KBO Tornado Step Thru Electric Bike Owner’s Manual

KBO Tornado Step Thru Electric Bike

Thank you for your purchase!

This manual contains details of the product, information on its operation and maintenance, and other helpful tips for owners. Read it carefully and familiarize yourself with the KBO Tornado Step-Thru before using it to ensure safe use and prevent tragic accidents. Be sure to retain this manual as your convenient KBO Tornado Step-Thru information source.

NOTICE: To prevent your KBO Tornado Step-Thru from being stolen and cannot be found, it is suggested that you record the Serial
Number of your bike(Near the left crank connection).

About Manual

All information in this manual should be carefully reviewed and if you have any questions you should contact KBO Bike immediately. The notes contained within the manual and marked by this dialogue balloons symbol should also be given special care. Users should also pay special attention to information marked in this manual beginning with NOTICE.

Because it is impossible to anticipate every situation or condition which can occur while riding, this manual makes no representations about the safe use of bicycles under all conditions. There are risks associated with the use of any bicycle which cannot be predicted or avoided, and which are the sole responsibility of the rider. You should keep this manual, along with any other documents that were included with your bicycle, for future reference, however all content in this manual is subject to change or withdrawal without notice. Visit www.kbobike.com to download the latest version. KBO Bike makes every effort to ensure the accuracy of its documentation and assumes no responsibility or liability

if any errors or inaccuracies appear within. Assembly and first adjustment of your KBO Bike require special tools and skills and it is recommended that this should be done by a trained bicycle mechanic if possible.

Product Specification

Battery| 48V 13Ah Lithium Battery| Front Fork| Front Suspension Fork
---|---|---|---
Motor| 500W Geared Motor| Bike Frame| 6061 Aluminum
Display| LCD Display| Brake| 160mm Brakes
Derailleur| 6-speed| Charger| 54.6V 2A
Speed| 20 mph| Freewheel| 6 Speed
Pedal Assist| Intelligent 5-level Pedal Assist| Shifter| Shimano
Throttle| Twist Throttle| Tires| 26’’x4’’ Tires
Charging Time| 6 Hours| Product Weight| 72 lbs
Recommended Rider Heights| 5’1″ – 6’2″| Package Weight| 92 lbs
Package Dimensions| 61.5”x12.2”x33.1”| Model Dimensions| 75.4”x48.9”x27.6”

Product Structure

Assembly Instructions

NOTICE: The following assembly steps are only a general guide to assist in the assembly of your KBO Bike and is not a complete or comprehensive manual of all aspects of assembly, maintenance and repair. We recommend you consult a certified bike mechanic to assist in the assembly, repair and maintenance of your bike. For detailed instructions, please view the KBO Tornado Step-Thru assembly video found at www.kbobike.com.

Unpack the bike

Open the bike box, with the help of another person capable of safely lifting a heavy object, remove the ebike from the bike box, and fully remove the packaging material protecting the bike frame and components. Keep the packaging materials in case you want to ship the bike. Remove the small box from the bottom of the bike box and carefully set out the contents.

Install the handlebar

Orient the handlebar properly. The brake levers should face forward and the shifter should be on the right side. Trace the brake housing from the left brake lever to the brake caliper and make sure the bundle of cables is not twisted. Remove the four screws from the stem, ensuring the linear markings on the handlebars are centered and handlebars are adjusted to a comfortable position. Finally, tighten the screws with the assembly tool.

Install the front wheel

Step 1: Remove the plastic axle guards from the front wheel being sure not to touch the brake rotor set. Open the quick skewer and remove the thumb nut and cone spring. Carefully lower the fork and ensure the brake rotor goes into the caliper.

Step 2: Next align the dropouts with the axle of the wheel hub to make sure the fork dropouts are fully seated on the axle. Install the quick skewer starting from the brake rotor side of the wheel and then push the quick release skewer through the hub. Keep two cone springs pointed towards the wheel hub. Tighten the thumb nut until the quick release lever is held in line with the axle.

Step 3: Use a 15mm wrench to tighten the bolts on both sides of the axle, and install the two thumb nuts by pressing them tightly

Install the headlight & front fender

The headlight and front fender are both secured by a single bolt, so the front fender must be installed together with the headlight. If you prefer not to have a front fender, you may install the headlight by itself.

