OWNER'S MANUAL IES Shadow Electric Bicycle With 6 Speed Shimano Gear System Copyright 2004 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 3/04 OWNER'S MANUAL ­ IES SHADOW IMPORTANT!! Congratulations on selecting the IES Shadow. 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 Shadow. 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 28 OWNER'S MANUAL ­ IES SHADOW SHADOW 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 28 OWNER'S MANUAL ­ IES SHADOW Table of Contents · · · · · · · · · · · · · · · · · · Record of serial number Photo of Shadow Table of Contents Cautions and Warnings Inspection of your Shipment Illustration of bike Assembly Instructions Operating Instructions Recharging your Battery Bicycle Care Safety Responsibility How to Adjust the Gear Shift How to Change the Fuse How to Adjust the V type Brakes Installing and Removing the Battery How to Install the Dynamo Light How to Install the Rear Accessory Light Specifications Page 2 3 4 5 6 7 8 13 16 18 19 20 21 22 23 24 26 28 INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 4 of 28 OWNER'S MANUAL ­ IES SHADOW 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 28 OWNER'S MANUAL ­ IES SHADOW INSPECTION OF YOUR SHIPMENT The following is a list of all the necessary parts and components of your new Shadow. Please make sure everything is enclosed in the boxes and in good working condition. Bicycle 1 Comfort Saddle and Seat Post 2 Pedals Battery Charger and Power Cord Battery Front Wheel with Motor Assembly Front Fender Front Basket with clamps, nuts, bolts and screws Rear Locking Carrier Reflectors Front and Rear Dynamo lights with wire cable, clamps, nuts, bolts and screws Tools 2 Mirrors Assorted nuts, bolts, washers and screws and extra fuses Keys Lock 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 1-866-7426274. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 6 of 28 OWNER'S MANUAL ­ IES SHADOW Figure 1 ­ Parts of your Shadow 29 11 31 23 30 21 7 19 12 28 22 8 10 6 26 10 17 15 14 24 25 16 2 13 9 18 2 17 20 3 1,6 1,5 27 4 SHADOW 1 ­ Brake Lever 2 ­ Reflectors 3 ­ Handlebar 4 ­ Shift Lever 5 ­ Front Brake 6 ­ Rear Brake 7 ­ Stem 8 ­ Front Fork Assembly 9 ­ Tire (Front & Rear) 10 ­ Rim (Front & Rear) 11 ­ Battery Indicator 12 ­ Battery 13 - Kickstand 14 - Pedal 15 ­ Crank Arm 16 ­ Chain Wheel 17 ­ Wire Harness 18 - Motor 19 ­ Seat Post 20 ­ Saddle 21 ­ Seat Post Quick Release 22 ­ Rear Brake 23 ­ Luggage Rack (can be used if you do not 24 ­ Rear Wheel Lug Nut 25­ Gears 26 ­ Rear Derailleur 27 ­ Charging Port 28 ­ Power On/Off 29­ Display 30 ­ Rear Locking Carrier 31 ­ Frame Tubes install rear locking carrier) INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 7 of 28 OWNER'S MANUAL ­ IES SHADOW ASSEMBLY INSTRUCTIONS Tools Required For Assembly A set of tools is provided for your convenience inside the shipping carton. Assembly Instructions Please read through and follow all instructions to ensure that your Shadow is properly assembled and ready for use. We recommend you assembly your Shadow on a mat or non-abrasive surface in order to avoid scratching your bike. 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. Position the handlebars so that the stem fits into the bicycle frame and loosely tighten the hex nut. Turn the bike upside down. Position the front wheel bolt between the front fork assembly, making sure the locking nut, washer, and fender and basket clamp are all on the outside of the front fork assembly. The final washer should be positioned inside the front fork assembly against the hub motor. Tighten the locking nuts and washers on the outside of the front fork assembly by turning until they are securely fastened to the front fork assembly. On the left front side, insert the black power cable protection clip which protects the power cable (See Figure below) outside the locking nut and power cable as shown, before securely tightening the locking nut. Turn the bike upright and lower the kickstand. Remove the rear locking nut and washer from the front brake assembly. Fit fender clamp over brake assembly screw and replace and tighten washer and nut. Attach the fender support with a screw and washer to the lower screw hole on each side of the front fork assembly. (See Figure 1) Connect the power cable