WattWheels BIGHORN 2019 User manual

BIGHORN ELECTRIC BIKE 2019 MANUAL
Welcome
First off, welcome to the Wattwheels family! We’re so happy to have you on board! You’ve picked a
great model and, in this manual, we’re going to break down the basics to make sure that your bike
remains in top shape and performs to the highest standard.
You’re about to experience the ride of your life. In order to get you out and having fun as quickly and
as safely as possible please read the all the manual carefully, paying close attention to the safety
section.
Also, we highly recommend familiarizing yourself with local laws for e-bikes and the components of
the model that you have before your first ride.
Wattwheels assumes that all persons involved in: using, repairing, maintaining, cleaning, or
disposing of this or any Wattwheels product must have fully read and understood the content and
meaning of these operating instructions.
Additionally, Wattwheels claims no responsibility for any injury or damage resulting in improper use
of any electric bike.
READY TO GET STARTED? LETS RIDE!
USING THIS MANUAL
This manual contains details of the product, its equipment, and information on its operation and
maintenance. Read it carefully and familiarize yourself with the Bighorn before using it to ensure a
safe use and prevent tragic accidents. Be sure to retain this manual as your convenient Bighorn
information source.
This Manual contains many Warnings and Cautions concerning the safe operation and
consequences, if safe setup, operation and maintenance are not performed. All information in this
manual should be carefully reviewed and if you have any questions you should contact your local
retailer immediately.

Because it is impossible to anticipate every situation or condition which can occur while riding, this
manual makes no representations about the safe use of bicycles under all conditions. There are risks
associated with the use of any bicycle which cannot be predicted or avoided, and which are the sole
responsibility of the rider. You should save this manual, along with any other documents that were
included with your bicycle, for future reference, however all content in this manual is subject to
change or withdrawal without notice. Visit www.wattwheels.co.nz to download the latest version.
Wattwheels makes every effort to ensure accuracy of its documentation and assumes no
responsibility of liability if any errors or inaccuracies appear within. Assembly and first adjustment of
your Bighorn Bike requires special tools and skills and it is recommended that this should be done by
a trained bicycle mechanic if possible.
LET’S GET STARTED:
1. COMPLETLEY CHARGE THE BATTERY BEFORE THE FIRST USE
(Red light is on when battery is charging, green when fully charged. Approx. time is around 4-5 hours)
2. ASSEMBLE THE HANDLEBARS
3. ATTACH THE PEDALS
(Beware: The left-hand pedal has a reverse thread. To tighten, please turn anti-clockwise)
4. ATTACH THE SEAT POST
5. ATTACH THE FRONT MUDGUARD AND ATTACH FRONT LIGHT
6. INSERT THE FRONT WHEEL WITH QUICK RELEASE
7. CHECK ALL SCREWS AND BOLTS ARE TIGHT, SEAT AT CORRECT HEIGHT, GEARS AND BRAKES
CHECKED AND WORKING PROPERLY
LCD DISPLAY FEATURES
The image shows the various features and information displayed on the wireless remote. The display
is controlled using the 3-button remote mounted on the left side of the handlebar. For more
information on the LCD display and operation please refer to the manual included. This is also on
located on our website at www.wattwheels.co.nz/manuals

LIGHTS
To activate the lights press the on/off button quickly. The display should light up and a little icon
appear above the PAS level indicator.. To turn off press repeat how you turned it on.
BATTERY DISPLAY CAPCITY
The LCD readout on the handlebar of your Bighorn Bike features a battery capacity gauge (much like
the fuel gauge on an automobile). Once the battery is fully depleted, the last remaining bar will
begin to flash, communicating to the user that they should cease operation immediately.
THROTTLE
The Throttle is located on the left-hand side of the handlebars in the form of a thumb piece. Please
be careful that these throttles are set to operate the Bighorn from stationary so any slight press of
this will propel the Bighorn forward. The throttle can be used when taking off from a stationary
start, as a cruise control or just if you’re in need of a break! Please be aware using the throttle will
drain the battery much quicker than normal riding. Also, the throttle is not designed to climb steep
hills. To get the maximum amount of power from the Bighorn on steep gradients select the highest
level of PAS and use the highest gear.
PAS (Pedal assist modes)
Pedal assist modes start from 1 and go up to 5 in some cases. This can be changed if required. Refer
to the Display manual. PAS level 1 is the first pedal assist level and will give you some slight
assistance. The rider however will still be doing most of the work. As you select the higher levels, the
assistance will increase with level 9 basically doing all the work for you. Using higher levels of PAS
will drain the battery faster. The recommended level is PAS 2-3 to ensure maximum battery life.
With these displays you have the option of programming the power level on each PAS level.
BRAKES

