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RAYVOLT Cruzer Owner's Manual

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Summary of Contents for RAYVOLT Cruzer

  • Page 1 owner manual...
  • Page 2 Rayvolt Bike S.L. c/ Montcada, 1 08003, Barcelona Spain www.rayvoltbike.com © 2021 All Rights Reserved.
  • Page 3 See the digital version here for easy access to all videos and links:...
  • Page 4 07. Troubleshooting • Inspection intervals table description • Saddle adjustment • Handlebar adjustment 08. Take care of your • Pedal assembly Cruzer • Battery connection • Battery installation • Lubricate the chain • Chain tension • Covers and wheels...
  • Page 5 Introduction...
  • Page 6 When carrying out this work, always keep in mind that the instructions and indications only refer to this Rayvolt bicycle and cannot be applied to other models. Due to the large number of versions, it is possible that the works described are not complete or not exactly the same.
  • Page 7 doing the work or lack of the necessary tools. This manual will not provide you with the knowledge of a bicycle mechanic or electrician. For this reason, this manual refers to the bicycle you have just purchased and the usual components, and includes the most important indications and warnings.

  • Page 8: Before Each Use

    Avoid sudden acceleration and braking. If you are in doubt about the operation of your Rayvolt Bike, it is best that you haven’t started riding and it is essential that you carefully examine the bicycle and repair or replace faulty components.
  • Page 9 Make sure chain is still in grenade on chainrings and sprockets. Check the position of the saddle. Finally finish by giving a general review of your Rayvolt Bike to confirm that everything is correct. However as an extra point, it should be noted that bicycles are vehicles...
  • Page 10 Rayvolt Bike is an electric bike and as we all know electricity and water are not good friends. Water conducts electricity and in the event of any type of leak it can cause a short...
  • Page 11 Hand washing allows us to detect paint deterioration, worn parts or other defects in time, improving the care of our Rayvolt bicycle. Once we have washed our bike, we wait for it to dry and, in order to protect the paint, metal surfaces, spokes, hubs, etc.,...
  • Page 12 Storage We will not always be riding our Rayvolt bicycle, so we have to know how to store it in order to keep it in the best of states. If your bicycle receives regular care, a short-term stop doesn’t require any special preventive measures, except for anti-theft protection.
  • Page 13 Serial number The serial number of the Rayvolt Cruzer is located on the front of the frame. Owner manual...

  • Page 14: Ec Declaration Of Conformity

    EC Declaration of Conformity This Declaration of Conformity applies only to countries following the CE marking directives. Download this page if needed in the following link: https://www.dropbox.com/s/0yypd1bj6ewyyai/Cruzer_EC_ declaration%20of%20conformity_2021.pdf?dl=0 Owner manual...
  • Page 15 Rayvolt Bike S.L. declares, under its exclusive responsibility, the conformity of these products: • Rayvolt Cruzer M or L, Smart Hub, Power Hub, Li-ion Battery or Dual Pack. Manufactured in: 2020 / 2021 With the standard(s) and other policy document(s): •...
  • Page 16 Bike scheme...
  • Page 17 Tire & tube Front disc brake Stem Frame Handlebar Spoke Fork Grip Front hub Head parts Brake lever Owner manual...
  • Page 18 Throttle Tank cover Pedal Kickstand Saddle Key switch Crankset Mudguard Quick release Charger plug Chain Motor Saddle nut Battery case Controller Chain tensor Owner manual...

  • Page 19: Maintenance And Inspection

    Maintenance and inspection...
  • Page 20 Inspection intervals table Component Inspection Interval Tires Check pressure Before each use Check drawing and Monthly side condition Lights Check status Before each use Chain Correctly lubricated Before each use Bottom bracket Check bearings Monthly clearance Re-grease Annual Direction Check bearings Monthly clearance Re-grease...
  • Page 21 Component Inspection Interval Brakes Pads thickness Monthly Wiring / Pipes Monthly Wheels and Check centering Monthly spokes and tension. Pedals Check bearings Monthly clearance Metal surfaces Check condition At most every and waxing half year Painting Check status At most every half year Nuts and bolts Check tension...

  • Page 22: Saddle Adjustment

    Saddle adjustment The position of the saddle is determined by pedaling. A correct adjustment will allow us to have a more comfortable ride and avoid injuries. M14 Wrench Owner manual...
  • Page 23 1. Seat height. Place the saddle tube on the saddle post and tighten using the quick release lever. Important: If your seat post is not inserted up to the minimum insertion mark, the seat post may break. Once the saddle is at the correct height, make sure the seat post should be up to its insertion mark.

