INSTRUCTION MANUAL For Turbo Unit The Unit for The Electric-Power Assist Intelligent Bike Sunstar Engineering Inc.

Transcription

1 INSTRUCTION MANUAL For Turbo Unit The Unit for The Electric-Power Assist Intelligent Bike For your safety, make sure to read this instruction manual before using the unit and understand the contents thoroughly. Always keep this manual in the designated place for easy access to the manual when needed. Sunstar Engineering Inc. 1

2 Introduction Introduction This instruction manual explains the installation and the handling of the turbo unit for the intelligent bike (electric-assist bicycle). Read and understand the contents of this instruction manual thoroughly to use the unit correctly. For use of the bicycle, please also refer to the instruction manual for the bicycle. If you have any questions or need further information about this manual, contact us. Never use the unit without clarifying unclear points. Illustrations and contents of this manual may slightly differ from those of the actual product due to changes in product specifications. Contents of this manual are subject to change without a prior notice. For resale or leasing this product, make sure to include this manual and a set of documents attached to this unit at the time of purchase with the machine. 2

3 Introduction Indications used in this manual In order to prevent accidents due to the wrong handling, this instruction manual uses the following marks to explain safety precautions. Be sure carefully read these safety precautions to understand the contents before handling the product. Symbol Definitions Indicates a potentially hazardous situation which, if ignored, could result in death or serious injury. Indicates a potentially hazardous situation which, if ignored, may result in minor or moderate injury. In addition to the above symbols, the marks below will also appear in this manual. Please read the following explanation in order to handle the product correctly. Symbol Definitions Indicates referential information or points to which special attention should be paid while handling the product. If ignored, the product could be damaged. Indicates referential information or points which are helpful for handling the product. Indicates items to be referred to. 3

4 Contents Introduction 2 Contents 4 Safety precautions 5 What bicycles can be made into intelligent bikes? 9 Adjustment for installing the assist unit 11 The front chainline dimension after installing the assist unit 11 What is an Electric-Power Assisted Bicycle? 12 Mechanism and special features of an Electric-Power Assisted Bicycle 12 Magnitude of the electric-assist force 13 Names of major parts and packing details of the Turbo unit 15 Names of major parts of the Turbo unit 15 Packing list of the Turbo unit 16 Order of installation 20 Confirmation of the Installation Sequence 20 List of tools you will need 21 1 Getting everything ready to install the Turbo unit 22 2 Installation of the assist unit 26 2' Installation of the assist unit (In case of a bicycle with a chain cover) 30 2'' Installation of the assist unit (Example for fixing on the front side) 33 3 Installation of cranks and pedals 36 4 Installation of the battery-hanger unit 37 4' Installation of the battery-hanger unit of type B 38 5 Installation of the control-switch unit and cords 39 6 Checks after installation 40 Reference diagram and notice when modifying the frames 41 Reference diagram when modifying the frames 41 Notice when modifying the frames 42 Contents How to interpret the indicating lamps of the control-switch 43 The control-switch with a lighting feature 44 Approximate riding distance per charge 45 Checks before Riding 46 Riding the intelligent bike 47 Riding the intelligent bike with the Turbo unit operating 47 Riding with increased power 49 Riding while conserving battery power 50 Riding without the assistance of the Turbo unit 50 Parking 51 Charging the battery 52 Precautions for handling the battery charger 52 Location for charging 52 Charging 53 Charging with installed battery 57 Concerning the battery 58 Battery type 58 Use in winter 58 Estimate for battery replacement 58 How to keep a battery in good condition 58 Maintenance and storage 59 Maintenance 59 Storage location 59 Long-term storage 59 Operation after long-term storage 60 Periodic inspections 61 Checklist 61 Initial inspection after 2 months 62 From the second inspection on 62 When you suspect trouble 63 Product specifications 65 Reference 65 4

5 Safety precautions Safety precautions Understand the contents of Safety precautions to use the product correctly. This section describes matters requiring attention for safety of users, etc. of the product. In regard to the bicycle itself, please refer to the instruction manual for the bicycle. About installation of assist unit Only those with sufficient knowledge about assembly/disassembly of bicycle parts must install the assist unit. Ignoring this could cause injuries. Improper installation also could cause injuries. About battery and battery charger Do not insert or pull out the power plug or charging plug with wet hands. Ignoring this could cause electric shock. Insert the power plug and the charging plug securely to the end. Ignoring this could cause electric shock or fire. Do not heat the battery or throw it into a fire. Ignoring this could cause injuries due to fire or battery burst. Do not leave the battery in a car with closed windows or expose it to direct sunlight. Ignoring this could cause injuries due to fire or battery burst. Do not charge or store the battery outdoors where it is exposed to rain or in a bathroom, toilet, etc. where it is exposed to water. Ignoring this could cause electric shock or fire. Do not use a battery charger with a damaged case, cord or plug. Ignoring this could cause electric shock or fire. Do not leave the battery or battery charger within the reach of children. Ignoring this could cause electric shock or serious injuries. Do not disassemble or modify the battery or the battery charger. Ignoring this could cause electric shock or fire. 5

6 Safety precautions About battery and battery charger (Continued) Do not contact the battery terminals with metal, etc. Do not place wires or other metals on the battery nor store the battery together with such materials. Ignoring this could cause fire. This is a special battery which must not be used for other bicycle models or applications than designated. Ignoring this may cause injuries due to fire or battery burst. Use the special battery charger to charge the battery, and observe the specified charging conditions. Using a different battery charger may cause injuries due to fire or battery burst. Use a power supply of AC100 to 240V (50/60Hz). Also use outlets and extension cords within the ratings. Ignoring this may cause fire. Do not impair the heat radiation of the battery or battery charger while charging. Ignoring this may cause fire. Avoid charging or storing the battery where there is excessive dust or dirt. Ignoring this may cause fire. While charging, do not keep the battery charger in contact with the same part of your skin for a long time. Ignoring this may cause low-temperature burns. Place the battery charger on a level surface. Ignoring this may cause injuries due to dropping of the battery charger. After completion of charging the battery, disconnect the charging plug from the battery. Ignoring this may cause fire. Always hold the plug when connecting or disconnecting the cord. Ignoring this may damage the cord and cause electric shock or fire. Do not lift the battery charger by holding the cord nor pull the cord. Ignoring this may damage the cord and cause electric shock or fire. Do not short-circuit the plug or cord. Ignoring this may cause fire. 6

