Ultra motor A2B Metro User manual

TM
A2B Metro Service Manual
TM
clean mobility technology
A2B Metro Service Manual

A2B Metro Service Manual
Ultra Motor USA
45 Broadway Street
San Francisco, CA 94111
Tel: [phone]
Fax: [phone]
www.ultramotor.com

Copyright © 2009 by Ultra Motor USA, Inc
First Edition
August, 2009
All rights reserved. No part of this publication may be repro-
duced or transmitted in any form or by any means without the
prior permission of Ultra Motor USA, Inc.
Although every precaution has been taken to assure this publi-
cation is complete and accurate, Ultra Motor USA assumes no
liability for errors or omissions. All information contained in this
publication is based on the latest information available at the
time of publication and is subject to change without notice.

TABLE OF CONTENTS
Chapter One: General Information 1-1
Terms
Lubricants
Threadlock
Special Tools
Specifications
Chapter Two: Steering and Front Suspension 2-1
Handlebar Replacement
Throttle
Handlebar Stem
Front Fender
Front Fork
Chapter Three: Brakes 3-1
Brake Lever
Brake Cable Inner Wire
Brake Caliper
Brake Pad Replacement
Brake Disc
Chapter Four: Shifter and Derailleur 4-1
Shifter
Shifter Cable Inner Wire
Derailleur
Chapter Five: Chain and Crankset 5-1
Chain
Crank Arm
Chainring
Pedal
Bottom-Bracket Cartridge
Chapter Six: Rear Suspension 6-1
Shock Absorber
Rear Wheel
Rear Fender
Swingarm
Chapter Seven: Electrical 7-1
Connector Identification
Battery Cap
Battery
Key Switch
Charger Port
Electrical Troubleshooting
Electrical Schematic

1-1
enough to penetrate tight places, they
should be durable so they can withstand
exposure to the elements, and they must
resist the accumulation of dirt.
Suitable oils include Alsop, Bullshot,
Campagnolo, Finish Line, Lube Wax, Phil
Wood Tenacous Oil, Pedros, Superlube,
and Triflow.
Motor oil, WD40, 3-in-1 Oil, sewing machine
oil, gun oil, and other common oils are not
suitable and should not be used.
In general, applying oil from a drip appli-
cator is superior to using aerosols. Aerosols
promote over-lubrication, which leads to
excessive accumulation of dirt. Apply oil
sparingly. Apply enough oil to do the job,
but not so much that it starts to drip from
the component. After applying any oil,
wipe off the excess.
THREADLOCK
A threadlocking compound should be
used on most fasteners on the A2B Metro.
Threadlocking compound prevents loos-
ening caused by vibration and helps seal
out moisture.
Loctite 242 (blue) or its equivalent is rec-
ommended for threadlocking applica-
tions. Loctite 242 is a medium-strength
threadlocking compound that permits dis-
assembly with common hand tools.
Before applying Loctite to threads, clean
oil, grease, and other residue from the
thread surfaces. Apply a small amount of
Loctite. Excess compound could work its
way down the threads and bond parts
together. Table 5 (this chapter) provides
torque specifications and Loctite recom-
mendations for particular fasteners.
TERMS
Left and Right
The terms left and right in this manual
refer to the rider’s point of view when
seated on the A2B Metro and facing for-
ward. The right side of the A2B Metro is the
chain side. The left side is the brake side.
NOTE, CAUTION and WARNING
The terms NOTE, CAUTION and WARNING
have specific meanings in this manual. A
NOTE provides additional information to
make a procedure easier or clearer.
A CAUTION emphasizes precautions that
must be taken to avoid damage to tools or
the A2B Metro. Disregarding a CAUTION
could lead to mechanical damage.
A WARNING emphasizes a situation where
negligence could lead to injury or death.
Take WARNINGS seriously. Failure to heed a
WARNING could result in serious personal
injury or death.
LUBRICANTS
Grease
In general, use a lithium-based grease
where grease is called for in this manual.
Always use grease made specifically for a
bicycle, such as grease from Bullshot,
Campagnolo, and Shimano.
Oil
Always use oils made specifically for
bicycle use. Bicycle oils need to be thin
Chapter One
GENERAL INFORMATION

