Woosh Zephyr 2017 User manual

1
Sales: 01702 435566 — Support: 01702 684444 — E-mail: [email protected]
Zephyr 2017 Manual
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.

2
Thank you for buying a Woosh Zephyr (2017 Edition) electric bike.
Please read this manual completely before putting your bike
together and riding it. As well as instructions on assembly and maintenance it also contains es-
sential information that may affect your consumer rights.
The Woosh Ethos
Our aim is to supply decent quality electric bikes but at very affordable prices.
This inevitably means importing from China, selling direct rather than through dealers and working on
much lower profit margins than many of our competitors. It also means working hard with our suppliers to
constantly improve quality and ensure that each bike is checked before leaving us - not something all
mail order electric bike companies do.
There is however only so much we can offer within our price range.
We would for example like our bikes finished to German standards, with every nut and bolt fully tightened,
immaculate paintwork and superb quality plastic on things like handlebars and battery cases. But this alas
would also push the prices up to those of German bikes - starting at £1800 - which clearly we don’t
wish to do.
That said, we are always happy with sensible comments for future improvements, so please do email me
with feedback, good or bad.
I look forward to hearing from you.
Hatti Lee
[e-mail]

3
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 suciently experienced, ask a local bike shop
to do this for you. A typical fee for this would be around £35-£45
A full inspecon should include (but is not limited to):
 Checking that the brakes are set correctly and work properly.
 All nuts, bolts, major xings, spokes and cranks etc. are correctly ghtened.
 Both wheels are properly trued
 Headset/stem properly adjusted
 Cranks are ght
 Boom bracket properly adjusted
•Pedals, saddle and handlebars are correctly ed 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 oce
and do this for you.
Visit www.cycletechuk.com for a full naonal lisng.
The type of motor used on this model may become noisier over me, if this is the case, you will need to
periodically send your wheel in to be serviced. The cost of servicing the wheel is £25 plus return postage.
This servicing is not covered by the warranty.
If you need to remove the motor wheel for any reason, you must re-grease the cavity where the cable
enters the wheel, this is to prevent moisture from geng into the motor. Doing this this will extend the
life of the motor and will avoid potenally expensive servicing costs. See the rear of this manual for de-
tails on this procedure.

4
Unpacking:
Two people are required to unpack the bike. The carton should be kept upright at all times.
Remove the shipping straps, cut the tape seals and then remove any/all loose packaging if any, and then
lift the bike out of the carton, and immediately down to the floor, and engage the kick-stand to keep it up-
right. DO NOT destroy the carton as it may be needed if the bike has to be returned for any reason in the
future.
When unpacking and preparing your bike, be very careful to not stretch, pull or bend any of the
cables. This applies when folding the bike as well, ensure that any cables are not caught in any
way. With the bike out of the box, remove all of the remaining packaging and detach the pedals and
charger box from the bike. This model comes almost fully assembled meaning that there is very little to do
to complete the basic assembly of the bike.

5
Handlebars:
The handlebars just need to be rotated into the correct position and the two bolts indicated below-right
need to be tightened with a 4mm Allen key to secure them in place.
Warning:
It is critical to ensure that the handlebars are properly secured. If they were to rotate or otherwise move
unexpectedly during use, it could result in an accident and/or serious injury. If you have any doubts re-
garding the correct configuration of this part (or any other part of the bike), you should take your bike along
to your nearest bike shop and have them prepare it for you at your cost.
Once the height has been adjusted, the handlebars will likely need to be rotated within the clamp as well.
Loosen the four bolts on the clamp slightly with a 4mm Allen key, rotate the handlebars to the desired po-
sition and then re-tighten the bolts.
Once secured, you can then make some adjustments to suit. The handlebars can be brought upwards
and towards the rider, or lower and away from the rider. To do this you will need to loosen the bolt shown
below-left with a 5mm Allen key. When the handlebars are in the desired position, fully tighten the bolt to
secure them in place.

