Electrically Assisted Pedal Cycles
Assembly Instructions
Version 4 – 24 Sept 2005
2
Introduction
Thank you for buying a PowaCycle Ranger electric bike. We hope it
brings you many hours of enjoyment.
For safe and compact shipping, we have despatched your PowaCycle
Ranger part assembled. It therefore requires some assembly work
before you can begin riding.
Please follow these instructions carefully. If you do not feel confident
to assemble the bike yourself, we recommend you visit your local
cycle store for professional help and advice.
Contents
Before assembly, please check that you have all the parts below:
Important:
A spare set of keys is supplied. Please keep these in a safe place as
lost keys cannot be replaced.
Front Wheel
Main Cycle Frame
Pedals
Mudguards
Small components for
fixing mudguards
3 x Small nuts & bolts
1 x Large nut & bolt
2 x Washers
2 x Brackets
Keys (Power, Battery Lock)
Saddle on stem
Battery Charger
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Assembly Instructions
Charge the Battery
Before assembling your PowaCycle, you should charge the battery.
This will allow you to test the electrical connections during assembly.
Remove the battery and charge it indoors. It may take up to 8 hours
to fully charge the battery. When charged, the LED turns from red to
green. Please note, the battery will deteriorate if it is left uncharged.
To remove the battery, turn the key on the
vertical tube. The barrel will release, allowing
the battery to be withdrawn.
A lever under the seat releases a latch,
allowing the seat to be lifted forward on a
hinge, this makes the battery accessible.
Using the handle provided, pull upward to
slide the battery from the base housing.
Charge the battery indoors, keeping it away
from water or combustible material.
Connect the round-ended charger plug to the
battery socket. Plug the charger into the
mains supply and switch it on at the plug.
A full charge can take 8 hours. The light is
green when the battery is charging and
changes to red when it is fully charged.
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Fitting the Handlebars
The handlebars are already attached to the
frame via cables.
They now need to be inserted into the frame
as shown.
Align the handlebars 90 degrees to the forks.
Finally, use an Allen key or hexagonal tool to
tighten the handlebars in place.
NOTE: We recommend that you make a final
adjustment of the handlebars once the bike is fully
assembled.
Fitting the Saddle
Insert the saddle stem into the frame. Use
the lever clip to secure the saddle in place. If
the clip is too loose or too tight, adjust the
lever in relation to its opposing nut to achieve
a firm closure.
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Fitting the Wheel
Remove the black plastic front fork
protectors, which are part of the protective
packing material.
We recommend that you turn the bicycle
upside down, resting it on the handlebars and
saddle.
Note: We suggest you remove the battery, to make the
bike lighter, before turning it upside down. Also, you may
need to adjust the saddle to make it more stable.
Remove the protective plastic nut from the
wheel. This is part of the packing material.
Insert the wheel into the front fork, ensuring
that the disc is placed within the brake
mechanism.
Insert the lock washer into the small hole
in the fork.
Use a spanner to adjust the inner wheel
nuts (arrowed) between the wheel and the
fork, to align the wheel and disc with the
disc brake mechanism.
The wheel needs to spin freely, so avoid over
ti
g
htening the inner nuts.
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Use a spanner or socket set to tighten the
outer nuts (outside the fork) so that the
wheel is secured firmly to the fork.
Brake Assembly
Use an Allen key to release the brake cable,
and then pull it through to take up the slack.
Tighten the Allen nut once the cable is tight
and retest the brakes. Adjust the cable until
the wheel turns freely and the brakes are
effective.
Fine adjustments to the brake tensions can be
made via adjustment controls located at the
junction of the brake lever and cable.
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Fitting the Mudguards
FRONT Fix the small bracket to the front
mudguard, then insert the front mudguard
between the wheel and the arch.
Attach the mudguard bracket and the front
light bracket to the arch (the front light is
already connected to the bike by its wires).
The mudguard bracket should be to the rear
of the arch and the front light bracket should
be at the front of the arch.
The brackets are fixed by a bolt through the
centre of the arch. A sculpted nut sits over
the rounded front surface of the arch with a
smaller, securing nut to the rear.
Note: Ensure that the mudguard is pulled up with
sufficient clearance from the wheel.
REAR Fix the rear mudguard directly to the
support bracket that is integral to the frame.
Insert the plastic barrel between the integral
frame supports. Place the mudguard supports
on the outside edges of the frame supports
and tighten the nut and bolt.
Fitting the Pedals
Pedals are marked L and R, for the left and
right hand side of the bicycle when it is facing
forward. Screw each pedal into the
appropriate pedal shaft by hand, and then
tighten with a spanner to secure.
The pedals have a reverse thread and
therefore need to be screwed in backwards.
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Completed PowaCycle Ranger
Finally …
Before mounting your cycle to ride, remember to check that:
the battery is fully charged.
the tyres are inflated to the correct pressure.
the brakes are operating effectively.
the handlebars are correctly adjusted and secure
the seat is at the correct height for the user
the lights are working
all nuts and bolts are secure (including pre-assembled ones).
Operation of the Ranger PowaCycle
Overview
The PowaCycle Ranger is an electrically assisted bicycle that operates
as a standard bicycle, with the assistance of a motor and battery.
The power provided supports the rider’s own efforts, giving increased
performance with less effort.
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Battery Charging, Care & Safety
Care of the battery is vital to maximise its long-term performance.
The battery must be removed from the bike for charging.
Regular Use – If you are commuting significant distances, it is
advisable to recharge the battery before the return journey.
Occasional Use – Recharge the battery at least once a week,
even if the cycle is unused.
Always recharge the battery after use.
Always charge the battery indoors.
Keep the battery away from water, to prevent shocks or shorting.
When attached to the bicycle, it is safe to operate in wet conditions.
Do not cover the battery or charger.
Do not leave the battery permanently charging from the mains supply.
Only use the charger provided to charge the battery.
Do not use the battery to power anything other than the
PowaCycle for which it was purchased.
Do not disassemble or modify the battery.
Do not expose the battery to fire or extreme temperatures.
Do not short circuit the battery.
Do not allow impact or force against the battery pack.
Dispose of the battery in a dedicated waste facility.
Additional Lights
As an additional safety feature, we recommend that night users
purchase independent front and rear lights that are NOT powered
from the cycle battery. After a long journey, there is a risk that the
cycle battery could be depleted, so lights relying on the cycle battery
could stop working.
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Tyres
Check the tyres regularly to ensure that the correct pressures are
maintained (pressure ranges are shown on the sides of the tyres).
Do not over-inflate the tyres.
There are different types of pumps available for cycles. Ask your
local cycle shop for the one best suited to your needs (do not use a
garage forecourt air hose to inflate your tyres).
Brakes
Make sure your brakes are adjusted correctly at all times.
Adjustment can be made at the wheel rim/brake mechanism with
tools. Fine tuning of the brakes can be made via adjustable twist
screws that are located at the join of the brake lever to the cable.
Replace the brake blocks when worn.
Power
Switch on the power by turning the key in the battery. The Ranger is
a “pedelec”. This means that, as soon as the rider begins to pedal,
the motor supplies energy to support the cyclist’s efforts. If the rider
prefers to cycle without the assistance of the motor, he or she should
leave the ignition off.
Gears and Bicycle Chain
Change through the gears one at a time and only when the bicycle is
being pedalled. To maintain performance, ensure that all the
mechanical parts of the gears are lightly oiled (avoid getting oil
deposits on the wheel rims). If the chain mechanism becomes
dislodged, turn the pedals forward gently to engage it. If the chain
becomes completely dislodged, re-engage it on the smallest gear cog.
Saddle
For maximum comfort ensure that the saddle is both correctly
adjusted and secure. Once set up correctly, the height of the saddle
can be adjusted without tools. Loosen the lever at the top of the
frame below the saddle to raise or lower the saddle. Once the saddle
is at the required height, secure it by tightening the lever. Tighten or
loosen the nut on the lever if required.
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User Safety
Cycle Helmets
Although there is no legal requirement to wear a cycle helmet, we
recommend that you do so for your safety. Wearing a cycle helmet
has been proven to reduce the likelihood of head injuries.
Professional Maintenance
We recommend that you have your cycle serviced by a professional
cycle engineer at least once a year to ensure ongoing safe
performance. Also, if you are unsure as to how to carry out a
particular assembly procedure or adjustment, we recommend that
you consult your local cycle shop.
Troubleshooting
1 – Brakes not working effectively
Check the distance between the brake blocks and the wheel rim.
Check that the blocks are parallel with the wheel rim.
Check for any wear on the brake blocks
Fine tuning to the brakes can be performed by the adjusters
between the brake lever on the handlebars and the brake cable.
Major adjustments are made at the brake blocks and you will
need the appropriate tools. See brake assembly instructions.
2 – Motor not working
Check that the ignition has been switched on
Check that the battery is properly inserted in its housing.
Check that the battery is charged.
Check that none of the electrical cables and connections has become
dislodged.
3 – Light(s) not working
Check that the wiring is not broken.
Check that the bulbs are inserted correctly.
Check that all connections are made properly
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Warranty
Information
1 – The frame – Has a warranty of two years.
2 – Other main parts – Have a warranty of one year.
3 – The battery – is covered by a 6 month warranty,
as battery life will be determined by user care.
4 – Bulbs, brake blocks, tyres etc – Are regarded as consumables,
therefore when replacements are required, these need to be
purchased from your local cycle shop or store.
PowaCycle, Ultima Networks PLC,
Akhter House, Perry Road, Harlow, Essex, CM18 7PN
Tel: 01279-821243
www.PowaCycle.co.uk
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