Sun Microsystems Electrolite Configuration guide
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Thank you for purchasing a Sun Bicycles product! We are happy to have you as
part of our cycling family, and will gladly help with any questions or concerns
along the way. We’ve also worked hard to establish one of the best dealer
networks in the industry. These dealers are the arms and legs to our body of
knowledge. We and each of these dealers are dedicated to providing you with
everything you need to have the best experience possible on your new Sun bicycle.
w w w . s u n b i c y c l e s . c o m
Distributed by:
J&B Importers, Inc.
PO Box 161859, Miami, FL 33116-1859
Notice: Sun Bicycles are partially assembled. They are intended to be sold only in a fully assembled and
adjusted condition. Final assembly and adjustment are to be performed by an authorized Sun Dealer.
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Front (Left) Brake
LED Power Indicator
Trigger Shifter for Rear Gears
Crankset with Pedals
Front Wheel
Quick Release
Kickstand
Hub Motor
with Gears
Battery Controller
Battery Carrier
Battery
Rear derailleur
Hub Motor Power Connector
Comfort Saddle
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TABLE OF CONTENTS: CONTACT US 1
GLOSSARY OF PARTS 2
REMOVING/INSTALLING THE BATTERY 4
CONNECTING/CHARGING THE BATTERY 5
OPERATING THE SMART-CHARGER 6
POWERING UP YOUR ELECTROLITE 7
USING THE PEDAL ASSIST MODE 8
USING THE THROTTLE ASSIST MODE 9
POWERING DOWN YOUR ELECTROLITE 10
FAQ 10
CLEANING/MAINTENANCE 14
REPAIR/REPLACEMENT PARTS 15
TROUBLESHOOTING 15
BATTERY CARE 20
SPECIFICATIONS 21
SAFETY PRECAUTIONS 22
WARRANTY INFORMATION 23
SUN ELECTROLITE KEY SERIAL NUMBER:
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CHARGING YOUR ELECTROLITE BATTERY:
REMOVING THE BATTERY:
Use included key to unlock battery from rear carrier of bike.
Slide battery rearward from carrier, being careful not to drop battery.
Turn battery over to reveal rubber cap covering charging port.
NOTE: Your Sun Electrolite battery can also be charged while installed in the bike if more convenient.
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CONNECTING THE BATTERY TO THE SMART-CHARGER:
Plug mini-jack into battery at charging port, with battery either installed or removed from bike.
If charging with the battery installed in your Electrolite, be certain that power to the LED Power Indicator
is turned OFF. (See Page 11 for details.)
Plug power cord into end of smart-charger body.
Plug smart-charger into active wall outlet. If outlet is switched be sure that it’s powered on.
Mini-Jack to Battery
Power Cord to Charger
Smart-Charger
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OPERATING THE SMART-CHARGER:
There is no on-off switch on the smart-charger. Power is automatically controlled.
Battery will show level of charge, with LED indicators showing as follows: Low-35%-55%-75%-100%
Battery will be fully charged in approximately 5 hours using the supplied smart-charger.
Smart-charger will show a red indicator light when plugged in and not charging.
Smart-charger will show an orange indicator light when charging.
Smart-charger will show a green indicator light when fully charged.
When done charging, always unplug smart-charger from wall and mini-jack from battery charging port.
Cover charging port on battery with attached rubber cap.
Slide battery back into rear carrier, use included key to relock battery into rear carrier.
Charge Indicator
Smart-Charger
Battery Level Indicator
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POWERING UP YOUR SUN ELECTROLITE:
With fully charged battery, push ON button [() symbol] on the left-hand LED Power Indicator.
LED Power Indicator will run through a quick systems-check and will illuminate all LEDs.
LED Power Indicator will show battery charge across top row of LEDs.
LED Power Indicator will also show Pedal Assist setting across lower row of LEDs.
LED Power Indicator will adjust its brightness according to ambient light for easy day or night use.
