GREEN LIGHT CYCLE URBAN CRUZER (01) PDF MANUAL

GREEN LIGHT CYCLE URBAN CRUZER (01) PDF SUMMARY:

How do I install the handlebars?

Install the handlebars by loosening the stem wedge bolt and turning the handlebar stem to face the front of the bike. Remove the stem faceplate and 2 bolts. Turn the handlebar to ensure that the wiring is not twisted and flows upward toward the handlebars without kinking. Place the handlebars in the half round stem cut-out making sure that the grooves (splines) are aligned correctly, in the centre of the cut-out. Replace the faceplate and tighten the bolts evenly so that the faceplate sits flat over the handlebar. Lastly, align the handlebars 90° to the front wheel and tighten the handlebar stem bolt.

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What if I receive my bike with the handlebars stem out of the steering tube?

Remove the protective cover on the stem wedge. Apply a bit of grease or oil to the stem wedge to help it insert into the rubber stem seal on the steering tube. Wiggle and turn the stem at the same time as you slide it down the steering tube. Insert wedge past or up to “MAX HT” mark on stem. Align the handle bars perpendicular to the front wheel and tighten the Allen head wedge expander bolt. Adjust the angle of the handlebar with the Allen bolt, located under the handlebar base (Fig. 1.7). Identify the black wire loom clamp on the handlebar stem and remove the screw. Move the wire loom to the side of the clamp and insert the screw and tighten to secure the loom to the stem clamp.

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How do I install the front wheel?

Install the front wheel by first inserting the Quick Release rod into the wheel axel. There are 2 small springs on the Quick Release rod that have different diameters on each end. Install the springs so that the ends with the larger diameter are next to the Quick Release and the round nut (Fig. 2.1). Make sure the round black nut is on the disc side of the wheel and the lock lever is on the opposite side (Fig. 2.3).

Tighten the round nut onto the rod so the rod threads are almost flush with the outside of the nut. Be careful not to cross the threads and tighten by hand only.

Place the Quick Release Lever in the open position. Have someone hold and lift the bike by the handlebars to position the front wheel into the forks. Make sure that you line up the brake disc with the brake calliper when inserting the front wheel axel into the fork drop outs (Fig. 2.4). Check to ensure that the axel has engaged all the way into the fork dropouts before clamping.

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How do I tighten the Quick Release and axel into the fork dropout?

Ensure the Quick Release is in the open position with the lever parallel to the ground (the lever should be at a 90° angle to the forks). With the lever in this position, tighten the round nut finger tight.

Next, loosen the nut approximately 3 quarter turns, counter clockwise and lift the lever upward to lock the wheel in place. The lever should be almost parallel to the front fork when locked. If the tension is correct, the lever should close tightly. When closing the lever it should leave a clear imprint in the palm of your hand (Fig. 2.6, the imprint may not be as deep as the hand model’s picture).

When the lever is locked in this position, parallel to the fork, it will not easily be opened if it catches on any objects while riding your bike. To increase or decrease the tension, open the lever and adjust the nut clockwise or counter clockwise, 1/8 turn at a time. Repeat until the tension is sufficient. Less than 1/2 a turn on the adjusting nut can make the difference between safe clamping force and unsafe clamping force. Install the front fender, with the supplied bolts, in the front forks and at the headlight (Fig 2.7).

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How do I install the pedals?

Note: “L” and “R” (“L” = left & “R” = right) is stamped on the threaded ends of the pedals (Fig. 3.1). The pedals have opposite thread directions and must go on a specific side of the bike. Left and right side of the bike is determined by sitting on the seat.

The Left Pedal has a reverse, non-standard thread and must be turned counter clockwise to be screwed in.

The Right Pedal has a standard thread and must be turned clockwise to be threaded in.

Apply some grease to the pedal threads before attaching. Install the Right Pedal to the chain sprocket side of the bike (Fig. 3.2) and the Left Pedal to the opposite side (same side as the battery key).

Start the pedal threads into the crank arm threads, by hand, at least 4 complete 360° turns to ensure the pedals are not cross-threaded. Incorrect installation of the pedals or stripped threads are not covered under warranty. Complete by securely tightening with a 15 mm wrench.

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How do I install the seat?

