Dillenger Hunter BBS 2015, User Manual

Page 1: ...his manual describes how to safely complete final assembly and includes tips for use and maintenance English Dillenger Hunter BBS 2016 Dillenger Hunter Hub Drive Dillenger Hunter BBS 2015 This manual covers the assembly of ...

Page 2: ...pick an area away from cars other cyclists obstacles or other hazards to become familiar with the controls features and performance of your new electric bike We highly recommend the purchase of the Dillenger electric bike repair toolkit It will make your setup and ongoing maintenance much easier This can be purchased online Thank you for purchasing your new Dillenger electric bike We know you ll l...

Page 3: ...every function and adjustment on the bike is perfect Item Check list Electric bike with front wheel and handlebars Charger box this may container other important parts Pedals left and right please note the left and right pedals are not identical Any loose boxes may container other parts such as a light if where a light is provided or purchase so please check all packaging thoroughly BBS shield and...

Page 4: ...UMMARY OF FINAL SETUP 5 UNBOXING 6 MAIN PARTS 7 ASSEMBLY 10 FRONT WHEEL 10 HANDLEBARS 14 PEDALS 17 SEAT 18 BBS SHIELD INSTALLATION 19 BATTERY OPERATION 24 LCD OPERATION 26 IMPORTANT POINTS 27 CHARGING 28 MAINTENANCE 29 TROUBLE SHOOTING 30 CONTACT US 33 ...

Page 5: ...al setup Your bike may arrive in a more assembled state than what is shown here These are the steps required for most customers packaging and final assembly can vary by country In summary these are the main steps Step 1 Unpacking Unboxing Step 2 Identify the pieces that require final assembly Step 3 Front wheel fastening Step 4 Handlebar alignment Step 5 Left and right side pedals Step 6 Seat Step...

Page 6: ...It s also much easier to unbox the bike with someone to help you Remove the protective packaging from the bike carefully with a pair of scissors or a box cutter Make sure you don t misplace any components in the lose packaging there can be quite a lot of protective packaging used A stand is shown in this photo for staging purposes only it is not included with the bike UNBOXING ...

Page 7: ...7 MAIN PARTS After you ve taken your Dillenger out of it s shipping carton you should have these parts 1 The complete bike 2 Front wheel ...

Page 8: ...8 3 handlebars attached by the wiring 4 Charger ...

Page 9: ... fastened to the bike separately 6 BBS Shield and Fixings Please note your keys will be securely fastened to the frame or handlebars of your bike Make sure you do not lose these as they are coded and a replacement set can only be fitted in a Dillenger factory ...

Page 10: ...stened Prior to assembling the front wheel we suggest removing the front brake caliper It s not essential but it does make it a lot easier Once you ve removed the caliper from the front fork you can insert the wheel into the forks as shown below It can be quite a tight fit this is intentional You will have to maneuver wheel and forks where needed so you can line up the through axle with the center...

Page 11: ...11 This stage shows the through axle almost in position Once in place tighten the through axle with the specialized nut provided ...

Page 12: ...12 Secure the through axle in place by tightening the 4 bolts that were loosened to remove the through axle ...

Page 13: ...move the packing shim spacer from the caliper and re attached as shown If you tighten the caliper almost 100 then engage the front brake lever this will align the caliper and then you can tighten completely ...

Page 14: ... rings on the head tube leaving 2 These 2 can be placed in any arrangement In these photos we have the handlebars in the highest position with 2 spacers under the stem Make sure none of the cables are twisted or too tight you may have the handlebars twisted Tighten as shown here making sure the handlebars are aligned to the front wheel This step fastens the stem down onto the headtube to remove an...

Page 15: ...15 Stem and handlebars are now in position on the headtube ...

Page 16: ...16 Fasten the stem onto the headtube Tighten each side evenly This is the final step in fastening the handlebars correctly ...

Page 17: ...to the right side crank if you were sitting on the bike and left side pedal on the left crank The right side pedal is a right hand thread it will tighten by turning clockwise normal The left side pedal is a left hand thread and will tighten by turning anticlockwise opposite normal It is essential not to confuse which pedal is used where and not to cross thread the pedal If it feels too tight you m...

Page 18: ...18 SEAT This is the easy part Simply insert your seat to the desired height about hip height as shown ...

