E-Bike 36V Service Manual

MANUAL36V MODELSSERVICE

SX model 26 x 1.95 in., CSK, puncture resistantPE model 26 x 1.95 in., black with reflective stripe, puncture resistantRimsDH-17Front 26 x 1.5 in., 14

Table 4: Torque SpecificationsItem kg-cm in.-lb. ft.-lb. Special InstructionsHandlebar-binder bolt 140~200 - 10~15 Apply LoctiteHandlebar-arm clamp bo

Frame SpecificationsFrame Size (Center to top)419 cm (16.5 in.)Wheel Base 1062.3 mm (41.8 in.)RC 431.5 mm (17.0 in.)72˚Head Tube163 mm (6.4 in.)Table

CHARGING THE BATTERIESThe E-Bike®includes a charger that is anintegral part of the battery pack. Batteries canbe charged when the battery pack is on-b

NOTEWhen a battery is new, the LED may rapidlyflicker instead of turning to green. This is not aproblem. The battery is fully charged and canbe used.

(Figure 3) sits in the bottom of the case (theend with the capacitor). Be sure the battery isproperly seated in the battery case.NOTEPerform the follo

6. Fit the cover onto the battery pack. Be sureno wire is pinched beneath the cover.7. Apply Loctite 242 (blue) to the threads ofthe two cover screws,

If there are no intermittent connections, replace the battery.Charger Output Test1. Remove the cover from the battery pack.2. Connect a digital voltme

Battery Voltage Test, After ChargingNOTEThe charger must be operational for this test tobe valid. Perform the charger output test beforeperforming thi

HANDLEBAR POSITIONNOTEThe handlebar may be adjusted to suit therider’s preference. The following proceduredescribes how to set the handlebar to the st

E-Bike®Service Manual36V MODELSEV Global Motors Company16201 Stagg Street Van Nuys, CA 91406 Tel: 818/756-0566Fax: 818/756-0563www.ebike.com

WARNINGThe "Minimum Insert" mark on the handlebarstem must not sit above the top of the headset.2. Raise or lower the stem within the fork c

7. Disconnect the front brake cable from theS-hook (C, Figure 1). Note how the front brakecable is routed around the headlight (LE andSX models) or ar

6. Loosen the mirror-mounting bolt (Figure10), and remove the mirror from the handlebarend.7. Roll the left handlebar grip from the han-dlebar. Do not

5. Slide the shifter body onto the left handle-bar. Guide the shifter cable around the head-light (LE or SX models) or battery holder (PEmodels).6. Sl

10. Visually inspect the position of cone in theadjustable race and in the fork crown. Notehow far each cone protrudes from its respec-tive cup (Figur

Assembly1. Clean the bearings, head-tube races, fork-crown race, and adjustable race with solvent.2. Lightly coat the upper head-tube race andthe lowe

er with the other. On PE and SX models,grasp a stanchion between the upperand lower fork bridges with one hand and grasp the lower slider with the oth

5-1Chapter FiveBRAKESV-BRAKESNOTEWhen working on the brake calipers and pads,the terms "left" and "right" refer to the techni-cia

CAUTIONDo not set the caliper-arm spring tension toohigh.c. If necessary, balance the caliper arms byturning the spring-tension adjuster (B,Figure 4)

3. Squeeze the caliper arms together, and dis-connect the cable guide from the bracket onthe left caliper arm (A, Figure 1).4. Loosen the adjuster loc

Copyright © 2000 EV Global Motors CompanyFirst EditionOctober, 2000LIT-82001-01-36All rights reserved. No parts of this publication may bereproduced o

connect the cable guide from the bracket onthe left caliper arm.2. Remove the brake pad nut (F, Figure 8) fromthe pad stud .3. Remove the plain washer

plane relative to the brake surface of the rim(Figure 10). The pad’s vertical plane shouldparallel the vertical plane of the brake surfaceof the rim.T

4. Inspect the caliper-mounting boss in theframe.a. Be sure the threads of the caliper-mount-ing boss are clean.b. The mating surface of the caliper-m

4. Thread the caliper-pivot bolt into the caliper-mounting boss. As you tighten the pivot bolt,be sure the pin engages then indexing hole inthe boss.5

5. Hold the adjuster with the Allen wrench,and tighten the locknut (B, Figure 16) securely.6. Set the pads by sharply apply the brakesfour or five tim

SHIFTERRemoval1. Remove the shift cable from the S-hook(Figure 1) that holds the cable to the frontbrake cable.6-1Chapter SixSHIFTER and DERAILLEURFIG

3. Slide the shim onto the handlebar. Install thehandlebar grip so the grip end is flush with thehandlebar end.4. Slide the shifter body against the g

11. Remove the shifter from the handlebar asdescribed in this chapter.12. Gently pry the cover plate from the insideface of the shifter housing (Figur

