KAYOBA Electric Bike Instruction Manual

: June 2, 2024
: KAYOBA

KAYOBA Electric Bike Instruction Manual

Introduction

Product description

The product is an electric bicycle .

Intended use

The product is intended to cycle on the road. Do not use the product for other tasks. The manufacturer is not liable for personal injury or damage to the product if it is not used as intended.

Symbols on the product

symbols Read the operating instructions carefully and make sure that you understand the instructions before you use the product. Save the instructions for future reference

This product complies with applicable EU directives and regulations.

Recycle as electrical waste.

Product overview

Introduction
(Figure 1)

Frame
Saddle post
Saddle
Adjustable head
Brake handle
Gear selector
Control panel
Bell
Bicycle basket
Front lamp
V-brake
Front wheel with hub motor
Front mudguard
Pedal
Pedal arm
Chain
Hub gear
Hub brake
Rear mudguard
Rear lamp
Battery On/Off button
Battery
Carrier rack

Control panel overview

(Figure 2)

Power assistance On/Off button
Walk assist
Button to select assistance level
Battery indicator

Battery overview

(Figure 3)

Battery indicator
Battery On/Off button
Key lock for battery

Safety

Safety definitions

Warning! If you do not obey these instructions, there is a risk of death or injury

Caution! If you do not obey these instructions, there is a risk of damage to the product, other materials or the adjacent area.

Note! Information that is necessary in a given situation.

Safety instructions for operation

The instructions describe how to ride safely and keep the product in good condition. Read the instructions carefully, and follow them. All the important servicing and adjustments of the product should be carried out at a bike shop. Follow these instructions if you do not have access to a bike shop or want to do the adjustments yourself
The product is a vehicle. Always follow local traffic regulations.
Do not let a passenger sit on the product.
Always wear a bike helmet.
If dark, use the lamps on the product. Wear bright clothes, if it is possible.
If wet, the power of the brake is reduced. Cycle more slowly and apply the brake earlier than in dry weather.
Do not modify the product.

Electrical safety

Do not let water penetrate into the hub motor. That causes short-circuit and damages that cannot be repaired.
Do not touch the battery terminals on the rear of the battery box. Make sure that no metal objects touch the battery terminal. That cause short-circuit and may result in electric shock, burn injuries and damage to the battery.
Only use the supplied charger to charge the battery.
Make sure that the voltage for the charger correspond to the mains voltage.
Do not open the charger. The charger is a high voltage unit.
Do not open batteries or cells.
Do not touch the 2 battery terminals at the same time. That can cause electric shock.
Do not remove the battery from the product when the battery charges.
Do not charge the battery near children.
Do not use the charger in direct sunlight.
Do not use the charger in dirty, wet or damp conditions.
Do not expose the battery to water or moisture.
Do not use the charger during thunderstorms.
Only use the charger in cool areas with god air flow.
Do not expose the battery to heavy vibrations.
Do not expose the battery to excessive heat or naked flames. Do not burn the battery.
Only connect the charger when the battery is in the charger.
Make sure that your hands are not wet when you connect or disconnect the charger.
Do not put objects on the charger.

Safety instructions for maintenance

Always let an approved service technician do the maintenance of the product and the electrical components.
Only use original spare parts.
Always disconnect the battery during maintenance.
Always disconnect the charger during maintenance.

Assembly

To install the saddle

Open the quick-release (A) for the saddle post and put the saddle post in the hole in the frame.

(Figure 4)
Lock the saddle post at the required height with the quick-release (B).

Note! Make sure that the marking for the top position for the saddle is below the edge of the saddle tube.

To install the front wheel

Align the center bolts of the wheel in the bottom part of the front fork. Make sure that wheel goes through all of the V-brake.
Install the center bolts of the wheel and tighten them.
Connect the cord from the motor with the cord on the front fork.

To install the handlebar tube

Install the handlebar tube to the frame.

Note! Make sure that the marking for the top position for the handlebars is below the edge of the handlebar tube.

To assemble the pedals

Note! The right pedal is marked with a R, and the left pedal is mark with a L. Install the right pedal on the right side of the bike, and the left pedal to the left side of the bike. If the pedals are not installed correctly, it can cause damage to the threads on the pedals.

Note! Put on some locking agent, for exampe Loctite, on the threads on the pedals before installation.

To fit the right pedal

Turn the pedal clockwise on the chain side of the crank arm.
Tighten with a combination spanner.

To fit the left pedal

Turn the pedal counter-clockwise, on the opposite side of the chain side of the crank arm.
Tighten with a combination spanner.

