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BOWHEAD RX Adventure Manual

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Bowhead Design Corporation
RX Adventure-E Bike

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Summary of Contents for BOWHEAD RX Adventure

  • Page 1 Bowhead Design Corporation RX Adventure-E Bike...
  • Page 2 January 2023 Version 1.00...
  • Page 3 This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Do not install any non-Bowhead approved accessories. Any modifications or installation of non-Bowhead-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.

  • Page 4: Table Of Contents

    Table of Contents 1 PREFACE ..............................8 1.1 .. W elcome to Team Bowhead ........................... 8 1.2 .. E xplanation of safety warnings ........................9 1.3 .. R etaining instructions ............................. 9 1.4 .. O btaining documentation and information ....................10 2 Description of the product ........................
  • Page 5 4 Preparation ............................. 20 4.1 .. U nboxing your Bowhead RX ......................... 20 4.1.1 R emoval of the transport and packaging restraints .................. 20 4.1.2 Unboxing the Bowhead RX ........................20 4.1.3 Packaging contents ........................... 21 4.1.4Further unboxing notes ..........................22 4.2 .
  • Page 6 Starting / stopping operation ........................38 6 Maintenance and cleaning ........................39 6.1 .. H ow to maintain the product ........................39 6.1.1 Torque specifications for the Bowhead RX ....................39 ............................6.1.1.1 Top view torque specs ............................
  • Page 7 6.1.1 4 Cleaning checklist ........................... 51 6.2 .. E lectrical components ........................... 52 6.3 .. H ow to clean the product ..........................53 7 Troubleshooting and repair ........................54 7.1 .. H ow to Identify and solve problems ......................54 8 Safety warning and instructions ..........................

  • Page 8: Preface

    Be sure to check all hardware for correct torque (see “Torque specifications for the Bowhead RX” on page 40). Before each ride, follow the recommendations in the “Pre- ride safety check” on page 37. And finally, take care of your new RX by following the guidelines in “How to identify and solve problems”...

  • Page 9: Explanation Of Safety Warnings

    1.2 Explanation of safety warnings Danger indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury Warning indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury.

  • Page 10: Obtaining Documentation And Information

    1.4 Obtaining documentation and information The latest version of the documentation is available at the following address: http://www.bowheadcorp.com Bowhead has created many resources and videos to help you learn about maintenance and riding tips, which can be found at https://www.youtube.com/c/Bowhead/videos...

  • Page 11: Description Of The Product

    2 Description of the product 2.1 Purpose of the product The Bowhead RX is designed to increase users’ ability to access the outdoors and places that may have been previously out of reach by the user. The Bowhead RX integrates the Bowhead FLOW™...

  • Page 12: Technical Data

    -10 ‘C - +50 ‘C Table __ Performance Line CX Motor Technical Data 2.4 Product Compliance The Bowhead RX and each OEM component complies the Machinery Directive and Low Voltage requirements. See last page in this user manual for Declaration of Conformity.

  • Page 13: Get To Know Your Bowhead Rx

    2.5 Get to know your Bowhead RX 2.5.1 A. Rear end Rear suspension Rear brakes Drive train Swing arm Rear wheel...

  • Page 14: Seat Assembly

    2.5.2 B. Seat assembly Lap belt Harness Side guards Batteries Skid plate 2.5.3 C. Bosch motor, batteries, and charge port...

  • Page 15: Cockpit

    2.5.4 D. Cockpit 2.5.5 E. Front end 2.5.6 F. Articulation...

  • Page 16: Instructions / Use

    NOTE: If the battery is outside its charging temperature range, three LEDs will flash on the battery level indicator as shown below. 3.1.2 Charging the battery while installed on bike • The Bowhead RX can accommodate up to two batteries, which can be charged simultaneously via the charge port located on the seat pan. •...

  • Page 17: B Attery Insertion And Removal

    3.1.3 Battery installation and removal To install: To insert and remove the batteries, you will need to locate the keyhole locations and remove the plugs as shown above. Step 1: Carefully align the battery with the pins. Step 2: Once the pins are properly contacting the battery, gently slot the battery into its location under the RX seat base.

  • Page 18: Waking The Battery

    3.1.4 Waking the battery The battery switches to sleep mode to protect itself when not used for a longer period. The LEDs on the operating status and battery level indicator do not light up. • Press the On-Off button (battery) •...

  • Page 19: Selecting Level Of Assistance

    3.1.8 Selecting level of assistance You can adjust how strongly the electric drive should assist you on the control panel when pedaling. 3.1.9 Operating the display The display is operated using five buttons on the control panel. Symbol Designation < Browse back button Select button >...

