HUFFY E4002 36V Electric Bike Installation Guide

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Owner’s Manual for 36-volt e-Bike

E4002 36V Electric Bike

*bike styles & colors may vary
NOTE: Models with Display please see manual KD58C-LCD included with this product
This manual contains important safety, assembly, operation and maintenance information.
Please read and fully understand this manual before operation.
Save this manual for future reference.
Always wear approved helmet and safety equipment when using this product.

Back Cover:

• Return and Service Contact information
• Registration QR Code Link
• Assembly QR Code Link

Tools Recommended:
Gather these tools for quick assembly.
(Metric Wrenches)

IMPORTANT! Before using the unit for the first time fullly charge the Battery. Battery Charger will shut off when Battery is fully charged, but never charge longer than 12 hours.

Warnings and Safety

e-Bikes Introduction
MEANINGS OF WARNINGS:
This symbol is important. See the word “CAUTION” or “WARNING” which follows it.
The word “CAUTION” is before mechanical instructions. If you do not obey these instructions, mechanical damage or failure of a part of the bicycle can occur.
The word “WARNING” is before personal safety instructions. If you do not obey these instructions, injury to the rider or to others can occur.
Riding an e-bike is similar to riding a regular bike but off ers a motor that provides assisted power when pedalling.

WARNINGS:

• When mounting your e-bike, always apply full front and rear brake lever pressure to keep the unit from moving while mounting and do not put feet on the pedals until you are sitting on the seat.
• Your e-bike travels at higher speeds than most riders are used to when pedaling a traditional bike. It is very important that you are aware of your surroundings and obstacles around you and be extra careful when you fi rst start  moving. It’s important to watch the path surface you are on which can cause tires to slip or flatten.
• An electric bike is heavier and requires more time to stop due to weight and faster speeds. Practice starting, riding and stopping in a closed space with no other vehicles and always ride with hands near the brake levers.
• Before riding, familiarize yourself with the products operation.
• Do not become distracted by the Display. Change Display settings only when stopped.
• Never ride at speeds faster than you are comfortable with.
• Always start riding with the lowest assist speed.
• Avoid riding this product on wet, frozen, oily or unpaved surfaces or under the influence of drugs and/or alcohol. Avoid uneven surfaces, potholes, surface cracks and obstacles.
• Avoid riding in rain and wet weather and always store e-bike indoors.
• Always obey State and Local Laws when using this product. Serious injury can result from the unsafe operations of this vehicle.
• This product is not designed to be jumped. If jumped, even from the curb, The e-bike Frame could break causing serious injury or death. If jumped, the warranty is void.

e-Bike Range:

• Higher assist setting will shorten the distance your e-bike can travel.
• Always keep tires at proper infl ation pressure (shown on side walls).
• Heavier riders will shorten riding range.
• Hills or rough terrain will shorten riding range.
• Starting and stopping eff ects riding range.
• Always fully charge your e-Bike before each ride.

This “Class 1” e-Bike complies with Federal Governments guidelines, with regard to total watts and top speed.

WARNING – TO AVOID SERIOUS INJURY:

Failure of the rider to obey the following Safety Warnings can result in serious injury or death. Check local laws governing the use of electrical vehicles.

• ADULT RIDERS ONLY.

• SUPERVISION NECESSARY WHEN USED NEAR CHILDREN.

• DO NOT USE THE VEHICLE IN AN UNSAFE MANNER OR AT AN UNSAFE SPEED. Not intended for jumps – this can damage the product.

• CHOKING HAZARD: Small parts, adult assembly required.

• Before using this product, fully understand the controls and safety issues. Riders must demonstrate the capability and skill to handle the vehicle and operate its controls to avoid falls or collisions.

• Obey all traffi c regulations, signs, and signals.

• Before each ride, check that the steering system is correctly adjusted and that all connection components are firmly secured and not broken.

• While using the product, keep hands and fingers away from wheels and other moving parts to avoid danger of pinching or entrapment.

• Riders should always wear a properly fitted helmet that complies with U.S. Consumer Product Safety Commission CPSC) Standard 16 CFR 1203 or equivalent standard for your country.

• Always wear shoes. Gloves, knee and elbow pads recommended.

• Ride on the correct side of the road, in a single fi le, and in a straight line.

• There are additional hazards of using the vehicle in areas other than private grounds.

