Smooth e500
Product Specifications:
Overall Length: 58.2”
Overall Width: 26.7”
Overall Height: 47.2”
GW: 200lbs. / NW: 187lbs.
Tire (Front/Rear): 16”x 3”
Front/Rear Drum style brakes
Battery: 48 Volt Lead Acid battery pack
Motor: 500W
Controller: 14amp
Maximum forward speed: 12-18MPH on a flat surface
Continuous range: 25 miles
Battery Charger: 110/220 Volt
Charge Time: 4-8 hrs.
Popcycle Motors LLC Tel: (314) 438-6253 www.popcyclemotors.com
Rearview Mirror
Braking Handle
Parking Button
Lift up armrest for easy access
Swivel Seat
Drive Motor
Brake Hub Housing
Brake Hub Housing
Front Suspension
Headlight
Turn Signal
Front Fender
Front Panel
Popcycle Motors LLC Tel: (314) 438-6253 www.popcyclemotors.com
Throttle (twist type - right handgrip)
Popcycle Motors LLC Tel: (314) 438-6253 www.popcyclemotors.com
Driving any electric bicycle demands a special effort on your part for safety issues.
- An inspection of the bike before starting off will insure safety – always check each tire’s pressure.
- Never let an inexperienced driver drive your electric bike.
- Wear bright color clothing while driving at night.
- Respect the laws of your state and local city or county.
- Respect the speed limits.
- Always signal before turning.
- Be very careful at intersections, parking exits, etc.
- Always ride with both hands on the handlebar handgrips and feet on the floor.
Protective Gear
- For your safety, always wear a helmet, glasses and protective clothing.
- Do not wear loose clothing with risk of getting it tangled on wheels, steering, or passing objects.
Bike Modification
Do not modify the electric bicycle. It could make riding very dangerous and would certainly void the
warrant of the device.
Quality Control
Thanks to the highest standards of quality control, the finest selection of components and assembly
processes built on years of experience, this electric bike is one of the best products in today’s market.
This device is equipped with a powerful motor which offers superior control while producing very little
sound with the power to climb most hills and delivers the longest possible battery life.
Applying the brakes automatically turns off the motor which adds an additional level of safety for the
driver and more efficiently uses the brakes.
Battery: Especially designed for your electric vehicle.
Frame: High quality stainless steel frame
This manual contains the safety precautions and recommended operating instructions. Even if you are
an experienced motorcycle user, it is in your own interest and safety to familiarize yourself with the
latest rules and regulations regarding safe use of your motorcycle or electric bike.
Please note that the illustrations show the Popcycle step through motorcycle or electric pedal type
series of bikes. Other motorcycle models may have different parts and controls. You should therefore
always refer to the Owner’s Manual of your particular motorcycle/scooter.
Because any powered cycle is a high-speed transportation device, some special safety precautions
must be observed as with any other vehicle to reduce the risk of personal injury. Careless or
improper use may cause serious or even fatal injury. Read and follow all safety precautions in the
current Owner’s Manual or Safety Manual. Always use two hands to operate the cycle.
Minors under the legal driving age should never be allowed to use a cycle. Bystanders, especially
children, and animals should not be allowed too close to the area where the cycle is in use. Never let
the bike be in the run position while unattended. Store it in its locked position away from children. Do
not lend or rent your cycle without the Owner‘s Manual. Be sure that anyone using your bike reads
and understands the information contained in this manual.
You must be in good physical condition and mental health and not under the influence of any
substance (drugs, alcohol) which might impair vision, dexterity or judgment. Do not operate a
motorcycle/scooter when you are fatigued. Be alert – If you get tired while operating your cycle, take a
break. Tiredness may result in loss of control. Driving any motor cycle can be strenuous. If you have
any condition that might be aggravated by strenuous activity, check with your doctor before operating
any cycle.
To reduce the risk of injury, the operator should wear proper apparel. Clothing must be sturdy and
snug-fitting, but allow complete freedom of movement. Avoid loose fitting jackets, scarves, long
neckties, jewelry, flared or cuffed pants, unconfined long hair or anything that
could become entangled with the device or your clothing. Wearing overalls or jeans and protecting
your hands with gloves is especially important in less than ideal conditions. Heavy duty, nonslip
gloves improve your grip and protect your hands. To reduce the risk of injury to your eyes never
operate a motorcycle unless wearing goggles, a helmet visor or properly fitted safety glasses with
adequate top and side protection complying with your state’s standard.
Never modify your bike in any way. Only attachments and parts supplied by Popcycle or expressly
approved by Popcycle for use with the specific Popcycle models are authorized. Although certain
unauthorized add-ons are useable their use may, in fact, be extremely dangerous.
Take extreme care in wet and freezing weather (rain, snow, ice). Put off the riding when the weather
is windy, stormy or rainfall is heavy.
Never operate a scooter that is damaged, has improperly inflated tires or not completely or securely
assembled. Follow the maintenance and repair instructions in the appropriate section of your Owner’s
Manual.
Use only Popcycle replacement parts for maintenance and repair. Use of parts manufactured by
others may cause serious or fatal injury.
Important Safety Instructions -
Always wear a helmet when operating this device
Popcycle Motors LLC Tel: (314) 438-6253 www.popcyclemotors.com
Know and observe all local traffic laws. Local traffic laws may differ so become aware and follow all
laws pertaining to the use of your scooter. Consult your Department of Motor Vehicles for assistance
understanding any rules that may govern the use of this device.
Never assume that a driver of another vehicle, or even a pedestrian can see you on your scooter – the
size of device makes it imperative that you drive defensively at all times: Assume that everyone is going
to hit you! And do not let them!!
Do not overload your scooter as it could damage components or cause an unstable and dangerous
condition. Refer to the owners manual for the specific weight restrictions of your Popcycle Model.
Do not submerge scooter in water as this could short circuit and damage electrical equipment and or
cause serious personal injury. Extra care should be done when riding in rain or snow conditions and
should be avoided if possible.
Never plug in the charger if the connections are wet – remember that water is a conductor of electricity
and grave danger can occur with any misuse or careless disregard for safety. Stand in a dry place –
with non-conductive shoes on both feet. Follow the instructions in the Owners Manual and use common
sense when handling any electrical device.
Use only the charger provided with your bike. If there is any damage or compromise to the wiring call
Popcycle for repair or replacement unit.
Replacement batteries must match the exact AMP hours specified by the owner’s manual for your
model. It is important that the batteries are matched to the controller used in this device so adherence
to the correct specification is very important for reliability.
Always handle batteries with a great deal of caution – they can be dangerous if any of the internal
chemicals leak and come into contact with the bike or a person. Never smoke or have any open flame
near a battery as the chemical reaction that makes it work can produce flammable gas.
In the event of a significant battery leak cover the liquid with baking power to neutralize the acid. The
resulting salt is not dangerous.
An improperly connected battery can result in significant heat, possible fire or even an explosion of the
battery – follow all instruction and when there are questions that are not crystal clear in this and other
manuals; consult either a dealer or call Popcycle Customer Service.
Remember that this is not a toy and that if properly used and maintained will give you years of reliable
service. Please be careful and follow all safety instruction – enjoy the ride.
Important Safety Instructions -
Always wear a helmet when operating this device
Popcycle Motors LLC Tel: (314) 438-6253 www.popcyclemotors.com
1)
Insert the key and turn it to the symbol on , the dashboard
lights up and the motor is ready to go
Ignition:
Before taking the road:
1) Check tire pressure
2) Check battery power level.
3) Check braking system efficiency and if motor shuts off when brakes are applied.
Driving
The electric bicycle is easy to drive. A smooth ride can help the life of the battery and the duration of
its charge.
Release the throttle to slow down - as the throttle goes back to its original position, the motor will shut
off automatically.
In case of emergency press on both brakes front and rear, this will shut off motor and stop the bike.
Once the brakes are released the motor is ready to go again.
Locking the steering
Put the steering towards the left and turn the key to the position of parking/lock and the steering
column will be locked.
Note: To unlock perform the opposite operation.
Popcycle Motors LLC Tel: (314) 438-6253 www.popcyclemotors.com
Use and Maintenance of the battery
Your electric bicycle is equipped with high quality batteries, which have these advantages:
1) Low unattended discharge
2) Leak resistant case
3) Deep cycle discharge
Make sure to fully charge your battery before the first usage, or after long use. In case of prolonged non
use, store the bike in a dry place and make sure to charge it at least once a month to avoid crystallization
of lead sulfates.
The original charger which was provided has to be used, as the use of a different charger could
irreparably damage the battery.
Battery indicator:
The level indicated is actual when the electric bicycle is in motion. If the level is low, make sure to
charge the battery as soon as possible.
Attention: Do not touch the battery terminals with wet hands. Do not cause a short circuit with metal
objects across the terminals. Battery’s are extremely hazardous if mishandled!
Use of the battery charger:
How to charge the battery:
1. Connect the exit of the charger onto the battery plug to charge
2. Connect the plug of the charger to an regular electrical socket
3. The red light is on while charging
4. The light will become green when the battery becomes fully charged
5. Unplug the charger from the bike and from the AC power source
Attention: BE SAFE! Remove the key from the ignition while charging the battery
State of charge:
The charge is automatically controlled and stops as soon as the battery is fully charged and the
red light of the charger turns off.