Fully-Charged Battery
LED Power Indicator
Systems Check
Rear Brake and Shifter
Rear Trigger Shifter
Hub Motor, Rear Gears
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PEDAL ASSIST MODE:
Pedal Assist mode is always active when the LED Power Indicator is powered on. Selecting (+) or (–) on
the LED Power Indicator will give you five different levels of electric assist from the hub motor when
pedaling. Simply choose the amount of assistance you desire and pedal the bike like a normal bicycle.
You can choose gears from the right trigger-shifter to pick a gear suitable for your riding terrain as well.
Gearing on the right trigger-shifter is easiest in the smallest numbers (gears 1, 2 for hills,) normal for the
middle numbers (gears 3,4,5 for standard riding,) and hardest for the highest numbers (gears 6, 7,8 for
straightaways and downhill riding.)
For safety, Pedal Assist mode will automatically stop providing power when you stop pedaling. The
brake levers also act as a safety switch to remove power from the hub motor. This prevents accidental
acceleration from pedal inputs while brakes are being applied.
LED Power Indicator
Systems Check
(+) () Pedal Assist
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THROTTLE ASSIST MODE:
Using Throttle Assist while pedaling will produce an additional boost of electric assist for hills and quick
acceleration, and will only activate after pedaling at least one revolution. Twisting the throttle
rearward while pedaling will give you extra help on hills, help you accelerate around other riders, or will
simply let you take a break from pedaling for a moment. Throttle Assist mode will only activate if
pedaling, but once activated you can stop pedaling and enjoy the ride until you release the throttle
again. Throttle Assist will override any Pedal Assist settings to provide up to 100% of available power,
and is limited to a top bicycle speed of 20mph due to federal safety regulations.
Remember that this Throttle Assist mode will reduce the range of your battery, so enjoy it
conservatively for best battery life and riding range.
The brake levers will still act as a safety switch to remove power from the hub motor. This prevents
accidental acceleration from throttle inputs while brakes are being applied.
LED Power Indicator
Systems Check
Throttle Assist Mode
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POWERING DOWN YOUR SUN ELECTROLITE:
When parking or storing your Sun Electrolite always turn off the LED Power Indicator on the left side of
the handlebar. This is done by holding the “OFF” button [lower button with () marking] for
approximately five seconds.
Your Electrolite does have a sleep mode, where the controller will turn itself off after about five
minutes. This helps to preserve battery life, and is used as a preventative measure only. For safety,
always turn your Electrolite off at the LED Power Indicator when parked or otherwise unattended.
FAQ:
Q. How far can I go on one battery charge?
A. Typical range is around 40-45 kilometers, or 25-28 miles. This will vary according to rider and cargo
weight, how hilly your terrain is, how much electric assist you choose to add, and how often and how
long you use the Throttle Assist mode.
Q. How long does it take to charge the battery?
A. The included smart-charger takes approximately five (5) hours to charge a completely drained
battery. Partially drained batteries will take less time to charge back to full capacity. The smart-charger
will not overcharge your battery, but it’s not recommended to leave your battery charging for more than
24 hours.
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Q. Why does the battery/charger get warm while charging?
A. The smart-charger reduces line voltage and creates heat in the conversion process. The smart-
charger is fan-cooled to remove internal heat. The battery uses an internal chemical reaction to convert
and store its voltage charge. This chemical reaction creates a small amount of heat. For safety we
require that the battery and charger remain uncovered to prevent overheating.
Q. What is battery “memory?”
A. It’s a term used to describe a very specific effect observed in a nickel-cadmium battery. We use
advanced Lithium-Polymer batteries paired with smart-chargers in your Electrolite so you don’t have to
worry about battery “memory.” This means that you can recharge your battery at any time, without it
having to be completely discharged.
Q. What’s the useful battery life of my Sun Electrolite?
A. Typically lithium-polymer batteries have a useful life of about 500-700 charge-discharge cycles.
However, average battery life is influenced by many conditions and rechargeable batteries do have a
finite lifespan. Be aware that temperature, terrain, rider weight, riding style and electric assist settings
all play a factor in both battery range and overall battery life. Please see your local Sun Bicycles dealer
for help with any issues involving battery replacement.