6
Seat-post/saddle:
To adjust the height of the saddle, simply open the clamp and then 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 on
the opposite side of the clamp to ensure that when the clamp is closed the seat-post is properly secured.
Adjust the thumb-screw as needed, there should be a reasonable amount of resistance in the clamp when
it’s being closed.
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. Also, if you force the pedals on to the wrong side
of the bike, it is very likely that they will come loose suddenly and unexpectedly.
The pedals can be identified in several ways: L or R is clearly visible on the pedal itself—see below-left. L
or R is also stamped onto the very end of the bolt, see below-right.
There are also grooves present on le pedal, that are not present on the right—see below.

7
Charging/locking the battery:
The battery will likely 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 on upper-left side of the frame towards the front of the bike, as
shown below. Lift the rubber cover to access the charging socket, ON/Off switch and USB socket (for
charging a smart phone or music player). Ensure that the charger is switched OFF at the mains be-
fore attaching the charger to the bike.
If you wish to charge the battery away from the bike, you will need to fold the bike first. To fold the bike,
you first need to lift the black catch—see below left, and then open the clamp—see below-right.
A full charge from flat can take up to around 8 hours. When re-fitting the battery, be careful not to push
the battery in too far, the black end piece of the battery should be flush with the frame. If it is not in the
correct position, you will not be able to lock the battery.
With the clamp disengaged, you can now fold the bike, this becomes easier the more times you do it, the
first few times you may find it a bit cumbersome. The bike folds in half and rests on the foot/plate at the
base of the frame. With the bike folded, you can now access the locking mechanism for the battery. Insert
the key and turn it anti-clockwise to unlock the battery, and then lift the silver handle and use it to pull the
battery from the frame. This should not require significant force, if the battery does not slide out fairly easi-
ly, check that it is properly unlocked before trying again.

8
Battery care:
The Zephyr comes with a modern light-weight lithium battery.
Some care is needed to ensure your battery performs at its best and lasts as long as possible. All batter-
ies age over time, meaning that the range will gradually decrease as the battery gets older, so to ensure
you get the most from your battery, follow the instructions below.
Charge the battery once or twice per week as needed, it is better to keep the battery topped up than to
allow it to run completely flat.
DO NOT charge the battery in extremely cold conditions. If the battery is not in regular use i.e. over the
winter, you should charge the battery for around 10 minutes every two to three weeks. This will slow the
aging process and will help the battery to last longer. When the bike is to be put back into service, fully
charge the battery to prepare it regular use.
General battery care:
Do not attempt to open the outer casing of the battery.
Do not attempt to repair the battery.
Do not immerse the battery in water.
Keep the battery away from children.
Do not drop, pierce or otherwise damage the battery.
Ensure the battery is not exposed to temperatures above 55 degrees Celsius or extreme humidity.
Do not use the bike in an environment where temperatures are below minus 5 degrees Celsius.
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 experienced and/
or are not absolutely sure about any aspects of your bike, you should take it to your nearest bike shop to
have it checked before riding it. Obviously the bike shop will you charge for this service. Woosh Bikes will
not reimburse you for these costs.
Before riding your bike, check the tyre pressures. The tyres should be inflated to approximately 50psi.
Check that all fixings and major components are tightened sufficiently. Check all nuts, bolts, rear carrier
fixings, crank-bolts, handlebars and seat-post/saddle etc.
You must also ensure that your brakes are working correctly before you ride the bike. If you need to ad-
just your brakes, refer to the “maintenance manual” that came with the bike. If you prefer, you can have
your local bike shop adjust them for you. The brakes are similar to those you would find on a regular non-
electric bike and so any bike shop should be able to adjust them for you. You would obviously have to pay
them for this service.

9
Riding the bike
Ensure that the master-switch on the battery is in the ‘ON’ position, see below-left. Then press (and hold)
the middle button on the display for a second or so. Press (and hold) the same button to turn OFF.
With the display now illuminated, the bike is now on and will provide assistance when ridden. Use the plus
(+) and minus (-) buttons to increase or decrease the amount of assistance given. The assistance levels
range from 0-5, 0 provides no assistance at all, then levels 1 through to 5 are used to determine the
amount of assistance provided, with level 5 giving the most assistance, and level 1 giving the least. There
are several other modes and features of the display that are covered in more detail towards the rear of this
manual, but the information given at this stage is just enough to get quickly up and running.
The bike will only assist you up to 15mph/25kph. Though of course you can use your own strength/power
to pedal beyond 15mph if you wish.
This bike features “start-assist”, meaning that when the minus (-) button is held, the bike will start moving
and will then hold steady at around 4mph. If you struggle with initially getting moving, this feature will help
get you started more easily. Once in motion, pedal the bike as you normally would and release the button.
The twist-grip cannot be used to start the bike from stand-still, use the “start-assist” feature as described
above if you need help to initially get moving. Once you have pedalled a short distance, the twist-grip will
become available should you wish to use it. You must pedal at least a short distance (a few metres) before
the twist-grip will function.