• If possible, avoid riding at night, dusk, dawn and any other time of poor visibility.

• IF YOU MUST RIDE AT NIGHT OR AT TIME OF POOR VISIBILITY:

• Use a correctly installed headlight and taillight.

• Headlights are required by all states for nighttime riding and taillights are required in some states.

• Battery-powered lights or flashing safety lights are also recommended.

• MAKE YOURSELF MORE VISIBLE TO MOTORISTS.

• Reflectors: For your own safety, do not ride the bicycle if the reflectors are incorrectly installed, damaged, or missing. Make sure the front and rear refl ectors are vertical. Do not allow the visibility of the refl ectors to be blocked by  clothing or other articles. Clean the reflectors, as necessary, with soap and a damp cloth.

• Wear light-colored or reflective clothing, such as a reflective vest and reflective bands for your arms and legs.

• Use reflective tape on your helmet.

• USE EXTRA CAUTION IN WET WEATHER:
  • Ride slowly on damp surfaces because the tires will slide more easily.
  • Allow increased braking distance in wet weather.

• AVOID HAZARDS TO PREVENT LOSS OF CONTROL OR DAMAGE TO YOUR WHEELS:
  • Be aware of drain grates, soft road edges, gravel or sand, pot holes or ruts, wet leaves, or uneven paving.
  • Cross railroad tracks at a right angle to prevent the loss of control.
  • Do not carry any passengers.

WARNING – TO AVOID SERIOUS INJURY:

• Do not carry any items or attach anything to your bicycle that could hinder your vision, hearing, or control.
• Do not ride with both hands off the handlebar.
• Do not tow or push the product.
• Do not modify the product.
• Replace worn or broken parts immediately with original equipment.
• If anything does not operate properly, discontinue use.
• DO NOT TAMPER WITH THE ELECTRICAL SYSTEM: Doing so may create a short, causing the fuse to trip or other damage including fi re.
• Risk of Fire: Do not bypass fuse. Replace only with original size and type.
• The supply terminals are not to be short-circuited.
• Non-rechargeable batteries are not to be recharged.
• Batteries are to be inserted with the correct polarity.
• Rechargeable batteries are only to be charged by adults.
• The battery chargers used with the product are to be regularly examined for damage to the cord, plug, enclosure and other parts, and in the event of such damage, they must not be used until the damage has been repaired.
• Changes or modifi cations to this unit not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.
• Do not use the vehicle in unsafe conditions such as snow, rain, loose dirt, mud sand or fine gravel. This may result in unexpected action such as tip over and skidding. Using the vehicle in loose dirt, mud, sand, or fi ne gravel may  damage the electronics and gear box inside the vehicle.
• Do not overload the vehicle. Do not drive in very hot weather, components may overheat.
• Do not allow water or other liquids to come in contact with the battery or other electric components.
• No modifications to the motor to allow it to exceed a power output greater than 500W and a speed greater than 32 km/h

ALWAYS WEAR YOUR HELMET WHEN RIDING THIS PRODUCT!

Always read the user manual that comes with your helmet to make sure it is fitted and attached properly to the wearer’s head according to the fi tting instructions described in the user manual.

Lithium-Ion Battery & charger Warnings:

The following safety hazards may result in serious injury or death to the user of the vehicle:

• Battery Charger for Indoor use only. Use of a battery or charger other than the supplied rechargeable battery and charger may cause a fi re or explosion. Only use the supplied rechargeable battery (or lead-acid or lithium suitable  replacement) and charger with the vehicle.
• Using the rechargeable battery and charger for any other product may result in overheating, fi re or explosion. Never use the rechargeable battery and charger with another product.
• Explosive gases are created during charging. Charge the battery in a well ventilated area.
• Do not charge the battery near heat or fl ammable materials.
• All large lithium batteries are a potential fi re risk and should be charged in a safe place, preferably in the middle of a garage fl oor.
• Never charge a lithium battery unsupervised.
• Only an adult who has read and understands the safety warnings should handle, charge or recharge of the battery.
• Contact between the positive and negative terminals may result in fi re or explosion. Avoid direct contact between the terminals. Picking up the battery by the wires or charger can cause damage to the battery and may result in a fi re. Always pick up the battery by its case or handles.
• Battery must be handled by adults only. Liquids on the battery may cause fi re or electric shock. Always keep all liquids away from the battery and keep the battery dry.
• Contact or exposure to battery leakage may cause serious injury. If contact or exposure occurs immediately call your physician. If the chemical is on the skin or in the eyes, flush with cool water for 15 minutes. If the chemical was  swallowed, immediately give the person water or milk. Do not give water or milk if the patient is vomiting or has a decreased level of alertness. Do not induce vomiting.
• Battery Posts, terminals and related accessories contain lead and lead compounds (acid), chemicals known to cause cancer, reproductive harm and are toxic and corrosive. Never open the battery.
• Tampering or modifying the electric circuit system may case a shock, fi re or explosion and permanently damage the system. Exposed wiring and circuitry in the charger may cause electric shock. Always keep the charger housing  closed.
• Non-rechargeable batteries are not to be recharged.
• Batteries are to be inserted with the correct polarity.
• The supply terminals are not to be short-circuited.
• Batteries are only to be charged by adults.
• The battery chargers used with the product are to be regularly examined for damage to the cord, plug, enclosure and other parts, and in the event of such damage, they must not be used until the damage has been repaired.

Owner’s Bicycle Identification Record

NOTE: This information is only available on the bicycle itself.
Each bicycle has a Recovery Code stamped into the frame. The Recovery Code  can be found on the bottom of the crank housing as shown.
Write this number below to keep it for future reference.
If the bicycle is stolen,  give this number and a description of the bicycle to the police.
This will help them find the bicycle.

Recovery Code:
Purchase Date:
Model Name:

Fitting the Rider to the Bicycle
A bike which you ride only on paved surfaces, should give you a minimum stand- over height clearance of 2 inches (5 cm). A bike that you’ll ride on unpaved surfaces should give you a minimum of 3 inches (7.5 cm) of standover height clearance.
And a bike that you’ll use off road should give you 4 inches (10 cm) or more of clearance.
NOTE: See Assembly sections for Seat adjustment.

Adjust the seat height so that you can put the heel of one foot on a pedal with leg extended straight A – and so the opposite foot can reach the ground with tip of foot B. This will give your knees a slight bend when pedalling with the ball of the foot.

Parts Assembly

NOTE: All features, components and accessories are not included on all models.

Assembly
9| Quick Release Axle – Rear| 24| Rear Brake Caliper
10| Front/Rear Brake Disc (set of 2)| 25| Front Brake Caliper
11| Grip Set| 26| Front Light
12| Brake Hand Levers| 27| Head Set Bearing (set)
13| Throttle Assembly| 28| Control Display
14| Seat| 29| Kickstand (not shown)
15| Seat Reflector| 30| Bell (various models)

Introduction to Assembly

This Owner’s Manual may be made for several different style products.

• Some illustrations may vary slightly from the actual product.
• Follow instructions completely.
• If the product has any parts that are not described in this manual, look for separate “Special Instructions” that are supplied with the unit.
• All features, components and accessories are not included on all models.
• Use the Index page to locate specifi c sections of this manual.
• Please read through this entire manual before beginning assembly or maintenance.
• If you are not confident with assembling this unit, contact customer service.

WARNING: Keep small parts away from children during assembly.
NOTE: All of the directions (right, left, front, rear, etc.) in this manual are as seen by the rider while seated.
Do not dispose of the carton and packaging until you complete the assembly of the product. This can prevent accidentally discarding parts of the unit.

Radio Frequency Information (if applicable)

WARNING: Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference  that may cause undesired operation.
NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a  residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on,  the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit diff erent from that to which the receiver is connected.
• Consult the dealer or an experienced radio/ TV technician for help.

Quick Release Axle Guide – various models

WARNING:

• Check QR axle and secure before every ride.
• If you hear any unusual noise from the wheels when riding – check the QR axle system.
• Do not ride with improperly adjusted or worn QR axle, this can result in serious injury.
• If you have any problems with the QR axle system, contact the bicycle manufacturer or a local bicycle shop.
• This product is not intended for use in stunt riding, ramp jumping,  acrobatics, or similar activities.
  

STEPS 1 :

• Move the QR Lever A to the OPEN position and loosen QR Nut B (turn counter-clock-wise) enough so the wheel axle fi ts into the Fork Dropouts C.
• Ensure the serrated Washers D sit inside Fork Recess E on both sides.

