Currier Tech Ezip Assembly Manual

ASSEMBLY GUIDE:

Izip & Ezip Electric Bicycles with

Rack-Mounted Batteries (“RMB Bicycles”)

Ezip Coastline

Diamond Frame Izip Via Lento

Low Step

Please Refer to your Owner’s Manual for Detailed Setup Instructions

Technical & Customer Service: 1-800-377-4532

Ezip Trailz

Low Step

Helpful Tools:Included in your parts box:

• Scissors

• Bicyclegrease

• Phillips-headscrewdriver

• Allenwrenches:2.5,4,5,&6mm

• Open-endwrenches:9,10,14,15,&17mm

oradjustablecrescentwrench

• Needle-nosepliers

• Pedals

• Quickreleaseskewer(somemodels)

• Reectors(ifnotalreadyinstalled)

• Stem

• Toolkit(4+5mmcomboAllenwrench,

13+15mmcomboopen-endwrench)

• Rackkeys

• Touch-uppaint

Assembly will take 1 - 2 hours

Note:Whenworkingonyourbicycleasinstructedbythisguide,pleaserefertothetorquevalueschartinyourowner’smanualfordetailedtorque

requirements.Under-orover-tightenedcomponentsmayloosenorbreak,causingafall.

Stepsinthisguidethatcallfortheuseofbicyclegreasedosointheinterestofkeepingyourbicycleinworkingconditionforaslongaspossible.Grease

isnotabsolutelyvitaltotheassemblyofthisproduct,butfailuretoapplyitasdirectedcouldcausepartstoseizeovertimeandirreparablydamagethe

frameorcomponents.

Becausebicyclepartstendtobegreasy,itisrecommendedthatyoulaydownatarporsheettoprotectyouroorifassemblingthebikeindoors.

Itisbesttoremovetheprotectivepackagingduringtheassemblyprocessonlyasneeded,leavingsomeintacttoprotectthebikeduringassembly.

Duringassemblyitmaybehelpfultoreferencethephotosonthecoverofthisguideandonthebicycleboxifyouareunsureofanysteps.

Pleasetakethetimetoreadthebatterycareandstoragesectionofyourmanualforusefulinformationonprolongingthelifeofyourbattery.

Assembly Tools

Unpacking and Preparation

Handlebars and Stem

1. Carefully remove the bicycle from the box. Youshouldhavea

friendhelpyouwiththis,asthebikeisheavy.Ifyouarealone,youcanlay

theboxonitssideandgentlyslidethebikeout.

Seat Tube

Top Tube

Down Tube

Chainstay Seatstay

Head tube

3. Cut the zip-ties holding the front wheel to the bike frame.Setthe

wheelasidefornow.

4. Rotate the fork so the brake faces away from the frame,thenrest the bike

upright on its rear wheel and fork,asshowningureA.Whenrotatingthefork,be

surethecablesruninfrontoftheframeanddonotwraparoundtheforkorheadtube.

5.Find the stem in the parts box (gureC).Remove the protective

caps from the stem and head tube,theninsert the stem into the bike’s

head tube facingawayfromtheframe.Remove the faceplatebyremoving

thetwoorfourfaceplatebolts(dependingonmodel)showningureD.

2.  At this point you can begin charging your

battery. Thebatteryispackagedinabrowncardboard

box underneath the bike. The charger is in a small

whitebox,usuallyrubber-bandedtotherack.

Recommendchargetimeis6-8hours.Plugthecharger

rstintothewalloutlet,thenintotheportunderneath

thebatteryhandle(gureB).

A solid red or blinking green light on the charger

(dependingonmodel)indicatesthebatteryischarging

properly.Asolidgreenlightindicatesthatthecharger

hasenteredtricklechargemode,andyourbatteryisat

least80%full.Formaximumrange,pleasechargefor

thefullrecommendedtimeperiod(6-8hours).

Fork

Pleaserecycle

packagingmaterials! Currie TechnologiesTechnical and Customer Service 1-800-377-4532

Protective cap

(remove and discard)

Izip stem

Faceplate

Ezip stem

Wedge bolt

(top of stem)

6.Cut the zip-ties securing the handlebar to the bike frame,arrangethebrakeand

shiftercablessotheyruninfrontofthebicycle,thenclamp the handlebars to the stem

usingthefaceplateasshowninphotoE.Thebarsshouldberotatedtoacomfortablegripping

positionwithcomfortableaccesstothebrakelevers,andcenteredaroundthestem.Besure

totighten the faceplate bolts evenlysothetopandbottomgapsareequal.