10
Riding the bike cont.
Your bike features an 8 speed Shimano rapid-fire shifter located on the right side of the handlebars.
To move up through the gears, PULL the upper lever/trigger with your index finger. To move down the
gears, PRESS the lower lever on the underside with your thumb.
The stiffness/travel of the forks can be adjusted to suit your weight (major reason), and/or riding style
(minor reason). The bigger the preload, the stiffer the spring, a higher preload is best for heavier riders
and/or for people who prefer a stiffer ride. Lighter riders should use less preload. Less preload will give
you a smoother ride, but the bike will dive more under braking. Turn the preload clockwise to stiffen, or
anti-clockwise to soften
Trigger/index finger
Thumb
You can also lock the front suspension, which is generally better for flat roads and hill climbing, and also
wastes less energy, whereas it’s better not to lock the suspension for rougher terrain and poorly main-
tained roads etc.
To lock the suspension, press down on the stanchion lever shown below-left, to unlock the suspension
once again, press the upper lever to unlock/release as shown below-right.

11
IMPORTANT:
LOOK AFTER SPOKES, TYRES AND KEYS!!
The vibrations on an electric bike can cause the fixings and also the spokes to become loose more quickly
than on a standard bike. You must maintain them (or have a local bike shop maintain them for you if it’s
something you cannot do yourself). If you do not regularly maintain your bike, you may damage the bike
and also there are likely to be safety issues for which Woosh Bikes will not be held liable.
Please read the following:
Your spokes will have been checked before despatch, but if you have a look, you will find some less tight
than others. This variation ensures the wheel is straight (or ‘trued’). If all the spokes were equally tight, or
all very tight, the wheel would not be straight. So it is normal that some spokes are tighter than others.
In future, check your spokes regularly, every two or three weeks if you ride daily, or once every couple of
months if you only ride occasionally. We normally supply a spoke tool (small round numbered metallic de-
vice) which comes in the same box as the battery charger.
How to check? Lightly ‘ping’ each spoke like a harp string with your index finger. If it feels very loose insert
the spoke key onto the nipple of the spoke in question, using the notch numbered 13. The nipple is the
metal part at the base of the spoke where it joins the wheel rim. Give it a quarter turn or so. Don’t over-
tighten the nipple as the spoke may then be too rigid and could snap during riding. If you’re not sure how
to do this, then have your local bike shop make these adjustments for you.
You can give your wheel a quick visual check by spinning it and making sure the brake pads are equal dis-
tances from the wheel when it spins and that it seems to spin straight and not wobble from side to side.
Get someone to help hold the bike if necessary. If the wheel is not true, then the wheel rim will likely rub
on the brake pads at various points as it rotates, use the spoke key to tighten or loosen the spokes at the
point where it rubs to bring the wheel back in to line. You may want to have this done at your local bike
shop if you are not experienced.
Also check your tyre pressures often (before each ride ideally), and inflate as required. The pressure
range of the tyres is printed on the side wall of the tyre, though we recommend inflating them to around 45
-50psi. For heavier riders, you may want to inflate them a little higher, but don’t go beyond 60psi.
These maintenance steps aren’t always needed quite as often on a standard bike but they are for an elec-
tric bike.
If you are not able to perform these checks yourself, you should have your local bike shop do them for you
at your cost.
Lastly, separate your keys and keep them in a safe place. We do not keep spares, and cannot pro-
vide duplicate keys at a later date.