Q. Can I ride my Sun Electrolite without using the battery assistance?
A. Of course. Simply leave the LED Power Indicator off, and you can ride your Sun Electrolite like a
normal recreational bicycle. You’ll still have normal pedaling control and can use the right-hand trigger-
shifter to adjust gear settings for anything from hills to straightaways.
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Q. How do I remove the rear wheel if I have a flat tire?
A. The removal process is the same as any other geared bicycle with the addition of simply
disconnecting the power lead to the real wheel before loosening and removing wheel. If you have any
concerns about this removal or reinstallation, we recommend having your local Sun Bicycles dealer
perform this process for you.
Q. Can I carry my Sun Electrolite on my bike rack?
A. Take great care when transporting your Electrolite. Many automotive bike rack manufacturers have
maximum bike weight limits in place to prevent damage to your bike rack, your bike and your car.
Failure to heed these maximum weight limits can result in damage or failure of your bike rack, damage
to your Electrolite, or damage to your car.
Auto rack failure can also pose a hazard to others around you. You should consult with your rack
manufacturer to be sure that your bike rack meets the demands of your usage including not only the
additional weight of your Sun Electrolite, but its low-standover frame design as well. The preferred
method of transport is a hitch-mounted tray-style carrier that holds your Electrolite securely without
touching frame components. Your local Sun Bicycles dealer can help you with these types of carriers.
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Q. What do I do if I’ve lost my battery key?
A. Please note the key serial number that is stamped on your key. You’ll have spares that can be kept in
different locations. Leaving one key at home with the charger is the most common example. If you do
lose all of your keys please provide the key serial number to your local Sun Bicycles dealer. They will be
able to order the proper replacement key only if you have this information.
This key serial number is not kept on record anywhere else. Make note of your key serial number on the
Table of Contents page.
Q. I didn’t see my question listed here. What should I do?
A. Feel free to contact your local Sun Bicycles dealer with any additional questions. Like we said earlier,
our network of dealers are the best resource for information and technical expertise, and will gladly be
there to assist you with any questions or concerns no matter how big or small.
Key Serial Number
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CLEANING AND MAINTAINING YOUR SUN ELECTROLITE:
Your Electrolite is a special bike and deserves some special attention. It doesn’t need lots, but there are
a few things to watch for when cleaning and maintaining an electronic assist bike.
Do not use any high-pressure streams of water to clean your Electrolite. High-pressure spray can pass
beyond seals meant to preserve delicate electrical connections and components. Irreparable damage
may occur if high-pressure spray is used. Harsh or abrasive cleaners are also not recommended.
The best products for cleaning your Sun Electrolite can be found at your local Sun Bicycles dealer. They
include gentle foaming cleansers for cleaning all painted surfaces, citrus-based degreasers for removing
heavy deposits on the chain drive and rear gears, and polishes for keeping the painted surfaces free of
road grime. A light rinse of water and application of the gentle foam cleanser is all that’s needed to
clean the painted surfaces of your Sun Electrolite. Be gentle with water around the LED Power Indicator,
and be sure that your Electrolite is powered down. Also be gentle with water around the Battery
Controller and Battery Housing.
Citrus degreasers are best for any heavy deposits of oil and dirt on the crankset, chain and rear gears.
Be conservative with application of any degreasers around the rear gears and hub motor. Too heavy of
an application here may leave degreaser in areas that can’t be rinsed well, and this degreaser may
eventually damage seals in the hub motor. Relubricate the chain with a Teflon-based chain lubricant for
best performance, found also at your local Sun Bicycles dealer.
DO NOT USE ANY LUBRICANTS OR POLISHES ON THE RIM BRAKING SURFACES OR TIRE TREADS!
