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RAYVOLT BIKES WORKSHOP MANUAL


CRUZER

 

INDEX

WELCOME                                                                                                                                 3

BEFORE EACH USE                                                                                                                 4

CLEANING AND CARE                                                                                                             5

STORAGE:                                                                                                                                 6

MAINTENANCE AND INSPECTION:                                                                                        7

GENERAL MAINTENANCE                                                                                                 7

BIKE SCHEME                                                                                                                7

INSPECTION INTERVALS TABLE                                                                                8

SADDLE ADJUSTMENT                                                                                                9

HANDLEBAR ADJUSTMENT                                                                                         9

PEDAL ASSEMBLY                                                                                                      11

BELL ASSEMBLY                                                                                                         11

BRAKING SYSTEM                                                                                                      12

CHANGE BRAKE PADS                                                                                        12

BLEED BRAKE FLUID                                                                                            13

CHAIN                                                                                                                           15

LUBRICATE THE CHAIN                                                                                       15

CHAIN TENSION                                                                                                    15

COVERS AND WHEELS                                                                                              16

CHANGE REAR WHEEL                                                                                        16

REAR RACK ASSEMBLY                                                                                            18

LIGHTS KIT ASSEMBLY                                                                                                    19

ELECTRICAL MAINTENANCE                                                                                          21

CONNECTIONS DIAGRAM                                                                                         21

COMPONENT DESCRIPTION                                                                                     22

TROUBLESHOOTING DESCRIPTION                                                                        26

SCENARIO 1: THROTTLE BATTERY LEVEL LIGHTS ON BUT NO BLUETOOTH CONNECTION AND NO THROTTLE OR PAS ASSIST.                                                                26

SCENARIO 2: BLUETOOTH WORKING AND PAS or THROTTLE NOT WORKING  27

SCENARIO 3: SUDDEN SHUTDOWN WHEN BRAKING                                    28

SCENARIO 4: SUDDEN ENGINE START                                                             28

SCENARIO 5: ENGINE OVERHEATED                                                                28

SCENARIO 6: KILOMETERS COUNTER AND SPEEDOMETER MALFUNCTION     28

SCENARIO 7: OVER/UNDER VOLTAGE                                                              29

SCENARIO 8: THROTTLE FAULT                                                                        29

SCENARIO 9: RBS STALL                                                                                     29

SCENARIO 8: PEDAL TURNS ON ITS OWN                                                       30

SCENARIO 9: BLUETOOTH WORK BUT NO SIGNAL IS RECEIVED.               30

WELCOME

This manual contains important instructions regarding the safety of your RayVolt bike. Read it carefully before you start riding it and follow the setup procedures one by one. After this, you will configure your electric bike correctly and can use it as a safe way.

For your own safety and so that you always enjoy your bike, we recommend that you read the entire manual carefully. If after reading this guide you have any further questions, please consult your local dealer or visit our website https://www.rayvoltbike.com/support/. You can also send your questions to the following email support@rayvoltbike.com .

A series of maintenance and repair work is described in detail on the digital data carrier accompanying this manual. When carrying out this work, always keep in mind that the instructions and indications only refer to this RayVolt bicycle and cannot be applied to other models. Due to the large number of versions, it is possible that the works described are not complete or not exactly the same. If this is your case, please contact support.

Bear in mind that the indications and advice given may be insufficient due to the lack of manual skill of the person doing the work or lack of the necessary tools.

This manual will not provide you with the knowledge of a bicycle mechanic or electrician. For this reason, this manual refers to the bicycle you have just purchased and the usual components, and includes the most important indications and warnings. It focuses exclusively on the bicycle you have just purchased and the most important indications and warnings and cannot teach you how to ride a bicycle or teach you the rules of the road.

When cycling, always keep in mind that it is a potentially dangerous activity and that the rider should always maintain control over it.

Never use the bicycle if you are under the influence of medicines, drugs, alcohol or if you are tired.

Always drive in a way that doesn’t endanger your own life or that of others and respect nature when driving through forests and meadows. Always wear the right gear for cycling. Find out about the regulations in force for riding on public roads in the country where you will use your bicycle. So always drive carefully and respect other road users.

BEFORE EACH USE

To improve the experience of our trip, it is essential to review the care of our bicycle and have it in the best conditions. Ride your bike only if it has passed all these tests perfectly and return home with extreme precautions. Avoid sudden acceleration and braking.

If you are in doubt about the operation of your Rayvolt Bike, it is best that you haven’t started riding and it is essential that you carefully examine the bicycle and repair or replace faulty components.

1. Maximum total weight. The recommended total weight for Rayvolt bikes should not exceed 120 kg (driver and luggage included).

2. Check the condition of the tires. Check that these aren’t in bad condition, scratched or worn and that they have enough pressure. Higher pressure provides better ride stability and increases puncture safety. The minimum and maximum pressure values (bar/psi) are indicated on the sidewalls of the tires.