Faceplate Bolts

Head tube

Wedge Bolt

(top)

Equal faceplate

gaps & bolt

tightness

7.Align the stem so it is facing forward in relation to the fork (gure F),then

tighten the wedge bolt securely.Besurethattheforkisrotatedwiththebrakesfacing

forward,andthatnocablesaretangledaroundit!Refertothephotosonthecoverofthis

manualforpropercablerouting.It is extremely important that you properly tighten the

wedge bolt.Leavingthisbolttooloosecanresultinthehandlebarsturningawayfromthe

wheel,causingacrash.

8.Ifnotalreadyinstalled,attach the square white reector to the handlebar using

aPhillips-headscrewdriver.

Wedge Bolt

Throttle

(right side)

Shifter

(left side)

Brakes face

forward!

(Top View)

Stem in line

with fork

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9.Apply grease to the inside of the seat tube,theninsert the

seatpostandclose the quick release tightly.Itwillhelpduringthenext

stepsifyoulowertheseatcompletely;itcanbeadjustedtoacomfortable

heightbeforeyourrstride.



Refertotheowner’smanualformoreinformationontheuseandadjustment

ofquickreleaselevers.It is vital to your safety that you understand and

properly secure this lever!

Swing QR Closed

Seatpost

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H10.Release the front brakebypullingbacktherubberboot,squeezing

thebrakearmstogether,thenremovingthenoodlefromitsholder.Thiswill

allowyoutoinstallthefrontwheel.Youwillneedtoreattachthebrakeby

reversingthissteponcethefrontwheelisinstalled.

Brake Noodle

Boot

11.Flip the bike

oversothatitrests

onitshandlebarsand

saddle.Becarefulnot

todamagethethrottle

orbrakelevers.



Removetheplastic

dropoutprotectorfrom

theendofthefork.

Front Wheel

12. Determine whether your front wheel uses a solid or quick release axle

(seephotoJ/K).

Solid axle with safety

washer and nut

Quick release

12a.Solid Axle:Loosen the axle nuts on each side of the wheel.Insert the wheel

into the fork,makingsurethesafetywasheroneachsideistotheoutsideofthefork,as

showninphotoL.

Orient the safety washers as shownsotheirhooksinsertintotheholesinthefork,then

tighten the axle nuts rmlywitha15mmopenendwrench(includedinyourpartsbox).

12b.Quick Release: Remove the end nut and one spring from the quick release

skewer,takingcarenottoloseeitherofthesmallsprings.Push the skewer through the

front hub, then replace the spring and end nut.Leavethenutloosefornow,abouttwo

turnsin.

Solid Axle

Safety washer hooks into dropout

Tension

adjusting

nut

SpringSpring Skewer

• Forsolidaxles,proceed to step 12a.

• Forquickreleaseaxles,proceed to step 12b.

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Insert the wheel into the fork,asshowninphotoN.

Securely close the quick release.Refertotheappendixofthisdocumentformoreinformation

ontheuseandadjustmentofquickreleaselevers.It is vital to your safety that you understand

and properly secure this lever!

Pedals

13. Find the pedals in your parts box. Grease the threadsand

thread them securely into the crank arms using a 15mm open-end

wrench.Notethatthepedalshaveoppositethreaddirectionsandmust

goonaspecicsideofthebicycle.Thepedalmeantforthedrive-side(the

sideofthebicyclewiththechainandgears)hasastandardthread,whichis

tightenedclockwise.Thenon-drive-sidepedalhasareverse,non-standard

thread.Itmustbeturnedcounter-clockwisetobescrewedin.

Thepedalsshouldbemarked‘R’and‘L’for“Right”and“Left,”howeverthey

canalsobeidentiedbytheirthreads,asshownindiagramP.

14.Turn the bike right-side-up,usingthekickstandtokeepitupright.

Close the front brakebyreversingstep10(gureH),pullingthebrake

noodlebackintoitsholder.Ifthecablefeelstight,checkthecablingtomake

sureitisproperlyorganizedinfrontofthebiketoallowenoughslacktore-

closethebrake.

15.Adjust your front and rear brakes.Yourbrakesmaynotbe

fullyadjustedfromthefactory;refertoyourowner’smanualfordetailed

instructionsonbrakeadjustmentorconsultaprofessionalbikemechanicif

youarenotcomfortablemakingtheseadjustmentsyourself.Do not attempt

to ride your bicycle without properly adjusting the brakes!

16.Adjust your shifters and derailleurs,referringtotheowner’s

manualforfullinstructions.Riding your bicycle without properly adjusting

the drivetrain can cause irreparable damage!Consultaprofessionalbike

mechanicifyouarenotcomfortablemakingtheseadjustmentsyourself.

