Voloci NiMH User Manual

Copyright 2002, Nova Cruz Products, Inc. All rights reserved. Revision of July 25, 2002

Nova Cruz and Voloci are trademarks of Nova Cruz Products, Inc.

TM

NiMH User’s Manual

This manual contains important safety, performance, and maintenance information.
Read this manual before you use your motorbike for the first time.
Keep the manual for future reference.
Voloci is a trademark of Nova Cruz Products, Inc.
The Voloci motorbike is protected by US and International patents pending.
 Copyright 2002, Nova Cruz Products, Inc., All rights reserved.

Warranty

Most of your Voloci motorbike is warranted against defects in materials and
manufacture for one year from the date of purchase except for the frame and
batteries. The frame of your motorbike is warranted for 10 years and the
batteries are warranted for 6 months.

Nova Cruz will repair or replace at its option your Voloci motorbike if it is defective
within the warranty period. You are responsible for the cost of transporting or
shipping your motorbike to an authorized dealer or to the Nova Cruz service facility.

You must provide proof of purchase to obtain warranty services.
This warranty does not cover normal wear and tear, including wear of brake pads,

tires, chains, and sprockets. This warranty also does not cover damage due to
jumping, crashes, submersion in water, or other abusive treatment.

Removal, modification, or tampering with electrical or electronic components of your
motorbike without prior authorization from Nova Cruz voids your warranty on those
components.

This is a consumer warranty and does not apply to vehicles used in commercial or
rental applications.

Contact

Service information you may need in the future is available at our website
http://www.voloci.com.

Most Voloci dealers are trained to perform maintenance and service tasks. Feel free
to contact your dealer for service or technical support. Dealers specially trained to
perform service are listed on our website http://www.voloci.com.

Technical support inquiries may be made by email to [e-mail].
You may also reach a technical support person by telephone during normal business

hours (Eastern Standard Time) at [phone].

Safety

Not For Children – Adults Only

The Voloci electric motorbike is designed for adults. It is a high­performance vehicle that can travel at speeds of up to 30 mph (50kph).
It is not intended for use by children under age 16. Keep your
motorbike away from children. Never leave the keys to your motorbike
where they could be found and used by children.

WARNING: The Voloci motorbike is a motor vehicle. Travel via any
motor vehicle subjects the rider to the risk of accident and injury.
Serious injury or death is possible as a result of falls, loss of control or
collisions with other vehicles or objects.

WARNING: The risk of accident and injury is substantially increased
in wet or icy road conditions. Not only is visibility impaired, but the
handling, braking, and control of the motorbike is substantially
diminished. Use great caution when operating your motorbike on wet
roads. NEVER ride your motorbike in snowy or icy conditions.

WARNING: Riding at night or in periods of low light is much more
dangerous than riding during the daytime. Your visibility and that of
other drivers is substantially impaired from dusk to dawn. Use great
caution when operating your motorbike in conditions of low light.
Always use your head and tail lamps when dark.

WARNING: Riding a motorbike without a DOT-approved helmet
dramatically increases the risk of head injury and death. Never ride
your motorbike without wearing a properly fitted and properly adjusted
helmet.

WARNING: The Voloci motorbike is designed for a single rider only.
Riding with one or more additional passengers is dangerous and may
result in personal injury to both the driver and passenger.

Copyright 2002, Nova Cruz Products, Inc. All rights reserved. Revision of July 25, 2002

Nova Cruz and Voloci are trademarks of Nova Cruz Products, Inc.

SAFETY NOTE: To minimize the impact of unintentional throttle twists when
the Voloci is stationary, the on-board microprocessor limits the power delivered
to the motor at very low speeds (less than 0.5 mph). Once the Voloci is traveling
over 0.5 mph, full power resumes.

Ride safely:

§ Don’t ride when it’s icy.

§ Use great caution when the roads are wet.

§ Use great caution when it’s dark out.

§ Wear your helmet.

§ Never ride with a passenger.

§ Ride in control at all times.

§ Never stunt ride.

Collisions

Your motorbike is designed to withstand years of normal riding. However, collisions
can substantially weaken the structure of the motorbike. If you accidentally have a
minor collision with a curb, wall, or other fixed object, inspect the motorbike for
loose or bent parts. If you find such parts, contact your dealer or Nova Cruz for repair
or replacement. If you collide with a fixed object at speeds in excess of 10 mph (16
kph) and/or are thrown from the motorbike after a collision, you could severely
damage the structure of the vehicle. In such cases, please contact your dealer or Nova
Cruz for repair or replacement.

