Sprint Nextel Bicycle Bike User Manual

www.eZeebike.com

SPRINT

USER MANUAL

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Contents

Simply moving

Guarantee conditions

Legal regulations

Technical data

Parts Identiﬁcation

Assembly

Checklist

Battery charging

How eZeebike works

Maintenance

Troubleshooting

Afterword

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Simply Moving

Congratulations on the purchase of your eZee bike. You’re

one step closer in realizing a whole new way of commuting that is

fast, fun and friendly to the environment.

The hub motor is brushless and uses a technology called

Pulse Wave Modulation control, so that its not subject to wear like

a regular DC motor. Planetary reduction gears incorporated into its

hub gives it a very strong torque, working in unison with your leg

power to ﬂatten out those hills and to overcome headwinds.

Under normal cruising conditions (26 kmh, 16 mph), the

motor draws about 5 amps at 140 watts with 5 Nm torque and has

an efﬁciency about 80%. Its electric consumption is about 1.0 kwH

for 100 km / 62 miles in ebike mode - even less energy than the food

you would consume riding by leg power alone. Making it by far the

most efﬁcient vehicle ever made.

While the eZee pledge to quality means our components are

high value and reliable. Its your part to understand safety implica-

tions and the possible risks of cycling. So please take some time and

read this manual. It explains the bike in detail, how to take care of it,

so that you can enjoy using the bike for many years to come.

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Guarantee Conditions

The following guarantee conditions complement your legal rights.

How the guarantee applies

As the makers, we guarantee against possible material or construction defects.

Provided the following conditions are satisﬁed :

Proof of purchase. The guarantee starts on the date of purchase.

Only the ﬁrst owner is entitled to the guarantee.

The bike is guaranteed for 2 years, this comprises of the frame, fork, all

mechanical and electrical parts, except normal wear and tear items.

1 year for the battery up to 70% depth of discharge from its original rated

capacity. This can be verﬁed by the eZee dealer you’ve purchased the bike from.

How the guarantee does not apply

When the bicycle is used negligently or results in damage due to trafﬁc

accident.

Damage ascribed to normal wear and tear.

Poor maintenance, or modiﬁcations that no longer complies with

regulations or original technical speciﬁcations.

Damage due to external causes.

The bicycle is put up for hire.

The battery pack is used incorrectly or tempered with. This also applies

during charging.

Compensatory costs arising from damages or accidents, or

cost incurred by loss of the bicycle’s usage.

How the guarantee covers

Original defective parts that are sent to the manufacturer for assessment

will be replaced by the same or equal value part.

Labour and transportation charges are not included. This are borne by

the owner.

eZee exclusively makes the decision whether or not the guarantee

applies.

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Legal Regulations

EU regulations state that your vehicle is an Electric Powered

Assist Cycle (EPAC) when the following conditions are met.

[ EU directive 2002/24/EC Chapter 1 Article 1 1(h) ]

“Cycles with pedal assistance which are equipped with an

auxiliary electric motor having a maximum continuous rated power

of 0.25 kW, of which the output is progressively reduced and ﬁnally

cut off as the vehicle reaches a speed of 25 km/h or if the cyclist

stops pedaling.”

With EU compliant conﬁguration, the power assist of an eZee

bike only functions while the rider is pedalling. The means of control-

ling the assistance is provided with either a dial or throttle system.

USA regulations allow a power assisted maximum speed of

20 mph. eZee bike made for the USA has a motor nominally rat-

ed at 350 watts but up to a maximum rated power of 700 watts.

The power assist can function without the aid of pedalling, however

there’s nothing to stop you from doing so. Putting in some effort will

greatly increase the mileage you get from your battery.

This means you do not require a license or moped certiﬁcate,

there is no age limit and you can take cycling paths. It conforms to

regulations of normal bicycles. Legal requirements concerning

insurance of your bicycle may differ, so do ﬁnd out about the rules

and regulations in your country.

