THIN has arrived! We’re so excited to see happy owners out riding their THINs, but first: let’s get it put together correctly! If you are unfamiliar with bike assembly, it is strongly recommended that you take your THIN to a local bike shop for assistance.  Most shops will be able to assemble and make any necessary […]

The post THIN Assembly Instructions appeared first on Sondors.

THIN Assembly Instructions

THIN has arrived! We’re so excited to see happy owners out riding their THINs, but first: let’s get it put together correctly!

If you are unfamiliar with bike assembly, it is strongly recommended that you take your THIN to a local bike shop for assistance.  Most shops will be able to assemble and make any necessary adjustments to your bike for a small fee.

If you are confident with doing the bike assembly on your own, please watch the following video as a guide for assembly of your SONDORS THIN>>

 

The following is a transcript of the video, to help guide assembly.

INCLUDED PARTS & TOOLS:

Box#1 = L&R pedals, included tools, reflectors & mounts, battery charger, (2)4mm allen bolts, (2) phillips head screws, aluminum ferrule, small black rubber button

Box #2=battery & battery lock keys

Included w/ your bike is a set of 5 allen wrenches (6mm, 5mm, 4mm, 3mm, 2.5mm), a stamped steel multi-wrench tool, and a T25 Torx Wrench

Phillips screwdriver required but not included.

We suggest that you start the initial charge as the first step so the battery can be charging while the bike is being assembled.

BATTERY CHARGE:

Position rocker to ‘off’ position

Open the charging port cap and insert the battery charging cable into the port

Plug charger into standard grounded household outlet or surge protector

When the charging unit is correctly connected the LED will show GREEN briefly and then it will switch to RED while the battery charge cycle is underway

When the battery is fully charged teh LED light will change from RED back to GREEN

When the battery is fully charged disconnect the charge from the wall socket, and then remove the charging cable from the battery

To charge on the bike, first positionthe battery rocker in the ‘off’ position

Open the battery compartment, unscrew and disconnect the metal socket from the battery

Cover the battery discharge port with the rubber cap

Open the charging port cap and insert the battery cable into the port

Plug the charger unit into a standard grounded household outlet or surge protector

When the battery is fully charged, disconnect the charger from the wall socket, and then remove the charging cable from the battery

Reconnect the bike controller power cable

**Battery Notes**

  • Do not interrupt the charging cycle until the battery is fully charged
  • Always follow the correct battery connection sequence
  • Do not exceed 8 hours charging time
  • Do not store the battery connected to the battery charger
  • Battery must be charged at least once every 3 months if it is not being used for extended periods of time
  • Read & follow the additional instructions and cautions listed on the battery labels

STEM & FORK ALIGMENT

Loosen the (2) 4mm pinch bolts and 5mm cap bolt

Rotate the stem so it is aligned with fork (as shown in Video)

Re-tighten the 5 mm cap bolt and (2) 4mm pinch bolts

Repeat this procedure after the wheel and handlebars are installed to ensure proper alignment

Rotate both the stem and fork into the forward position

ATTACH HANDLEBAR & ALIGN CONTROLS

Remove the (4) 4mm bolts & faceplate

Rotate the handlebar assembly up into the stem

Be careful not to twist or kink the cables attached to the brake levels & throttle

Replace the faceplate & lightly tighten the (4) 4mm bolts

Double Check that the handle bar is L/R centered in the stem and the bar is rotated in the position that will be ideal for your riding comfort

Finish tightening down the Faceplate bolts

Loosen the 5 mm bolt on the bottom of the brake levers, rotate to the desired position and re-tighten

To adjust the throttle: loosen the throttles 2.5mm set crew, rotate unit to your preferred position and re-tighten

*Be careful not to over tighten as it can inhibit throttle operation & make sure the throttle operates freely & doesn’t bind on the grip

Loosen the 3mm bolts on the grip locks, rotate the grips into your preferred position & retighten

Insert rubber cap onto 5mm stem cap bolt

FRONT BRAKE CABLE ATTACHMENT

Loosen the cable clamp on the caliper arm using the 5mm allen wrench

Pull the brake cable up approx 9.5″ to provide slack to install the cable in the brake lever

Rotate the black ferrules to align their slots with the slot on brake’s forward edge

Pull brake lever in and swing the cable end basket out

Place cable in basket and move cable through the forward edge slot

Tighten black ferrules down to secure cable, being certain their slots no longer align with brake lever slot

Arrange and secure cables using the 3 black plastic clips that were attached to the bike cables during shipping

FRONT WHEEL ATTACHMENT

Remove the plastic foot from the axle dropouts in the front fork

Loosen the R&L side axle nuts until they are slightly beyond the outside ends of the axel

