VOLCON BRAT Owner's Manual
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VOLCON BRAT Owner's Manual

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VOLCON BRAT OWNER'S MANUAL
Rev A
OWNER'S MANUAL
Please read this manual in its entirety before taking your first ride!
For assistance, contact Volcon Support.
support@volcon.com
Support Contact:
NOTE:
Manual graphics are for demonstration purposes only.
Graphics may not show exact appearance of actual product.

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  • Page 1 VOLCON BRAT OWNER’S MANUAL Rev A OWNER’S MANUAL Please read this manual in its entirety before taking your first ride! For assistance, contact Volcon Support. support@volcon.com Support Contact: NOTE: Manual graphics are for demonstration purposes only. Graphics may not show exact appearance of actual product.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SAFETY WARNINGS ................4 BEFORE YOU BEGIN ................. 6 TIPS FOR SAFE RIDING ..............8 Riding Your Brat ............... 8 Off-Road Riding ............... 9 Wet Weather Riding ..............10 Night Riding ................10 Extreme Riding ................ 10 Electric Bike Safety ..............
  • Page 3 VOLCON BRAT OWNER’S MANUAL Horn ..................48 SUSPENSION ..................49 Front Suspension ..............50 Rear Suspension ..............51 MAINTENANCE ................. 52 Battery Maintenance & Storage ..........52 Recommended Maintenance ............ 54 Cleaning .................. 55 COMPONENT MAINTENANCE ............57 Tires / Wheels ................57 Chain Care ................

  • Page 4: Safety Warnings

    This handbook contains information about the Volcon electric bicycle the BRAT. Always store this Owner’s Manual with your Volcon vehicle and refer to it for information whenever necessary. The information contained in this publication is based on the most up-to-date information available at the time of publishing.
  • Page 5 • Do not block sidewalks or emergency exits. • Every Brat e-bike comes programmed as a Class-2 e-bike, which allows for throttle operation and pedal-assist riding up to 20mph. This allows the Brat to be legally ridden on most bike paths without a license, insurance, or registration.

  • Page 6: Before You Begin

    Please read this owner’s manual carefully before riding and retain it for future reference. • Do not operate or ride your Brat until you have completely read this manual. Please read the important safety items in this manual before your first ride.
  • Page 7 VOLCON BRAT OWNER’S MANUAL • Using third-party Non-Volcon-Approved parts or aftermarket accessories. • Riding over stairs, performing wheelies, taking it off jumps or doing stunt/trick- like activities. • Used in competitions or for commercial use. This vehicle is IP54 rated and is water resistant but cannot wade through excessive water or snow.

  • Page 8: Tips For Safe Riding

    DO NOT use the electric bicycle without fully understanding its capabilities and limitations. • DO NOT use any non-Volcon-approved third-party accessories, alter, or disassemble any OEM parts without direct consent from Volcon. If you do, your warranty will be invalid. • DO NOT use other electronic devices while riding.

  • Page 9: Off-Road Riding

    VOLCON BRAT OWNER’S MANUAL Be Alert and Aware: • Cars turning in front of you. • Parked car doors opening. • Children and pets. • Bad conditions such as potholes, sewer grates, railroad tracks, and other obstructions. • Ride in lanes and trails designated for bikes only.

  • Page 10: Wet Weather Riding

    Increase the braking distance when braking to ensure safety. Night Riding DANGER: ALWAYS USE YOUR VOLCON BRAT’S HEADLIGHT SYSTEM WHEN RIDING AT NIGHT OR AT ANY OTHER TIMES OF POOR VISIBILITY. RIDING AT NIGHT OR AT ANY OTHER TIME WITHOUT AN ADEQUATE LIGHTING SYSTEM AND WITHOUT REFLECTORS MAY RESULT IN DEATH OR SERIOUS INJURY.

  • Page 11: Electric Bike Safety

    VOLCON BRAT OWNER’S MANUAL Electric Bike Safety Cycling involves the risk of injury, and is the rider’s responsibility to assume those risks. By choosing to ride, you are automatically assuming responsibility for that risk. To reduce the risk of injury, you must know and follow the rules and safety regulations for riding and proper maintenance.

  • Page 12: Component Location

    VOLCON BRAT OWNER’S MANUAL COMPONENT LOCATION Figure 1 - Component Location A 7. Bottom bracket 1. Display 8. Pedal 2. Throttle 9. Crank set 3. “Tank” Storage 10. Kickstand compartment 11. Swing arm 4. Headlight 12. Motor 5. Electronic speed 13.
  • Page 13 VOLCON BRAT OWNER’S MANUAL Figure 2 - Component Location B pg. 13...