Identify the “Minimum Insert Line” on the seat post (Fig. 4.1). Insert the seat post into the seat tube so the Minimum Insert Line is not visible (Fig. 4.3). The seat post shaft must be installed so that the Minimum Insert Line is at least 1/4 inch below the Quick Release Lever.

With the Quick Release Lever in the open position (the lever should be at a 90° angle to the seat tube), insert the seat post into the seat tube. Tighten the Quick Release clamp by turning the tension adjusting nut clockwise, with one hand on the cam lever to keep it from rotating. Lift the Quick Release Lever up to the locked position.

Grab the seat by the saddle with both hands to attempt to rotate the seat. If you are unable to force the seat out of alignment with the frame, the clamp is tight enough. If the seat moves out of alignment with the frame, increase the tension on the adjusting nut approximately a 1/4 turn and try again. The seat height can be adjusted from 34 to 39 inches (863 mm – 990 mm) from the ground or 30 to 35 inches (762 mm – 889 mm) from the pedals.

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How do I ensure the tires have the correct pressure?

Using a hand pump, fill the tires with air to the rating on the sidewall (Fig. 5.1). We recommend a hand pump to avoid over inflating the tires, which can easily happen when using a high pressure air line at a gas station or automotive tire store.

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How do I remove and install the battery?

Unlock the battery from the battery slide by inserting the battery key into the lock, located on the top of the battery near the handle (Fig. 6.1). Push the key inwards to depress the lock into the battery and turn the key one half turn counter clockwise to unlock the battery slide pin. Remove the key before trying to lift the battery away from the bike. Remove the seat to slide the battery straight up and out of the battery slide, using one hand on the folding handle and the other hand to hold the bike steady.

Install the battery in the reverse order of removal. Ensure the top of the controller box, where the base of the battery rests, is clear of any dirt or debris. Align the battery base so that it inserts into the battery slide and with the half round grooved cradle against the seat post tube. Insert the battery gently until the base rests tightly on the control box and the connecting blades are inserted firmly into the battery base sockets. The blades and sockets are greased to make removal and replacement easier. Lubricate as necessary.

Do not use excessive force to fit the battery into the base, as it could damage the connection sockets or blades. Be sure to always lock the battery after placing in the cradle.

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How do I charge the battery?

• Turn the key to “OFF” and remove the key from the battery (Fig. 7.1).
• Locate the charging port on the battery on the top right side and turn the dust cover to the side to expose the charging port (Fig. 7.2).
• Insert the battery charger plug into a 120 Volt wall socket receptacle with a grounded circuit. Do not use an extension cord. The light on the charger should illuminate to steady green.
• Insert the round plug of the charger into the battery charging port, the LED should illuminate to steady red (Fig. 7.5).
• When the light on the charger changes to a steady green, the battery is charged (Fig. 7.4). Unplug the charger from the wall receptacle and then from the bike battery. Always disconnect the plugs in this order.

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How do I charge my smartphone using the USB port?

Remove the protective cover from the USB port. Determine the correct orientation of your USB charger cable and insert it into the USB port on the Urban Cruzer battery. Plug your charging cable into your smartphone device and turn the E-bike battery key to the “ON” position. Check the battery indicator on your smartphone to determine that it is now charging.

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What are some tips for long term battery care?

When storing your battery for a long period of time (more than 60 days):

Charge the battery to about 75%, then recharge every 60 days as needed to maintain this level. Allowing your battery to sit for longer than 60 day periods in a discharged state could lead to permanent capacity loss and void your warranty.

• Ideally batteries should be stored between 50°F/10°C to 80°F/27°C. Avoid long periods of freezing and extreme heat, 104°F/40°C or higher.
• Do not leave the battery in direct sunlight for prolonged periods of time.
• Keep the bike in the shade during summer months.
• Store the battery in a clean dry location with low humidity conditions.
• Do not allow the battery to accumulate condensation such as dew, heavy fog or rain, as this could cause shorting.
• Do not clean or wash the battery with pressurized water; wipe with a damp cloth only and towel dry completely.
• Do not connect the battery to the bike in wet conditions.
• Do not submerse the battery in water.

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What are some tips for extending the life of the battery?

