ROULIK BIKES USER S MANUAL E-BIKE

Transcription

1 ROULIK BIKES USER S MANUAL E-BIKE This manual contains important safety, assembly, operation and maintenance information. Please read and fully understand this manual before operation. Save this manual for future reference. LITHIUM TRANSENERGY LLP

2 LITHIUM TRANSENERGY LLP Page 1

3 INDEX Sl. No: Contents Page No: 1 Introduction 5 2 Safety First The Owner s Responsibility Rules of the road Helmet Reflectors 8 A Know your e-bike with electric details 8 A1 General Maintenance and safety advice 8 FigureA1.1: E-Bike part view 9 A2 Quick start guide 9 A3 Display 10 A3.1 Steps to install display 10 Figure A3.1: Installed LCD Display 10 A3.2 Display function overview 11 A3.3 Button Definition 11 A3.4 Basic operation 11 A3.5 Display interface 12 Figure A3.5.1: Display 1 interface 12 Figure A3.5.2: Display 2 interface 14 Figure A3.5.3: Display 3 interface 15 A3.6 Battery capacity indicator 15 A3.7 PAS Ratio 16 A3.8 Power Push Function (Walk Assist) 16 A3.9 Cruise function 16 A3.10 Backlight and headlights 17 A3.11 Motor Operating Power and Temperature 17 A3.12 Atmospheric temperature 17 A3.13 Single Data Clearing 17 A3.14 Set a startup password 18 A3.15 Error Code and Definition 19 A3.16 Motor operating temperature alarm 19 A4 Battery 20 LITHIUM TRANSENERGY LLP Page 2

4 A4.1 Installing and Removing the Battery 20 Figure A4.1: Battery installation procedure 20 A4.2 Charging the battery 21 Figure A4.2: Charger LED indication 21 A4.3 Taking care of your batteries 21 A4.4 Range and lifespan 22 A4.5 Battery Safety Instructions 22 A5 Motor 23 A6 CONTROLLER UNIT 23 A7 Throttle 23 A8 PEDAL ASSIST SYSTEM (PAS) 24 A9 E-Brake 24 A10 CONNECTION DIAGRAM SCHEMATIC 25 Figure A10: Electrical connection schematic 25 diagram B Know your e-bike with mechanical details 26 B1 Parts Identification 26 Table B1.1 Parts and Torque 26 Figure B1.1 Parts Assembly View 28 B2 Installation, Adjustment & Maintenance 29 B2.1 Getting Started 29 B2.2 Handlebar and Stem 29 Figure B2.2.1 Handlebar Components 30 Figure B2.2.2 Lock-on Grip Installation 30 B2.3 Saddle and Seat post 31 Figure B2.3.1 Saddle height setting 33 Figure B2.3.2 Micro adjust saddle 34 B2.4 Derailleurs 35 B2.4.1 Rear Derailleur Adjustment 35 Figure B2.4.1 Rear Derailleur Parts View 35 B2.4.2 Front Derailleur Adjustment 36 Figure B2.4.2 Front Derailleur Parts View 37 B2.5 Shift System 38 Figure B2.5.1 Lower gear combinations 38 Figure B2.5.2 Higher gear combinations 39 Figure B2.5.3 Medium gear combinations 40 LITHIUM TRANSENERGY LLP Page 3

5 B2.6 Brakes 40 B2.6.1 Disc Brakes 40 Figure B2.6.1 Disc brake part view 42 B2.6.2 Rim Brakes 42 Figure B2.6.2 V-Brake part view 43 B2.7 Wheel 44 B2.7.1 Quick Release Hub 44 Figure B2.7.1 Quick release hub part view 44 B2.8 Tire 45 Figure B2.8.1 Inflating the tire 46 B2.9 Crank arms and Bottom Bracket 47 Figure B2.9.1 Crank arms parts view 47 B2.10 Pedals 48 B2.11 Chain 48 B2.12 Suspension 49 B Front suspension 49 Figure B Suspension fork part view 49 B Rear suspension 50 Figure Rear suspension part view 50 B3 Lubrication 51 B4 Troubleshoot Chart 52 3 Warranty Lithium Transenergy Limited Warranty 53 LITHIUM TRANSENERGY LLP Page 4

6 1. INTRODUCTION Thank you for purchasing ROULIK E-bike and becoming a ROULIK family. We are sure that you will enjoy the ride. Your E-bike is equipped with electric motor, battery and control unit. For safety reasons, it is most important that you read this User Guide BEFORE you operate the bike. Improper handling can reduce its riding performance and most importantly, pose danger to your safety and health. 1.1 Owner s Bike Identification Mark Each Lithium bike has a Serial Number stamped into the frame. The Serial Number (1) can be found on the bottom of the crank housing as shown. Write this number in the cover page of this manual to keep it for future reference. If the bicycle is stolen, give this number and a description of the bicycle to the police. This will help them find the bicycle. 2. SAFETY FIRST 2.1 The Owner s Responsibility WARNING: This bicycle is made to be ridden by one rider at a time for general transportation and recreational use. It is not made to withstand the abuse of stunting and jumping. If the bicycle was purchased unassembled, it is the owner s responsibility to follow all assembly and adjustment instructions LITHIUM TRANSENERGY LLP Page 5

7 exactly as written in this manual, and any Special Instructions supplied and to make sure all fasteners and components are securely tightened. NOTE: Periodically check that all fasteners and components are securely tightened. If the bicycle was purchased assembled, it is the owner s responsibility, before riding the bicycle for the first time, to make sure the bicycle has been assembled and adjusted exactly as written in this manual, and any Special Instructions supplied and to make sure all fasteners and components are securely tightened. 2.2 Rules Of The Road WARNING: Failure of the rider to obey the following Rules of the Road can result in injury to the rider or to others. Obey all traffic regulations, signs, and signals. Always wear a bicycle helmet that meets safety standards. Ride on the correct side of the road and in a straight line. If you ride at night or at time of poor visibility: Purchase, install, and use a headlight and taillight. Make sure the reflectors of your bicycle are correctly positioned. Make yourself more visible to motorists. Wear light-colored or reflective clothing, such as a reflective vest and reflective bands for your arms and legs Use reflective tape on your helmet. Use extra caution in wet weather: Ride slowly on damp surfaces because the tires will slide more easily. Avoid these hazards to prevent loss of control or damage to your wheels: Be aware of drain grates, soft road edges, gravel or sand, pot holes or ruts, wet leaves, or uneven paving. LITHIUM TRANSENERGY LLP Page 6