STEPS 2 :

• Pushing down on fork to ensure wheel axle is fully seated in Fork Dropouts, tighten QR Nut B (turn clock-wise) hand tight.
• Position QR Lever pointing UP or BACK and partially close.
• Adjust QR Nut and push QR Lever A closed with palm of hand.

STEPS 3 :

• Ensure QR Lever is tight and fully CLOSED F.
• Ensure wheel is centered in fork and held securely.

WARNING:

• Ensure the Quick-Release (QR) is properly tightened F before each ride (refer to QR use instructions in this manual).
• Ensure QR Lever does not come in contact with Disc Brake G or Spokes before each ride.
• DO NOT RIDE WITH THE QR IN THE OPEN POSITION H.

Assembly

Installing the Front Wheel – various models

WARNING:

• Do NOT use Axle Nuts A without serrations to attach the front wheel.
• Ensure wheel spins freely without contacting fork or fender.
• Failure to obey these steps can allow the front wheel to loosen while riding. This can cause injury to the rider or to others.

1. If the Axle Nuts and Washers are already attached to the front wheel axle, remove and set aside.

2. Set the wheel into the Front Fork B making sure the Disc Brake C fi ts up into the Disc Brake Caliper.
   TABBED WHEEL RETAINERS OR FLAT WASHERS D:

3. Install Wheel Retainers or Washers D making sure Wheel Retainer tabs are in the fork E tab holes.

4. Install Axle Nuts A with serrated surface facing IN.

5. With the wheel in the center of the fork, tighten both Axle Nuts securely. INFLATE ALL TIRES BEFORE RIDING!

Handlebar and Stem Installation – Threadless Stem (as equipped):

CAUTION:

• Threadless Stem B should be installed with bike sitting on the ground and both wheels installed.
• Make sure Fork is fully inserted from the bottom and Front Brake is pointing FORWARDS.
• Disc Brake models: Disc Brake will generally be on the LEFT side of the Fork.

STEP 1:

1. Add Spacers A as needed for proper Gap E.

2. Insert the Stem B fully onto the Fork Tube C.

3. Point the Stem towards the front of the bike and in line with the fork and wheel.

4. With downward pressure on Stem, move bicycle fork/wheel back and forth so there is no looseness in Headset Bearings D.
   NOTE: Ensure the Steerer Tube C extends at least 1-2mm above the top of the Stem E.

5. Place Cap F into stem and tighten screw securely G. Try to move Fork back and forth. There should be no movement in Headset Bearings D.
   If needed, redo above steps.

6. If supplied, insert Rubber Cap I securely..
   STEP 2:

7. Tighten the stem bolts H securely.

WARNING: Ensure handlebar and fork turn left to right smoothly and without friction.

Handlebar Installation

1. If necessary, loosen the Handlebar Clamp Bolt(s) A and rotate Handlebar B into a comfortable riding position.
2. Tighten Handlebar Clamp Bolts(s) Asecurely. NOTE: On four bolt stems, tighten Bolts A evenly in a cross-pattern as shown. Do not over tighten.
   

NOTE: (various models)

1. Position FRONT Refl ector C so it points straight forward.
2. Tighten Clamp Screw.

Testing Stem and Handlebar Tightness
TO TEST THE TIGHTNESS OF THE STEM:

• Straddle the front wheel between your legs.
• Try to turn the front wheel by turning the handlebar 1.
• If the handlebar and stem turn without turning the front wheel, realign the stem with the wheel and tighten the stem bolt(s) tighter than before (about 1/2 revolution only at a time) until the handlebar and stem do not turn without turning the front wheel.

TO TEST THE TIGHTNESS OF THE HANDLEBAR CLAMP:

• Hold the bicycle stationary and try to move the ends of the handlebar up and down 2.
  CAUTION: Do not exceed 100 lbs (45 kg) downward force.

Seat Installation

WARNING: To prevent the seat coming loose and possible loss of control, the “MIN-IN” (minimum insertion) mark A on the seat post must be BELOW the top of the seat tube B.

STEP 1- INSERT SEAT POST INTO SEAT TUBE:

• If needed, loosen seat post clamp screw D or open the quick release lever E.
• Point the seat forward and put the seat post C into the seat tube B with the “MIN-IN” marks BELOW the top of the seat tube as shown.