Step 1:  Loosen the bolt on the fork brace. Align the bolt holes of both your front fender together with the hole on the fork brace, then reinsert the bolt through all holes and tighten the bolt.

Step 2: Pull one end of the fender brace until the loop at the end is centered in the bracket, reinsert the bolt through the loop at the end of the brace, and tighten completely with a 4mm hex wrench and a 8mm bolt extractor holding the nut. Repeat on the other side.

Install the pedals

Make sure your pedals are installed on the correct side, as installing on the wrong side will damage the threads.

Indicators for the right pedal (R) and the left pedal (L) can be found at the bottom of the pedal threads. Start threading the pedal on by hand to ensure the pedal is going in perfectly straight, rotating in the direction of the pointer shown on the crank. If it is not spinning smoothly, make doubly sure that you have the correct left or right pedal. After initial hand-tightening, finish tightening the pedals with a standard 15mm wrench.

Adjust the seat

Open the seatpost quick release lever. Adjust the seatpost height by sliding the seatpost up or down to a height appropriate for your leg length and preferred riding position. Do not extend the seatpost beyond the minimum insertion marking etched onto the seatpost.

Recommended Torque Values

Hardware Location

|

Torque Required (Nm)

|

Hardware Location

|

Torque Required (Nm)

---|---|---|---
Handlebar| 18-20| Bottom Bracket Parts| 35-55
Stem| 18-20| Pedals| 35
Saddle| 18-20| Disk Mounting Bolts| 6
Front Wheel| 16-25| Disk Caliper Mount| 10
Rear Wheel| 35-40| Crank Bolts| 40
Rear Derailleur Cable Pinch| 6| Front Derailleur Clamp| 7

Display Features

The image shows the various features and information displayed on the display.

1 BATTERY LEVEL INDICATOR (Current / Max / Average)

2 SPEED INDICATOR (Current / Max / Average)
3 ERROR CODE INDICATOR (In the Event of a Problem)
4 5 LEVELS OF ASSIST (0: No Assist. 5: Max Assist)
5 WALK MODE (On / Off)
6 BACKLIGHT INDICATOR (On / Off)
7 MULTI-FUNCTIONAL DISPLAY AREA:
DISTANCE INDICATOR (Current Trip / System Mileage) VOLTAGE OUTPUT INDICATOR (Real-Time)

Routine Operation

GETTING STARTED

1. The display pad is equipped with 3 buttons including “M”, “UP” and “DOWN”. The M button is the mode/switch button.
2. Press and hold the “M” button on the handlebar controls to turn on the display. Now, your ebike is ready to ride. To turn off, press and hold “M” for 3 seconds.
3. Press the “M” button on the handlebar controls to switch the contents of the multi-functional display area.
4. The Level ebike offers pedal assist. When using pedal assist, an electric motor supplements the rider’s own effort. To use the pedal assist, simply start pedaling, then tap the “UP” or “DOWN” arrows to increase or decrease the amount of pedal assist.
5. Press and hold the “DOWN” for 3 seconds to activate the push-assist function of the ebike.

NOTICE: When the error code is displayed, please promptly remove the fault. After the fault occurs, the electric bike will not be able to ride normally.

Driving Range

The range of your KBO Bike is the distance the bike will travel on a single full charge of the onboard battery pack. The range values in this manual are estimates based on expected usage characteristics. Some of the factors which affect the range include changes in elevation, speed, payload, and acceleration, number of starts and stops and ambient air temperatures. Tire pressure and terrain are also important variables to consider.

We suggest that you select a lower pedal assist level when you first get your KBO Bike to get to know your bike and travel routes. Once you become familiar with the range requirements of your travel routes, and the capabilities of your KBO Bike you can then adjust your riding characteristics if you desire.

The following table provides general estimates and outlines various factors’ effective range and their combined estimated effects on range. This table is meant to help owners understand the factors that can increase or decrease range, but KBO Bike makes no claims to the range that individual users might obtain.

Best Practices for Extending Range and Battery Life

1. **** Do not climb hills steeper than 15% in grade.
2. Pedal to assist the motor when climbing hills and accelerating from a stop.
3. Avoid sudden starts and stops.
4. Accelerate slowly

Parking Storage and Transport

Please follow these basic parking, storage and transport tips to ensure your bike is well cared for on and off the road.

