Chapter 6: Tire, Tube, Wheel Or Axle Repair; Removing The Rear Motor Wheel; Installing The Rear Motor Wheel - Prodeco Technologies Genesis 500 User Manual

Chapter 6: Tire, Tube, Wheel and Axle Repair
The G Plus Genesis 500 was designed for ease of servicing. Repairs are no more difficult than on a traditional
bicycle. Any neighborhood bicycle shop should be able to repair a flat, change a tire or replace a wheel. Please
review the following chapter on how to remove and replace the front and rear wheel of your G Plus Genesis 500.
a. Removing the rear motor wheel
The wheel incorporates a motor wire quick disconnect for removing the wheel. To remove the wheel, follow these
instructions, it will only take a few minutes. Read the instructions fully before first attempting to remove the wheel.

Prior to removing the wheel, shift the bicycle into gear 6 or 7 (the small COG/sprocket on the rear
cassette. It will be easy to remove the wheel if the chain is at the end of the cassette. Make sure to spin
the crank while shifting gears.

Next, turn the battery ignition key to the "UNLOCK" position (lock pin locked into battery) and remove the battery.

To work on bicycle, it may be easier to turn the bicycle upside down by placing blankets on the ground
and resting the bicycle on the saddle and handlebar.

Locate the motor disconnect weather proof plug on the left side of the bike frame 6 inches from the
motor axle and separate the connector.

Locate the cable tie which ties the motor wire to the frame. Cut the cable tie with snips.

On each axle nut there is a rubber nut protector, remove these protectors simply by pulling on them.
On the wired side of the axle, slide the rubber protector up the wire only a few inches.

Using a wrench, turn counter clockwise each axle nut until the axle washers are loose.

Remove the wheel from the frame by pulling on the wheel.

The 7 speed freewheel mounted to the motor can be slid out away from the chain with no issue. The
spring of derailleur may cause the lower pulley to get in the way of removing the wheel. Simply pull the
pulley out of the way.
b. Installing the rear motor wheel
The rear motorized wheel easily installs onto the rear frame dropouts within a few minutes. Follow the instructions
below on installing the rear motor wheel. Your G Plus Genesis 500 included additional cable ties with the User
Guide. 1 cable tie will be needed to install the motor. Read the instructions fully before attempting to install the
wheel. (SEE PHOTOS ON NEXT PAGE)

Pull or push the rear derailleur lower pulley with chain out of the way of the drop outs.

Now check to make sure the chain is not in the way and align the wheel above (below if bike is on kick
stand and not upside down) the dropouts and pay attention to the lining up of the disk brake rotor into
the brake caliper (between the pads).

Prior to inserting the wheel into the dropouts, pull the chain onto the cassette.
 Slide the motor into the frame drop outs by aligning the axle into the dropouts. The axle has flat edges
which require the axle to enter the dropouts with the flat edges facing front and back. The axle with the
motor wire protruding is to enter the left side dropout (the left side is when standing behind the handlebar).

Now check to make sure the chain is not in the way and align the wheel above (below if bike is on kick
stand and not upside down) the dropouts and pay attention to the lining up of the disk brake rotor into
the brake caliper (between the pads).

Each axle side has washers and a nut. Slide the washers over the axles and tighten nuts by hand.

Using a wrench, fully tighten axle nuts. Axle nuts should be tightened to 250 lb*in.

Plug motor connection by aligning arrows on each end of the connector and slide together.

Once connectors are plugged, you must test connection. Install the battery as described in Chapter 8
"Battery Management" section c "Installing and locking the battery". Turn the ignition key to "ON" at the
battery. LED lights on throttle will light up displaying power to the motor. Pull the rear motor wheel off
the ground (if the bicycle is not turned upside down) and turn the throttle to test the motor. If the motor
turns, the connection is solid. If motor does not turn, turn key to "OFF" position at battery and then
check the motor connector to ensure a solid connection has be made. Test again after checking.

After confirming a solid connection, use the cable tie to connect the motor cable to the side of the frame
and once tightened, cut off the extended amount.
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