More Power To The Pedal Owner s Manual Register your Byocycles electric bike to claim your Five year extended warranty absolutely free by completing the form on our website www.byocycles.com SEPTEMBER 2017
Introduction Thank You For Choosing A Byocycle Electric Bike. To ensure your safety when riding, please read this manual carefully before you make your first journey. The dealer you have purchased your ByoCycle from will have performed a pre delivery inspection (PDI). This can be located on page 21 of this manual. Before riding your ByoCycle, it is advisable to check your tyres are the right pressure and your brakes are in good working order. Both of these will affect the quality of your ride. Please be aware that in adverse weather conditions the braking and tyre performance will decline, so please take extra care. When riding your ByoCycle please observe the highway code, this is not only for your safety but also the safety of other road users. When cycling we recommend wearing a helmet and high visibility clothing. We advise to use the bike lights at all times. By following the steps laid out in this manual, you will prolong the usage of your Byocycle as well as increasing your overall enjoyment. We wish you many happy miles of cycling. Regards The ByoCycles Team Page 2
Table Of Contents Contents...3 Legal Information...4 Getting to Know Your Bike...6 Control and Equipment... 10 Battery Information... 12 Battery Care... 14 Looking After Your Bike... 16 Trouble Shooting... 18 Warranty... 19 Extended Warranty... 21 Pre Delivery Inspection... 22 Service Schedule... 23 Page 3
Legal Information EU Declaration of Conformity The Manufacturers authorised representative ByoCycles Ltd, 53 Kent Road Southsea, Hampshire, PO5 3HU. United Kingdom of Great Britain Tel: +44 (0) 2392 88362 Hereby confirms for the product, Product name: Year of construction: 2016 ZEST, ZEST+, IBEX, IBEX+, TORNADO, CHAMELEON LFD, CHAMELEON FDXL, CITY SPEED, BOXER BYO-16-ZES, BYO-16-ZESCD, BYO-16-IBX, BYO-16-IBXCD, BYO-16-FDH, BYO-16-LFD, BYO-16-FDXL, BYO-16-MTF, BYO-16-MTFXL The Conformity with all applicable directives from the guideline: General Product Safety Directive 2001/95/EC Machinery Directive 2006/42/EC LVD Directive 2014/35/EU EMC Directive 2014/30/EU ROHS Directive 2011/65/EU The following harmonising Standards were applied to the product: Technical documentation by: DIN EN 15194: Bicycles electrically power assisted cycles EPAC bicycles. ByoCycles ltd, 36 New Lane Havant, Hampshire, PO9 2JL United Kingdom of Great Britain I hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications. The unit complies with all applicable Essential Requirements of the Directives. Zack Pollard Date 22/12/2015 Brand Development Manager Page 4
Legal Information In Great Britain (excluding Northern Ireland), if you re 14 or over you don t need a licence to ride an electric bike. Nor will they need to be registered, taxed or insured. Electric bikes meeting the requirements are called electrically assisted pedal cycles (EAPCs). They can be 2-wheeled bicycles, tandems or tricycles. Your Byocycles Electric Bike meets or surpasses all of the following regulations. EAPC Requirements The requirements are: The bike must have pedals that can be used to propel it The electric motor shouldn t be able to propel the bike when it s travelling more than 15.5mph The motor shouldn t have a maximum power output of more than 250 watts It must also display one item from each of the following: The power output or manufacturer of the motor The battery s voltage or maximum speed of the bike The bike cannot be propelled past 6km/h without human input Where You Can Ride An EAPC If a bike meets the EAPC requirements it s classed as a normal pedal bike. This means you can ride it on cycle paths and anywhere else pedal bikes are allowed. Use On Public Roads Before riding your ByoCycle, ensure you are familiar with the road laws of your specific country, observing the highway code at all times. Pedelecs fall under the jurisdiction of the same EU laws as bicycles. Pedelecs are also subject to the same laws as bicycles when using cycle paths. Page 5
Getting to Know Your Bike Your bicycle has been designed to do the following things: CHAMELEON TORNADO - On road use, commuting, leisure (excluding off road use). CHAMELEON LS - On road use, commuting, leisure (excluding off road use). CHAMELEON FDXL/XL/BOXER - On road use, commuting, leisure (including light off road use, canal paths, forest paths). ZEST/ZEST+ - On road use, commuting, leisure (including canal paths and unsealed roads). IBEX/IBEX+ - On road use, commuting, leisure (including light off road use, canal paths, forest paths, unsealed roads). CHAMELEON FD/CITY SPEED - On road use, commuting leisure (excluding off road use). Chameleon TORNADO Chameleon LS Chameleon FDXL ZEST ZEST+ IBEX IBEX+ Page 6
Getting to Know Your Bike ZEST Models Pannier Rack Saddle LCD Display Battery Handle Bar Adjustment System LED Display ZEST (Left Hand Side Of Handlebars) Stem Height Adjusting System Seatpost Motor (Zest+ Model) Front Light Gear Cable Motor (Zest Model) Pedal Power Chain Switch Derailleur Chainwheel IBEX Models Display Inner Tube Valve Fork Reflector Disk Brake Handlebar Brake Lever Saddle Seat Post Battery Motor (Ibex Model) Motor (Ibex+ Model) Deraileur Chain Chainwheel Pedal Brake Fork Tyre Page 7