  • Page 20: Preparation

    4 Preparation 4.1 Unboxing your Bowhead RX 4.1.1 Removal of the transport and packaging restraints Your bike is here, and you are excited to ride! Follow the simple steps below to safely remove your bike from the crate it was shipped in.

  • Page 21: Packaging Contents

    Packaging contents Every bike that leaves the shop is packaged with extreme care and attention to detail. Please ensure all the items listed below are included with your Bowhead RX and contact Bowhead immediately if anything is missing. Crate content list:...

  • Page 22: 4Further Unboxing Notes

    4.2.1 Weight of Bowhead RX for transport The total weight of the base model RX with two batteries is approximately 96lbs. This weight will fluctuate depending on accessories and upgrades. For example, the Titanium frame rails save approximately 6lbs.

  • Page 23: Lifting, Handling, And Transporting The Product

    4. Remove the KIOX display, batteries, and accessories prior to transporting. 5. If transporting on the back of a vehicle, you must use a suitable bike rack or Bowhead approved system.

  • Page 24: Using The Brake Transport System

    4.2.3 Storing your Bowhead RX Risk of fire and explosion due to high temperatures Temperatures over 60’C can also cause liquid to leak from the battery and the battery will become damaged.

  • Page 25: Preparing A Break In Operation

    The battery discharges when not in use. This can cause irreparable damage to the battery. • The battery must be recharged every 6 months. The battery may become damaged if it is permanently connected to a charger • Never connect the battery to a charger permanently. The KIOX display battery discharges when it is not in use.

  • Page 26: Conditions For Assembling

    4.2.6 Conditions for assembling The Bowhead RX comes fully assembled so you are only a few short steps from your very first ride! 4.2.7 Using the articulation (AR) pin The RX comes with a pin that is used to prevent the bike from articulating when the bike is not being ridden.

  • Page 27: Adjusting The Harness

    Rear bolt (right side) Front bolt (right side) 1. Remove the batteries from both sides of the bike using the keys provided. 2. Loosen clamping bolts on both sides of the bike (shown in images above). 3. You may need to use a rubber mallet to gently tap the seat assembly forward or backward into the desired riding position.

  • Page 28: Adjusting The Footrest

    2. Test the current size and determine if it is too tight or too loose. The harness should be snug, with just enough room to slide a few fingers down one side. 3. Open the tabs on the left and right side (circled in red) and adjust evenly on both sides. 4.

  • Page 29: Adjusting The Crank Width

    4.2.11 Adjusting the crank width The crank arms can be moved outwards from the stem to widen the crank position. Both crank arms must be moved to adjust the width and ensure optimal riding positions are maintained. There are 3 distinct width locations to adjust for rider comfort. 1.

  • Page 30: Adjusting The Calf Rests

    4. Reinstall bolts and torque to 2.5 Nm. 5. Realign the calf rest foam and attach Velcro. 4.2.13 Seat modifications The seat assembly on your Bowhead RX performs multiple functions and is a highly complex and sensitive module. Overview of Functions: 1.

  • Page 31: Adjusting The Brake Lever

    4.2.14 Adjusting the brake lever Brake failure due to incorrect setting If the pressure point is set with brakes where the brake linings and brake disc have reached their wear limit, the brakes may fail and cause an accident with injury. Before you set the pressure point, ensure the brake linings, and brake disc have not reached their wear limit.

  • Page 32: Commissioning

    Bowhead. • Mark the charger clearly to prevent mix-ups – with the Bowhead Universal Bike Code (UBC) for example. Only trained specialist staff and Bowhead builders may perform initial commissioning. Bowhead bikes will be delivered fully assembled, unless shipping to a trained technician who is capable of safe assembly.

  • Page 33: Installing The Front And Rear Wheels

    NOTE: Front wheels do not need to be removed in order to repair flats and replace tires on the Bowhead RX. You can simply remove the tire and tube on the outer side of the rim. 4.3.1 Front wheel removal and installation 4.3.1.1...

  • Page 34: Rear Wheel Removal And Installation

    4.3.2 Rear wheel removal and installation 4.3.2.1 Rear wheel removal 1. To remove the rear wheel, we recommend shifting your RX into the highest gear (smallest cassette cog, furthest from bike) in order to get the derailleur and chain out of the way. 2.

  • Page 35: Udh Hanger Information

    4.3.2.3 UDH Hanger Information The UDH rear derailleur hanger (A) and UDH bolt (B) are used to secure the derailleur. UDH frame washers (C) are frame specific. Ensure the washer is compatible prior to replacing. The axle is UDH compatible and has a M12x1.0 thread pitch and thread length measuring 12.7mm. Crash caused by loose axle A faulty or incorrectly installed axle may cause a crash if the axle comes out.