  • Page 24: Handlebar Adjustment

    Handlebar adjustment On your Rayvolt Cruzer the ends of the handlebar are curved. Adjust the handlebar so that your wrists are relaxed and not too far out. Visual support: https://www.youtube.com/watch?v=OVdiQ1ZLby8&t=16s M4 Allen M5 Allen M6 Allen Owner manual...
  • Page 25 1. Adjust the angle of the handlebar. You will find 4 hex bolts attaching your stem. Use an M5 allen key (or an M6 allen key depending on your version) to loosen them. Once loosened, position the handlebar angle to your liking and retighten the stem bolts.
  • Page 26 3. Adjust the position of the brake handles. You will find 2 hex bolts securing each brake handle to the handlebar. Use an M4 allen key to loosen them. Once loosened, position the brake handles to your liking and retighten the bolts. It is recommended to adjust the position of the hand allowing a comfortable brake application while driving.

  • Page 27: Pedal Assembly

    Pedal assembly Visual support: https://www.youtube.com/watch?v=OVdiQ1ZLby8&t=16s 15mm Wrench Owner manual...
  • Page 28 1. Pick the appropriate pedal on each side. Note that the right pedal is labeled “R” and the left pedal is labeled “L”. L E F T R I G H T 2. Lock each pedal with the 15mm wrench. Owner manual...

  • Page 29: Battery Connection

    Battery connection Generally the battery comes separated from the bike for preventive reasons. Follow this steps for a proper installation before using the bike. The installation may be done with the battery case attached to the bike or separated. Consult the section “Battery installation”...
  • Page 30 1. Open the battery case. First open the zipper and then open the battery case. 2. Place the battery inside. Place the battery on the anti-slipping battery base, leaving the cables on the upper part of the case. B AT T E RY B AT T E RY B A S E 3.

  • Page 31: Battery Installation

    Battery installation The battery case of the Rayvolt Cruzer may be extracted from the bike. Follow this steps for a proper removal and installation of the case. Owner manual...
  • Page 32 1. Check whether the safety lock is closed or opened. WR O N G CO R R E C T P O S I T I O N P O S I T I O N 2. Place or remove the battery case from the left side of the bike.

  • Page 33: Lubricate The Chain

    Lubricate the chain Regularly check the condition of the chain: it must always be lubricated and clean. Chain Degrease Common rag lubricant Owner manual...
  • Page 34 1. Choose lubricant. Select the lubricant that best suits the conditions of use. There are special lubricants for wet weather, snow, rain or dry weather. 2. Clean the chain. Apply some type of degreaser to the chain. You will get them in all bike shops or even in various shopping centers.

  • Page 35: Chain Tension

    Chain tension Regularly check the tension of the chain: it must be tight enough to only allow a little movement up and down. If there is no slack, it is too tight. If there is too much slack, then a tighten is needed. 21mm Wrench M5 Allen M4 Allen...
  • Page 36 1. Release the chain tensioner. On each side of the rear wheel, there is a chain tensioner holding the wheel to the frame. Using an M5 allen key, remove the lateral screws, and use a 21mm wrench to remove the flange nut of each side. 2.
  • Page 37 Covers and wheels Change front wheel M5 Allen Owner manual...
  • Page 38 1. Remove the thru axle. Use an M5 allen key to loosen the thru axle head. Once unscrewed, pull the axle until it comes out completely. 2. Remove the front wheel. Once the axle is out, pull the wheel downwards to succesfully remove the front wheel. 3.

  • Page 39: Change Rear Wheel

    Change rear wheel Visual support: https://youtu.be/FZoTOesSoxA 21mm Wrench M5 Allen M4 Allen 1. Turn off the bike. Make sure the bike is turned off and there is no power supply. 2. Disconnect the motor wire. Detach the cable from its fixation.
  • Page 40 3. Remove the two chain tensioners and axle nuts. Using the M5 allen key and M4 allen key, unscrew the bolts of each side and release the wheel. Using the 21mm wrench, remove the flange nuts on both sides of the wheel. For more details consult the previous section "Chain Tension".
  • Page 41 Change bike tube Rayvolt Cruzer has two sizes, L and M, for which a different inner tube is required in each case. Tube 26x3.0 Schrader for Cruzer L or 24x3.0 Schrader if it is Cruzer M. Tube 26 x 3.0 Schrader / Tire lever Tube 24 x 3.0 Schrader...
  • Page 42 1. Remove the wheel from the bike. For more information, consult the section “Change front wheel” or "Change rear wheel" in this manual. 2. Remove the bike tube. Using the tire levers, separate the cover from one side, little by little, from its place. Once separated, remove the damaged bike tube.
  • Page 43 Accessories...

