OWNER'S MANUAL IES Intrepid II Electric Bicycle Copyright 2004 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 INTREPID II IMPORTANT! Congratulations on selecting the IES Intrepid II. 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 is 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 Intrepid II. 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 24 OWNER'S MANUAL ­ IES INTREPID II INTREPID II 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 24 OWNER'S MANUAL ­ IES INTREPID II TABLE OF CONTENTS · · · · · · · · · · · · · · · · · Record of serial number Photo of Intrepid II Table of Contents Cautions and Warnings Inspection of your shipment Illustration of bike components Assembly Instructions Operating Instructions ­ Power Operating Instructions ­ Throttle and Controls Operating Instructions ­ Recharging the Battery Operating Instructions ­ Opening the Seat Illustrated Assembly Tips Bicycle Care Safety Responsibility Bicycle Components Troubleshooting Specifications PAGE 2 3 4 5 6 7 8 12 13 14 17 18 19 20 21 23 24 INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 4 of 24 OWNER'S MANUAL ­ IES INTREPID II 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! Keep the power switched off until you are seated on the bike and ready to ride. Turning the power on when not seated, and then accidentally twisting the hand throttle can result in the bike accelerating or "jumping" and cause damage or injury. 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 24 OWNER'S MANUAL ­ IES INTREPID II INSPECTION OF YOUR SHIPMENT The following is a list of all the necessary parts and components of your new Intrepid. Please make sure the listed parts are enclosed in the boxes and in good working condition. Bicycle 2 Pedals Battery Charger and Power Cord Battery Allen Wrench Open end / box combination wrench Philips head screwdriver Front Wheel Front Fender Front Basket and Parts Keys Rear Locking Carrier 2 Rear View Mirrors Assorted nuts, bolts, washers and screws Owner's Manual Please check the bike along with the parts and components thoroughly for any damage that may have occurred 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 24 OWNER'S MANUAL ­ IES INTREPID II FIGURE 1 ­ Parts of your Intrepid 5 4 2 12 1 8 17 3 6 26 21 22 19 7 27 11 20 25 24 18 23 14 15 13 1 - Front Brake Lever 2 - Rear Brake Lever 3 - Reflectors 4 - Handlebar 5 - Front Brake 6 - Handlebar Stem 7 - Frame Tubes 8 - Front Fork Assembly 9 - Tire (Front & Rear) 10 - Rim (Front & Rear) 10 9 16 21 - Rear Brake 22 - Rear locking Carrier 23 - Rear Wheel Lug nuts 24 - Gears 25 - Charging Port 26 - Power On/Off 27 - Display 11 - Battery Indicator 12 - Battery (Under Mat) 13 - Kickstand 14 - Pedal 15 - Crank Arm 16 - Chain Wheel 17 - Wire harness 18 - Motor 19 - Seat Riser 20 - Saddle INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 7 of 24 OWNER'S MANUAL ­ IES INTREPID II 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 Intrepid 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. Attaching the front wheel and fender. a) First loosen the front brake assembly by loosening the knurled nut (as shown in figure on Page 10) so the brake pads can be easily moved. b) Loosen the washer and locking nut on the front wheel bolt and position the front wheel on the front fork assembly, making sure that the washer and locking nut are positioned on the outside of the front fork assembly. c) Install the front fender. Remove the screw from the center front of the front brake assembly, reattach the screw through the fender clip. Attach the fender supports with screws to the front fork assembly as shown in Figure 1. Figure 1 Attaching front fender. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 8 of 24 OWNER'S MANUAL ­ IES INTREPID II Installing the front wheel and fender supports. 3. Install the pedals. Install the pedals by carefully threading through crank arm, then tightening securely with a wrench 4. Adjusting the Brakes - Adjust the front brake by first loosening the nut on brake assembly as shown in figure which follows on Page 10. 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, turn the knurled knob at the shaft of the adjusting bolt all the way down to the brake lever to lock the brake setting in place. (See section which follows on brake testing) You may also adjust the front brake pad distance to the rim using an Allen wrench as shown. Loosen brake screw and position pad so it does not touch rim, then tighten screw. The right brake lever controls the rear brake. The rear band brake has been preadjusted 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 adjustment is too loose, the extra play will cause insufficient braking power. The play is properly adjusted if the brake pads of the front brake meet the rim fully when the brake lever is pulled one-third of the way. If you have any questions, please call our Service Department at 1-866-726-6856. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 9 of 24 OWNER'S MANUAL ­ IES INTREPID II Adjusting the front brake 5. Install the battery as indicated in Figure 2. Connect the power cable to the battery. Lock the battery in place using the key. Figure 2 6. Install the front basket as shown in Figure 3. Remove the Phillips head screw beneath the front headlight from the front bike frame. Place basket on front basket support, reattach Phillips head screw through basket frame. Install screw and washer through bottom basket screw holes into clamp which is attached beneath the front basket support. 7. Install the rear locking carrier (See illustration below) Align the three holes in the bottom of the rear carrier with the holes in the rear bracket. Insert screw and washer through rear carrier bottom and rear bracket. Secure with a nut on each screw. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 10 of 24 OWNER'S MANUAL ­ IES INTREPID II 8. 9. Install the rear view mirrors as shown in Figure 4. Install the mirrors to the front handlebar assembly. Remove the screw and nut from the right and left brake lever as shown. Slide the mirror through the screw hole and tighten the nut securely. (You do not need the screw which you have removed once mirrors have been attached) See the "Assembly Tips" section of this book for pictures showing assembly tips for your bike. Fill tires with air to the recommended pressure 40-PSI and charge the battery before riding. 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, call the IES Service Department at: 1-(866) 726-6856. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 11 of 24 OWNER'S MANUAL ­ IES INTREPID II OPERATING INSTRUCTIONS - Power 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. Power On/Off The Power On/Off switch is a key switch located on the bicycle frame. The Intrepid uses the same key to lock the battery box and accessory box. Insert the key into the ignition key switch. Turn the key clockwise. Computer / Display You will find 5 lights which indicate battery strength. When all 5 lights are on, the battery is fully charged. Always turn the ignition switch to the `off' position if you are not using the electric bike. Notes: Do not recharge your battery until at least 3 of 5 battery level indicators are off. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 12 of 24 OWNER'S MANUAL ­ IES INTREPID II OPERATING INSTRUCTIONS ­ Throttle & Controls The throttle is located on the right side of the handlebar . Hold it with your right hand and turn it towards your body (counter clockwise) to increase speed. L·R switch: Right & Left turn signal. Red light switch: Front & rear light. When braking the rear light works as a brake light Green switch: Horn Caution: we recommend you ride at a slow speed until you become familiar with operation of the electric bike. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 13 of 24 OWNER'S MANUAL ­ IES INTREPID II OPERATING INSTRUCTIONS ­ Charging the battery 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 a 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 bike is not being used. If you let your battery completely discharge due to prolonged storage and lack of use, it can become damaged and may need to be replaced. Recharging the Bat ...