Gocycle G2 User Manual

Owner’s Manual

for Gocycle® G2

Version December 2015

www.gocycle.com

Gocycle® Owner’s Manual for G2, December 2015

CONTENTS

1 Disclaimer, Copyrights and Trademarks ................................................................................................ 1

1.1 Original Instructions, Translations and Updates .............................................................................. 1

1.2 Disclaimer ............................................................................................................................................... 1

1.3 Copyright Notice ................................................................................................................................... 1

1.4 Trademarks ............................................................................................................................................ 1

1.5 Standards and Conformity ................................................................................................................... 2

2 Safety ............................................................................................................................................................. 3

2.1 General Warning ................................................................................................................................... 3

2.2 Intended Use .......................................................................................................................................... 3

2.3 Modifications and Refinishing ............................................................................................................ 3

2.4 Maximum Design Limit ....................................................................................................................... 4

2.5 Riding in Low Light Conditions .......................................................................................................... 4

2.6 Stopping the Gocycle ............................................................................................................................ 4

2.7 Riding in Wet, Cold or Icy Conditions ............................................................................................... 5

2.8 Limited Life Span .................................................................................................................................. 5

2.9 First Ride ................................................................................................................................................. 6

2.10 Steerer Stop ........................................................................................................................................ 6

3 Warranty ........................................................................................................................................................ 7

3.1 Warranty Registration .......................................................................................................................... 7

3.2 Gocycle Frame Number ........................................................................................................................ 7

4 Recommended Assembly Sequence ........................................................................................................ 8

4.1 Pre-ride Checks and Service Interval ................................................................................................ 11

4.2 Warning! Take Care during Assembly ............................................................................................. 12

4.3 Handlebar Height and Reach Adjustment ....................................................................................... 13

4.4 Assembling the G2 Seatpost Tool Holder ........................................................................................ 18

4.5 Assembling the Front and Rear Reflectors ....................................................................................... 21

4.6 Assembling the Bell ............................................................................................................................. 25

4.7 Gocycle Quick-Fit Accessories ........................................................................................................... 26

4.8 Gocycle Registration ........................................................................................................................... 27

4.9 Gocycle App Installation – Frequently Asked Questions .............................................................. 28

5 Gocycle Lithium Battery........................................................................................................................... 30

5.1 Important Information: Lithium-Ion Batteries ................................................................................ 30

5.2 Getting to Know Your Gocycle Lithium Battery ............................................................................. 30

Gocycle® Owner’s Manual for G2, December 2015

5.3 Gocycle Lithium Battery: Usage ........................................................................................................ 31

5.4 Gocycle Lithium Battery: Care and Maintenance ........................................................................... 35

5.5 Shipping and Handling of Lithium Batteries .................................................................................. 36

5.6 Battery Pack Disposal ......................................................................................................................... 36

6 Operation .................................................................................................................................................... 37

6.1 Familiarising Yourself with Gocycle Dashboard Display .............................................................. 37

6.2 Understanding Electronic Gear Shifting .......................................................................................... 37

6.3 Riding Modes ....................................................................................................................................... 38

6.4 Energy Consumption Meter .............................................................................................................. 44

6.5 Maximising Your Gocycle’s Motor Performance and Reliability ................................................. 44

6.6 Heat and Over-Temperature Protection .......................................................................................... 45

7 Maintenance and Adjustments ............................................................................................................... 47

7.1 Maintenance and Service Centre Location ....................................................................................... 47

7.2 Service interval .................................................................................................................................... 47

7.3 Visual Inspection Guide – (Every 3 Months/ 500 Miles) ................................................................ 47

7.4 Cleaning and Preventing Corrosion ................................................................................................. 49

7.5 Lubrication ........................................................................................................................................... 50

7.6 Checking for Cracking and Fatigue Failures ................................................................................... 50

7.7 Adjusting the Shifting ......................................................................................................................... 55

7.8 Adjusting the Brakes ........................................................................................................................... 56

7.9 Adjusting the PitstopWheel Quick Release Cam Levers ............................................................... 68

7.10 Tyres ................................................................................................................................................. 73

7.11 Adjusting the Headset ................................................................................................................... 74

7.12 Adjusting the Stem Quick Release Lever .................................................................................... 77

7.13 Adjusting the Bearings on the Rear Hub ..................................................................................... 79

8 Troubleshooting ........................................................................................................................................ 82

8.1 Unknown Gear State: Gears Will Not Shift ..................................................................................... 82

8.2 Gears Will Not Shift Down Automatically ...................................................................................... 82

8.3 Diagnosis Modes ................................................................................................................................. 83

8.4 LED Reference Tables ......................................................................................................................... 88

9 Contact Information .................................................................................................................................. 89

Gocycle® Owner’s Manual for G2, December 2015

1 DISCLAIMER, COPYRIGHTS AND TRADEMARKS

1.1 Original Instructions, Translations and Updates

Original instructions are produced in English language. Translations of the original instructions to other languages may take place, however Karbon Kinetics Ltd accepts no responsibility for any errors or misinterpretation of information as a result of such translation.