  • Page 44: Light Kit Assembly

    Light kit assembly Front light installation M5 Allen Owner manual...
  • Page 45 1. Place the front light on the fork crown screw holes. Use an M5 allen key to tighten the screws. Tighten both of them until the front light is firmly seated. 3. Open the tank and locate the front light wire. Identify the front light cable by its two-pin red plug.
  • Page 46 Rear light installation 10mm Wrench S P R I N G N UTS A N D S PA C E R S Owner manual...
  • Page 47 1. Take the saddle off. Consult the section “Saddle adjustment” in this manual for more information if needed. 2. Remove the spring nuts and spacers. Use the 10 mm wrench to remove both spring nuts and separate the springs from the saddle. Remove the spacers too. 3.
  • Page 48 Change mudguards 21mm Wrench M5 Allen M4 Allen M3 Allen Owner manual...
  • Page 49 1. Remove the front mudguard. Use an M3 allen key to remove both screws attaching the bracket to the sides. Use an M4 allen key to remove the front screw holding the mudguard on the fork. 2. Remove the rear wheel for the rear mudguard.
  • Page 50 Bell assembly Phillips screwdriver Owner manual...
  • Page 51 1. Open the bell screw. Use a Phillips screwdriver to open the bell. Separate the bottom part for better placement on the handlebar. 2. Place the bell on the handlebar. Place it in such a way that it is comfortable to use. We recommend the left side next to the brake.
  • Page 52 Torque sensor installation Visual support: https://www.youtube.com/watch?v=yi2DoA4TNaI 15mm Bottom Cassette M8 Allen Wrench bracket tools extractor Owner manual...
  • Page 53 1. Remove the pedals. Use the 15mm wrench. 2. Remove the left crank arm. Use the cassette extractor to loosen the centre screw and remove it. Use the same tool to remove the crank arm. 3. Take out the PAS. Once removed the left crank arm, the Pedal Assisted Sensor is next.
  • Page 54 7. Remove the fixed cap of the torque sensor. Place it on the left side (non-driving) and lock it with the Bottom bracket tool. 8. Introduce the Torque sensor. First run the cable through the middle hole, then introduce the full body and lock it with the bottom bracket tool.

  • Page 55: Electrical Maintenance

    Electrical maintenance...

  • Page 56: Component Description

    Component description This brief description of the electrical components of the Rayvolt Cruzer will help identify and understand each part and its wire, in the following wiring diagram. Motor: Responsible for transmitting movement to the chain in order to move the wheel. It is directly connected to the controller.
  • Page 57 Battery: 48 V Battery. The battery is the component that will keep the entire system alive. To provide long battery life, ALWAYS charge the battery after using the bike. STD BATTERY DUAL BATTERY Controller: The brain of the entire electronic system. Inside it is loaded the firmware in charge of managing the input and output signals of the controller itself.
  • Page 58 PAS: Offers assistance when pedaling. Depending on the sensitivity of the sensor, the motor will understand that it must be activated. A low PAS level translates into high sensitivity to motor activation, that is, a small fraction of a turn is sufficient to activate the motor. We can also regulate the power transmitted to the motor.
  • Page 59 Throttle: The throttle has three functions. Accelerate, check the battery level and turn on the front lights and rear lights. The 3 LEDs indicate the battery level, with 3 LEDs on full and 1 LED on low battery. Torque sensor: Sensor capable of detecting the force exerted on the pedal.
  • Page 60 Light Kit: Rayvolt Bikes have a front light and a rear light. Both lights are powered directly by the battery at 48 V. FRONT LIGHT REAR LIGHT DC Converter: It is a DC-DC voltage rectifier that allows 7 to 60 V inputs and 3.3 to 33 V outputs.
  • Page 61 • Tank wire: Secondary connection to the controller. It serves both as a power supply and as a data bus. It shares bidirectional signals between controller-throttle controller-brake sensors. It is used to power both the throttle LEDs and the front and rear lights and all sensors / actuators.
  • Page 62 EIVA 2.0 App. For more information see the “MicroEIVA manual”. End Plug: Rayvolt Cruzer wiring is designed to work with a MicroEIVA device, therefore, when it is not installed on the bike, an End plug is needed to close the electrical circuit. It works as a closed switch.

  • Page 63: Wiring Diagram

    Wiring Diagram This is the wiring diagram of the Rayvolt Cruzer, for the Controller V4. Owner manual...
  • Page 64 B AT T E R Y B R U S H L E S S M OTO R CO N T R O L L E R V4 Controller Cruzer V4 I. Power wire II. Controller wire 1 III. Controller wire 2 1.

