Currier Tech Ezip Owner's Manual

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HYBRID ELECTRIC BICYCLE OWNER’S MANUAL Enlightened Series Additional information covering Seat Tube Batteries (STB) Series included in this manual Rack Mount (RMB) Series ...

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2 FULLY CHARGE BATTERIES BEFORE FIRST USE - Batteries should be fully charged immediately when they are received and immediately after each use for the recommended charge times (see below). Li-Ion (Lithium Ion) batteries 4-6 hours• NiMH (Nickel...

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3 CORRECT FITTING - MAKE SURE YOUR HELMET COVERS YOUR FOREHEAD. INCORRECT FITTING. FOREHEAD IS EXPOSED AND VULNERABLE TO SERIOUS INJURY. • ALWAYS WEAR A PROPERLY FITTED HELMET WHEN YOU RIDE YOUR BICYCLE. • DO NOT RIDE AT NIGHT. • CPSC ...

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4 Personal Care from Currie Technologies® Congratulations on your new purchase! Our Service Department is dedicated to your satisfaction with Currie Technologies® and its products. For questions regarding performance, assembly, operation, parts ...

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5 Serial Number Location Bike Shown Upside Down #### Serial Number CURRIE TECHNOLOGIES® 9453 Owensmouth Avenue | Chatsworth, CA 91311 Phone (818) 734-8123 | Fax (818) 734-8199 www.CurrieTech.com | www.iZipUSA.com Customer Service (800) 377-4532 The ...

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6 Please Retain your Sales Receipt as Proof of Purchase. Attach receipt here. Notes: _______________________________________________________________ _______________________________________________________________________ _____________________________...

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7 DIRECTORY Warning / Important - Take notice of this symbol throughout this manual and pay particular attention to the instructions blocked off and preceded by this symbol. ! PART 1 Parts Identification and Tools. . . . . . . . . . . . . . . . . ....

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8 1. PARTS IDENTIFICATION . . . . . . . . . . .9-13 Electric Bikes . . . . . . . . . . . . . . . . . . . . 11-12 Tools Required . . . . . . . . . . . . . . . . . . 13 2. BEFORE YOU RIDE . . . . . . . . . . . . . .14-30 Correct Frame Size . . ...

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9 Gear Control Cable Rear Derailleur PART 1 - PARTS IDENTIFICATION MOUNTAIN BICYCLES . Mountain bicycles are designed to give maximum comfort over a wide variety of road surfaces. The wider handlebars and convenient shift lever position make them ve...

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10 BMX BICYCLES - BMX style bicycles are a popular general purpose type most suited for young riders. They are valued because of their sturdy and simple construction, and low maintenance. Seat Seat Post Seat Post Binder Bolt or Quick-Release Skewer...

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11 FOLDING BICYCLES - Super portable, and easy folding design. Perfect for camping, and fits perfectly in RV's, boats and car trunks. Seat Seat Post Quick Release Battery Pack Rear Reflector Rear Brake Wheel Reflector Freewheel Handlebar Thro...

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12 3EAT 3USPENSION3EATPOST 1UICKRELEASE 2EAR"RAKE 2EAR2IM 2EAR$ERAILLEUR 0EDAL #RANK!RM #HAINRING #HAIN "ATTERY0ACK INSIDE 3TEM (EAD3ET (EAD4UBE 4OP4UBE (ANDLEBAR 4HROTTLE "RAKE,EVER "RAKE...

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13 Your new bicycle was partially assembled in the factory and then partially disassembled for shipping. You may have purchased the bicycle already fully assembled and ready to ride OR in the shipping carton in the partially disassembled form. The ...

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14 BEFORE YOU RIDE ABOUT THIS MANUAL It is important for you to understand your new bicycle. By reading this manual before you go out on your first ride, you’ll know how to get better performance, comfort, and enjoyment from your new bicycle. It i...

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15 CORRECT FRAME SIZE When selecting a new bicycle, the correct choice of frame size is a very important safety consideration. Most full sized bicycles come in a range of frame sizes. These sizes usually refer to the distance between the center of th...