3. With the bike completely stopped, pull firmly on the brake levers. Check that a pressure point is generated and that the levers don’t reach the handlebar. In the case of hydraulic brakes, there should be no oil leakage.

4. In the case of using your bicycle on public roads or at night, you must inspect the lighting system. Check that the lights are correctly connected and when pressing the throttle button they turn on with their normal intensity.

5. Check the condition of the bearings and threaded connections. Bounce your Rayvolt bike close to the ground and try to identify the source of any noise.

6. Verify that the wheels are still positioned correctly and that the tires remain centered on the frame and fork.

7. Make sure chain is still in grenade on chainrings and sprockets.

8. Check the position of the saddle.

9. Finally finish by giving a general review of your Rayvolt Bike to confirm that everything is correct.however

As an extra point, it should be noted that bicycles are vehicles that adapt to each driver, so some time after being used it is advisable to carry out a general inspection and adjust the tension of parts such as spokes or screws.

CLEANING AND CARE

Dirt, impurities, minerals and many other factors can damage the condition of your bike, so taking good care of it will help us maximize its life. Therefore, it is essential to properly clean all components and protect them against corrosion.

Rayvolt Bike is an electric bike and as we all know electricity and water are not good friends. Water conducts electricity and in the event of any type of leak it can cause a short circuit, damaging part or the entire system, so if we want to wash our bicycle it is advisable to do it carefully and watch out for contact with water. RayVolt bikes are protected, but it is recommended to wash them with non-conductive distilled water or to insulate electrical components.

The so-called quick cleaning has serious drawbacks: the high pressure water jet can pass through the seals and penetrate the bearings. Water tends to dilute the lubricant, increasing friction and corrosion. More suitable and highly recommended is to wash the bike with a hose or bucket of water and a large sponge or brush. Hand washing allows us to detect paint deterioration, worn parts or other defects in time, improving the care of our RayVolt bicycle.

Once we have washed our bike, we wait for it to dry and, in order to protect the paint, metal surfaces, spokes, hubs, etc., we apply a layer of hard wax, never on the brake discs, and polish the waxed surfaces with a soft cloth so that they shine and don’t make direct contact with water.

Finally, it remains to grease the chain if this is necessary. Check the condition of the chain, in the case of having too much friction it should be greased.

 

STORAGE:

We will not always be riding our Rayvolt bicycle, so we have to know how to store it in order to keep it in the best of states. If your bicycle receives regular care, a short-term stop doesn’t require any special preventive measures, except for anti-theft protection.

It is recommended to store your bike in a dry and well ventilated area. Remove the saddle and allow any moisture it may contain to dry. It is recommended to apply a little oil and distribute it inside the seat tube.

Clean your bicycle as described in the “Cleaning and care” section.

Charge the battery before storage and every 3 months minimum.

Finally, it is recommended to regularly check the pressure of the wheels, hang them or hang the entire bicycle. The tubes required to lose air when they aren’t used for a long time, if your bicycle is supported on flat tires it can end up damaging its structure.

 

MAINTENANCE AND INSPECTION:

GENERAL MAINTENANCE

BIKE SCHEME


 

INSPECTION INTERVALS TABLE

ComponentInspectionInterval
TiresCheck pressureBefore each use
Check drawing and side conditionMonthly
LightsCheck statusBefore each use
ChainCorrectly lubricatedBefore each use
Brakes Pads thicknessMonthly
Wiring / PipesMonthly
Bottom bracketCheck bearings clearanceMonthly
Re-greaseAnnual
DirectionCheck bearings clearanceMonthly
Re-greaseAnnual
BushingsCheck bearings clearanceMonthly
Re-greaseAnnual
Connecting rod Re-tightAnnual
Wheels and spokesCheck centering and tension.Monthly
PedalsCheck bearings clearanceMonthly
Metal surfaces  Check condition and waxingAt most every half year
PaintingCheck statusAt most every half year
Nuts and boltsCheck tensionMonthly
ValvesCheck locationBefore each use
Stem / seatpostDisassemble and re-greaseAnnual
PiezaInspecciónIntervalo
HandlebarReviewEvery 2 years maximum
 ChangeAfter a fall or 3 years.
CablingReviewAnnual

SADDLE ADJUSTMENT

Tools needed: M14 Wrench.

The position of the saddle is determined by pedaling. A correct adjustment will allow us to have a more comfortable ride and avoid injuries.

To correct the inclination of this you will find a nut under the saddle that will allow you to adjust it to your comfort.

HANDLEBAR ADJUSTMENT

Tools needed: M6, M4, M2 ALLEN.

On your Rayvolt Bike the ends of the handlebars are curved. Adjust the handlebars so that your wrists are relaxed and not too far out.