To help extend the life of the battery, assist the bike as much as possible. A few tips to prolong the battery life during certain conditions are as follows:

• Always turn your battery key “OFF” after each use, as the electrical system will still draw minute power from your battery.
• Charge the battery frequently. If possible, before using 50% of the power.
• When starting from dead stop, use the pedals to bring the bike up to speed.
• When riding uphill or against the wind, pedal to supplement the battery power.
• When the battery meter indicates the voltage is low, switch to the lowest pedal assist mode or 0 to avoid using the battery and shortening the battery life.
• Do not ride your bike in heavy rain storms, thunder showers, or extreme conditions.
• When riding downhill, you must have the key and King Meter® Controller in the “ON” position, as the motor will generate electricity. Having the key in the “OFF” position may damage your battery, controller, or electrical parts, and may void your warranty.
• Store your battery in a location with a temperature above 50°F/10°C for best results.

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How do I power up the E-Bike?

To turn on the bike battery, turn the key on the battery to the “ON” position clockwise 1/8 turn until you hear the click and the key stops (Fig. 8.1). The battery power is now turned on.

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How do I use the King Meter®?

To turn the bike motor on and illuminate the King Meter® Display. Identify the “30 Button” on the handlebar, beside the King Meter® Display.

Hold down the centre “MODE” button between the UP and DOWN arrows for approximately 2 seconds, until the display illuminates (Fig. 9.2).

When the King Meter® display is illuminated and the “ASSIST” indicates a number (1 to 5), the motor can be started by actuating the thumb throttle or the pedal assist.

For safety, use the DOWN arrow to set the “ASSIST” to “0” while programming the King Meter® (Fig. 9.3).

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How do I set the time on the King Meter®?

After LCD display lights up, hold the UP and DOWN arrows at the same time for 3 seconds; the LCD will display the default setting mode.

After entering into the setting mode, first set the hour by using the up and down arrows. Press the MODE button to confirm the setting. Next, set the minutes using the UP and DOWN arrows. Press the MODE button to confirm the setting.

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How do I set the top riding speed?

The default setting on the top riding speed has been set to 32 km per hour. The top riding speed can be set from 10 km/h to 32 km/h by using the UP and DOWN arrows. Press the MODE button to confirm the setting. The top riding speed in Canada is 32 km per hour in all cities, streets, and highways (Fig. 10.1). Check with Police to determine the local laws and bylaws to confirm the maximum legal speed setting in your riding area.

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How do I set the display units?

Press the Up or Down Arrow to choose between Imperial or Metric display units. Press the Mode button to confirm the setting.

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How do I set the wheel diameter?

Press the Up or Down Arrow to choose a corresponding wheel diameter to ensure the accurate display of speed and distance on the LCD. This Urban Cruzer™ wheel size is 24 inches. Press the Mode button to confirm the setting.

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How do I set the backlight brightness?

Press the Up or Down Arrow to modify the backlight brightness. You can choose from levels 1 to 3. Level 1 is the minimum brightness and uses the least power from the battery. Level 3 is the brightest and will use more power from the battery. Press the Mode button to confirm the setting.

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How do I exit the settings?

When in a setting mode, press the Mode button within 2 seconds of making your choice to confirm. Press and hold the Mode button for more than 2 seconds to save the current settings and exit the setting interface (Fig. 10.2).

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How do I normally operate the E-Bike?

Before you turn on the battery power to ride the bike, sit on the bike seat and assume a comfortable position to ride forward.

With the key in the “ON” position, press the Mode button and the display will illuminate. The motor is now powered. Keep one hand brake depressed after turning on the King Meter® until you are ready to ride forward.

When the King Meter® is turned on (display illuminated), holding or pressing the Mode button again will turn the power to the bike motor off. If no controls are pressed for approximately 5 to 7 minutes and the bike is not in motion, the King Meter® will power off.

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How do I turn the power off?

In the power “OFF” state, the King Meter® uses minimal power to keep the clock running. It is advisable to turn the key on the battery to the “OFF” position to conserve energy and keep your bike and the people around you safe.

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How do I see the speed display?

When the King Meter® illuminates, the display will automatically show the current speed. By pressing and holding the Up Arrow for 2 seconds, the display will show the average (AVG) speed during this ride. Press and hold the Up Arrow again and the display will change to show the maximum (MAX) speed during this ride. Repeat to show current speed again.

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How do I select the pedal assist level and throttle power?