  • Page 14: Display & D-Pad

    VOLCON BRAT OWNER’S MANUAL DISPLAY & D-PAD DISPLAY & D-PAD NOTE: If the e-bike is not used for more than 10 minutes, the display will automatically shut down Figure 3 - Display & D-Pad pg. 14...

  • Page 15: Identification Numbers & Safety Label Locations

    VOLCON BRAT OWNER’S MANUAL IDENTIFICATION NUMBERS & SAFETY LABEL IDENTIFICATION NUMBERS & SAFETY LOCATIONS LABEL LOCATIONS Figure 4 - Identification Code Locations 1. Manufacture Label 2. Vehicle QR Code (under storage compartment cover) 3. Display QR Code 4. Controller QR Code (on battery cradle underneath battery) 5.
  • Page 16 VOLCON BRAT OWNER’S MANUAL Figure 5 - Class 2 Label Location Figure 6 - Warning Label Location pg. 16...
  • Page 17 VOLCON BRAT OWNER’S MANUAL Figure 7 - Safety Label Location pg. 17...

  • Page 18: Technical Specifications & Features

    Hydraulic disc Display 4 ride modes, Bluetooth compatible, D-Pad connected Classifications ***The Brat is a Class 2 e-bike with multi- mode capability Weight Capacity 340 lbs. (154 kg) * Fully unlocked in unlimited off-road mode ** In ECO mode. However, variables such as rider weight, temperature, terrain, pedal input and usage will affect the overall range.
  • Page 19 VOLCON BRAT OWNER’S MANUAL Model Features • Bluetooth Compatible • USB Charger • 4 Ride Modes • Storage Compartment • Headlight/Taillight • Horn • App-Based Vehicle Controls • Half Grip Throttle • Chain Drive ACCESSORIES/OPTIONS (Visit www.volcon.com for all available accessories) •...

  • Page 20: Unboxing Instructions

    2. Lift the entire box top up and away from the bike and bottom base of the box. 3. Leave the Brat in the base for more stability until you have installed the kick stand. 4. Install the kickstand before removing the Brat from the base of the box.
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  • Page 22: What's In The Box

    VOLCON BRAT OWNER’S MANUAL WHAT’S IN THE BOX If your Brat is delivered directly to you, it will come partially assembled NOTE: and will need to be assembled with the following parts. Tools and Hardware Included Parts Fasteners Tools 1 x Handlebar set 4 x 5mm Allen Bolts 2.5mm Allen Wrench...

  • Page 23: Assembly & Setup

    VOLCON BRAT OWNER’S MANUAL ASSEMBLY & SETUP 1. Leave your Brat in the base of the box for added support until kickstand is installed. 2. Remove and open the small box under the bike, which contains the parts and tools needed to assemble your Brat.

  • Page 24: Handlebar Installation

    VOLCON BRAT OWNER’S MANUAL Handlebar Installation Figure 10 - Handlebar Installation 1. Attach the handlebar by placing the riser assembly into the mounting slot of the upper triple tree. 2. Then insert 4 x 5mm Allen bolts into the holes from the top.

  • Page 25: Fender Installation

    VOLCON BRAT OWNER’S MANUAL Fender Installation FRONT FENDER Figure 11 - Front Fender Installation 1. Secure front fender bracket, with a 3mm screw to the lower triple tree, in front of the lower triple tree. 2. Use the 3mm Allen wrench to torque the screw to 1.47 ft lbs (2.00 Nm).

  • Page 26: Headlight Installation

    VOLCON BRAT OWNER’S MANUAL Headlight Installation Figure 13 - Headlight Installation 1. Remove the mounting bolts from the headlight using the 14mm box wrench. 2. Loosen the headlight bracket bolts using the 4mm Allen wrench. 3. Slide the headlight in between the mounting brackets with the wire connection pointing down.

  • Page 27: Pedal Installation

    VOLCON BRAT OWNER’S MANUAL Pedal Installation Figure 14 - Pedal Installation Figure 15 - Left and Right Pedal 1. Separate the left and right pedals marked with (R) and (L). (Figure 15) 2. Install the left pedal (non-chain side) by spinning it counter clockwise.

