PopCycle Montana Operating instructions

How to Build a Popcycletm Montana
When receiving a Popcycle Montana in the Factory packaging this short
document is designed to assist with proper removal from that package and
assembly for a safe ride.
WARNING!! Always be certain that bike parts are carefully inspected for
damage –and be certain that everything –especially the wheels, are
securely tightened before riding.
Step 1
Using scissors –cut the plastic straps
Step 2
Open the top flaps of the box and remove the Styrofoam
Everything is strapped together –this bike can be lifted straight up and
out of the box
Place the bike on a soft protective surface!
Please be careful lifting boxes and watch for
sharp metal where the boxes are stapled!
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Step 3
Carefully lift the bike straight up from the box and place it on the floor noting that the
bike must be leaned against the box or some other stable surface.
Step 4
Using scissors with rounded ends - Carefully!!! Remove all of the outer shrink wrap and
bubble wrap from the bike. Pay special attention not to scratch the surface paint of the
bike. Most of the bubble wrap is secured with few pieces of clear tape and when cut,
the bubble wrap will easily come off the bike.
Remove the Battery Charger, Water Bottle, Pedals, Quick Release bolt and the
Instruction Manual –located in a bundle behind the saddle
Leave the wrap on the main crossbar as shown in the photo on the right for now
figure 3
X
No Sharp Scissors!

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Step 5
Install the front wheel
The fork fits over the wheel – be careful to insert the disk brake correctly into its slot as you rest the bike on the wheel’s axle
Use finesse… Do not force this – when properly aligned the fit is perfect
Step 6
Insert the Quick Release bolt into the front wheel axle _ BE CAREFUL!!!
Watch this video if you have ANY questions on the proper installation of a quick release assembly
http://www.youtube.com/watch?v=zHTyVSf8VlQ
Half way completed already…
QUICK RELEASE

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Step 7
Unwrap the foldable pedals and note the stamped “R” for right and “L” for left on each. Screw in the
right side using a clockwise turn –but the left side is reverse threaded and is installed with a
counterclockwise turn. Use a wrench to firmly turn each into the crank arm
Step 8
Unwrap the kickstand –there are two parts to this adjustable stand. Completely remove the extension holder before
sliding the bottom half of the kickstand in the slot –and then re-install the extension holder
Step 9
Adjust the seat height and lock the quick release lever FIRMLY in
place before riding the bike
http://www.youtube.com/watch?v=zHTyVSf8VlQ is an excellent
video on a quick release lever for a wheel –this information is
equally useful for the seat and folding hinge –please take a
moment if you are not familiar with the quick release lever and
watch this short educational video.
Tighten the fork after the front wheel is aligned with the handlebars.
Extension Holder

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Step 10
Plug the battery into the bike Step 11
Insert the key into the battery switch and rotate clockwise to
activate the battery pack.
WARNING –the bike is now live and if the throttle is turned (right
hand control) the bike will move forward –and may jump out of the
user’s hand – BE CAREFUL…
SAFETY TIP
It is best to turn the key to theActive position only while seated on
the bike. Reaching behind to do this is simple and helps insure that
the bike stay in control of the operator.
As an added safety feature, applying a brake will immediately
disengage the electric motor even if the throttle is rotated to the on
position.
Step 12
Included with the bike is a short document on operating the electronic display pad.
First, press the center button until the display is active –the motor will not operate
until the display is on. Second, select the level of pedal assist desired by pressing the
up or down arrow keys –5 is the most assist and zero is no assist.
Step 13
While pedaling the shift lever and
backshift release button act to change
the speed of the wheel versus the
speed of the user’s foot power.
Enjoy the Ride - END