ENVO D Series User Manual
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ENVO D Series User Manual

Conversion kit
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D-SERIES + R-SERIES
CONVERSION KIT
U S E R M A N U A L
+1 (604) 423-3381
E N V O D R I V E .C O M

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Summary of Contents for ENVO D Series

  • Page 1 D-SERIES + R-SERIES CONVERSION KIT U S E R M A N U A L +1 (604) 423-3381 E N V O D R I V E .C O M...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. I N T R O D U C T I O N 5 . O P E R AT I N G Y O U R P R O D U C T 3 7 1.1. Use of Manual 5.1.

  • Page 3: Introduction

    W E L C O M E T O T H E E N V O FA M I LY Thank you for choosing an ENVO Conversion Kit. As a leader in electric bike design and distribution in Canada, we are passionate about our customers riding their bikes more and driving their cars less.

  • Page 4: Safety & General Tips

    If at any point ENVO Drive Systems is asked to implement upgrades, we will notify you if the modifications exceed street legal limits •...

  • Page 5: Rules Of The Road

    2 . 2 . R U L E S O F T H E R O A D Failure to follow recommendations outlined in this section may cause damage to property, injury, or even death. • Always obey all the traffic rules, regulations, signs, and signals •...

  • Page 6: Before Your First Ride

    If you have an impairment or disability such as visual impairment, hearing impairment, physical impairment, cognitive impairment, and/or a seizure disorder, consult your physician before riding any ENVO Drive Systems product • Before going on your first ebike adventure, take time to get familiar with your ebike •...

  • Page 7: Battery & Charger Safety

    Take care of the pins. Always be gentle when pulling the charging pin out. Rough use of the pins can cause irreversible damage to the pins and battery • Always use the charger provided by ENVO for the ENVO battery • Make sure you always seal the USB port when not in use •...

  • Page 8: First Charge

    Do not use the ENVO battery charger for any purpose other than charging your ebike. Do not use the ENVO battery as a power source for any other devices than your ENVO ebike. If you do so the warranty will not be applicable, and ENVO Drive Systems will not be liable for any damage to the system or injury to the persons.

  • Page 9: Battery Removal & Installation

    2 . 6 . B AT T E R Y R E M O VA L & I N S TA L L AT I O N Figure 2.6.A B AT T E R Y R E M O VA L •...

  • Page 10: Charging Your Battery

    70% of its capacity for about 500 full discharge/recharge cycles. As capacity diminishes, you will notice a gradual drop off in max range capability. When range falls to an unacceptable level, contact your local ENVO dealer to purchase a new battery.

  • Page 11: Battery Transport

    Batteries should never be thrown in the garbage • Contact ENVO for more information about how to recycle your batteries Disposing of Lithium-Ion batteries incorrectly can allow moisture and oxygen to enter the battery. This can lead to the oxidation of lithium components and which can cause a heat reaction that may include fire or explosion.

  • Page 12: General Riding Tips

    2 . 1 1 . G E N E R A L R I D I N G T I P S Read, understand, and follow all of the instructions and safety precautions in this manual. Electric Bikes can be dangerous to use. The user or consumer assumes all risk of personal injuries, damage, or failure of the bicycle or system and all other losses or damages to themselves and others and to any property, arising out of or as a result of using the bicycle.
  • Page 13 • Always ride at a speed that’s appropriate for the conditions. Higher speed means higher risk • Ensure brakes and motor cut off switch are working prior to every ride • Ensure nothing is loose (ie bolts, battery, wheels, pedals, and handlebar) and everything is secured on the bike prior to every ride •...

  • Page 14: Safe Operating Conditions

    • Always wear an approved helmet and ensure it fits according to the manufacturers’ instructions. Ensure your helmet meets the latest certification standards and is appropriate for the type of riding you do and if there are any special requirements for riding an electric bike •...

  • Page 15: Product Description

    3. Controller 4. Motor 1. Controller Bag 5. Battery Charger 2. Motor Cable 6. Battery Parts provided in your ENVO Conversion Kit Box: 1. Controller Bag (20A controller) 2. Motor extension cable 3. Controller 4. Front/Rear Hub Motor 5. Battery Charger 6.

  • Page 16: Assembly Instructions

    It is highly recommended to get help from an experienced mechanic. Find a local ENVO dealer or book an appointment with us for an installation session. If you choose to do it yourself, please refer to our online guides at support.envodrive.com, to ensure you install your product safely.