  • Page 36: Operation/Use

    5 Operation/Use 5.1 How to use the product 5.1.1 Pre-ride safety check To ensure rider safety and to prevent damage to the bike, it is important to ensure your bike is in good working order prior to each ride. Complete the following checklist to prevent injury or damage: Component Action...

  • Page 37: Operational Environment

    5.1.3 Tips for greater range How far can your Bowhead RX actually travel? There is no simple answer to this question as range depends on many influencing factors. A single battery charge may last fewer than 20 kms but more than 80 is also possible.

  • Page 38: Starting / Stopping Operation

    Terrain Terrain plays a large role in the expected range from your Bowhead RX. If you are planning a large ride with bumpy trails and significant elevation, then you can expect your average range to decrease. Gear shift Shifting gears correctly also makes your RX more efficient. It is best to set off and ride up hills using a lower gear and switch up a gear depending on the speed and terrain.

  • Page 39: Maintenance And Cleaning

    There is a risk of injury if the drive system is activated unintentionally. Remove the battery before maintenance. 6.1 How to maintain the product. 6.1.1 Torque specifications for the Bowhead RX 3D printed top-cap assembly bolts Footrest plate bolts Stem clamping and collar bolts...

  • Page 40: Top View Torque Specs

    6.1.1.1 Top View Steering pin bolts (suspension arm and steering connection) Keyhole cover and charge port insert Rear swing arm securing bolts Wooden seat base bolts Caliper mounting bolts 6.1.1.2 Rear end Rear swing arm pivot bolt Suspension rocker pivot bolts Seat post to sideguard bolts Rear trunnion suspension mount Rear axle bolt...

  • Page 41: Front End Torque Specs

    Steering column Stem clamping bolts Upper sleeve clamping bolt. This torque may be insufficient on some earlier RX models. A max torque of 10Nm is allowable. For more info, please contact Bowhead. Lower sleeve clamping bolt Pitman arm / steering connection...

  • Page 42: Articulation Torque Specs

    6.1.1.5 Articulation The torque setting on the Articulation bolts is crucial to the operation and performance of the RX bicycle. These bolts are first primed with Loctite SF 7649 Primer and Loctite 242 (blue) and then tightened to a torque of 45Nm. This setting is high and will require both heat and leverage to loosen and service this area.

  • Page 43: Installing The 3D Printed Top Cap Assembly

    3. The accessories mount, KIOX mount, and brake cable guides are press fit into each half. Gently remove these if needed. 4. Replace damaged components as necessary. 6.1.3 Installing the 3D Printed top cap assembly To reinstall the top cap assembly, complete the following steps. 1.

  • Page 44: Replacing The Brake Cable Guide Arms

    6.1.4 Replacing the brake cable guide arms To replace the brake cable guide arms, complete the following steps Removal: 1. Remove the bolt circled in red. 2. Note: use caution when removing bolt circled in red. Do not fully remove from guide not to avoid losing part.

  • Page 45: Installing New Grips

    5. Reinstall the brake lever. Torque 5-6Nm. 6. Reinstall brake cable guide arm. Hand tight such that the guide cannot rotate. NOTE: New grips can be ordered directly from Bowhead. If you are modifying your own grips for install, be sure to align the holes properly.

  • Page 46: Steering Column Structure

    6.1.7 Steering column structure The steering column on your RX features components that serve multiple functions. You can see the following components highlighted in the diagram: Sleeve-Bottom (A), Sleeve- Top (B), Stem (C), Spindle-Crank (D), Pitman Arm and Steering Knuckles (E). The Sleeve-Bottom (A) is used to set the correct headset compression during assembly and maintenance.

  • Page 47: Geometry Of Steering

    The Spindle-Crank (D) is fastened through the Stem and holds the Freewheel and both crank arms. The width of the crank arms is adjustable via the Spindle-Crank. A special tool is required to service the Spindle-crank and the components it houses, please contact Bowhead for support when servicing this area.

  • Page 48: Toe-In / Toe-Out

    6.1.9 Toe-in / toe -out 6.1.9.1 Effects of Toe-in: 1. Toe-in can cause increases in slip angle of the front tires which helps to increase the grip between tire and road. 2. The increased grip due to the toe-in angle resists the bike motion and reduces the acceleration of the bike.

  • Page 49: Adjusting The Top Chain Tension

    6.1.11 Adjusting the top chain tension To adjust or set the top chain tension, complete the following steps. 1. First, you must identify where the chain should be set. Is the current tension too loose or too tight? To check this, use your index finger and push on the rear chain loop as shown above.

  • Page 50: Lubricating The Chains

    6.1.13 Replacing the chains The Bowhead RX has three chains. As chains are a wearable component, they will likely need to be replaced during the life of the bike. In order to do so, please follow the steps below. Note: it is important to connect the new chain PRIOR to removing the old chain.