Chapter One
1-2
SPECIAL TOOLS
The following special tools are needed when servicing the A2B Metro.
Tool Part number
Hex wrench set: 4mm, 5mm, 6mm Park AWS-1
Hex wrench set Park AWS-11C
Hex wrench set: 2mm, 5mm, 3mm Park AWS-3
Fourth-hand cable stretcher Park BT-2
Chain checker Park CC-2C
Chain breaker (screw type) Park CT-3
Crank wrench Park CCW-14R
Cable and housing cutter Park CN-4C
Gearclean brush Park GSC-1
32mm & 36mm head wrench Park HCW-15
Pedal wrench Park PW-3
Spoke wrench (black) Park SW-0
Spoke wrench (red) Park SW-2
Tire lever set Park TL-1C
Freewheel tool Part Tool FR-1
Bottom-bracket-cartridge tool Park Tool BBT-2

SPECIFICATIONS
Table 1: Mechanical Specifications
Component Specification
Headset VP-A50AC
Stack height 10.3 mm (0.41 in.)
Dimensions 1 1/8 x 44 x 30
Front fork Spinner
Type FK-001
Handlebar Kalloy AL-021
Rise 9°
Width 670 mm (26.38 in.)
Handlebar stem MJ Cycle ST-001
Seatpost Kalloy SP-600
Tires Kenda K1032 20 in. x 3.0 in.
Rims Alex DX 32
Rim runout (with or without tire)
Axial runout 1 mm (0.039 in.)
Radial runout 1 mm (0.039 in.)
Spokes
Front 14 gauge
Rear 13 gauge
Bottom bracket (B/B) Chin Haur CH-52
Freewheel Long Yi LY1107, 7-speed, 11/28t
Chainring Hsiang An HA-804G, 170 mm, 46T
Chain KMC Z50 ½ x 3/32 x 158L
1-3
GENERAL INFORMATION

Chapter One
1-4
Table 2: Gear Ratios
Chainring Freewheel Gear Inches Ratio
46 11 83.6 6.3
46 13 70.8 5.3
46 15 61.3 4.6
46 18 51.1 3.8
46 21 43.8 3.3
46 24 38.3 2.9
46 28 32.9 2.5
Table 3: Electrical Specifications
Component Specification
Battery 36-volt
Type Lithium ion
Capacity 11.4 amp-hrs (422 watt-hrs)
Charger High Power, HP8204C(10s)
Input 115/230 VAC, 60/50 Hz, 1.5/0.9 A
Output 42VDC/2A
Table 4: Performance Specifications*
Item Specification
Top speed 20 mph (per regulation)
Range (flat terrain, no wind) 20 miles
*180-pound rider with tires inflated to 60 psi.

Table 5: Torque Specifications
Item Nm in.-lb. ft.-lb. Special Instructions
Bottom-bracket cartridge
adapter ring 29.4-38 - 21.7-28 Apply grease to the threads
Brake caliper anchor bolt 5-7 40-60 -
Brake caliper CPS bolt 8-10 70-90 -
Brake caliper mounting bolt 5-7 40-60 - Apply Loctite 242
Brake disc bolt 6.2 55 - Apply Loctite 242
Brake lever clamp bolt 3-3.9 26.5-34.7 -
Chainring bolt 6-8 53-71 -
Crank arm bolt 35-40 - 26-30 Apply grease to bolt threads
Derailleur anchor bolt 4.1 36.5 -
Derailleur mounting bolt 7.9 70 -
Front fender 3 26.5 -
Handlebar binder bolt 6 53 - Apply grease to the bolt threads
Handlebar stem clamp bolt 12 106 -
Pedal 3-4.9 26.5-43.4 - Apply grease to the stud threads
Rear axle nut 60-65 - 44-48
Rear fender bolt 4 35 -
Rear fender stay bolt 2 17.7 -
Seat post clamp bolt 10-12 89-106 -
Shifter set screw 3-3.9 26.5-34.7
Shock absorber bolt 16-20 - 12-14.5 Apply Loctite 242
Swingarm bolt 18-22 - 13-16 Apply Loctite 242
Throttle set screw 3-3.9 26.5-34.7 -
Torque arm bolt 9-10 80-89 - Apply Loctite 242
1-5
GENERAL INFORMATION

