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How to Assemble Your Sondors Electric Bike

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Download print edition here: https://drive.google.com/file/d/0B8KayVCg4zE4dGQyTWJTYk4wSkE/view?usp=sharing

 

Congratulations on your Sondors electric bike purchase and thanks very much for helping bring this exciting eBike to the market.

PLEASE NOTE:
If you are not familiar with assembling bicycles then it is STRONGLY recommended that you take your Sondors electric bike to a local bike shop. Most shops will be able to assemble and make any necessary adjustments for your new bike for a small fee. That said, if you are familiar with bike assembly, please refer to the below as a preliminary guideline for the Sondors electric bike.

NEEDED FOR ASSEMBLY: (but not included with your bike):

  • Extra Hand: Ideally 2 people are needed to help lift the bike out of carton and an extra hand can be useful to help secure the position of the bike for some assemblies – especially if you don’t have a bike mechanics stand/ or work station.
  • 15mm open end wrench – Used to tighten the wheel nuts and attach the pedals to the cranks.
  • Phillips Screw Driver (for attaching the reflectors to the bike wheels and the F/R reflectors on the Handle Bar and Seat Posts
  • Optional: Wire/cable cutter to trim the front Brake cable shorter at the disc brake caliper arm lever)

INCLUDED TOOLS:

  • Set of 5 Allen Wrenches (6mm, 5mm, 4mm, 3mm, 2.5mm.
    A T25 Torx wrench (used for the screws that attach the disc brake to the wheel hubs).

CARTON OPENING AND UNPACKING:

  • With the carton in the upright position (as shown indicated by the up arrows) open the top of the box carefully avoiding the staples as they can be sharp.
  • With the box flaps pulled back remove the Seat/Seat post assembly and the cardboard accessory box containing the Allen wrench set and the accessory items.
  • Open and unpack the smaller cardboard Accessory box – Removing the pedals, battery charger, bag of fasteners, reflectors and Allen wrenches.
  • With the help of another person, team lift the bike out of the box and position it where the packaging materials on the bike frame and fork can be removed.
  • Carefully clip the 2 white zip tie connectors to release the larger cardboard box from the front wheel. This larger cardboard box contains the bikes battery. At this point please refer to the charging directions in the below for the process to start the initial conditioning charge for the battery so that it can be charging while the remainder of the bike is being assembled.

Accessory Box Contents:

Here is the full step-by-step video with individual videos linked below each of their sections below:

BATTERY CHARGING PROCESS:

  • BATTERY: Inside the larger rectangular cardboard box is the bike’s Lithium Ion battery. It is shipped in a protective bubble sleeve. Remove the battery from the sleeve and confirm the power switch on the black base of the battery is in the “OFF” position.
  • IMPORTANT: The battery’s power switch should always be in the “OFF” position when the battery is being charged. It should be left in the “OFF” position when it is not being used for powering the bike. Never keep the battery power switch in the “ON” position when it is not being used to power the bike. The Battery is designed to be used only with the Sondors E-Bike and charging system.

BATTERY CHARGER - IMPORTANT: Read the operating instruction that were shipped with the charging unit. Charger unit is intended for indoor use only.

  • Within the smaller cardboard Accessory box (removed with the seat when the carton was opened) is the Battery Charger Transformer and power cord and instructional sheet. Remove them from the box and review the Operating instructions included with it.

  • IMPORTANT: Insure the Battery’s power switch (rocker switch) at the base of the battery is in the “OFF” position for every charging cycle and that it remains “OFF” during the charging stage. The battery is never to be connected to the charging transformer with the power switch in the “ON” position as damage can occur.

  • Connect the outlet power cord to the black rectangular battery transformer, matching the power cord end (opposite the wall outlet end) to the same shaped socket on the rectangular transformer.

  • Connect the cylindrical end of the other cable on the transformer to the charging port on the base of the battery (opposite the rocker switch on the battery). To do this you will need to lift the rubber flap on the side of the battery’s base charging port. Always keep this flap covering the charging port when it is not being charged.

  • After reconfirming the battery is in the “OFF” position you can put the charging plug into a grounded house hold outlet (100 to 240 VAC). It is advised to use a surge protector to plug into as an extra precaution.

  • When initially plugged in the LED on the transformer will momentarily be Green. If the battery is not fully charged it will switch to Red color while the battery is being charged. The battery is fully charged when the Red LED changes back to the Green LED. It is important to fully charge the battery prior to use.

