WattWheels BIGHORN HUB 2020 User manual

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BIGHORN HUB HUB EBIKE 2020
MANUAL

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CONTENTS:
INTRODUCTION PAGE 3
INSTALLATION PAGE 4
LCD DISPLAY PAGE 5-6
THROTTLE PAGE 7
BRAKES, TYRES, CHAIN PAGE 8
BIKING RANGE PAGE 9
RIDER SEAT HEIGHT & COMFORT PAGE 10
BATTERY & CHARGING PAGE 11
USEFUL TIPS PAGE 13
PARKING STORAGE & TRANSPORT PAGE 14
SAFETY CHECKS & BASIC TROUBLESHOOTING PAGE 15-16
ERROR CODES PAGE 17
SERVICING PAGE 18
WARRANTY INFORMATION PAGE 19-21

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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 regulations for e-bikes and the components of the model that you have before your first ride.
Please also ensure that the bike is regularly serviced as per the instructions later in this document. Failure to get the bike serviced can result warranty claims
being void if they are required. A bike is a vehicle and like a car needs to be serviced on regular occasions.
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.
USING THIS MANUAL
This manual contains details of the electric bike, its equipment, and information on its operation and maintenance. Read it carefully and familiarize yourself
with the Bighorn Hub before using it to ensure safe use and prevent accidents. 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.

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INSTALLATION IF REQUIRED:
(Refer to Video on our website for detailed instructions)
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)
(PLEASE BE CAREFUL NOT TO PRESS THE BRAKES LEVERS WHILE THE FRONT WHEEL IS NOT INSERTED. DOING SO WILL RESULT IN THE BRAKES PADS
CLAMPING TOGETHER, AND YOU WILL NOT BE ABLE TO INSERT THE FRONT WHEEL WITHOUT BLEEDING THE BRAKES IN WHICH YOU WILL NEED A BIKE
WORKSHOP TO PERFORM)
2. ATTACH THE HANDLEBARS
3. ATTACH THE PEDALS
(Beware: The left-hand pedal has a reverse thread. To tighten, please turn anti-clockwise, right hand pedal is clockwise))
4. ATTACH THE SEAT POST
5. ATTACH THE FRONT MUDGUARD AND ATTACH FRONT LIGHT (if applicable)
6. INSERT THE FRONT WHEEL WITH QUICK RELEASE
7. CHECK ALL SCREWS AND BOLTS ARE TIGHT, SEAT POST THE CORRECT HEIGHT AND BRAKES WORKING PROPERLY

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LCD DISPLAY FEATURES
The image shows the various features and information displayed on the LCD display. The display is controlled using the 4-button remote mounted on the left
side of the handlebar.
LIGHTS & BACKLIGHT DISPLAY
To activate the lights and illuminate the display hold down the + key, located on the keypad. A little icon should appear above the on the top left indicating
the light is on. This will turn on the front and rear lights. To turn off, hold down the + key again

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TRIP/ODO/MAX SPEED & TIME
To toggle between the various modes short press the on/off key to switch between them. The selected item is located in the bottom left corner of the display
BATTERY DISPLAY CAPCITY
The LCD readout on the handlebar of your Bighorn Hub Bike features a battery capacity gauge (much like the fuel gauge on an automobile). It is
recommended that users stop operating the bike on electric once the bike comes up with a flash icon in the battery indicator and recharges. Remember you
can still ride without using the electric motor or display!
PAS (Pedal Assist Modes)
Pedal assist modes start from 1 and goes up to 5. PAS level 1 is the first pedal assist level and will give you some slight assistance. Press the up and down
arrows on the control panel to toggle between the levels. As you select the higher levels, the assistance will increase with level 5 basically doing all the work
for you. Using higher levels of PAS will drain the battery faster. The recommended level is PAS 1-3 to ensure good battery life. Note- PAS 0 means no
assistance from the motor and you would have this on if you wanted to ride without assistance but measure km/speed etc.
WALK MODE
To activate the walk mode, hold down the - key for three seconds. This will propel the bike forward at around 6km/r. This can be used if you need to walk the
bike up a hill and need some assistance in doing so.
SPECIAL MENU
Please refer to the display manual in the document to access this. But to get into the menu hold down the + & - keys simultaneously for two seconds
Here you can reset trip meter, limit the speed, change PAS power and Sensitivity. We recommend if changing the power or sensitivity of the bike you should
get this done by your local bike shop
Please contact your local retailer if you need any assistance on this. Alternatively, you can check Wattwheels website for up to date instructional videos.