When the King Meter® is illuminated, pressing the UP or DOWN Arrows will change the output power of the motor for the pedal assist, or turn off the power to the motor completely (set assist to “ASSIST 0”). The pedal assist power ranges form Level 1 to 5. Level 1 is the minimum power the motor will supply by turning the pedals and Level 5 is the maximum power (100%). The default level when the King Meter® is started is Level 1.

When the “ASSIST” is set to “0”, no power will be supplied from the motor by pedalling or by using the thumb throttle. Use this mode when you want to ride the bike without any motor assist.

The thumb throttle (Fig. 11.1) allows you to immediately increase the power to the motor with the touch of your thumb, similar to the throttle on a motorcycle. Increasing pressure on the thumb throttle will increase the power and speed.

The “ASSIST” settings (Level 1 to 5), will not adjust the power to the thumb throttle.

When the “ASSIST” selection is set at “0”, the thumb throttle is “OFF”. When the assist selection is set at Level 1 to 5, the thumb throttle is “ON”.

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How do I turn on the King Meter® display backlight and bike headlight & taillight?

To turn the backlight and bike headlight “ON” and “OFF”, hold the UP Arrow and MODE button together for 3 seconds (Fig. 11.2). Use this feature at night or in low light conditions to illuminate the display and your headlight and tailight for safe riding.

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How do I check the distance and time display?

When the King Meter® is illuminated, it will display the odometer setting “ODO” which is the total distance the bike has been ridden. Press the MODE button to change the display to show the riding distance for this trip.

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How do I check the battery capacity?

When the battery charge is full, the battery symbol will show 5 segments illuminated in black. As the battery is consumed, the segments will disappear to indicate the amount of power available, until all the segments have disappeared and the battery symbol is white, indicating the level is severely low.

When the battery symbol is completely white, it will begin to flash. A flashing battery symbol means that you need to recharge immediately. We advise that you do not use the electric power to assist your bicycle in this state. Set the “ASSIST” to “0” and use only your own pedal power until you can recharge the battery (Fig. 11.3). This will help give your battery a longer life.

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What do the display malfunction codes mean?

Should there be something wrong with the electronic controls, motor, or battery, the King Meter® will automatically show an error code below:

• Code 21 Electrical Current Abnormality – Check to see if all plugs are connected properly or have been damaged.
• Code 22 Throttle Abnormality – This is often a result of holding down the thumb throttle while turning on the E-bike.
• Code 23 Motor Open-Phase – This means there is a connection error between the plug and the motor. Check all plugs.
• Code 24 Motor Hall Signal – This means there is a connection error between the motor and controller. Check all plugs.
• Code 25 Brake Abnormality – This is often a result of holding down the brake handle while turning on the E-bike.
• Code 30 Communication Abnormality – This means there is a connection error between the display and controller. Check all plugs.
• batt LU Button Battery Low – This means that the button battery in King Meter® needs to be replaced.

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How do I replace the button battery?

To replace the display battery, first detach the display from the handlebar. Remove the battery cap and old batteries. The battery model is # CR2032. Install the new battery, ensuring it is in the correct position (+/-). The life of the battery is approximately 2 years. After replacing the battery you may need to reset the time.

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How does the pedal assist and thumb throttle work?

With the King Meter® illuminated and “ASSIST” set from Level 1 to 5, the thumb throttle is active (Fig. 12.1). When pressed downward, the bike will drive forward. The thumb throttle delivers up to 100% of the motor power depending on how much the lever is depressed.

The Pedal Assist function watches the rotation of the pedals to deliver power to the motor (Fig. 12.2). Depending on which level the “ASSIST” is set to (Level 1 to 5), the King Meter® will determine how much power the motor delivers to move the bike forward. Using the “ASSIST” on the lowest setting will consume the least amount of power from the battery and give you the longest riding distance.

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How does the braking system work?

The bike is equipped with two brake levers located on the left and right sides of the handlebar. To stop the bike, depress both break levers. The brake levers also activate a stop light in the taillight.

In USA-STANDARD configuration, the left brake lever controls the front wheel and the right brake lever controls the rear wheel.

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What are the Power Assisted Bicycle Controls?