• When pushing the vehicle manually, turn off the power to avoid accidental acceleration from the motor.
• It is recommended to park indoors.
• Switch the power off, and any lights to conserve battery. Remove the key from the bike and ensure the battery is locked to the frame or removed and brought with you for security.
• In public places, your KBO Bike must be parked in accordance with local rules and regulations.
• If you must park outdoors in rain, or wet conditions you should only leave your KBO Bike outside for a few hours and proceed to park the bike in a dry location afterwards to allow all the systems to dry out. Much like a regular bike, use in wet conditions mandates a more regular maintenance schedule to ensure your bike does not become rusty, corroded and to ensure all systems are always working safely.
• Do not park, store, or transport your KBO Bike on a rack that is not designed for the size and weight of the bike.
• Locking up your bike is recommended to ensure your bike is secure and the chance of theft is reduced. KBO Bike makes no claims or recommendations on the proper lock hardware or procedures to secure your bike, but we do recommend you take the appropriate precautions to keep your KBO Bike safe from theft.
• When storing your bike or carrying your bike on a rack for transport, you can remove the battery pack to reduce the weight of the bike and make lifting and loading easier.

Basic Battery Charging Tips

• The battery should be recharged after each use. There is no memory effect, so you can charge the battery after short rides without damage.
• The battery can be recharged on or off the bike.
• Remove the battery by turning the key and then pulling the battery forward and up until the battery detaches from the mating receptacle.
• The charger will automatically stop charging when the battery pack is full.
• Always charge in dry locations and indoors away from direct sunlight, dirt or debris.
• Do not cover up the charger when plugged in or charging, it air cools and needs to be left in an open space.
• Do not charge with the charger in the inverted position which can inhibit cooling and reduce the charger’s life.
• Check the charger cables, charger and battery for damage before beginning each charge.
• The light on the charger will turn green when charging is complete and stay red while the battery charges. Ensure the light faces upward when charging

Charging Time
When the input and output plugs of the charger are connected properly, and the battery is not fully charged, the red charging indicator light  should illuminate, showing that the battery is charging. The time that the battery takes to fully charge the battery is dependent on various factors including distance traveled, riding characteristics, terrain, payload, and battery age.

NOTICE: The battery pack can take longer to charge when fully depleted and when the battery is new. As your battery ages you might also experience increased charging times, but this is only expected after 3-5 years of regular use. If your battery does not seem to be charging normally, and taking longer to charge than expected, please discontinue charging and contact KBO Bike immediately

Bicycle Care 16

To ensure safe riding conditions you must ensure your bike is properly maintained. You should follow these basic guidelines and see your certified bicycle mechanic at regular intervals to ensure your bike is safe for use.

1. Properly maintain batteries by keeping them fully charged when not in use.
2. Never immerse the bike or any components in water as the electrical system may be damaged.
3. Periodically check wiring and connectors to ensure there is no damage and the connectors are secure.
4. To clean, wipe the frame with a damp cloth soaked in a mild non-corrosive detergent mixture. Dry with a cloth.
5. Store under shelter; avoid leaving it in the rain or exposed to corrosive materials. If exposed to rain, dry your bicycle afterwards and apply anti-rust treatment to chain and other unpainted steel surfaces.
6. Riding on the beach or in coastal areas exposes your bicycle to salt which is very corrosive. Wash your bicycle frequently and wipe or spray all unpainted parts with anti-rust treatment. Damage from corrosion is not covered under warranty so special care should be given to extend the life of your bike when used in coastal areas or areas with salty air or water.
7. If the hub and bottom bracket bearings have been submerged in water, they should be taken out and re greased. This will prevent accelerated bearing deterioration.
8. If the paint has become scratched or chipped in the metal, use touch up paint to prevent rust. Clear nail polish can also be used as a preventative measure.
9. Regularly clean and lubricate all moving parts, tighten components and adjust as required.