Note: A shorter charge is acceptable as this type of battery has no “memory” and can be charged
without concern for changed in capacity due to cycle depth.
Attention: During the charging make certain the device and the charger is out of the reach of
children at all times.
During the charging, the charger must exhaust some heat. Do not cover or put it next to flammable
materials. If the charger doesn’t stop charging after 10 hours, stop charging and call customer
service.
Use only the original charger. Don’t leave the charger in the electric bicycle; it could be damaged
by the vibrations of the bike.
Attention: In case the charger overheats (≥65°C), stop immediately the charging.
Popcycle Motors LLC Tel: (314) 438-6253 www.popcyclemotors.com
To preserve the life span of your motor, it is recommended that a complete check up of the
electric bicycle be done.
Don’t ride on a road where the water submerges more than a third of the power assisted wheel,
because water could penetrate into the motor and cause a malfunction to the motor.
Special Declaration: Concerning Lithium battery
Attention:
1. Do not connect the positive and negative terminals of this battery.
2. Do not expose this battery to high temperature such as on or beside heating appliances or in
direct sunlight.
3. Do not submerge this battery in liquid of any kind.
4. Do not disassemble this battery unless you are a qualified electrician and then only after reading
the technical guide. Disassembly of this battery voids all guarantees.
5. Store in a cool, dry area out of direct sunlight. If this battery is to be stored for more than two
months please charge the battery for two hours every two months of storage.
6. Do not use any other charger except for the one supplied with this battery.
7. When this battery is no longer of use please dispose of properly by returning to a retailer or
battery collection point. Do not dispose of this battery with your household waste.
Maintenance
The following maintenances have to be done as regularly as possible, general rule, once a
week:
1) Clean the surface of the motor and of the entire electric bicycle.
2) Verify the motor and the pod of connection.
3) Check the fixation of each element, retighten the screws if necessary.
Regular maintenance:
Check up every 6 months:
- Check and adjust the braking system
- Check and tighten the fixation screws
- Check the wear and tear of tires
- The output of voltage from the charger
- The battery capacity
- Check and adjust the lights
- Check the control system
Every 6 months:
Greasing the front and back axles, the stand and the brake cable.
Be aware of the state of usage of the brake lining. If the cables get stuck, you must take
apart, clean and grease and put back together.
Popcycle Motors LLC Tel: (314) 438-6253 www.popcyclemotors.com
Symptom
Possible causes
Solution
Ignition on ,and the display
board doesn’t turn on
1.
The battery did not charged
2.
The fuse has melted
3.
The display board is defective
4.
Wrong connection of
dashboard
5.
Low battery charge
1.
Clean the battery terminal
2.
Change the fuse
3.
Change the display board
4.
Observe and remedy
5.
Charge the battery
Ignition on, the motor
doesn’t engage when
throttle is activated
1.
The motor is not activated
2.
The throttle not connected
properly
3.
The controller out of service
1.
Check the connection
2.
Check the connection
3.
Contact customer
service
Throttle released and
motor still engaged
1.
Defective throttle
2.
The controller out of service
1.
Contact customer service
Lack of power
1.
Low battery level
2.
Brakes are applied
1.
Charge the battery
2.
adjust the brakes
Speed unstable
1.
Bad connection with the
battery
2.
Brake lever is defective
1.
Check the ignition
2.
Check and change if
need be
The charger does not
function
1. Short circuit in wall socket
Charger fuse is burned
2.
Battery fuse is burned
3.
Charger is out of service
1.
Check and repair
2.
Change the fuse
3.
Change the fuse
4.
Change the charger
Troubleshooting Guide
In case of a problem
The braking system becomes inefficient
A braking system that fails represents a grave danger of accident. It is strongly recommended to
check the efficiency of the brakes and to do the necessary adjustments before taking the road.
In the case where, while on the road, you realize that the brakes are inefficient make sure to slow
down and to stop immediately in order to adjust the brakes.
Temporary motor failure
The causes for a temporary motor failure are multiple, before calling customer services:
1. Dust and dirt build up on the battery terminal.
2. The main cable not connected to the battery terminal
3. The switch of the braking system that shuts motor off might be wet and is creating a short
circuit, dry the switch if needed. Avoid prolonged exposures of the electric bicycle to the rain.
4. The switch of the braking system that shuts motor off should be at its original position, if it is not
or if it is blocked by a foreign object. Place back to its original and remove blocking object
Popcycle Motors LLC Tel: (314) 438-6253 www.popcyclemotors.com
Connector controller:
Popcycle Motors LLC Tel: (314) 438-6253 www.popcyclemotors.com
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