Visit www.gocycle.com/manuals to check for any new revisions or updates to this manual.

1.2 Disclaimer

The specifications, information and performance of the Gocycle and other products manufactured by or sold under license granted by Karbon Kinetics Limited and featured in this document may change without notice. The use of this information or products and the conditions under which the products are used are the sole responsibility of the buyer and/or the rider. It is the buyer’s and/or rider’s responsibility to determine the correct and safe selection of settings and conditions of use of the products and to periodically check the products for secure and proper operation. To the extent that the law permits, any liability which may be incurred as a result of the use of a product manufactured by or sold under license granted by Karbon Kinetics Limited is limited to the cost of repairing or replacing the failed product or component at the discretion of Karbon Kinetics Limited, either within or outside of warranty periods, and does not extend to any loss or damage which may be caused as a consequence of misuse or failure of the products. Damages to the product, other property or any persons are the responsibility of the buyer and/or rider. By using this product manufactured by or sold under license granted by Karbon Kinetics Limited, you are stating that you have read this disclaimer and agree to hold Karbon Kinetics Limited, its owner/s and any of its employees or directors free from all liabilities, that you agree you are using and operating the product at your own risk, and that no warrantees or guarantees are made by Karbon Kinetics Limited, expressed or implied, on performance or operation.

1.3 Copyright Notice

This material provided by Karbon Kinetics Limited is the property of Karbon Kinetics Limited and is protected by copyright, trademark and other intellectual property laws. You may view this material and print this material only for personal use, provided that you maintain all copyright, trademark and other proprietary rights or notices. You may not otherwise use, reproduce, store, post, broadcast, transmit, modify, sell or make available to others or the public, content from this material without the prior written approval of Karbon Kinetics Limited.

1.4 Trademarks

Gocycle®, PitstopWheel®, Cleandrive® and Magflow® are registered trademarks of Karbon Kinetics Limited.

Gocycle-to-Work™, EmpowerPack™, Vgonomic™ Adjustment, Lockshock™, Shocklock™ and Performance Commuting™ are trademarks of Karbon Kinetics Limited.

All trademarks and the Gocycle logo may not be used without the prior written approval of Karbon Kinetics Limited, a United Kingdom Registered Company Number 4357956.

Gocycle® Owner’s Manual for G2, December 2015

1.5 Standards and Conformity

Gocycle is an electric power assisted cycle developed in accordance with:

2006/42/EC The Machinery Directive

2004/108/EC The Electromagnetic Compatibility Directive

and is in conformity with the applicable requirements of the following documents:

EN 15194:2009+A1 Cycles - Electrically power assisted cycles - EPAC Bicycles EN 14764:2005 City and trekking bicycles - Safety requirements and test methods

Gocycle® Owner’s Manual for G2, December 2015

2 SAFETY

2.1 General Warning

This manual contains many warnings and cautions, which if ignored, may increase the risk of injury to

you as a rider, may cause damage to the product or may invalidate the warranty. We recommend that you read and understand this manual in its entirety, prior to your first ride. Before riding your

Gocycle you must visit www.gocycle.com/safety for up to date important safety related

information.Riding any bicycle involves the risk of product damage, serious injury or even death. Such

risks are increased in busy, urban environments with moving traffic. By choosing to ride a Gocycle,

you assume the responsibility for these risks, and it is important that you know how to ride

responsibly and to exercise proper maintenance to minimise such risks and potential damage. Do not

try to ride beyond the limits of your ability or the limits of the Gocycle.

We strongly recommend that you learn more about the inherent risks associated with riding bicycles and suggest that you:

 Ask your local bike retailer for information or instruction on safe cycling.

 Ride within your means and ability.

 Attend a training session or safe cycling workshop run by many local bike clubs, police

departments, schools or government support groups.

 Search “bicycle safety” online for reference information.

Skills of riders can vary; for example, it takes a highly skilled rider to travel at high speeds and/or close to obstacles, cars or other cyclists. Do not ride in a manner that exceeds the limits of your ability.