8 Cross railroad tracks at a right angle to prevent the loss of control. Avoid unsafe actions while riding. Do not carry any passengers. Do not carry any items or attach anything to your bicycle that could hinder your vision, hearing, or control. Do not ride with both hands off the handlebar. Replace worn or broken parts immediately. If anything does not operate properly, discontinue use. 2.3 Helmet WARNING: ALWAYS WEAR YOUR HELMET WHEN RIDING THIS PRODUCT CORRECT INCORRECT Helmet should sit level on your head and low on your forehead. Adjust the strap sliders below the ear on both sides. Buckle the chin strap. Adjust strap until it is snug. No more than two fingers should fit between the strap and your chin. A proper fitting helmet should be comfortable and not rock forward/backward or side to side. LITHIUM TRANSENERGY LLP Page 7

9 2.4 Reflectors WARNING: For your own safety, do not ride the bicycle if the reflectors are incorrectly installed, damaged, or missing. Make sure the front and rear reflectors are vertical. Do not allow the visibility of the reflectors to be blocked by clothing or other articles. Dirty reflectors do not work well. Clean the reflectors, as necessary, with soap and a damp cloth. This user s manual is divided into two parts. First part describes all the electric components of the bicycle and second part describes the mechanical components. A. KNOW YOUR EBIKE WITH ELECTRIC DETAILS ROULIK E-bikes are packed with the following electrical items. Please ensure that you received all of it. 1. Battery unit with cells. 2. Controller cum battery holder. 3. Display Unit including switch. 4. Preinstalled motor. 5. Pedal assistant sensor (Preinstalled). 6. E-brake system. 7. All the required connecting wire and cables. A1. General Maintenance and safety Advice 1. Users of ROULIK E-bike should observe road and traffic regulations for the standard bicycle. 2. Please read this manual before riding the e-bike. 3. Ensure that the power switch on the handlebar is in Switch OFF position when the e-bike is not in use. 4. Always check that the front and rear brakes are working and LITHIUM TRANSENERGY LLP Page 8

10 the tyre pressures are correct before riding the e-bike. 5. Do not wash your bike with high jet stream when the battery unit is connected. 6. Do not submerge the battery in water. 7. Do not tamper with the electrical unit on your e-bike. This could endanger the rider and invalidate the warranty. Figure A1.1: E-Bike Part View A2. Quick Start Guide 1. Fully Charge the battery following the battery charging instructions given in this manual. 2. Adjust the height of the seat and handlebars o your preferred position ensuring that you do not exceed the height safety line indicated on the seat post. LITHIUM TRANSENERGY LLP Page 9

11 3. Install the battery unit to the holder which is fitted on the frame by clipping into the slot provided. 4. Long press, power button of the display to turn on the controller. 5. Press up button of the display to activate throttle and pedal assist. 6. Select the PAS range from 1-5 depend on your riding conditions 7. Enjoy your ride.. A3. DISPLAY This portion helps the user to understand and familiarize themselves with the display function, operation of the display so as to achieve the best out of the three (motor, controller and display) to improve electronic control performance of the electric motor. The installation, operation and parameter setting of the display are explained below. A3.1 Steps to install Display 1. Using the appropriate methods and fixtures, mount the LCD screen and button box onto the handlebar to the rider s desires. 2. While the vehicle is OFF, connect the necessary wires. 3. Check to make sure all connections are firmly attached. 4. Finally remove the protection film from the display. Figure A3.1: Installed LCD Display LITHIUM TRANSENERGY LLP Page 10

12 A3.2 Display Function Overview ROULIK e-bike display provides a variety of functions such as vehicle controls and vehicle status digitized displays to meet the trip demands. Trip time display (with displays of single trip time (TM) and total trip time (TTM)). Trip speed display (with display of real time speed (Km/Hr) and a single maximum speed (MXS) and a single average speed (AVS)). Trip distance display (with displays of a single trip distance (DST) and total trip distance (ODO)). 6Km/H power push ( ) function. Cruise function (CRUISE). Battery capacity indicator ( ). Real-time battery voltage (VOL) display. Motor power and temperature (MOTOR) display. Brake display ( ). Turn on backlighting and lights ( ). Environment temperature ( C or F) display. Data clearing. Fault code display. A3.3 Button Definition There are three buttons on the operating panel of the box, which are icons of button (UP), button (DOWN) and button (POWER). A3.4 Basic Operation On/Off LITHIUM TRANSENERGY LLP Page 11

13 To turn on or off, hold down button for 2 seconds. System will automatically shut down when vehicle is stationary and not in use for longer than five minutes. When powered off, the power consumption of the meter and controller is zero. A3.5 Display Interface Display 1: The meter is configured to enter this display on startup. Figure A3.5.1: Display 1 interface. The following are shown on display 1. Battery Capacity Indicator Single Trip Time (TM) LITHIUM TRANSENERGY LLP Page 12

14 Power Assist Real-Time Trip Speed (Km/H) Single Trip Distance (DST) 6Km/H Push Function Motor Operation Power Environment Temperature Backlight and Headlights Brake Status Cruise function (Cruise) Motor running temperature LITHIUM TRANSENERGY LLP Page 13

15 Display 2: To enter display 2, press the button whilst in display 1. The interface will display as shown below. Figure A3.5.2: Display 2 interface The following are shown on display 2 Total Trip Time (TTM) Total Trip Distance (ODO) Single Average Speed (AVS) Motor Operating Temperature Once the vehicle is in riding mode, after five seconds display 2 automatically reverts to display 1. LITHIUM TRANSENERGY LLP Page 14

