Wisper 806 Alpino Troubleshooting guide

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Owner’s Manual
Operation and Maintenance Instructions
Wisper 806 Alpino
April 2010 1st edition
Revised August 2010
We strongly recommend that you read this entire manual before
using your Wisper bike
Wisper Limited

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User Guide
Introduction Page 3
Part 1 Caring for your Wisper bike and pre use checks
1 Before you set off for the first time Page 4
2 Before each use Page 5
3 Battery care Page 5
4 Recharging your battery Page 6
5 Water Page 6
6 Maintenance and adjustments Page 6
7 Technical specifications and performance Page 7
8 Simple trouble shooting Page 8
Part 2 Controls and Equipment
9 Battery on off and battery lock Page 9
10 LCD Function Page 10
11 The lights Page 12
12 Pedelec mode Page 12
13 Throttle Page 12
14 Gear shifter Page 13
15 Brakes Page 13
16 The front connection box Page 14
17 Saddle height and handlebar adjustment and folding procedure
Page 14
18 Rims and spokes Page 14
19 Chain and drive wheel Page 15
20 Derailleur Page 15
Warranty Page 15
Service contacts Page 16

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Introduction
Thank you for choosing a Wisper electric bicycle.
By making the decision to use an electric bike you are helping to safeguard our
environment by saving our planet’s precious resources and reducing carbon pollution.
Before you use your Wisper bike it is important that you read this manual carefully. If
there is anything you do not understand completely please contact your retailer.
Please observe traffic regulations, and don’t lend your bicycle to anyone who is
unfamiliar with it. The bicycle can only legally be used on the road by a person aged 14
years or older.
We strongly advise you to always wear a cycle helmet when using your bicycle and if you
are unfamiliar with cycling to attend a cycle proficiency course prior to using it. Your
Wisper Works 806 Alpino is not a toy and should be considered a serious mode of
transport.
As with all bicycles it is important that you stay within safe limits, if you feel as if you are
traveling too quickly for the road conditions you probably are, so slow down. High speed
will increase forces in the case of an accident and increase the possibility of injury.
Test your brakes prior to using the bike every time you use it and remember the bike will
not stop as quickly in wet or icy conditions as it would on a dry road.
Before you use the bike for the first time you must make absolutely certain that it has
been correctly assembled. You can do this by either taking it to your nearest cycle
engineer or if you are proficient in cycle mechanics inspecting it yourself. In particular
you must make sure that the pedals, saddle, handle bars and any self assembled items
have been correctly fitted.
NEVER drink alcohol and ride your electric bike. The use of alcohol greatly reduces
reflexes and limits your ability to ride safely. Even a very small amount of alcohol will
limit your ability to be safe on the road.
When you need to replace your battery please either dispose of it properly or preferably
send it back to us or your supplier and we will make sure it is properly recycled.
Happy cycling!
Wisper Ltd

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Part 1 Caring for your Wisper bike and checks
Although your Wisper bike has been thoroughly tested prior to delivery, it is very
important that you check the bike again before its first use. Equally important are
frequent and regular spot checks, they will protect you and your Wisper bike.
Please read this manual carefully. Only on full understanding of all the functions of this
electric bicycle should you attempt to use it.
Your Wisper bike has been transported in a strong seven-layered corrugated carton. To
save space it has been delivered with the handlebar stem, seat post seat, and pedals
ready for assembly with the tool kit provided.
Your retailer may have assembled your bike for you if not you will find fitting instructions
on the Wisper website www.wisperbikes.com
1 Before you set off for the first time
1.1 Check the handle bars and handle bar stem are properly tightened
1.2 Check all other nuts and bolts and fixings are properly tightened, pay particular
attention to the motor fixings, side kick stand, yoke and steering head bearings
1.3 Check brakes and brake isolators are functioning properly
1.4 Check tyre pressures are correct and tyres are not damaged
1.5 Check reflectors and lights if fitted are functioning properly
1.6 Make sure battery is fully charged
1.7 Load battery into your bicycle’s rear carrier and turn on the power ON/OFF
button on the battery. Lock the battery into the rear carrier to ensure the
battery’s output connection is always connected properly. Remove the key.
1.8 Press on/off switch to check the battery capacity and the power assistance
level selected on the left hand side of the handle bars.