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THROTTLE
The throttle is located on the left-hand side of the handlebars in the form of a thumb piece as pictured below. Please be careful as these throttles are set to
operate the Bighorn Hub from stationary so any slight press of this will propel the Bighorn Hub forward if the bike is in PAS 1 or above. 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 Hub on steep
gradients select the highest level of PAS and use the lowest gear.
When using the throttle from a standing start please ensure you start in a lower gear and low PAS. Starting the bike in Level 5 PAS and the highest gear can put a
lot of stress on the motor and will wear the motor faster. As a preventative measure we have included a program on the bike that the throttle will only allow 50%
power until the bike reaches 10km/r. Once it’s over 10km/r the throttle will allow 100% power if required. This is to help preserve the motor and prevent wear and
tear on the chain and cogs.

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BRAKES
The Bighorn Hub electric bikes are equipped Tektro E350 hydraulic disk brakes. Please be aware the hydraulic disk brakes are very strong, so care is to be
taken braking initially, when getting familiar with the bike. The front wheel brake is located on right hand side with the rear wheel brake on the left. For riders
which prefers the brakes the other way around please get your nearest bike shop to switch over if required.
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. We recommend
a pressure of between 35-50PSI
CHAIN
The Bighorn Hub has a mid-drive motor which transfers immense torque through the chain when shifting. In response, KMC has developed e-bike specific,
torsion resistant chains to managing these extreme drivetrain conditions – the X e-Bike Series.
The direct force from the mid-motor to the cassette causes an enormous strain load on the chain which means a stronger and more durable chain is crucial.
KMC has contended with this by combining 20% upgraded durability with the highest Pin Power on the market to ensure longer chain life and higher torsion
and stress resistance for the KMC X e-Bike Series Chains. When replacing a chain please make sure you get an e-bike graded one to cope with the torque as
mentioned above. Also ensure the chain is lubricated on a regular basis so talk to your local bike shop on what they suggest.
The current model chain supplied with the bikes is a KMC -X10E

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BIKING RANGE
The range of your Bighorn Hub is the distance the bike will travel on a single full charge of 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. Tyre pressure and terrain are also important variables to consider.
We suggest that you ride conservatively when you first get your Bighorn Hub 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 Hub 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 or decrease range, but Wattwheels makes no claims to the range that individual users might obtain.
Expected
Range
Operating Conditions
30 Km
o Hilly Terrain
o Heavy Payload
o High Throttle use
o High Speeds
o High PAS
45 Km
o Flat Terrain
o Normal Payload
o Not Windy
o Medium Speeds
o Moderate PAS
60+ Km
o Flat Terrain
o Normal Payload
o Not Windy
o Low Pedal Assist Level
o Moderate to Heavy Pedalling

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With the battery gauge located on the bottom left of the display please take note on new bikes the gauge can drop quite quickly initially. If this happens don’t be
alarmed as this is normal and is due to the BMS (battery management system) we use in the bikes and it will take a few charges for the cells to balance out. There
will also be instances of voltage sag where the voltage drops when using a high level of PAS, biking up hills or under a heavy load which again is normal. As
mentioned it is good to do a few smaller rides first to get familiar with the bike and the range you can get depending on what settings you have the bike on. Pay
close attention to the section in looking after your battery to prolong and maximise its life.
ADJUSTING THE SEAT HEIGHT
Use the quick release seat post clamp to release the seat post and pull upwards or push downwards to reach desired height.
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 pedalling 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 pedalling. 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.