16 Display 3: To enter display 3, press the button whilst in display 2. The interface will display as shown below. Figure A3.5.3: Display 3 interface The following are shown on display 3 Single Maximum Speed (MXS) Real-Time Voltage (VOL) Once the vehicle is in riding mode, after five seconds the single maximum speed will return to real-time speed (Km/H). A3.6 Battery Capacity Indicator When the battery capacity is over 70%, four bars from the battery indicator will be displayed. As the battery capacities drop, the bars will change accordingly. Once the power capacity is less than 15%, the battery indicator will be empty and show zero bars. If the power LITHIUM TRANSENERGY LLP Page 15

17 display frame flashes, it is due to voltage shortage where the controller will power off. A3.7 PAS Ratio Press button or button to adjust the power assist ratio, changing the motor output power. Range of power assist is between 1 and 5 (this can also be configured according to the rider s requirements), where one provides the lowest power and five provides the highest. When the PAS ratio is set to zero, the power assist function is off. A3.8 Power Push Function (Walk Assist) Users can use power push function for assistance in vehicle take-off. Hold button and the motor will provide power until vehicle reaches 6 Km/H. The meter assist function icon the function is active. By releasing the revoked. A3.9 Cruise Function When the vehicle is traveling above 7Km/H, hold button for 3 seconds to set the cruise function. The LCD will display "CRUISE" and "C" to indicate that the cruise function has been activated (as seen in the figure below). Brake or hold any button to revoke cruise. will flash indicating button, the function will be LITHIUM TRANSENERGY LLP Page 16

18 A3.10 Backlight and Headlights To turn on or off LCD backlight and vehicle headlights, hold button for 3 seconds. When this function is activated, the display will show sign to indicate it is on. A3.11 Motor Operating Power and Temperature Whilst vehicle is in use, real time feedback of input power to the motor is displayed on the display. The operating temperature of the motor can be displayed with supporting sensors installed in the inner motor to output the temperature for signal detection. When the motor operating temperature exceeds the warning value, temperature display flashes to alarm the rider. In this circumstance, the motor controller will offer the appropriate protection to motor. A3.12 Atmospheric Temperature Upon start-up, the environment temperature is displayed on the bottom right hand corner. The displayed figure may not accurately indicate the environment temperature immediately after start up, however will adjust within 10 minutes. A3.13 Single Data Clearing After five seconds of startup, whilst on display 1 hold both the button and the button simultaneously for 3 seconds. The single trip time (TM) and LITHIUM TRANSENERGY LLP Page 17

19 single trip distance (DST) will flicker. Press button and the record contents of both will be cleared. If there are no operations within five seconds of (TM) and (DST) flashing, the meter will return to display 1, and the original record content will be saved. A3.14 Set a Startup Password The user can enable or disable a 3 digit password for the display unit. It provides added security to the e-bike. To set the password follow the below steps. 1. Go to C9 window Turn on display, and within 5 seconds of startup simultaneously hold button and button for 3 seconds to enter general project settings. Press button 3 times to stop the blinking. When display ceases flashing, simultaneously hold button and button again for 3 seconds to enter P parameter settings. Press button 5 times to stop the blinking. When display ceases flashing, simultaneously hold button and button again for 3 seconds to enter C parameter settings. Now use button to navigate to C9. 2. Now, your LCD will display as follows: 3. C9 is the settings for password feature upon startup. The default value is 0. Refer to the following table for definition of the function. C9 Value Password Function 0 Disabled 1 Enabled LITHIUM TRANSENERGY LLP Page 18

20 4. When the feature has been enabled and confirming by pressing the button, the rider can set the 3 digit passcode starting from the left and sequentially progress to the right. Password value range is Select the values with the and button. button, and confirming the selection with the 5. Long press button to return to main display. A3.15 Error Code and Definition Error Code Display: When there are issues with the electronic control system of the vehicle, the meter will automatically display (flicker) a fault code. This cannot be removed until fault is fixed. Refer to error code & definition table for reference. button Error Code 01_info 03_info 04_info 05_info 06_info Definition Throttle abnormality Motor hall signal abnormality Torque sensor signal abnormality Axis speed sensor abnormality Motor or controller short circuited A3.16 Motor operating temperature alarm When the motor operating temperature exceeds the warning value, the motor operating temperature display flashes to alarm the rider, whilst the controller will provide the appropriate protection to the motor. If any of the error codes are displayed, please contact our customer care cell or nearest authorized dealer. LITHIUM TRANSENERGY LLP Page 19

21 A4. BATTERY Proper maintenance of the batteries will maximize their lifespan and available ride time. ROULIK Bikes warrants your new batteries from the date of purchase but only if properly cared for. Refer to the limited warranty for details. ROULIK Bikes uses Li-Ion (Lithium Ion) batteries in all of our electric bicycles. These are very user friendly types of batteries when cared for properly. The cell details of your ROULIK battery is as shown below but it may vary depending on the model. Type Li-Ion Brand LG Model Number of cells used 30 Rated battery voltage 36V Rated battery current 7.8Ah A4.1 Installing and Removing the Battery To remove the battery, unfasten the lock which is located along the battery s box. Remove the battery by pulling it out. To put the battery back into place, insert the battery along to the guide rail. Push it closely against the controller box. Fasten the lock. Figure A4.1: Battery installation procedure LITHIUM TRANSENERGY LLP Page 20

