OWNER'S MANUAL IES Colt Electric Bicycle Copyright 2003 by IES I E S International Ecological Systems, Ltd. 51 Hartz Way. Secaucus, NJ 07094 1-866-742-6274 info@cycleies.com www.cycleies.com OWNER'S MANUAL ­ IES COLT IMPORTANT!! Congratulations on selecting the IES Colt. In order to use and enjoy your bicycle safely and to get the best performance and durability from this product, please read this manual before riding. Warning! Even on the best days, riding or operating any sort of vehicle can be hazardous. Always wear a helmet and use extra caution to avoid accidents. This manual contains many cautions and warnings. It is important that you read and understand the material outlined in this manual. We want you to be completely satisfied with your Colt. If you have any questions or concerns, please call the IES team at 1-866-742-6274. Each bicycle comes with a Vehicle Identification Number (VIN) embossed into the frame. Please record the VIN along with other pertinent information below in the event that the bicycle is lost or stolen. It may also be a good idea to register your VIN number with the local police department. VIN: Model: Color: Date of Purchase: Place of Purchase: INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 2 of 18 OWNER'S MANUAL ­ IES COLT COLT If you have any difficulty with the final assembly of your electric bike, please call the IES Service Department at 1-866-726-6856. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 3 of 18 OWNER'S MANUAL ­ IES COLT Table of Contents · Record of serial number · Photo of Colt · Table of Contents · Cautions and Warnings · Inspection of your Shipment · Illustration of bike · Assembly Instructions · Operating Instructions · Bicycle Components · Bicycle Care · Safety Responsibility · Specifications Page 2 3 4 5 6 7 8 11 13 15 16 17 INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 4 of 18 OWNER'S MANUAL ­ IES COLT CAUTIONS AND WARNINGS! Please read this section! It is very important for your safety and satisfaction that you read these cautions and warnings. Thanks! Warning! Always wear your helmet, obey local laws, and exercise caution when riding. Warning! If you are not certain that your bike is safe to ride, call the IES Service Department at 1-866-726-6856 for detailed advice and information. Warning! Never attempt to disassemble the battery, motor, controller, or throttle. This can result in injury, fire, or damage to the bike. Warning! Only use the charger that was supplied with your bike to charge the battery. Use of an improper charger can result in fire or explosion. Read and follow the charging instructions in the manual for complete information about the operation of your charger. Warning! Substituting batteries, changing motors or controllers will void the warranty and may result in various types of safety problems including fire, explosion, excessive speed, or lack of control. All service should be performed by the IES Service Department or authorized dealer referred by the IES Service Department. Warning! Avoid contact with live wires, or the battery terminals. Although the voltage is low, the amperage is high. Burns and other injuries can result from contact with any body part. Warning! Keep the battery and charger out of the reach of children. Caution! Fully charge the battery before the first use. Failure to do this can result in decreased battery performance for the life of the bike. Fully charge the battery each time you use the bike. Caution! Do not store your new bike where it will be exposed to high heat, high humidity, or rain for extended periods. All of these will decrease the life and appearance of your bike. Caution! Do not immerse your bike in water especially sea water. This can damage or destroy the electrical components. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 5 of 18 OWNER'S MANUAL ­ IES COLT INSPECTION OF YOUR SHIPMENT The following is a list of all the necessary parts and components of your new Colt. Please make sure everything is enclosed in the box and in good working condition. Bicycle 1 Comfort Saddle 2 Pedals 2 Mirrors Battery Charger with Power Cord Battery Tool Kit Assorted nuts, bolts, screws and washers Keys Basket and Accessories Owner's Manual Please check the bike along with the parts and components thoroughly for any damage that may have been sustained during shipping. Be careful to avoid scratching the frame when untying or unpacking the bicycle and components. If you find that something is missing, please call the IES team at 1-866-742-6274. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 6 of 18 OWNER'S MANUAL ­ IES COLT Figure 1 ­ Parts of your Colt and Location of Quick Releases 4 3 10 - 26 27 1 19 25 16 6 22 21 11 5 8 18 20 24 23 17 9 13 2 7 14 10. Battery Indicator 11. Battery 12. Kickstand 13. Pedal 14. Crank Arm 15. Chain Wheel 16. Wire harness 17. Motor 18. Seat Post 2 8 12 2 15 1. Front Brake 2. Reflectors 3. Handlebar 4. Rear Brake 5. Handlebar Stem 6. Frame Tubes 7. Front Fork 8. Tire (Front & Rear) 9. Rim (Front & Rear) 19. Saddle 20. Seat Post Adjustment 21. Rear Brake 22. Luggage Rack 23. Rear Wheel Lug nuts 24. Gear 25. Charging Port 26. Power On/Off 27. Mirrors INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 7 of 18 OWNER'S MANUAL ­ IES COLT ASSEMBLY INSTRUCTIONS Tools Required For Assembly This bicycle can be assembled with the following tools which are included in the shipping carton. - Metric Allen wrenches - Combination open end/box wrench - Phillips screwdriver Assembly Instructions Please read through and follow all instructions to ensure that your Colt is properly assembled and ready for use. 1. Remove the bicycle from the box by cutting the plastic strapping, then cutting two sides of the box away. Avoid lifting the bike straight up out of the box. Remove all of the wrappings and ties that protect the bicycle during shipment. 