KAYOBA 010457 Electric Bicycle Instruction Manual

: June 5, 2024
: KAYOBA

KAYOBA 010457 Electric Bicycle

KAYOBA-010457-Electric-Bicycle-
Product

SAFETY INSTRUCTIONS

The electric bike is a vehicle. Always follow local traffic regulations. Passengers are not allowed to ride on electric bike. Reduce your speed and increase the distance to other road users in rain, snow or slippery conditions.
You should not attempt to dismantle parts from the bike for maintenance. Contact a qualified service technician.
Do not ride through pools of water or other accumulations of water. Water can penetrate into the hub motor and cause short-circuiting and irreparable damage.
The two metal connector plates on the back of the battery box are the battery’s positive and negative terminals. Do not touch the battery terminals, especially with wet hands. Make sure that metal objects do not come into contact with the battery terminals as this can cause short-circuiting and result in electric shock, severe burn injuries and damage to the battery.
Never allow persons who are not familiar with electric bikes, or who have not read these instructions, to use th is product.
Do not make any modifications to the product.

WARNING
Like all other mechanical equipment, a bike is exposed to wear when in use. Different materials and components read in different ways to wear and stress. If the life span of any part of the bike (including the frame, forks and components) has been exceeded there is a risk of the part suddenly breaking, and that you lose control and fall off. Cracks, scratching or changes in colour in areas exposed to high levels of stress indicate that the component has reached the end of its useful life and should be replaced.

CHECK BEFORE USE

Check that:

The tyres are in good condition and have the correct tyre pressure. See side of tyre for recommended pressure.
The battery is charged.
The stem, handlebars and saddle post are correctly fitted and tightened.
The axle nuts are correctly tightened.
The bell is working.
The rims are in good condition and undamaged. A worn rim is a safety risk and should be replaced.
Screw unions and components are properly tightened and not worn or damaged.
The seat is comfortably adjusted.
The brakes are working properly.
The steering does not jam, or has too much play.
The wheels are not warped and the wheel bearings are correctly adjusted.
The wheels are properly attached in the back/front forks.
The pedals fit properly in the crank arms.
The gears are correctly adjusted.
All the reflectors are fitted.
After adjusting, check that all screw unions are correctly tightened and that the wires are undamaged and correctly drawn along the frame.
The maximum load including the bike, cyclist and baggage is 120 kg.
Check the function of the brakes. Use the brake handle on the left side of the handlebars to brake the front wheel, and use the brake handle on the right side to brake the back wheel.

BATTERY AND CHARGER

The battery is half-charged when new. Charge the battery for 10-12 hours the first three times.
Charge the battery when the battery charge is low.
Make sure the charger voltage corresponds to the mains voltage.
Do not open the charger, the charger isa nigh-voltage unit.
Never touch the two battery terminals at the same time this can cause an electric shock.
Never take the battery out of the electric bIke when charging.
Charge the battery for at least 2 hours every three months. Failure to do this will invalidate the warranty.
Protect the battery from contact with liquid or metal objects.
Never charge the battery in the vicinity of small children or babies.
Never use the charger in dirty, wet or damp conditions. Avoid charging the battery in direct sunlight.
Do not use the charger during thunderstorms.
Only use the charger in cool and well-ventilated areas.
Do not expose the battery to heavy vibrations or knocks.
Opening the battery will invalidate the Warranty.
Never short-circuit the battery’s charging or discharging terminals.
Never attempt to charge the battery via the discharging terminals or discharge the battery Via the charging terminals.
Do not expose the battery to excessive heat or naked flames. Do not burn the battery.
Do not expose the battery to water or moisture. Protect the battery’s charging and discharging terminals trom rain, flooding or immersion in water
Operating temperature when charging the battery: O to 45°C.
Operating temperature when discharging: -20 to +45C.
Relative humidity when discharging: 80%.
Store the battery out of the reach of children and animals.
Ir the battery Is not going to be used for some time, remove it from the battery holder and store separately.
Contact your dealer if you have any questions concerning the battery.
Never dismantle batteries or cells.
Follow the markings on the battery.
The charger should be placed at least 1 metre from computers, television receivers, whitegoods and other electrical equipment while charging is in progress.
The charger is only intended for indoor Use. It must only be used in a dry and well-ventilated area with a maximum temperature of 45°C.
Disconnect the charger immediately it it emits an abnormal smell during charging, and take it to your dealer.
The battery must only be charged with the charger recommended by the manufacturer. Ihe charger must only be used for the battery for which it iS intended, not for other batteries from other manutacturers.
Do not use the charger in dusty or damp
Conditions, or where it cannot remain stable.
When the battery is fully charged, first disconnect the charger from the mains and then disconnect it from the battery
Make sure that nobody, especially children, touches the charger while charging is in progress.
Do not place any objects on the charger.
Make sure your hands are not wet when
Connecting disconnecting the charger.
Do not turn or move the charger or battery while charging Is in progress
Do not use the charger in direct sunlight.
Do not disconnect the charger from the battery while charging is in progress.
Do not carry out any maintenance on the bike while charging is in progress.
Do not connect the charger to the mains if it is not connected to the battery.
The electric bike works reliably in all kinds of weather, but the electrical components and/or motor can be damaged during prolonged or excessive exposure to water.
Do not touch the electrical components with wet hands, or touch the positive and negative terminals on the battery at the same time; short circuiting can result in personal injury.
If there is a fault on any of the electrical components, consult a specialist. Do not attempt to repair the fault yourself.
Never use the electric bike for riding on extreme terrain, jumping, or carrying heavy loads. This can damage the electric bike and result in personal injury.