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16 RIDING POSITION Seat Height In order to obtain the most comfortable riding position and offer the best possible pedaling efficiency, the seat height should be set correctly in relation to the rider’s leg length. The correct saddle height shoul...

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17 Handlebar Height Maximum comfort is usually obtained when the handlebar height is equal to the height of the seat. You may wish to try different heights to find the most comfortable position. Threadless headsets and clamp-on stems are not adjust...

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18 SAFETY CHECKLIST Before every ride, it is important to carry out the following safety checks: 1. Brakes Ensure front and rear brakes work properly.• Ensure brake shoe pads are not over worn and are correctly positioned in relation to the rims. ...

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19 5. Bearings Ensure all bearings are lubricated, run freely and display no excess movement, grinding or rattling.• Check headset, wheel bearings, pedal bearings and bottom bracket bearings.• 6. Cranks and Pedals Ensure pedals are securely tig...

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20 Helmets It is strongly advised that a properly fitting, ANSI or SNELL approved, bicycle safety helmet be worn at all times when riding your bicycle. In addition, if you are carrying a passenger in a child safety seat, they must also be wearing ...

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21 Reflectors Your bicycle is supplied with one front (white), one rear (red), two wheel (white), and four pedal (orange) reflectors. (Please Note: Sidewalk bikes, 12” and under, may not have reflectors.) These are an important safety and legal re...

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22 Seat and Handlebar Mounting Reflectors First attach the reflector to the reflector bracket with the reflector screw, see the top diagram. Next, remove the clamp screw and open the clamping reflector bracket. Place clamping reflector bracket arou...

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23 RIDING SAFELY General Rules When riding obey the same road laws as all other road vehicles, including giving way to pedestrians, and stopping at red lights and stop signs. For further information, contact the Road Traffic Authority, police depart...

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24 Wet Weather IT IS RECOMMENDED TO NOT RIDE IN WET WEATHER This hybrid electric bicycle is not meant for use in the water (damp roads, puddles, rain, streams, etc.). Never immerse this product in water as the electrical system may be damaged. In w...

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25 Hill Technique Gear down before a climb and continue gearing down as required to maintain pedaling speed.• If you reach the lowest gear and are struggling, stand up on your pedals. You will then obtain more power from • each pedal revolu...

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26 GEARS - HOW TO OPERATE Derailleur Gears Most multi-speed bicycles today are equipped with what are known as derailleur gears. They operate using a system of levers and mechanisms to move the drive chain between different sized driving gears or ...

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27 Recommended Chainwheel/Rear Sprocket Gear Combinations Hand Grip Shifters Some bicycles are now being equipped with a shifting mechanism called Grip Shift™, which is built into the handlebar grips and does not make use of separate levers. The ...

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28 Below the Bar Shifters Many mountain style bicycles now use a shift lever arrangement mounted on the underside of the handlebars, which use two levers operated by the thumb and index finger. To select a lower gear push the larger (lower) right ...

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29 BICYCLE CARE Basic Maintenance The following procedures will help you maintain your hybrid electric bicycle for years of enjoyable riding. Properly maintain the batteries by keeping them fully charged when not in use. Do not ride your hybrid elect...

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30 Storage Keep your bicycle in a dry location away from the weather and the sun. Direct sunlight may cause paint to fade or rubber and plastic parts to crack. Before storing your bicycle for a long period of time, clean and lubricate all componen...

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31 ELECTRONIC COMPONENTS Battery Gauge When the throttle or sensor is engaged (powering the motor) and the bicycle is in motion, the LED’s on the battery gauge (on the throttle or separate unit) indicate instantaneous line voltage as measured at ...

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32 Battery Gauge with Power Adjuster This unit is featured on the Enlightened series of bicycles. Not only does it act like a battery gauge but it also enables the rider to vary the level of power assistance (1 LED = least amount of power assistanc...

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33 PAS Sensor PAS / TAG Selector Switch Throttles Throttles are equipped on some models of electric bicycles. Throttles operate by rotating the throttle towards the rider much like a motorcycle. They generally are the inner half of the right side ...