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Sprint

Technical Data

Weight

Motor

26.7 kgs

Electric brushless hub motor

250W (EU) / 350W (US) with planetary

reduction gears

Battery Pack

Lithium Ion with battery management circuit

37V 10Ah (370 Wh capacity)

3.1 kgs

Low voltage protection 28 V

Discharge temperature limit -15°C to +55°C

Controller

Charger

PWM

LED self diagnostic system

Overload protection 20 amps

2 amps

Smart charger

Maximum charge time 6 hrs

charging temperature +5°C +35°C

Interface

Fuse

Forward magnetic motion sensor with 0 -

4.5 V VPA dial or throttle

E-bike throttle with safety ON/OFF switch

Pedelec throttle with light switch

30 amps

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Sprint

Parts Identifcation

26 27 28 29 30 31

32 33 34 35 36 37

21 20 19 18 17 16 15 14 13 12 11 10

Brake cables

Front LED lighting

Mudguards

V-Brakes

Rims

Spokes (13g)

Hub motor

Reﬂectors

Tyres 26” x 1.95”

Suspension front fork

Motor wire casing

Bearing race

Frame

Chainguard

Shimano roller brakes

Shimano Nexus Internal gears

Tensioning bolt and plate

Rear LED lighting

Al. luggage rack

Controller / Ignition

Battery

Saddle ﬂip catch

Saddle

Seat post

Seat post clamp (quick ﬁx)

Headstem

Handle grip (Throttle)

Brake levers

Gear shifter

Battery level gauge

Handlebars

Pedals

Chainwheel 48T and crank

Pedal sensor

Central support stand

Chain 1/2 x 3/32

Chain stay

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Sprint

Assembly

If you have received your bike through mail instead of picking

it up from your local bike specialist, please read this section before

proceeding to assemble.

Unpack

Carefully remove the bicycle by lifting it straight out

of the box. Becareful not to scratch yourself on the carton staples.

Remove the packing material around the bike and stand the bike on

a clean ﬂat surface. Be sure to keep any part packages that comes

along with the bike. Discard box and packaging material only.

Dispose responsibly, recycle when possible.

Check

This box should contain....the eZee Sprint bicycle!

An accessory box containing.

3 Ignition keys

1 Pair of pedals

1 Battery charger

1 Power cord

2 Fuses (30 amps)

Nylon ties

Heat shrink tubes (assorted pre-cut sizes)

1 Hex Key #5

1 Hex Key #3

1 eZee Sprint User manual

Shimano Gear and Brakes Manual

1 Battery, Lithium Ion 37V 10Ah

and check the box again for any additional purchases or variations

that should be included, according to your eZeebike dealer.

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Sprint

Assembly

Tools required

Tools are the ﬁrst step to proper assembly,

you will need a

Allen / Hex key metric set

Philips head screwdriver

Open-end ﬂat wrenches metric

measurements 6mm - 17mm

Front wheel

Insert the hub motor wheel into the front fork,

ensuring that it is properly seated in the dropout slots. Tighten the

nuts alternatively on both sides till the wheel is secured.

Tightening torque 35 Nm

Seat post

and align. Tighten clamps and ensure seat is ﬁrmly fastened.

Tigtening torque 16 Nm

Insert into the seat tube of the bicycle frame

Do not adjust the seat post beyond its maximum extension

mark.

Handlebar / Stem / Headset

Handlebar

and stem comes pre-assembled. Loosen

bolts on the stem and insert and turn the

handle bar assembly until it is in right angles

with the frame. Then tighten.

Tightening torque 18 Nm

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Sprint

Assembly

Pedals

Pedals are marked “L” and “R”

for left and right respectively. Screw in clock-

wise for the “R” pedal and counter-clockwise

for “L”. Tighten both with a wrench ﬁrmly

but not excessively as the crank threads are

made of aluminum alloy.

Front Mudguard The supports are

attached to the sides and top of the front

fork, the mudguards are made of polycarbonate and should not

rattle when they’re securely fastened.

Brakes

One of the most important safety features on

the bicycle. To minimise the risk of injury, its vital to ensure they are

corrected adjusted. Ensure that the V-brake blocks are parellel to

the rim, and that the distance between them do not exceed 2mm,

then tighten the brake mounting bolts. Fine tune with a philips head

screwdriver. Squeeze brakes to test its responsiveness.

For more information about the rear Shimano Roller brake, please

read the Shimano manual that comes along with your purchase.

Models that come with disc brake options, check that the wheels

rotate freely without touching the pads.

If you have little experience with bicycle maintenance. We

recommend you get this done with your local bike shop.