7 Safety precautions About battery and battery charger (Continued) Do not drop the battery or battery charger. Do not expose them to shocks. Ignoring this may cause battery breakage and fire. Do not damage the power cord or charging cord. Ignoring this may cause electric shock or fire. Make sure that the power plug and charging plug are free from dirt or oil. Ignoring this may cause electric shock or fire. Do not use benzene, thinner, alcohol, polishing powder, etc. at the time of cleaning. Ignoring this may damage parts and cause fire. Make sure to pull out the power plug from the outlet when not using the battery or battery charger for a long period of time. Ignoring this may cause electric shock or fire. Do not discard the battery together with general garbage. Ignoring this may cause injuries due to fire or battery burst. If fluid should leak from the battery, observe the following: Take care to prevent it from contacting with skin and clothing. If battery fluid should get into your eyes, immediately wash your eyes with clean water and consult a doctor. If battery fluid should get onto your skin, immediately wash it off with clean water and consult a doctor. In the following cases, immediately stop using the battery or battery charger and contact your dealer. The battery or battery charger is immersed in water. Water or foreign matter has entered the inside. Either unit is dropped. Either unit is exposed to excessive shock. The case is damaged. Abnormal noise comes out. Smoke comes out. Abnormal odor comes out. 7

8 Safety precautions About electric-power assisted bicycle Do not kick yourself forward while standing on one pedal. Always start while sitting on the saddle. When force is given onto the pedal, the Turbo unit will be activated and the bicycle could fall over or cause a minor collision. Do not park, stop or push the bicycle with the control-switch set to ON. The Turbo unit will operate when the pedals are touched by foot or luggage, causing injuries due to a fall-over of the bicycle. Do not operate the control-switch during traveling. Operate the switch after stopping the bicycle. Otherwise, the bicycle could fall over, causing accidents. Do not disassemble or modify the electric-power assisted bicycle or assist unit. Ignoring this could cause electric shock or injuries. Never ride on the bicycle with the battery not securely fixed. The battery may come off, causing injuries due to a fall-over of the bicycle. Never ride on the bicycle with another person. Touching the battery or giving an excessive impact, in particular, may shift the battery mounting position and cause accidents. Do not drive through deep puddles. Do not drive in the heavy rain during the typhoon, etc. If the assist unit is exposed to lots of water or immersed in water, current leakage or electric chock may occur. If abnormal noise is produced or other abnormality is observed during traveling, stop using the bicycle to have it inspected and serviced by the dealer. Using the bicycle continuously may cause accidents. Always park the bicycle on a level surface. Ignoring this may cause injuries due to a fall-over of the bicycle. Do not lift the bicycle by holding the battery. The battery may come off, causing injuries. Do not touch the assist unit immediately after traveling is finished. The assist unit may be highly heated and cause burn injuries. 8

9 What bicycles can be made into intelligent bikes? What bicycles can be made into intelligent bikes? Bicycles with a bottom bracket shell width of 68 mm or 70 mm. For a bottom bracket shell width of 68 mm, use shims to bring the bottom bracket shell width to 70 mm. Bicycles with a bottom bracket shell hole diameter (inner thread diameter when there is a thread) of 33.8 mm to 34.2 mm. Bicycles without projections in the bottom bracket shell hole. When using the type B battery, the bicycle is required to secure the following condition between its rear-tire and seat pipe. The rotary radius (a), which is from the rotary center of the battery to the handle, is more than 150 mm. The rotary radius (b), which is from the rotary center of the battery to the projection on the front side, is more than 135 mm. The rotary radius (c), which is from the rotary center of the battery to the projection on the rear side, is more than 120 mm. The distance (d), which is between the bottom attachment hole of the battery-hanger unit and the bottom bracket center, is more than 86 mm. (d) is the distance when there is a bottom bracket hole just under the seat pipe. When using the type B battery, modifying the frames is needed. For details for the battery type, refer to Packing list of the Turbo unit (page 16). For modifying the frames, refer to Reference diagram and notice when modifying the frames (page 41). 9

10 What bicycles can be made into intelligent bikes? Installation may not be possible even when all of the conditions on the previous page are met. For details, please contact your dealer. For bicycles with front gear change, use of the front gear change becomes impossible. If the front sprocket of the bicycle and the accessory sprocket provided with the kit are not the same size, the chain length must be adjusted. For bicycles with hub-brakes, use of the hub-brakes becomes impossible. Installing rear-brakes is required. No projections in the bottom bracket shell hole Bottom bracket shell width: 68mm or 70mm Bottom bracket shell hole diameter Rotary center (Inner thread diameter when there is a thread) of the battery 33.8mm to 34.2 mm (a)(b) (c) (d) 10

11 Adjustment for installing the assist unit/the front chainline dimension after installing the assist unit Adjustment for installing the assist unit Adjust the gear development to 6.3 m or less. The gear development is the distance which bicycles are moved by one turn of the crank (the value of the outer circumference of the rear-tire to the power of the gear ratio). When the gear development is more than 6.3 m, adjust the rear-sprocket and rear-tire to make the gear development 6.3 m or less. Adjust the rear-sprocket in order to use the external 1 to 7 speed chain. The front chainline dimension after installing the assist unit 55.4 mm. The front sprocket is designed so that the chain can not be broken off easily during turning. Frame Sprocket Assist unit A front chainline dimension 11

12 What is an Electric-Power Assisted Bicycle? What is an Electric-Power Assisted Bicycle? Mechanism and special features of an Electric-Power Assisted Bicycle Riding is possible with little force. When the pedals are pressed, a sensor detects the pressing force. The assist force (electric-assist force) of the turbo unit acts corresponding to the force acting onto the pedals, and riding is possible with little force. Riding uphill, against the wind, or with luggage is possible easily. Riding is possible with comfortable speed. When the riding speed increases, the ratio of the electric-assist force for the pedal force decreases, and the electric-assist force becomes zero when the speed becomes 24 km/h or more in normal mode or turbo mode or 15 km/h or more in economy mode. For this reason, the electric-assist force will not cause an excessively high speed. When there is no pedaling or when the pedals are moved in reverse direction, no electric-assist force act. Riding in the same way as a normal bicycle is also possible. When the electric assist is set to OFF, use is possible in the same way as a normal bicycle. Normal use is possible even when the battery is exhausted. Pedal (pedal force) Turbo unit (electric-assist force) Pedal force + electric-assist force = Easy riding 12

