Ultra motor A2B Metro Service Manual
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Ultra motor A2B Metro Service Manual

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A2B Metro Service Manual
A2B Metro Service Manual

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Summary of Contents for Ultra motor A2B Metro

  • Page 1 A2B Metro Service Manual A2B Metro Service Manual...
  • Page 3 A2B Metro Service Manual Ultra Motor USA 45 Broadway Street San Francisco, CA 94111 Tel: (415) 693-3110 Fax: (415) 693-3121 www.ultramotor.com...
  • Page 4 Ultra Motor USA, Inc. Although every precaution has been taken to assure this publi- cation is complete and accurate, Ultra Motor USA assumes no liability for errors or omissions. All information contained in this publication is based on the latest information available at the...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Chapter One: General Information Terms Lubricants Threadlock Special Tools Specifications Chapter Two: Steering and Front Suspension Handlebar Replacement Throttle Handlebar Stem Front Fender Front Fork Chapter Three: Brakes Brake Lever Brake Cable Inner Wire Brake Caliper Brake Pad Replacement Brake Disc Chapter Four: Shifter and Derailleur Shifter...

  • Page 7: Threadlock

    Campagnolo, Finish Line, Lube Wax, Phil seated on the A2B Metro and facing for- Wood Tenacous Oil, Pedros, Superlube, ward. The right side of the A2B Metro is the and Triflow. chain side. The left side is the brake side.
  • Page 8 Chapter One SPECIAL TOOLS The following special tools are needed when servicing the A2B Metro. Tool Part number Hex wrench set: 4mm, 5mm, 6mm Park AWS-1 Hex wrench set Park AWS-11C Hex wrench set: 2mm, 5mm, 3mm Park AWS-3 Fourth-hand cable stretcher...

  • Page 9: Specifications

    GENERAL INFORMATION SPECIFICATIONS Table 1: Mechanical Specifications Component Specification Headset VP-A50AC Stack height 10.3 mm (0.41 in.) Dimensions 1 1/8 x 44 x 30 Front fork Spinner Type FK-001 Handlebar Kalloy AL-021 Rise 9° Width 670 mm (26.38 in.) Handlebar stem MJ Cycle ST-001 Seatpost Kalloy SP-600...
  • Page 10 Chapter One Table 2: Gear Ratios Chainring Freewheel Gear Inches Ratio 83.6 70.8 61.3 51.1 43.8 38.3 32.9 Table 3: Electrical Specifications Component Specification Battery 36-volt Type Lithium ion Capacity 11.4 amp-hrs (422 watt-hrs) Charger High Power, HP8204C(10s) Input 115/230 VAC, 60/50 Hz, 1.5/0.9 A Output 42VDC/2A Table 4: Performance Specifications*...
  • Page 11 GENERAL INFORMATION Table 5: Torque Specifications Item in.-lb. ft.-lb. Special Instructions Bottom-bracket cartridge adapter ring 29.4-38 21.7-28 Apply grease to the threads Brake caliper anchor bolt 40-60 Brake caliper CPS bolt 8-10 70-90 Brake caliper mounting bolt 5-7 40-60 Apply Loctite 242 Brake disc bolt Apply Loctite 242 Brake lever clamp bolt...
  • Page 13 Chapter Two STEERING and FRONT SUSPENSION HANDLEBAR REPLACEMENT 1. Note the position of the throttle and the shifter relative to its handlebar grip. If nec- essary, measure the gap between each item and its handlebar grip or make a drawing so these components can be reinstalled with the proper positioning and orientation.

  • Page 14: Throttle

    Chapter Two d. Install a grip spacer and handlebar 9. Pull the wire and string through the cable grip onto each handlebar end. shroud. Untie the string from the throttle e. Position the throttle or shifter relative to connector and remove the throttle. Leave its handlebar grip as noted during remov- the string in place so it can be used to pull al.
  • Page 15 STEERING and FRONT SUSPENSION HANDLEBAR STEM Removal 1. If necessary, remove the handlebar binder bolts (Figure 3), and remove the handlebar from the handlebar stem. Use a bungee cord to suspend the handlebar from the frame. 2. Loosen the handlebar stem clamp bolt (A, Figure 4).

  • Page 16: Front Fork

    Chapter Two 3. Perform the following to set the headset FRONT FORK bearings and to secure the handlebar stem in place and in alignment with the Removal front wheel. a. Tighten the handlebar stem bolt (B, The front fork is not serviceable. If the fork Figure 4) until there is no play in the steer- is damaged, it must be replaced.
  • Page 17 STEERING and FRONT SUSPENSION 8. Visually inspect the seal (B, Figure 11) Installation and the cone on the upper-bearing collar (C) for nicks or other damage. 1. Slide the fork column up into the head tube until the lower-bearing collar (Figure 13) rests against the lower bearing (Figure 12).

  • Page 19: Brake Lever

    Chapter Three BRAKES BRAKE LEVER (Chapter Two) to ease shifter or throttle removal. Removal 1. Note the position of the throttle or the shifter relative to its handlebar grip. If nec- essary, measure the gap between the item and its handlebar grip or make a drawing so these components can be reinstalled with the proper positioning and orientation.

  • Page 20: Brake Cable Inner Wire

    Chapter Three 4. While and assistant pulls the string, guide 15. Install a new cable tie around the top the brake switch wire through the shroud, of the cable shroud. Tighten the cable tie into the frame cutout, and through the to the diameter noted during removal.