Registration and Insurance Information

The laws regulating electric motorbikes vary widely from state to state and from
country to country. In most regions, the Voloci motorbike is classified as a “moped”
for regulatory purposes. However, in some areas, electric motorbikes are unregulated,
and in other areas they are regulated by very specific laws. You must check the laws
in your country, state, and municipality to determine the licensing, registration, and
insurance requirements in your area.

Certificate of Origin

A “certificate of origin” and/or a bill of sale may be required to register and/or insure
your motorbike. These documents are provided as separate items and should be
included with the documents provided to you by your dealer (or by Nova Cruz if you
purchased directly from the factory).

Insurance

Insurance against various types of possible incidents is probably not provided by your
existing insurance policies. Please check with your insurance company about the
details of your coverage and if insurance requirements exist in your state.

Unpacking and Assembly

If you purchased your Voloci motorbike from a dealer, your dealer has already
completed any required unpacking and assembly tasks.

If you purchased your motorbike directly from Nova Cruz, you must follow these
assembly instructions. If you get stuck or encounter any difficulties, please call us at
1-888-353-4464 in the U.S. or outside the U.S. at 603-742-1037.

1. The following tools are required for assembly.

- 5 millimeter Allen wrench - Adjustable wrench

- 10 millimeter Open-End wrench - 14 millimeter Closed-End wrench

- Standard pliers - Torque wrench (optional)

Note: If you are uncomfortable performing this level of assembly or if you
cannot secure the required tools, please contact any bike, moped, or
motorcycle shop and ask them for assistance.

2. Remove your motorbike from its shipping carton by lifting it straight up out
of the box. Using two people for this makes removal from the box much
easier. When practical, retain your shipping carton and packing material in
case you need to package or ship your motorbike in the future.

IMPORTANT: REMOVE THE BATTERY FROM THE VOLOCI
BEFORE PROCEEDING WITH ASSEMBLY. Pull the battery handle

toward the seat and lift up to remove. If you would like to make battery
charging progress while you assemble your Voloci, plug the battery into the
battery charger now.

3. Remove the handlebar assembly from its packaging. Within the secondary
box locate the assembly hardware pictured in the photo below. These are
identified by the letters in the photo.

A

B

C

D

G

F

E

H

Copyright 2002, Nova Cruz Products, Inc. All rights reserved. Revision of July 25, 2002

Nova Cruz and Voloci are trademarks of Nova Cruz Products, Inc.

4. Install horn (A) using two M6x16 screws (B) inserted through holes from
the front and putting an M6 Nylock nut (D) on each screw. Torque to
moderate tightness using a 5mm Allen wrench and a 10mm Open-end
wrench. The perforations on the horn should be facing forward. The two
electrical connections should be facing in toward the bike – if they are not,
rotate the circular part of the horn until they do.

Step 4/5: Installation position for horn and directional on front end of Voloci

5. Install the two front directionals (F) (from the bag) using a 10mm Open-end
wrench and a 5mm Allen wrench. It does not matter which directional goes
on which side – they are symmetrical. Feed the wires for each directional
into the larger hole in the headlight bracket and press the post on the
directional into the wire hole. Align the hole on the directional with the
smaller hole in the headlight bracket and insert the M6x16 bolts (B) from the
outside in. Attach the M6 Nylock (D) nuts to each bolt on the inside of the
headlight bracket and torque to moderate tightness. Note: be very careful
with all of the directionals as they protrude from the bike and are easily
subject to damage.

6. Position the handlebar assembly on top of the handlebar mounts with the
throttle controls on the right side of the Voloci (looking forward). The
throttle handle is the handle that twists and has a red switch on it.

7. Making sure that no wires from the handlebar go below or between the
handlebar mounts, assemble the handlebar assembly to the front steering
assembly using the two handlebar clamps (E) and four M6x30 screws (C).
The handlebar should be centered side-to-side between the clamps and set to
the front-to-back angular position that the rider prefers before tightening (see
photo below with suggested orientation). The clamp screws should be
tightened with a 5mm Allen wrench to 1.0 kg-m (7 ft-lb) of torque. (Very
tight.) As you tighten the clamps rotate among the four clamping screws
until all are tightened equally and have even gaps between the top and
bottom clamps in all 4 places.

Step 7: Handlebar orientation Step 8: Headlight tilted forward

8. Loosen the headlight bolt in the side-to-side orientation with a 14mm
Closed-end wrench on one side and an adjustable wrench on the other and
tilt forward. A 14mm socket is also useful to loosen and tighten the
headlight bolt – DO NOT FORCE headlight to rotate forward.

9. Connect the electrical wiring on the front end of the Voloci in the following
order. Firmly push each connector set together after aligning.

