Woosh Big Bear User manual

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Sales: 01702 435566 — Support: 01702 684444 — E-mail: support@wooshbikes co uk
Big Bear User Guide
Please read this manual.
It contains important information regarding
your safety, the correct use of the bike and
how to avoid expensive repair fees
in the future .
Support is available Mon to Fri from 10am to 5pm on
01702 684444 If there is no answer, leave a message and
we will call you back

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The Big Bear from Woosh
The Big Bear is a strong sturdy bike which can be used for commuting to and from work. It has a 15Ah bat-
tery which means that distances of up to 50- 0 miles can be achieved on a single charge in ideal condi-
tions. If you rely heavily on the throttle and do not put much effort in yourself, then the battery will run
down more quickly and the distance able to be travelled on a single charge will be reduced accordingly.
The Big Bear can be used on roads and cycle paths, it is not suitable for off-road use and should not be
used in competition events. It should not be used for jumping, stunting or aerobatic activities and should
not be ridden through deep puddles or fords. Incorrect use of your bike could result in injury and will void
your warranty.
You must be a minimum of 14 years of age to ride an electric cycle in the UK
The maximum weight including rider and luggage is 140kg (22 stone).
Before you ride your bike, and for your ongoing safety, familiarise yourself with the “user manual” and
the “maintenance manual”. There are many components on the Big Bear, and it is critical that they are
checked regularly and maintained where necessary. Details of how to maintain the various aspects of your
bike are included in the “maintenance manual”.
If you have any issues which are not covered by the manuals, it is likely that you would need to enlist the
help of a professional. Most people don’t have a complete set of tools for maintaining a bike, so things
like adjustments to the bottom bracket will need to be done by your local bike dealer. You should enlist
the help of your local dealer whenever something needs adjusting that you are not able to do yourself.
Your safety is paramount, so you must ensure that the bike is maintained in the correct manner, if in
doubt, consult your nearest bike dealer.

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Important Safety Notice — please read
Your bike has had a full electrical check before despatch.
It has also had a general mechanical check, but you need to ensure yourself that when you complete the
assembly of your bike, that you also check the whole bike over before riding it.
You should be prepared to do this yourself, or if you are not sufficiently experienced, ask a local bike shop
to do this for you. A typical fee for this would be around £35
A full inspection should include (but is not limited to):
• Checking that the brakes are set correctly and work properly.
• All nuts, bolts, major fixings, spokes and cranks etc. are correctly tightened.
• Both wheels are properly trued
• Headset/stem properly adjusted
• Cranks are tight
• Bottom bracket properly adjusted
Pedals, saddle and handlebars are correctly fitted and properly secured.
See the maintenance manual for how to adjust and maintain the various components of the bike.
Please note that failure to carry out these checks properly could result in serious injury for which Woosh
Bikes Ltd will not be held liable.
If you have any doubts about your own ability to perform the necessary checks, we strongly recommend
you visit your local bike shop and pay their fee. If you are unable to take your bike to a local bike shop
there will almost certainly be a mobile bike technician in your area who will come to your home or office
and do this for you.
Visit www.cycletechuk.com for a full national listing.

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Unpacking:
Two people are required to unpack the bike.
Stand the carton upright as shown.
emove the shipping straps, cut the tape seals and then remove all of the polystyrene packaging.
Keep the carton/bike in the upright position, and then lift the bike out of the carton and then lean it against
a sturdy surface. DO NOT destroy the carton as it will be required if the bike needs to be returned for any
reason in the future.
Once you have the bike out of the box, detach the wheel and remove all of the remaining packaging (if
applicable). This model sometimes comes 95% assembled meaning that the front motor wheel and
torque arms are already fitted, if this is the case you can skip those sections.
Slide the handlebars into the frame but don’t fully tighten them yet, this step is just to ensure that the han-
dlebars are out of the way and cannot scratch the frame whilst you are fitting the front wheel.
You are now ready to fit the front wheel to the forks. This is done by simply lowering the forks onto the
spindle. As you lower the frame, ensure that the brake disc lines up correctly within the calliper's
and that the axle is fully inserted. You must also ensure that the motor cable is pointing upwards
Once in position, tighten the nuts either side to secure the wheel in position.
See next page for how to fit the “torque arms”
Plug the cable coming from the motor on the right side of the wheel into the receptacle on the bike—see
below.
Now that the front wheel has been fitted, you can use the stand to keep the bike in the upright position.
When attaching the motor cable, ensure
that the arrow on each side of the connec-
tors line up with each other, otherwise you
may damage the connector.
You may find that the cables from the han-
dlebar components are detached when
you receive the bike. If this is the case, line
up the arrows on the connectors and re-
attach them to their corresponding col-
oured connector.