Getting to Know Your Bike Folding Models The same basic components for TORNADO, LS, FD, CITY SPEED, XL, FDXL and BOXER. Display Saddle Handlebar Brake Lever Folding Stem Rear Carrier Motor Seat Post Frame Clamp Front Light Front Fender Rear Fender Crank Chainwheel Tyre Deraileur Chain Chainwheel Pedal Brake Fork Tyre Cockpit Parts Identification Your ByoCycle comprises of various components you should take note of. These vary from items that affect safety to the bike s operational features. The image below lists the equipment for the various styles of LED Specification bikes. Brake Lever Display - Assistance Level & Light Control Bell Brake Lever Grips Page 8 Height Adjustment Stem Clamp Gear Shifter Throtle (Pre 2016)
Getting to Know Your Bike DHMC LCD LCD Screen Operation From top to bottom (buttons) 1: Long press = Turn power on/off Short press = turn light on/off 2: Assistance/menu up 3: Assistance/menu down. 1 2 3 Bafang LCD Headlight On/Off Mode Down Up Full LCD operating instructions available on our website. www.byocycles.com Page 9
Controls And Equipment LED Display The LED display is fitted to lefthand side of the handlebars. This display will allow you to operate the front light as well as the power input for the motor. Using the MODE button you can scroll through the amount of assistance you wish to receive from the motor. This is indicated by the 5 LED Lights. Pedelec Control Your ByoCycle has a pedelec control, this means the motor will provide assistance whilst you pedal. To operate the pedelec function, press the button on the LED display and start pedalling. To control the assistance level press the MODE button on the LED display which will cycle through the assist levels. Lights Your ByoCycle is fitted with front and rear lights. The front light is powered by the main Lithium-Ion battery pack, and the rear light is powered by standard AA batteries. To operate the front light, press the Light button on the LED display. To operate the rear light, press the Light Switch on the underside of the light unit itself. Gears Your ByoCycle uses Shimano 6-21 speed gear system, this gives you a range of gears to get you up hills as well as down them. The gears are operated by the indexed shifter on the right hand side handlebars. i To improve your riding experience, always ensure you are in the optimum gear when you are going up-hill or when you have come to a stop at a junction. Being in the correct gear will enable you to get going again easier. Dérailleur gears are not designed to be changed when the bicycle is stood still. Brakes The brakes fitted to your ByoCycle are cable operated V-style brakes or disc brakes. The brake levers are fitted with motor cut-out switches. The moment pressure is applied to the brakes, even lightly, the motor will cut-out. The Ibex+ comes equipped with hydraulic disc brakes. Motor cut out cable Cable guide Ferrules Please contact your local Byocycles dealer for more advice. Page 10
Controls And Equipment Manifold Wire/Harness The manifold wire is a great way to simplify the service and replacement of electronic components on your ByoCycle. On the FD, LS, FDXL, ZEST and IBEX the electrical components on the handlebars filter into one wire and run back to the control box. In the event your bicycles electronics do not appear to be working correctly, we strongly recommend seeking advice from your ByoCycle specialist before attempting to work on the bike yourself. A simple check you can do, is to check the plug and play connections have not come apart, as shown below. Handlebar Adjustment We recommend that you refer to your Byocycles Specialist to adjust the handlebars for comfort and safety before leaving the premises if an ajustment is required. WARNING! Do not extend the seat post beyond its maximum height, this can cause failure without warning, resulting in serious injury to the rider and fellow road users. Wheel Removal In the event you need to remove either or both wheels, you will need to undo the wheel nuts using a spanner/socket. If your bike is fitted with V-Style brakes, you will need to disconnect the brakes to remove the wheel, this can be done by undoing the brake cable clamp on the right hand brake arm. Please make sure the brakes are re-connected before riding again. When removing the motor wheel ensure you disconnect the motor wire at the junction point half way between the wheel and the control box. When reconnecting ensure that the arrows on both sides of the connector matchup. Damage can be caused if the bike is powered on with the arrows misaligned. Page 11