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1.9 To avoid dangerous unplanned acceleration, always make sure that the
electrical system is turned off and the power indicator lamps are not
illuminated when mounting, dismounting or leaving the bike unattended. For
your safety, please turn off the power switch on the battery when stopped or
walking the bike
1.10 Remember to validate your warranty by visiting
www.wisperbikes.com/mywarranty and filling in your details.
2 Before each use
It is important you perform a quick check of your bike every time you use it, checks
should include the following, if you find any damage or problems do not use the bike
until the problem has been solved or you have had the faulty item checked by a bike
mechanic or your retailer.
2.1 Check tyres for any visible damage
2.2 Check tyre pressures
2.3 Check for any loose nuts bolts or fixings
2.4 Check brake functions
2.5 Check electronic functions
2.6 Check reflectors are in place and lights are working
2.7 Check your battery for any visible signs of damage
3 Battery care
3.1 Before you use the battery for the first time it is best to give it a full deep charge
for 12 hours. To fully condition your new battery give it complete deep
charge/discharge cycles for the first three charges. This is achieved by charging
your battery for 12 hours and then using the bike until the battery is completely
drained. After this “conditioning” process you can then charge and discharge
the battery as and when you require for long or short periods

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3.2 If you are going to leave your battery uncharged for more than eight weeks it is
best left half charged. You should then re charge it every four weeks for two
hours to keep it in top condition
3.3 Before setting off on any journey it is always better to have a fully charged
battery
3.4 Do not expose the bicycle or battery pack to fire, heat sources, acid or alkaline
substances
3.5 When leaving your bicycle during hot weather always leave in a shaded well
ventilated area
3.6 For best results always recharge the battery at
room temperature
3.7 Before unloading the battery make sure it is
turned off at the switch and unlocked, then pull
the battery box from the rear carrier housing.
Please refer to the picture.
3.8 If your battery is damaged or appears to be
overheating for any reason immediately return it to your retailer for advice and
a safety check
4 Recharging your battery
4.1 Make sure the charger is turned off and connect
the charger to your battery then turn on the
charger. Red and yellow lamps on the charger
indicate the battery is charging, when the yellow
light turns green the battery is fully charged.
Always turn off the charger and disconnect from
the mains after charging. Always disconnect the
charger from the mains before disconnecting
the charger from the battery. It is possible that the battery will take up to 12
hours to charge on the first three charges.
4.2 Always charge the battery in a well ventilated area.
4.3 Do not leave the charger connected to the mains when not in use.
5 Water
5.1 Your electric bicycle is rain and splash proof and can be used in all weathers.
5.2 The electrical components of the vehicle, such as motor, battery, and controller,
must not be submerged in water.
6 Maintenance and adjustments
6.1 IMPORTANT! Do not attempt to open the casings of the battery, motor or

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controller it could be dangerous and all warrantees will become void. If you
experience a problem contact our service department or your retailer.
6.2 Wheel spokes should be adjusted after 300 miles riding. The saddle post should
never be raised beyond the maximum indicated by a safety line around the
tubes. The recommended torque on the nuts is as follows:
(A) Front axle nuts. 70N.M
(B) Back axle nuts. 70N.M
(C) Handlebar stem expander bolt. 18 to 20N.M
(D) Seat pillar clamp nut/bolt. 5-8N.M
(E) Brake cable anchor bolt. 5N.M
(F) Brake centre bolt. M6:11N.M
(G) Seat clamp nuts. 24N.M
(H) Crank axle nuts. R:42N.M L: 46N.M
(I) Gear shifter nuts. 4N.M
(J) V brake caliper nuts. 10N.M
(K) Rear carrier nuts. 8N.M
(L) Mudguard bracket nuts. 8N.M
Other nuts/bolts torque depends on their size. M4:2.5-4.0N.M5：
M5:4.0-6.0N.M M6:6.0-7.5N.M
6.3 Your bike has a rear derailleur that will automatically tension your chain.
However if the chain becomes loose or frequently comes off the chain wheel
please seek advice from your dealer.
6.4 The brake leavers should lock the wheels when compressed half way between
their open position and touching the handle bars. When they need adjusting
please do so according to the instructions below.
6.5 Warning: Handlebar hand grips or tube end plugs should be replaced if
damaged, as bare tube ends have been known to cause injury.
6.6 Warning: Any replacement forks must have the same rake and same tube inner
diameter as those originally fitted to the bicycle.
IMPORTANT braking distances increase on wet or icy roads.
6.7 Lubrication:
6.7.1. Once a month lubricate all pivot points on derailleur, and derailleur chain
guides with chain lube.
6.7.2. Every three months lubricate the brake lever pivots, the gears and chain
with light oil and the brake pivot bushes (not the brake shoes or disc) with a
little grease.
6.7.3 Once a year, have your dealer re-grease the headset bearings, wheel
bearings and pedal bearings.
6.8 Recommended tools for proper maintenance:
Torque wrench with Nm gradations 2, 4, 5, 6, 8 mm Allen wrenches
9, 10, 15 mm open-end wrenches 15 mm box end wrench
Socket wrench, 14, 15, and 19 mm socket T25 Torque wrench
No. 1 Phillips head screwdriver Bicycle inner tube repair kit, tyre pump