13 What is an Electric-Power Assisted Bicycle? Magnitude of the electric-assist force The magnitude of the electric-assist force changes according to the force with which the pedals are pressed and the riding speed. There are three modes for the intelligent bike. Normal mode Refer to Riding the intelligent bike (page 47). When starting to ride and the largest assist force is needed, the ratio between pedal force and electric-assist force is 1:1. When the riding speed increases, the electric-assist force gradually decreases. At speeds of 24 km/h or more, the electric-assist force becomes zero. Turbo mode Refer to Riding with increased power (page 49). From 0 to 15 km/h, the ratio between pedal force and electric-assist force is 1:1. When the riding speed increases in the range from 15 to below 24 km/h, the electric-assist force gradually decreases. At speeds of 24 km/h or more, the electric-assist force becomes zero. Driving force (human pedaling force + electric -assist force) Human pedaling force : electric-assist force = 1:1 The electric -assist force decreases gradually. The electric -assist force becomes zero. Electric-assist force Turbo mode Normal mode Human pedaling force Start 15km/h 24km/h Bicycle speed 13

14 What is an Electric-Power Assisted Bicycle? Economy mode Refer to Riding while conserving battery power (page 50). When starting to ride and the largest assist force is needed, the ratio between pedal force and electric-assist force is 1:1. When the riding speed increases, the electric-assist force gradually decreases. At speeds of 15 km/h or more, the electric-assist force becomes zero. Human pedaling force : electric-assist force = 1:1 Driving force (human pedaling force + electric -assist force) The electric -assist force decreases gradually. The electric -assist force becomes zero. Electric-assist force Economy mode Normal mode Human pedaling force Start 15km/h 24km/h Bicycle speed 14

15 Names of major parts of the Turbo unit Names of major parts and packing details of the Turbo unit Names of major parts of the Turbo unit The names of the major parts of the Turbo unit are shown below. For the bicycle itself, please refer to the instruction manual for the bicycle. Control-switch Battery-lock key Battery-hanger Battery Assist unit Charging plug Power plug Battery Charger 15

16 Names of major parts of the Turbo unit Packing list of the Turbo unit No. Name Quantity Remarks 001 Battery charger 1 For charging the battery 002 Power cable (Correspondence to UL and CL) 1 For the Battery charger 003 Battery 1 Select one of the two types (Type A or Type B) 004 Assist unit Battery-hanger unit 1 Select one of the two types (Use the same type as the battery type) 006 Battery-lock key 2 For locking the battery 007 Chassis fixing fitting Chassis fixing ring Chassis fixing ring whirl-stop 1 Normally, the battery and battery-hanger unit provided are type A. Installing type B will require remodeling the seat pipe. When remodeling the seat post, contact the bicycle manufacturer or dealer (Type B) 003 or (Type A) (Type B) 005 (Type A) 004 or

17 Names of major parts of the Turbo unit No. Name Quantity Remarks 010 Chassis whirl-stop fitting 1 1 For installing on the rear side (Type R) 011 Chassis whirl-stop fitting 2 1 For installing on the rear side (Type R) 012 Flanged hexagonal nut 2 For attaching the cranks 013 Spacer 2 For bottom bracket shell width adjustment 014 Crank cap Large sprocket 1 Select either 48T or 40T 016 Crank L 1 Left crank 017 Crank R 1 Right crank 018 Control-switch 1 For installing the switch circuit board (Selecting a control-switch with lighting feature is available.) 019 Control-switch fixture 1 For installing the control-switch The prepackaged parts cannot fix the assist unit on the front side. For the details concerning a part to fix the assist unit on the front side, contact the bicycle manufacturer or dealer. For details concerning the control-switch with a lighting feature, refer to The control-switch with a lighting feature (page 44). : Packed in one bag (Type R) L 016 (Type R) 017 R

18 Names of major parts of the Turbo unit No. Name Quantity Remarks 020 Tie band (width: 4.8, total 2 For tying the battery cord length: 250, black) 021 Tie band (width: 2.5, total 5 For tying the switch cord length: 100, black) 022 Hexagonal socket-head bolt 2 For attaching the assist unit (M6 x 30),plated 023 Washer (M6) 2 For attaching the assist unit 024 Spring washer (M6) 2 For attaching the assist unit 025 Hexagonal socket-head bolt 1 For attaching the assist unit (M6 x 40) 026 Washer (M6) 1 For attaching the assist unit 027 Pan-head screw (M3 x 10) 2 For attaching the control-switch to the handlebars : Packed in one bag

19 Names of major parts of the Turbo unit No. Name Quantity Remarks 028 Hexagonal socket-head 5 For attaching the sprocket set-bolt (M5 x 10 and plate-washer) 029 Hexagonal socket-head bolt (M6 x 35),plated 1 For attaching the type A battery-hanger Packed only when the battery is type A 030 Spring washer (M6) 1 For attaching the type A battery-hanger Packed only when the battery is type A 031 Washer (M6) 1 For attaching the type A battery-hanger Packed only when the battery is type A 032 Nut (M6),plated 1 For attaching the type A battery-hanger Packed only when the battery is type A 033 Hexagonal socket-head bolt (M5 x 12),plated 2 For attaching the type B battery-hanger Packed only when the battery is type B 034 Spring washer (M5) 2 For attaching the type B battery-hanger Packed only when the battery is type B 035 Installation manual 1 : Packed in one bag

20 Order of installation Order of installation Confirmation of the Installation Sequence Please install the turbo unit in the following order. [1] Getting everything ready to install the Turbo unit (page 22) [3] Installation of cranks and pedals (page 36) [5] Installation of the control-switch unit and cords (page 39) [4] Installation of the battery-hanger unit (page 37) [2] Installation of the assist unit (page 26) [6] Checks after installation (page 40) 20

21 Order of installation List of tools you will need Tools in the following table are not supplied with the product. Please prepare them before installing the assist unit. Name Crank puller Hexagonal wrench (5 mm) Hexagonal wrench (4 mm) Phillips screwdriver Flat-tip screwdriver etc. Nippers Spanner (10 mm) Socket wrench (14 mm) Application For crank removal 5 mm: Installation of the assist unit 4 mm: Installation of the sprocket Installation of the control-switch etc. Bending of the chassis fixing ring whirl-stop claw Installation of the tie band for cord fixing 10 mm: Installation of the battery-hanger Installation of the flanged nut Chain cutter Pedal wrench (15 mm) Spanner wrench (46mm) Adjustment of the chain length (when the front sprocket of the bicycle and the sprocket supplied with the product do not have the same size) Pedal removal and installation Chassis fixing ring tightening For the steps describing the torque at the time of installation of the assist unit, use a tool permitting torque management. 21