The Bighorn electric bikes are equipped Tektro hydraulic disk brakes. Please be aware the hydraulic
disk brakes are very strong, so care is too be taken when braking. The front wheel brake is located
on left hand side with the rear wheel brake on the right. All the brakes are equipped with a cut-out
feature which means if either of the brakes are pressed the motor will automatically cut out.
TYRE PRESSURE
To avoid flats, keep tyre pressure at the recommended PSI. On off-road terrain a slightly lower PSI
will provide more grip, but flats can occur.
WARNING Caution should be exercised when inflating tires with compressor air pressure equipment
(e.g. gas stations). Due to the relatively small volume of air required be sure not to overinflate the
tires as this can cause them to burst. Correct tire pressure should be adjusted according to the
terrain within the range of. 25 to 55 psi
DRIVING RANGE
The range of your Bighorn Bike is the distance the bike will travel on a single full charge of the
onboard battery pack. The range values in this manual are estimates based on expected usage
characteristics. Some of the factors which effect range include changes in elevation, speed, payload,
and acceleration, number of starts and stops and ambient air temperatures. Tire pressure and
terrain are also important variables to consider.
We suggest that you ride conservatively when you first get your Bighorn Bike to get to know your
bike and travel routes.
Once you become familiar with the range requirements of your travel routes, and the capabilities of
your Bighorn Bikes you can then adjust you riding characteristics if you so desire.
The following table provides general estimates and outlines various factors effecting range and their
combined estimated effects on range. This table is meant to help owners understand the factors
that can increase of decrease range, but Bighorn Bikes makes no claims to the range that individual
users might obtain
EXPECTED RANGE
Expected Range
Operating Conditions

45 Km
o Hilly Terrain
o Heavy Payload
o Windy
o High Speeds
o High PAS levels
68 Km
o Flat Terrain
o Normal Payload
o Not Windy
o Medium Speeds
o Moderate PAS levels
90 Km +
o Flat Terrain
o Normal Payload
o Not Windy
o Low Pedal Assist Level
o Moderate to Heavy Pedaling
ADJUSTING THE SEAT HEIGHT
Use the quick release lever to free the seat post and pull upwards or push downwards to reach
desired height.
Notice: Ensure seat post and seat are properly adjusted before riding. Do not raise the seat post
beyond the minimum insertion marking etched into the seat post tube. If your seat post projects
from the frame beyond these markings, the seat post or frame may break, which could cause you to
lose control and fall. Prior to first use, be sure to tighten the seat clamp properly. A loose seat clamp
or seat post binding bolt can cause damage to the bicycle or can cause you to lose control or fall.
Periodically check to make sure these the seat clamp is properly tightened.
RIDER COMFORT
To obtain maximum comfort, the rider should not overextend his or her arms reach when riding. In
order to obtain the most comfortable riding position and offer the best possible pedaling efficiency,
the seat height should be set correctly in relation to the rider’s leg length. The correct saddle height
should not allow leg strain from over extension, and the hips should not rock from side to side when
pedaling. While sitting on the bicycle with one pedal at its lowest point, place the ball of your foot on
that pedal. The correct saddle height will allow the knee to be slightly bent in this position.

BATTERY & CHARGING
The battery can be either charged by leaving the battery in the bike or by removing it.
To remove the battery firstly flick the seat up using the quick release switch located at the back of
the seat. This will enable you to take the battery out of the bike. Insert the keys then press in and
turn anti clockwise until the locking mechanism retracts from the battery mount.
When the battery is on you can see the current charge state by pressing on the button located on
top of the battery. This will give you 4 bars. A full battery will indicate three bars lighting up green
and one red at the bottom.
Removing the battery from the bike when storing it for a long period of time is recommended. In this
case store it in a cool, dry area away from water. The charge left in the battery should be 50%-75%
for long storage times.
Cleaning the battery and battery housing should only be done while disconnected and powered off.
Use a dry rag, and if need be a lightly damp rag.
DO NOT spray with high-pressured water to prevent damage or possible short-circuiting. Only
charge the battery with the supplied charger as others may not function properly, and this increases
the possibility of fire or explosion.
Charging the battery during the day in a dry space with a smoke/fire alarm is recommended, while
placing the battery on a non-flammable surface. Do not store the charger or battery in a wet place or
in direct sunlight.
Lithium-ion batteries are meant to be recharged with 10%-15% of the charge remaining to prevent
damage to the cells. Keep both the battery and charger out of the reach of children and If there
appears to be an issue with the charger or battery, stop use immediately and contact either the
manufacturer or Wattwheels at [e-mail]
CHARGING:

•Firstly, insert plug of the charger into charging socket of the battery box.
•Second, Insert the charger into the socket of the home power supply. It shows the power has
already been put through when the indicator lamp of the charger is on and turned green.
•It is charging when the indicator light is red. When the light turns from red to green, it indicates
that the battery is fully charged.
•After the green light is on, the charger is in little electric current and “fill slowly mode". It will not
be harmful to the battery if left to charge for a longer period or overnight. We do recommend not
leaving for longer than 48hours if possible
Please don't use the charger of other brands to charge. The electric apparatus contains a high-
pressure circuit.
USEFUL TIPS
While starting or climbing, please ride with feet auxiliary as much as possible, otherwise the energy
consumption will be very high. By doing this it can lengthen the life of battery and motor.
• This specified load of the Electric Bicycle is 120kg, please don't overload.
• While riding if the level of charge shows only one bar is recommended to ride as a normal bike at
this time and charge as soon as you can.
• Close the power and take down the key, while parking.
• The power switch of the LCD panel should be turned every time making the Electric Bicycle won’t
start suddenly and cause accidents.
• Try and reduce please reduce braking frequently while riding, in order to save the electric energy.
• Do not turn on the bike when the brake levers are depressed as this will l trigger the faulty brake
sensor and disable the motor.
• Inspect the bolts on a regular basis, to ensure that they are tight and all components are secure.
This is especially important if you are riding in demanding conditions.
As with all bikes pay particular attention to the crank bolts, as they are subject to more loosening
forces than any other bolt.
Regularly check the brake pads, the provided Tektro pads should be replaced if they have:
-Been contaminated
-Have less than .8mm of material
-Cracks or deformation
To replace the brake pads or perform other maintenance take it to a qualified professional at your
local bike shop.

Properly inflate your tyres according to riding conditions. Under-inflated tyres are prone to pinch
flats, especially if riding off-road.
Please don't dismantle and repair parts by yourself, please go to your local bike repair shop. This
bike comes with a manufacturer’s warranty (document included) so any standard repairs please
contact Wattwheels and we will arrange a service agent close to you to look at the bike. We carry
spare parts so anything electrical that a standard bike shop doesn’t have we will ship to you.
BEST PRACTISES FOR EXTENDING BATTERY LIFE
Notice: It is recommended that users pays close attention and rides within the following limitations
to ensure the mid-drive/rear hub motor does not overheat or become damaged from excessive
loading.
o Do not climb hills steeper than 20% in grade.
o Pedal to assist the motor when climbing hills and accelerating from a stop.
o Avoid sudden starts and stops.
o Accelerate slowly.
PARKING, STORAGE & TRANSPORT
Please follow these basic parking, storage and transport tips to ensure your bike is well cared for on
and off the road.
o When pushing the vehicle manually, turn off the power to avoid accidental acceleration from the
motor.
o It is recommended to park indoors.
o Switch the power off, and any lights to conserve battery. Remove the key from the bike and ensure
the battery is locked to the frame or removed and brought with you for security.
o In public places, your Bighorn Bike must be parked in accordance with local rules and regulations.
o If you have to park outdoors in rain, or wet conditions you should only leave your Bighorn Bike
outside for a few hours and proceed to park the bike in a dry location afterwards in order to allow all
the systems to dry out. Much like a regular bike, use in wet conditions mandates a more regular
maintenance schedule to ensure your bike does not become rusty, corroded and to ensure all
systems are always working safely.
o Do not park, store, or transport your Bighorn Bike on a rack that is not designed for the size and
weight of the bike.
o Wide tyres, as used on Bighorn Bikes, cannot fit into all bike racks, please select an appropriate
rack for the width of tyres used on your bike.
o Locking up your bike is recommended to ensure your bike is secure and the chance of theft is
reduced.
Bikes makes no claims or recommendations on the proper lock hardware or procedures to secure
your bike, but we do recommend you take the appropriate precautions to keep your Bighorn Bike
safe from theft.
o When storing your bike or carrying your bike on a rack for transport, you can remove the battery
pack to reduce the weight of the bike and make lifting and loading easier.