WARNING!
The electric bike has a lithium-ion battery. Never charge the battery with any other charger than the one supplied with the battery. Using another charger to charge the battery can cause it to catch fire, or explode. If your charger is damaged or lost, contact the nearest Jula store for a replacement charger.
SERVICE

Only use identical spare parts when replacing parts that are essential for safety. Contact an authorised service centre for original parts. This will guarantee that the bike remains safe to use.

ROAD SAFETY

Always wear an approved bike helmet.
Follow local traffic regulations.
Follow the laws and regulations that apply in your country when riding an electric bike.
The electric bike is designed for normal roads and in normal traffic.
The bike is intended for one person.
In slippery conditions – note that the braking distance can be longer than normal to stop the electric bike safely.
Do not put anything on the bike that can get caught up and obstruct the functions of the bike.
Use lights and reflectors when cycling in the dark.
Do not ride on the same side as oncoming traffic.
Do not ride alongside another bike.
Do not give rides on bikes not intended for this.
Do not swing out into traffic.
Do not hang anything from the handlebars that makes it difficult to steer, or which could fasten in the front wheel.
Do not hang onto another vehicle.
Do not ride too close to a vehicle in front.
The braking power is reduced by water and ice.
Cycle more slowly in wet weather and brake earlier than in dry weather.
Follow local regulations when cycling in the dark. The bike must have a front lamp with a white light and a back lamp with a red light, plus the necessary reflectors.
Wear bright clothes and a high-visibility jacket if possible.
Check that the bike’s reflectors are correctly positioned, properly attached, clean and not obscured. Replace damaged reflectors immediately.

WARNING!
Like all mechanical components a bike is also exposed to wear and fatigue. Different materials and components show signs of wear and fatigue in different ways. If a mechanical component has reached the end of its useful life this can cause the component to suddenly malfunction, which can result in personal injury. Pay attention to changes in colour, cracks and scratches at exposed points. Such signs can be indications that components need to be replaced.

SYMBOLS

TECHNICAL DATA

MOTOR

BATTERY

BATTERY CHARGER

CONTROL UNIT

DESCRIPTION

Frame
Saddle post
Saddle
Adjustable head
Brake handle
Gear selector
Control panel
V-brake
Front/amp
Front-wheel with hub motor
Front mudguard
Pedal
Crank section
Chain
Hub gear
Hub brake
Back mudguard
Back lamp
Battery, on/off
Carrier rack
Battery

CONTROL PANEL

Power switch, on/off
Assistance 6 km/h
Button to select assistance level
Battery indicator

BATTERY

Battery indicator
Battery, on/off
Key lock, battery

ASSEMBLY

SADDLE
Open the quick-release for the saddle post and put the saddle post in the hole in the frame. Lock the saddle post at the required height with the quick- release. KAYOBA-010457-Electric-Bicycle-fig-4
WARNING!
Do not put the saddle over the marking for the max height on the saddle post. The marking means that at least one-third of the saddle post must be inserted in the frame.
FRONT WHEEL
Fit the front wheel by aligning the wheel’s centre bolt in the bottom part of the front fork, making sure that the wheel goes through the V-brake all the way. Fasten the wheel’s centre bolts and tighten. Connect the cord from the motor with the cord on the front fork.
HANDLEBARS
Fit the handlebars in the recess on the column. Put the clamp over the handlebars and tighten the two screws.
WARNING!
Do not raise the handlebars over the marking for maximum height.
PEDALS
Screw the pedals onto the pedal arms and make sure to fit them the right way round. The pedal is marked with R for right and L for left.
BATTERY
Fit the battery by putting it in the battery holder on the carrier rack. Lock it in place with the key lock.

USE

Before Using for the first time

The battery is half-charged on delivery. Charge the battery for 10-12 hours before using for the first time the next two or three times.
Be careful when using the power assistance the first time because the electric bike accelerates faster than a normal bike.
Ride the bike on a smooth surface first to get used to the acceleration.