  • When the battery is fully charged and the LED shows a constant Green color you may remove the transformer cord from the charging port on the battery base.
    Do not store your fully charged battery connected to the plugged-in charger as this can damage your battery.

 

 

 

HANDLE BAR ATTACHMENT:

Clip the zip ties that hold the front wheel and the handle bar assembly to the fork and frame. Remove the protective cardboard tubing, plastic wrapping and foam sheeting from the bike and handle bar assembly.

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IMPORTANT – FORK POSITION:

  • Prior to attaching the handle bars you need to position the fork and stem in the correct position. The fork has a slight angle away from the bike and the front brake is on the left side of the fork as seen by the bike operator when it is in the correct position.

  • If it looks like the fork is angled back towards the rear of the bike and the front brake is on the bike operators right side, then the fork needs to be rotated 180 degrees so the fork is angle away from the rear of the bike and the front brake caliper unit is on the Left side when you are riding the bike.

IMPORTANT – STEM POSITION:

  • With the included Allen wrenches loosen the 3 Allen screws that hold the stem to the top of the fork.

  • Position the stem with the face plate forward toward the front of the bike.

  • Tighten the Stem on the top tube of the fork. There is a 5mm screw on the circular cap on the top of the stem. loosen this cap and the 2 Allen screws on the side of the handle bar stem shaft.

IMPORTANT: HANDLEBAR POSITION:

  • Using the 4mm wrench remove all 4 forward facing screws and the face plate from the stem.

  • Center the handle bars (L/R) on the stem and rotate the bar into a position where the brake angle seems comfortable to you.

  • Reattach the stem face plate using the 4mm allen screws.
    IMPORTANT: The thumb throttle will be on the bike riders Right side and the front disc brake will be on the bike riders left side of the fork when both Fork and Stem/Bars are in the correct position.

  • Tighten the grips and the brake lever units using the Allen Keys. The allen bolts for brake lever units and the handle grips on the on the under side of handle bar.

Tighten the Thumb Throttle Allen screw also.

ALIGNMENT OF HANDLE BARS / STEM and FRONT WHEEL:

  • Loosen the yellow circular Stem Cap with the 5mm Allen wrench.

  • Loosen the 2 screws on the sides of the stem.

  • Standing with your legs straddling the front wheel and looking towards the handle bars align the handle bars and stem with the front wheel.

  • Once wheel/stem/bar alignment is achieved, tighten the top stem cap (5mm) and the 2 side 4mm Allen Screws found on the stem post to secure it on the upper tube of the fork.

FRONT WHEEL ATTACHMENT:

  • IMPORTANT: A 15mm open ended wrench is needed to tighten the wheel nuts.

  • Rotate the front axle nuts until they are approx half way off the threaded axle. This will allow for any easier attachment to the front fork.

  • Carefully place the front wheel in the front fork drop out slots so the wheels’ brake disc aligns with disc brake unit. The break unit is on the left side of the bike rider when it is in the correct position.

  • Alternate tightening the Left side and Right side nuts onto the fork tabs so as to keep the wheel centered on the fork and the wheels disc aligned in the brake calipers.

  • Finish tightening the wheel nuts using the 15mm wrench.

FRONT BRAKE ATTACHMENT:

  • Loosen the 5mm nut on the cable stop at the front brake activation arm. Push about an inch of slack upward the Bike riders Left lever.

  • Pull back the lever allowing the ferrel basket to swing out.

  • Using the created slack from loosing the cable clamp, take the end of the cable with the cylindrical ferrel and place the ferrel in the basket on the brake lever and swing the basket into the brake lever housing while pulling the cable through the slot in the front of the lever housing.

  • Then tuck the cable along the front slot in the Brake Levers and place the end of the cable jacket into the silver tube at the edge of the brake cable.

  • Rotate the silver collar on the slotted tube to lock the cable into place.

  • On the front brake caliper, pull the created slack out of cable and tighten it down with the 5mm Allen wrench to secure the brake cable on the brake actuator arm.

  • Please refer to the manufactures web site for details on the proper adjustment of the TekTro disc Brake systems.

 

CABLE MANAGEMENT - IMPORTANT: The throttle controller is designed to cut the power to the motor if the brake is applied. It is critical to keep the cables in their proper place and away from the brake levers to insure the proper function of the bike.