22 A4.2: Charging the Battery The battery s voltage is indicated by the 4 LED lights located on the side of the battery, and also on the display unit located on the handlebar. Your battery must be charged in an ambient temperature, on a nonflammable and dry surface, away from any sources of heat, humidity or flammable materials. Also, it must not be covered. Here are the steps to be followed when charging your battery: Step 1 Turn the battery off, the LED lights will be off Step 2 Plug the charger into the socket and then insert the charger s plug into the battery. Step 3 The charger s LED indicators lit up in the following manner: The red LED lights on: the battery is being charged.(a) The red LED light becomes green: the battery is full charged; you can unplug the charger. (B) Figure A4.2: Charger LED indication Use only the supplied charger for your bicycle. Using any other charger will damage the batteries and void your warranty. It takes 3-6 hours for the battery to be fully charged when using the standard charger that s supplied with your bike. A4.3: Taking Care of Your Batteries 1. Batteries should be fully charged immediately when they are received for the recommended charge times. LITHIUM TRANSENERGY LLP Page 21

23 Fully Charge Batteries Before First Use. 2. Charge batteries at least every 90 days until normal use is resumed. 3. Always store bicycle with fully charged batteries. 4. Never charge the batteries for more than 24 hours. 5. Always disconnect the charger from the wall outlet and bicycle when charging is complete (as indicated by the status on the charger) before storing the bicycle. 6. Do not store batteries below 10º Celsius and never allow batteries to freeze (below 0º Celsius). 7. Bikes are equipped with a 5 minute sleep mode. If no activity is detected after 5 minutes the bike will go into sleep mode to conserve the batteries. 8. Always be sure to turn the bike OFF when not in use via the Ignition/Battery Lock or the display switch. If you have left the power on or your product has not been charged for a long period of time, the batteries may reach a stage at which it will no longer hold a charge. 9. Be friendly to the environment. Be sure to recycle your old batteries at a local battery recycling center. Do not throw them in the garbage. 10. Frequent stops and starts will drain a battery more quickly than sustained, long-term use. 11. Even with proper care, rechargeable batteries do not last forever. Average battery life depends on use and conditions. A4.4: Range and Lifespan The distance the e-bike can cover with a single full charge of the battery ranges from 30 to 50 kilometers, as it depends on many different factors (degree of assistance used, topology, rider s weight, frequent stops/start-ups, hills, tire pressure, etc.). A4.5: Battery Safety Instructions Your bike's battery is an electric component made up of chemical elements. For your safety, it is imperative that you obey the following rules: LITHIUM TRANSENERGY LLP Page 22

24 Always handle with great care. Always keep it away from children. Do not take it apart or hit, pierce or submerge it. Keep it away from temperatures exceeding 60 0 Never create a connection between contacts located at the bottom of the battery. Never let the battery charge unattended. Never sleep near a battery that is charging. Only use the charger that came with the bike or that is supplied by the authorized dealer. If your battery is damaged, never use it and take it back to the dealer as soon as possible. A5: MOTOR ROULIK E-Bikes are equipped with geared motor mounted to the rear hub of the bicycles. It is a BLDC motor (Brushless Direct Current) with a voltage of 36V at a maximum output power of 250W and maximum output torque of 30Nm. A6: CONTROLLER UNIT ROULIK E-Bikes are coming with factory tuned controller unit. The user need not do anything with it. The controller unit is placed inside the battery box holder. Controller unit drives the motor and protects the motor and other components by avoiding high current to pass through the system. All the wired connections from other electric components are connected to the controller unit. Details of connections are mentioned in this manual later. A7: THROTTLE Throttles are equipped on some models of ROULIK E-Bikes. Throttles operate by rotating the throttle towards the rider much like a motorcycle. The more you twist the throttle, the faster the motor system will propel the bicycle. The throttle will actuate the motor in all the assist level (0-5). LITHIUM TRANSENERGY LLP Page 23

25 Once you have twisted the throttle all the way, the motor will accelerate you to its full speed of approximately 25Kmph. The speed of your E-Bike is limited to 25Kmph due to ARAI terms. A8: PEDAL ASSIST SYSTEM (PAS) Using the Pedal Assist function allows the rider to have the bike match their pedaling power at five levels of support (1-5), High giving you the most assistance. Once you start pedaling, a rotation sensor fitted to the Bottom Bracket of bicycle picks up your movement and power integrates seamlessly while you ride. Just pedal and go. Once you use the brakes or quit pedaling, the power is deactivated and you need to pedal again (lightly) to reactivate pedal assistance. It is possible to be in Pedal Assist Mode and use the Throttle for an extra boost. However, this will significantly drain battery power. Note: When only using the Throttle mode you will use more battery power in general and thus shorten range of the bicycle per charge. A9: E-BRAKE E-Brakes are a safety accessory that cuts power to your motor when you apply your bike s brakes. These are high quality long lasting brakes which use a hall-effect sensor and a small magnet instead of an electro mechanical switch. LITHIUM TRANSENERGY LLP Page 24

26 A10: CONNECTION DIAGRAM SCHEMATIC:The various components such as display, motor, throttle, etc. are connected to the controller unit via electrical cables. ROULIK E-Bikes are coming with all the connections made. User s are advised not to remove any of the connections. A schematic of the connection diagram is given below. Figure A10: Electrical connection schematic diagram LITHIUM TRANSENERGY LLP Page 25

27 B. KNOW YOUR EBIKE WITH MECHANICAL DETAILS B1. PARTS IDENTIFICATION The table below shows the different bicycle parts and the corresponding maximum torque which can be applied during the assembly. This will help with assembly, maintenance, and troubleshooting. Parts may vary depending on the model. Refer figure 3.1 to understand various parts mentioned in the table. Some parts and components may vary depending on the bicycle model you have. Table B1.1 Parts and Torque Sl. Part Name No: 1 Handle Grip Torque Nm (In-lb) 2 Front Brake Lever (55-70) 3 Brake Cable 4 Handlebar 5 Stem Binder Bolt ( ) 6 Handlebar Binder Bolts ( ) 7 Stem 8 Headset ( ) 9 Front Disc Brake Assembly 9A Disc Brake Caliper ( ) LITHIUM TRANSENERGY LLP Page 26