2. Attach the front wheel and fender. Remove the locking nut and washer clamp from the wheel bolt. Position the front wheel on the front fork assembly. Remove the rear locking nut and washer clamp from the front brake attachment. Attach the fender clamp to the front brake attachment screw, and replace and tighten with the washer and locking nut. Replace the washer clamp on each side of the front fork assembly, inserting clamp edge into hole on fork assembly. Next position the front basket frame on each side of the wheel bolt outside of the front fork assembly. Position the front fender support on each side of the front wheel bolt and replace and tighten washer and nut securely on each side of wheel bolt. Front basket frame Front fender frame 3. Position the handlebars so the stem fits into the bicycle frame. Line the handlebars up with the front wheel and tighten the handlebars with an Allen wrench. Observe the handlebar stem ­ there is a mark on the stem that indicates the minimum safe insertion. The line or mark must be inside the frame. If the stem is not inserted far enough into the frame, it may break and cause the rider to lose control. 4. Install the front basket. Insert 2 screws through the basket frame and attach to bracket on handlebar stem using a washer and nut. Place basket on front basket support, install screw through bottom basket screw holes into clamp which is attached beneath the front basket support and secure with a nut. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 8 of 18 OWNER'S MANUAL ­ IES COLT 5. Install the pedals by carefully threading through crank arm, then tightening securely with a wrench. 6. Pull up on the seat release lever under seat (See Figure which follows on Page 9) and pull rear of seat forward. Slide the battery into the holder between the seat post and rear fender. Use key to lock the battery to the seat post frame tube. Push seat back until seat lever locks in place. 7. Adjust the seat height by loosening the bolt and locking nut, raising to correct level for rider's height, and then tightening again. 8. Adjust the front brake by first loosening the nut on brake assembly as shown in figure below. Read below section on brake testing. If brake tension is too lose, pull inner wire cable towards you, then tighten nut. If brake tension is too tight, release inner wire cable until you achieve proper tension, then tighten nut. When you have determined the proper setting, tighten Allen key nut securely to the brake lever to lock the brake setting in place. (See section which follows on brake testing) If you find that the brake requires adjustment, please follow the following steps: 1. Loosen the Allen key nut to widen the clearance between the brake rubber pads and the tire rim. Brake pad clearance adjustment. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 9 of 18 OWNER'S MANUAL ­ IES COLT 2. Loosen the Allen key nut to adjust the tension on the brake cable. Adjust the wire inner brake cable to the desired length, and tighten nut. Brake cable length adjustment. The right brake lever controls the rear brake. The rear brake is a band brake which has been pre-adjusted at the factory. Brake Testing Squeeze the brake levers. The brake levers should be easy for you to reach, and engage the brakes completely when pulled in. You should not be able to pull the brake lever in until it touches the handlebar or grip. Test the brakes and the brake lever adjustment; you should be able to comfortably control your brakes. If the brake is adjusted too loose, the extra play will cause insufficient braking power. The play is properly adjusted if the brake pads meet the rim fully when the brake lever is pulled one-third of the way. If you have any questions about the operation or adjusting the brakes, contact the IES Service Department at 1-866-726-6856. 9. Fill tires with air to the recommended pressure 40-PSI using the adaptor found in the carton. Local bicycle shops are usually willing to assemble bicycles for a fee. They will often check a bicycle for safety at no charge. If you have any questions please call the IES Service Department at 1-866-7266856. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 10 of 18 OWNER'S MANUAL ­ IES COLT OPERATING INSTRUCTIONS Before You Ride Make sure all parts, components and accessories are in good working order. Check all fittings and be sure that they are tight and secure. Inspect your bike completely. Batteries CAUTION: DO NOT ATTEMPT TO OPEN OR TAMPER WITH THE BATTERY IN ANY WAY. DOING SO MAY CAUSE CHEMICAL, ELECTRICAL AND/OR FIRE HAZARDS. Batteries that lay dormant for an extended period of time will lose their ability to accept charge. Please make sure you ride and recharge your bike periodically to prevent this from happening. Charge the batteries every two months, even if the vehicle is not being used. You should recharge the batteries after every use for optimum performance and battery life. The average battery life for a Nickel Metal Hydride battery is about 300 cycles. One cycle is one complete charge and discharge of the battery. You will need to replace your batteries when they no longer hold a sufficient charge. RECHARGING THE BATTERIES It is important that you charge your batteries after every use. This will extend the total life of your battery. Once the charger has indicated that the battery is fully charged, unplug the power source from the bicycle and from the electrical outlet and store in a cool (59° - 86°F or 15° - 30°C), dry (10% - 70% humidity) place. WARNING: Do not leave the battery charger plugged in for long periods of time. This can damage the batteries. The battery does not have to be removed from the bike for recharging. If you choose to remove the battery box from the bicycle frame during recharging exercise care to avoid damaging the charging cables. To charge your batteries: 1. Turn the on/off switch to the "off" position. 2. Insert the charger's plug into the battery box charging port. 3. Plug the battery charger into the wall outlet. 4. Turn the charger on. The first time you charge the battery, you must charge for a minimum of 10 hours, but do not charge for more than 20 hours. After the initial battery charge, your Colt battery can be completely charged in 4 hours. 5. The charger will take up to 4 hours to recharge the battery completely. When the green light appears the battery is sufficiently charged. 6. Do not charge for more than 4 hours (after the initial charge) to avoid overcharging and damaging the battery, especially in hot weather. 7. Charge the bike in a dry and clean place. Keep the charger dry and clean. The charger will become warm during charging. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 11 of 18 OWNER'S MANUAL ­ IES COLT OPERATING INSTRUCTIONS ­ Recharging the battery (continued) PRECAUTIONS WHILE RECHARGING THE BATTERY 1. Using your power source incorrectly or leaving the power source connect ...