2-1
Chapter Two
STEERING and FRONT
SUSPENSION
7. Install the handlebar by reversing the
removal procedures.
a. Make sure the handlebar is centered
and properly oriented within the handle-
bar stem.
b. Apply grease to the handlebar binder
bolts (Figure 3), and evenly tighten the
bolts in a star pattern so the gap at the top
of the clamp is the same as the gap at the
bottom. Torque the handlebar binder bolts
to the specification in Table 5.
c. Slide the reflector, each bake lever, the
throttle and the shifter onto their respec-
tive handlebar ends.
HANDLEBAR REPLACEMENT
1. Note the position of the throttle and the
shifter relative to its handlebar grip. If nec-
essary, measure the gap between each
item and its handlebar grip or make a
drawing so these components can be
reinstalled with the proper positioning and
orientation. Also note the orientation of
the handlebar within the handlebar stem.
2. Remove the left and right handlebar
grip. Remove the grip spacer on the
inboard side of each spacer.
3. Loosen the throttle set screw (A, Figure
1), shifter set screw (A, Figure 2), the reflec-
tor clamp bolt, and the clamp bolt on
each brake lever (B, Figure 2)
4. Remove the handlebar binder bolts
(Figure 3).
5. Lower the handlebar from the handle-
bar stem.
6. Slide the throttle, shifter, each brake
lever and the reflector assembly from the
handlebar ends, and remove the handle-
bar.
FIG. 1
B
A
A
B
FIG. 2
FIG. 3