28 9B Disc Brake Rotor 10 Disc Brake Attaching Bolt 11 Tire 12 Rim 13 Spokes 14 Wheel Axle Nut (Quick Release Optional) 14A Wheel Axle Nut (Front) ( ) 14B Wheel Axle Nut (Rear) ( ) 15 Front Fork Sl. Part Name Torque No: Nm (In-lb) 16 Crank Arm 44.1 (390) 17 Pedal ( ) 18 Chain Wheel 19 Bottom Bracket Lock ring 33.9 (300) 20 Front Derailleur 21 Chain 22 Chain Stay 23 Rear Derailleur 24 Freewheel 25 Rear Disc Brake Assembly 25A Disc Brake Caliper ( ) 25B Disc Brake Rotor 26 Saddle (Seat) LITHIUM TRANSENERGY LLP Page 27

29 27 Seat Post Attaching Hardware ( ) 28 Seat Post 29 Seat Post Quick Release (60-80) 30 Frame 31 Front Suspension 32 Rear Suspension Figure B1.1 Parts Assembly View LITHIUM TRANSENERGY LLP Page 28

30 B2. INSTALLATION, ADJUSTMENT AND MAINTENANCE B2.1 Getting Started You re probably pretty excited to get out and ride. Don t forget to read this user manual before your first ride and it is compulsory to inspect all the parts before each ride. Your new bicycle was assembled and tuned in our factory and then partially disassembled for shipping. You may have purchased the bicycle already fully assembled and ready to ride or in the shipping carton in the partially disassembled form. The following instructions will enable you to prepare your bicycle for years of enjoyable cycling. The below mentioned tools are required for the assembly and adjustment of your bicycle. 1. Head screw driver mm, 4mm, 5mm, 6mm and 8mm Allen Wrench 3. Adjustable wrench or 9mm, 10mm, 14mm and 15mm open and box end wrenches. 4. A pair of pliers with cable cutting ability. B2.2 Handlebar, Stem and Grip 1. Turn the front fork to face forward (i.e.: the fork dropout is in the furthest forward position). 2. Using a 5 mm Allen wrench loosen the top cap bolt on the steerer tube and remove the top cap and bolt. Important! Do not remove the spacers. 3. Position the handlebar assembly over the steerer tube. 4. While holding the fork assembly in place, use a 6 mm Allen wrench and loosen the stem pinch bolts. Slide the handlebar assembly onto the steerer tube. LITHIUM TRANSENERGY LLP Page 29

31 Figure B2.2.1 Handlebar Components 5. Align and center the stem to the fork and wheel. Tighten the stem pinch bolts until there is no play between the stem and stem tube. Note: There should be a 3 to 5 mm (1/8" - 3/16") gap between the top of the stem and stem post. 6. Place the top cap onto the top of the steerer tube. Insert and tighten the top cap bolt until it is snug. Do not over tighten. 7. Using a 5 mm Allen wrench tightens the top cap bolt. Do the following checks to determine if the headset is properly set. Tighten or loosen the top cap bolt if necessary. Lift up the front wheel of the bicycle, if the wheel does not move freely left to right the headset is too tight. Hold the handlebar, close the brakes and rock the fork back and forth. If you hear a knock or clunking sound the headset is too loose. Follow the steps as mentioned below to install the grips provided with your bicycle. This procedure is for lockon grips. Please note, not all the bicycles are provided with lockon grips. Figure B2.2.2 Lockon Grip Installation LITHIUM TRANSENERGY LLP Page 30

32 1. Clean the handlebar surface. 2. Slide the lockon grip over the handlebar as far as it can go. Note: Rotate the clamp so the clamp screws are on the underside of the handlebar. Figure Adjust the grip to how you want it to feel. 4. Using a 2.5 mm Allen wrench tighten the clamps on both ends of the lockon grip. Check the grip is securely attached and does not rotate or slip. B2.3 Saddle and Seat Post The saddle supports most of your weight on the bicycle. It also controls the extension of your legs and the position of your body on the bicycle. The saddle is connected to the frame by the seat post and seat post clamp bolt. The seat post and saddle clamp bolts or quick release seat clamp controls the adjustment of the saddle. LITHIUM TRANSENERGY LLP Page 31

33 1. Unlock the quick release lever and insert the seat post into the seat tube. 2. Adjust the seat height up or down until the rider feels they have control of the bicycle and is comfortable. 3. Close the quick release lever and lock the seat in place. To adjust the height of the saddle 1. While someone holds the bicycle, sit on the saddle without shoes. 2. Move the quick release lever to OPEN position. LITHIUM TRANSENERGY LLP Page 32

34 3. With the crank arms parallel to the seat tube, put your heel on the bottom pedal. Extend the seat post until your extended leg is straight as in figure B When you wear shoes there will be slight bend on your knees as shown in the figure B Make sure the minimum insertion marks on the seat post (Figure B2.3.1) do not go past the top of the seat clamp and is not visible. Figure B2.3.1 Saddle Height Setting To adjust the saddle position The saddle can be moved forward or backward along the seat post to add comfort and to adjust the distance from the handlebar. 1. Place the bottom plate on the seat post. Be sure the holes in the LITHIUM TRANSENERGY LLP Page 33

35 bottom plate and the holes in the seat post are aligned. 2. Place the washer on the hex bolt and insert the bolt through the bottom hole of the pillar seat post and bottom plate. 3. Place the rails of the seat into the grooves of the bottom plate. 4. Place the top plate over the top of the seat rails. The hex bolt should be inserted through the hole in the top plate. 5. Insert the square nut onto the hex bolt and tighten completely. Figure B2.3.2 Micro adjust saddle LITHIUM TRANSENERGY LLP Page 34