Battery Information CHAMELEON LS, FDXL, FD, BOXER, CITY SPEED Battery On/Off/Lock To lock your battery into position, turn the key 1 click clockwise to the OFF position. This will prevent the battery being stolen when the bike is not in use. To turn the battery on, rotate the key clockwise another click to the on position. This will make the bicycle s electrical system live, when in this position the key cannot be removed from the battery. To turn the battery OFF, rotate the key anti-clockwise by 1 click. To disengage the battery lock, push the key into the battery and rotate the key anti-clockwise a further 1 click to the unlock position. Turn the key clockwise, by one click, to the OFF position, to engage the battery lock (by turning the key only one click the electronic system will remain inactive), the battery is now secure in the frame. To remove the battery, insert the key to the lock, push it in and turn anticlock-wise, this will release the battery enabling you to lift it free, using the handle, from the bike. Battery Display On the top of the battery is an LED indicator, this will indicate how much power the battery has remaining. The LEDs will either light up green or red. If they light up red, connect the battery to a charger as soon as possible. To test the power level insert the key to the battery and turn clockwise to the on position, then press the red button to display the battery power. Power Levels Are As Follows: 3 green lights = 75% to 100% 2 green lights = 50% to 75% 1 green light = 25% to 50% 1 red light = less than 25% Page 12
Battery Information IBEX, IBEX+, ZEST, ZEST+ Battery on/off switch Within the IBEX and ZEST ranges, on the battery itself there is a simple on/off rocker switch. The lock on the battery is for removal of the battery from the bike for charging. TORNADO The TORNADO LCD controls the on/off of the bike. The lock on the bottom of the bike is for battery removal only. CHARGING Your new Byocycles Electric bike comes with a charger similar to the one pictured below. Charge The Battery A. Before using your ByoCycle, we advise that you charge the battery fully. This is done by firstly connecting the supplied charger to the battery then connecting the charger to the mains socket. By connecting the charger in this sequence it minimizes the chance of short circuiting the system. B. Turn the plug on and observe the light on the charger, this should be red in colour C. Once the light goes green it means the battery is fully charged and you re good to go! (charging may take upto 3 hours). The charging port for the TORNADO is located on the bottom of the bike. The charging port for the ZEST is located on the left hand side, near the crank. The charging port for the ZEST+, IBEX+, IBEX, CHAMELEON FD, FDXL, CITY SPEED and BOXER are all located on the battery. WARNING! If you are not planning on using your battery for an extended period of time, fully charge the battery before putting it into storage, we recommend you give the battery a top up charge every 4 weeks during this time to prevent any of the cells breaking down. Page 13
Battery Care Cleaning When cleaning your battery, do not use any corrosive solvents or cleaners. Ensure that the connections are free from water at all times. WARNING! If the battery is left for an extended period of time with the display having the red indicator light lit, damage can be caused to the battery. The consequences of this will mean that the usable life of the battery will decrease. Storage & Transport When storing your battery, whether it is for the short term or the long term, store in a dry and warm environment. The batteries capacity will be adversely affected and possibly cause the battery cells to break down if the battery is left in cold temperature environments. This will cause the battery to give a lower than stated range. The optimum temperature for storing your battery is 22 C. WARNING! If you are not planning on using your battery for an extended period of time, fully charge the battery before putting it into storage, we recommend you give the battery a top up charge every 4 weeks during this time to prevent any of the cells breaking down. Maintenance Your battery requires very little maintenance. The lithium-ion technology allows the battery to be charged at any point in its cycle, whether nearly full or nearly empty. If you are not going to use the battery for an extended period of time, you are required to fully charge the battery and then give it a top up charge once every 4 weeks. Disposal Your battery must be disposed of by the proper method. It is best to contact your local council to see how they wish to dispose of such an item. Page 14
Battery Care Capacity/Range/Usage It is important to note that there are many factors that will affect the performance/range of your battery (distance between charges). This will include the level of pedal assist you use, the terrain you are riding (surface as well as incline vs decline); weather conditions, tyre pressure as well as rider and load weight. To maximise the range of your battery, it is advisable to pedal away from a standing start as this is where the most power is used. You can do this by minimising the use of the throttle/ walk assist mode, which can lower the level of assistance. Most people will find the low level of assistance to be more than enough power. Under high loads the handlebar display will dip occasionally. This is nothing to be worried about, as when the loading on the battery decreases, it will naturally recover a small portion of its voltage. Both the LED and LCD display on the handlebars as well as the display on the battery will indicate the capacity the battery has remaining. The four LEDs indicate 25% capacity each, however due tothe variations when using the battery we recommend, if the situation allows, recharging the battery when it drops below 50%. WARNING! When using your ByoCycle in very cold weather, your battery range will decrease as the cold temperatures reduce the batteries capacity and efficiency. So plan ahead and make sure you have enough charge to complete your journey. Page 15