This can lead to brake failure, tire failure, loss of traction or other dangerous conditions
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REPAIR / REPLACEMENT PARTS:
Please see your local Sun Bicycles dealers for any repairs to or replacement parts for your Sun
Electrolite. Any repairs to electronic components performed by parties other than authorized Sun
Bicycles dealers will void any warranty claims. Use of parts not authorized by Sun Bicycles will void any
warranty claims.
TROUBLESHOOTING:
BATTERY CHARGING:
Orange light is off during charging:
Check that connections to battery are fully engaged.
Check that line voltage is not too low, or switched off.
Line voltage should be at least 100V AC and no more than 240V AC.
Orange light does not turn to Green:
Remove from AC power for at least five (5) seconds.
Reconnect power to continue charging.
Orange light turns to Green immediately:
Check that battery is not already fully charged.
If any of these procedures do not work, have your local Sun Bicycles dealer check both the battery and
charger for issues.
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LED POWER INDICATOR:
LED Power Indicator won’t power on:
Check that battery is fully seated and locked into the rear carrier.
Check that the battery is charged. The battery’s rear indicator lights should show at least a minimum
charge.
Check that wiring harness to LED Power Indicator is not frayed, crimped or otherwise damaged.
Check that connection plug to LED Power Indicator is firmly connected.
Check that the () ON/OFF button is pressed firmly to begin the Systems Check.
An “E” light on the LED Power Indicator blinks constantly and I get no electronic assistance:
The blinking “E” on the battery indicator reminds you that your battery is exhausted and should be
recharged before further use. You’ll want to turn off the LED Power Indicator and finish your ride
without electronic assistance to protect the battery and other components. Fully recharge your battery
when you are home.
I pedal with the LED Power Indicator turned on, but I get no electronic assistance:
With your Electrolite stopped, turn off LED Power Indicator and wait about five seconds. Turn the LED
Power Indicator back on, being sure that you aren’t pedaling. This will reset the controller and should
now send power to the motor.
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I tried powering-off the LED Power Indicator, but still get no electronic assistance:
Does the Throttle-Assist still work? If so, there may be a problem with the battery controller.
Does the Throttle Assist not work either? First, check the connector to the hub motor. It’s located just
behind the crankset, on the right-hand side of the bike. Check that it’s plugged securely, and that it’s
free of corrosion or water. If there’s still no electronic assistance, there may be a problem with the
magnetic crank sensor located behind the crank set on the right side of the bike.
Problems with either the battery controller or the magnetic crank sensor should be taken to your local
Sun Bicycles dealer for inspection and repair.
OTHER ISSUES:
I removed the rear tire to replace a tube, and now I don’t get any electronic assistance:
Check that the rear hub motor is reconnected. The connector is located behind the crankset, on the
right hand chain stay. Be sure that the connector is plugged securely and is free of corrosion and water.
Hub Motor Input Wire Hub Motor Connector Plug Magnetic Crank Sensor
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I use the brakes to begin slowing down but the electronic assistance remains active:
Check that the brake sensors on the brake levers are in good condition. They can be damaged by sharp
pulls on their wiring harness. Activation of either brake lever should remove power to the hub motor.
Check that the wiring harnesses to the brake levers are not crimped, frayed or otherwise damaged.
Front Brake Sensor & Wire Rear Brake Sensor & Wire
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Your Sun Electrolite battery is protected by two fuses in the front of its casing, as facing forward:
One 20A/250V 314-series fast-acting ceramic fuse located on the left side front of battery
One 5A/250V 314-series fast-acting ceramic fuse located on the right side front of battery
These two fuses protect both the battery and the controller. In the event of an overload these fuses will
remove ALL BATTERY POWER by disconnecting the overloaded circuit. The overloaded fuses must be
replaced if this happens. Do not, under any circumstances, bypass these fuses. Do not replace these
fuses with anything other than the exact size and specification of fuse. Use of non-specification fuses
may result in battery damage, controller damage, or risk of fire.
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