  • Page 28: Tire Inflation

    VOLCON BRAT OWNER’S MANUAL TIRE INFLATION The tires are partially inflated when shipped from the factory. After NOTE: completing the assembly steps, please refer to the following instructions to inflate you tires. Figure 16 - Tire Inflating Figure 17 - Tire Pressure •...

  • Page 29: Battery & Charger

    VOLCON BRAT OWNER’S MANUAL BATTERY & CHARGER BATTERY & CHARGER Battery Figure 18 - Battery • Make sure your battery is fully charged, as it will be shipped at 20-30% level to conform to industry regulations for battery shipment. •...

  • Page 30: Charger

    VOLCON BRAT OWNER’S MANUAL Charger Figure 19 - Charger The charger is a switched-mode power supply so it will work with both NOTE: 100v - 240v. How to install the battery in the bike • Use the battery key to unlock the battery from the frame to remove battery.

  • Page 31: Charging The Battery

    VOLCON BRAT OWNER’S MANUAL Charging the Battery 1. Plug the charger into a standard wall outlet. 2. Lift the small rubber charge port cover on the battery. 3. Plug the charger cable into the charge port. 4. The charger has an LED status indicator: 5.

  • Page 32: Tips For Charging

    Volcon directly at service@volcon.com. • The Battery is not repairable by users. If there is any abnormal occurrence, please contact the after-sales department for maintenance or Volcon directly at service@volcon.com. • Disassembling the battery without permission will void your warranty.

  • Page 33: Pre-Ride Safety Check

    VOLCON BRAT OWNER’S MANUAL PRE-RIDE SAFETY CHECK Make sure the brakes are applied before getting on to your bike. If the NOTE: pedal assist mode is turned on, the e-bike will start moving as soon as you push on the pedal. This unfamiliar push can otherwise cause a fall, hazard, or accident.
  • Page 34 VOLCON BRAT OWNER’S MANUAL CHECKLIST: 1. Wheels □ Check the condition of both tires making sure the tread is in good condition free from punctures, cracks, and deformations. □ Maintain proper tire pressure. We recommend a range of 20-25 PSI (1.37-1.72 bar) dependent on the weight of the rider and the type of terrain.

  • Page 35: Proper Riding Gear

    VOLCON BRAT OWNER’S MANUAL PROPER RIDING GEAR Helmet A properly fitting approved bicycle helmet that covers the forehead should be worn at all times when riding your bicycle. Look for these two approved stickers on the back of your helmet. CPSC (U.S. Government’s Standard, which has been U.S. Law since March 10, 1999) or SNELL (B-95 is a Premium Standard;...

  • Page 36: Operating Instructions

    VOLCON BRAT OWNER’S MANUAL OPERATING INSTRUCTIONS DANGER: ALWAYS CONFIRM THAT THE BATTERY IS FULLY INSERTED AND LOCKED IN PLACE BEFORE RIDING. A LOOSE BATTERY CAN FALL OUT WHILE RIDING AND COULD LEAD TO A CRASH AND DAMAGE TO THE BATTERY.

  • Page 37: Understanding The Battery

    VOLCON BRAT OWNER’S MANUAL Understanding the Battery Battery Percentage Figure 22 - Battery Level The battery level will display as a percentage and can vary due to NOTE: factors such as temperature and humidity. Tip: If the battery power is low (20% or less), change to a lower power Quick mode to conserve power.

  • Page 38: Range

    VOLCON BRAT OWNER’S MANUAL Range It is important to remember all electric bicycles have a riding range that NOTE: can vary greatly depending on the age of your battery, riding style, amount of pedaling, speed, terrain, tire pressure, temperature, payload, and wind.

  • Page 39: Powering On The Bike

    (remove battery key). 2. Flip the power switch to the “ON” position, on the right side of the battery. 3. Press the power button on the D-Pad until the display illuminates the Volcon name. 4. After the display is powered on, it shows the real-time speed and the single trip mileage by default.

  • Page 40: Turning Off The Bike

    Next reach down and turn the battery off, by switching the power switch to the off position. • Remember you can charge the battery while it is on the brat, or by removing the battery from the frame mount and charging it separately. pg. 40...

  • Page 41: Selecting A Ride Mode

    VOLCON BRAT OWNER’S MANUAL Selecting a Ride Mode Figure 24 - Ride Mode Selector 1. When you power on your e-bike for the first time, the bike will be on level 1 ride mode. This mode is a pedal assist only mode and the throttle will not be NOTE: activated when this mode is being used.
  • Page 42 VOLCON BRAT OWNER’S MANUAL LOCKED MODE Functionality Performance Level Top Speed Pedal Assist Only Mild Acceleration 20 MPH Pedal Assist Mild Acceleration 20 MPH Throttle Enabled Pedal Assist Medium Acceleration 20 MPH Throttle Enabled Pedal Assist Max Acceleration 20 MPH...