STEP 2 – BOLT SEAT CLAMP: (various models)

• With seat post C inserted according to STEP 1 – Tighten screw D securely so seat supports the rider without moving.

STEP 3 – QUICK RELEASE LEVER: (various models)
CAUTION: Operate the quick release lever by HAND ONLY – DO NOT USE TOOLS.

1. As needed, open and close the quick release lever Ewith one hand and tighten or loosen the adjusting nut G by hand, so that you fi rst feel resistance to the quick release lever when it is in the “OPEN” position 1.
2. Push the quick release lever to the “CLOSE” position 2 – It will take strong force to clamp securely so that the quick release Lever lays against the seat post clamp F.

NOTE: I Suggested Torque 20-22NM – Verify seat does not move while riding.
REFLECTOR: (as equipped)
Position seat post refl ector (if equipped) H so it points straight backwards. Tighten clamp screw.

Seat Bolt Saddle Adjustment (various models)

SINGLE BOLT CLAMP:

1. Loosen the clamp bolt A suffi ciently to allow any serrations B on the mechanism to disengage before changing the saddle’s angle.

2. With serrations fully re-engaged and saddle in a comfortable riding position, tighten the clamp bolt A securely to ensure the saddle will not come loose.
   WARNING: Serrations on the mating surfaces of the clamp can wear with use and adjustment. Check that the clamp is tight and secure before each ride.
   DUAL CLAMP:

3. Loosen clamp bolt/nut C as needed and adjust seat to a comfortable riding position.

4. With clamp fully on seat post as shown, tighten bolt/nut C securely so that seat does not move when in use.

Testing Seat Clamp and Post Clamp Tightness
To test the tightness of the seat clamp and the post clamp:

• Try to turn the seat side-to-side and to move the front of the seat up and down.
• If the seat moves in the seat clamp:
• Loosen the Seat clamp nut.
• Put the seat in the correct position and tighten the seat clamp tighter than before.
• Do this test again, until the seat does not move in the seat clamp.
• If the seat post moves in the seat tube clamp:
• Loosen the seat clamp lever.
• Put the seat post in the correct position and tighten the seat clamp nut tighter than before.
• If necessary, tighten or loosen hand nut so that quick release tightens securely.
• Do this test again, until the seat post does not move in the seat tube clamp.

Pedal Installation

CAUTION: There is a RIGHT pedal marked R and a LEFT pedal marked L.
NOTE: A Pedal Wrench is preferred for attaching Pedals.
A thin open-end wrench can also be used.

• The pedal marked R has right-hand threads. Tighten it in a clockwise direction.
• The pedal marked L has left-hand threads. Tighten it in a counterclockwise direction (anti-clockwise).
• Turn the right pedal marked R into the right side of the crank arm, and the left pedal marked L into the left side of the crank arm.

Tighten the pedals:

• Make sure the threads of each pedal are fully into the crank arm.

Three-Piece Cranks (various models)
Maintenance: Both Crank Arms A were tightened to the spindle B at the factory. After riding the bicycle the fi rst few times, make sure the crank arms have not loosened. If either crank arm has loosened during this “break-in” period, re- tighten or have it tightened by a bicycle service shop.

Frequently check the tightness of the crank arms.
If loose, tighten or have them tightened by a bicycle service shop.
WARNING: If you ride the bicycle with a loose crank arm, the crank arm may fall off .
The spindle may also damage the crank arm.

Drive Battery Installation
STEPS:

1. On bottom of Battery, align base A with Slot B on Battery Mount and swing fully into place.
2. Insert and turn Key D fully to open position.
3. With Battery C fully in place, turn Key fully to locked position.
4. Gently pull on battery to make sure it does not come lose. Remove key and keep in a safe place.
   

Charging the Drive Battery:
IMPORTANT! Before using the unit for the first time fully charge the Battery.
Battery Charger will shut off when Battery is fully charged, but never charge longer than 12 hours.
NOTE: Your e-Bike Li-Ion Battery can be charged either installed in the bike or removed.

WARNINGS:

• All large Li-Ion batteries are a potential fire risk and should be charged in a safe place, preferably outside or in the middle of a garage floor.

• Never charge a lithium battery unsupervised inside a house or building.

• Only an adult who has read and understands the safety warnings should handle, charge or  recharge of the battery.

• See other Battery Warnings in this manual.