5. Feed the inner wire along the cable groove(Figure 12) in the shifter housing and outthrough the barrel adjuster.6. Fit the twist unit into the shif

FIG. 1617. Loosen the pinch-mechanism nut, and usethe fourth-hand tool to pull the slack from theinner wire.18.Torque the pinch-mechanism nut (B,Figur

TABLE OF CONTENTSChapter One: General Information 1-1Beep/LED CodesVehicle Identification NumberHow to Read the Model CodeTer msLubricantsThreadlockRe

3. Turn the shifter barrel adjuster to its fully-inposition, and then back out the adjuster onefull turn.NOTEDo not pull the inner wire so much that t

b. Chain length is acceptable if the tensionpulley is 1.75 in. or less forward or rear-ward of the guide pulley.4. Examine the chain.a. The chain is t

5. Shift the derailleur so the chain rides on theinnermost cog.6. Examine the chain as it passes through thederailleur.a. If the chain passes through

2. Take the non-riveted end of the chain andfeed it under and around the rear of the tensionpulley on the derailleur. Following the derailleurcage, ro

4. Inspect the position of the spindle end. Theend of the spindle should be recessed withinthe crank-arm square hole. If the spindle end isflush with

2. Inspect the square hole in the crank arm(Figure 12). The flats of the hole should bestraight and even. Replace the crank arm if itssquare hole show

5. Set your hand against the frame down tubewith the end of your forefinger touching theinside of the chainring (Figure 14).6. Rotate the crank arm an

A bottom-bracket-cartridge tool (Park ToolBBT-2) is required for removing and installingthe bottom-bracket cartridge.Removal1. Remove both crank arms.

8-1CONNECTOR IDENTIFICATIONAll electrical components in the E-Bike®connect to the controller, which is mountedbetween the side covers. Refer to Figure

5. Remove the three left-side-cover screws.One is located behind the steering head (B,Figure 2), one is above the controller (A,Figure 4), and the thi

Code Meaning Beep LEDsGood beep The system has been 1 continuous beep checked and is operational sounds for 1 second.Bad Beep A problem exists in a

each left-side-cover mounting screw, andinstall each screw finger tight. See (B, Figure2 and A & B, Figure 4) along with the washer.5. Torque the

10. Gently pull the left side cover away fromthe frame, and pull the controller half of the QRconnector between the frame and side cover.See Figure 10

1. Shift the chain to the outermost rear cog onthe freewheel.2. Squeeze the top of rear brake arms togeth-er and free the rear brake cable from thebra

6. If removed, loosely reinstall the axle nutsand washers. Be sure the textured side of thewashers faces inward toward the hub.7. Finger tighten the a

Headlight Bulb Replacement1. Remove the reflector from the headlighthousing as described above in this chapter.2. Release the arms (C, Figure 16) of t

2. Disconnect the taillight/brake light connectorunder the seat (Figure 20).3. Remove the two taillight mounting nuts(Figure 21), and remove the taill

E. The system turns on, but the headlightdoes not operate.1. Remove the battery, and turn the powerknob to ON to discharge the capacitor in thecontrol

Battery voltage test1. Remove the battery pack from the E-Bike®.2. Use a digital volt ohmmeter to measure thevoltage across the terminals at the botto

Horn resistance test.1. Disconnect the horn connector (G, Figure1) from the controller.2. Connect the positive (+) probe of a digitalvolt ohmmeter to

CONTROLLER5 AMP FUSEHEADLIGHT123123123412345612345671212HORNLEFTTAIL LAMPRIGHTBRAKE LEFTBRAKE RIGHTPOWER + REDPOWER - BLACKREDMOTOR +BROWNMOTOR -12312

Code Meaning Beep LEDsBattery state-of-charge 80% to 60% of run time None Green and yellowremaining LEDs on.60% to 40% of run time None Yellow LED o

RIGHT BRAKE SWITCHLEFT BRAKE SWITCH TAILLIGHT HORNHEADLIGHT1234561234567HORN SWITCHCRUISE SWITCHECONOMY SWITCHHEAD LIGHT LEDHEAD LAMP SWITCHACCESSORY

EV Global Motors Company 16201 Stagg Street Van Nuys, CA 91406 www.ebike.com818-756-0566 tel / 818-756-0563 faxP/N: LIT-82001-01-36a Lee Iacocca Enter

OilAlways use oils made specifically for bicy-cle use. Bicycle oils need to be thin enough topenetrate tight places, they should be durableso they can

RECOMMENDED MAINTENANCE SCHEDULEComponent or Condition Inspect before every ride Inspect every 5 to 10 rides*Brake pad adjustment XWheel quick release

Table 1: Mechanical SpecificationsComponent SpecificationHeadsetStack height 33 mm (1.30 in.)Dimensions 25.4 mm x 34 mm x 30 mm w/sealForks (LE)Type P