36 B2.4 Derailleurs Although the derailleurs are initially tuned and adjusted at the factory, you will need to inspect and re-adjust before riding the bicycle. B2.4.1 Rear Derailleur Adjustment To adjust the smallest sprocket position 1. Move the chain to smallest rear sprocket and largest front chain ring. 2. Loosen the cable clamp bolt until it is free. (See figure 4.4.1) 3. Check whether the smallest sprocket, chain and both derailleur pulleys are in alignment. 4. If they are not in alignment, turn the High limit screw (See figure 4.4.1) until they are aligned. 5. While pulling the cable, move the shift lever to smallest sprocket position. 6. On the shift lever turn the barrel adjuster fully clockwise. On the rear derailleur turn the barrel adjuster fully clockwise, then turn one round counter-clockwise. 7. Pull the derailleur cable tight, and tight the bolt with Nm (44-60-In-Lb) Figure B2.4.1 Rear Derailleur Parts View LITHIUM TRANSENERGY LLP Page 35

37 To adjust the largest sprocket position 1. Turn the low limit screw (See figure 4.4.1) until the derailleur can move freely. 2. Carefully move the chain to largest sprocket and smallest chain ring position. 3. Move the rear derailleur pulleys in alignment with the largest sprocket. 4. Turn the low limit screw clockwise until it doesn t turn easily. To align the index system 1. Move the chain to largest chain ring and smallest sprocket position. 2. Turn the rear shifter to one click. 3. Check whether the chain shifted to second smallest sprocket. 4. If the chain does not change gear or if the chain makes noise, turn the barrel adjuster slightly counter clockwise. 5. If the chain shifted to third smallest sprocket, turn the barrel adjuster clockwise until the derailleur pulleys align with second smallest sprocket. Note: If the derailleur cannot be adjusted with these steps, derailleur hanger may be out of alignment. In this case, contact our Customer Care Cell or take your bicycle to the Authorized dealer. B2.4.2 Front Derailleur Adjustment The front derailleur has two adjusting screws, Low limit screw and High limit screw. The low limit screw limits how far the front derailleur and chain move towards the frame. The high limit screw limits how far the front derailleur and chain move away from the frame. Setting the low limit screw 1. Shift the chain onto third largest rear sprocket and smallest front chain ring. 2. Turn the lever barrel adjuster all the way in. (See figure 4.4.2) 3. Loosen the cable clamp nut. LITHIUM TRANSENERGY LLP Page 36

38 4. Turn the low limit screw so the left inside edge of chain guide and chain just do not touch. 5. Remove the slack from the cable wire and tighten the Nut of the cable clamp. Setting the high limit screw 1. Shift the chain onto largest front chain ring and smallest rear sprocket. 2. Turn the high limit screw (See figure B2.4.2) so that right inside edge of chain guide and chain just do not touch. 3. Shift through every gear, using the barrel adjusters to fine tune each transition. The barrel adjuster for the front derailleur is located on the front shifter where the cable comes out of the shifter. Clockwise will loosen the cable tension and direct the chain closer to the frame while counter clockwise will tighten the cable tension and direct the chain away from the frame. Figure B2.4.2 Front Derailleur Parts View LITHIUM TRANSENERGY LLP Page 37

39 B2.5 Shift System A shift lever controls the front and rear derailleur to change to gears from one to another. Before each ride, check that the shift levers are firmly attached to the handlebar. Check the operation of shift lever by inspecting derailleur. The position of shift levers can be adjusted on the handlebar. The number of gears on a bicycle varies depending on the type and model. There is no correct gear to ride the bicycle. The correct gear is the one that is comfortable to you. To select a gear or sprocket combination while riding While pedaling, shift the chain onto different front and rear sprocket combinations. You will feel a difference in the rhythm and ease of pedaling. Shift the chain to the gear that allows you to pedal at a rhythm and effort that is comfortable to you. When riding uphill or against the wind, you may wish to keep the chain on the smallest front sprocket (A) and shift the chain on the rear sprocket cluster (B). (See figure B2.5.1) Figure B2.5.1 Lower gear combinations LITHIUM TRANSENERGY LLP Page 38

40 These are the lower gear combinations. They allow you to pedal easier and at a faster rhythm, but with less distance traveled per pedal revolution. For the best performance in this case, do not use the smallest rear sprocket (C). Figure Higher gear combinations When riding downhill or with the wind, you may wish to keep the chain on the largest front sprocket (D) and shift the chain on the rear sprocket cluster. (See figure B2.5.2) These are the higher gear combinations. They allow you to pedal harder and at a slower rhythm, but with more distance traveled per pedal revolution. For the best performance in this case, do not use the largest rear sprocket (E). On bicycles with three front sprockets, you may wish to keep the chain on the middle front sprocket (F) and shift the chain on the rear sprocket cluster. These gear combinations are middle range which overlaps some of the higher and some of the lower gear combinations. LITHIUM TRANSENERGY LLP Page 39

41 Figure Middle gear combinations B2.6 Brakes The brake system allows the rider to stop or slow down the bicycle and is essential for the safety of rider. The rider must ensure both rear and front brakes are fitted and working properly before each ride. If not, we recommend to adjust or refit it as given in this manual. We highly recommend to consult the Customer Care Cell or Authorized dealer for the brake adjustment. There are different types of brakes. Disc brakes and V brakes are some of them. The type of brake used may vary depending on the model you have. B2.6.1 Disc Brakes Disc brakes are sharp, Keep fingers away from the brake caliper and rotor. If fingers contact the disc brake while rotating serious injury may occur. LITHIUM TRANSENERGY LLP Page 40

42 Adjusting the disc brake A) Center the wheel 1. Rotate the wheel and look at the gap between the rim and fork. If the gap is uneven, loosen the axle nuts and adjust until the wheel and disc rotor are centered. B) Realign the caliper body 1. Using a 5mm Allen wrench, loosen the two centering adjustment screws. Adjust the caliper body until the gap between the disc rotor and the brake pads in the caliper body is as shown in the figure B Then tighten the centering adjustment screws. C) Center the b rake pads 1. Using a 5mm Allen wrench, turn the Brake pad adjusting screw (Figure B2.6.1) to move the brake pads. Clockwise rotation will move the brake pads towards disc rotor and counter-clockwise rotation away from the disc rotor. 2. Adjust the pad until the gap between disc rotor and pads are even on both side and is approximately 1/32 inch. D) Adjusting the cable tension 1. At the caliper body or brake lever, slightly loosen the jam nut next to the adjustment barrel. 2. Turn the adjust barrel to adjust the cable tension. 3. Turning clockwise will loosen the cable tension and counterclockwise turning will tighten the cable tension. When you have the brake tension you want then tighten the jam nut. LITHIUM TRANSENERGY LLP Page 41