12
Adjusting the brakes:
The Zephyr comes with disc brakes both front and rear. These are checked and set up before the bike is
dispatched but you must check that the brakes are working properly before you ride the bike.
See the maintenance manual for help on how to you adjust your brakes, but if you aren’t able to manage
this yourself, you should take it to your local bike shop and have them adjust them for you. Obviously you
would have to pay for this service.
Discs brakes do require a certain amount of bedding in, so be aware of this when you ride the bike for the
first few miles.
Essential maintenance:
See the “Maintenance Manual” for the full details of how to look after your bike.
The Zephyr is a low maintenance bike, however it is essential that you carry out some maintenance regu-
larly to ensure that your bike is both safe and going to last for years to come.
You must check your spokes as outlined earlier.
You must regularly check and tighten as necessary ALL nuts/bolts/fixings.
You must ensure that the handlebars are tight, if the handlebars are not checked and they work loose,
they could move suddenly and unexpectedly.
You must check that the saddle clamp is sufficiently tight and also that the saddle itself is properly secured
to the post. The bolt securing the seat to the post is on the underside of the saddle.
You must monitor the cranks, if they work loose or there is movement in the bottom bracket, do not contin-
ue to ride the bike until the issue has been resolved.
Failure to carry out essential maintenance on your bike on a regular basis could result in an injury,
for which Woosh Bikes Ltd will not be held liable.
Please ensure this is done to ensure your safety.

13
Display—Advanced features
To turn the bike/display On or Off, press and hold the middle button.
In its default mode when the display is first switched on, it shows the current level of assistance at the top-
right of the screen, the battery status along the top-left, and the current speed—as per the picture below.
To adjust the pedelec assistance level, use the (+) to increase the assistance and (-) to reduce the assistance. There are 5 levels
of assistance (1 to 5) and also a ‘0’ mode. Level ‘0’ will provide no assistance but allows you to keep the display on and use the
other features such as the trip computer etc.
The display is also capable of showing the following:
Trip—distance travelled on the current journey (will connue to record distance across mulple trips unless reset, see below).
ODO—total distance travelled since the bike was new.
Ridme—the length of me since the bike/LCD has been switched on.
AVG—the average speed of the current trip.
MAX—the maximum speed achieved during the current journey.
To switch between these modes, tap the middle buon to cycle through them. Aer a few seconds of showing the selected
info, the display will revert back to the default screen showing the current speed and pedelc level.
The advanced features are made available by pressing and holding both the plus (+) and minus (-) keys together.
Opon 1 - is used to reset the trip back to zero.
Opon 2 - is used to select whether to display the speed in Miles or Kilometres.
Making changes to opons 3, 4 or 5 will void your warranty with immediate eect.
To move through the items on the list, use (+) to move down the list and (-) to move up the list. Press the middle buon to
select the chosen opon, then use (+) or (-) to change the seng. Press and hold the middle buon to save changes and/or to
return to normal operaon.
The brightness of the backlight can be adjusted by pressing and holding the plus (+) key, there are two sengs, normal and
dimmer.

14
Woosh Bikes
DECLARATION OF CONFORMITY
Product name Commercial name(s)
Electrically power as-
sisted cycle
Woosh Sirocco Woosh Sundowner
Woosh Sirocco CD/L Woosh Big Bear LS
Woosh Big Bear Woosh Gale
Woosh Krieger Woosh Zephyr 2017 Ed.
Woosh Zephyr B Woosh Gallego
Woosh Pete Woosh Bermuda
Woosh Sant Ana/2 Woosh Bali
Woosh Sant Ana CD/CDL
Manufacturer, address
Made in China for Woosh Bikes Ltd
42-46 Queens Road, Southend-on-Sea, Essex, SS1 1NL, UK
The product (system) idened above is in conformity with the listed European Direcve(s).
The following table idenes 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 2006 L 157/24
Applicable Non Applicable
- Applied Standards
 EN 15194
 EN61000-4-2
 EN 55022
- Applied Standards
 EN 15194
- Applied Standards
 EN 15194
Date
01/01/2013
Signature Authorised representave
Director—Woosh Bikes Ltd
XX
X

15
© 2014 Woosh Bikes Limited
Woosh Support:
If you need to get in touch, our contact details are below.
It can sometimes be useful to see the issue you have, so if possible, send us a brief email with a couple of
photos illustrating the problem and we’ll get back to you as soon as we can (usually the same day).
Support staff are not available at the weekends, so any emails sent over the weekend will normally be re-
sponded to on the following Monday.
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 we will call
you back.