Basic Troubleshooting

1. Insufficient battery power
2. Faulty connections
3. Battery not fully seated in tray
4. Improper turn on sequence
5. Brakes are applied

|

1. Charge the battery pack
2. Clean and repair connectors
3. Install battery correctly
4. Turn on bike with proper sequence
5. Disengage brakes

Irregular acceleration and/or reduced top speed|

1. Insufficient battery power
2. Loose or damaged throttle

|

1. Charge or replace battery
2. Replace throttle

When powered on the motor does not respond|

1. Loose wiring
2. Loose or damaged throttle
3. Loose or damaged motor plug wire
4. Damaged motor

|

1. Repair and or reconnect
2. Tighten or replace
3. Secure or replace
4. Repair or replace

Reduced range|

1. Low tire pressure
2. Low or faulty battery
3. Driving with too many hills, headwind, braking, and/or excessive load
4. Battery discharged for long period of time without regular charges, aged or damaged
5. Brakes rubbing

|

1.  Adjust tire pressure
2. Check connections or charge battery
3. Assist with pedals or adjust route
4. Replace the battery

The battery won’t charge|

1. Charger not well connected
2. Charger damaged
3. Battery damaged
4. Wiring damaged

|

1. Adjust the connections
2. Replace
3. Replace
4. Repair or replace

Wheel or motor makes strange noises|

1. Damaged motor bearings
2. Damaged wheel spokes or rim
3. Damaged motor wiring

|

1. Replace
2. Repair or replace
3. Repair or replace motor

Warranty Info

Every bike is covered under a manufacturer’s two-year all-inclusive warranty for the original owner against all manufacturing defects. KBO Bike warrants this product, including all individual components against defects in material or workmanship as follows:

KBO Bike LIMITED 2-YEAR WARRANTY

KBO Bike bicycle components including frame, forks, stem, handlebar, headset, seat post, saddle, brakes, lights, bottom bracket, crank set, pedals, rims, spokes, wheel hub, freewheel, cassette, derailleur, shifter, motor, throttle, controller, wiring harness, LCD display, kickstand, reflectors and hardware are warranted to be free from manufacture defects in materials and/or workmanship for a 2-year period from the date of original purchase.

Wear and tear is not covered under warranty. KBO Bike lithium-ion batteries are warranted to be free from manufacturing defects in materials and/or workmanship for a 2-year period from the date of original purchase. The battery warranty does not include damage from power surges, use of improper charger, improper maintenance or other such misuse, normal wear or water damage.

The Following are Also Excluded from the Warranty:

• Liability for material defects does not cover normal wear which occurs from the manufacturers intended use of the product. Components such as the battery pack, motor system, braking system, drivetrain system, saddle, grips and pedals are all subject to intended use-related wear and are not covered under the warranty from normal wear.
• Damage arising from the use of the bike in a competition or other applications outside of normal intended use.
• Damage arising by improper tools or inadequate maintenance performed on the bike.
• Damage resulting from adding non-standard equipment, parts or technical modifications.

Additional Warranty Terms

This warranty does not cover any damage or defects resulting from failure to follow instructions in the owner’s manual, acts of God, accident, misuse, neglect, abuse, commercial use, alterations, modification, improper assembly, wear and tear, installation of parts or accessories not originally intended or compatible with the bicycle as sold, operator error, water damage, extreme riding, stunt riding, or improper follow-up maintenance. This warranty does not include consumables or normal wear and tear parts (tires, tubes, brake pads, cables and housing, grips). KBO Bike will not be liable and/or responsible for any damage, failure or loss caused by any unauthorized service or use of unauthorized parts.

In no event shall KBO Bike be responsible for any direct, indirect or consequential damages, including without limitation, damages for personal injury, property damage, or economic losses, whether based on contract, warranty, negligence, or product liability in connection with their products. All claims to this warranty must be made through KBO Bike. Proof of purchase may be required with any warranty request. Components of the KBO Tornado Step- Thru are subject to higher wear when compared to bicycles without power assistance. This is because the KBO Tornado Step-Thru can travel at higher average speeds than regular cycles and has a greater weight. Higher wear is not a defect in the product and is not subject to warranty. Typical components affected are the tires, brake pads, suspension forks, spokes/wheels and battery

NOTICE: When the useful life of a component is surpassed, it can cause unexpected loss of function. This can result in serious injuries or even death. Therefore, pay attention to wear characteristics such as cracks, scratches or changes in the color or operation of components which could indicate useful life has been exceeded. Worn components should be immediately replaced

Warranty Card

Contacts

Support Center: https://kbobike.com/pages/support-center
Support Link: https://kbobike.com/pages/contact-us
Phone: Weekdays: (415) 800 4696 / 8:00 – 15:00 PST
Weekends: (415) 357 7516 / 9:00 – 15:00 PST

www.kbobike.com

References

• Ebikes | The Best Value eBikes For All Lifestyles | KBO Bike
• KBO Bike | Contact Us
• Electric Bikes Support Center | KBO Bike

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