Looking After Your Bike Tyres And Wheels To ensure your tyres are at the appropriate pressure, seek the information on the side walls of the tyre. This will give you a guide for the correct air pressure. Check your tyres for any wear marks, such as cracking in the side walls, cuts, embedded debris such as glass and/or stones, and also the general shape of the tyre to see if it is free of any bumps or being squared (over worn in the centre of the tyre). To ensure your brakes work, apply pressure to the brake levers and try to move the bike, pulling the rear brake will cause the wheel to lock up as you move forward. Pulling the front brake will cause the rear wheel to raise from the ground. Check your wheels on a regular basis for buckles and bends in the rim. The line around your rim is a wear indicator if this isn t visible, then you must seek replacement ASAP. Before Each Ride Before each ride ensure the following items are checked: Tyres are pumped up correctly and are free of damage and foreign objects. Brakes are working correctly. Gears work correctly Handlebars and stem are fitted correctly If you have a folding bike, ensure the folding clamps are securely fastened. Wheels run true and smoothly. Frame and fork are free of damage All nuts and bolts are tight as well as all quick release clamps being secure. WARNING! If you are unsure about any part of the bike being below the appropriate standards, stop riding and consult your ByoCycle specialist. Failure to do so could result in the bicycle failing without warning, possibly causing serious injury to the rider. After Each Ride After each ride ensure the following items are checked: The bike is clean and free of any dirt that can cause degradation to the frame and components The battery is stored in a warm place free of moisture. The bike is secure and not likely to fall over or be stolen. Wipe the bicycle clean with a damp cloth. Page 16
Looking After Your Bike Servicing Your ByoCycle electric bike should be serviced by a competent cycle mechanic at least once every 6-12 months. Water Resistance Your ByoCycle is designed to be ridden in all weather conditions, this includes wet weather. The bicycle and it s electrical components are splash resistant. However leaving your bicycle to endure the elements, without appropriate cover or protection, will cause corrosion, especially in coastal areas where salt and grit is most common. Negligence is not covered under the warranty. WARNING! Do not submerge your motor, controller, throttle, LED display, battery or wiring loom in water. Mechanical Maintenance All bicycles require maintenance to their mechanical parts, there is no set time to do this as riding style and conditions will effect the wear life of the bicycle components. Components that will require regular maintenance and possible replacement are: Gear cable Brake cables Tyres Cassette Bearings Spokes Chain Ring Brake pads Nuts and bolts Gear Cables Chains If there is any doubt about the condition of these items, please seek help from you ByoCycle specialist. Tyre Maintenance Tyres take a lot of punishment and should be inspected regularly. When inspecting your tyres you should look out for the following: Any cuts in the tyre from sharp objects. Any debris embedded into the tyre. Any cracking in the tyre walls. Any bulges or parts of the tyre that are misshaped. The centre of the tyre being over worn, giving a squared shape to the centre of tyre. WARNING! Failure to properly look after your tyres could result in the tyre failing without warning, in the worst cases, this can cause the rider to have an accident, resulting in serious injury to the rider and other fellow road users. Spares Spares are available from your ByoCycle retailer or any good bike shop. Page 17
Trouble Shooting Fault Possible Cause Action Bike seems underpowered Battery Charge Low Display Issue Motor Issue Recharge Battery Contact ByoCycle Specialist Contact ByoCycle specialist Power on but no drive from the motor Motor connection loose Motor failure Check motor connection is secure Contact ByoCycle specialist 4th LED flashing Motor connection loose Check motor connection Short range after full battery charge Battery damaged Tyre pressures low Charger issue Frequent riding uphill, on high assist or overloading Contact ByoCycle specialist Re-inflate tyres to a higher pressure Contact ByoCycle specialist Change pedal assist setting and pedal away from a stand still 1st LED flashing Connection issue Battery low Contact Byocycles Specialist Charge Battery Charger going straight to green Broken charger Damaged battery Replace Charger Replace Battery Page 18