TO BEAR IN MIND WHEN RIDING

Follow local traffic regulations.
Wear a bike helmet.
Be careful when braking, brake first with the more gentle back brake.
The power assistance works up to max 25 km/h and then switches off. When the speed drops below 25 km/h and the rider continues to pedal the power assistance starts again.
Do not use the power assistance in slippery conditions, or on loose gravel or clay.
Switch off the power assistance if the electric bike behaves “unusually” to avoid damaging the electrical system.
The front and back lights have two modes: flashing and constant. Press the light button once for constant and twice to flash.
Remember to switch off the bike and the lights after use.

WARNING!

Check that the front and back brakes are working properly.
Check that the front and back wheels are properly screwed on and that there is no play.
Check that the pedals, saddle and handlebars are properly screwed on and that there is no play.
Check that the quick-release on the saddle is properly tensioned and that there is no play.

RIDING THE BIKE

Start the battery and press ON on the control panel.
The motor is activated when you start pedalling and assists all the time while the battery lasts, switches off during braking, or as soon as you stop pedalling.
Adjust the assistance level of the electric motor by pressing the MODE button. The power assistance stops at 25 km/h and resumes when the speed drops below 25 km/h, assuming that you continue pedalling and the battery is not flat.
The electrical system on the bike has a low voltage protection that switches off the power if the battery drops below a certain level.

TOTAL DISTANCE

The total distance per full charge is measured on the horizontal at 20°C, in calm conditions, at a speed of 25 km/h and with the bike loaded with a total weight of 75 kg.
The actual real distance varies with the load, road conditions, wind speed, temperature, biking behaviour (number of starts etc.), tyre pressure and correct battery charging routines.
To obtain the longest possible distance all the above factors should be checked and adjusted as far as is possible – avoid overloading, pedal smoothly and with the correct tyre pressure, and charge the battery regularly.

BRAKES
WARNING!
It is very important to understand how the brakes work on the bike. If the brakes are not used properly you could loose control of the bike and seriously injure yourself. Note that different bikes can behave differently when braking.
Safe braking

Brake a bit sooner with the back brake than with the front brake.
Never brake with the front brake when turning. It is especially important to remember this on sharp curves, or on slippery surfaces such as clay, sand and snow.

WARNING!

Braking too hard with the front brake can brake the bike so suddenly that the rider can be thrown off the bike.
The braking power is reduced on wet roads. Bike more slowly and brake earlier in wet conditions.
Check that the brakes are working properly. Do not ride the bike if the brakes are not working properly.
Check that the brake pads are not worn down and that they are properly in place.
Make sure that the brake cables are properly in place.

Adjusting the front brake
The tension for the front brake is adjusted with the adjuster screw on the brake handle. KAYOBA-010457-Electric-Bicycle-fig-5
GEARS
Change gear by turning the inner part of the right handle on the handlebars.

CHARGING THE BATTERY

Battery mounted on the bike

To charge the battery on the bike, connect the charger to the outlet on the battery.
Plug the charger into a PowerPoint.

WARNING!
Do not connect the charger to a power point if it is not connected to the battery.
Battery removed from the bike

Switch off the bike on the control panel and with the battery’s power switch.
Turn the key (marked with a ring) to unlock the battery.
Pull back the battery to release it from the bike.
Connect the charger to the outlet on the battery.
Plug the charger into a power point.

WARNING!
Do not connect the charger to a power point if it is not connected to the battery.

Charge indicator

The charger light turns red while charging is in progress.
When the battery is fully charged the charger light turns green.
A flashing red and green light indicates a fault. Contact an authorised service centre.

MAINTENANCE

WARNING!
The battery must not be mounted on the bike during maintenance or repairs.

GENERAL

Use a sponge moistened with a mild detergent when cleaning. Do not use acidic detergents, they can damage the bike.
Avoid leaving the bike unprotected in the rain or snow.
If the bike gets wet, wipe it with a towel after use.
If the bike is used on a salted surface, clean it after use with fresh water.
Do not clean the bike with a high-pressure washer- risk of water and moisture penetrating into the electrical components and motor.

REGULAR MAINTENANCE
Run the following checks at intervals of 7 to 2 months:

Check that the stem, handlebars and saddle post are correctly fitted and tightened.
Check that the axle nuts on the wheels are correctly tightened.
Check that the rims are not cracked and that the spokes are in good condition and well tensioned.
Check that the tyres are not worn or damaged.
Check that the tyre pressure is correct.
Check that the battery contactors on the frame are clean and free from oxide.
Check that the battery is sufficiently charged.
Check that the lights are working properly.
Check that the front and back brakes are working properly.
Check that the wires are well lubricated and that the brake pads are in good condition.
Check that the welds on the frame are in good condition and free from rust.