Accessories

Install any optional accessories you have

purchaed with your bike. Read the manufacturer’s manual

provided.

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Sprint

Assembly

Battery

Insert key into keyhole located by the

controller box and turn key counter clockwise while pressing it in, so

that it arrives in the open position. Release the catch located at the

underside of the saddle to ﬂip it over. Locate the battery ﬂanges in

their slots in the battery holder; then push the battery ﬁrmly into the

holder until the connecting pins are ﬁrmly in the battery sockets.

The ﬁt can be tight when new, so it may be required to apply gentle

pressure. Once the battery is in position, lock into place by turning

the key one click clockwise to the “OFF” position. Ensure that the

key is in “OFF” position until you are ready to ride.

Do not use excessive force to ﬁt the battery, which could

result in damaging the connection sockets or pins.

If there is an A/C outlet near to where your bicycle is parked. It may

not be necessary to remove the battery from the bicycle to charge.

Tyres

Ensure that the tyres are inﬂated to the correct

pressure of 60 psi. Well inﬂated tyres enhances the comfort, safety

and efﬁciency of your ride.

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Sprint

Checklist

Usage

The eZee Sprint is best described as a

‘commuters’ bike and is best suited for usage in urban environment

and roads. While cycling, it is your responsbility to be attentive of

your environment and trafﬁc rules, as this concerns the safety of all

who share the paths, especially you.

wear shoes that stay on your feet and grip ﬁrmly to the pedals. No barefoot or

sandles.

dress to be visible on the road and avoid loose clothes that will tangle with

moving parts of the bicycle.

keep your speed at levels appropriate to road conditions

be aware of wet weather conditions, as these affect braking distance. Brake

earlier than you normally would on dry roads.

familiarise with the trafﬁc rules in the country you are riding in.

avoid cycling in poor weather and visibility conditions such as fog, night, heavy

rain and snow. keep your lights on in such conditions.

familiarise yourself with the usage of the bike and how to maintain it.

Inspect

Before every ride, make a quick inspection of your bike’s mechanical and electronic

features. Be safe, not sorry.

frame & fork

Visually check for damage, do not ride if bent or fractured.

Check for missing or damage spokes. Feel spokes to ensure

wheels and tyres

tightness. wheels should be true (straight) and tyres inﬂated to its correct pressure.

handlebar and stem

Tightened ﬁrmly in the ‘face forward’ positions, the handlebars

will rotate the front fork and wheel, ensure that the grips are also ﬁrmly seated.

Brakes

Squeeze brake levers, gap between brake blocks and rims

should not exceed 2mm.Brake cables should remain unobstructed by other cables or

accessories.

Chain

Turn crank arms to ensure chain runs smoothly. Keep the chain

lubricated and clean. Chain tension is adjusted by the tensioning bolt located at the end of

the frame.

Electronics

Red light from the controller unit should be illuminated when

the electric bike is ‘ON’. All wires to be fastened securely in place

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Battery Charging

Before your ﬁrst ride, the battery needs charging. Bring it to a

wall socket. (220V - 230V AC EU other countries or 115V AC US)

Fuse / Fuse holder (30 amps)

Battery grip

Charging socket

Battery slot guides

Batter lock slot

Serial number, battery information

Insert charging plug into socket on

battery and connect charger power

cord to A/C outlet. Turn on A/C outlet.

Turn the ‘1’ switch on the charger.

It’s important that to follow this

sequence of actions everytime you

charge the battery.

Do not remove the plug by

pulling the cord, always grip the

charging port by its metal body.

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Battery Charging

Check the indicator lights on the front of the charger.

RED

light indicates that the charger is connected and

running from an A/C outlet.

YELLOW

GREEN

light indicates that the battery is charging

light indicates that the battery is fully charged

It will take a maximum of 6 hours to fully charge your battery. You

may interrupt the charging at any time.

As Li Ion batteries do not suffer from memory effect, it is not

required for the battery to be empty to commence a recharge.

Top-up charging everytime you’ve completed your cycle ride is

recommended.

Kept in good condition Li Ion battery will perform at least 350 full

charge cycles, with a retention of 70% from its original capacity.