  • Page 17: Rear Hub Motor

    4 . 3 . R E A R H U B M OT O R 4 . 3 .1. R E M O VA L O F T H E R E A R W H E E L • Shift the chain into the smallest gear before attempting to remove the wheel.
  • Page 18 • Repeat sliding and lifting all around the rim until the whole side (bead) of the tire is off the rim • Now starting on the opposite side of the valve, pull the inner tube from the tire. Lift valve from valve hole and remove tube from wheel.
  • Page 19 Figure 4.3.4.A 4 . 3 . 4 . T R A N S F E R R I N G Y O U R C A S S E T T E • To remove the cassette, you must first loosen the lockring using the chain whip and the lockring tool, Figure 4.3.4.A some cassettes may need a more specific tool •...
  • Page 20 Figure 4.3.5.A 4 . 3.5. I N S TA L L I N G M O T O R I Z E D R I M T O T H E F R A M E Locking Nut Locking Washer •...

  • Page 21: Downtube Battery Installation

    4 . 4 . D O W N T U B E B AT T E R Y I N S TA L L AT I O N There are multiple options available for installing a battery, it can be customized to fit on any frame with varying techniques such as mounting on the downtube or placed on the rear rack;...
  • Page 22 Figure 4.4.1.D • Your bike frame should have a bottle mounting option, most of the ENVO batteries can be attached where a bottle mount would typically attached Figure 4.4.1.D, Figure 4.4.1.E Battery mounting area • If you do not find any mounting options on the frame purchase clamp nuts for the battery mount •...

  • Page 23: Rack Battery Installation

    Figure 4.4.2.A 4 .4 . 2 . O P E R AT I N G T H E B AT T E R Y S W I T C H • Initially the battery is sent to you in the off position •...
  • Page 24 4.5.1. I N S TA L LI N G T H E BAT T E RY TO T H E R AC K • Remove the plastic cover from the battery and detach the mounting bracket from the battery. Keep the battery aside to charge. We have to mount the bracket to the metal rack •...
  • Page 25 Figure 4.5.2.A 4.5. 2 . I N S TA L LI N G T H E R AC K TO T H E B I K E F R A M E • Install the rack supports on either side of the motor using an Allen Key Figure 4.5.2.A •...

  • Page 26: Display, Throttle & Brake Sensors

    Figure 4.5.3.A 4 . 5 . 3 . O P E R AT I N G T H E B AT T E R Y S W I T C H • Initially the battery is sent to you in the off position •...
  • Page 27 Figure 4.6.1.A 4 .6 .1. I N S TA L L I N G T H E D I S P L AY • You can find the KT-LCD display in the controller box; it has a separate box with all the mounting fixtures and manual •...
  • Page 28 Figure 4.6.4.A 4 .6 . 3 . T H R O T T L E I N S TA L L AT I O N • Remove the right handlebar grip • lose up the gear shifters and brakes on the right side •...
  • Page 29 Figure 4.6.5.A 4 .6 .5. E - B R A K E S E N S O R I N S TA L L AT I O N The Main function of the E-brake sensor is to shut off power of the motor when you apply the brake.

  • Page 30: Pedal Assist Sensor Installation

    It does not matter how much force is applied or the terrain, all that matters to the sensor is if the pedals are rotating or not. ENVO conversion systems provide 5 Levels of PAS assist. •...
  • Page 31 Figure 4.7.2.A 4 .7. 2 . I N S TA L L AT I O N O F T H E PA S S E N S O R T O T H E B I K E F R A M E •...

  • Page 32: Wiring

    4 . 8 . W I R I N G Figure 4.8.1.A In this section we are going to look at how everything is Match up the slots before pushing the connected together, please remember to always be gentle pieces together with the connectors whenever connecting or disconnecting.
  • Page 33 Figure 4.8.2.A 4 .8 . 2 . W I R I N G O F DATA C A B L E , C O N T R O L L E R , A N D M O T O R With these connections you have to be extra cautious as there are more pins in this connector.

  • Page 34: Wiring Map

    4 . 9 . W I R I N G M A P Figure 4.9.A Display E-Brake E-Brake Throttle Optional Headlight Junction ENVO Battery Standalone Controller PAS Sensor Motor EN VO D -SERIES + R-S ERIES CON VER SION KIT M A NUAL VER S ION 1.0...

  • Page 35: Controller & Controller Bag Setup

    4 . 1 0 . C O N T R O L L E R & C O N T R O L L E R Figure 4.10.A B A G S E T U P • All the electrical components in an ebike are operated through a controller.