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Front mudguard:
To fit the front mudguard, the upper mounting tag is fitted to the rear of the forks as shown. The upper
mounting tag has an elongated hole which is used to adjust the height of the mudguard. Once the mud-
guard has been secured, you can then attach the hangars (silver arms) to the forks as shown. Once at-
tached it may be necessary to adjust the height and/or flex the hangars to get a little extra clearance be-
tween the mudguard and the tyre.
Fitting the torque arm(s):
The torque arm is a secondary measure to secure the motor wheel to the bike. It is essential that this de-
vice is fitted to ensure your safety.
The torque arms should be fitted to the both sides of the bike as shown. emove the wheel nut and slide
the arm into position on the axle and then refit the nut to secure it in position.
Protect the frame using the rubber piece supplied and then loosen the jubilee clip and slide it through the
hole on the torque arm and around the fork as shown. Tighten the jubilee clip ensuring that the rubber
piece stays in place.

Handlebars:
If you haven’t already, slide the handlebar stem into the frame at the desired height, remove the weather-
proof cap and then tighten the allen bolt indicated below to secure the stem in position whilst ensuring that
the handlebars line up correctly with the front wheel.
Warning:
It is extremely important to ensure that the handlebars are properly secured. If they were to rotate or other-
wise move unexpectedly during use, it could result in an accident and/or serious injury. If you have any
doubts regarding the correct configuration of this part (or any other part of the bike), you should take your
bike along to your nearest bike dealer and have them prepare it for you (at your cost).
Once the stem has been secured, you can now fine tune the positioning of the handlebars. The handle-
bars can be adjusted in two ways. They can be rotated, and they can also be raised/lowered. You should
adjust the height first. This is done by loosening the large bolt on the underside of the handlebars (shown
below left). This bolt secures a stepped piece that locks the handlebars into position. You will need to
loosen the bolt enough so that the handlebars can be rotated, then tighten this piece back into position
when you have the handlebars at the desired height.
To adjust the rotation of the handlebars, loosen the front-most bolt on the underside of the handlebars as
shown above right. otate the handlebars into the desired position and then re-tighten the bolt. Check the
adjacent bolt is sufficiently tight and tighten if required.

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Seat-post/saddle:
The seat-post simply slides into position and then the clamp is used to secure it. To adjust the height of
the saddle, simply open the clamp and position the seat-post at the desired height and then close the
clamp to lock it into position. It may be necessary to tighten the thumb screw a little to ensure that when
the clamp is closed the seat-post is properly secured. Adjust the thumb-screw as needed. There are two
different seat-post options on this model, but the clamp works in the same way regardless of which post
you have, the standard sprung post or the NCX post. See the preparation/maintenance manual to deter-
mine the correct saddle height.
Pedals:
Important—the pedals fit a specific side of the bike If you attempt to fit the pedals to the wrong
side, you will damage the threads on the cranks and also possibly the pedals as well Also if you
force the pedals on to the wrong side of the bike, it is very likely that they will come loose sud-
denly and unexpectedly
The pedals are marked ‘L’ (left) and ‘ ’ (right) which indicates the side of the bike the pedal is for. To de-
termine which pedal is for which side, see the pictures below showing where this marking is found.
Fit each pedal into position and finger-tighten, then use a 15mm spanner to secure the pedals in place,
tighten to approx. 40Nm (see torque/tightness guide in the maintenance manual).

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Charging/locking the battery:
When the bike is shipped, the battery is secured with cable-ties instead of being locked with the key. This
is done to avoid damage to the battery locking mechanism in transit. Some delivery drivers take more care
than others, so by securing the battery in this way, we can prevent this issue from occurring. Simply re-
move the cable-ties and lock the battery in place using the key once you’ve unpacked the bike.
The battery may not leave us fully charged. You should fully charge the battery before using your
bike The battery can be charged on the bike or it can be removed and charged separately. The socket
used to charge the battery is located at the left rear of the battery as shown below. Ensure that the
charger is switched OFF before attaching the charger to the bike You should keep the battery
topped up and not let it go completely flat to ensure it lasts as long as possible. The on/off switch for the
battery is located on the opposite side to the charger socket.
To charge the battery, simply lift the weatherproof cover and connect the charger to the socket and then
plug the other end into a regular mains socket. On the charger is a small light which is red while charging.
When charging is complete, this light will turn green.
The battery can be removed from the bike and charged in a convenient location such as in your home or
office. To remove the battery from your electric bike, use the supplied key to unlock the battery by turning
it anti-clockwise. Once unlocked remove the key and then slide the battery from the bike using the grip at
the rear underside of the battery.
A full charge from flat can take up to 10 hours.
emember to separate your keys, Woosh
Bikes is not able to supply replacements if
you lose them.