Pull the fishtailed washers up to the inside surface of the axle nuts

Making sure the brake disc is on the left side of the wheel (same side as brake caliper) carefully place the axle in the front fork dropouts

The kickstand can now be lowered to stabilize the bike

On both the L&R sides: Insert the tail of the washers into the hole above the axle dropout slot on the fork

With the washers in the locked position, hand-rotate both nuts clockwise until they contact w/ the fork sides

*Make sure your wheel is centered, relative to the front fork

Tighten the axle nuts using the 15mm end of the stamped tool or a 15mm wrench

*after tightening, check again to make sure your wheel is still centered in the forks

FRONT BRAKE ADJUSTMENT

Use the 5mm allen key to loosen the clamp bolt on the brake caliper arm

Remove slack from the cable by pulling the inner cable into the brake caliper arm

Place metal end of cable jacket in the receivers of the lever unit and the upper end of the brake unit

Rotate the caliper arm upward approx 1/2″, hold the cable tightly below the caliper arm while tightening 5mm bolt

Loosen the rear facing upper and lower caliper attachment bolts using the 5mm allen key

when loosened, the brake caliper unit can move L/R over the disc rotor

Pull the brake lever to align the loosened brake unit over the disc rotor

With the brake lever still pulled, tighten both 5mm caliper attachment bolts on the brake caliper mount

Check for brake alignment and re-adjust brake cable in the caliper arm if needed

Front brake cable can be tripped with heavy wire cutters and the aluminum ferrule can be crimped on end of the cable

PEDAL ATTACHMENT

This bike includes a R&L pedal, they are marked with a “R” and an “L” on the end of the threaded post

The pedal orientation refers to the riders LEFT and RIGHT as you sit on the bike

Start w/ left pedal: Slowly rotate the threaded post onto the left side crank counter clockwise

It should turn easily into the crank by hand when aligned correctly

Tighten the pedal with a 15mm open-ended wrench or the included multi-tool

Right Pedal: Slowly rotate the threaded post onto the right side crank clockwise

It should turn easily into the crank by hand when aligned correctly

Tighten the pedal with a 15mm open ended wrench or the included multi-tool

REFLECTOR ATTACHMENT

The wheel reflectors have a vertical spoke slot through the side where the clip attaches

Position the reflector in the wheel and align the spoke in the reflector slot

Carefully push the clear connector button into the hole

Slowly slide reflector upwards until it fits snug between opposite spokes

Slide white reflector into handle bar mount until it clicks into place, repeat w/ red reflector & seat post mount

Spread the assembled white reflector and slip over handle bar

Insert included black phillips screw and tighten

Slide red reflector assembly up the seat post & insert the included black phillips screw and tighten when positioned in desired location

SEAT ATTACHMENT

Open the quick release seat tube clamp & insert the seat post

Close the quick release and finger-tighten the knurled nut

Open the lever & tighten the knurled nut an additional approx 180 degrees

The lever should now be somewhat difficult to close when the clamp pressure is correct

Adjust the seat height and alignment as needed

BATTERY INSTALLATION

Prior to installing, ensure the battery rocker power switch is in the “OFF” position

Open the battery compartment

Note the 2 slots in the bottom edge of the battery and their corresponding rails on the battery mount

Remove the rubber cap from the metal discharge port on the side of battery & insert battery key

While holding the frame, rotate key 1/4 turn counter clockwise and firmly push the battery until the lock clicks into place

Remove & secure battery key

The controller connection socket has a slot that is keyed to fit in the battery charge port

When aligned, it will fit easily into the port

Once inserted, slide the metal knurled collar towards the battery and rotate clockwise to secure the socket

Close the battery compartment and secure with the threaded toggle

POWER-ON AND POWER-OFF (NO LCD INSTALLED)

First, remove the rubber cap on the lower right side of the bike’s battery compartment to access the power switch

Put the power switch to the “ON” position and replace the cap

To power-on the bike, press the grey button on the throttle

The LEDs on the throttle will light up when powered-on

*The number of LEDs will vary depending on the battery charge level and the draw being applied to the system

To power-off the bike, press the gray button again and the LEDs on the throttle will turn off when the bike is powered-off

Then, remove the rubber cap, push the power switch to the “OFF” position and replace the cap

Anytime the battery is not being used, it is recommended the battery be in the “OFF” position

Congratulations on your SONDORS THIN & thanks for your support!

Warning: Do not replace SONDORS eBike original components with third-part “after-market upgrades” like controller, battery, LCD screen, throttle, motor, or charger sold from anywhere other than gosondors.com. Replacing parts with anything other than SONDORS genuine parts can cause serious damage to your SONDORS eBike.

The post THIN Assembly Instructions appeared first on Sondors.