  • Page 51: Cleaning Checklist

    7. Disconnect the old chain and link the new chain to itself. Note: This method can be used on all three chains on the Bowhead RX. Please contact Bowhead Customer Service for more info or if you require additional support.

  • Page 52: Electrical Components

    Once a month Check disc rotors Every 4-6 months Table 5 Planned maintenance for the Bowhead RX 6.2 Electrical components Cleaning the Plugs and motor connections Do not remove plugs when your RX is below room temperature. The plastic becomes brittle and will break.

  • Page 53: How To Clean The Product

    Water may enter the inside of the bearings if you use a pressure washer. This dilutes the lubricant inside, the friction increases and, as a result, the bearings are permanently damaged in the long term. Do not use a pressure washer on your Bowhead RX. Cleaning the drive elements 1.

  • Page 54: Troubleshooting And Repair

    7. Troubleshooting and repair 7.1 How to Identify and solve problems WARNING: Once a problem is identified, do not ride your Bowhead bike until the necessary steps have been taken and has been repaired to factory standards. NOTICE: Contact Bowhead for additional support on troubleshooting errors and solutions. If any issues persist beyond the below solutions contact Bowhead immediately.
  • Page 55 32, and contact Bowhead if issue persists. Adjust your shock sag. This should be set with the rider in the bike at 25% sag. Chain interferes with skid Chain rub under seat plate in low gears Also ensure all seat wiring as per image 32 is free and clear of chain motion.
  • Page 56 Inflate tires to recommended Low tire pressure PSI. Reduced range Low battery Charge battery. Adjust the brakes according Brakes rubbing to the instructions on page 32 Table 6 Troubleshoot the Bowhead RX...

  • Page 58: Safety Warning And Instructions

    EQUIPMENT MODIFICATIONS Your Bowhead RX is designed to provide safe operation when used as directed. Modifications to your bike may negatively impact stability and safety. Failure of critical machine components may result from operation with any modifications. This vehicle may become less stable at speeds higher than those for which it is designed.

  • Page 59: Safety Information For Vulnerable People

    The brake system must be repaired immediately if brake fluid leaks out. Dispose of leaking brake fluid in an environmentally responsible way in accordance with statutory regulations. Personal safety Do not leave children unattended with your Bowhead bike or any of the electrical • components. •...

  • Page 60: Checking The Battery

    • Only operate the battery and accessories if they are in perfect condition. • Only use batteries which are approved for use on your Bowhead. • Do not use a battery with connecting cable or defective contacts. • If the battery becomes deformed or begins to smoke, keep at a safe distance, disconnect the power supply at the socket, and notify the fire service immediately.
  • Page 61 Remove batteries with external damage from service immediately and never charge them. Only operate the battery and accessories if they are in perfect condition. Only use batteries which are approved for use on your Bowhead bike. Do not use the battery with defective connecting cables or defective contacts.
  • Page 62 Store in a dry place until disposal. Never store in the vicinity of flammable substances. Never open or repair the battery. Charge the battery before use. Only use the charger provided with your bike or purchased through Bosch. Electric shock in case of damage Damaged chargers, cables and plug connectors increase the risk of electric shock.
  • Page 63 Risk of fire and explosion due to high temperatures Excessively high temperatures will damage the battery. The battery may self-ignite and explode. Protect the battery against heat. Never expose the battery to sustained direct sunlight. Fire caused by overheated charger The charger heats up when charging the battery.

  • Page 64: Crash Caused By Incorrectly Adjsuted Torques

    Always observe the indicated torques on the screw or in the operating instructions. Only a correctly adjusted Bowhead will guarantee you the desired ride comport and health- promoting activity. Therefore, adjust the seat position, grips, crank width, crank height, and suspension to your body and your preferred riding style before the first ride.

  • Page 65: Injuries And Death Caused By Riding Incorrectly

    • Wear a cycling helmet and high-visibility, reflective clothing if riding on the road. • Always take a defensive approach to riding. • Avoid the blind spots of vehicles turning off and reduce your speed as a precaution when other roads users turn right. Injuries and death caused by riding incorrectly Crashes are possible when riding on terrain that is above the rider’s skill level or that they are unfamiliar with.

  • Page 66: Recycling And Disposal

    9. RECYCLING and DISPOSAL 9.1 How to dispose of components To dispose of the batteries: 1. Never dismantle the charger, batteries, or other components for disposal. 2. Refer to Bosch manuals found on our website for battery disposal information. 9.1.11 Disposal of electronic components To dispose electronic components: 1.

  • Page 67: Declaration Of Conformity

    Declaration of Conformity...