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7 Technical specifications & performance
Type Wisper Works 805fe
Performance (with 75kg 165lb rider)
Assisted range Up to 50km
Maximum speed 25kph (15.5mph)
Weight with battery 22.5kg max
Maximum load 130kg (240kg)
Battery specifications
Cell Type Advanced Environmental Panasonic Lithium Cells
Capacity 9Ah
Rated voltage 36V
Main Controller specifications
Low voltage safeguard 31.5V
Overload current safeguard 14A
Main hub motor specifications
Motor type Hi speed brushless
Rated power Aus Singapore 200W / NZ Europe 250W
Rated voltage 36V
Charger Lithium 115 to 230V 24V fan cooled
8 Simple Trouble shooting
Problem
Possible reasons
Trouble shooting
Top speed too
slow
1. Low battery voltage
2. Damage to motor driveline
1. Recharge battery fully
2. Call service
Power on but
motor not working
1. Battery not connected
2. battery fused
3. Motor connection damaged
4. Handle bar control problem
1. Re install battery
2. Replace fuse
3. Call service
4. Call service
Driving shorter
distance per
recharge
1. Tyre pressure too low
2. Undercharge or charger fault
3. Battery capacity loss or
damage
1. Check pressures
2. Recharge completely or
have charger inspected
3. Replace battery

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Problem
Possible reasons
Trouble shooting
Top speed too
slow
1. Low battery voltage
2. Handle bar control problem
3. Damage to motor driveline
1. Recharge battery fully
2. Call service
3. Call service
Power on but
motor not working
1. Battery not connected position
2. Fused
3. Motor connection damaged
4. Handle bar control problem
1. Re install battery
2. Replace fuse
3. Call service
4. Call service
Driving shorter
distance per
recharge
1. Tyre pressure too low
2. Undercharge or charger fault
3. Battery capacity loss or
damage
4. Hill climbing, frequent stops,
strong head winds, over
loading
1. Check pressures
2. Recharge completely or
have charger inspected
3. Replace battery
4. Use power assist and try and
avoid throttle only
LCD diagnostics
02 flashes
Motor current is too high.
03 flashes
Motor cable connection may
be loose.
04 flashes
Battery voltage is too low.
05 flashes
Brake lever cut out function
problem.
07 flashes
The throttle is faulty.
08 flashes
Controller faulty
09 flashes
Battery output voltage is too
high.
Part 2 Controls and Equipment
In this section we will describe the functions and any specific maintenance needed on all
the main controls and ancillary equipment.
9 Battery on off and battery lock
9.1 Your Wisper bike has one key. This key is for
locking the battery into the bike. Please keep a
careful note of the key number as we cannot
replace it without this number should it become
mislaid.
9.2 The battery is connected to the electrical system

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on the bike automatically when you push the battery into the rear carrier
housing. To turn on the bike’s electrical system, switch the on/off button in the
battery box to on, to turn off the bikes electrical system, switch the on/off
button in the battery box to off. (Please refer to the picture)
9.3 After the battery has been turned on the bike is ready for use. The battery box
capacity indicator is on the handle bar for ease of use. Assistance from the
battery is then available.
9.4 To lock the battery into the bike frame turn the key clockwise so the locking bolt
secures the battery in position. To unlock turn the key anti clockwise. Please
remove the key when riding. Please read 3 and 4 for battery care and advice
on charging at the beginning of this manual.
9.5 The battery can be charged either on or off the bike.
9.6 To remove the battery first turn off the power by switching the on/off button to
off. Unlock the battery and pull out from the rear carrier housing.
On the handle bars
10 LCD function description
10.1 The LCD display has the following functions (Refer to the picture below).
A: Power ON/OFF button. For details refer to the paragraph below.
B: Up (increase) adjusting button. For adjusting the pedal assistance strength,
and back light brightness.
C: Down (decrease) adjusting button.
D: Set. When pressed, you can set the back light of the LCD and the
single trip distance. If you press it together with C button, you can set the bike’s
tyre size.
E: This shows the instant power consumption extent. A longer bar means the
motor’s power output is higher.
F:
Battery capacity. Three bars indicate 80% capacity left, two bars indicate 70%
left, one 55% capacity left, half bar 5% capacity left.