OWNER'S MANUAL IES Shark 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 SHARK Congratulations on selecting the IES Shark. 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. Serious injury or death can occur as a result. 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 Shark. 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 21 OWNER'S MANUAL ­ IES SHARK SHARK 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 21 OWNER'S MANUAL ­ IES SHARK Table of Contents · · · · · · · · · · · · · · · Record of serial number Photo of Shark Table of Contents Cautions and Warnings Inspection of your Shipment Illustration of bike Assembly Instructions Adjusting the brakes Operating Instructions Recharging your Battery Bicycle Components Bicycle Care Safety Responsibility Troubleshooting Specifications Page 2 3 4 5 6 7 8 9 12 13 15 17 18 19 20-21 INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 4 of 21 OWNER'S MANUAL ­ IES SHARK 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 21 OWNER'S MANUAL ­ IES SHARK 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 Front Wheel Front Fender 1 Comfort Saddle and Seat Post 2 Pedals Battery Charger and Power Cord Battery Rear Wheel with Motor Assembly Rear Locking Carrier Tools 2 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 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 21 OWNER'S MANUAL ­ IES SHARK Figure 1 ­ Parts of your Shark and Location of Quick Releases 4 6 3 25 2 12 19 2 24 17 10 8 14 13 9 15 16 18 26 21 1 26 5 7 11 23 20 22 1 ­ Brake Lever 2 ­ Reflectors 3 ­ Handlebar 4 ­ Front Brake 5 ­ Rear Brake 6 ­ Handlebar Stem 7 ­ Frame Tubes 8 ­ Front Fork 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 ­ Luggage Rack 23­ Rear Locking Carrier 24 ­ Gear 25 ­ Charging Port 26 ­ Power On/Off INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 7 of 21 OWNER'S MANUAL ­ IES SHARK 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 Shadow 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. Position the front wheel on the front fork assembly. Place washer clamp, washer and locking nut on outside of each side of front fork assembly and tighten securely. Install the front fender by removing the screw from front brake assembly as shown. Insert screw through fender clip, tighten washer and nut. Attach fender supports to lower opening in front fork assembly with screw and washer as shown. Removing screw to install front fender Fender support attaches here 3. Position the handlebars so that the stem fits into the bicycle frame. Line the handlebars up with the front wheel and 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. Install the pedals by carefully threading through crank arm, then tightening securely with a wrench. 5. Install the seat and adjust the height. Since your Shark has a bicycle type quick release mechanism to secure the seat, it is essential that you understand how to use this correctly. Read section which follows on quick release lever. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 8 of 21 OWNER'S MANUAL ­ IES SHARK Loosen the quick release lever, adjust seat to desired height and tighten the lever. See section on quick release lever for complete information on Page 12 of this manual. CAUTION: Do not adjust the saddle height above the safety line found on the seat pole. Quick release level open for adjusting seat height Quick release level closed for locking seat in place. 6. Lower the battery into the frame and lock in place with key. See Figure 2 Figure 2 7. Adjusting the Brakes - Adjust the front brake by first loosening the nut on brake assembly as shown in figure below. Read section which follows 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 below. Loosen brake screw and push on pad so it does not touch rim, then tighten screw. Adjusting brake pad distance Adjusting brake cable tension INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 9 of 21 OWNER'S MANUAL ­ IES SHARK The right brake lever controls the rear brake. The rear brake is a band brake which has been pre-adjusted at the factory. The left brake lever controls the front brake. 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. 8. Install the rear locking carrier. a) Remove the screws, washers and nuts from the rear light bracket as shown. Rear light bracket b) Following the sequence in the picture above, attach the carrier to the rear light bracket with a screw, washer, metal bracket, rubber bracket, rear carrier and a locking nut. 9. Install the front basket. Remove the Phillips head screws beneath the front headlight from the front bike frame. Place basket on front basket support, reattach Phillips head screws through basket from screw hole. Install screw and washer through bottom basket screw holes into clamp which is attached beneath the front basket support. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 10 of 21 OWNER'S MANUAL ­ IES SHARK 10. 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) INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 11 of 21 OWNER'S MANUAL ­ IES SHARK Operating Instructions Before You Ride Make sure quick release is locked and secure. 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. Quick Release Operating Instructions: 1. To release the lever, pull it away from the bike and towards you until it turns 180° and the word "open" is visible facing the outside, away from the bicycle. If your quick release lever is not marked "open" and "closed", it 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 the word "open" is no longer visible, 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. 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. INTERNATIONAL ECOLOGICAL SYSTEMS, LTD. 1-866-742-6274 Page 12 of 21 OWNER'S MANUAL ­ IES SHARK OPERATING INSTRUCTIONS ­ Charging the battery Batteries CAUTION: DO NOT ATTEMP ...