Please use only the Li ion charger as provided.

a. Male charging plug

d. Charger serial no.

g. Charger ‘ON’ LED

j. Power switch

b, Charging cord

e. Cooling fan

h. Charging status LED i. Warning label

k. A/C voltage switch l. Power cord socket

c. Charger speciﬁcations

f. Fuse 10 Amps

A new battery might take 2 - 3

charges before it performs at its

stated capacity.

Dispose your battery

responsibly, refer to your town

council or eZee dealer.

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Battery Charging

Sometimes after temporary disconnection, the charging

status light may give a false green reading. To verify that your

battery is fully charged, switch the charger off, wait for the charger

lights to go out and switch it back on again. The charging status

light should quickly return from amber to green, when the battery is

fully charged.

The battery may be also charged on the bicycle, do make

sure that the bicycle is switched off so as to not waste electricity.

If the battery refuses to accept a charge, refer your eZee

dealer for more information.

Battery charging is automatically regulated, there is no

danger of overcharging. We advised that you disconnect the

battery and switch the charger off when the charging process is

completed.

Do not charge the battery in wet conditions.

Never allow children to play with the battery or charger.

Do not leave your battery in a fully discharge state for long

periods of time. The battery will continue to self-discharge,

resulting in damage.

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How eZeebike works

Your ﬁrst ride

Before you wheel your bike out into the world,

we recommend you practice handling the bike in a safe area away

from obstructions and trafﬁc. The motor may look small, but it’s

powerful! You’ll be riding faster than you think.

Turn the key to the ‘ON’ position. A red LED

will illuminate below the key socket. If the light

ﬂashes, read the Troubleshooting section of

this manual. If it shines steadily, you’re ready

for the next step.

EPAC / Pedelec

As you pedal, rotation on the crank is picked

up by a sensor in the bottom bracket. This allows the drive system

to be engaged. A twist of the throttle then provides power-on-

demand, reducing the pedalling effort required.

E-Bike

The motor runs as soon as you turn the

throttle. Ensure that you are seated and ready to ride off before

you use the throttle. You may toggle the throttle on and off with the

switch located on it.

In E-bike mode, the range of your bike will be approximately 40

kms (25 miles). The hillier the terrain, the less you pedal, shortens

your range. While EPAC, judicious use of gears, power assistance

all contributes to increasing the mileage you can get out of your

ride. 40 - 60 kms (25 - 40 miles).

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How eZeebike works

Variable Power Assist (VPA)

In lieu of a throttle, you may

have received or chosen a potentiometer dial. This set-up is only

compatible with EPAC mode eZeebikes.

The dial settings from 0 - 8 correspond accordingly to the level of

continous power assistance acheived by the motor during

pedalling. The level of assistance remains the same throughout

regardless of road conditions until you re-set the dial to another

position. This is especially useful for long treks or when you do not

wish to fuss about with a more sensitive throttle.

You can always choose to ride your bicycle as an ordinary bicycle.

Battery level gauge

When riding a fully charged

bicycle, the battery level gauge shows ‘green’. Powerful

acceleration or uphill riding causes the battery voltage to drop and

may bring the level gauge to ‘amber’ or even ‘red’ (in the cases of

very steep hills).

As you continue to cycle and the battery power drops, the level

gauge will correspond to the state of charge remaining. When it

remains in ‘amber’ and dips into ‘red’, you have approximately a

1/3 of the charge left. Best to recharge the battery soon.

To prevent the battery from deep discharge, the controller has a

low voltage protection cut-off set at 30.0 V. You may reboot the

bicycle if it cuts off however,

Continued use of an empty battery by ‘pulsing’ will cause

deep discharge, this is detrimental to the battery and reduce its life.

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How eZeebike works

Lighting system eZee bikes features wide angle high

performance reﬂectors at the front, sides and rear. Front and rear

LED lights are powered by the main battery, electrical consumption

is negligible, be safe, use them often.

Lock

When parking your bicycle, turning the key to

the ‘OFF’ position and removing it will shut the system off and lock

the battery in place. Use a chain lock to further secure your bicycle

when necessary. We also recommend you insure your bike against

theft. Consult your eZee dealer or LBS for more information.

Central support stand

This spring loaded stand supports your

eZeebike straight up. Use your feet to depress the stand

downwards and pull the bike in reverse. Ensure the stand is ﬁrmly

rested on the ground before leaving the bike.