9. Pull the wire and string through the cable
shroud. Untie the string from the throttle
connector and remove the throttle. Leave
the string in place so it can be used to pull
the new throttle wire through the frame.
Installation
1. Slip a new piece of heat shrink tubing
over the top of the cable shroud.
2. Tie the string to the connector at the
end of the throttle wire.
3. While an assistant pulls the string at the
battery compartment, guide the throttle
wire through the shroud, into the frame
cutout, and through the frame downtube
until the connector emerges from the bat-
tery compartment.
4. Untie the string from the throttle connec-
tor. Connect the 4-pin throttle connector
and the 3-pin state-of-charge connector
to their mates.
5. Install the battery and the battery cap
(Chapter Seven).
6. Slide the throttle onto the handlebar
end, and seat it against the brake lever
bracket.
7. Install a grip spacer and handlebar grip
onto each handlebar end.
8. Position the throttle relative to its handle-
bar grip as noted during removal.
Temporarily tighten the set screw (A, Figure
1).
9. If necessary, slide the brake lever so its
bracket seats against the throttle or shifter.
Rotate the brake lever to the position
noted during removal, and torque the
brake lever clamp bolt (B, Figure 1) to the
specification in Table 5.
10. Rotate the throttle so its wire barrel rests
against the brake lever bracket, and
torque the throttle set screw (A, Figure 1)
to the specification in Table 5.
11. Install a new cable tie around the top
of the cable shroud. Tighten the cable tie
to the diameter noted during removal.
12. Slide the heat shrink tubing over the
cable tie and shroud end. Use a heat gun
to shrink the tubing.
d. Install a grip spacer and handlebar
grip onto each handlebar end.
e. Position the throttle or shifter relative to
its handlebar grip as noted during remov-
al. Tighten their set screws.
f. Slide each brake lever so its bracket
seats against the throttle or shifter. Rotate
the brake lever to the position noted dur-
ing removal, and torque the brake lever
clamp bolts to the specification in Table 5.
g. Rotate the throttle and shifter so their
barrels rest against the brake lever. Torque
the throttle set screw and the shifter set
screw to the specifications in Table 5.
THROTTLE
Removal
1. Note the position of the throttle relative
to its handlebar grip. If necessary, measure
the gap between the throttle and the right
handlebar grip or make a drawing so the
throttle can be properly positioned and
oriented during installation. Also note the
orientation of the handlebar within the
handlebar stem.
2. Remove the battery from the battery
compartment (Chapter Seven).
3. Disconnect the 4-pin throttle connector
and the 3-pin state-of-charge connector.
4. Tie a string to the throttle half of a con-
nector. Make sure the string is long enough
run through the frame. It will be used to pull
the new throttle wire through the frame.
5. Remove the handlebar grip and grip
spacer from the right handlebar end.
6. Loosen the throttle set screw (A, Figure
1), and remove the throttle from the han-
dlebar end. If necessary, remove the han-
dlebar (this chapter) to ease throttle
removal.
7. Carefully pull the throttle wire until the
connector and string emerge from the
frame cutout at the steering head. If nec-
essary, have an assistant guide the con-
nector up the frame downtube.
8. Carefully remove the heat shrink tubing
from the top of the cable shroud, and clip
the cable tie. Note how tightly the cable
tie sits around the shroud and cables. A
new cable tie will have to be tightened to
the same diameter.
Chapter Two
2-2

Installation
1. If removed, install the upper bearing by
performing the following:
a. Press the front fork up into the head
tube.
b. Slip the upper bearing over the fork
column, and seat the bearing in the head
tube (Figure 7). Make sure the bevel in the
bearing inner race faces up.
c. Install the collar (Figure 6) so its cone
seats against the bevel in the bearing
inner race.
d. Install the seal, and press it into the
head tube until the seal bottoms (Figure
5).
2. Set the handlebar stem onto the head
tube, and turn in the handlebar stem bolt
and washer (B, Figure 4).
WARNING
The handlebar stem bolt and clamp bolt
must be tightened as described below.
Overtightening the stem bolt can damage
the headset bearings. If the handlebar
stem clamp bolt is not properly torqued,
the fork may not turn when the handlebar
is turned.
2-3
STEERING and FRONT SUSPENSION
HANDLEBAR STEM
Removal
1. If necessary, remove the handlebar
binder bolts (Figure 3), and remove the
handlebar from the handlebar stem. Use a
bungee cord to suspend the handlebar
from the frame.
2. Loosen the handlebar stem clamp bolt
(A, Figure 4).
3. Remove the handlebar stem bolt (B,
Figure 4) and washer from the top of the
handlebar stem
4. Lift the handlebar stem (C, Figure 4)
from the head tube.
5. If necessary, remove the upper bearing
by performing the following:
a. Lower the fork within the head tube as
needed, and remove the seal (Figure 5).
b. Remove the collar (Figure 6) and upper
bearing (Figure 7). Note that the bevel on
the bearing inner race faces up.
A
B
FIG. 4
C
FIG. 5
FIG. 6
FIG. 7