22 Order of installation 1 Getting everything ready to install the Turbo unit Wear safety goggles, gloves, etc. during the installation work. Ignoring this may cause injuries. Remove the original pedals, cranks, chain cover, sprocket, chain cover stay, and bottom bracket parts from the bicycle to install. 1. Lower the bicycle stand. 2. Remove the right and left pedals. Tool Pedal wrench (15 mm) Install the removed pedals later on the cranks supplied with the product. Steps 2 to 7 differ depending on the specifications of the bicycle. For details, contact the bicycle manufacturer or dealer. Pedal wrench Pedal wrench Right pedal Left pedal Step 2 22

23 Order of installation 3. Remove the right and left cranks. Tools Socket wrench (14 mm) Crank (4) Remove (1) Remove the flanged nuts securing the cranks. (2) Screw the crank puller nut in. (3) Tighten the crank puller bolt. (4) Remove the cranks. Screw the crank puller (bolt) (3) Tighten. Screw the crank puller (nut) (2) Install. Flanged bolt (1) Remove. Step 3 4. For bicycles with installed chain cover, remove the chain cover. 5. Remove the original sprocket from the bicycle. Take the chain off the sprocket. When installing the Turbo unit, use the sprocket supplied with the product. Sprocket Step 5 6. For bicycles with installed chain cover, remove the chain cover stay. 23

24 Order of installation 7. Remove the bottom bracket parts. Bottom bracket parts 8. Check the bottom bracket shell width and the inner diameter of the bottom bracket shell to confirm that there are no projections in the bottom bracket shell hole. The Turbo unit can be installed only on bicycles with a bottom bracket shell width of 68 mm or 70 mm. Installation is not possible on bicycles with a bottom bracket shell hole diameter (inner thread diameter when there is a thread) below 33.8 mm or larger than 34.2 mm. Installation is not possible on bicycles with projections inside the bottom bracket shell hole. No projections in the bottom bracket shell hole Check the bottom bracket shell hole diameter (Inner thread diameter when there is a thread) Check the bottom bracket shell width. Before removal After removal Step 8 24

25 Order of installation 9. When using the type B battery, check if there is a space to install the battery between the rear-tire and the seat pipe. When using the type B battery, modifying the frames is needed. For bicycles where the rotary radius of more than 150 mm from the rotary center of the battery to the handle (a) cannot be secured, the battery cannot be installed. For bicycles where the rotary radius of more than 135 mm from the rotary center of the battery to the projection on the front side (b) cannot be secured, the battery cannot be installed. For bicycles where the rotary radius of more than 120 mm from the rotary center of the battery to the projection on the rear side (c) cannot be secured, the battery cannot be installed. For bicycles where the distance of more than 86 mm from the bottom fixing hole of the battery-hanger unit and the bottom bracket center (d) cannot be secured, the battery cannot be installed. (d) is the distance when there is a bottom bracket hole just under the seat pipe. For details for the battery type, refer to Packing list of the Turbo unit (page 16). For modifying the frames, refer to Reference diagram and notice when modifying the frames (page 41). Rotary center of the battery (a)(b) (c) Check the rotary radius, which is from the rotary center of the battery to: the handle (a) the projection on the front side (b) the projection on the rear side (c) (d) Check the distance (d), which is between the bottom attachment hole of the battery-hanger unit and the bottom bracket center. Step 9 25

26 Order of installation 2 Installation of the assist unit This is an installation method for fixing the assist unit on the rear side. For an example for fixing the assist unit on the front side, refer to 2'' Installation of the assist unit (Example for fixing on the front side) (page 33). 1. Install the large sprocket with hexagon socket-head set bolts (M5 x 10) to the assist unit (standard torque value: 3 N m). Tool Hexagonal wrench (4 mm) Tighten the five hexagon socket-head set bolts (M5 x 10) sequentially in the order of drawing a five-pointed star with one stroke. Hexagonal socket-head set-bolt (M5 x 10) Assist unit Large sprocket Step 1 2. Install the assist unit on the bicycle (1) If the bottom bracket shell width is 68 mm, install the accessory spacers, one on the left and one on the right. (These spacers are not required if the bottom bracket shell width is 70 mm.) (2) Set the chain onto the sprocket. (3) Install the assist unit from the right side of the body of the bicycle to the bottom bracket shell hole. Steps 2 to 4 differ according to the bicycle specifications. For details, contact the manufacturer of the bicycle or the dealer. Chain (2)Set Spacer (1)Insert (When the bottom bracket shell width is 68 mm) Bottom bracket shell hole Crank Assist unit (3)Install Step 2 26

27 Order of installation 3. Use hexagon socket-head bolt (M6 x 40) and washer (M6) to temporarily secure the chassis whirl-stop fitting R1 and R2 onto the body of the bicycle. Hexagon socket-head bolt (M6 x 40) Washer (M6) Chassis whirl-stop fitting R1 Chassis whirl-stop fitting R2 Step 3 4. Use hexagon socket-head bolts (M6 x 30), spring washers (M6), and washers (M6) to temporarily secure the chassis fixing fitting, the chassis whirl-stop fitting, and the assist unit. Tool Hexagonal wrench (5 mm) Chassis fixing fitting Washer (M6) Chassis whirl-stop fitting Adjust the position of the chassis whirl-stop fitting and the chassis fixing fitting to within 55 mm ± 0.15 mm from the end of the bottom bracket and to a radius for mm from the bottom bracket center. Refer to Reference diagram and notice when modifying the frames (page 41). For the positions of bolts, washers, and metal fittings, please refer to the side view. Spring washer (M6) Hexagonal socket-head bolt (M6 x 30) Step 4 Hexagonal socket-head bolt (M6 x 30) Assist unit Chassis fixing fitting Chassis whirl-stop fitting Side View Spring washer (M6) Washer (M6) 27

28 Order of installation 5. Install the chassis fixing ring whirl-stop and the chassis fixing ring. (1) Install so that the projection on the inner circumference of the chassis fixing ring whirl-stop matches the recess in the chassis fixing fitting. (2) Temporarily fix the chassis fixing ring. The chassis fixing ring has a front and a rear side. Install with the flat side to the outside. Confirm that the chassis fixing ring whirl-stop and the chassis fixing fitting are engaged. Chassis fixing ring (2)Tighten temporarily Chassis fixing ring whirl-stop (1)Install engaged 6. Fix the chassis fixing ring securely (55.0 N m). Tool Spanner wrench (46mm) Step 5 Control the torque (55.0 N m). Chassis fixing ring Tighten securely Step 6 7. Securely tighten the two hexagon socket-head set bolts (M6 x 30) temporarily tightened to the chassis fixing fitting (standard torque value: 12.0 N m). Tool Hexagonal wrench (5 mm) 28