Tighten

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Installation:

Yourelectricbicyclecomeswitha24voltsealedlead-acid(SLA)battery.Toinstallthebattery,simplyslide it into the rear

rack(asshowningureQ,Currielogofacingoutward)makingsureyourstremove the rubber terminal cover if present.

Thistypeofbatterydoesnothaveamemory,andridingonapartialchargewillnotharmthebatteryinanyway.Recharge

timeforthisbatteryis6-8hourstoreachafullcharge.

Locking:

LocksareincludedwiththeRMBracktoholdthebatteriesinplacewhenriding.Itisrecommendedthatthebatterypackbe

lockedwheneveryouareridinginordertomaintainastrongconnection.After sliding a battery pack into place, lock it

with one of the included keys (usuallyinthepartsboxorrubber-bandedtotherack),makingsurethelockcylinderfully

engagesintothebatterycase.Allkeysincludedwithyourbicycleareidentical.

Operation

To turn your bicycle on:

Ezip RMB Bicycles & Izip RMB bicycles prior to 2010: Flip the three-position

battery selector switch, located on the rack behind the rear reector, to the side

corresponding to the attached battery you wish to use.Thisturnsthebicycleon,indicated

bytheglowinglightsonthethrottle.Toturnthebikeoff,ipthebatteryselectorswitchtothe

neutralcenterposition.

Izip RMB Bicycles:Flip the two-position battery selector switch, located on the rack

behind the rear reector, to the side corresponding to the attached battery you wish to

use.Onceyouhaveselectedyourbattery,press the “ON/OFF” switchnexttothethrottleon

thehandlebars(asshowninphotoS1)toturnthebikeon.Toturnthebikeoff,simplypress“ON/

OFF”again;thereisnoneedtochangethepositionofthebatteryselectorswitch.

PAS/TAG System:

Using the “PAS/TAG” selector button on the throttle, you can switch between PAS

(PedalAssist) and TAG (TwistAnd Go) modes. TAG mode uses a straight throttle

system;motorpowerisdirectlycontrolledbythethrottleonyourhandlebars.When

thebikeisswitchedtoPASmode,asensorinthedrivetrainisactivated,allowingthe

motortoautomaticallyrunatupto50%powerwhenitsensespedaling.ThisPASmode

helpstomaximizerangeasitonlyactivatesthemotorwhentheriderispedaling.

For Izip RMB

Bicycles Only

ON/OFF

Button

For Ezip RMB

Bicycles Only

Izip: ON/ON

(Battery selector)

Ezip: ON/OFF/ON

(Power and selection)

PAS/TAG

SELECTOR

PAS/TAG

SELECTOR

Battery

Before your rst ride...

• Remove all remaining packaging on the bike,includingtheplasticcoversontheoutsideofthewheels

• Check the operation of your front and rear brakesbypushingthebikeforwardandoperatingthebrakelevers.

• Check the tightness of all nuts and bolts,especiallythefrontandrearwheelnuts,thestembolts,andtheboltssecuringthebrakeleversand

shifterstothehandlebars.

• Make sure the stem’s wedge bolt is tight.Checkthatitistightenedproperlybystandingoverthefrontwheel,holdingitwithyourthighs,then

tryingtoturnthehandlebars.Ifthehandlebarscanbeturnedindependentlyofthewheel,thewedgeboltmustbetightenedfurther.

• Make sure your front wheel is secure in the frame.Refertothequickreleasesectionintheowner’smanualfordetailedinstructionsonusing

quickreleases.

• Make sure your tires are lled to the pressure recommended on the sidewall. Over-or under-inatedtirescanblowofftherimandcause

afall.Werecommendusingabicyclepumpwithpressuregauge.

• Test power:leanthebikeonitskickstand,raisingtherearwheelofftheground.Whenthebikeispoweredon(indicatedbythethrottlelights)

youcantestsystempowerbytwistingthethrottleinTAGmodeandwatchingtherearwheel.Refertothetroubleshootingchartonthispagefor

assistanceifthebikewillnotpoweron.

Bike won’t turn on (no lights on

throttle)

Batteryselectorippedtowrongside

Batterynotseatedproperlyagainstrackterminals

NeedtopresshandlebarON/OFFswitch

Batterynotcharged

Throttle lights work, but motor

will not run

BikemaybeinPedalAssistmode.Presstheredbuttononthe

throttletochangetoTwist-and-Gomode.

