Gocycle G2 Owner's Manual

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Version August 2015

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Page 1 Owner’s Manual ® for Gocycle Version August 2015 www.gocycle.com...
Page 2: Table Of Contents
Pre-ride Checks and Service Interval ....................11 Warning! Take Care during Assembly ..................... 12 Handlebar Height and Reach Adjustment ..................13 Assembling the G2 Seatpost Tool Holder ..................18 Assembling the Front and Rear Reflectors ..................21 Assembling the Bell ..........................25 Gocycle Quick-Fit Accessories ......................
Page 3 Understanding Electronic Gear Shifting ..................37 Riding Modes ............................38 Energy Consumption Meter ......................44 Maximising Your Gocycle’s Motor Performance and Reliability ..........44 Heat and Over-Temperature Protection ..................46 Maintenance and Adjustments ....................... 47 Maintenance and Service Centre Location ..................47 Service interval ............................
Page 4: Disclaimer, Copyrights And Trademarks
Gocycle-to-Work™, EmpowerPack™, Vgonomic™ Adjustment, Lockshock™, Shocklock™ and Performance Commuting™ are trademarks of Karbon Kinetics Limited. All trademarks and the Gocycle logo may not be used without the prior written approval of Karbon Kinetics Limited, a United Kingdom Registered Company Number 4357956.
Page 5: Standards And Conformity
® Gocycle Owner’s Manual for G2R, August 2015 1.5 Standards and Conformity Gocycle is an electric power assisted cycle developed in accordance with: 2006/42/EC The Machinery Directive 2004/108/EC The Electromagnetic Compatibility Directive and is in conformity with the applicable requirements of the following documents:...
Page 6: Safety
Such risks are increased in busy, urban environments with moving traffic. By choosing to ride a Gocycle, you assume the responsibility for these risks, and it is important that you know how to ride responsibly and to exercise proper maintenance to minimise such risks and potential damage.
Page 7: Maximum Design Limit
Gocycle to a complete stop. Do not release the brakes until it is safe to do so.
Page 8: Riding In Wet, Cold Or Icy Conditions
See Section 7.4 Checking for Cracking and Fatigue Failures for parts of the Gocycle that require visual inspection from time to time. An impact to your Gocycle, either major or minor, can cause stress and fatigue on the Gocycle and its components or compromise the integrity of the electronics, including the battery, electronic controller, motor drive system or wiring.
Page 9: First Ride
WARNING! First familiarise yourself with the modes of operation, controls and performance of your Gocycle before venturing onto busy streets. We strongly recommend that you familiarise yourself with your new Gocycle by first riding it in a controlled environment, away from potential hazards such as moving traffic and obstacles. It is important to become familiar with the modes of operation, controls, brakes and the different performance characteristics inherent in the electric motor.
Page 10: Warranty
3.1 Warranty Registration For your continued satisfaction and safety whilst riding your Gocycle, we strongly encourage you to register your Gocycle with us. Doing so will enable us to contact you with important product safety- related information, should the need arise.
Page 13 Owner’s Manual for G2R, August 2015 IMPORTANT ASSEMBLY ADVICE! Continue reading for important assembly advice, including how to register your Gocycle. Unless you register your Gocycle, after 60 miles (100 km), your Gocycle motor will cease to operate. See Section 4.8 Gocycle Registration.
Page 14: Pre-Ride Checks And Service Interval
Owner’s Manual for G2R, August 2015 Pre-ride Checks and Service Interval Before riding your Gocycle you must complete the pre-ride checks. This will ensure your safety and that your Gocycle is operating optimally. © Karbon Kinetics Limited. All Rights Reserved.
Page 15: Warning! Take Care During Assembly
During assembly or disassembly, do not over-fold the Cleandrive more than is necessary to engage or disengage the Gocycle Lockshock™. Over-folding the Cleandrive can cause the internal cables to become taut and in some cases may result in cables becoming disconnected, ultimately affecting the operation of the product.