NOTE: If you need to disconnect any connectors, be sure to pull only on the
connectors and not the wires. If the wires are pulled they will separate from
the connector and cannot be restored without crimping on a new connector.

a. Note: Leave all wire ties in place. They are holding the wiring

harness in the desired position.

b. Plug the 3 pin connector from the throttle on the handlebar

assembly into its mate emerging from behind the headlight mount.
If you need to disconnect there is small tab to pull up on one half of
the connector.

c. There is 1 black wire with a rectangular pink connector emerging

from behind the headlight mount. Connect this wire to the bottom
contact on the horn.

d. There are 3 black wires with round red connectors emerging from

behind the headlight mount. Connect 1 of these wires to either of
the 2 wires emerging from the left directional. Connect 1 of these
wires to either of the 2 wires emerging from the right directional.
Do not connect the 3rd black wire yet.

e. Connect the large 10-pin connector emerging from behind the

headlight mount to its mate coming from the handlebar assembly.
Push firmly together. If you need to disconnect there is small tab to
depress on the smaller half of the unit.

f. Connect the white wire emerging from the large connector to the

blue wire emerging from the headlight.

Copyright 2002, Nova Cruz Products, Inc. All rights reserved. Revision of July 25, 2002

Nova Cruz and Voloci are trademarks of Nova Cruz Products, Inc.

g. Connect the orange wire emerging from the large connector to the

other wire emerging from the LEFT directional (as you are sitting
on the bike and facing forward).

h. Connect the purple wire emerging from the large connector to the

other wire emerging from the RIGHT directional (as you are sitting
on the bike and facing forward).

i. Connect the black wire emerging from the large connector to the

remaining black wire with the red round connector emerging from
behind the headlight mount.

j. Connect the last wire (either brown or pink) emerging from the

large connector to the top contact on the horn.

10. Positioning the large connector either vertically to the right of the headlight
mount (while sitting on the bike and looking forward) or horizontally just
above and behind the headlight mount (whichever seems to naturally fit
better), neatly bundle the loose wires and rotate the headlight up to its
forward facing position. CAUTION: BE VERY CAREFUL NOT TO

TRAP OR CUT WIRES BEHIND HEADLIGHT AS IT IS ROTATED
BACKWARD. The headlight will passively hold the wires in place when it

is in the upright position. After ensuring that the headlight is aiming straight
forward, tighten headlight bolt with 14mm Closed-end wrench and
adjustable wrench to 1kg-m (7ft-lb) or moderately tight. Make sure that the
wires are not pinched as the handlebars are turned all the way to the left and
right.

Step 10: Connector in vertical position (left) and horizontal position (right)

11. Install the two rear directionals (already on the Voloci) using a 10mm Open­end wrench and a 5mm Allen wrench. On each directional remove wire ties
and locate 2 M6x16 (A) bolts and 2 M6 Nylock nuts (D). If your Voloci
arrived with a rear rack these fasteners may already be installed next to the
directional wires. Feed the wire for each directional into the hole in the seat
frame and press the post on the directional into the wire hole. Align the
other hole on the directional with the hole in the seat frame and insert the
bolts from the outside in. Attach the nuts to each bolt on the underside of
the seat frame and tighten. Be careful not to damage any of the wiring under

the seat. Note: be very careful with all directionals as they protrude from the
bike and are easily subject to damage.

12. Start with the left brake (as you are facing forward on the bike) which
controls the rear brake assembly. Locate the rear brake cable. It protrudes
from the bottom of the bike coming out under the Voloci logo on the
chassis.

13. On the inside of the left brake lever on the handlebar, you will find two
rotating barrel screws – these are brake adjusters. Turn these clockwise so
that they are screwed in as far as possible into the brake levers. Then back
each screw out until the slots on both are lined-up with the slot in the brake
lever housing (see photo in step 15).

Steps 13 and 14: Rotating barrel screws and brake cable insertion

14. While pulling the left brake lever, slide the metal bulb at the tip of the rear
brake cable into the hole in the left brake lever and slide in as far as it will
go. IMPORTANT: Make sure that the brake cable goes between the

horn and the headlight and travels behind the headlight as it goes to the
brake lever. When fully inserted you should see just wire through the hole

in the lever. Insert one of the brake lever pins (G) in the hole from the top
with the larger opening on the pin away from the brake cable sleeve (black
part). If inserted properly the pin should “capture” the wire and seat flush to
the top of the brake lever.

Step 15: Three lined up slots (left) and brake wire in first slot before full

insertion (right)

Barrel Screws

Brake Lever

Brake Lever Housing

Brake Cable