Warranty 1. Standard Warranty ByoCycles LTD warrants by way of replacement components, to items purchased new from an approved dealer subject to the terms and conditions set out below in items 3-8 for a period of 2 years for the frame and fork and 1 year for all non-consumable parts. 2. Extended Warranty By registering online you can upgrade your warranty to the periods listed in the table below. Provided your new ByoCycle is purchased new from an approved dealer and the registration is made on our website within 3 weeks of purchase. (Please ask your place of purchase if you need assistance). Part Standard Warranty Extended Warranty Frame and Fork 2 years 5 years Battery & Electrical Components 1 year 2 years Non Consumable Parts 1 year 2 years 3. Bicycle Components ByoCycles LTD warrant all components excluding consumable items. 4. Electrical Components Electrical Components including Controller, LED or LCD Display, Pedelec Sensor, battery, motor and charger. 5. Battery a. Battery capacity is warranted not to fall by more than 22% in the first year after purchase. b. If you have Extended Warranty the battery capacity is warranted not to fall by more than 40% during the second year of purchase. c. Your battery warranty will be void if any attempt is made to open the battery by anyone other than ByoCycles trained technicians. 6. Frame and Forks a. Your frame and fork have a 2 year warranty. b. If you have extended your warranty, it is extended to 5 years. C. The permissible total weight of a rider and luggage of all of the ByoCycles range is 125kg. Page 19
Warranty cont. 7. Your warranty does not cover damage due to the following a. Improper use, servicing, assembly or maintenance. b. Wear and tear to consumable items such as: tyres, saddles, innertubes, chains, chainwheels, freewheels/cassettes, brake pads, cables, handlebar grips, bottom brackets, headsets or frame bearings. c. Corrosion, rust, hairline cracks in paint, chips in paint, water damage, the results of metal fatigue. d. Failure or loss cause by accident, misuse, abuse and theft. e. Neglect (poor care and maintenance) overloading with excessive weight and towing f. Incorrect assembly. g. Modifications to the bike and the mounting of accessories. 8. General Conditions of Warranty a. Your bike will only be covered under this warranty if the cycle was purchased from an official Byocycles dealer. b. Only the first owner of the bicycle is covered by this warranty. The warranty is not transferable. c. You must be able to provide proof of purchase with date of purchase if requested. d. All warranty work must be undertaken by an approved Byocycles dealer. e. Warranty includes the cost of replacement parts and shipping to an approved Byocycles dealer only. No labour charge is expressed or implied, this is down to the individual retailer to decide. f. Claims for loss of use or compensation of any kind are excluded and will not be warranted under any circumstances. g. In the event of a claim for warranty, the original warranty period will not extend. h. Your warranty will be null and void if you elect to repair a defective component yourself or if you use a replacement component not supplied by Byocycles or an approved reseller. i. In the case of a claim for a damaged frame, the frame or complete bike (cleaned) must be returned to your place of purchase for examination. If your place of purchase is no longer trading, Byocycles reserve the right to charge for any labour/delivery/collection. j. Disassembling any part or component beyond which is shown in the users manual is a complete void of warranty. Your statutory rights remain unaffected. Page 20
Warranty Registration 5 YEAR FRAME AND FORK EXTENDED WARRANTY 2 YEAR NON-CONSUMABLE PARTS EXTENDED WARRANTY To register for your extended warranty, please log onto the Byocycles website www.byocycles.com/customer-zone/ and follow the prompts to register your bike/s. You MUST register your NEW bike within 21 days of purchase. Please note only NEW bikes sold from an approved byocycles dealer can be registered. Page 21
Pre Delivery Inspection Battery q Dealer Stamp Charger Handle bars secure Brakes set up Gears set up Tyre pressure Throttle active Pedal assist active Wheel alignment Wheel nuts secure Frame condition Frame Number Battery Number Checked by: Position: Signed: q q q q q q q q q q q q Page 22
Service Schedule Service To Be Completed Annually Or Every 1,000 Miles Which Ever Is Achieved Earliest: Initial inspection 1st Service 2nd Service (After approx 100 miles) Work Completed: (After approx 1,000 miles) Work Completed: (After approx 2,000 miles) Work Completed Parts Used: Parts Used: Parts Used: Date: Signature: Dealer Stamp Date: Signature: Dealer Stamp Date: Signature: Dealer Stamp 3rd Service 4th Service 5th Service (After approx 3,000 miles) Work Completed: (After approx 4,000 miles) Work Completed: (After approx 5,000 miles) Work Completed Parts Used: Parts Used: Parts Used: Date: Signature: Dealer Stamp Date: Signature: Dealer Stamp Date: Signature: Dealer Stamp Page 23
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