• Check the drive battery and charger (supply cord, connector) for wear and damage before charging. Do not charge the battery if damage has occurred. Only replace with the same type and voltage  rechargeable battery and charger  supplied by the manufacturer.

• Only use the rechargeable battery (or equivalent replacement) and charger supplied with your vehicle.

• The drive battery should be charged when depleted, or if not used regularly, once a month. Failure to charge the battery as directed will cause permanent damage to the battery and will void the warranty.

• Charge only when battery has cooled to room temperature after a ride.

Operation

Display User Manual
NOTE: Models with Display please see manual KD58C-LCD included with this product

Maintenance

e-Bikes Maintenance:
GENERAL: The vehicle should be checked for damage, missing or badly worn parts before each use. If any part of the product does not operate properly – discontinue use.

• Check the tightness of the fasteners before each use. Replace any fasteners that are damaged.
• Inspect the product frequently. Failure to inspect the product and to make repairs or adjustments, as necessary, can result in injury to the rider or to others. Make sure all parts are correctly assembled and adjusted as written in this manual and any “Special Instructions.”
• Immediately replace any damaged, missing, or badly worn parts.
• Make sure all fasteners are correctly tightened as written in this manual and any “Special Instructions.” Parts that are not tight enough can be lost or operate poorly. Over tightened parts can be damaged. Make sure any replacement fasteners are the correct size and type.
• Check the tightness of the wheels.
• Keep the product clean and free of dirt, dust and water. This will prolong the useful life of the product.
• Always remove the battery when replacing a component or performing maintenance.
• Periodically check your e-Bike’s wiring and motor condition and mounting.
• Always store your e-Bike indoors. Bike’s left outside in weather can deteriorate very quickly. Store your e-Bike in a clean dry environment. Do not cover with plastic which will hold moisture inside and aff ect your bike’s electrical system.
• Store your battery indoors during cold weather to optimize battery performance.

CAUTION: Self-locking nuts and other self-locking devices may lose their eff ectiveness when re-used.
CLEANING: Do not submerge the drive unit in water or wash with a pressurized hose. Keep all components clean, especially the battery pack contact points. Clean carefully with soft, damp cloth using only mild soap and water.
STORAGE: Always store the battery pack in a cool dry place. Keep it away from sources of heat, such as stoves and heaters. During periods of prolonged storage, battery pack should be charged at leased once every 6 months at a minimum of 60% or every 3 months at 40%. Do not charge higher than 60% when storing.
NOTE: If the instructions in this manual or any “Special Instructions” are not suffi cient for you, please contact customer service.

Chain Adjustment

STEPS:
The chain must be at the correct tightness. If too tight, the bicycle will be difficult to pedal. If too loose, the chain can come off the sprockets.
When the chain A is at the correct tightness, you can rotate the crank freely and you can pull chain no more than onehalf inch B away from a straightedge as shown. !HUFFY E4002 36V Electric Bike - Adjustment 2

Adjust the tightness of the chain as follows:

• Pull off axle nut Covers C. NOTE: Right side will have wire harness attached. Use caution.
• Loosen the Axle Nuts D (both sides) so they are hand tight.
• Turn Adjuster Nut E so that the Chain A is the correct tightness as shown above.
• Turning clockwise tightens the chain.
• Counter-clockwise loosens the chain.
•  With chain at corrected tightness and wheel centered in frame F, tighten both Axle Nuts D fully and securely so wheel does not come loose.
• Replace both axle nut Covers C fully.

Removing Rear Drive Wheel

SHOULD YOU NEED TO REMOVE REAR DRIVE WHEEL, FOLLOW THESE STEPS:

1. Pull off axle nut Covers A.
   • NOTE: Right side will have wire harness attached. Use caution.

2. Unplug Wire Harness B.

3. Loosen the Axle Nuts C (both sides).

4. Loosen Chain Adjuster D enough to lift chain off sprocket.

5. Gently remove rear wheel assembly.
   • To reinstall wheel, follow the steps above in reverse order – making sure chain adjustment arm E is on outside of frame and disc brake fits evenly into disc brake housing F.
   • Adjust chain tension according to Chain Adjustment instructions in this manual.