  • Page 43: The Brat App

    FOR COLLISION AND SERIOUS INJURY. Every Brat comes programmed as a Class-2 e-bike, which allows for throttle operation and pedal-assist riding up to 20mph. This allows the Brat to be legally ridden on most bike paths without a license, insurance, or registration.

  • Page 44: Lights

    Horn Button Figure 25 - Headlight Button The Brat comes equipped with a Front Headlight and Rear Tail / Brake Light. Front headlight activation 1. Press the headlight button on the D-pad and the headlight will illuminate. 2. Press the headlight button once more to shut off the headlight.

  • Page 45: Throttle

    VOLCON BRAT OWNER’S MANUAL Throttle Figure 26 - Throttle WARNING: THE THROTTLE IS EXTREMELY SENSITIVE. ALWAYS USE CAUTION WHEN ACCELERATING. How the throttle works • Rotate the throttle backward (towards you) to accelerate. • Release throttle - bike will return to Neutral (no acceleration).

  • Page 46: Braking

    Be careful when braking, turning, and accelerating under adverse conditions. Figure 27 - Handlebar features • The Brat has both front and rear hydraulic brakes. The brake levers are equipped with brake sensors that cut power to the motor when either of the levers are compressed. •...

  • Page 47: Usb Port

    VOLCON BRAT OWNER’S MANUAL USB Port Figure 28 - USB Port USB Charge Port – This feature is located inside the storage compartment. Tip: Use the open slot above the USB connection to route your cables Quick forward, if you are mounting a phone or other wired accessory to the handlebars.

  • Page 48: Horn

    VOLCON BRAT OWNER’S MANUAL Horn Horn Button Figure 29 - Horn Activating horn • Press the Horn Button on the bottom of the D-pad as shown in Figure 29. pg. 48...

  • Page 49: Suspension

    IF ANY OF THE FOLLOWING INSTRUCTIONS ARE BEYOND YOUR MECHANICAL ABILITY, WE RECOMMEND TAKING YOUR BRAT TO A CERTIFIED E-BIKE SPECIALIST OR PROFESSIONAL CYCLE MECHANIC FOR ADJUSTMENTS. The Brat is equipped with an adjustable inverted fork and adjustable NOTE: mono-shocks for the rear.

  • Page 50: Front Suspension

    VOLCON BRAT OWNER’S MANUAL Front Suspension Compression damping helps the suspension absorb bumps or road NOTE: irregularities as the wheel moves upward in the stroke. The LEFT fork handles rebound and the RIGHT fork handles compression. Figure 30 - Front Suspension Adjusting front suspension •...

  • Page 51: Rear Suspension

    VOLCON BRAT OWNER’S MANUAL Rear Suspension Preload Essentially, preload means that the spring is pushing outward on the shock before the shock has even started compressing. To make the shock start to compress, you have to overcome that preload force. The more preload force there is, the more force you have to...

  • Page 52: Maintenance

    VOLCON BRAT OWNER’S MANUAL MAINTENANCE WARNING: FAILURE TO PROPERLY CHARGE, STORE OR USE THE BATTERY WILL VOID YOUR WARRANTY. Battery Maintenance & Storage WARNING: ALL LITHIUM BATTERIES HAVE A TECHNICAL STANDARD FOR THEIR ELECTRIC CONSUMPTION DURING STORAGE. FOLLOW THESE INSTRUCTIONS FOR SAFE STORAGE & USE.
  • Page 53 DANGER: Do not dispose of the Brat battery in your trash. There are proper disposal methods for lithium-ion batteries. Please check your local waste management regulations.

  • Page 54: Recommended Maintenance

    VOLCON BRAT OWNER’S MANUAL Recommended Maintenance Schedule 1. BEFORE AND AFTER EACH RIDE □ Check the alignment of the wheels. □ Check the state of charge of the battery. If it is below 30% after riding, charge the battery before storing it.