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34 Crankset with PTS Torque Sensor Torque Sensors Electric bicycles with this system have no throttle. They must be pedaled like a normal bicycle in order to engage the motor drive system. PTS (Pedal Torque Sensor) Electric bicycles with this system...

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35 Electric Bikes with Seat Tube Mounted Battery (STB) Packs - Remove the power cable from the charger port and attach charger. Electric Bikes with internal battery packs - Rotate the charger port cover and attach charger. Electric Bikes with Ra...

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36 Battery FAQ's Q: Do I need to charge the batteries before using them? A: Yes, you should charge the batteries fully before fi rst using them. Q: What is conditioning (NiMH only)? A: The conditioning process is performed by fi rst draining ...

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37 Q: Will I get more performance from my bike if I leave the batteries to charge longer? A: No, once the batteries are fully charged (as indicated by the light on the charger) it is best to unplug them from the charger. Leaving the batteries chargi...

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38 Charger The hybrid electric bicycle comes with its own "Smart Charger” that connects with an easy-access charger port for recharging the batteries. This charger unit has lights that show the battery charge status. Refer to the instructions...

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39 ! Use only Currie Authorized Li-Ion chargers with bicycles equipped with Li-Ion batteries. Using any other charger will damage the batteries and void your warranty. Use only Currie Authorized NiMH chargers with bicycles equipped with NiMH batteri...

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40 Use only Currie Authorized SLA chargers with bicycles equipped with SLA batteries. Using any other charger will damage the batteries and void your warranty. ! XLR Plug 2v1h Plug 3v Plug How to use the SLA Chargers (standard) Plug the charger into...

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41 Main Power Switches STANDARD POWER SWITCHES The power switch may be located, depending on the model of bike, in the following locations On the battery pack itself (CX and STB Series)• On the side of the downtube (Enlightened Series)• On the...

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42 Fuses All Currie Technologies® Hybrid Electric Bicycles are equipped with fuses. The fuse may be located, depending on the model of bike, in the following locations CX Series (40a glass type fuse) - On the battery pack, • externally accessib...

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43 Wiring Diagram - Via Mezza (TAG system) w/ STB Bicycles (Diagram is for representational purpose only. Your bicycle's wiring system may differ) Via Mezza (STB w/ SLA Batteries) Bikes (2008 USA) WIRING DIAGRAM BATTERY CASE (Complete) BATTERY B...

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44 THROTTLE MOTOR S/N 245061215135 BRAKE INHIBITOR (Front Brake Lever) CONTROLLER 24v / 35a S/N 070104525 Make Date 2007-01-17 BATTERY 12V / 10Ah BATTERY 12V / 10Ah FUSE 40a Glass Type ENCLOSED BATTERY BOX (Box 1 is standard with bike) (The fuse is ...

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45 WIRE HARNESS, SWITCH SWITCH WIRE HARNESS, BATTERY PORT WIRE HARNESS, BATTERY PORT BATTERY PORT BATTERY PORT Secondardy Battery Box (optional) ASSIST CONVERTER (a.k.a. “WHITE BOX”) 1:1 ASSIST SENSOR (a.k.a. “BLACK BOX”) MOTOR CONTROLLER THR...

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46 HUB MOTOR 12 3 ON OFF ON OFF FUSE 30a Blade Type BATTERY NiMH 24v / 9a 4th pin not used Rear View of Crankset (PTS Sensor is removeable from crankset) Controller Connector not used Wiring Diagram - PTS w/ NiMH Battery Bicycles (Diagram is for repr...

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47 iZip Trekking Li (2007) WIRING DIAGRAM BATTERY GAUGE POWER ADJUST Rear View of Crankset (PTS Sensor is removeable and available seperate from crankset) SWITCH ON OFF 5 30 12 3 CHARGER PORT WHEEL, REAR w/ HUB MOTOR BATTERY CONTROLLER BATTERY GAUGE ...