• Bell – Signals to traffic you are there.
• Pedals – Drive the bike forward.
• Headlight & Taillight – LED light controlled by pressing the Mode and Up Arrow buttons at the same time.
• Bike Keys – Turns the battery electrical supply off/on to the bicycle controls and locks the battery in place on the bike.
• King Meter® – Controls the Pedal Assist speed level, records trip information, controls the headlight, and turns thumb throttle “ON/OFF”.
• Handlebars – Contain the controls (King Meter®, Brakes, Gear Shifter, Bell, & Thumb Throttle), and steer the bike left or right.
• Brake Handles – Stop the bike by squeezing the handle toward the hand grips. The brake handles also have kill switches built in to them that stop the electricity flow to the motor, turning it off. Any time the brakes are applied, the motor will stop pushing the bike in a forward direction and the stop light will illuminate on the carrier.
• Shimano® 7 Speed Shifter – Switches between gears on the rear wheel to adjust ease of pedaling in order to climb grades or ride at different speeds.

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What is the “10 Point” Check List – Before your First Ride and Every Ride After?

1. Battery is connected, locked, and charged.
2. Electrical devices are working correctly.
3. All nuts and bolts are tight.
4. The front and rear wheels are secured to the bike frame and cam locks are tight.
5. The tires are filled to the correct pressure, as indicated on the tire side wall.
6. The brakes are adjusted and operating correctly, including the brake kill switches.
7. The seat is locked and the seat stem is adjusted to the correct height.
8. Handlebars are tightened firmly.
9. Chain and crank arms run smoothly and are lubricated.
10. The rider is wearing appropriate safety gear, including: high visibility reflective clothing, helmet, and eye protection.

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What are some general usage tips?

• Wear shoes that grip firmly to the pedals, no bare feet.
• Wear high visibility clothing no loose clothing and dress to be seen.
• Always wear an approved bicycle helmet and eye protection.
• Keep your speed levels appropriate to road conditions and speed limits.
• Ride slow on wet or slippery surfaces and brake sooner than anticipated.
• Avoid cycling at night or in poor weather such as fog, rain, snow, or icy conditions.
• Familiarize yourself with usage of the bike and know how to maintain it.
• Be familiar with traffic signs, rules and laws, and be aware of other traffic.
• When possible, ride in bike lanes and in the correct direction of traffic flow.
• Do not ride on the sidewalk and dismount when using pedestrian crossings.
• Keep both hands on the handlebars when riding.
• Keep in mind that other traffic may underestimate the speed of an electric bicycle.
• Ride defensively, keep alert, and have fun!

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What should I do when learning to ride my E-Bike?

We suggest that you ride the bike as a bicycle with no power assist turned on (set “ASSIST” to “0”), to familiarize yourself with the bike’s extra weight and slow handling and stopping. Test the bike’s braking ability to determine your stopping distances. Once you become confident in your riding and braking ability, set the assist level to the lowest setting, Level 1, and begin riding the bike.

When you feel confident and familiar with the feel from the powerful 500 watt motor, try using the thumb throttle and higher Assist Levels. Pay special attention to the weather and road conditions when learning to ride your E-Bike. Wet roads require longer stopping distances than dry roads. Always look ahead when riding to give yourself time to stop in emergency situations. Remember that pedestrians may not be able to hear or see you approaching from behind. Slow down and use extra caution when passing foot or vehicle traffic, parked cars, or other cyclists. Do not be afraid to use your bell, it’s there to signal “Here I Am”.

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What do I do if the King Meter® is illuminated, but does not display speed?

• Magnet on front wheel spoke is not aligned to King Meter® receiver on right fork. The magnet should line up to the round bottom of the receiver.

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What do I do if the King Meter® is illuminated, but the motor will not start?

• “ASSIST” is set to 0.
• Battery level is too low.
• Brake lever is slightly depressed.
• Controller is defective.

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What do I do in the event of a thumb throttle failure where the pedal assist still works?

• Thumb throttle is defective.
• Thumb throttle has bad connection.
• Controller is defective.

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What do I do in the event of the thumb throttle working, but the pedal assist failing?

• Pedal Assist connection to controller.
• Pedal Assist sensor is defective.

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What do I do if when riding, you stop and the throttle will not restart the motor?

• Brake lever has not released.
• Brake lever kill switch is defective.
• Controller is defective.

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What do I do if the motor has low power?

• Check tire pressure.
• Check brake calliper is sticking closed.
• Check battery is charged.

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What do I do if the headlight will not turn on, but the King Meter® backlight works?

• Wire is loose or disconnected at light.
• LED’s in headlight are defective.