2.2 Intended Use

Gocycle is an electric bicycle developed and designed for commuting usage and/or simple riding in fair weather and at speeds relevant to safe and appropriate travel in an urban or suburban environment. Where applicable, the product meets the minimum requirements outlined in EN 14764:2005 and EN 15194. Abusive riding styles or inappropriate use will invalidate any warranty protection offered in this agreement.

WARNING! Understand your Gocycle and its intended use. Using your Gocycle in the wrong manner

or for the wrong purpose can be dangerous and may impact the service life of the product.

The Gocycle is a power-assisted bicycle intended for sensible use by physically competent riders. If you have any concerns or doubts about your use or enjoyment of such a product due to a medical condition, an illness or if you are recovering from treatment for a condition or illness, you should consult your doctor regarding the suitability of the product for you. If you are the user of an implanted medical device such as a pacemaker or defibrillator, you agree to seek appropriate advice from the manufacturer of such device prior to the usage of Karbon Kinetics Limited products.

2.3 Modifications and Refinishing

WARNING! Do not modify or refinish your Gocycle or Gocycle components in any way. Such

modifications or refinishing will void any applicable warranty.

Gocycle® Owner’s Manual for G2, December 2015

Modifications can cause damage which can increase the risk of failure and accident which may result in serious injury or death. Refinishing can hide structural damage, such as fatigue cracks or structural problems which may also result in an accident.

2.4 Maximum Design Limit

WARNING! This product has been designed with a maximum recommended weight limit of 100kg

(220lbs) for the rider, clothing and all luggage, and is intended for use on paved roads. For rider and

luggage weight 100-115kg (220-250lbs): riding style, road condition, tire pressures and luggage

position may reduce product service life. Luggage weight should not exceed 10% of total rider and

luggage weight. Never exceed rider and luggage weight of 115kg (250lbs) at any time. Exceeding this

limit will void all warranties and may result in the product being unsafe for operation.

2.5 Riding in Low Light Conditions

In low light conditions at night, dawn, dusk or during adverse weather conditions such as fog, the visibility of cyclists is dramatically reduced.

WARNING! Never ride a bicycle in low light conditions without appropriate front and rear lights fitted

and “on” (illuminated) that meet or exceed the national standards of the country in which it is being

ridden.

We recommend that you consult the relevant national safety organization or a reputable cycle dealer on what the minimum recommended lighting requirements are in your particular country or region.

 For reference when selecting lights, your Gocycle has a 34.9mm diameter seat post and upper

handlebar stem. We recommend that you choose a light with a variable length strap mounting system.

The following are additional recommendations:

 Wear bright, reflective clothing such as reflective vests, leg and arm bands

 Ensure that your Gocycle is equipped with correctly positioned reflectors (see 4.5 Assembling

the Front and Rear Reflectors)

2.6 Stopping the Gocycle

The Gocycle is equipped with front and rear hydraulic disk brakes, operated by two levers on the handlebars (shown). Before riding, it is important to familiarise yourself with which brake lever operates the front brake and which operates the rear brake. Proper use of your brakes will slow and bring your Gocycle to a safe and controlled stop.

WARNING! To slow or stop the Gocycle in normal operation, apply the brakes appropriately. In the

event that an emergency stop is required, apply the brakes appropriately and in a safe and controlled

manner until you have brought the Gocycle to a complete stop. Do not release the brakes until it is

safe to do so.

Gocycle® Owner’s Manual for G2, December 2015

Aggressive use of the brakes may cause your Gocycle to skid, potentially resulting in loss of control.

Anticipate your need to stop and slow using appropriate pressure on the brake levers.

2.7 Riding in Wet, Cold or Icy Conditions

Under wet, cold or icy conditions, the stopping power of your brakes and tyres (as well as the brakes of other vehicles sharing the road) is dramatically reduced. This makes it harder to control speed and easier to lose control. It also makes skidding during turning more likely. Ride more slowly and cautiously when in wet weather. If it is cold, near or below the temperature when water freezes, be careful of ice on the roads which could be dangerous.

WARNING! Wet or icy conditions impair traction, braking and visibility, both for the cyclist and for

other vehicles sharing the road. The risk of an accident is dramatically increased in wet conditions.

To make sure that you can slow down and stop safely in wet conditions, ride more slowly and apply your brakes more gradually than you would under normal, dry conditions.

We do not recommend riding in heavy rain or standing water, but we do understand that this is not always avoidable. If your Gocycle gets wet, clean and dry it within 15 minutes of heavy wet weather riding. See 7.4 Cleaning and Preventing Corrosion for more information.

2.8 Limited Life Span

WARNING! Bicycles have a limited life span for safe operation and are not indestructible.