clip attachment from the front wheel to the wire harness connector. Slide the protective plastic cover over the cable connection. Figure 1 (power cable protection clip) Left front wheel shown Front basket frame Fender support Power cable protection clip INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 8 of 28 OWNER'S MANUAL ­ IES SHADOW 3. Line the handlebars up with the front wheel and securely tighten them with an Allen wrench. Observe the stem ­ there is a marking on the stem that indicates the minimum safe insertion. The line or marking must be inside the frame. If the stem is not inserted this far into the frame it may break and the rider may lose control. 4. Install the pedals by carefully threading through crank arm, then tightening securely with a wrench. 5. (See Figure 2) Install the seat and adjust the height. Since your Shadow has a bicycle type quick release mechanism to secure the seat, it is essential that you understand how to use this correctly. How to adjust seat height Loosen the quick release lever, adjust seat to desired height and tighten the lever. Read section below for complete information on Quick Release Operating Instructions. CAUTION: Do not adjust the saddle height above the safety line found on the seat pole. Figure 2 Seat release open Seat release closed Quick Release Operating Instructions: 1) To release the lever, pull it away from the bike and towards you until it turns 180° away from the bicycle. The quick release lever is open when the lever curves away from the bicycle. 2) The tightness of the lever is adjusted with the nut opposite the release lever and by rotating the quick release lever. Turn the nut by hand to adjust the tension while holding the lever stable. 3) To lock the release lever, push lever up and over towards the bike frame until it turns over 180° and or the lever curves toward the bicycle. The lever is securely tightened when it leaves an imprint on the palm of your hand from pushing it closed. 4) Once the lever is securely closed, you should not be able to move it unless you open it again (Step 1). If you can easily move it, then open the quick release lever again and tighten the nut another half turn clockwise. Continue with Step 3. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 9 of 28 OWNER'S MANUAL ­ IES SHADOW 5) If you have adjusted the nut too tightly and cannot push the lever to the "closed" position, open the quick release lever again and turn the nut a half turn counterclockwise. Continue with Step 3. Failure to properly tighten, adjust and fasten these mechanisms may result in loss of control of the bicycle. If in doubt, take your shadow to a local bicycle dealer for instruction or call IES Service Department at 1-866-726-6856. DO NOT RIDE YOUR BICYCLE WITHOUT THE SEAT QUICK RELEASE SECURELY LOCKED. 6. Adjusting the brakes (See Figure 3 ­ how to adjust the V-type brakes) - Adjust the front brake by turning the adjusting nuts located at the junction of the brake cable and brake lever. When you have determined the proper setting, (see section which follows on brake testing) 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. The right brake lever controls the rear brake. To tighten brakes, turn the adjusting nut clockwise. To loosen brakes, turn the adjusting nut counterclockwise. The left brake lever controls the front brake. To tighten brakes, turn the adjusting nut counterclockwise. To loosen brakes, turn the adjusting nut clockwise. Do Not remove the protective plastic spiral cover from the brake cable. 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 please call our Service Department at 1-866-7266856. 7. Install the battery (See Figure 4 ­ for detailed instructions) INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 10 of 28 OWNER'S MANUAL ­ IES SHADOW 8. Install the rear locking carrier ­ Position the carrier on the rear bike rack as shown. Insert screw and washer through two holes in supplied metal bracket, then through two holes in locking carrier. Next mount screws through rubber pad. Place assembly on rear bike rack and after positioning second metal bracket under rear bike rack, firmly tighten entire assembly using two washers and nuts. 9. a) Install the front basket ­ Attach the basket clamp to the clamp ...