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On the rear of the battery is a meter which gives you a rough idea of the remaining battery capacity. To
activate this meter, simply press the button in the middle as shown below. The more lights that come on,
the greater the remaining capacity. For a more accurate idea of the battery status, you should look at the
battery indicator on the display module on the handlebars—this module is covered in more depth later in
the manual. The outermost lights are always red, this is not an indication of an issue with your battery.
Important:
Although our bikes are checked prior to despatch, you must fully inspect your bike again yourself before
riding it, and satisfy yourself that it is correctly assembled and safe to ride. If you are not absolutely sure
about any aspects of your bike, you should take it to your nearest bike shop to have it checked before rid-
ing it. Obviously the bike shop will you charge for this service. Woosh Bikes not reimburse you for these
costs.
Before riding your bike, perform the checks and set up your bike as outlined in the maintenance manual.
Check that all fixings and major components are tightened sufficiently. Check that all nuts, bolts, rear car-
rier fixings, handlebars and seat-post/saddle are also sufficiently tightened.
You must also ensure that your brakes are working correctly before you set off. If you are unsure how to
adjust your brakes yourself, there are guides on our website to help you with this. If you prefer, you can
have your local bike shop adjust them for you. The brakes are the same as you would have on a regular
bike and so any bike shop should be able to adjust them for you. You would obviously have to pay them
for this service.
See the preparation/maintenance manual for details on how to adjust/maintain your bike and its compo-
nents.

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Riding the bike
To begin using the bike, ensure the battery is switched on then press (and hold) the ‘Mode’ button to
switch on the ‘King-Meter’. The bike is now effectively on, and if you ride it in this state, the motor will pro-
vide assistance when pedalling and you will also be able to use the throttle if you wish. To vary the
amount of assistance provided by the motor, use the up/down buttons to cycle through the 5 assistance
levels.
There are several other features available on the King-Meter and these are covered later in the manual.
The information provided so far is just enough to get you up and running as quickly as possible.
Important note about the maximum speed. You may not reach the maximum speed on throttle alone.
You can increase the maximum speed on throttle by setting the assistance level to high but to achieve the
maximum legal speed of 15mph, you need to be using pedal assist. Your maximum speed will be then be
limited by your highest cadence.
The motor will only assist you up to 15mph. Though of course you are free to pedal as fast as you like, be-
yond 15mph if you wish, but the motor will not help you beyond the 15mph limit. This limit is in accordance
with current UK law.
The Big Bear comes with a throttle control. The throttle is located on the right side of the handlebars as
shown below. When the throttle is pulled fully, the motor will provide the most assistance. The throttle fea-
ture is enabled/disabled by the red button as indicated below. The red button does not affect pedal-assist
which is always on.

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Riding the bike cont
Your bike features 7 speed Shimano index shifting gears which are changed using the thumb selector on
the right side of the handlebars. When the thumb stick is fully extended, the bike is in first gear (the easi-
est to pedal). To move up through the gears press the black (+) button as shown.
To move back down the gears, simply push/extend the thumb selector again, one gear at a time.
Most of the time, you will likely use the bike in it’s highest gear once you are in motion, but to get the best
performance out of your bike on hills, you should change down to a suitable gear before you start your
ascent.
The Big Bear also comes equipped with a horn which is powered from the main battery on the bike. To
activate the horn (which is quite loud), simply press the red button indicated below.

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Fitting/Operating the lights:
The rear light is already fitted, to operate the rear light, simply press the button on the top of the light as
shown below.
To change the batteries in this unit, simply reach under the bottom edge and then pull the lower edge of
the light rearwards. This unit requires 2x AA batteries.
If your light doesn’t work initially, it is likely that the insulating material fitted at the factory to stop the bat-
tery going flat is still in place. Simply pull the external tag or if necessary, access the battery compartment
and remove the small plastic insulator that sits between the battery and terminal of the light.
The front light is supplied but may need to be fitted. It attaches to the handlebars as shown, but first you
will need to fit the batteries. Unscrew the base of the light and remove the battery cartridge. The batteries
should be fitted so that the negative terminal meets the spring end of the cartridge. Once the batteries
have been fitted, simply slide the cartridge back in place and re-fit the end cap.

