User Manual

Introduction

Fitting Revos will transform your bike into an ebike

Revos is very simple to install. It comes in three main parts: the drive unit, the pedal assist sensor and the battery. The instructions below will take you through each of these three parts in simple step by step stages.

Contents

1. Fitting the Revos drive unit

2. Fitting the battery

3. Fitting the pedal assist sensor

4. Completing the set up

5. Riding with your Revos

6. Charging and care of the battery

7. Maintenance and adjustment

8. Diagnostics

9.Health and safety

1. Fitting the Revos drive unit

1. We suggest that you place battery on charge at the beginning of your set up so that you are able to head for the hills as soon as possible after you have completed the set up.

2. Pump up the rear tyre on your bike to the pressure advised on the side of tyre. It’s a good idea to check the pressure of the front tyre at the same time.

3. Select the thickness of black rubber  strip (1) from the thicknesses provided to suit the diameter of the bike frame seat  tube so that the two halves of the mount (2) compress the strip when the mounting bolts (3) are tightened and securely fix the mount to the seat tube. The ends of the rubber  strip should not overlap. The end of the strip may be cut off with scissors if necessary.

4. Place the two parts of the mount (2) together around the seat tube, using the bolts (3) provided, with the rubber  strip between the mount and the bike frame.

The drive strip (4) on the drive drum (5) should be positioned to rest on the tyre. To operate at maximum efficiency the drive drum should run true to the tyre, that is the axis of the drive drum (5) should be parallel with the axis of the rear wheel. The easiest way to do this is to make sure that the centre of the drive strip is in line with the centre of the tyre.

Tighten the two parts of the mount around the seat tube in this position, when fully tightened the two halves of the mount should be in contact. The unit MUST be firmly fixed to the seat tube so that it is not possible to rotate the drive unit around the seat tube. THIS IS IMPORTANT for correct operation.

5. The drive drum now needs to be pressed into the tyre so that it doesn’t slip when the drive drum is being driven by the motor. To do this turn the drive drum position adjustment screw clockwise, the drive drum will push into the tyre slightly. The lever on this screw is spring loaded to allow it to be repeatedly turned back to continue tightening the screw if needs be. Then tighten the grub screw to lock the drive drum in place with the small hex key provided. Check that the drive drum doesn’t slip by attempting to turn it against the tyre whilst holding the wheel still. If it slips then repeat the process.

6. Some bikes have derailleur or gear cables running down the seat post. If your bike has this then it will be necessary to pass the cable through the hole provided in the drive unit mount. There is a small black plastic tube in the hole to protect the mount from rubbing against the aluminium mount. Take the tube out and slide the cable through the slot in the cable, then put the cable through the slot in the drive unit mount and slide the tube into the hole. Depending upon the design of the bike sometimes the whole of the cable, both inner and outer pass through the mount.

2. Fitting the battery

 1. To fit the battery holder to the down tube of your bike, screw in the bolts provided into the two threaded holes in the down tube normally used to fix the water bottle holder. The bolts provided have low profile heads which will not damage the battery casing. These are therefore to be used in preference to the bottle cage mounting ones. If preferred, the battery may be fitted using the seat tube threaded holes (sometimes the front derailleur fitting prevents this).

2. For insertion of battery into carrier, see label on battery.

IMPORTANT: Before riding the bike, lock the battery into the carrier to prevent it falling out. The battery should be transported to you with a low charge and so the charge indicator will show red. You can use the battery like this, but if you want to go for an extended first trip you should charge the battery first. (See Charging and care of the battery)

3. Fitting the pedal assist sensor 

 

4. Completing the set up

1. Connect the Revos drive unit to the battery by connecting the cable from the Revos drive unit to the cable from the bottom of the battery holder using the connector provided, line up the arrows on the two halves of the connectors and make sure that they are pushed fully together up to the line marked on the connector. Secure the cables back to the bike frame using the cable ties provided.

2. Put the battery into the battery holder and secure by turning key in lock.

3. Check that the red indicator light on the end of the sensor is lit up. A continuously-lit indicator light shows that the pedal assist sensor is switched on. The indicator light will flash when the pedal assist mode is switched off. 

4. To check that the pedal assist sensor is correctly positioned, backpedal quickly for two rotations and check that the red indicator light is flashing. This indicates that the sensor is correctly positioned and is detecting the pedalling movement as it should.

5. Now switch the pedal assist back on again by pedalling backwards a second time. The red sensor indicator light should be on continuously.

6. Your Revos is properly set up and will provide pedal assist as you pedal forwards. For your first ride we recommend that you cycle somewhere traffic free and flat for 10 minutes or so until you get used to riding with Revos.