29 Order of installation 8. Securely tighten the hexagon socket-head set bolt (M6 x 40) temporarily tightened to the chassis whirl-stop fitting R1 and R2 (standard torque value: 3.0 N m). Tool Hexagonal wrench (4 mm) This step is for only when using the chassis whirl-stop fitting R 9. Bend the chassis fixing ring whirl-stop claw at one of the three recesses of the chassis fixing ring. Tool Flat-tip screwdriver etc. Bend Step 9 29

30 Order of installation 2' Installation of the assist unit (In case of a bicycle with a chain cover) Installing a chain cover differs according to the bicycle specifications. For details, please contact the manufacturer of the bicycle, or the dealer. 1. Install the large sprocket with hexagon socket-head set bolts (M5 x 10) to the assist unit (standard torque value: 3 N m). Tool Hexagonal wrench (4 mm) Tighten the five hexagon socket-head set bolts (M5 x 10) sequentially in the order of drawing a five-pointed star with one stroke. Hexagonal socket-head set-bolt (M5 x 10) Assist unit Large sprocket Step 1 2. Install the assist unit on the bicycle (1) If the bottom bracket shell width is 68 mm, install the accessory spacers, one on the left and one on the right. (These spacers are not required if the bottom bracket shell width is 70 mm.) (2) Install the chain cover stay. (3) Set the chain onto the sprocket. (4) Install the assist unit from the right side of the body of the bicycle to the bottom bracket shell hole. Steps 2 to 5 differ according to the bicycle specifications. For details, contact the manufacturer of the bicycle or the dealer. Chain (3)Set Assist unit (4)Install Crank Spacer (1)Insert (When the bottom bracket shell width is 68 mm) Bottom bracket shell hole Chian cover stay (2)Install Step2 30

31 Order of installation 3. Set the chain cover to the assist unit and secure the chain cover with screws. Tool Phillips screwdriver After installation of the chain cover stay, the chain cover stay cannot be rotated by itself. For adjustment of the screw hole positions, rotate the screw hole together with the assist unit. 4. Use hexagon socket-head bolt (M6 x 40) and washer (M6) to temporarily secure the chassis whirl-stop fitting R1 and R2 onto the body of the bicycle. Hexagon socket-head bolt (M6 x 40) Step 3 Washer (M6) Chassis whirl-stop fitting R1 Chassis whirl-stop fitting R2 Step 4 5. Use hexagon socket-head bolts (M6 x 30), spring washers (M6), and washers (M6) to temporarily secure the chassis fixing fitting, the chassis whirl-stop fitting, and the assist unit. Tool Hexagonal wrench (5 mm) Chassis fixing fitting Washer (M6) Chassis whirl-stop fitting Adjust the position of the chassis whirl-stop fitting and the chassis fixing fitting to within 55 mm ± 0.15 mm from the end of the bottom bracket and to a radius for mm from the bottom bracket center Refer to Reference diagram and notice when modifying the frames (page 41). Spring washer (M6) Hexagonal socket-head bolt (M6 x 30) Step 5 31

32 Order of installation For the positions of bolts, washers, and metal fittings, please refer to the side view. When the thickness of the chain cover stay is not 0.5 mm, installing method differs. For details, please contact us. When the chassis fixing fitting is used to fix the assist unit where the chassis whirl-stop fitting R can not be used, prepared a separate washer (M6) with thickness of 0.5 mm. Insert it between the chassis fixing fitting and the assist unit Hexagonal socket-head bolt (M6 x 30) Assist unit Chassis fixing fitting Chassis whirl-stop fitting Spring washer (M6) Washer (M6) Side View After Step 6, refer to Step 5 to Step 9 in 2 Installation of the assist unit (page 28). 32

33 2'' Installation of the assist unit (Example for fixing on the front side) Order of installation The prepackaged parts cannot fix the assist unit on the front side. For the details concerning a part to fix the assist unit on the front side, contact the bicycle manufacturer or dealer. This is an example when the assist unit cannot be fixed on the rear side or small wheeled bikes. 1. Install the large sprocket with hexagon socket-head set bolts (M5 x 10) to the assist unit (standard torque value: 3 N m). Tool Hexagonal wrench (4 mm) Tighten the five hexagon socket-head set bolts (M5 x 10) sequentially in the order of drawing a five-pointed star with one stroke. Hexagonal socket-head set-bolt (M5 x 10) Assist unit Large sprocket Step 1 2. Thread chassis whirl-stop fitting F2 with chassis whirl-stop fitting F1 and wind them on the main pipe to fasten. Chassis whirl-stop fitting F2 Install the chassis whirl-stop fitting F1 with its 2 bracket holes on the left side of the body. Thread the chassis whirl-stop fitting F2 with the upper bracket hole of the chassis whirl-stop fitting F1 placed on the left side of the body. When the chassis whirl-stop fitting F2 is too long for the main pipe, cut the chassis whirl-stop fitting F1 to adjust its length. Chassis whirl-stop fitting F1 Step 2 33

34 Order of installation 3. Install the assist unit on the bicycle (1) If the bottom bracket shell width is 68 mm, install the accessory spacers, one on the left and one on the right. (These spacers are not required if the bottom bracket shell width is 70 mm.) (2) Set the chain onto the sprocket. (3) Install the assist unit from the right side of the body of the bicycle to the bottom bracket shell hole. Chain (2)Set Spacer (1)Insert (When the bottom bracket shell width is 68 mm) Bottom bracket shell hole Crank Assist unit (3)Install Step 3 4. Use hexagon socket-head bolts (M6 x 30), spring washers (M6), and washers (M6) to temporarily secure the chassis fixing fitting to the chassis whirl-stop fitting F1 and the assist unit. Tool Hexagonal wrench (5 mm) Chassis fixing fitting Adjust the position of the chassis whirl-stop fitting F1 and the chassis fixing fitting to within 55 mm ± 0.15 mm from the end of the bottom bracket and to a radius for mm from the bottom bracket center. Washer (M6) Spring washer (M6) Hexagonal socket-head bolt (M6 x 30) Step 4 34

35 Order of installation For the positions of bolts, washers, and metal fittings, please refer to the side view. Chassis whirl-stop fitting F1 Chassis whirl-stop fitting F2 Chassis fixing fitting Assist unit Side View Spring washer (M6) Washer (M6) Hexagonal socket-head bolt (M6 x 30) After Step 5, refer to Step 5 to Step 9 in 2 Installation of the assist unit (page 28). 35