If you need to adjust the position of the handlebar:

You will find 4 hex bolts attaching your handlebar. Use an M6 allen key to loosen them. Once loosened, position the handlebar to your liking and retighten the bolts.

It is recommended to tighten screws diagonally first.

If you need to adjust the position of the brake handles:

You will find 2 hex bolts securing each brake handle to the handlebar. Use an M3 allen key to loosen them. Once loosened, position the brake handles to your liking and retighten the bolts.

It is recommended to adjust the position of the hand allowing a comfortable brake application while driving.

If you need to adjust the throttle position:

You will find a hex bolt attaching the throttle to the handlebar. Use an M2 allen key to loosen it. Once loosened, position it to your liking and retighten the screw.

It is recommended to adjust the position of the seated accelerator, simulating the action to be carried out.

PEDAL ASSEMBLY

Visual support:

1. Pick the appropriate pedal on each side. Note that the right pedal is labeled “R” and the left pedal is labeled “L”.

2. Put it in place and lock by turning the crankset. Turn it counterclockwise.

BELL ASSEMBLY

Tools needed: Flat blade screwdriver

1. Take the bell and unscrew the bolts with a flat-head screwdriver. Remove the bottom for better placement on the handlebar.

2. Place the bell on the handlebar. Place it in such a way that it is comfortable to use. We recommend that you do it sitting on the bike and simulating its use.

3. Tight the bolts again. Place the bottom part and fix the bell in the desired position.

 

BRAKING SYSTEM

The brakes help us to adapt the speed of travel to the traffic conditions and, in an emergency, they must be able to stop your bicycle as quickly as possible. The intensity of the deceleration is limited by the possible overturning of the bicycle and only secondly by the grip of the wheels. Therefore, when braking, the user must shift their weight backwards.

The left lever operates the front brake and the right lever the rear brake.

In disc brakes, used on the Rayvolt Bike, constant braking or continuous friction from the pads causes the brake system to overheat and wear the pads. Below, we can find a short guide to changing the pads and bleeding the brake fluid.

CHANGE BRAKE PADS

Tools needed: Cotton stick, brake piston grease, pad strainer or a large flat screwdriver.

Visual support:

https://www.dropbox.com/s/6wcl9b0ycfjix7x/PAD_CHANGE.mp4?dl=0

Instructions:

1. Remove the wheel: The first step is to separate the wheel from the brake of interest. For more information, consult the section “Covers and wheels”.

2. Clean pistons: We go to the brake lever and, ensuring that the pistons come out a short distance, we apply the brake a couple of times carefully. When we press the brake, we maintain the pressure and with the help of a cotton stick we clean the tracks.

3. Caliper preparation: In this section, pistons should be lubricated with a little special grease for brake pistons. Then we will use the pad setter or a large enough flat screwdriver to be able to put the pistons back in place.

With a paper, all the excess fat inside the caliper must be cleaned so that it does not contaminate the new pads.

4. New pads: We put the new pads and put them in the same place where they were. Look at which pads go which side.

We will put the pin that secures them and we will tighten it without using much force.

5. The wheel in place: We place the wheel on the fork ensuring that the caliper is centered and in its correct position.

6. Adjustment: To check if we have done a good job, a little light should enter each side of the disc.

To check it, turn the wheel and listen for friction. If we are lucky, there will be no noise when we spin the wheel; if there is, we must look for the micro-adjustment.

 

BLEED BRAKE FLUID

Tools needed: Mineral oil bleed kit.

Visual support:

https://www.dropbox.com/s/1o7ulgxv9d4fffn/break_bleeding_video.mp4?dl=0

1. (Recommended) Remove the wheel and brake pads: See “Covers and wheels” and the previous section. To prevent oil from contaminating surfaces such as discs or pads.

2. (Recommended) Separator: With the pads out of the caliper, we place the separator so that the pistons do not come out of their place. In the opposite case, we can unintentionally extract the piston and thus spill all the oil inside the circuit.

3. Remove the oil tank cap: With the torx wrench included in the kit and the rest of the bleed kit in hand. Loosen the thread of the oil tank cap located on the lever and in its place we are going to place a tank glass that comes with the kit.

4. Deposit in the caliper brake: Loosen the cap located on the clamp and put the container tank in its place.

5. Bleed with mineral oil: Fill the tank with mineral oil and squeeze the brake until you feel pressure on the lever.

6. Remove the container: We remove the tank located in the caliper brake and screw the cap back on.

7. Expel air: In order to remove possible air bubbles inside the circuit, we operate the brake lever until they are completely expelled. Then, using the syringe, we remove the remaining mineral oil.

8. Everything in its place: We remove the empty glass. We place the cap and screw it on. Once this is done, we have to feel pressure on the brake lever, confirming the correct execution of the bleeding process.