Page 16: Handlebar Height And Reach Adjustment
In addition to Gocycle’s patented Vgonomic adjustment (changing the effective cross-bar length when lowering or heightening the saddle), it is also possible to make further adjustments to accommodate most riders comfortably by changing the handlebar height and reach.
Page 17 ® Gocycle Owner’s Manual for G2R, August 2015 Completely remove the quick release. A. Top position The handlebar stem adjuster has two positions: Use the top position for aft adjustment. (Shorter rider: least reach, handlebars B. Lower closest to saddle).
Page 18 ® Gocycle Owner’s Manual for G2R, August 2015 With the quick release inserted, rotate clockwise to tighten Close the quick release lever. The lever should feel harder to close at it reaches a 90- degree position. 4.3.2 Handlebar Height Adjustment Undo and remove the handlebar stem bolt using a Torx tool, as shown.
Page 19 ® Gocycle Owner’s Manual for G2R, August 2015 A. Lower Lift the rubber dust cover to expose the position lower position. Note! Hole “B. Upper position” denotes the maximum height of the handlebar stem. B. Upper position Push down to align the lower position A.
Page 20 ® Gocycle Owner’s Manual for G2R, August 2015 Reinsert the stem bolt and tighten to a torque of 6-8 Nm. CAUTION! Ensure the bolt passes through either “A. Lower position” or “B. Upper position” hole of the stem upper. Tidy the rubber dust cover.
Page 21: Assembling The G2 Seatpost Tool Holder
® Gocycle Owner’s Manual for G2R, August 2015 4.4 Assembling the G2 Seatpost Tool Holder 1.1. Orientate the Tool Holder as shown 1.2. Locate the Snap Rail Tool Holder (B) above the saddle rails as shown. 1.3. Apply pressure onto the...
Page 22 ® Gocycle Owner’s Manual for G2R, August 2015 1.4. Apply pressure onto the left hand side of the Snap Rail Tool Holder (B) until this side is properly located onto the left saddle rail. 1.5. Confirm both sides of the...
Page 24: Assembling The Front And Rear Reflectors
Gocycle Owner’s Manual for G2R, August 2015 4.5 Assembling the Front and Rear Reflectors Front and rear reflectors are supplied as standard with your Gocycle and can be found in the small parts bag. To install the rear reflector: Mount the rear reflector on the upper seat...
Page 25 ® Gocycle Owner’s Manual for G2R, August 2015 Mount the rear (red) reflector onto the bracket and listen for a “click” Adjust the bracket to ensure that the reflector is vertical Fix the assembled reflector in a vertical position as shown To install the front reflector: ©...
Page 26 ® Gocycle Owner’s Manual for G2R, August 2015 Lift the rubber stem cover to expose the upper handlebar stem Open the reflector bracket Place the bracket around the upper stem and tighten, using a screwdriver, to secure in the position as shown...
Page 27 ® Gocycle Owner’s Manual for G2R, August 2015 Mount the front (white) reflector onto the bracket and listen for a “click” Adjust the bracket to ensure that the reflector is vertical Fix the assembled reflector in a vertical position as shown...
Page 28: Assembling The Bell
® Gocycle Owner’s Manual for G2R, August 2015 4.6 Assembling the Bell Bell and O-ring for mounting bell (Supplied in small parts bag) Loop the rubber O-ring over the bell as shown Insert the base of the bell through the gap...
Page 29: Gocycle Quick-Fit Accessories
Assembled bell Check that the bell is orientated such that it can be easily rung whilst riding 4.7 Gocycle Quick-Fit Accessories Gocycle is readied for quick-fit accessories, including mudguards, kickstand and integrated light kit. © Karbon Kinetics Limited. All Rights Reserved.
Page 30: Gocycle Registration
Gocycle since new. 4.8.2 Pre-Registration: Delivery State Explained Gocycle is shipped in Delivery State and will require registration via the GocycleConnect App to gain full functionality. Delivery State allows 60 miles (100 km) of normal usage before the motor will cease to operate.
Page 31: Gocycle App Installation - Frequently Asked Questions
How do I register the Gocycle and gain normal operation? Download and install the Gocycle Connect App from either the Apple App Store or Google Play for your Apple iOS or Android device. Follow the registration directions. For more details, see www.gocycle.com/app.
Page 32 From time to time, we need to make you aware of important announcements regarding the correct maintenance and servicing of your Gocycle. We may also have to send you important safety related information relating to your particular Gocycle.