Page 19: ...his step First you must remove the bolt from the BBS motor as shown in the photos below The next step is to place all the washers spacers and the mounting plate on the main bolt in the correct order The order is two big washers first then the plastic spacer another big washer the mounting plate a small washer and finally the nut This is shown in the photos below This order is not 100 necessary but...

Page 20: ... mount to your bike easily Make sure the nut is tightened at the end of the cutout of the mounting plate and that the angled part of the mounting plate is facing up The correct position of the mounting plate is shown in the first photo below You must also ensure that the mounting assembly is tightened at the bottom of the cutout in the BBS shield This is shown in the second photo below 20 ...

Page 21: ...olt into the angled part of the mounting plate as shown in the second photo below Two more washers should now be added to the bolt as shown in the third photo below Now you should insert the skinniest bolt shown in photo 4 Place the skinny bolt in the BBS shield and the put the washer followed b the long space onto the bolt 21 ...

Page 22: ...t set in place Before tightening this bolt move any cables out of the way so that the middle of the three bolt holes are clear This is shown below in the second photo You should now tighten the bolt from the mounting plate into the frame photo 3 and tighten the skinny bolt to secure the shield to the motor Ensure that all of the spacers and washers stay in the correct order as shown on the previou...

Page 23: ...That completes the BBS shield installation Your Hunter is now ready to ride BBS SHIELD INSTALLATION CONTINUED 23 ...

Page 24: ...4 BATTERY OPERATION The battery for your Dillenger is the most expensive single component and the most crucial The battery can be removed following these steps Use the key provided to unlock the battery ...

Page 25: ...shion that it was removed The base of the battery should be inserted first It should be firmly against the bottom of the cavity Then rotate the top of the battery into the battery cavity It is a tight fit and this may take a couple of attempts to become proficient It is very important that the battery is locked into place before you use the bike again Pull gently on the battery handle to make sure...

Page 26: ...26 LCD OPERATION We have an LCD manual on the product page online or follow this link Dillenger C955 manual click here to download ...

Page 27: ...ike flat Just make sure you charge the bike after every ride 3 Make sure you routinely check the tightness of key fasteners nuts and bolts such as the front wheel rear wheel seat handlebars forks pedals brakes etc 4 Make sure you keep the battery topped up as often as practical Charge the bike after every use at least once a month if not being used and before each ride if you have not charged it i...

Page 28: ... Once one of the charger indicator lights changes from green to red the battery is fully charged There is no way to over charge the battery When it is full the charger will stop charging the battery automatically Charging time can vary from 1 to 5 hours if fully empty The battery should be charged once every month as a minimum to maintain healthy cells The best way to charge your battery is to plu...

Page 29: ...ed over and above a normal bicycle One of the main things you may come across is that your spokes need to be tightened more often than a non electric wheel Our wheels use 12G and 13G spokes which handle the load and torque of these motors very well but are more susceptible to coming loose A spoke tightening tool such as the one including in the Dillenger hub motor conversion toolkit is ideal Check...

Page 30: ...s however there are some really good youtube tutorials on how to adjust spoke tension Spokes has snapped or missing Dillenger stocks spare spokes for very reasonable prices just check out our spares section online and you can find the right type and length for your product Display won t turn on unless the battery charger is plugged in Check all the connections make sure the battery is charged If t...

Page 31: ...f you have overloaded the controller or dropped the voltage below the low voltage cut off which is more prevalent at low power This isn t a fault with the kit it s just physics I would like my battery capacity tested Please contact Dillenger by submitting a support ticket to arrange the return of your battery for testing If the battery tests above 85 capacity within the first year from purchase da...

Page 32: ...g on pedal assist even after the last battery indicator bar starts blinking 3 Hills riding style other factors a The ranges quoted are from real world testing with some hills and some flat areas If your commute involves a lot of hills that s going to impact on the range High powered e bikes are especially susceptible to being drained a lot more on hills If you need to purchase a second charger to ...

Page 33: ...33 CONTACT US Dillenger Head Office 3 13 Olympic Circuit Southport QLD 4215 AUSTRALIA Tel 617 5532 9235 dillenger zendesk com www dillengerelectricbikes com Dillenger 2016 ...