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To attach the light to the handlebars, undo the thumbscrew and slide the fitting over the handlebars, then
re-tighten the thumbscrew to secure the fitting in place. Once in place you can slide the light/torch into po-
sition a shown. It may be necessary to adjust the thumbscrew on the left side of the light to hold it firmly in
position. As you have probably realised by now, the light doubles up as a torch simply by sliding the light
from the mounting.
To turn the light on/off, simply depress the button at the base of the battery as shown below.

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King-Meter—Advanced
The King-Meter has many advanced features and modes, these include back-lit display (for night riding),
indicator options for max speed, average speed and current speed, a digital clock and a battery power in-
dicator.
2.
3.
1.
5.
4.
1. Battery Level Indicator
2. Assistance Level (Pedal Assist)
3. Odometer
4. Digital Clock
5. Speed Indicator
Warning:
The King-Meter comes pre-configured specifically for your bike. Incorrect settings could cause damage to
the bike components and also result in a bike that is not UK road legal. Any modifications made to the
controller configuration will void your warranty with immediate effect.
Turning King-Meter On/Off
To turn on the King-Meter press and hold the middle (Mode) button. Press and hold the same button to
turn off the module and disable all electric features of the bike.
Turning Backlight On/Off
To turn on the display backlight, press and hold the “Mode & Up” button, press and hold the same two
buttons to turn it off.
Varying Pedal Assist Level
To alter the level of assistance provided simply press the Up/Down arrows to cycle through the 5 levels of
assistance. Level 1 offers the least assistance while level 5 offers the greatest assistance.
Speed Display Mode
There are three different modes for the speed display, these are current speed, average speed and maxi-
mum speed. To switch between these modes, press and hold the “Up” button for approx. 1 second to cy-
cle through the modes.
Walking Mode
The bike also supports a walking mode which is basically a very slow mode allowing you to walk next to
the bike at approx. 6Km/h. This is activated by pressing and holding the “Down” button. As soon as the
button is released, the bike will stop.

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Riding Distance/Total Distance
To change the display between riding distance and total distance, press the Mode button. The current
mode is indicated by “Trip” for “Current Trip Distance” and by “Odo” for “Total Distance”.
Control Module Battery
The “control module” itself has a battery which retains the settings within the module. This battery should
last for around 2 years. The battery is a standard type and is readily available. If you need a battery in the
future, contact us and we can supply one to you or alternatively you can buy from outlets such as Maplins.
Make sure you replace the battery with the correct type to avoid causing damage to your module. If you
are not sure how to change the battery, contact us for assistance.

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Woosh Bikes
DECLARATION OF CONFORMITY
Product name Commercial name(s
Electrically power as-
sisted cycle
Woosh Sirocco Woosh Sundowner
Woosh Sirocco CDL Woosh Big Bear LS
Woosh Big Bear Woosh Gale
Woosh Krieger Woosh Zephyr CDN
Woosh Zephyr B Woosh Gallego
Woosh Petite
Woosh Sant Ana
Woosh Sant Ana CD/CDL
Manufacturer, address
Made in China for Woosh Bikes Ltd
42-4 Queens Road, Southend-on-Sea, Essex, SS1 1NL, UK
The product (system) identified above is in conformity with the listed European Directive(s).
The following table identifies the applied standards and the conformity assessment procedure.
EMC DIRECTIVE
2004/108/EC
OJ DEC. 2004 L 390/24
Applicable Non Applicable
TWO or THREE-WHEEL MOTOR
VEHICLES DIRECTIVE
2002/24/EC
OJ May 2002 L 124/1
Applicable Non Applicable
MACHINE DIRECTIVE
2006/42 EC
OJ MAY 200 L 157/24
Applicable Non Applicable
- Applied Standards
• EN 15194
• EN 1000-4-2
• EN 55022
- Applied Standards
• EN 15194
- Applied Standards
• EN 15194
Date
01/01/2013
Signature Authorised representative
Director—Woosh Bikes Ltd
X X
X

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© 2014 Woosh Bikes Limited
Woosh Support:
Be sure to check the FAQ section on our website before calling as the answers to the most common que-
ries are there and you may find that the solution to your problem is already online. If you do need to get in
touch, our contact details are below.
It can sometimes be useful to see the issue you have, so if possible, email a couple of photos illustrating
the problem and we’ll normally get back to you within a an hour or two (on weekdays).
Support staff are not available at the weekends, though if you send an email, it will normally be read on
the following Monday morning.
If you need support on a bike purchased from our Cambridge outlet, please note that you should call our
Southend office on the number below.
Support articles and FAQ’s: www.wooshbikes.co.uk/?support
Email: [e-mail]
Telephone: [phone] (If there is no answer, leave a brief message and contact no. and someone will
call you back asap).
Support staff are available 10am to 5pm Monday to Friday.