How to Assemble Your New Electric Bicycle

If you purchased your e-bike unassembled, please follow these instructions to assemble your e-bike under the guidance of an adult or a qualified technician. Assembly is quite easy as most of parts are already assembled; you need only to put a few large pieces together to complete the job.

You may click to the following link to view the demonstration of assembling the e-Bike:
http://www.youtube.com/watch?v=bxA6AZ8NRIk&feature=PlayList&p=9D1077C3DB0B ED9D&index=0&playnext=1

Remarks: The link is subject to change without advance notice. For more information, please refer to the following websites:

• www.electricbike.net.au
• www.electricscooter.net.au
• www.electricbike.org.uk
• www.electricbike.uk.com
• www.electricscooter.org.uk
• www.electricscooter.uk.com
• www.electricbike.us.com
• www.electricscooter.us.com
• www.elektrofahrrad-berlin.de

Check the Package is Complete and Undamaged
Your e-bike comes in a carton containing the following:

• The main body of the e-bike - consisting of the frame, the rear wheel, the gear and chain, the rear brake, the battery receptacle, the rear fender.
• The handle bar subassembly - the handle bar subassembly is not really separate, as it is connected to the main body by the brake cables and electrical wires. The handlebar also has the brake levers and gear controls already assembled. Additionally, the right handle also has an integrated control for the throttle mode power-assisted, and a battery charge level indicator. The throttle control is factory-configured to be disabled, however.
• The Seat - the seat is attached to its pedestal stem.
• The front wheel
• The front wheel fender with supports
• Battery and charger - these are contained in a separate box.
• Front light and dynamo assembly
• Pedals - there are a pair of foot pedals
• Tools and small parts - One multi-wrench, big hex wrench, small hex wrench, nuts and bolts, keys, and this manual.

Assemble - Step 1: Attach the handle bar subassembly
Stand the main body of the e-bike on the kickstand. Insert the stem of the handle bar subassembly into the steering column that is at the front of the main body frame. Make sure that the fork (that will hold the front wheel) is pointing forward, and orient the handle bar accordingly. Insert the stem all the way and tighten from the top using the big hex wrench.

Assemble - Step 2: Attach the Front Wheel Fender
Make sure that the fork from the steering column is pointing forward. Place the front fender within the fork: locate the small projection with a screw hole at the top of the fender, fit it to the bolt at the back of the base of the steering column; attach the supports (two on each side) to the base of the fork using four small bolts (supplied). After all five points (the dorsal point and the 4 support points) are properly attached, use the multi-wrench to tighten.

Assemble - Step 3: Attach the Front Wheel
Make sure that the fork from the steering column is pointing forward. Place the front wheel within the fork and between the two brake pads on either side, seat the axial stem properly within the receptacles at the tips of the fork, and tighten the nuts with the multi-wrench. Make sure that the front wheel moves freely and does not wobble from side to side. Reposition the wheel and re-tighten if necessary.

Assemble - Step 4: Assembling and Adjusting the Front Brake
You may need another person to help you with this step. The front brake is installed and assembled except that the cable was relaxed to allow the installation of the front wheel. After properly installing the front wheel, the cable can be tightened again.

Using the small hex wrench, loosen the screw that tightens the cable so that the cable is completely free to slide back and forth. Arrange the several pieces of metal and rubber along the brake cable in their correct positions by referencing the rear brake. Squeeze the brake arms so that the brake pads are against the wheel, but leave sufficient clearance of 1/8 inch on each side (you might want to insert some scrap material, such as a piece or cardboard, between the wheel and the brake pad to ensure there is sufficient clearance). Pull the cable at the end to take out all the slack, tighten the cable by means of the small hex wrench.

Test the brake by lifting the front of the e-bike and setting the wheel in motion (turn it) and apply the brake at the handlebar to stop it. If you could not set the wheel in free motion, or if you could not stop it by apply the brake, you need to re-adjust by increasing or decreasing the clearance.

Caution: Do not operate the e-bike until you are satisfied that both the front and rear brakes are operational.

Assemble - Step 5: Installing the Light and Dynamo Assembly
(Note: Installing of the light and dynamo assembly is optional. Some people prefer battery-powered LED light as opposed to dynamo-powered light.)

Attach the light and dynamo assembly to the special receptacle on the right side of the fork for the front wheel. Tighten slightly. The front light has a wire already connected to the dynamo. Connect the loose electrical wire that runs from the rear light to the same connection point at the dynamo. Operate the lever to check that the two dynamo positions are properly assembled to the effect that the dynamo can engage and disengage from the front wheel. Tighten the nut and bolt. Test the installation again by checking that, in the engaged position with the front wheel turning, the lights are turned ON.

Assemble - Step 6: Installing the Seat and Pedals
Insert the pedestal stem of the seat into the seat column of the main body frame, use the built-in lever to tighten.

Attach a pedal on each side of the crank, tighten with the multi-wrench.

Inflate the tires to proper pressure.

At this point, your e-bike is a completely functional bicycle, although without any battery operated function as yet. Check all tightening points to make sure. Take a short ride. Adjust the height of the handlebar, and the height and the tilt of the seat, if necessary for maximum comfort.

Assemble - Step 7: Installing and Charging the Battery
Remove the battery from the box and turn the switch to the ON position. The LEDs on the battery should light up to indicate that the battery is functional and that there is an appreciable amount of charge in the battery. Install the battery by first seating it at the base at an angle and then gently push it into a vertical position. You need to insert and turn the key anti-clockwise to lodge battery snugly into the top bracket. You should also see the charge level indicator at the handlebar will also light up. Remove the key, make sure the battery is in position and not movable. Turn OFF the battery.

Remove the charger from the box, attached the power cord and insert that to any wall outlet. Insert the plug at the end of the smaller cable into the charging terminal of the battery and start charging. The charging terminal is on the side of the battery opposite to that of the switch. The LED on the charger glows RED while charging and glows GREEN when charging is complete. The battery should be turned OFF while being charged. When the LED on the charger turns Green, disconnect the charging cord and cover the charging terminal with the metal cap. The battery has a series of LEDs as charge level indicators. There is a similar series of LEDs on the handlebar. If a battery is installed on the e-bike and turned ON, the LED indicators will show the charge level of the battery.

You are now ready to start using your e-bike.