Currier Tech Ezip Assembly Manual

Category
Bicycles
Type
Assembly Manual

This manual is also suitable for

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,asshowningureA.Whenrotatingthefork,be
surethecablesruninfrontoftheframeanddonotwraparoundtheforkorheadtube.
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.Asolid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
A
B
Pleaserecycle
packagingmaterials! Currie TechnologiesTechnical and Customer Service 1-800-377-4532
Protective cap
(remove and discard)
Izip stem
Faceplate
C
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
D
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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E
F
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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G
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.
I
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
J
L
K
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.
M
N
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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
O
P
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Q
S
R
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)
1
2
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 TechnologiesTechnical 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 TechnologiesTechnical 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
c
Springs
a
Tension
adjusting nut
b
open
Currie TechnologiesTechnical and Customer Service 1-800-377-4532
9453OwensmouthAve,Chatsworth,CA91311
Phone:+1800.377.4532
Fax:+1818.734.8199
www.currietech.com
Ezip Trailz
Diamond Frame
Izip Via Lento
Diamond Frame
Ezip Coastline
Low Step
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Currier Tech Ezip Assembly Manual

Category
Bicycles
Type
Assembly Manual
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