FRONT FORK
Removal
The front fork is not serviceable. If the fork
is damaged, it must be replaced.
1. Remove the handlebar (this chapter).
2. Carefully pry open the cable holder on
the fork slider (A, Figure 9), and release the
front brake cable (B) from the holder.
3. Remove the caliper mounting bolts (A,
Figure 10), and slide the front brake caliper
(B) from the brake disc. Suspend the cali-
per with a bungee cord.
4. Remove the front wheel.
5. Remove the handlebar stem and the
upper bearing as described in this chap-
ter.
6. Lower the fork until the fork column
clears the head tube, and remove the
front fork.
7. Visually inspect the seal on each side of
the upper bearing (A, Figure 11) for dam-
age. Manually turn the bearing inner race,
and confirm that the bearing rotates
smoothly.
3. Perform the following to set the headset
bearings and to secure the handlebar
stem in place and in alignment with the
front wheel.
a. Tighten the handlebar stem bolt (B,
Figure 4) until there is no play in the steer-
ing.
b. Tighten the stem bolt an additional 120
degrees (clockwise), and then loosen it 90
degrees (counterclockwise).
c. With the front wheel off the ground,
turn the handlebar from full stop to full
stop. The fork should turn smoothly.
d. Torque the handlebar stem clamp bolt
(A, Figure 4) to the specification in Table
5.
e. Tighten the handlebar stem bolt (B,
Figure 4) an additional 30 degree (clock-
wise).
f. With the front wheel off the ground,
again turn the handlebar from full stop to
full stop. The fork should turn smoothly.
FRONT FENDER
Removal/Installation
1. Remove the front wheel.
2. Remove the fender bolt (A, Figure 8)
from each side of the slider.
3. Remove the inner fender bolt (B, Figure
8), and remove the fender from between
the fork legs.
4. Install the front fender by reversing the
removal procedures. Torque the fender
bolts (A and B, Figure 8) to the specifica-
tion in Table 5.
Chapter Two
2-4
A
B
FIG. 8
A
B
FIG. 9
A
B
FIG. 10
A

2-5
STEERING and FRONT SUSPENSION
Installation
1. Slide the fork column up into the head
tube until the lower-bearing collar (Figure
13) rests against the lower bearing (Figure
12).
2. Install the upper bearing and the han-
dlebar stem as described in this chapter.
3. Install the front wheel.
4. Carefully slide the front brake caliper
onto the brake disc so the disc does not
mar the brake pads. Apply Loctite 242 to
the threads of caliper mounting bolts (A,
Figure 10), and evenly tighten the bolts.
Torque the caliper mounting bolts to the
specification in Table 5.
5. Install the handlebar (this chapter).
8. Visually inspect the seal (B, Figure 11)
and the cone on the upper-bearing collar
(C) for nicks or other damage.
9. Inspect the lower bearing in the head
tube (Figure 12). Note that the bevel on
the lower-bearing inner race faces down,
away from the head tube. A new bearing
must be installed with the same orienta-
tion.
10. Inspect the cone of the lower-bearing
collar (Figure 13).
11. If either bearing is faulty, replace both
bearings, the upper-bearing collar (C,
Figure 11) and the lower-bearing collar
(Figure 13) as a set.
A
B
FIG. 11
C
FIG. 12
FIG. 13