Page 33: Gocycle Lithium Battery
The following important information applies to your Gocycle lithium battery. Read carefully to ensure the proper and safe operation and storage of the battery.  Your battery has been designed for use only with a generation-two (G2) Gocycle. Do not use the battery with any other product. ...
Page 34: Gocycle Lithium Battery: Usage
® Gocycle Owner’s Manual for G2R, August 2015 5.3 Gocycle Lithium Battery: Usage 5.3.1 Proper Charging Sequence Open the rubber charging port cover, as shown While holding open the rubber charging port cover, insert the charging lead as shown Plug the charger into mains electricity and...
Page 35 DO NOT LEAVE THE BATTERY ON CHARGE FOR MORE THAN 24 HOURS. The battery charge level is displayed on the Gocycle dashboard. (See 6.1 Familiarising Yourself with Gocycle Dashboard Display for more information). When fully charged, the dashboard will display 10 LEDs on the left side.
Page 36 5.3.2 Battery Operation Mode (Wakes the Battery for Use) The battery must be in Operation Mode before you can use your Gocycle. If the battery is not in Operation Mode, the Gocycle will not function, the gears will not shift and the motor will not work.
Page 37 During riding when using the motor, the battery charge level will decrease over time, with fewer LEDs displayed accordingly. The Battery Low Level Indicator is represented by one flashing LED. When this is displayed, the Gocycle will default to Power Save mode. See 6.3.2.5 Power Save for more information.
Page 38: Gocycle Lithium Battery: Care And Maintenance
The battery will enter Sleep Mode automatically if not in use for 15 hours. Check that the battery is in Operation Mode before attempting to ride. If the Gocycle is plugged into the charger, it will never enter Sleep Mode. Best practice if you have a green light on your charger or you have 10 LEDs on the dash is to unplug the charger and put the Gocycle battery into Sleep Mode.
Page 39: Shipping And Handling Of Lithium Batteries
Never return your battery to Karbon Kinetics Ltd without first making contact with techsupport@gocycle.com. Do not discard any of the battery packaging materials. 5.6 Battery Pack Disposal When your Gocycle lithium battery has reached the end of its service life, you must recycle or dispose of it properly: ...
Page 40: Operation
Gear selection display Speed display NOTE: If the Gocycle is stationary (including when on charge) for more than one minute (60 seconds), the display screen saver will be shown. Press either button to view the charge state. 6.2 Understanding Electronic Gear Shifting Your Gocycle is equipped with electronic shifting.
Page 41: Riding Modes
Allows user to turn predictive shifting ON/OFF 6.3 Riding Modes You can operate your Gocycle in different modes to suit your personal riding style. The motor assistance will start and stop at different speeds—you can control this with either the red power button (A) or the rider pedal input, or a combination of both.
Page 42 The following sections explain the differences between the riding modes and how to select them. NOTE: In addition to riding modes 1 through 4, your Gocycle comes pre-programmed with a number of helpful modes to assist with gear shift adjustment and fault-finding. You should not attempt to ride your Gocycle, unless prompted by mode instructions, in any other mode preinstalled on your Gocycle.
Page 43 ® Gocycle Owner’s Manual for G2R, Version 4 6.3.1 Riding Modes Reference Table Starting and Stopping the Motor Motor Operating Speed (No. of LEDs) (E) Controlling Motor Speed Continuously Power Reduces Press Red Button above this Pedal Input Low Battery...
Page 44 6.3.2.1 City Mode City mode utilises your Gocycle’s torque sensor, with the motor assistance level controlled by rider pedal input. (Hard pedalling = high motor assistance, soft pedalling = less motor assistance). In this mode, within the motor operating speed and whilst the rider is providing pedal input, the motor will start automatically and will continue to operate until the maximum speed is reached.
Page 45 See 6.5 Maximising Your Gocycle’s Motor Performance and Reliability for more information as to how to get the best out of your Gocycle. WARNING! The motor will continue to operate while the red button is pressed and the pedals are rotating.