43 Figure B2.6.1 Disc brake part view B2.6.2 RIM BRAKES (V BRAKES) In rim brakes brake pads apply pressure to the rim. The pressure is controlled by a hand lever that is connected to the brake by a cable. A) To adjust the alignment of brake pads 1. Loosen the pad clamp bolt (Figure B2.6.2). 2. Align the brake pads and tighten the clamp bolt with Nm (40-60 In-Lb). 3. Make sure the brake pads engage the rim at ninety degree angle and the pads do not touch the tyre. LITHIUM TRANSENERGY LLP Page 42

44 Figure B2.6.2 V Brake Parts View B) To adjust the clearance between brake pad and rim 1. Turn the barrel adjuster (Figure B2.6.2). 2. When you turn the barrel adjuster clockwise, it will increase the clearance between brake pad and rim. And when you turn it counter-clockwise it will decrease the clearance between pad and rim. 3. If you cannot adjust the clearance with barrel adjuster take your bicycle to our Authorized dealer or contact our Customer Service Unit. LITHIUM TRANSENERGY LLP Page 43

45 B2.7 Wheels The wheels hold the rider up when riding and allow him to roll along smoothly. Its inspection and adjustment are important for the safety. Wheels include wheel hub, spokes and rim. Common types of wheel attachment devices are Quick release hub and threaded axle and nut. In this manual we illustrate the adjustment of Quick release hub only. Because other type is very common and ROULIK use mostly Quick release hubs in their models. B2.7.1 Wheel Installation Quick Release Hub Wheel installation with a quick release hub is very easy and anybody can do it. This mechanism will help to remove the front and rear wheel for easy transportation and for maintenance purpose. The steps are described below with figure for representation. Figure B2.7.1 Quick release hub parts view LITHIUM TRANSENERGY LLP Page 44

46 To install wheel, 1. Insert the wheels into frame and forks. 2. On models with disc brakes make sure the disc goes between the pads at the caliper. 3. Make sure the quick release skewers are tight. 4. Quick release should be done up so there is strong resistance to the lever when you close it. 5. Ensure the lever is tucked in against the frame and fork, not sticking out. To remove a wheel 1. Release the quick release lever, move it to the OPEN position. 2. For the front wheel, loosen the tensioning nut, turn it three rounds. 3. Move the wheel out of the frame or fork. B2.8 Tires Frequently check the tire inflation pressure because all tires lose air slowly over time. For extended storage, keep the weight of the bicycle off the tires. Do not use unregulated air hoses to inflate the tire/tubes. An unregulated hose can suddenly over inflate bicycle tires and cause them to burst. Replace worn tires immediately. WARNING: Do not ride or sit on the bicycle if a tire is under inflated. This can damage the tire, inner tube and rim. Inflating the Tires: 1. Use a hand or a foot pump to inflate the tires. Service station meter-regulated air hoses are also acceptable. 2. The maximum inflation pressure is shown on the tire sidewall. LITHIUM TRANSENERGY LLP Page 45

47 If two inflation pressures are on the tire sidewall, use the higher pressure for on- road riding and the lower pressure for off-road riding. The lower pressure will provide better tire traction and a more comfortable ride. Figure B2.8.1 inflating the tire Before adding air to any tire, make sure the edge of the tire (the bead) is the same distance from the rim, all around the rim, on both sides of the tire. If the tire does not appear to be seated correctly, release air from the inner tube until you can push the bead of the tire into the rim where necessary. Add air slowly and stop frequently to check the tire seating and the pressure, until you reach the correct inflation pressure (See figure B2.8.1). LITHIUM TRANSENERGY LLP Page 46

48 B2.9 Crankarms and Bottom Bracket The crankarms connect the pedals to the bottom bracket. They transmit power from the rider to the rear wheel. The bottom bracket is the bearing system that allows the crankarms to turn in the frame. To check the crankarms Figure B2.9.1 Crankarms parts view Both crankarms (A) are tightened to spindle (B) at the factory. Each month during maintenance make sure the crankarms have not loosened. If loose, tight them or have them tightened by our Authorized dealer. Tightening torque required is Nm(395 In-Lbs). LITHIUM TRANSENERGY LLP Page 47

49 To check the bottom bracket 1. Lift the chain from the chainrings. 2. Turn the crankarms so that they are parallel to the seat tube. 3. Try to move the crankarms towards and away from the seat tube. 4. Turn the crankarms. If the crank feels or sounds loose, the movement stops suddenly or you hear a grinding noise, do not ride your bicycle. The adjustment of the bottom bracket requires special tools and training. Take your bicycle to our nearest Authorized dealer for the maintenance. B2.10 Pedals Pedals hold the rider s feet so that he can rotate the cranks. To install the pedals 1. Apply small amount of grease to each pedal threads. 2. Install right pedal ( R located on pedal axle or spindle) with pedal wrench by threading into the drive side crank arm in clockwise direction (for reference this is the right side of the bike if you were sitting on the saddle). 3. Install left pedal with pedal wrench by threading into the nondrive side crank arm in a counter clockwise direction. B2.11 Chain Chain connects the chainrings (crankarms) to the rear wheel. It transmits the crank rotation to rear wheel. For bicycles with rear derailleur, the chain tension need not be inspected. The derailleur automatically adjusts the chain tension. But, for bicycles without rear derailleur correct chain tension is required to prevent chain from falling off. LITHIUM TRANSENERGY LLP Page 48