  • Page 36: Testing Of Sensors & Motor

    4 . 1 1 . T E S T I N G O F S E N S O R S & M OT O R When all the wires are connected, which are the headlight, e-brakes, PAS, battery, motor, display and throttle.

  • Page 37: O P E R At I N G Y O U R P R O D U C

    Your ENVO Conversion Kit LCD meter monitors pedal assist, speed, odometer, trip distance, riding time, and battery energy level. To turn the meter on, make sure the ENVO battery is fully inserted into the and the on/off switch is ON.

  • Page 38: Display Content

    5 . 2 . D I S P L AY C O N T E N T Backlights and 6 km/h Power Assist Brake Status Headlight Status Push Function Battery Capacity Running Counter Indicator Motor Operation Power or Vehicle Speed Motor Running Temperature Power Assist Ratio Gear and Cruise Function...
  • Page 39 Please make sure you store your ebike in a safe and closed environment away from children, the display has a small battery inside which has to be charged fully. If by accident someone applies throttle the motor may get activated. ENVO Drive Systems will not be liable for any consequences.

  • Page 40: Hand Throttle Control

    5 . 4 . H A N D T H R OT T L E C O N T R O L • ENVO conversion kit are equipped with a thumb throttle, which is located on the right side of the handlebar •...

  • Page 41: Operating Range

    5 . 6 . O P E R AT I N G R A N G E Your ENVO Conversion kit has an expected range of 40km with average rider weight, medium pedal assist and throttle use, level terrain and light winds and a maximum range of 80km with light motor use.

  • Page 42: Maintenance & Repair

    • ENVO bikes have two ways of securing the wheels – front wheels are secured using the hollow axle with a shaft (“skewer”) running through it which has an adjustable tension nut on one end and an over –center cam on the other.

  • Page 43: In Case Of Accident

    6. Realign the components if necessary and carefully tighten the bolts to ensure reliable clamping of the components. The maximum torque values are printed directly on the components and/or specified in the enclosed operating instructions. If neither are available, contact ENVO support for assistance 7.
  • Page 44 16. At no time should you make any modifications to your ebikes electrical systems, unless they are explicitly approved by the manufacturer in writing 17. Contact your dealer or ENVO support for repairs and replacement parts in case of damage EN VO D -SERIES + R-S ERIES CON VER SION KIT M A NUAL...

  • Page 45: Quick Troubleshooting

    6 . 3 . Q U I C K T R O U B L E S H O OT I N G If your Electric Bike is not working, check the Quick Disconnect Fittings to make sure they did not come loose or unplugged.
  • Page 46 Battery Charger does not function Green LED may turn on when charger is plugged into battery but not connected to the wall. Check all connections are tight Try different plugs as well as different charger cables Not getting enough range Check your tire pressure, Make sure tires are at check brakes for rubbing,...
  • Page 47 For any additional troubleshooting help, refer to support.envodrive.com or contact your local ENVO Electric Bike dealer. EN VO D -SERIES + R-S ERIES CON VER SION KIT M A NUAL VER S ION 1.0...

  • Page 48: Transportation & Storage

    7. TRANSPORTATION & STORAGE 7 . 1 . T R A N S P O R TAT I O N • Please remove the battery and turn it off before transporting the bike. Batteries are not designed to be on the bike while being transported •...

  • Page 49: General Terms & Warranty

    8. GENERAL TERMS & WARRANTY 8 . 1 . W A R R A N T Y • All products including ebikes and conversion kits, as well as components purchased including motor, controller, display, battery, charger, throttle, PAS sensor, brake sensors are covered by 12 months FREE warranty unless otherwise specified.

  • Page 50: Registering Product Warranty

    8 . 3 . E X C L U S I O N S ENVO is released and discharged of any liability for any damages, injuries or claims occurring as a result of neglect, the owner is responsible for the maintenance and safety of all structural and mechanical components of their ebike such as brakes, headset, forks, etc.
  • Page 51 • In case the issue is not diagnosed by standard ways; for our hub motor kits, ENVO ebikes, and other house brand products, since the electrical system is modular and has easy access. We would be able to easily send you replacement parts such as a controller to swap and test and return the defective one.

  • Page 52: Contact

    CONTACT L O C AT I O N ENVO Drive Systems Inc. 1685 Ingleton Avenue Burnaby, BC V5C 3V6 Canada B U S I N E S S H O U R S Monday – Friday: 10am – 5pm PST Saturday: 11am –...

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