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What do I do if the charger is plugged in, but green or red LED indicator light does not illuminate?

• Check the wall receptacle; move to another and retest.

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What do I do if the charger is plugged in, but will only show green light illuminated?

• Battery is fully charged.
• Charger fuse may be burnt.

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How do I transport an electric bicycle?

Make absolutely certain that the bike rack on your car is suitable for the increased weight and the frame style of your Urban Ryder™ E-Bike. A rack that is not suitable for the increased weight can be damaged or even break during the transport. Remove the battery and protect the electronics from inclement weather; your motor and system connections should be protected from the elements. Also remember that most commercial flights will not accept a lithium battery even when installed in the bike.

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What maintenance should I perform on my E-Bike?

Squeeze the brakes and rock the bike to check for any looseness with each forward or backward movement. Look at the headset, brake disc and callipers, wheels, wheel nuts, forks, pedals and crank, and saddle. Check cables for rust kinks and fraying. Squeeze the spokes in adjoining pairs between your thumb and index finger to confirm they have the same tension.

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How do I maintain the wheels?

Check the wheel nuts are secure and tight by removing the plastic caps and inspecting.

Spin the wheels and check for side to side wobble and up and down oblongata. The wheels when true will not have more that 1.0 mm on each side or up and down. Wheels should only be adjusted by certified mechanics.

Check for damaged stainless spokes regularly. Replace broken, bent or fatigued stainless spokes with the manufacture’s suggest spokes only.

Check tires for cuts or punctures and wear. Tire pressure should be adjusted as per the sidewall specifications.

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How do I maintain the chain?

The chain should run smoothly when clean and lubricated. Lubricate the chain regularly at least every 3 months or after a wet ride.

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How do I maintain the brakes?

Check the pads for wear. They are held into the caliper with a cotter pin inserted through the brake pad lip and held apart with a pad connecting spring. The braking surfaces face each other. Once the caliper mounting bracket is unbolted from the bike frame, you can remove the cotter pin and slide the pads out of the caliper. Pads worn unevenly, on an angle or with less than 0.50mm of pad may need replacement (new pad thickness is 2.23mm). Refer to Tektro installation instructions for complete details.

Adjust cables as needed to increase braking power. Check the brake cable tension and adjust by either using the adjusting screws on the brake levers or the adjusting screws at the brake callipers, or retention the cable with the cable adjuster bolt/ nut clamp.

After riding, remove any dirt, mud or other contamination from the rotor slot in the calliper. Clean the calliper body and rotor slot with brake cleaner and lubricate the brake lever pivot with thick oil or grease. Check to make sure that all bolts are tightened to torque specifications.

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How do I clean my E-Bike?

Never use a high pressure washer or a garden hose to clean your bike. The force of the water jet could damage the electrical components. We recommend a soft cloth or brush to clean the bike. Use a moist cloth to clean the battery and docking station. Always use very little water and keep water away from the electrical contacts. Check the plug-in connections for moisture after cleaning and let these dry if necessary before using or charging the bike.

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How do I locate my serial number?

Frame Serial Number

The serial number can be found at the lowest part of the frame, between where the crank arms are connected (Fig. 13.1), on the underside of the frame (Fig. 13.2). The serial number begins with the letters “LM”, “SS” or “HC” and is also located on the box, on a white label.

Motor Serial Number

The motor serial number is located on the rear wheel hub motor, on the outer edge. Imprinted on the outer edge is “8-FUN” with an arrow pointing towards the 10 digit serial number, starting with the number 1 (Fig. 13.3).

Battery Serial Number

The battery serial number is located on the base of the battery and on the same side as the keyhole.

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How do I claim warranty?

To begin a warranty claim, the Warranty Registration information (found on the last page of the User Manual), must be completed and returned to Green Light Cycle Ltd.™ We recommend you record this information as soon as you have completed reading the User Manual and keep a copy for your own records. Please go to our website http://www.greenlightcycle. com/product-registration to register your information electronically. Electronic registration helps the environment by creating a green, paperless tracking record of your electric bicycle’s warranty information.

To claim warranty, please have the Warranty Registration information ready and call Green Light Cycle Ltd.™ (1-855-476-7933), between the hours of 8:00 am to 4:30 pm Monday to Friday Pacific Standard Time, or send an email to: contact@greenlightcycle.com.