36 Order of installation 3 Installation of cranks and pedals 1. Adjust the chain tension. 2. Install on the bike the left and right cranks supplied with the kit using the flanged nuts. Tool Socket wrench (14 mm) The right and left cranks are different parts. Mount them in the correct directions respectively. The right crank is marked 'R' and the left crank is marked 'L'. Right crank R Final tightening of the flanged nuts should begin with the crank and the socket wrench in the positions of the hands of a clock at 10:10. Left crank L 3. Insert the crank caps into the right and left crank installation holes. 4. Install the pedals on the cranks. Tool Pedal wrench 36

37 Order of installation 4 Installation of the battery-hanger unit Do not install the battery at this stage. Installing the battery by ignoring the produce could turn ON the power accidentally and cause electric shock or injuries due to malfunction. 1. Install the battery-hanger unit on the seat post. (1) Remove the seat post from the bicycle frame. (2) Pass the seat post through the battery-hanger unit. (3) Install the seat post again into the bicycle frame. Do not push the seat post all the way down to its lowest position. The battery cord might be caught between the battery-hanger unit and the bicycle frame and it might be damaged. 2. Securely tighten the Hexagonal socket-head bolt (M6 x 35), and the nut (M6). (standard torque value: 4.5 N m). Tool Spanner (10 mm) Hexagonal wrench (5 mm) Seat post 1. (1) Remove. 1. (3) Install. Battery-hanger unit 1. (2) Pass through. Hexagonal socket-head bolt (M6 x 35) Nut (M6) Spring washer (M6) Washer (M6) 2. Tighten securely. Steps 1 and 2 Make sure that the battery-hanger unit is aligned with the saddle. 3. Connect the connector of the power supply harness and the connector of the assist unit. From the assist unit Connector Step 3 37

38 Order of installation 4' Installation of the battery-hanger unit of type B Do not install the battery at this stage. Installing the battery by ignoring the produce could turn ON the power accidentally and cause electric shock or injuries due to malfunction. Installing the type B of a battery-hanger unit, remodeling frames of the bicycle is required. For modifying the frames, refer to Reference diagram and notice when modifying the frames (page 41). 1. Connect the connector of the power supply harness and the connector of the assist unit and store the connector part on the inside of the battery-hanger terminal block. Pass through the notch in the terminal block Connect the connector cord of the assist unit so that it passes through the notch in the battery-hanger terminal block. Battery-hanger Connector Step 1 2. Secure the battery-hanger with Hexagonal socket-head bolts (M5x12) and spring washers (M5) to the frame (standard torque value: 6.4 N m). Tool Hexagonal wrench (4 mm) Bolts fastening location must be provided in advance on the frame side. For bicycles already having a holder fixing seat etc., the battery holder can be installed without frame modification. For detailed dimensions etc., please contact us. Hexagonal socket-head bolt (M5 x 12) Spring washer (M5) Step 2 38

39 Order of installation 5 Installation of the control-switch unit and cords Always tie the cords with tie bands to prevent them from being caught up by feet. Otherwise, they may be caught up by feet, causing injuries due to a fall. Control-switch 1. Install the control-switch unit with two screws (M3 x 10) to the handle bars. Tool Phillips screwdriver Switch fixing part Screw (M3 x 10) Step 1 2. Secure the battery power cord with attached tie bands along the frame. Tool Nipper Leave some slack at the top of the cord. Otherwise it will not be possible to adjust the height of the seat post. Please make sure to tie the lower part of the cord along the frame. Otherwise, the cord may be disconnected by contact with the chain, tire or pedal. Tie band Secure along the frame. Battery power cord Step 2 3. Secure the switch cord along the cable for the rear brake. Make sure that the operation of the rear brake is not impaired by the installation of the switch cord. Step 3 Secure along the rear brake cable. Tie band Switch cord 39

40 Order of installation 6 Checks after installation 1. Check that the cords are not in contact with any chain, tire or pedal. Check also that the cords are not in contact with your feet when you sit on the saddle. 2. Check that each unit is fixed securely. 3. Insert the battery into the battery-hanger unit until it clicks. Confirm operation of the battery lock. When using the bicycle for the first time after the purchase, charge the battery. Refer to Charging the battery (page 52). Perform the same kind of operation confirmation also for a battery of type B. Battery-hanger unit Battery Battery Step 3 Battery-hanger unit Step 3 4. Raise the rear wheel off the ground, and then press the ON button of the control-switch. 5. Check that the three indicating lamps light. For details, refer to How to interpret the indicating lamps of the control-switch (page 43). 6. Check that the Turbo unit operates when you push the pedal. Test-drive the bicycle in a safe location. Ignoring this may cause injuries due to fall-over. After the test drive, check again that each part is mounted securely. If any parts come off, it may cause injuries. 40

41 Reference diagram and notice when modifying the frames Reference diagram and notice when modifying the frames When the chassis whirl-stop fitting of prepackaged parts is not suitable to the bicycle, modifying the frames is needed. Refer to the following measurement diagram. When the prepackaged parts are suitable for use, do not modify the frames. Reference diagram when modifying the frames Battery-hanger attachment hole: Breadth 5.5mm Length 7.5mm More than 4.3mm 81.1mm φ40 40mm 35.7mm 51.5mm 180mm 100mm 80mm 70mm 65mm±0.3mm 25mm 38.5mm 25mm 195mm 36mm 8mm Long hole for Attachment 55.4mm The distance from the left side of the chassis whirl-stop fitting R to the right side of the bottom bracket has to be 55 mm ± 0.15 mm. 41

42 Reference diagram and notice when modifying the frames Notice when modifying the frames The rotary radius (a), which is from the rotary center of the battery to the handle: more than 150 mm The rotary radius (b), which is from the rotary center of the battery to the projection on the front side: more than 135 mm The rotary radius (c), which is from the rotary center of the battery to the projection on the rear side: more than 120 mm Rotary center of the battery (a) (b) (c) The distance (d), which is from the lowest attachment hole of the battery-hanger unit to the bottom bracket center: can secure more than 86 mm (d) is the distance when there is a bottom bracket hole just under the seat pipe. (d) The rotary radius from the bottom bracket center to the assist unit attachment hole is mm For fixing the assist unit on the rear side, making a new chassis whirl-stop fitting is needed. For fixing the assist unit on the front side, welding a bracket onto the frame to fix the assist unit is needed. 42

