PowaCycle Milan User manual

Assembly Instructions
Version 1 - 4 May 2006
PowaCycle, Ultima Networks PLC, Akhter House, Perry Road, Harlow, Essex, CM18 7PN
01279 821243 www.PowaCycle.co.uk
TM

Thank you for buying the PowaCycle Milan
electric bike. We hope it brings you many hours
of enjoyment.
For safe and compact shipping, we despatch the
PowaCycle Milan part assembled. This minimises
any risk of damage during transit, so that the
bike reaches you in good condition. It therefore
requires some assembly work before you can begin
riding.
Please follow these instructions carefully. Before
starting assembly of the Milan, arrange for a
second person to be on hand. Help is required
in supporting the bike, when attaching the front
wheel and mudguard. If you do not feel confident
in carrying out the assembly, we recommend that
you contact your local cycle shop for professional
assistance.
Open the box and remove the contents. Remove
the protective packaging, keeping tools clear of
cables and paintwork.
2
Main Frame
Front Wheel
Battery Charger
Pedals (L&R)
Keys x 2
Mudguards
Basket Support bracket
Basket/Mudguard fixings
Basket
Contents
Before beginning assembly, please check that all the parts are included.
Note that some nuts and bolts and other parts come attached to the frame by the packing.
Your PowaCycle comes with a spare set of keys. The spare key needs to be kept in a safe place, as replacements
cannot be obtained.
Introduction
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Assembly Instructions
1.Charging 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 normally takes
8 hours to fully charge the battery, however the first charge can take longer. Once charged, the
LED turns from red to green. Please note; the battery will deteriorate, if it is left discharged for a
prolonged period.
To release the battery turn the key in the barrel on the
vertical tube.
Use the handle to lift the battery free of the frame.
The Milan battery can be charged, while in place on the
bike, however charging should always be performed
indoors away from any risk of contact with water.
Generally the battery should be removed to ensure safety
when charging. When charging is complete the light
changes from red to green.
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The pedals are each marked with an L and R, which
correspond to Left and Right when the cycle is facing forward.
These can be screwed into position on the respective sides
of the bike. It is best to hand tighten these and then use a
spanner to secure them.
They are then tightened using a 15mm spanner from the
PowaCycle toolkit. Each pedal should rotate freely after
tightening – if it does not turn freely, it is too tight.
The pedals have a reverse thread and therefore need to be
turned in the opposite direction of the normal pedal turn.
2.Fitting the Pedals

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2.Fitting the Handlebars
The handlebars are already attached to the frame via cables.
They now need to be inserted into the frame as shown.
Using an Allen key in the toolkit, lock the handlebars into
place. Do not to over-tighten as they will require further
adjustment once the wheel is attached.
Carefully turn to reposition the light unit back into place.
Finally, use the Allen key supplied or hexagonal tool to tighten
the handlebars in place.
Note:
We recommend that you make a final adjustment of the
handlebars once the bike is fully assembled.
Loosen the small screws on the wheel fork. Attach the
mudguard support arm and retighten these screws.
Remove top mudguard fitting screw from the frame (if
attached). Position the mudguard by sliding the mudguard
through the wheel arch.
Refit the nut and bolt.
3. Fitting the Front Mudguard
Rest the main bike section onto the floor with the back wheel
and the front forks on the floor (keep the forks straight).
A second person will be needed to support the bike while
fitting the mudguard and front wheel.
The Front brake cable and brake cradle clip should be
disconnected giving clearance for the mudguard and wheel
to be attached.

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4.Fitting the Front Wheel
Undo the nuts on the wheel and put the washer lock locators
to one side.
One person needs to support the bicycle frame, whilst the
other places the wheel into the forks, keeping clear of the
washers.
5. Brake Assembly (Front & Back)
Front:
Pinch in the callipers to slacken off the brake cable. Pull
the cable tight through the brake lever locking nut a little
at a time and tighten. Test the brakes to ensure effective
functionality and adjust accordingly.The brake will need to
be re-adjusted again after 2-4 weeks to compensate for the
normal stretching of the new brake cable.
Back:
This brake is found on the left hand side of the bike, next to the wheel. In order to get the handle bars on, or take
them off, this cable must be loose. (Note, if handle bars are ever removed this process needs to be reversed).
Process: Tightening the brake cable
i) Loosen the nut under the wheel hub until slack.
ii) See photo, arrow A B
Push the brake arm toward the front of the bike
– note small, finger lever.
iii) Re-tighten the nut.
iv) Pull the brake lever.
The lock in locator points are then placed in their respective
holes and the nuts tightened. After tightening ensure that the
wheel turns freely. With the front wheel attached, the bike can
be supported by its stand, however care should be taken to
avoid knocking the bike over as assembly work is continued.
Reconnect the front brake cable and brake cradle clip
It is important that the brake is sufficiently tight, but over tightening can also cause
problems so try adjusting a little at a time – testing the back brake each time until
you are totally satisfied.
Fine adjustments to brakes are made at the hand lever end, via a twist wheel where
the cable meets the hand lever.
It is imperative that bike brakes are adjusted correctly. If you are not sure that
the brakes are functioning effectively then do not use the bike – seek help from a
professional bike shop.
A
B