  • Use the small black plastic clips on the cables to secure the cables in place to insure the cables are not causing the throttle controller to stop the power flow to the motor.

  • Refer to the video update for clip positions.

Cable Management for Front Handlebars

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PEDAL ATTACHMENT:

  • IMPORTANT: You will need a 15mm wrench (not included) to tighten the pedals onto the crank arms.

  • IMPORTANT: The pedals are marked on the threaded end with “L” and “R”.

  • The pedal marked with an “R” on the threaded end is to be attached to the bike riders Right pedal crank arm. “L” is marked on the end of the riders left pedal. Please note it is easier to thread the pedal onto the crank when it is in the higher position.

  • The Right pedal will be rotated clockwise to tighten onto the crank arms and the Left pedal gets rotated counterclockwise onto the crank to attach and tighten.

  • Tighten both pedals with the 15mm open ended wrench.

 

 

SEAT (Assembly) ATTACHMENT: (Watch video for red reflector attachment directions)

  • Remove the cardboard and packing materials the seat.

  • Open the yellow anodized lever slide the seat post into the seat tube.

  • Position seat for the riders comfort and rotate the seat so it is centered over the frame.

  • Tighten the seat clamp back down by moving the lever back to the closed position. The knurled nob on the side opposite the lever may need to be rotated clockwise a small amount to insure the clamp is tight on the seat post.

 

BATTERY INSTALLATION:

  • On the Left side of the bike, open the battery door by locating the latching toggle bolt on the upper right hand corner of the house. Rotate the toggle counter clockwise to loosen it and open the battery box door.

  • IMPORTANT: Battery Holder Keys.- the keys zipped tied to the silver throttle controller in the battery box are needed to attach and release the battery from the battery holder on the bike. Do not loose these. Carefully clip the plastic zip tie and place a key in the left side upper slot of the battery holder.

  • With the Battery’s power switch in the “OFF” position, align base of the charged battery into the battery holder and pivot it down and into the holder into the holder until it rests with the top of the battery just off the holder. This is a snug fit but it is easier with each additional effort.

  • Rotate the key at the top of the holder while pressing down on the battery to lock the battery into position on the bike.

 

Battery Charged on the Bike – closed battery box door:

  • The battery can be charged on the bike.
  • Remove the circular caps on both sides of the battery box
  • Bike throttle at handle bars should be powered off.
  • Confirm the battery’s power switch on the battery base is in the “OFF” position (rocked towards the rear of the bike).
  • Flip small rubber flap off the charging port.
  • Connect outlet power cord to the battery charging transformer.
  • Connect the battery charging cylindrical end cable end to the charging port on the battery base.
  • Connect the power cord to grounded household outlet. Ideally the transformer will be plugged into a surge protected outlet or surge protected power strip.
  • LED on transformer will momentarily show green then switch to Red until the battery is fully charged.
    When light shows steady green on the battery transformer the battery is fully charged and ready for your next ride.
  • Remove charger cable from battery base and store charger unit according to the instructions shipped with the battery.

 

Battery Charged on the Bike – Battery box door left open.

  • Same process as charging through the left side circular cap opening but with the battery door open instead of just the small cap.
  • Throttle on handle bars must be powered “OFF”
  • Battery must be placed in “OFF” position. Confirm by feeling through the riders right side circular opening that the switch is rocked back towards the rear tire.

 

Powering Up of E-Bike:

  • The bike is powered up by removing the circular rubber cap near the bottom of the riders Right hand side.
  • Turn on the battery by rocking the battery power switch to the forward “ON” position. Replace the cap onto the battery box.
  • Turn on the throttle controller on the right side of the handle bars by pressing the grey switch to the throttle once. With a fully charged battery attached installed all 3 of the LED’s will illuminate on the throttle control when it is powered on.

 

Powering Down of E-Bike:

  • The bike is powered down by reversing the ‘power up’ steps.
  • Thumb Throttle on right side of handle bars is shut off by pressing the grey button once. The LED lights on the throttle unit will shut off.
    Battery is powered down by moving the rocker switch on the battery base to “OFF” position.
  • Do not store you E-Bike in the “ON” position.

 

Attachment of Reflector accessories to the Bike:

Please refer to the video for reflector assembly details. 

 

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