Page 46 6.3.2.5 Power Save Your Gocycle will default to Power Save when the battery has reached a low level. The mode is represented by the battery low level warning indicator (one flashing LED) on the dashboard display. All riding modes will default to Power Save mode when a low battery level is reached.
Page 47: Energy Consumption Meter
As with a car, top speed and range (related to fuel consumption) are difficult to define as both factors are greatly affected by a large number of variables. For the Gocycle, this is including but not limited to rider weight (including clothing and luggage), tyre type, tyre pressure, terrain, surface texture, wind conditions and of course, how much pedal input the rider is providing.
Page 48 Wet conditions: Gocycle is a British product, designed with British weather in mind. However, it is important that your Gocycle is dry before storage. A city atmosphere can be a corrosive environment made worse with high humidity. We recommend a simple check and towel- down (if necessary) after using your Gocycle in wet conditions.
Page 49: Heat And Over-Temperature Protection
Gocycle’s motor is extremely compact and lightweight. While this design offers benefits, certain drawbacks exist—specifically, the motor can get hot. Gocycle’s motor will get hot under normal operation similar to the exhaust pipe or engine of a motorcycle or moped.
Page 50: Maintenance And Adjustments
7.3 Cleaning and Preventing Corrosion We do not recommend that you ride your Gocycle in heavy rain or store it in damp or wet areas. Please read 2.7 Riding in Wet, Cold or Icy Conditions for safety recommendations for riding in wet conditions.
Page 51: Lubrication
Gocycle Owner’s Manual for G2, August 2015  If your Gocycle has water on it, we recommend that you wipe it dry as soon as possible with a towel or dry cloth.  The less you expose your Gocycle to moisture or water, the longer it will last.
Page 52 Gocycle. Nevertheless, you must inspect the Gocycle every 500 miles to see if any of the components have cracks and need replacing. To do this, clean the Gocycle thoroughly with a damp cloth. Wipe away all dust or dirt. Look carefully at all the components under good lighting.
Page 53 ® Gocycle Owner’s Manual for G2, August 2015 Check for fatigue cracking around the Check for seat tube frame joint cracking here Check the head tube junction for fatigue cracking Check for cracking here © Karbon Kinetics Limited. All Rights Reserved.
Page 54 ® Gocycle Owner’s Manual for G2, August 2015 Check for cracking here Check the head tube junction for fatigue cracking Check under the head tube junction for fatigue cracking Check for cracking here © Karbon Kinetics Limited. All Rights Reserved.
Page 55 ® Gocycle Owner’s Manual for G2, August 2015 Check the Lockshock plunger for signs of fatigue cracking WARNING! When not properly assembled, the Lockshock plunger (the grey part as indicated at left) is susceptible to impact damage from a side load, for example when folding to take in or out of a car, transporting inside a building or through a doorway.
Page 56: Adjusting The Shifting
From time to time, it might be necessary to adjust your shifting; for example, if you hear a noise from your rear hub or your Gocycle is not holding in gear. Your Gocycle’s electronic shifting is calibrated during production, but you can recalibrate it by adjusting the servo electronically as follows:...
Page 57: Adjusting The Brakes
As with all hydraulic brakes, for the best possible performance, we recommend that the hydraulic brakes on your Gocycle are bled every 12 months. We advise that your Gocycle brakes are bled by a skilled bicycle mechanic with experience with bleeding hydraulic cycle brakes.
Page 58: Replacing The Brake Pads
® Gocycle Owner’s Manual for G2, August 2015 7.7.2 Replacing the Brake Pads 7.7.2.1 Replacing the Front Brake Pads Locate and remove the six securing bolts on the motor cover Remove the motor cover © Karbon Kinetics Limited. All Rights Reserved.
Page 59 ® Gocycle Owner’s Manual for G2, August 2015 Locate and remove the two calliper securing bolts Slide the calliper off the disk rotor Compress the spit pin using a pair of pliers, as shown. © Karbon Kinetics Limited. All Rights Reserved.
Page 60 ® Gocycle Owner’s Manual for G2, August 2015 With the split pin compressed, pull the pin out using a pair of pliers. Carefully push the brake pads from the top of the calliper, as shown. Pinch both brake pads and remove from the calliper.