SPOKES

Spoke tension
The spokes should be equally tensioned round the wheel.

Check the spoke tension by squeezing two adjacent spokes on the same side of the wheel together.
Go round the wheel to check if any spokes are loose.
Check that the rim is not warped by turning the wheel and using the brake pad as a reference point.
Tension loose spokes with a spoke key. If you are not sure how to do this, take the bike to an authorised service centre to tension the spokes.

Broken spoke
Note that a warped rim or broken spoke indicates that the wheel is damaged. Take the bike/wheel to a workshop to be repaired.
HUB BEARINGS
Check for play in the hub bearings by holding the wheel on the bike and moving it back and forwards. Adjust any play immediately, otherwise there is a risk of damaging the bearings and bearing races.

MAINTENANCE OF BATTERY AND CHARGER

If the battery is not going to be used for some time it should be kept charged to about 50% (takes about 2-3 hours of charging for a fully discharged battery) and stored in a dry and well-ventilated place. Charge the battery for 2-3 hours every other month for maintenance.
The battery and charger should be stored in a clean, dry and well-ventilated place, protected from corrosive substances, excessive heat and naked flames.
Storage conditions for battery: temperature -20 to +35 °C, relative humidity 5 to 65%.
Do not immerse the battery in water. When transported the battery should be packed in its original packaging and protected from knocks and blows, vibration and direct sunlight.
Disconnect the charger from the battery for storage.

REPLACING THE BACKLIGHT

Unscrew the screw holding the red plastic glass on the back light and remove it.
Insert two AA batteries with the correct polarity.
Replace the glass and screw on.

MAINTAINING THE CHAIN

Lubricate the chain

The chains should be lubricated at regular intervals. Use a suitable chain oil. Check that the chain does not knock when cycling, or is damaged.

Lubricate the chain.
Pedal a few turns so that the oil comes in the links.
Wipe the chain with a cloth or sponge.

Tensioning the chain

The chain should be well-tensioned and move 7 cm up and down when pressed with a finger. A chain that is not properly tensioned can be dangerous. If the chain can be moved more than 7 cm up or down it must be tensioned.

Undo the nuts on the back wheel and pull the back wheel backwards.
Tighten the nuts. Make sure the wheel is fitted straight.
Check that the chain is tensioned.
Check that the wheel is properly tightened.

RIM BRAKE

Adjusting the brake handle
Full braking power should be achieved when the handle is pressed in halfway. The brake must not press against the rim when the handle is not pressed. It should not be possible to press the handle all the way to the handlebars. Increase or reduce the play by turning the adjusting sleeve on the brake handle. If a larger adjustment is needed, release the wire lock on the brake arm, move the wire to the required position and firmly tighten.
Adjusting the spring tension
The spring tension counteracts the brake touching the rim when the brake handle is released. Turn the adjusting screws on each side with a suitable Phillips screwdriver until the arms move in parallel.
Adjusting the brake pads
It is important that the brake pads press against the middle of the rim and do not touch the tyre or go below the bottom edge. Undo the hex screw that holds the brake pad and adjust the position of the pad when necessary. Pads that are still not worn out do age and lose their capacity. Replace the pads when necessary. KAYOBA-010457-Electric-Bicycle-fig-11
ADJUSTING THE GEARS
The gear wire tension is adjusted with the adjuster screw on the hub of the back wheel.

Engage second gear by turning the gear lever on the right-hand side of the handlebars.
Turn the adjusting screw on the derailleur on the right side of the back hub so that the yellow marker in the window is between the two white lines and tighten the lock nut.

TYRES AND RIMS

Regularly check that the spokes are correctly tensioned and that the wheels are not buckled or out of round.
Check the wear line on the side of the rim that indicates the amount of wear from the brakes. Replace the rim if the wear line can no longer be seen.
Check the tyre pressures at regular intervals. The recommended tyre pressure is given on the side of the tyre.
Check at regular intervals that the tyres are not worn or cracked.
Avoid contact with oil, petrol, paraffin and other agents that dissolve rubber.

LUBRICATION
Lubricate regularly as instructed below to keep the electric bike in good working condition:

Lubricate the chain and derailleur with transmission lubricant at 7 to 2-month intervals, or more often if necessary.
Grease the saddle post and lubricate the eccentric brake screw, the front hub and pedals with grease at 7 to 2-month intervals, or more often if necessary,
to avoid unnecessary friction and to prevent the saddle post fastening.

NOTE: Make sure not to use too much lubricant -the risk of it accumulating on the brake discs and pads and reducing the braking power. The speed control, brake pads and rims should be kept free of grease and other lubricants.