  • Page 55: Cleaning

    VOLCON BRAT OWNER’S MANUAL Cleaning WARNING: DO NOT CLEAN YOUR BRAT WITH A STRONG WATER JET OR STEAM JET LIKE ONE FROM A POWER WASHER. THE WATER CAN PASS THROUGH THE SEALS AND GET INSIDE THE BEARINGS AND DILUTE THE LUBRICANTS WHICH COULD INCREASE FRICTION.
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  • Page 57: Component Maintenance

    If you find a tire that is worn unevenly, have a professional cycle mechanic check the wheel alignment. Chain Care The Brat comes equipped with a chain tensioner. We recommended that you inspect the chain tensioner for wear and periodically clean and lube the chain and tensioner. pg. 57...

  • Page 58: Brakes

    WARNING: IF ANY OF THE FOLLOWING INSTRUCTIONS ARE BEYOND YOUR MECHANICAL ABILITY, WE RECOMMEND TAKING YOUR BRAT TO A CERTIFIED E-BIKE SPECIALIST OR PROFESSIONAL CYCLE MECHANIC FOR ADJUSTMENTS. Check to see if the rotor and pads have contact with each other. On a hydraulic disc brake, pad wear is compensated automatically.

  • Page 59: Lighting System

    6. Align the holes then install a new cotter pin. Lighting System The Brat lighting system is wired into the main harness of the electric bike. Replacement 1. Disconnect the cable going to the headlight and replace the entire headlight assembly.

  • Page 60: Seat

    VOLCON BRAT OWNER’S MANUAL Seat It is not possible to adjust the seat height of the Brat. It is fixed to the frame by bolts. The minimum seat clamping torque on the frame is 3.00 ft lbs (4.07 Nm). For maintenance, use a cloth and water with gentle soap for cleaning.

  • Page 61: Troubleshooting

    VOLCON BRAT OWNER’S MANUAL TROUBLESHOOTING Problem Potential Cause Troubleshooting Turn the power on, 1) No power to the 1) Check battery switch power but the vehicle has no Vehicle is on power 2) Battery has a low 2) Check that the power is...

  • Page 62: Display Error Codes

    VOLCON BRAT OWNER’S MANUAL Display Error Codes Contact us directly at service@volcon.com if any of the following error codes in Table 6 are showing. Schedule 1: Error Code Definition Table Protocol Fault Code: Fault Code Fault Name Fault Code Fault Name...
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  • Page 64: Warranty

    Volcon will initially work with you on the problem to identify any possible simple fixes. You must provide Volcon with photographs and information as reasonably requested by Volcon in order to evaluate your claim.
  • Page 65 WHAT ARE YOUR REMEDIES UNDER THIS LIMITED WARRANTY? If Volcon determines that the defective Covered Component or battery is covered by the limited warranty, Volcon will, at its sole discretion, directly or through one of its certified service centers or dealerships, replace the defective Covered Component or battery (as applicable).
  • Page 66 This Limited Warranty does NOT cover damage, defects, or other issues due to any of the following (and Volcon will have no liability or responsibility arising out of or relating to damage, defects, or other issues caused in whole or in part by any of the following): (a) Normal wear and tear.
  • Page 67 YOU AGREE THAT ALL DISPUTES WITH VOLCON ARISING OUT OF OR RELATING TO THE LIMITED WARRANTY OR THE SALE, VALUE, CONDITION, OR PERFORMANCE OF THE BIKE MUST BE RESOLVED IN A STATE OR FEDERAL COURT IN WILLIAMSON COUNTY, TEXAS.
  • Page 68 VOLCON BRAT OWNER’S MANUAL WAIVER OF RIGHT TO PARTICIPATE IN CLASS ACTIONS: YOU AGREE THAT ALL DISPUTES WITH VOLCON ARISING OUT OF OR RELATING TO THE LIMITED WARRANTY OR THE SALE, VALUE, CONDITION, OR PERFORMANCE OF THE BIKE WILL NOT BE COMBINED OR CONSOLIDATED WITH A DISPUTE INVOLVING ANY OTHER PERSON’S OR ENTITY’S PRODUCT OR CLAIM, AND...
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  • Page 70: Contact Us

    VOLCON BRAT OWNER’S MANUAL CONTACT US CONTACT US For service and warranty - email: service@volcon.com For support/questions - email: support@volcon.com FOLLOW US ON SOCIAL MEDIA https://www.instagram.com/volcon.EV/ https://www.facebok.com/volcon.EV/ https://www.youtube.com/c/VolconePowersports https://www.twitter.com/volcon_ev/ https://www.linkedin.com/company/volcon-ev/mycompany Make sure to Tag us! @Volcon.ev #volconEv #EmpoweringAdventure pg. 70...

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