As with all mechanical components, bicycle components are subject to wear and high stresses. Different materials and components may react to wear, stress or fatigue in different ways. Exceeding the useful life of your Gocycle may be hazardous.

The expected life span of a Gocycle or Gocycle component will vary with the material and construction of the frame and components, the maintenance that is received over its life and the type and amount of riding. Any unusual or abusive riding style, such as off-road cycling, competitive riding, stunt cycling, jumping or riding at excessive speed and braking hard, can accelerate wear and fatigue of components to the point where premature and sudden failure of a component may occur without warning and risk of injury is increased.

Any form of crack, scratch or change of colouring in highly stressed areas indicates that the life of the component has been reached and you should replace it before any further use.

See Section 7.6 Checking for Cracking and Fatigue Failures for parts of the Gocycle that require visual inspection from time to time.

An impact to your Gocycle, either major or minor, can cause stress and fatigue on the Gocycle and its components or compromise the integrity of the electronics, including the battery, electronic controller, motor drive system or wiring. In the event of an accident and if safe to do so put your battery into sleep mode. (see Section 5.3.4.) Check for visual damage before continuing to ride the Gocycle. If the Gocycle has sustained damage other than light cosmetic scratches such as dented, cracked, bent or misaligned components, do not ride your Gocycle until it has been inspected by an authorised Gocycle service centre. If you are not comfortable inspecting your Gocycle, consult

techsupport@gocycle.com.

Gocycle® Owner’s Manual for G2, December 2015

2.9 First Ride

WARNING! First familiarise yourself with the modes of operation, controls and performance of your

Gocycle before venturing onto busy streets.

We strongly recommend that you familiarise yourself with your new Gocycle by first riding it in a controlled environment, away from potential hazards such as moving traffic and obstacles. It is important to become familiar with the modes of operation, controls, brakes and the different performance characteristics inherent in the electric motor.

WARNING! Your braking efficiency will increase during the first few rides as your brake disks and

pads “bed in”. To accelerate the increase in braking performance, perform a number of controlled

stops under hard braking.

2.10 Steerer Stop

Your Gocycle is fitted with a steerer-stop to prevent over-rotation of the handlebars, which would cause the internal cables to be stressed under tension. Do not attempt to force your handlebars past 90 degrees from straight.

CAUTION! Do not attempt to rotate the handlebars beyond 90 degrees from straight.

Never over-rotate the handlebars. Damage caused by ignoring the warning will not be covered under warranty.

Gocycle® Owner’s Manual for G2, December 2015

Frame number

Compliance information

Minimum leg height with standard seat post (compact seat post available at

www.gocycle.com)

3 WARRANTY

Please view current warranty terms and conditions at www.gocycle.com/terms.

3.1 Warranty Registration

For your continued satisfaction and safety whilst riding your Gocycle, we strongly encourage you to register your Gocycle with us. Doing so will enable us to contact you with important product safetyrelated information, should the need arise.

In the event that you wish to make a warranty claim, you must provide your original proof of purchase (sales receipt or order confirmation). Keep this information in a safe place. Before we can process a warranty claim, you must have registered your Gocycle.

Please visit www.gocycle.com/safety to register your Gocycle in order to stay informed of important

safety notices.

3.2 Gocycle Frame Number

Your Gocycle comes with a unique identifier called a frame number, positioned on the rear of the Gocycle. An example is shown below:

Your Gocycle frame number will be required when registering your Gocycle, making a warranty claim or making contact with Karbon Kinetics Ltd. Make a note of your frame number and keep it in a safe place.

Gocycle® Owner’s Manual for G2, December 2015

4 RECOMMENDED ASSEMBLY SEQUENCE

Gocycle® Owner’s Manual for G2, December 2015

IMPORTANT ASSEMBLY ADVICE! Continue reading for important assembly advice, including how to

will cease to operate. See Section 4.8 Gocycle Registration.

Gocycle® Owner’s Manual for G2, December 2015

4.1 Pre-ride Checks and Service Interval

Before riding your Gocycle you must complete the pre-ride checks. This will ensure your safety and that your Gocycle is operating optimally.

Gocycle® Owner’s Manual for G2, December 2015

Location

Correct cable positioning

Caution! Incorrect positioning

4.2 Warning! Take Care during Assembly

When folding the handlebar stem there is potential for the internal cabling to be pinched by the folding mechanism. Severe pinching may compromise the integrity of the cabling, which in the worst case may cause the product to not function correctly.

Thoroughly inspect the handlebar folding mechanism when folding/unfolding, taking care not the pinch any internal cabling (pictured). Never force the handlebar stem. If a cable is positioned incorrectly, STOP and ensure the cable is repositioned before continuing.