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48 TMM4 (Tentative 2008) WIRING DIAGRAM CONTROLLER BATTERY GAUGE POWER ADJUST SWITCH ON OFF 5 30 12 3 CHARGER PORT WHEEL, REAR w/ HUB MOTOR BATTERY BATTERY GAUGE w/ TORQUE ADJUSTER TMM4 SENSOR ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ...

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49 DERAILLEUR GEARED BICYCLES Includes 20", 24” and 26" Wheel Mountain Bikes assembly is the same for men’s and women’s bikes. Getting Started Open the carton from the top and remove the bicycle. Remove the straps and protective wra...

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50 NOTE: Some models of bicycles may be equipped with a stem that has an adjustable angle. In addition to the normal assembly, these stems will require angling the stem to the desired position, and securely tightening the 6mm Allen bolt located unde...

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51 If the stem is not inserted into the top nut to at least the “Minimum Insertion” mark, it is possible to over-tighten the stem bolt and damage the fork steerer tube. If these instructions are not followed, it could cause an unsafe conditio...

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52 Tighten all bolts that clamp the shifters, brake levers and bar ends to the handlebar using a 5mm Allen key or Phillips head screwdriver. (Figure 1) Handlebar with Grip Shifter. (Figure 2) Top mounted thumb shifter. Failure to properly tighten cl...

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53 Forks There are two different types of forks that vary in styles and dimensions. One type is a rigid fork (Figure 1) consisting of sta- tionary tubing with curved blades. The other type is a suspension fork (Figure 2) consisting of inner stanchio...

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54 Seat and Seat Post Attach the seat to the seat post by loosening the nuts on the seat clamp. Insert the tapered end of the seat post into the seat clamp until it is at the top of the clamp. Partially tighten the nuts on the seat clamp until the ...

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55 Attachment of an incorrect pedal into a crank arm can strip pedal threads and cause irreparable damage. Before your first ride, please check to insure your pedals are attached correctly. Pedals & Crank Set Look for the letters “R” for r...

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56 Front Wheel Check the wheel hub before attaching it to the fork by rotating the threaded axle. It should be smooth with no lateral movement. Insert the front wheel into the fork dropouts. Tighten the wheel nuts using the appropriate 14mm or 15m...

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57 The wheel is tightly secured when the serrated surfaces of the 5. quick release clamping parts actually begin to cut into the bicycle frame/fork surfaces. Note that the same procedure applies when operating a quick 6. release seat post binder ...

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58 V-Style Brakes If not already assembled, take the brake noodle from the parts box and slide the cable through the larger opening. The cable housing will then seat into the end of the noodle. Slide the cable through the cable lead on the end of ...

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59 V - Brake If fitted with V-Brakes, insert the brake body into the center spring hole in the frame mounting boss, and then secure the brake body to the frame with the link fixing bolt. 1. While holding the shoe against the rim, adjust the amoun...

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60 While holding the shoe against the rim, tighten the shoe fixing nut. 3. Adjust the balance with the spring tension adjustment screws. 5. Depress the brake lever about 10 times as far as the grip to check that everything is operating correctly ...

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61 Check your Brakes Press each brake lever to make sure that there is no binding and that the brake pads press hard enough on the rims to stop the bike. The brake pads should be adjusted so they are 1 mm to 2 mm away from the rim when the brakes ar...

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62 Disc Brakes (if equipped) If fitted with a front disc brake, the components should already be attached. However, please check all connections before attempting to ride the bicycle. Secure tightly the 6 bolts that hold the disc to the front whee...

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63 These brakes require breaking in! Ride and use the brakes gently for 13 miles before using the brakes in downhill conditions, for sudden stops, or any other serious braking. Please be aware that your brake system will change in performance throu...

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64 Derailleur Although the front and rear derailleurs are initially adjusted at the factory, you will need to inspect and readjust both before riding the bicycle. Rear Derailleur Begin by shifting the rear shifter to largest number indicated, disc...