3-1
(Chapter Two) to ease shifter or throttle
removal.
11. Carefully remove the heat shrink tubing
from the top of the cable shroud, and clip
the cable tie. Note how tightly the cable
tie sits around the shroud and cables. A
new cable tie will have to be tightened to
the same diameter.
12. Slide the brake lever from the handle-
bar end. Carefully pull the brake switch
wire until the connector and string emerge
from the frame cutout at the steering
head.
13. Pull the wire and string through the
cable shroud. Untie the string from the
switch connector and remove the brake
lever assembly. Leave the string in place
within the shroud and frame.
Installation
1. Slide the new brake lever onto the end
of the handlebar.
2. Slip a new piece of heat shrink tubing
over the top of the cable shroud.
3. Tie the string to the connector at the
end of the brake switch wire.
BRAKE LEVER
Removal
1. Note the position of the throttle or the
shifter relative to its handlebar grip. If nec-
essary, measure the gap between the
item and its handlebar grip or make a
drawing so these components can be
reinstalled with the proper positioning and
orientation. Also note the orientation of
the handlebar within the handlebar stem.
2. Remove the battery from the battery
compartment (Chapter Seven).
3. Disconnect the halves of the left or right
brake switch connector.
4. Tie a string to the brake-lever half of the
connector. Make sure the string is long
enough to run through the frame. It will be
used to pull the new switch wire through
the frame.
5. At the brake lever, loosen the adjuster
locknut (A, Figure 1) and turn the adjuster
barrel (B) from the brake lever.
6. Turn the adjuster barrel and the locknut
until their slots align with the slot in the
brake lever housing.
7. Pull the cable housing from the adjuster
barrel (B, Figure 1), and slide the inner wire
(C) through the slots in the lever housing,
adjuster barrel and locknut.
8. Press the brake lever toward the handle-
bar, and disconnect the inner wire end (A,
Figure 2) from the anchor (B) on the brake
lever.
9. Remove the handlebar grip and grip
spacer from the handlebar end.
10. Loosen the set screw, and remove the
shifter or the throttle from the handlebar
end. If necessary, remove the handlebar
Chapter Three
BRAKES
A
B
FIG. 1
C

15. Install a new cable tie around the top
of the cable shroud. Tighten the cable tie
to the diameter noted during removal.
16. Slide the heat shrink tubing over the
cable tie and shroud end. Use a heat gun
to shrink the tubing.
BRAKE CABLE INNER WIRE
Removal
The cable inner wire can be replaced
without removing the cable housing.
1. Remove the battery from the battery
compartment (Chapter Seven).
2. Clip the cable ferrule from the brake
cable inner wire.
3. Turn out the anchor bolt (A, Figure 3),
and release the inner wire from the pinch
mechanism.
4. Pull the cable housing and inner wire
from the caliper barrel adjuster.
5. At the brake lever, loosen the adjuster
locknut (A, Figure 1) and turn the adjuster
barrel (B) from the brake lever.
6. Turn the barrel adjuster and the locknut
until their slots align with the slot in the
brake lever housing.
7. Pull the cable housing from the adjuster
barrel, and slide the inner wire (C, Figure 1)
from the slots in the housing, adjuster barrel
and locknut.
8. Press the brake lever toward the handle-
bar, and disconnect the inner wire end (A,
Figure 2) from the anchor (B) on the brake
lever.
9. Pull the inner wire from the cable hous-
ing until the far end emerges from the
cable housing.
4. While and assistant pulls the string, guide
the brake switch wire through the shroud,
into the frame cutout, and through the
frame downtube until the switch connec-
tor emerges from the battery compart-
ment.
5. Install the battery (Chapter Seven).
6. Untie the string from the brake lever
switch connector. Connect the switch con-
nector to its mate in the battery compart-
ment, and install the battery cap (Chapter
Seven).
7. Make sure the slots in the adjuster barrel
and the locknut align with the slot in the
brake lever housing (Figure 1).
8. Connect the end of the brake cable
inner wire (B, Figure 2) to the anchor (A) on
the brake lever.
9. Pull the cable housing, and slide the
cable inner wire (C, Figure 1) through the
slots in the brake lever, adjuster barrel (B)
and locknut (A). Seat the cable housing
ferrule into the adjuster barrel.
10. Slide the throttle or shifter onto the
handlebar end.
11. Install a grip spacer and handlebar grip
onto the handlebar end.
12. Position the throttle or shifter relative to
the handlebar grip as noted during remov-
al. Temporarily tighten the set screw.
13. Slide the brake lever so its bracket seats
against the throttle or shifter. Rotate the
brake lever to the position noted during
removal, and torque the brake lever clamp
bolt to the specification in Table 5.
14. Rotate the throttle or shifter so its barrel
rest against the brake lever. Torque the
throttle set screw or the shifter set screw to
the specification in Table 5.
Chapter Three
3-2
A
B
FIG. 2
A
B
FIG. 3
C
B