SAFETY CHECK
Safety Check
Basic Steps
1. Brakes
o Ensure front and rear brakes work properly.
o Ensure brake pads are not over worn and are correctly positioned in
relation to the rims.
o Ensure brake control cables are lubricated, correctly adjusted and
display no obvious wear.
o Ensure brake control levers are lubricated and tightly secured to the
handlebars.
2. Wheels and Tyres
o Ensure tyres are inflated to within the recommended limits displayed on
the tire sidewalls.
o Ensure ties have tread and have no BULGES OR EXCESSIVE WEAR.
o Ensure rims run true and have no obvious wobbles or kinks.
o Ensure all wheel spokes are tight and not broken.
o Check axle nuts and quick releases to ensure they are tight. If your
bicycle is outfitted with quick release axles, ensure the locking levers are
correctly tensioned and in the closed position.
3. Steering
o Ensure handlebar and stem are correctly adjusted and tightened, and
allow proper steering.
o Ensure the handlebars are set correctly in relation to the forks and the
direction of travel.
4. Chain
o Ensure the chain is oiled, clean and runs smoothly.
o Extra care is required in wet or dusty conditions
5. Bearings
o Ensure all bearings are lubricated, run freely and display no excess
movement, grinding or rattling.
o Check headset, wheel bearings, pedal bearings and bottom bracket
bearings.
6. Cranks and Pedals
o Ensure pedals are securely tightened to the cranks.
o Ensure the cranks are securely tightened and are not bent.
7. Derailleurs
o Check that the derailleur(s) are adjusted and functioning properly.
o Ensure shift and brake levers are attached to the handlebar securely.
o Ensure all brake and shift cables are properly lubricated.
8. Frame and Fork
o Check that the frame and fork are not bent or broken.
o If either are bent or broken, they should be replaced.
9. Accessories
o Ensure all reflectors are properly fitted and not obscured.
o Ensure all other fitting on the bike are properly secured and functioning.
o Ensure rider is earing helmet and any other required riding safety gear.
10. Motor Drive Assembly and
Throttle
o Ensure hub motor is spinning smoothly and the motor bearings are in
good working order.
11. Battery Pack
o Ensure battery is charged before use.
o Ensure there is no damage to battery pack.
o Lock battery to frame and check to see that it is secured.

BASIC TROUBLESHOOTING
Symptoms Possible Causes Most Common Solutions
1 It doesn’t work
1. Insufficient battery power
2. Faulty Connections
3. Battery not fully seated in
tray
4. Improper turn on sequence
5. Brakes are applied
1. Charge the battery pack
2. Clean and repair connections
3. Install battery correctly
4. Turn on bike with proper sequence
5. Disengage brakes
2
Irregular acceleration
and/or
reduced top speed
1. Insufficient battery power
2. Loose or damaged throttle
1. Charge or replace battery
2. Replace throttle
3
When powered on the
motor does
not respond
1. Loose wiring
2. Loose or damaged throttle
3. Loose or damaged motor
plug wire
4. Damaged motor
1. Repair and or reconnect
2. Tighten or replace
3. Secure or replace
4. Repair or replace
4 Reduced range
1. Low tire pressure
2. Low or faulty battery
3. Driving with too many hills,
headwind, braking,
and/or excessive load
4. Batter discharged for long
period of time without
regular charges, aged or
damaged.
1. Adjust tire pressure
2. Check connections or charge
battery
3. Assist with pedals or adjust route
4. Replace the battery
5 The battery won’t
charge
1. Charger not well connected
2. Charger damaged
3. Battery damaged
4. Wiring damaged
1. Adjust the connections
2. Replace
3. Replace
4. Repair or replace
6
Wheel or motor makes
strange
noises
1. Damaged motor bearings
2. Damaged wheel spokes or
rim
3. Damaged motor wiring
1. Replace
2. Repair or replace
3. Repair or replace motor.
ERROR DECTECTION
Your Bighorn Bike is equipped with an error detection system integrated into the LCD display and
motor controller. In the case of an electronic control system fault an error code should display. The
error codes are listed in the manual and the most common and can aid in troubleshooting. If your
bike has an error code displayed at any time it is recommended that you cease operation and
contact Wattwheels immediately.
FINALLY, WE WOULD LIKE TO SAY THANKS AGAIN AND ENJOY YOUR NEW E-BIKE!
AND PLEASE CONTACT YOUR LOCAL DEALER OR WATTWHEELS IF YOU HAVE ANY
ISSUES OR QUESTIONS.
“POWER TO THE PEOPLE”