43 How to interpret the indicating lamps of the control-switch How to interpret the indicating lamps of the control-switch The indicating lamps of the control-switch show the battery capacity remaining and the status of the Turbo unit. Status of the indicating lamps All three lamps lit red. Indication contents The remaining battery charge is sufficient. Two lamps lit red. The remaining battery charge has decreased. One lamp lit red. Low battery charge. Please charge the battery. The left lamp is flashing fast. The battery is nearly completely discharged. Please charge the battery as soon as possible. The left lamp is flashing slowly. The battery is completely discharged. Please charge the battery as soon as possible. Mode lamp Mode lamp Turbo mode The blue lamp is lit. Economy mode The blue lamp is flashing. The two left side lamps are flashing. The mode is Turbo mode with stronger electric-assist force. For details, refer to Riding with increased power (page 49). The mode is Economy mode with a longer riding distance. For details, refer to Riding while conserving battery power (page 50). The temperature of the assist unit has risen. Set the control-switch to OFF and wait until the temperature has dropped. The yellow lamp is lit. Other flashing The headlight is lit. There is no lighting lamp when not using the control-switch with lighting feature. Set the control-switch to OFF and contact your dealer. The indication of the remaining battery charge is an estimate. The timing for the red lamps to go out differs according to the air temperature and the road condition. The indication of the remaining charge uses detection of the battery voltage, and when the air temperature is low in winter etc., the battery voltage decreases and the red lamp may go out early although there is still a sufficient remaining charge. The voltage is also low directly after riding uphill, and the red lamp may go out early. Check the number of red lamps again after waiting for a while. 43

44 How to interpret the indicating lamps of the control-switch The control-switch with a lighting feature Installing the control-switch with a lighting feature allows its light button on the control-switch of the assist unit to turn on/off the lighting. Also, the lighting lamp shows the headlight's condition, on or off. A normal control-switch doesn't have a lighting feature. For the detailed control-switch with a lighting feature, please contact us. Light lamps Light button Normal control-switch Control-switch with a lighting feature The lighting must be under DC 5 V and 400 ma. For the lighting to be installed, contact the bicycle manufacturer or dealer. Turning on the lighting causes shorter riding distance. The lighting button can be used only when the assist unit is set to ON. After setting the assist unit to OFF, you can turn on/off the light for one minute. 44

45 Approximate riding distance per charge Approximate riding distance per charge This is an estimate for the riding distance in normal mode until the remaining charge of the battery becomes zero after a full charge. The riding distance is given for a new battery, an air temperature of 25ºC, a load of 60 kg, a dry road surface, and no wind according to the data of our company. General roads Type of riding 15km/h 10km/h 20km/h 15km/h 15km/h Repeated riding over a course with three level sections of 1 km each and an upslope and a downslope section at an angle of 2o of 1 km each (stop for 10 sec after each section of 1 km) Continuous riding at 15 km/h Riding distance (km) About 40km Level road In case of continuous riding without start and stop (speed: 15 km/h) About 45km Riding at 10 km/h Uphill slope 2 In case of continuous riding on a 2 uphill slope (speed: 10 km/h) About 10km Riding at 7 km/h Steep uphill slope In case of continuous riding on a 4 uphill slope (speed: 7 km/h) 4 About 6km The riding distance in turbo mode becomes 40% to 60% of that in normal mode. The riding distance in economy mode becomes 140% to 160% of that in normal mode. In winter, the riding distance becomes shorter because of the properties of the battery. With increasing number of charges, the riding distance per charge becomes shorter. In case of use for a long time, the driving distance per charge may become about one half of that with a new battery even with a small number of charges. The riding distance differs according to the road condition, the air temperature, the weather, and the way of riding. The battery gets exhausted faster with a higher pedal force. 45

46 Checks before Riding Checks before Riding After purchase, the battery must be charged before the first use. When purchase, the battery is not fully charged. Is the battery installed securely? Has the battery lock key been pulled? Pull the battery lock key before you start to ride. Is the battery sufficiently charged? Check that the three red indicating lamps are all lit. Indicating lamps When the battery charge is not sufficient, refer to Charging the battery (page 52). Perform checks according to the instruction manual for the bike. 46

47 Riding the intelligent bike Riding the intelligent bike Riding the intelligent bike with the Turbo unit operating 1. Raise the stand and sit on the saddle. Adjust the height of the saddle so that both heels are on the ground. 2. Press the ON button of the control-switch before you start pedaling. The indicating lamps light with a slight delay. 3. Check the red indicating lamps 2. Press the "ON" button. Always keep your feet off the pedals when setting the control-switch to ON. The shaft connecting the left and the right pedal (crank) has a built-in sensor to detect the force with which the pedal is pressed. When the control-switch is set to ON while a foot is on a pedal, the sensor recognizes the condition at that time as the start (zero load) condition and the electric-assist force becomes smaller than normal. The same phenomenon also occurs when the control-switch is set to ON while riding and pedaling. 3. Check that all three red indicating lamps are lit. When the lighting/flashing status is other than stated above, refer to How to interpret the indicating lamps of the control-switch (page 43). 47

48 Riding the intelligent bike 4. Start pedaling. The Turbo unit will operate according to the force applied to the pedals. If there is no force on the pedals for five minutes after the ON button of the control-switch has been pressed, the switch will be switched off automatically. 4. Start riding. Do not kick yourself forward while standing on the pedals. Always start while sitting on the saddle. When force is given onto the pedal, the Turbo unit will be activated and the bicycle could fall over or cause a minor collision. Do not park, stop or push the bicycle with the control-switch set to ON. The Turbo unit will operate when the pedals are touched by foot or luggage, causing injuries due to a fall-over of bicycle. Do not drive through deep puddles. Do not drive in the heavy rain during the typhoon, etc. If the assist unit is exposed to lots of water or immersed in water, current leakage or electric chock may occur. 48

49 Riding the intelligent bike Riding with increased power A turbo mode has been provided. In turbo mode, the electric-assist force is set at the upper limit value specified by the road traffic law. For this reason, the electric-assist force becomes more powerful than in the normal mode, but the riding distance per one charge becomes approximately 60% of that in the normal mode. Press the Mode button of the control-switch. The blue mode lamp lights up and the turbo mode is selected. The mode is economy mode when the blue lamp is flashing. Mode lamp "Mode" button To cancel turbo mode, press the Mode button again. The blue mode lamp goes out and the unit returns to normal mode. When the Mode button is pressed longer and the blue lamp starts flashing, economy mode has been reached. Do not operate the control-switch during traveling. Operate the switch after stopping the bicycle. Otherwise, the bicycle may fall over, causing accidents. 49