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65 Front Derailleur Shift both shifters to the smallest number indicated and place the chain on the corresponding cog and chainwheel. Disconnect the front derailleur cable from the cable anchor bolt. Check the position of the front derailleur; it ...

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66 Dual Suspension Dual Suspension bikes (DS) are equipped with a front fork as well as a rear suspension generally located below the seat. The piston works in conjunction with a spring to allow the bike to rotate on a pivot point. Ensure all atta...

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67 Rear Pivots The pivot assembly is a simple mechanism that allows the rear swingarm to move up and down in combination with a rear suspension. Size, shape, and compounds will vary between models; however, operating principles are the same. A sh...

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68 Accessories If your bike is supplied with a water bottle and cage, attach the cage to the bicycle using the Allen bolts provided. Some bikes come equipped with a saddle bag or frame bag. The saddle bag installs under the seat with the zipper fac...

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69 figure 1 figure 2 Fenders Front Fender The front fender is mounted at the fork crown. There are two ways in which to mount your front fender. The first is the caliper brake mounting system (see figure 1), and the second is the 10mm nut and bolt...

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70 Rear Fender The rear fender is mounted at the seatstay brace. There are two ways in which to mount your rear fender. The first is the screw mounting system (see figure 3), and the second is the 10mm bolt and screw system (see figure 4). Identif...

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71 Final Check After all adjustments have been made, shift through • every gear several times at varying speeds. This will ensure all your adjustments are correct and will allow you to pinpoint any trouble areas. If you encounter any problems, ...

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72 SINGLE SPEED & BMX Includes 16" and 20" BMX Bikes Assembly is the same for boy’s and girl’s bikes. Getting Started Open the carton from the top and remove the bicycle. Remove the straps and protective wrapping from the bicycle. ...

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73 Seat Loosen nut on the seat clamp and add 3 or 4 drops of oil onto the threads of the bolt. Place the smaller end of the seat post into the seat clamp until it stops with the bolt to the rear of the seat post. Thread the nut on the seat clamp l...

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74 Front Wheel Make sure the brakes are loose enough to allow the wheel to 1. pass through the brake pads easily. Place wheel into fork drop outs.2. Install retaining washers with raised lip pointed towards the 3. fork, and insert into the small ...

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75 Side Pull Brake Loosen the cable anchor nut and thread the brake cable through it. Tighten the nut by hand until it holds the cable in place. Squeeze the brake arms together against the rim of the wheel. Loosen the nuts on the brake shoes and t...

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76 V-Style Brake If fitted with V-Brakes, insert the brake spring into the center spring hole in the frame mounting boss, and then secure the brake body to the frame with the pin fixing bolt. 1. While holding the shoe against the rim, adjust the ...

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77 While holding the shoe against the rim, tighten the shoe fixing nut. 3. Adjust the balance with the spring tension adjustment screws. 5. Depress the brake lever about 10 times as far as the grip and check that everything is operating correctly...

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78 Rotors Some freestyle BMX bicycles come equipped with a cable detangler system that will allow the handlebar to spin 360-degrees without binding the cables. It is very important that this system is adjusted correctly. Installation should only b...

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79 Failure to adjust correctly may result in loss of braking power and personal injury. Barrel End Single Cable Casing Cable Adjuster Cable Splitter Upper Cable (short casing) Upper Cable (long casing) Upper Plate Bearing Football Ends Lower Plate L...

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80 Axle Peg Assembly Instructions Non-Threaded First remove the axle nut from the wheel. There will be either a retaining washer or a step retaining washer included. Place this washer between the peg and the frame of the bicycle. Slide the peg ont...

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81 Training Wheels There are two options when attaching the training wheels to the wheel brace. Determine which option is used on your bicycle and follow the given instructions for that option. Option 1 First attach the training wheels to the wheel...

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82 Attaching Training Wheel Brace to Bicycle There are two different braces used to attach the training wheels to the bicycle: the C-Shape Brace and the Flat Brace. Determine which brace was included with your bicycle and follow the given instruct...