Page 61 ® Gocycle Owner’s Manual for G2, August 2015 Replace the brake pads as necessary before reassembly. Replace the brake pads as necessary. Pinch together with the spring and reassemble into the calliper. Replace the split pin to secure the brake pads in position.
Page 62 ® Gocycle Owner’s Manual for G2, August 2015 Using pliers, bend open the split pin to lock it in place. WARNING! Do not attempt to ride your Gocycle without re-installing the brake pads and securing split pin. Doing so may result in injury.
Page 63 ® Gocycle Owner’s Manual for G2, August 2015 Replace the six motor cover securing screws. Tighten to a torque of 3–4Nm. WARNING! The braking performance of new brake pads will increase over time. Ensure that you “bed-in” your brakes by performing a number of stops.
Page 64 ® Gocycle Owner’s Manual for G2, August 2015 Remove the forward calliper securing bolt with an Allen key, as shown. Remove the rear calliper securing bolt with an Allen key, as shown Slide the calliper off the disk rotor. © Karbon Kinetics Limited. All Rights Reserved.
Page 65 ® Gocycle Owner’s Manual for G2, August 2015 Compress the spit pin using a pair of pliers, as shown. With the split pin compressed, pull the pin out using a pair of pliers. Carefully push the brake pads from the top of the calliper, as shown.
Page 66 ® Gocycle Owner’s Manual for G2, August 2015 Pinch both brake pads and remove from the calliper. CAUTION! The pads are sprung. Be careful not to accidentally release the spring. Replace the brake pads as necessary before reassembly. Replace the brake pads as necessary. Pinch together with the spring and reassemble into the calliper.
Page 67 ® Gocycle Owner’s Manual for G2, August 2015 Replace the split pin to secure the brake pads in position. Using pliers, bend open the split pin to lock it in place. WARNING! Do not attempt to ride your Gocycle without re-installing the brake pads and securing split pin.
Page 68 ® Gocycle Owner’s Manual for G2, August 2015 Ensure that the brake calliper is parallel to the disk rotor when tightened. WARNING! The braking performance of new brake pads will increase over time. Ensure that you “bed-in” your brakes by performing a number of stops ©...
Page 69: Adjusting The Pitstopwheel Quick Release Cam Levers
® Gocycle Owner’s Manual for G2, August 2015 7.8 Adjusting the PitstopWheel Quick Release Cam Levers 7.8.1 General Adjustment All three Pitstopwheel quick release cam levers should have equal resistance when closing or opening. As per the pre-ride checks there must be a maximum of 10mm free play measured at the tip of the cam lever when open.
Page 70 ® Gocycle Owner’s Manual for G2, August 2015 3. Keep 2 cam levers in the closed position and open one cam lever fully so that the back edge touches the next closed cam lever. 4. Lightly move the cam lever back and forth to gauge the extent of the free play.
Page 71 ® Gocycle Owner’s Manual for G2, August 2015 6. Insert the 4mm Allen key into the stud and turn clockwise to reduce the cam lever free play and anticlockwise to increase cam lever free play. Hold the cam lever lightly while...
Page 72 ® Gocycle Owner’s Manual for G2, August 2015 9. Ensure all cam levers are securely closed. 11. Repeat the process for the other wheel on the other hub. NB: If you do swap wheels between hubs while riding ensure to check the cam lever...
Page 73 From time to time, consider moving the rear PitstopWheel to the front and vice-versa. Typically, in normal usage, the rear of a Gocycle will carry more load than the front, thus subjecting the rear hub, wheel and tyre to greater stresses. Periodically swapping the front and rear PitstopWheels will distribute wear more evenly.
Page 74: Tyres
7.8.3 Fleet management and Tour Operators If you operate a fleet of Gocycles that are lent to people who are not accustomed to the Gocycle or are running a tour operating service with the Gocycle as the chosen vehicle we would highly recommend fitting the tamper proof security bolts.
Page 75: Adjusting The Headset
® Gocycle Owner’s Manual for G2, August 2015 Forwards Fitting the tyres and tyre tread orientation Centreline grooves Note orientation of tyre tread 7.10 Adjusting the Headset From time to time it may be necessary to tighten the headset if it becomes loose. This process is...
Page 77 ® Gocycle Owner’s Manual for G2, August 2015 Tighten the headset until there is no “play” felt in the steerer assembly—not less than 3Nm torque Tighten the bottom securing screw to a torque of 6–8Nm © Karbon Kinetics Limited. All Rights Reserved.