50 Riding the intelligent bike Riding while conserving battery power An economy mode has been provided. In economy mode, the electric-assist force is set to an upper limit of 15 km/h. For this reason, the electric-assist force becomes weaker than in normal mode, but the riding distance per charge becomes approximately 160% of that in normal mode. Press the Mode button of the control-switch for a longer time. When the blue lamp starts flashing, economy mode has been reached. The mode is turbo mode when the blue lamp is lit. Mode lamp "Mode" button To cancel economy mode, press the Mode button again for a longer time. The blue lamp will go out and the mode will return to normal mode. When the Mode button is pressed and the blue lamp lights, the mode becomes turbo mode. Do not operate the control-switch during traveling. Operate the switch after stopping the bicycle. Otherwise, the bicycle may fall over, causing accidents. Riding without the assistance of the Turbo unit When the OFF button of the control-switch is pressed, the intelligent bike can be used as an ordinary bicycle. Even when the battery has been run out, the intelligent bike still can be used as an ordinary bicycle. 50

51 Riding the intelligent bike Parking 1. Stop the intelligent bike. 2. Press the OFF button of the control-switch. The red indicating lamps go out. Indicating lamps 2. "OFF" button 3. Get off the intelligent bike and raise the stand. Always park the bicycle on a level surface. Ignoring this may cause injuries due to a fall-over of the bicycle. Do not lift the bicycle by holding the battery as shown below. The battery may come off, causing injuries. Lock the intelligent bike. 51

52 Charging the battery Charging the battery Charging can be done when the battery is on the bike or removed from it. For details, refer to Charging (page 53) and Charging with installed battery (page 57). When not charging, always pull out the charging plug from the battery and the power plug from the outlet before storing the battery charger. Precautions for handling the battery charger Do not disassemble or modify the battery charger. Please use the battery charger with the battery in the kit. Do not drop the battery charger. Do not bring the terminals of the charging plug in contact with metal. Location for charging Please perform charging at a location satisfying the following conditions. A level and stable location A location not exposed to rain or water A location not exposed to direct sunlight A location with good ventilation and no moisture A location out of the reach of children and pets. A location with a temperature from 0 C to 45 C at the time of charging Do not use (discharge) the battery while charging. Damage to the battery charger or the battery is to be feared. Charging will start only when the battery temperature is in the range from 0ºC to 45ºC. As the battery temperature is higher directly after riding, charging may not start, but this is not a defect. Charging will also not start when the temperature is too low (0ºC or lower). When the temperature inside the battery is not suitable, the orange charging standby lamp continues to flash, and charging starts when the temperature inside the battery is in the range from 0ºC to 45ºC. For this reason, charging may take time. Always perform charging in an environment with normal temperature (0ºC to 45ºC). 52

53 Charging the battery Charging 1. Press the OFF button of the control-switch. Do not remove the battery with the control-switch set to ON. Ignoring this could cause electric shock. 2. Insert the battery-lock key into the key hole of the battery-hanger unit. 3. Pull the battery out, with the battery-lock key turned clockwise. Battery Battery-lock key Perform the same kind of operation confirmation also for a battery of type B. Battery-lock key Battery 4. If the battery is wet or dirty, wipe it clean with a dry cloth. 53

54 Charging the battery 5. Insert the power plug into an outlet. 6. Charging plug Battery 6. Insert the charging plug into the battery. 5. Power plug Battery charger 7. Indicating lamps 54

55 Charging the battery 7. Use the indicating lamps of the battery charger to check the charging status. Indicating lamps of the battery charger Status Indicating lamps (Green) (Green flashing) (Green) (Green) (Not lit) (Not lit) (Green) (Not lit) (Green) (Orange) (Green) (Orange flashing) Charging. Charging has been completed. Power of AC 100 to 240 V is not being supplied (the power plug is not plugged into an outlet). The battery charger is being supplied with power, but the battery is not connected to the battery charger. Follow the procedure and insert the charging plug into the battery. It is possible that the temperature of the battery is too high or too low or that the voltage is too low. Charging does not start and the unit enters standby status. As soon as the conditions are fulfilled, charging starts automatically (it is recommended to start charging after the battery temperature has become normal). The battery charger or the battery is abnormal. Stop use immediately and contact your dealer. When the two indicating lamps do not light after charging is started, immediately disconnect the power plug and contact your dealer. While charging, the temperature of the battery charger and the battery rises, but this is normal. Charging is completed in max. two hours. However, the time until completion of charging becomes longer in case of standby status. 8. Pull out the charging plug from the battery when both indicating lamps change to light up in green and charging is completed. 9. Pull out the power plug from the outlet. 55

56 Charging the battery 10. Insert the battery into the battery-hanger unit as shown on the right until it clicks. Battery-hanger unit Battery Battery lock key Perform the same kind of operation confirmation also for a battery of type B. Battery lock key Battery Battery-hanger unit 11. Pull out the battery lock key. Keep the key not to lose it. 56

57 Charging the battery Charging with installed battery It is possible to charge the battery installed on the bicycle as shown below. The charging method is the same as for charging the removed battery. Battery Charging plug Power plug Battery charger Do not charge the battery with the control-switch set to ON. Ignoring this may cause fire. When not charging, always pull out the charging plug from the battery and the power plug from the outlet before storing the battery charger. 57

58 Concerning the battery Concerning the battery Battery type A lithium ion battery is used. Use in winter The battery is susceptible to temperature, and when the temperature drops in winter etc., the riding distance may become short. For use in cold weather in winter etc., store the battery indoors and install it on the bicycle before riding. Do not use it in an environment of 0ºC or lower. Estimate for battery replacement The battery should be replaced when the riding distance with a full charge becomes notably short (in cold areas, the possible riding distance may be short even after charging). Please contact your dealer for replacement of the battery. (You have to pay for the replacement.) Do not discard a used rechargeable lithium ion battery, but recycle it to protect precious resources. How to keep a battery in good condition After use, set the control-switch to OFF and charge the battery. However, when the battery temperature is too high or too low, start charging after the battery temperature has returned to the normal range (0 C to 45 C). A small amount of current runs in the assist unit even if the control-switch is set to OFF. If there is one red indicating lamp for the remaining battery charge, charge the battery or uninstall the battery from the bike. Not doing so causes early expiration. When the unit is not used for a long time, charge the battery once a year. After charging, use the battery until one red indicating lamp for the remaining battery charge is lit, and then store the battery again. It is recommended to perform charging and storage at a cool location (-20 C to 20 C recommended). When charging has been completed, immediately disconnect the charging plug. Do not charge the battery again immediately after charge completion. 58 Li-ion Logo of Supporting dealer