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BATTERY & CHARGING
The battery can be either charged by leaving the battery in the bike or by removing it. To charge while in the battery open the rubber cap located on the
right-hand side of the downtube and plug the charging pin into the slot.

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To remove the battery, turn the wheel slightly so you have better access to battery. Turn the key to the unlock position and then turn the lever on the battery
case to release the battery. Note on the low step frames the battery is removed from the top.
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 or if needed 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.
Do not store the charger or battery in a wet/damp place or in direct sunlight.
Lithium-ion batteries can last longer if you recharge 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]
BEST PRACTISES FOR EXTENDING BATTERY LIFE
o Use Pedal to assist when climbing hills and accelerating from a stop. Keep throttle to a minimum
o Avoid sudden starts and stops.
o Accelerate slowly
o Keep within the recommended weight limit
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.
•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.

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•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
DO NOT use the charger of other brands to charge. The electric apparatus contains a high-pressure circuit and is not compatible with some brands
USEFUL TIPS
• When starting off or climbing hills, please try and ride with the pedal assist over the throttle, 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 130kg, please don't overload otherwise it will void the warranty
• While riding if the level of charge shows only one bar flashing is recommended to ride without power in PAS 0 at this time and charge as soon as you can.
• Turn off the display and remove the key, while parking or storing the bike.
• Inspect the bolts on a regular basis, to ensure that they are tight, and all components are secure. In particular pay close attention to crank bolts, cranks,
stems, quick release front and rear.
This is especially important if you are riding in demanding conditions.
• Regularly check the brake pads. The provided Shimano 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 bicycle mechanic at your local bike shop.
• Properly inflate your tyres according to riding conditions. Under-inflated tyres are prone to get flats, especially if riding off-road.

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• 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 your nearest retailer
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 bike 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 into the frame or removed and
brought with you for security if needed.
o In public places, your Bighorn Hub 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 Hub 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, using 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 Hub Bike on a rack that is not designed for the size and weight of the bike.
o Wide tyres, as used on Bighorn Hub 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. Wattwheels 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 Hub 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

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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.
2. Wheels and Tyres
o Ensure tyres are inflated to within the recommended limits displayed on the tyre sidewalls.
o Ensure tyres 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 the 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 wearing a helmet and any other required riding safety gear.
10. Motor Drive Assembly and Throttle
o Ensure mid-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.

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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
Incorrect distance, speed
readings and/or
reduced top speed
1. Insufficient battery power
2. Speed sensor is not centered or missing
1. Charge or replace battery
2. Check on the rear wheel that the silver disk matches
up in the center of the black sensor.
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 tyre 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 tyre pressure
2. Check connections or charge battery
3. Assist more with pedals or adjust route
4. Replace the battery
5 The battery won’t charge
1. Charger not connected properly
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.

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ERROR DECTECTION
Your Bighorn Hub 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 below and can help detect what the issue is on the bike. If your bike has an error code
displayed at any time it is recommended that you cease operation and contact your local dealer or Wattwheels.
0 Normal
21 Current error or MOS damaged
22 Throttle Error
23 Motor Phase Error
24 Motor Hall Signal Error
25 Brake Error
30 A communication controller receiving error

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SERVICING
To ensure your bike remains in great shape just like a car it requires regular servicing. Failure to do so may void any potential warranty claims. Please retain
your receipts for proof of service
2-3 MONTHS: 12 MONTHS:
DATE: DATE:
STORE/MECHANIC: STORE/MECHANIC:
SIGNATURE: SIGNATURE:
6 MONTHS:24 MONTHS:
DATE: DATE:
STORE/MECHANIC: STORE/MECHANIC:
SIGNATURE: SIGNATURE:

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WARRANTY
To activate your warranty please go to https://www.wattwheels.co.nz/warranty. A link is located at the bottom of our
webpage.
Wattwheels Ltd warrants that all new products are warranted to the Buyer against manufacturing defects in materials and/or workmanship for the following periods:
Motor/Battery 24 months
Frame 60 months (Folding bikes & trikes is 36months)
Additional Components 12 months
For commercial operations where the bikes are being used a hire bike then the following applies:
Motor/Battery 12 months
Frame 24 months (Folding bikes is 18months)
Additional Components 6 months
The warranty period is calculated from the point of delivery. The original receipt of purchase is required to establish proof of purchase and must be provided to
Wattwheels for all warranty claims. Wattwheels will require the customer to complete a MANDATORY standard procedure for warranty claims that will involve media
such as photos and videos to help Wattwheels after sales staff establish the fault with the product.
Goods we sell are subject to a full comprehensive warranty. The costs/inconvenience caused by the loss of use of the product, is not covered whilst the warranty
procedure takes place. The warranty for replacement components will be based on the date of delivery. Under no circumstance will a replacement component have
a warranty date different than the original date of delivery. If a replacement is necessary due to a defect in materials and/or workmanship, then upon return to
Wattwheels, the component will be replaced during the warranty period.
Wattwheels will have no obligation under this warranty in the event the product is damaged or destroyed as a result of any of the following events: components
used on a non Wattwheels product, damage or destruction by abuse; collision; theft; improper maintenance or mishandling of the product; natural forces such as
wind, lightning, hail, etc.; any wilful or negligent act; penetration, or opening of the product casings in any manner. Replacement will be honoured only by
Wattwheels.

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This is Wattwheels exclusive warranty. No party is granted express or implied authority to change or annul this warranty in any manner. Implied warranty including
that of merchantability and fitness for a particular purpose are expressly limited in duration to the duration of this warranty. Wattwheels disclaims any liability for
special, incidental or consequential damages.
This warranty is not meant to suggest or imply that the products cannot be broken or will last forever. It does mean that the product is covered subject to the terms
of the warranty. This warranty applies only to the original Buyer of the product and is not transferable to subsequent owners or any other party. This warranty is void
if the product is subjected to abuse, neglect, improper repair, improper maintenance, alteration, modification, an accident or other abnormal, excessive, or improper
use, at the sole discretion of Wattwheels.
Warranty Exclusions
This warranty does not cover:
• normal wear and tear
• damage or failure from abuse, neglect, misuse, or accident
• damage from stunt riding, ramp jumping, acrobatics, competitive events, such as bicycle racing, bicycle motocross racing, or similar activities or any activity that is
not consistent with the intended use of the product
• damages resulting from improper charging of the battery pack or use of any charger not supplied by Wattwheels
• installation of any parts, accessories, or electrical component(s) not originally intended for or compatible with the product as sold, or any modification of the frame
or any component(s) originally supplied; tires, brake pads, chains, lights, motors, battery packs, displays, or vehicle controllers that have been opened for any
purpose whatsoever, other than by Wattwheels
• All warranties are void if the product is used for any purpose other than the reasonable intended use of the product. Additionally, this warranty does not cover
damage associated with commercial use.
• Aftermarket components or modifications
All implied warranties, including the warranties of merchantability and fitness for a particular purpose, are limited in duration to that of the express warranties stated
above.
Warranty Procedure
Proof of purchase must be provided. The original Purchaser must contact a Wattwheels representative to discuss the problem with the product. The original
Purchaser is responsible for the return of the product, undamaged in transit, to Wattwheels for warranty work and for the costs associated with shipping the
component(s) when returning them. If Wattwheels determines a warranty claim is valid and conforms with this warranty, Wattwheels will replace component(s). For
valid warranty claims hereunder, Wattwheels will reimburse the original Purchaser for shipping costs incurred as a result of returning the product to Wattwheels for
warranty work at standard ground shipping rates, and Wattwheels will pay for shipping costs to return the product to the original. You must retain and send us the
receipts for shipping.
Limited Liability