Do not sit on the bike with the stand parked. The central

support stand is made of aluminum alloy and meant to only take

the weight of the bicycle and not with the rider on it.

Luggage rack

The luggage rack provided comes equipped

with a spring loaded catch and elastic strap. If you plan to carry

luggage on the rear, make sure everything is securely fastened

and clear from the rear wheel. There are many useful accessories

that can be ﬁtted on the rear rack, from panniers to child seats. Do

however, take note that the load limit is 25 kgs.

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Maintenance

Maintaining your bicycle ensures you’ll get the most out of

every ride and out of the entire life of your eZee bike. How much of

your bike’s maintenance you can do yourself will depend on your

knowledge, skill, experience and whether you have the necessary

tools for the job.

Learning from available cycling literature and joining cycling

communities can be an enjoyable way of improving your skill and

knowledge about maintaining bicycles. Beyond this manual, it is

good to consult your LBS and eZee dealer for advice regularly.

Before every ride Mechanical safety checks, use a fully charged

battery, visual inspection for damages.

Every 150kms (100 miles) Clean the bike, incl. chain rings and

sprocket. Clean and lightly oil the chain and gears.

Every 20 - 30 hours of riding Squeeze the brakes and rock the

bike to check for any looseness with each forward of backward

movement. If the headset is loose, have your dealer check it.

Lift the front wheel and rotate handlebars to check for tightness of

steering, it may be necessary to lubricate ball bearings.

Check and recalibrate the brakes, replace if worn out.

Squeeze spokes in adjoining pairs between your thumb and index

ﬁnger. They all should have the same tension. Have your dealer

respoke or true the wheel if necessary.

Check cables for rust, kinks and fraying, have your dealer replace

them if necessary.

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Maintenance

Repairing a punctured tyre

If you have a punctured tyre, we

recommend that you get a specialist to carry out the repairs. You

can always of course consult a specialist and carry out the repairs

on your own.

As there are no electronic components on the rear wheel, its

removal follow standard proceedures as with normal bicycles with

internal gears. Read the Shimano gear manual provided for more

instructions.

As the front wheel contains the hub motor,

there are additional steps in the case you

require the entire wheel to be removed from

the bike.

A philips head screwdriver will be required to

open the cable housing (shown on left) to ﬁrst

unplug the wires than run from the motor to

controller. There should be 1 x 6 pin

connection and 3 colour coded wire connections (Blue, Yellow,

Green). Unplug these before proceeding to remove the front wheel.

Be mindful of the tightening assembly sequence of washers, nuts

and spacers.

Hub motor and general inspection

After 5,000 kms (3,000 miles) of cycling. We recommend you

arrange to have a thorough inspection of your bicycle by an eZee

dealer. This includes opening up the hub motor to inspect and

lubricate the gears.

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Troubleshooting

Electronic self-diagnostic system

When the bicycle is functioning normally, the red LED that is

situated by the controller is lit continually.

In the case of an electronic malfunction, the controller comes

programmed with diagnostic capabilities to determine where the

fault lies. The red LED will emit a series of blinks, count them and

refer to the table below for its explanation and solutions.

No. of

blinks

Explanation

Solution

Brake lever cut off in

contact

check brake lever spring, brake levers should

return to position (applicable with electric cut-off

levers)

Brake lever cut off in

contact

check wiring connection, inspect for damage to

the battery level gauge

Throttle not in position

Throttle failure

low voltage

check if throttle spring is faulty

check throttle connections or replace

recharge battery or loose battery cable

connection

excessively high voltage measure battery voltage, contact your eZee

dealer

sensor fault

contact your eZee dealer

allow to cool, reboot system

motor incompatibility

overheat, thermostat

activated

thermostat failure

replace controller

amps control / controller replace controller

failure

No light Power failure

check battery, power cables or replace controller

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Troubleshooting

The faults listed may not cover every possible failure. In the

event of moisture or water entering the controller, haphazard

signals might appear. We’ve designed the eZeebike to repel water

as much as possible, encapsulating circuit boards with silicone

resins and connections with silicone grease.

Since this manual simply cannot cover every detail that

might occur during the lifetime of your product. Check our websites

and dealers website routinely for updates, or contact us directly for