PowaCycle Coaster User manual

Electrically Assisted Pedal Cycles
Assembly Instructions
Version 4 – 24 Sept 2005

2
Introduction
Thank you for buying a PowaCycle Coaster electric bike.
We hope it brings you many hours of enjoyment.
For safe and compact shipping, we have despatched your
PowaCycle Coaster part assembled. It therefore requires
some assembly work before you can begin riding.
Please follow these instructions carefully. If you do not
feel confident to assemble the bike yourself, we
recommend you visit your local cycle store for
professional help and advice.
Contents
Before assembly, please check that you have all the parts below:
Important: A spare set of keys is supplied. Please keep these in a safe place as
lost keys cannot be replaced.
Front Wheel Battery Charger
Pedals
Keys (Power, Battery Lock) Saddle & Battery
Main Cycle Frame

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Assembly Instructions
Charge the Battery
Before assembling your PowaCycle, you should charge the battery.
This will allow you to test the electrical connections during assembly.
Remove the battery and charge it indoors. It may take up to 6 hours
to fully charge the battery. When charged, the LED turns from red to
green. Please note, the battery will deteriorate if it is left uncharged.
To release the battery turn the key in the
battery to the open position – key aligns
with symbol of a battery.
A lever under the seat releases a lock,
allowing the seat to be lifted forward on a
hinge, this makes the battery more
accessible.
Slide the battery from the base housing.
Open the cover on the battery socket and
connect the charger connection plug. Plug
the charger in to the mains supply and
switch on. Charge indoors away from water
and combustibles.

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Fitting the Handlebars
The handlebars are already attached to the
frame via cables.
They now need to be inserted into the
frame, then adjusted and secured.
Insert the handlebar stem into the frame as
shown.
Align the handlebars with the rest of the
bicycle, then use an Allen key or hexagonal
tool to tighten them.
NOTE: We recommend that you make a final
adjustment of the handlebars once the bike is
fully assembled.
Fitting the Saddle
Insert the stem of the saddle and battery
assembly into the frame. Align the saddle
correctly with the frame and at the required
height.
Then, fix it in place by tightening the lever at
the top of the frame.

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Fitting the Wheel
Remove the black plastic front fork
protectors, which are part of the protective
packing material.
We recommend that you turn the bicycle
upside down, resting it on the handlebars
and saddle.
Note: We suggest you remove the battery, to make the
bike lighter, before turning it upside down. Also, you
may need to adjust the saddle to make it more stable.
Place the wheel between the forks, ensuring
that the brake disc is on the same side as
the Brake Caliper (coloured Red).
Then fasten the nuts and washers to each
side of the wheel spindle, tightening them
evenly. The wheel needs to spin freely, so
avoid over tightening.
Fitting the Wheel – Brake Assembly
With the cycle upside down, adjust the front
disc brake mechanism. Use an Allen key (or
similar), to release, adjust and retighten the
brake cable, until the wheel spins freely and
the brake operates effectively when applied.
If you are not confident to carry out these adjustments
yourself, we suggest you consult your local cycle
stockist.

6
Fitting the Pedals
Pedals are marked L and R, for the left and
right hand side of the bicycle when it is
facing forward. Screw each pedal into the
appropriate pedal shaft by hand, and then
tighten with a spanner to secure.
The pedals have a reverse thread and
therefore need to be screwed in backwards.
Making the Electrical Connections
Join the electrical connectors
from the frame to those from
the battery housing.
Link the connections by
matching the wire colours
and clip shapes (see below).
NOTE – The battery will need to be
charged for this test to be carried out.
Turn the key in the battery
to turn the power on, then
twist the throttle (ensure the
back wheel is off the
ground). The back wheel
should rotate.
Test the lights by pressing the red button on the handlebar.
If the lights or the motor do not work then re check all connections.
Once you have checked that
the connections are correct,
tidy the wiring by easing it
into the gap in the frame,
taking care not to break the
connections.

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Fitting the Front Light
The front light is
already secured to
the frame via wires.
Screw the front light
bracket to the arch in
front of the front fork,
and then secure the
light on the bracket.
Completed PowaCycle Coaster
Finally …
Before mounting your cycle to ride, remember to check that:
the battery is fully charged.
the tyres are inflated to the correct pressure.
the brakes are operating effectively.
the handlebars are correctly adjusted and secure
the seat is at the correct height for the user
the lights are working
all nuts and bolts are secure (including pre-assembled ones).

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Operation of the Coaster PowaCycle
Overview
The PowaCycle Coaster is an electrically assisted bicycle that
operates as a standard bicycle, with the assistance of a motor and
battery.
The power provided supports the rider’s own efforts, giving increased
performance with less effort.
The Coaster has an independent throttle. This allows the user to
choose whether or not to use the power and, if using it, to vary it
according to requirements.
Battery Charging, Care & Safety
Care of the battery is vital to maximise its long-term performance.
The battery must be removed from the bike for charging.
Regular Use – If you are commuting significant distances, it is
advisable to recharge the battery before the return journey.
Occasional Use – Recharge the battery at least once a week,
even if the cycle is unused.
Always recharge the battery after use.
Always charge the battery indoors.
Keep the battery away from water, to prevent shocks or shorting.
When attached to the bicycle, it is safe to operate in wet conditions.
Do not cover the battery or charger.
Do not leave the battery permanently charging from the mains supply.
Only use the charger provided to charge the battery.
Do not use the battery to power anything other than the
PowaCycle for which it was purchased.
Do not disassemble or modify the battery.
Do not expose the battery to fire or extreme temperatures.
Do not short circuit the battery.
Do not allow impact or force against the battery pack.
Dispose of the battery in a dedicated waste facility.

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Additional Lights
As an additional safety feature, we recommend that night users
purchase independent front and rear lights that are NOT powered
from the cycle battery. After a long journey, there is a risk that the
cycle battery could be depleted, so lights could stop working.
Tyres
Check the tyres regularly to ensure that the correct pressures are
maintained (pressure ranges are shown on the sides of the tyres).
Do not over-inflate the tyres.
There are different types of pumps available for cycles. Ask your
local cycle shop for the one best suited to your needs (do not use a
garage forecourt air hose to inflate your tyres).
Brakes
Make sure your brakes are adjusted correctly at all times.
Adjustment can be made at the wheel rim/brake mechanism with
tools. Fine tuning of the brakes can be made via adjustable twist
screws that are located at the join of the brake lever to the cable.
Replace the brake blocks when worn.
Power
Switch on the power by turning the key in the battery. As soon as
the rider begins to pedal, the motor supplies energy to support the
cyclist’s efforts. Power can also be supplied by the throttle. If the
rider prefers to cycle without the assistance of the motor, he or she
should leave the ignition off.
Gears and Bicycle Chain
Change through the gears one at a time and only when the bicycle is
being pedalled. To maintain performance, ensure that all the
mechanical parts of the gears are lightly oiled (avoid getting oil
deposits on the wheel rims). If the chain mechanism becomes
dislodged, turn the pedals forward gently to engage it. If the chain
becomes completely dislodged, re-engage it on the smallest gear cog.

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Saddle
For maximum comfort ensure that the saddle is both correctly
adjusted and secure. Once set up correctly, the height of the saddle
can be adjusted without tools. Loosen the lever at the top of the
frame below the saddle to raise or lower the saddle. Once the saddle
is at the required height, secure it by tightening the lever. Tighten or
loosen the nut on the lever if required.
Do not attempt to adjust the lower bolt and nut fitting on the circular
slot below the saddle. This is not intended for adjustment.
User Safety
Cycle Helmets
Although there is no legal requirement to wear a cycle helmet, we
recommend that you do so for your safety. Wearing a cycle helmet
has been proven to reduce the likelihood of head injuries.
Professional Maintenance
We recommend that you have your cycle serviced by a professional
cycle engineer at least once a year to ensure ongoing safe
performance. Also, if you are unsure as to how to carry out a
particular assembly procedure or adjustment, we recommend that
you consult your local cycle shop.
Troubleshooting
1 – Brakes not working effectively
Check the distance between the brake blocks and the wheel rim.
Check that the blocks are parallel with the wheel rim.
Check for any wear on the brake blocks
Fine tuning to the brakes can be performed by the adjusters
between the brake lever on the handlebars and the brake cable.
Major adjustments are made at the brake blocks and you will
need the appropriate tools. See brake assembly instructions.

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2 – Motor not working
Check that the ignition has been switched on
Check that the battery is properly inserted in its housing.
Check that the battery is charged.
Check if the electrical cables or connections has become dislodged.
3 – Light(s) not working
Check that the wiring is not broken.
Check that the bulbs are inserted correctly.
Check that all connections are made properly
Warranty
Information
1 – The frame – Has a warranty of two years.
2 – Other main parts – Have a warranty of one year.
3 – The battery – is covered by a 6 month warranty,
as battery life will be determined by user care.
4 – Bulbs, brake blocks, tyres etc – Are regarded as consumables,
therefore when replacements are required, these need to be
purchased from your local cycle shop or store.
PowaCycle, Ultima Networks PLC,
Akhter House, Perry Road, Harlow, Essex, CM18 7PN
Tel: [phone]
www.PowaCycle.co.uk