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Congratulations, your completed PowaCycle is now ready to ride. Before
mounting please check that:
lThe battery is fully charged
lTyres are inated to the correct pressure
lBrakes are operating eectively
lHandlebars are correctly adjusted and secure
lThe seat is at the correct height for the user
lLights are working
lAll nuts and bolts are secure, including those
pre-assembled
6.Fit the Basket
The basket is fixed to a support bracket which is then
attached to the bike.
Turn bolt outward from the inside of the basket, attaching
the basket to the bracket with the nut to locks the basket in
place.
Attach the basket to the bike using the bracket screws to the
front of the bike, below the handlebars and above the forks.
7.Saddle Height & Suspension
Once set up, the height of the saddle can be adjusted
without tools.
Tighten or loosen the bolt opposing the lever, if necessary to
ensure the lever applies sufficient grip.
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.
The saddle also has a tension spring underneath (black). This
acts as the rear suspension. Anti-clockwise slackens it off and
clockwise tightens.

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Operation of the Milan PowaCycle
The Milan PowaCycle is an electrically assisted bicycle that operates like 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. As soon as the rider begins to pedal, the motor supplies energy to support
the rider’s efforts. A throttle also supplies power and works independently of pedalling. If the rider
prefers to cycle without the assistance of the motor, he or she can leave the ignition off.
Battery Charging, Care & Safety
Care of the battery is vital to maximise its long-term performance.
lThe battery should ideally be removed from the bike for charging.
l Regular Use – If you are commuting significant distances, it is advisable to recharge the battery
before the return journey.
lOccasional Use – Recharge the battery at least once a week, even if the cycle is unused.
lAlways recharge the battery after longer and power draining hilly journeys.
l Always charge the battery indoors.
l Keep the battery away from water, to prevent shocks or short circuiting.
l Do not cover the battery or charger.
l Do not leave the battery permanently charging from the mains supply.
l Only use the charger provided to charge the battery.
l Do not use the battery to power anything other than the Milan PowaCycle.
l Do not disassemble or modify the battery.
l Do not expose the battery to fire or extreme temperatures.
l Do not short circuit the battery.
l Avoid impact or force against the battery pack.
l Dispose of the battery in a dedicated waste facility.
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 relying on the cycle battery 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 the brakes are adjusted correctly at all times.
Adjustments can be made at the wheel rim/brake mechanism with tools.
Fine tuning of the brakes can be made via adjustable twist screws which are located where the hand pull
brake lever joins the cable.
Replace the brake blocks when worn.
lYou will need to adjust the brakes after the first 2–4 weeks of use as they may loosen during this time,
as the new brake cable stretches.
lAlways ensure that you fully loosen the back brake cable if you need to remove the handlebars.
Failure to do so is likely to cause damage to the back brake cable.
continued overleaf

Power
Switch on the power by turning the key in the
battery. Power is applied via the throttle located on
the right-hand handlebar. The use of the throttle
applies and regulates the motor power assistance.
Gears & Chain
Change through the gears one at a time and only
use 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, re-engage it on
the smallest gear cog.
Saddle
For maximum comfort and safety, ensure that the
saddle is correctly adjusted for the rider.
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.
The saddle also has a tension spring underneath
(black). This acts as the rear suspension. Turning
anti-clockwise slackens it off and clockwise
tightens.
Cycle Helmets
Although there is currently no legal requirement to
wear a cycle helmet, in the UK we recommend that
you do so for your safety. Wearing a cycle helmet
has been proven to reduce the likelihood of head
injuries in the event of an accident.
Professional Maintenance
We recommend that you have your PowaCycle
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 store.
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 using
adjusters between the brake lever on the handlebars
and the brake cable. Major adjustments are made at
the brake blocks (you will need the appropriate tools).
See brake assembly instructions.
2 – Motor not working
• Check that the ignition is 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 have
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 properly made.
Warranty
1. The frame has a 2 year warranty.
2. Other main parts have a 1 year warranty.
3. The battery has 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.
Warning– PowaCycle Milan
It is essential to slacken off the back brake
significantly should you ever need to remove the
handlebars. This is performed at the back wheel end
and is the reverse process to that described in the
BACK BRAKE section.
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