5. Riding with your Revos

1. After putting in the battery, Revos will switch on as you pedal forwards. It will then always assist you for as long as you are going less than 15.5mph (25kph) and  you are pedalling. If you go faster than 15.5mph then Revos will no longer assist you. If you wish to cycle without assistance then quickly backpedal for two rotations  and then pedal normally again. To switch Revos back on again, quickly back pedal for two rotations  and then pedal forwards.

2. When pedal assist is not switched on the drive drum will rotate against the tyre with almost no resistance and it is perfectly OK to ride your bike like that. If you wish to move the drive drum off the tyre entirely then this can be done by turning the drive drum position adjustment screw (6) anti-clockwise to lift the drive drum away from the tyre a few millimetres.

3. Please observe all local regulations applying to ebikes where you ride.

4. To make most effective use of Revos use gears on your bike in the same way as if Revos were not fitted, especially changing into a lower gear before starting up an incline.

6. Charging and care of the battery

1. Press the button on the top of the battery. A red light should show indicating the low charge that the battery should have when it is transported to you.

2. Plug the charger into a mains supply socket using the mains lead and plug provided. The battery can be taken out of the battery carrier to charge it or it can be left in place in the battery carrier on the bike and charged there.

3. Plug the charger’s charging lead into the circular charging socket in the base of the battery.

4. The indicator light on the charger will show red initially. When the indicator light on the charger shows green the battery is fully charged and the charger should be disconnected from the battery. The level of charge on the battery can be checked after it has been disconnected from the charger by pressing the button on top of the battery.

5. There are four indicator light colours on the top of the battery. Blue = Fully Charged. Green = Good level of charge. Red = Partially Discharged (approx 50% or less). Flashing Red = Almost Empty. If no indicator light is shown then the battery is fully discharged.

6. The battery when not in use should be kept in dry conditions at normal room temperature separated from the battery carrier. To keep the battery in good condition It is recommended that the battery is kept charged (ideally with the indicator light showing green) when stored. If stored for long periods the level of charge should be checked every 3 months and the battery recharged if necessary.

7. At the top of the battery there is a USB port. Mobile devices can be charged from this port by using a USB cable (not provided). The battery CANNOT be charged via the USB port.

7. Maintenance and adjustment

1.    KEEP THE REAR TYRE PROPERLY INFLATED. Revos works by pressing slightly into a properly inflated tyre. Tyres will lose pressure over time so it’s recommended to check the tyre pressure every week. The recommended tyre pressure is shown on the side of the tyre.

2. If the drive unit, pedal assist sensor or battery get dirty then they can be cleaned down with a damp/wet cloth.

8. Diagnostics

Issue	Possible Cause	Action
1. The drive drum slips.	1. Tyre pressure is too low. 2. The drive drum isn’t pressed into the tyre enough.	1.Inflate tyre to pressure indicated on side of tyre. 2.Follow procedure in (4) in Fitting the Revos Drive Unit.
2. The drive unit makes a chirping sound when it rotates	1.Tyre pressure is too low. 2.The drive drum isn’t pressed into the tyre enough. 3.The locking grub screw on top of the drive unit isn’t tightened up enough	1.Inflate tyre to pressure indicated on side of tyre. 2.Follow procedure (5) in 1. Fitting the Revos Drive Unit. 3.Follow procedure in (5) in 1. Fitting the Revos Drive Unit.
3. The drive drum fails to power up and rotate when the pedal is turned forwards.	1. Revos is off due to backpedal. (The red indicator light will be flashing on and off) 2. The drive drum isn’t pushed into the tyre. 3.The pedal assist sensor head has been dislodged or not in the correct position. 4.The cable connector to the drive unit isn’t fully pressed home. 5. Poor connection at the battery/carrier contact. (Red light on the sensor won’t show) 6. The controller has entered a sleep mode due to low battery.	1. Backpedal quickly for two rotations to start the drive drum. (Red Indicator light will be lit continuously) 2. See Fitting the Revos Drive Unit No. 5. 3. Put the pedal assist sensor head back so that it is behind the sensor disc (see fitting the PAS No. 3). 4. Press the connector together so that the cap is pushed up to the line on the connector. 5. Remove battery and wait 15 seconds and put battery back in. The red light should now show and the drive drum turn when the pedals are turned forward. 6. Charge Battery
4. The battery won’t charge fully/doesn’t hold its charge.	1.The battery has been charged too many times. Cell capacity is reduced to between 70%-80% after 300-500 charge cycles. All lithium-ion batteries have this characteristic.	1. Purchase another battery from Revolutionworks. Please dispose of your battery responsibly.

9. Health and Safety

1. Before maintaining or adjusting the Revos drive unit remove the battery to remove the risk of the drive unit starting up.

2. At all times keep fingers away from a rotating drive drum to avoid trapping fingers between the tyre and the drive drum.

3. NEVER attempt to adjust Revos whilst cycling along.