Disc Brake System
NOTE: Please refer to component manufacturer’s documentation for product specific instructions. For Hydraulic Brakes, see Manufacturer’s instructions included with this product.
BRAKE SYSTEM MAINTENANCE:

• Check brake operation and adjustment before each ride.
• Keep the brake system free of dirt, mud, oil, and other foreign substances that will inhibit proper operation.
• Frequently check:
• All components for damage.
• The pads – for wear.
• The lever – for smooth operation.
• The cable – ensure there are no frayed ends, cuts, or kinks that inhibit operation. Add cable lube if the cable is dry.
• All bolts and fasteners – ensure the bolts are tightened, replace any that are damaged.

Tires (as equipped)

MAINTENANCE:

• Frequently check the tire inflation pressure because all tires lose air slowly  over time. For extended storage, keep weight off of the tires.
• Do not use unregulated air hoses to inflate the tire/tubes. An unregulated hose can suddenly over inflate tires and cause them to burst.
• Replace worn tires.

WARNING: Do not ride or sit on the unit if a tire is under inflated. This can damage the tire, inner tube and rim.
INFLATING THE TIRES:

• Use a hand or a foot pump to infl ate the tires.
• Service station meter-regulated air hoses are also acceptable.
• The maximum infl ation pressure is shown on the tire sidewall.
  Before adding air to any tire, make sure the edge of the tire (the bead) is the same distance from the rim, all around the rim, on both sides of the tire A. If the tire does not appear to be seated correctly, release air from the inner tube  until you can push the bead of the tire into the rim where necessary. Add air slowly and stop frequently to check the tire seating and the pressure, until you reach the correct infl ation pressure.

Inspection of the Bearings
Maintenance:
Frequently check the bearings of the bicycle. Have a bicycle service shop lubricate the bearings once a year or any time they do not pass the following tests:
Headset Bearings:
The fork should turn freely and smoothly at all times. With the front wheel off the ground, you should not be able to move the fork up, down, or side-to- side in the head tube.
Crank Bearings:
The crank should turn freely and smoothly at all times and the front sprockets should not be loose on the crank. You should not be able to move the pedal end of the crank from side-to-side.
Wheel Bearings:
Lift each end of the bicycle off the ground and slowly spin the raised wheel by hand. The bearings are correctly adjusted if:

• The wheel spins freely and easily.
• The weight of the spoke reflector, when you put it toward the front or rear of the bicycle, causes the wheel to spin back and forth several times.
• There is no side-to-side movement at the wheel rim when you push it to the side with light force.

Lubrication

WARNING:

• Do not over lubricate. If oil gets on the wheel rims or the brake shoes, it will reduce brake performance and a longer distance to stop the bicycle will be necessary. Injury to the rider or to others can occur.
• The chain can throw excess oil onto the wheel rim. Wipe excess oil off the chain.
• Keep all oil off the surfaces of the pedals where your feet rest.
• Using soap and hot water, wash all oil off the wheel rims, the brake shoes, the pedals, and the tires.
• Rinse with clean water and dry completely before you ride.
• Using a light machine oil (20 W), lubricate the bicycle according to the following table:

Lubrication Table (as equipped)

pedals.
Chain| every six months| Put one drop of oil on each roller of the chain. Wipe all excess oil off the chain.
Derailleurs| every six months| Put one drop of oil on each pivot point of the derailleurs.
Brake Levers| every six months| Put one drop of oil on the pivot point of each brake lever.
Wheel Brakes| every six months| Put one drop of oil on the pivot point of each cantilever brake.
Brake and cable| every six months| Put four drops of oil into both ends of each cable. Allow oil to soak back along the cable wire.
Rear Sprocket Cluster| every six months| Lay the bicycle on its left side. Slowly turn the rear wheel clockwise. Put four drops of oil in the crack between the rear sprockets (which are stationary) and the freewheel body (which is turning clockwise).
Shock Fork| every six months| Lift up the rubber fork boot and dab a small amount of grease on the fork leg just above the plastic bushing.

Drive Battery Replacement

STEPS:

1. Insert and turn Key D fully to open position.
2. Holding key in open position, tilt Batter to the right and lift out.
3. Position new Battery as shown.
4. On bottom of Battery, align base A with Slot B on Battery Mount and swing fully into place.
5. With Battery C fully in place, turn Key fully to locked position.
6. Gently pull on battery to make sure it does not come lose. Remove key and keep in a safe place.

