.
Fig. 12. Chain placed on the sprocket
2.3.2 Front boom assembly Long frame with Pinion and motor
For this assembly you will need Inbus (Allen) key set
Fig. 13. Front boom
Do not clean the inserting part of the boom, we use special friction paste!
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Due to Pinion shifting cables, boom assembly is placed inside of front leaf springs for
transport. Carefully unpack assembly, do not hold the assembly via plastic part for magnet holder
which is placed on the left crank near bottom bracket axle. Be sure that the main stainless-steel
clamp on the frame is not tightened.
Fig. 14. Handlebar position for boom inserting
Be sure that the right handlebar is directing horizontally backwards. Boom installation needs
all slack of shifting cables.
Fig. 15. Front boom insertion
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Place the boom inside the frame and slide it with force inside the frame. Adjust the boom to your
desired leg length position and align the bottom bracket axis to be horizontal. Tighten stainless-steel
clamps temporarily.
Fig. 16. Assembled all electric assist cable connectors. Each one has a specific shape
Fig. 17. Final cable assembly should look like above
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Fig. 18. Pinion cable attachment near the motor. Be sure that nothing is in contact with the moving
parts of the motor.
Fig. 19. Loose attachment of Pinion shifting cables by zip-ties to the frame and handlebar
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Fig. 20. Installation chain on chainring and chain tube holder on the boom
Check that the chain is correctly fitted to all sprockets and chainrings. Make sure that the chain line
is straight and that the chain is centered in the chain tube. Check that the Rohloff chain tensioner
bracket is not touching the engine and that the chain tensioner always has a little extra slack to
tension the chain when the rear axle moves due to the suspension. Check the extension of the pedal
boom with your leg length and block it by tightening the steel clamp.
2.3.3 Front boom assembly Long frame with Rohloff and motor
Be sure that the front boom clamp is free and not tightened on the frame tube.
Fig. 21. Front boom clamp
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Place the boom inside the frame and slide it with force inside the frame. Do not clean the
boom, we use special friction paste for better friction.
Fig. 22. Boom insertion
Install chain tensioner onto frame, Fig. 23. The chain tensioner must rotate freely on the
main tensioner bolt (M10x1 bolt for rear mech hook for standard bicycles).
Fig. 23. Chain tensioner installation
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Install chain on chainring. Be sure that chain is engaged correctly on the whole sprocket.
Fig. 24. Chain-chainring installation
Adjust the boom for your leg length and tighten the boom clamp. Be sure that the front boom clamp
is located cca 5 mm from the edge of the main frame tube, shown on picture below.
Fig. 25. Right front boom clamp position
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To finalize your Pony4 you need to connect three remaining cables for electric assist. All
have specific connectors to avoid misplacement. Cables are positioned along the frame. Sensor and
display connectors are located next to each other.
Fig. 26. Sensor and display connectors
Fig. 27. Battery connector is located under the seat
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