To install the battery

Install the battery in the battery holder on the carrier rack. Make sure that it fits correct when you lock it with the key lock.

Operation

To do before operation

Make sure that the product is adjusted correctly.
Make sure that the product is assembled with brakes and a bell.
Make sure that the product has a front lamp with a white light and a rear lamp with a red light. Make sure that the lamps can lit.
Do a check that the reflectors of the product are correctly installed, clean and not obscured. Replace damaged reflectors.
Make sure that the battery is charged.
Learn how to use the components and accessories on the product correctly. If you do not learn how to use the brakes on the product you can get seriously injured.
Make sure that the brakes stop the wheels when applied. Make sure that the brake pads are not worn out.
Make sure that all screw and components are tight and correctly installed.
Make sure that the wheels are correctly installed in the front fork and the rear fork.
Make sure that the rims are not damaged.
Make sure that the tyres are not damaged. Make sure that the tyres have the correct air pressure.
Make sure that the steering moves correctly.
Do a check that the quick-release on the saddle is tensioned correctly

To charge the battery

Warning! Do not connect the charger to a power source if it is not connected to the battery.

The battery is half-charged when it is new. Charge the battery for 10-12 hours the first 3 times.
Charge the battery when the battery charge is low.
Charge the battery for at least 2 hours every 3 months. Failure to do this will invalidate the warranty.
Protect the battery from contact with liquid or metal objects.
Do not turn or move the charger or the battery during charging.
When the battery is fully charged, disconnect the charger rom the mains outlet before you disconnect the battery from the charger.
Do not charge the battery through the dischargingN terminals.
Do not discharge the battery through the charging terminals.
The charger is for indoor use. It must only be used in a dry area with god air flow. Make sure that the temperature is 0-45°C when the charger is used.
Make sure that the temperature is -20-+45°C and the relative humidity is ≤ 80%, when the battery is discharged.
Follow the instructions on the marking on the battery.
Put the charger 1 m from electrical equipment such as computers, television and receivers, when in use.
Disconnect the charger if there is an abnormal smell

To charge the battery on the bike

Connect the charger to the outlet on the battery. (Figure 5)
Connect the charger to a power source.

To remove the battery from the bike and charge it.

Press the On/Off button on the control panel to stop the power assistance.
Press the On/Off button on the battery to turn the battery off.
Turn the key lock on the battery (A) and pull back the battery to release it from the bike (B). (Figure 6)
Connect the charger to the outlet on the battery.
Connect the charger to a power source.

The power assistance

Stop the power assistance if the product behaves abnormally.
Press the Mode button to adjust the assistance level.
The power assistance stops at 25 km/h.
When the speed drops below 25 km/h and the rider continues to pedal the power assistance starts again.
The electrical system has a low voltage protection. The power assistance stops when the battery has low power

To start the power assistance

Press the On/Off button on the battery to start the battery.
Press the On/Off button on the control panel to start the power assistance.
Start to pedal to activate the motor.

The brakes

Warning! Do not use a product with brakes that do not operate correctly

The bike has a rim brake that controls the rear wheel.
The bike has a brake handle that is located on the left side of the handlebar. The brake handle controls the front wheel.

To use the brakes

Apply the rear brake before you apply the front brake

Warning! Do not apply the front brake when you turn the product or on a slippery surface.

The Gears

The product has 3 hub gears. The shift lever on the right side of the handlebars indicates which gear is engaged; 1, 2 or 3.

(Figure 7)

Operation

Make sure that the gears are correctly adjusted.

To change gea

Turn the inner part of the right handle on the handlebar to change gear. 5

Maintenance

Warning! Always disconnect the battery during maintenance.

To clean the product

Clean the product regularly.
Clean with a mild detergent. Do not use degreasing products that can penetrate the bearings and chain and interfere with the lubrication.
If the product gets wet, wipe with a towel after use.
If the product is used or salted surface, clean it with fresh water after use.
Do not clean the product with a high-pressure washer. There is risk that water go into the electrical components.
Make sure that battery contactors on the frame are clean and free from oxide.
Do a check that the welds on the frame are not damaged and free from rust.

To lubricate the product

Lubricate the chain and the derailleur with transmission lubricant at 1 to 2 month intervals, or more often ifM necessary. Refer to “5.2.2 To lubricate the chain” on page 30.
Lubricate the saddle post, the front hub and the pedals with grease at 1 to 2 month intervals, or more often if it is necessary

Note! Do not use too much lubricant. The speed control, brake pads and rims should be kept free from lubricants

To lubricate the wires

Make sure that the wires are well lubricated. If it is necessary, lubricate with applicable oil.