Lithium-Ion Battery Storage and Disposal

Do not leave batteries unused for extended periods of time, either in the product or in storage. When a battery has been unused for 6 months, check the charge status and charge or dispose of the battery as appropriate.
STORAGE:

• Charge or discharge the battery to approximately 50% of capacity before storage.
• Charge the battery to approximately 50% of capacity at least once every six months.
• Remove the battery and store it separately from the product.
• Store the battery at temperatures between 5 °C and 20 °C (41 °F and 68 °F).
• Do not store battery in extreme hot or cold temperatures.
• Wipe the battery clean with a dry cloth prior to storage. Wash cloth separate from other clothes.

BATTERY DISPOSAL:

• Lithium-Ion batteries must be recycled or disposed of in an environmentally sound manner.
• Lithium-Ion batteries are subject to disposal and recycling regulations that vary by country and region. Always check and follow your applicable regulations before disposing of any battery.
• Do not dispose of battery in a fi re. The battery may explode or leak acid.
• Do not dispose of the battery in household trash. The incineration, land filling or mixing of sealed Li-ion/lead-acid batteries with household trash is prohibited by law.
• Return an exhausted battery to a federal or state approved Li-ion/lead-acid battery recycler. (check local battery disposal regulations).

Troubleshooting

Symptoms

| Possible Cause|

Solution

---|---|---

Display is on, motor does not work or works slowly/ intermittently

| Battery voltage is low| Charge Battery
Battery is loose in compartment| Re-seat Battery
Wire Harness connectors loose| Check that Harness connectors are firmly attached

Reduced ride time

| Battery is low| Recharge
Battery does not hold a charge| Replace Battery

Battery does not fully charge

| Battery at end of life| Replace Battery
Charger not connected correctly| Re-check charger connections at battery and wall socket
Battery not fully seated| Re-seat Battery

Display does not turn on

| Wire Harness connectors loose| Check that Harness connectors are firmly attached
Display bad| Replace Display
 | Power is off| Turn Power on

No Pedal assist

| Wire Harness connectors loose| Check that Drive Motor Harness connectors are firmly attached
Motor bad| Replace Motor
Speed sensor magnet not aligned| Align magnet on wheel with sensor on frame near motor

Warranty

Limited Warranty – US

General:
Part or model specifications are subject to change without notice.
This Limited Warranty is the only warranty for the product. ALL WARRANTIES OTHER THAN STATED HEREIN ARE DISCLAIMED INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A  PARTICULAR PURPOSE, TO THE EXTENT ALLOWABLE BY APPLICABLE LAW. ALL LIABILITY FOR INCIDENTAL, PUNITIVE, SPECIAL, OR CONSEQUENTIAL DAMAGES ARE EXPRESSLY DISCLAIMED, TO THE EXTENT  ALLOWABLE BY APPLICABLE LAW.
The only uses for this product are described in this manual.
Warranty registration is not required.
The Limited Warranty extends only to the original consumer and is not transferable to anyone else.
What does this Limited Warranty cover?
This Limited Warranty covers defects in workmanship and materials for all parts of the product except those indicated below as not warranted.
What must you do to keep the Limited Warranty in effect?
This Limited Warranty is effective only if:

• Product is completely and correctly assembled.
• Product is used under normal conditions for its intended purpose (see the following section for excluded activities).
• Product receives all necessary maintenance and adjustments.
• Product is used for general transportation and recreational use only.

What is not covered by this Limited Warranty?
This product is designed for recreational use only.
This Limited Warranty does not cover normal wear and tear, normal maintenance items, or any damage, failure, or loss that is caused by improper assembly, maintenance, adjustment, storage, or use of the product. This Limited Warranty does not extend to future performance.
This Limited Warranty will be void if the product is ever:

• Used in any competitive sport
• Used for stunt riding, jumping, aerobatics or similar activity
• Modifi ed in any way

[ USA ]
PLEASE – BEFORE RETURNING TO STORE:
Contact Huff y Customer Service.
We are glad to assist you with any parts or assembly problems you might have!

For Fast Customer Service and email:
www.huffybikes.com/contact
OR TEL: 1 800 872 2453 (US)
To Order Parts:
www.huffybikes.com/parts

Please REGISTER your Product:

https://www.huffybikes.com/global-contacts/
for current contact information

References

• ybikes.com/contact
• ybikes.com/global-contacts
• ybikes.com/parts

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