Page 78 ® Gocycle Owner’s Manual for G2, August 2015 Tighten the top securing screw to a torque of 6–8Nm Insert and tighten the quick release (clockwise) Close the quick release © Karbon Kinetics Limited. All Rights Reserved.
Page 79: Adjusting The Stem Quick Release Lever
® Gocycle Owner’s Manual for G2, August 2015 7.11 Adjusting the Stem Quick Release Lever It is unlikely that you will need to adjust Steam Quick Release Lever, however in the event that you need to replace the lever you will need to adjust the clock nut on the opposite side of the stem adjuster to ensure the quick release lever closes with the correct force.
Page 80 ® Gocycle Owner’s Manual for G2, August 2015 Open the QR Lever to 90 degrees and slowly rotate the clock nut until it stops against the handlebar stem lower. Rotate so that one of the holes in the clock nut aligns with...
Page 81: Adjusting The Bearings On The Rear Hub
WARNING! Check the hub gear bearing adjustment every 500 miles (800 km) or 6 months. Regular checks will ensure best possible performance for your Gocycle. Failure to inspect the hub gear bearing adjustment may have serious consequences and could result in serious bodily injury or even death.
Page 82 ® Gocycle Owner’s Manual for G2, August 2015 Remove the hub cap Adjusting the rear hub gear bearing cups First, loosen the Second, tighten the lock nut. inner adjuster nut. Using (2) 14mm wrenches, adjust the rear hub gear bearing cups ©...
Page 83 ® Gocycle Owner’s Manual for G2, August 2015 Between adjustments, check that the rear hub rotates in the freewheel direction. The bearing cup nuts should be tightened until the wheel does not have more than 1mm of “free” play at the rim, and the wheel is able to rotate freely.
Page 84: Troubleshooting
No LEDs visible Resolution: To return to normal shifting, stop riding and remain stationary for up to 5 seconds with both brakes applied. The Gocycle will reset to first gear and the gear shift LEDs will return to the dashboard.
Page 85: Diagnosis Modes
Owner’s Manual for G2, August 2015 8.3 Diagnosis Modes Your Gocycle is pre-programmed with a number of modes to assist in fault diagnosis, should an issue occur. Should an issue arise, a Gocycle technical support executive may request you to perform a number of checks in an attempt to properly diagnose a problem.
Page 86 ® Gocycle Owner’s Manual for G2, August 2015 Now rotate the pedal cranks in a backwards direction, as shown. When movement of the pedal cranks is detected, two LEDs will light on the left hand side of the dashboard display.
Page 87 ® Gocycle Owner’s Manual for G2, August 2015 8.3.2 Motor Check To check operation of red power button and motor: Select Motor Check, mode 13. Lift the front wheel so that is it off the ground. Press red power button (A) to initiate the motor.
Page 88 ® Gocycle Owner’s Manual for G2, August 2015 8.3.3 Pedal Torque Sensor Present Check To check the presence and operation of the pedal torque sensor: Select Pedal Torque Sensor Present Check, mode 14. With both brakes held, apply pressure to the left hand (non- drive side) pedal crank.
Page 89 ® Gocycle Owner’s Manual for G2, August 2015 8.3.4 Pedal and Wheel Sensor Ratio Check Follow the next steps to check function of the wheel and pedal sensors in all gears: Place the Gocycle in a cycle stand, so the rear wheel and pedal cranks are free to turn.
Page 90: Led Reference Tables
® Gocycle Owner’s Manual for G2, August 2015 8.4 LED Reference Tables 8.4.1 Dashboard Display Battery Charge Level Gear (Displayed when motor is Speed Selection OFF) Energy Consumption Meter Gear (Displayed when motor is Speed Selection 8.4.2 Energy Consumption Meter...
Page 91: Contact Information
® Gocycle Owner’s Manual for G2, August 2015 ONTACT NFORMATION Gocycle is a product of Karbon Kinetics Limited, a UK-registered company. Karbon Kinetics Limited Unit 30, Barwell Business Park Chessington, Surrey KT9 2NY UNITED KINGDOM Registered number 4357956 www.gocycle.com For details of your local Gocycle reseller visit www.gocycle.com/map.

Gocycle G2 Owner's Manual

1 Disclaimer, Copyrights and Trademarks

2 Safety

3 Warranty

4 Recommended Assembly Sequence

5 Gocycle Lithium Battery

6 Operation

7 Maintenance and Adjustments

8 Troubleshooting

9 Contact Information

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