To lubricate the chain

The chain should be lubricated at regular intervals. If the chain is dry, it can rust and get damaged.

Lubricate the chain with applicable chain oil.
Move the pedal a few turns to let the oil go into the link.
Wipe the chain with a cloth.

To tension the chain

The chain should be well-tensioned and move 1 cm up and down when it is pressed with a finger. A chain that is notcorrectly tensioned can be dangerous. If the chain can be moved more than 1 cm up or down it must be tensioned.

Loosen the rim brake screw
Loosen the nuts on the rear wheel and pull the rear wheel rearwards.
Tighten the nuts. Make sure that the wheel installed straight and correctly.
Make sure that the chain has the correct tension.
Make sure that the rear wheel is correctly tightened.
Tighten the rim brake screw.

To adjust the brake handles

The brake should apply full power when the brake handle is pushed halfway. The brake must not press against the rim when the brake handle is not pressed. The handle must not be pressed fully to the handlebar.

Adjust the tension for the front brake with the adjuster screw on the brake handle.
(Figure 8)
If larger adjustment is necessary, release the wire lock on the brake arm. Move the wire to required position and fully tighten the wire lock.
To replace the brake wires, speak to an authorized service center.

To adjust the spring tension

The spring tension prevents that the brake touches the rim when the brake handle is released.

when the brake handle is released.
Turn the adjusting screws on each side of the brake with a suitable screwdriver until the arms move in parallel. when the brake handle is released.
Turn the adjusting screws on each side of the brake with a suitable screwdriver until the arms move in parallel.

(Figure 9)

To adjust the brake pads

The brake pads should press against the middle of the rim.N The brake pads must not touch the tyre or move below the bottom edge.

If it is necessary, loosen the hex screw that holds the brake pad and adjust the position of the pad.

(Figure 10)
● If it is necessary, replace the brake pads. Speak to your service center.

To adjust the gears

The gear wire tension is adjusted with the adjuster screw on the hub of the back wheel.

Release the locking nut for adjusting screw.
Turn the gear lever on the right-hand side of the handlebar to apply second gear. (Figure 7)
Turn the adjusting screw on the derailleur on the right side of the rear hub. **

(Figure 11)

**

Make sure that the yellow marker in the window is between the 2 white lines.
Tighten the lock nut for the adjusting screw.

To do a check of the tyre and rims

Regularly examine that the spokes are correctly tensioned and that the wheels are not buckled or out of round.
Do a check of the wear line on the side of the rim. The ear line indicates the wear from the brakes. Replace the rim if the wear line can no longer is visible.
Do a check of the air pressure in the tyres at regular intervals. Refer to the side of the tyre for the correct air pressure.
Regularly make sure that the tyres are not damaged.
Do not let the tyre touch oil, petrol, paraffin or agents that can cause damage to rubber.

To do a check of the spokes

The spokes should be equally tensioned round the wheel.

To do a check of the tension, push 2 adjacent spokes on the same side of the wheel together.
Do a check round the wheel to find loose spokes.
Make sure that the rim is not warped. Spin the wheel and use the brake pads as a reference.
Tension loose spokes with a spoke key. If you do not know how to tension the spokes, let an authorized service center tension the spoke

Note! A warped rim or broken spoke indicates that the wheel is damaged. Speak to an authorized service center.

To do a check of the hub bearings

Make sure that the hub bearings are not loose. Hold the wheel and move it forward and rearward.
Adjust the hub bearing to make sure that the bearings and bearing races do not get damage.

To replace the rear light batteries

Loosen the screw that holds the red plastic glass on the rear light and remove it.
Remove the 2 batteries and install 2 new AAA batteries with the correct polarity.
Install the red plastic glass and tighten the screw

Transportation

Transportation of the battery

Put the battery in its original package and protect it from vibration and direct sunlight.
Make sure to protect the battery from water.

Storage

Store the bike in a dry area, protected from direct sunlight.
Do not leave the product with no protection in rain or snow.
If the battery is not to be used for a long period, remove the battery from the holder and store separately.
Remove the battery from the charger and disconnect the Ncharger from the power source.
Charge the battery to 50% before long time storage. Charge the battery for 2-3 hours every other month for maintenance.
Store the battery and charger in a locked area to preventN access for children and animals.
Store the battery and charger in a clean, dry area with god air flow. Make sure that they are protected from corrosive substances, excessive heat and naked flames.
Make sure that the storage temperature for the battery is –20 to +35°C, and that the relative humidity is 5-65%.