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83 Training Wheel Stabilizer Bracket Your bicycle may include a stabilizer bracket to attach the training wheel to the bicycle. First remove the nut and washer from the rear wheel axle. Align the stabilizer bracket onto the brace. Align the brace ...

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84 Final Check Install any additional parts that are supplied with your bike. NOTE: Your bicycle may be equipped with different style components than the ones illustrated. Reflectors: Attach the white reflector to the front bracket and the red refle...

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85 Correct routine maintenance of your new bike will ensure smooth running - Longer lasting components - Safer riding - Lower running costs Every time you ride your bicycle, its condition changes. The more you ride, the more frequently maintenance w...

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86 Schedule 2 - Service Checklist Frequency Task Page Reference Before every ride Be sure batteries are fully charged 35-40 Check tire pressure 89 Check brake operation 99-102 Check wheels for loose spokes 88 Perform safety check 18-19 After every r...

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87 Tools Required Open ended wrench or ring wrenches: 8mm, 1. 9mm, 10mm, 12mm, 13mm, 14mm, 15mm Open end or pedal wrench 15mm2. Allen key wrenches: 2.5mm, 3mm, 4mm, 3. 5mm, 6mm, 8mm Adjustable wrench4. Standard flat head screwdriver5. Standard P...

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88 DETAILED MAINTENANCE WHEELS AND TIRES Wheel Inspection It is most important that wheels are kept in top condition. Properly maintaining your bicycle's wheels will help braking performance and stability when riding. Be aware of the following p...

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89 Tire Inspection Tires must be maintained properly to ensure road holding and stability. Check the following areas: Inflation: Ensure tires are inflated to the pressure indicated on the tire sidewalls. It is better to use a tire gauge and a hand...

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90 Hub Bearing Adjustment When checked, the hub bearings of either wheel will require adjustment if there is any more than slight side play. Check to make sure neither locknut is loose.1. To adjust, remove wheel from bicycle and loosen the locknut ...

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91 Remove tire bead from the rim. Pull tire back onto the rim. Remove the tire completely and inspect for a nail, glass, etc. and remove if 7. located. Also inspect the inside of the rim to ensure there are no protruding spokes, rust or other poten...

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92 HANDLEBARS AND STEM Handlebar Stem The handlebar stem fits into the steering column and is held firmly by the action of a binder bolt and expander wedge which, when tightened, binds with the inside of the fork steerer tube. When removing the ste...

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93 When re-fitting the stem, make sure the handlebars are correctly aligned and tightened using the appropriate hex wrench or allen key. Do not over tighten. Test the security of the handlebar within the stem, and the stem within the fork steerer ...

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94 GRIP SHIFTERS Grip Shift™ - Installation Slide front Grip Shift™ assembly over left side of handlebar leaving proper clearance for handlebar grip. If necessary, 1. move the brake lever to accommodate Grip Shift™ and handlebar grip. Rotate a...

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95 Cables and Cable Housing Cables and housing are one of the most overlooked parts on the bicycle. The first indication that your cables and housing need to be replaced is an increased amount of pressure needed to operate the brakes or shifters. ...

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96 HEADSET Inspection The headset bearing adjustment should be checked every month. This is important as it is the headset which locks the fork into the frame, and if loose, can cause damage or result in an accident. While standing over the frame ...

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97 SADDLE AND SEAT POST Inspection The seat fixing bolt and the seat post binder bolt should be checked for tightness and adjustment every month. On removing the seat post from the frame, you will notice a mark about 65mm up from the bottom with t...

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98 Adjustment As mentioned in Part 2, the seat can be adjusted in height, angle and distance from the handlebars to suit the individual rider. Seat angle is a matter of personal preference but the most comfortable position will usually be found when ...

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99 BRAKES The correct adjustment and operation of your bicycle's brakes is extremely important for safe operation. Brakes should be checked for effective operation before every ride. Frequent checking of adjustment is necessary as the control c...

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100 Some brakes have a quick release mechanism to allow easier wheel removal. Whenever you adjust the brakes, make sure the quick release mechanism is in the closed position. Never ride unless the quick release is firmly locked in the closed positio...