Brakes rub when riding Re-adjustbrakes,referringtoowner’smanual

Gears/chain make clicking or

grinding noises while riding

Re-adjustdrivetrain,referringtoowner’smanual

Can someone help me with...? CalltheCurrieTechnologiestechnicalandcustomerservice

departmentat1-800-377-4532

Refer to owner’s manual for detailed troubleshooting chart

Currie TechnologiesTechnical and Customer Service 1-800-377-4532

ManyIzipandEzipbicyclemodelsusequickrelease(QR)leverstofacilitatecommontaskssuchasfrontwheelremovalandseatheightadjustment.

Whenproperlyadjusted,quickreleaseleversarebothsafeandconvenient,butyoumustunderstandandapplythecorrecttechniquetoadjustthem

properlybeforeridingyourbicycletopreventseriousinjuryordeathfromafall.

Quickreleaseleversuseacamactiontoclampthewheelorothercomponentsinplace.Becauseoftheiradjustablenature,itiscriticalthatyou

understandhowtheywork,howtousethemproperly,andhowmuchforceyouneedtoapplytosecurethem.

Warning: Thefullforceofthecamactionisneededtoclampthewheelsecurely.Holdingthenutwithonehandandturningtheleverlikeawingnutis

NOTasafeoreffectivewaytocloseaquickreleaseandwillnotclampthewheelorothercomponentssafely.

QUICK RELEASE USAGE

Ridingwithanimproperlyadjustedwheelquickreleasecanallowthewheeltowobbleorfalloffthebicycle,whichcancauseseriousinjuryordeath.

Therefore,itisessentialthatyou:

 1.Askyourdealeroralocalbikeshoptohelpyoumakesureyouknowhowtoinstallandremoveyourwheelssafely.

 2.Understandandapplythecorrecttechniqueforclampingyourwheelinplacewithaquickrelease.

 3.Eachtime,beforeyouridethebike,checkthatthewheelissecurelyclamped.

Installing a quick release front wheel

Inaquickreleasesystem,thewheelhubisclampedinplacebytheforceofthequickreleasecampushingagainstonedropoutandpullingthetension

adjustingnut,bywayoftheskewer,againsttheotherdropout.Theamountofclampingforceiscontrolledbythetensionadjustingnut.Turningthe

tensionadjustingnutclockwisewhilekeepingthecamleverfromrotatingincreasesclampingforce;turningitcounterclockwisewhilekeepingthecam

leverfromrotatingreducesclampingforce.Lessthanhalfaturnofthetensionadjustingnutcanmakethedifferencebetweensafeclampingforceand

unsafeclampingforce.



Appendix: Quick Release Levers

Currie TechnologiesTechnical and Customer Service 1-800-377-4532

1. Removethetensionadjustingnutandoneofthesmallsprings,thenslidethequickreleaseskewerthroughthehub.Ifyourbicyclehasadisc

brake,inserttheskewerstartingonthesidewiththebrakerotor.Replacethespringandtensionadjustingnut(ga).



2. Ifyourbicyclehasrimbrakes,disengagethemtoincreasetheclearancebetweenthetireandbrakepads.

3. Installthewheelintothedropouts,makingsurethequickreleaseleverisontheleftsideofthebicycle.

4. HoldingthequickreleaseleverintheOPENpositionwithonehand,tightenthetensionadjustingnutwithyourotherhanduntilitisngertight

againsttheforkdropout.

5. Whilepushingthewheelrmlytothetopoftheslotsintheforkdropouts,andatthesametimecenteringthewheelriminthefork,movethequick-

releaseleverupwardsandswingitintotheCLOSEDposition(gb&c)Thelevershouldnowbeparalleltotheforkbladeandcurvedtowardthe

wheel.Toapplyenoughclampingforce,youshouldhavetowrapyourngersaroundtheforkbladeforleverage,andthelevershouldleaveaclear

imprintinthepalmofyourhand.



WARNING: Securely clamping the wheel takes considerable force. If you can fully close the quick release without wrapping your ngers

around the fork blade for leverage, and the lever does not leave a clear imprint in the palm of your hand, the tension is insufcient. Open

the lever; turn the tension adjusting nut clockwise a quarter turn; then try again.

6. Ifthelevercannotbepushedallthewaytoapositionparalleltotheforkblade,returnthelevertotheOPENposition.Thenturnthetension

adjustingnutcounterclockwiseone-quarterturnandtrytighteningtheleveragain.

7. Re-engagethebraketorestorecorrectbrakepad-to-rimclearance;spinthewheeltomakesurethatitiscenteredintheframeandclearsthebrake

pads;thensqueezethebrakeleverandmakesurethatthebrakesareoperatingcorrectly.

closed

Springs

Tension

adjusting nut

open

Currie TechnologiesTechnical and Customer Service 1-800-377-4532