  • Page 65: Technical Specifications

    Technical Specifications...
  • Page 66 Saddle: Motor: Rayvolt Deluxe Genuine Leather Smart Hub 50 Nm - 250 W Power Hub 100 Nm - 250 W Brakes: Rayvolt Oil Disk Brakes with Battery: E-Regenerative 10 A - 50 A Life of 1000 cycles (optional) Smart Battery...
  • Page 67 General: Dimensions: Weight: M: 1890 x 990 x 720 mm 29 kg - 33 kg L: 2165 x 1030 x 720 mm 2165 1470 1030 25º 1890 1240 28º (mm) Owner manual...
  • Page 68 Troubleshooting description...
  • Page 69 Troubleshooting description Note that there is the option of a faulty wire that will be the source of the problem, so verify that the condition of all wiring is correct and that the circuit has power. You will then test your scenario solution. Scenario 1: Bike doesn’t turn on and three lights on the throttle are off, no microEIVA installed.
  • Page 70 3. End plug wire not connected: If the bike is still not working, the next step is to open the tank case of your Cruzer. Inside, you will find some of the wiring system of the bike. There may be a black plastic cover hiding some of the connections.
  • Page 71 If you can not see this wire, search for the 6 pin green connector. If it is free and not connected to anything, it is the source of the problem. Contact your nearest distributor in order to claim this wire. 4.
  • Page 72 the controller case it is needed to remove the three screws under the frame, just below the battery case. Contact your nearest distributor or shop and explain the process done and if the red led was on the controller, they will give you further instructions.
  • Page 73 3. MicroEIVA wire not connected: If the bike is still not working, the next step is to open the tank case of your Cruzer. Inside, you will find some of the wiring system of the bike. There may be a black plastic cover hiding some of the connections.
  • Page 74 In the event all is well connected and the problem is not solved, it is needed to unplug the DC-Converter. Disconnect it and test if the bike works now. 4. Brake sensors issue: If it still has the same behaviour, disconnect the brake sensors from the tank case.
  • Page 75 1. EIVA detects an error: Open the EIVA 2.0 app on your phone and connect with your bike. In the event that an error appears on the main screen, click on the error message and a pop-up with more information will appear. Consult the "EIVA 2.0 manual"...
  • Page 76 In the case that without pedalling nor applying throttle, the wheel runs by itself, Reset Parameters is needed on the bike. Consult the "EIVA 2.0 manual" to see how to do this. If it happens after applying throttle or pedalling and the Reset Parameters did not work, the chain may be too tight, so it is needed to adjust it.
  • Page 77 first loose the caliper screws. Then, press the right brake lever and tighten the screws while pressing the lever. If you have used your bike a lot, the brake pads may need to be changed, consult the section “Braking system” in this manual to learn how to do it..
  • Page 78 Scenario 6: Noise on the front wheel. Check that there is nothing touching the wheel while turning (wires, stones, mudguard, rear rack…). If there is nothing touching the wheel, the spokes tension needs to be adjusted. It is a procedure that needs to be done periodically, since the torque of the motor makes the spokes get loose.
  • Page 79 charger and the battery are working correctly. If it is not full, it seems there is a problem. First, try to connect the charger to another plug and check if the problem is solved. If you have another battery, use the same charger to charge this battery inside the battery case of the first one.
  • Page 80 BLOWN FUSE INTACT FUSE more important than the color). If they are in a good condition, place them again in their position. Contact your nearest dealer. 2. Charger problem: Remove the charger fuse and check if it is in a good condition.
  • Page 81 Take care of your...
  • Page 82 Conditions for riding the Rayvolt Cruzer This pedal electric assistance bicycle is designed for riding on road or riding on a paved surface where the tires do not lose ground contact. It must be properly maintained according to the instructions found within this book;...
  • Page 83 Battery To ensure a longer battery life and protecting it from damage, please use and maintain it according to the guideline below. During your riding, when you find the power decreased to 5% on the LCD. The battery must be charged in short time! Remember to charge the battery full before you will ride for a long trip.

  • Page 84: Battery Charger

    Battery Charger Before charging the battery please note the following points. The battery can be charger by the AC, the switch is not necessary to be turned on. Insert charger output plug into the battery securely and then, plug the main cable of the charger into a reachable AC outlet.
  • Page 85 The charger is forbidden to be disassembled. You should only use the charger provided with the electric bike, otherwise damage could occur to your battery and void the guarantee. When charging, the battery and charger should be minimum 10 cm away from the wall, or under a condition of ventilation for cooling.

  • Page 86: Warranty Terms

    First, you should pay attention to protect it from impact and avoid any damage. Second, make regular check on all bots and nuts, and fasten them securely. Warranty terms For Warranty terms on your Rayvolt, please refer to our website: www.rayvoltbike.com Owner manual...
  • Page 87 www.rayvoltbike.com...

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