During assembly or disassembly, do not over-fold the Cleandrive more than is necessary to engage or disengage the Gocycle Lockshock™. Over-folding the Cleandrive can cause the internal cables to become taut and in some cases may result in cables becoming disconnected, ultimately affecting the operation of the product.

Gocycle® Owner’s Manual for G2, December 2015

Open the quick release lever, as shown.

Undo the quick release lever (anticlockwise).

Height

adjustment

Reach

adjustment

4.3 Handlebar Height and Reach Adjustment

In addition to Gocycle’s patented Vgonomic adjustment (changing the effective cross-bar length when lowering or heightening the saddle), it is also possible to make further adjustments to accommodate most riders comfortably by changing the handlebar height and reach.

4.3.1 Handlebar Reach Adjustment

Gocycle® Owner’s Manual for G2, December 2015

Completely remove the quick release.

The handlebar stem adjuster has two positions:

Use the top position for aft adjustment. (Shorter rider: least reach, handlebars closest to saddle).

Use the lower position for forward adjustment. (Taller rider: greatest reach, handlebars furthest from saddle).

Align the desired position and re-insert the quick release, as shown.

A. Top

position

B. Lower

position

Gocycle® Owner’s Manual for G2, December 2015

With the quick release inserted, rotate clockwise to tighten

Close the quick release lever. The lever should feel harder to close at it reaches a 90- degree position.

Undo and remove the handlebar stem bolt using a Torx tool, as shown.

4.3.2 Handlebar Height Adjustment

Gocycle® Owner’s Manual for G2, December 2015

Lift the rubber dust cover to expose the lower position.

Note! Hole “B. Upper position” denotes the

maximum height of the handlebar stem.

Push down to align the lower position

Ensure the bolt hole and stem upper position or lower position hole are fully aligned.

A. Lower

position

B. Upper

position

A. Lower

aligned

B. Upper

position

Gocycle® Owner’s Manual for G2, December 2015

Reinsert the stem bolt and tighten to a torque of 6-8 Nm.

CAUTION! Ensure the bolt passes through

either “A. Lower position” or “B. Upper position” hole of the stem upper.

Tidy the rubber dust cover.

Gocycle® Owner’s Manual for G2, December 2015

1.1. Orientate the Tool Holder as shown

1.2. Locate the Snap Rail Tool Holder (B) above the saddle rails as shown.

1.3. Apply pressure onto the right hand side of the Snap Rail Tool Holder (B) until this side is properly located onto the right saddle rail.

4.4 Assembling the G2 Seatpost Tool Holder

Gocycle® Owner’s Manual for G2, December 2015

1.4. Apply pressure onto the left hand side of the Snap Rail Tool Holder (B) until this side is properly located onto the left saddle rail.

1.5. Confirm both sides of the Snap Rail Tool Holder (B) are properly located onto the saddle rails.

1.6. Push the Snap Rail Tool Holder (B) towards the front of the saddle.

Gocycle® Owner’s Manual for G2, December 2015

1.7. Insert the 4mm Allen key

(A) supplied with the Gocycle.

Tool Holder installation is complete.

Gocycle® Owner’s Manual for G2, December 2015

Mount the rear reflector on the upper seat post

CAUTION! Do not assemble the rear

reflector too close to the saddle as it may

be obscured by clothing

Open the rear reflector bracket

Place the bracket around the upper seat post and tighten, using a screwdriver, to secure in a position as shown

Preferred

range

4.5 Assembling the Front and Rear Reflectors

Front and rear reflectors are supplied as standard with your Gocycle and can be found in the small parts bag.

To install the rear reflector:

Gocycle® Owner’s Manual for G2, December 2015

Mount the rear (red) reflector onto the bracket and listen for a “click”

Adjust the bracket to ensure that the reflector is vertical

Fix the assembled reflector in a vertical position as shown

To install the front reflector:

Gocycle® Owner’s Manual for G2, December 2015

Lift the rubber stem cover to expose the upper handlebar stem

Open the reflector bracket

Place the bracket around the upper stem and tighten, using a screwdriver, to secure in the position as shown

Gocycle® Owner’s Manual for G2, December 2015

Mount the front (white) reflector onto the bracket and listen for a “click”

Adjust the bracket to ensure that the reflector is vertical

Fix the assembled reflector in a vertical position as shown

Gocycle® Owner’s Manual for G2, December 2015

Bell and O-ring for mounting bell

(Supplied in small parts bag)

Loop the rubber O-ring over the bell as shown

Insert the base of the bell through the gap between the brake hose and handlebar, as shown

4.6 Assembling the Bell

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Gocycle G2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual