PowaCycle Milan2 Configuration guide

Assembly Instructions
And User Guide
Version 1 – 12 Sept 2006

2
Introduction
Thank you for buying a PowaCycle Milan2 electric bike. We hope it brings you
many hours of enjoyment.
For safe and compact shipping, we have despatched your PowaCycle Milan2
part assembled. It therefore requires some simple assembly work before you
can begin riding.
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. Some assembly details may vary due to the recent product
improvements.
Contents
Before assembly, please check that you have all the parts below:
Battery Charger with plug and
dedicated charger socket Pedals – left and right
Main Cycle Frame folded in it’s protective wrapping

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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. Normally charging takes from 6 to 8 hours to fully
charge the battery, however the first charge can take up to 12 hours. When charged, the LED
turns from red to green. Please note - the battery will deteriorate if it is left uncharged. Begin
by removing the battery from the frame.
A lever at the base of the saddle column releases it, allowing
the hinged saddle to be lifted clear out of the path of the
battery, making it accessible for removal.
Lift the handle on the battery and slide the battery from the
base housing. The battery can now be connected to the
charger.
Charge the battery away from water or combustible material.
Connect the round-ended charger plug to the battery socket.
Plug the charger into a 220/240V mains supply and switch it
on at the plug.
For the first charge allow up to 12 hours, thereafter only 6-8
hours are needed.

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Fitting the Handlebars
The handlebars are already attached to the frame via cables.
They must be inserted into the frame as shown at least the
minimum depth marker line.
Align the handlebars 90 degrees to the forks.
Finally, use an Allen key or hexagonal tool to tighten the
handlebars in place.
NOTE: We recommend that you also make a final adjustment of the
handlebars once the bike is fully assembled.
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.

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Checking Brakes
Safety Check
As a standard precaution check that the brakes are working
effectively, that brake blocks are clear of the wheels and
evenly aligned. Wheels should turn freely until brakes are
applied. As with all new cables some stretching will occur with
use so adjustment should be carried out as soon as needed.
To tighten the brakes, a nut is fixed to the brake mechanism,
holding the wire cable. Loosen this nut to allow you to pull the
cable through and take up any slack. Then re-tighten the nut.
Check that the wheel spins freely and the brake operates
effectively when applied.
Fine adjustments to the brake tensions can be made via
adjustment controls located at the junction of the brake lever
and cable.

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Completed PowaCycle Milan2
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 (not included) are working
•all nuts and bolts are secure (including pre-assembled ones).

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Operation of the Milan2 PowaCycle
Overview
The PowaCycle Milan2 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.
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 charge the battery indoors after use.
•Do not handle the charger or battery with wet hand or charge in a wet area or and area
exposed to water splash.
•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 whilst charging.
•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 with 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.
Lights
We recommend that users purchase and fit independent front and rear lights.
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.

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Power
Switch on the power by pressing the switch on the battery. The Milan2 can be operated as a
“pedelec”. This means that, as soon as the rider begins to pedal, the motor supplies energy to
support the cyclist’s efforts. If the rider prefers to cycle without the assistance of the motor, he
or she should turn the power off.
Throttle
In order to use the throttle power, the red button on the handle bar must be pressed (this
activates the throttle) and then the throttle (located on the right handle bar) can be used.
Mechanical Adjustment
The tightening torque of the handlebar stem, seat post and front wheel shall not be less than
18NM. The torque of the wheel axles shall not be less than 30NM.
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.
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.
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 you have your cycle serviced by a professional cycle engineer at least once a
year to ensure ongoing safe performance. If you are unsure as to how to carry out an
assembly procedure or adjustment, we recommend that you consult your local cycle shop.

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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.
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 that none of the electrical cables and connections has become dislodged.
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 – 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.

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PowaCycle, Ultima Networks PLC,
Akhter House, Perry Road, Harlow, Essex, CM18 7PN
Tel: [phone]
www.PowaCycle.co.uk
Milan2 Assembly Instructions and User Guide – ref JN1006