50 Use neutral detergent to clean the chain. Do not use alkali-based or acid based detergent such as rust cleaners as it may result in damage and/or failure of the chain. B2.12 Suspension Bicycle suspension system includes front suspension and rear suspension. It may vary depends on the model. The suspension lets the wheels to move up and down to absorb small bumps while keeping the tire in contact with the ground for better control. It also helps the rider and bike to absorb large amount of shocks when landing jumps. B Front Suspension Common type of front suspension used is suspension fork. The bottom part of the fork, which holds the wheel, fits over the tubes that connects the fork to the frame. When the fork moves up (when the bike hits a bump), the spring gets compressed and the piston forces fluid through the orifice. Figure B Suspension fork part view LITHIUM TRANSENERGY LLP Page 49

51 Prevent or reduce scratches to the stanchions. If these get nicked from a rock or tool, the rough edge can tear up the dust seal and bushings as it slides past, diminishing the life and performance of the suspension. Clean the stanchions after every ride with a soft cloth and mild cleaning solution, flossing around the tube and down to the seal in the top of the lowers. Note: Your suspension fork may have a lockout option (marked as external compression adjustment), which will allow the rider to lock the front suspension action for a faster road riding. B Rear Suspension Rear suspension is only available on full suspension mountain bikes. And is commonly referred as rear shock. You can adjust the suspension, as you prefer for a softer or a firmer ride. Figure B Rear suspension part view LITHIUM TRANSENERGY LLP Page 50

52 WARNING: Make sure there are at least two threads showing (C) above the adjusting nut (A) so the shock does not come loose (See figure B2.12.2). To adjust the suspension 1. For a softer ride, turn the adjusting nut (A) clockwise, so the suspension spring (B) is compressed less. 2. For a firmer ride, turn the adjusting nut (A) counter clockwise, so the suspension spring (B) is compressed more. B3. LUBRICATION Table below mention the type and frequency of lubrication for different parts of the bicycle. Refer this table before lubricating each part What When How Pedals every six months Put four drops of oil where the axles go into the pedals. Chain every six months Put one drop of oil on each roller of the chain. Wipe all excess oil off the chain. Shift Levers never Do not lubricate the shift levers. Derailleurs every six months Put one drop of oil on each pivot point of the derailleurs. Brake Levers every six months Put one drop of oil on the pivot point of each brake lever. Cantilever Brakes every six months Put one drop of oil on the pivot point of each cantilever brake. Brake and cable every six months Put four drops of oil into both ends of each cable. Allow oil to soak back along the cable wire. LITHIUM TRANSENERGY LLP Page 51

53 What When How Rear Sprocket Cluster every six months Lay the bicycle on its left side. Slowly turn the rear wheel clockwise. Put four drops of oil in the crack between the rear sprockets (which are stationary) and the freewheel body (which is turning clockwise). Shock Fork every six months Lift up the rubber fork boot and dab a small amount of grease on the fork leg just above the plastic bushing. Spring Shock never Do not lubricate the spring shock. B4. TROUBLESHOOT CHART PROBLEM If the chain falls to the crank side. If shifting is difficult from the intermediate chain ring to the largest chain ring. If shifting is difficult from the intermediate chain ring to the smallest chain ring. If there is interference between the chain and the front derailleur inner plate at the largest chain rings. If there is interference between the chain and the front derailleur outer plate at the largest chain rings. TROUBLESHOOT Tighten the top adjustment screw clockwise (about 1/4 turn). Loosen the top adjustment screw counterclockwise (About 1/8 turn). Loosen the low adjustment screw counterclockwise (About 1/4 turn). Tighten the top adjustment screw clockwise (about 1/8 turn). Loosen the top adjustment screw counterclockwise (About 1/8 turn). LITHIUM TRANSENERGY LLP Page 52

54 If the intermediate chain ring is skipped when shifting from the largest chain ring. If there is interference between the chain and front derailleur inner plate when the rear sprocket is shifted to the largest sprocket when the chain wheel is at the intermediate chain ring position. If the chain falls to the bottom bracket side. If the lever is stiff when shifting from the intermediate chain ring to the largest chain ring Loosen the outer casing adjustment barrel counterclockwise (1 or 2 turns). Tighten the outer casing adjustment barrel clockwise (1 or 2 turns). Tighten the low adjustment screw clockwise (about 1/2 turn). Loosen the top adjustment screw counterclockwise (about 1/4 turn). 3. WARRANTY 3.1 LITHIUM Transenergy Limited Warranty Part or model specifications are subject to change without notice. This Limited Warranty is the only warranty for your Lithium Transenergy LLP. Product. There are no other expressed or implied warranties. This Limited Warranty extends only to the original consumer and is not transferable to anyone else. Warranty registration is required. Bike registration must be done before 1 month of the date of purchase through or warrant card is required. Limited warranty covers all parts of the bicycle. LITHIUM TRANSENERGY LLP Page 53

55 This Limited Warranty is effective only if: 1. Bicycle is registered in the website within 1 month of purchase date. 2. Bicycle is completely and correctly assembled. 3. Bicycle is used under normal conditions for its intended purpose (see the following section for excluded activities). 4. Bicycle receives all necessary maintenance and adjustments. 5. Bicycle is used for general transportation and recreational use only. What is not covered by this Limited Warranty? This Limited Warranty does not cover normal wear and tear, normal maintenance items, or any damage, failure, or loss that is caused by improper assembly, maintenance, adjustment, storage, or use of the bicycle. This Limited Warranty will be void if the bicycle is ever: 1. Used in any competitive sport. 2. Used for stunt riding, jumping, aerobatics or similar activity. 3. Installed with a motor other than Lithium recommended/supplied electric kit or modified in any other way. 4. Ridden by more than one person at a t i m e. 5. Rented 6. Used in a manner contrary to the instructions and warnings in this user s Manual. 7. Owner does not have either of warranty registration card or online bike registration. For how long does this Limited Warranty last? 1. The motor is warranted for 1 year from the date of purchase. 2. Battery is warranted for 2 years. For any additional warranty contact customer care. LITHIUM TRANSENERGY LLP Page 54