  • Page 21: Brake Caliper

    BRAKES Installation 11. Pull in and hold the brake lever. Check that the rotor is still centered within the A fourth-hand tool (Park Took BT-2) is caliper body. needed for this procedure. 12. Pull in and hold the brake lever. Torque 1.

  • Page 22: Brake Pad Replacement

    Chapter Three 4. The brake pads are color coded and must be installed on the correct side of the brake disc. Install the black pad (A, Figure 7) on the outboard side of the brake disc. Install the blue pad (B, Figure 7) on the inboard side of the disc.

  • Page 23: Shifter

    Chapter Four SHIFTER and DERAILLEUR SHIFTER 4. If the brake lever was moved perform the following: Removal a. Slide the brake lever so its bracket rests against the shifter. 1. Note the position of the shifter relative to b. Rotate the brake lever to the position the left handlebar grip.
  • Page 24 Chapter Four 5. Remove the cable housing and inner align with the smallest cog (high gear) as wire from the derailleur barrel adjuster (C, shown in Figure 5. Figure 2). b. If necessary, adjust the outward limit by 6. Remove the hand grip from the left turning the H-screw (high-gear limiter handlebar end.
  • Page 25 SHIFTER and DERAILLEUR tool, and torque the derailleur anchor bolt (B, Figure 2) to the specification in Table 5. Make sure the inner wire still sits in the pinch-mechanism groove. 13. Cut the excess from the inner wire. Leave a couple of inches for future adjust- ment.
  • Page 26 Chapter Four b. Loosen the anchor bolt (B, Figure 2). 3. Set the derailleur’s outward limit as fol- Use the fourth-hand tool to pull the slack lows: from the inner wire. a. Shift the derailleur so the chain sits on c.
  • Page 27 SHIFTER and DERAILLEUR Derailleur Installation (clockwise) of the stop tab on the derail- leur hanger. 1. Lubricate the derailleur as described 4. Turn the mounting bolt into the hanger. above. Finger-tighten the bolt. 2. Align the mounting bolt (D, Figure 2) with 5.

  • Page 29: Chain

    3 or more: the chain is worn beyond the wear limit. Checking Chain Length 1. Secure the A2B Metro in a stand at an angle that matches the angle when the FIG. 2 bike sits upright on a level surface.
  • Page 30 Chapter Five FIG. 5 FIG. 3 NOTE Press the rivet the minimum distance need- ed to separate the chain and stop. Do not drive the rivet completely from the inner plate on the inboard side of the chain. The Insufficient chain can be separated once the rivet bend extends 0.5 to 1.0 mm into the inside of the...

  • Page 31: Crank Arm

    FIG. 8 attention to the following: a. If the tool has two cradles, use the 2. If the chain is installed on the A2B Metro, back pedal for 30 seconds. If the chain is cradle furthest away from the tool han- not installed, wiggle the chain for 30 sec- dle.
  • Page 32 Chapter Five 3. Turn out and remove the crank arm 7. If removing the right arm, remove the bolt. chain from the chainring. 4. Inspect the position of the spindle end. It 8. Turn the crank-wrench handle clock- should be recessed within the crank-arm wise, and press the crank arm off the square hole.

  • Page 33: Chainring

    CHAIN and CRANKSET Installation Installation When installing both crank arms, install 1. Fit the chainring onto the spokes (spider) the right crank arm first, and then install the so the chainring mounting holes align with left crank arm so it is oriented 180 degrees the holes on the spokes.

  • Page 34: Pedal

    BOTTOM-BRACKET CARTRIDGE 3. Break the pedal loose. 4. While facing the crank, hold the pedal The A2B Metro uses a Chin Haur bottom- with one hand and the wrench with the bracket cartridge. The bottom-bracket on other. Rotate the pedal forward (normal the A2B Metro is a cartridge that threads pedaling motion) and remove the pedal.
  • Page 35 CHAIN and CRANKSET The adapter ring on this cartridge has stan- Installation dard right-hand threads. The main body, however, has left-hand threads. NOTE A bottom-bracket-cartridge tool (Park The bottom-bracket cartridge has very Tool BBT-2) is required for removing and fine threads. These can be easily dam- installing the bottom-bracket cartridge.

  • Page 37: Shock Absorber

    Chapter Six REAR SUSPENSION SHOCK ABSORBER Removal/Installation 1. Securely support the swingarm so it will not collapse once the shock absorber is removed. 2. Before removal, measure the spring length, which is the distance from the upper spring seat (A, Figure 1) to the lower adjusting ring (B) on the shock absorber.

  • Page 38: Rear Wheel

    Chapter Six c. Apply Loctite 242 to the bolt threads, 9. Remove the left axle nut, and lower the and torque each shock absorber bolt (C, wheel from the dropouts. Watch for the Figure 1) to the specification in Table 5. spacer collar on the right side of the axle d.

  • Page 39: Swingarm

    REAR SUSPENSION 4. Install the fender by reversing the remov- 7. Pull the shifter cable from the hole in the al procedure. Torque the fender bolts and center-stand boss on the swingarm. the fender stay bolts to the specifications 8. Support the swingarm arm to relieve in Table 5.

  • Page 41: Connector Identification

    Chapter Seven ELECTRICAL CONNECTOR IDENTIFICATION Some types of connectors are used more than once. When disconnecting any con- Figure 1 identifies the connectors found nector, label the connector halves so they within the battery compartment, which is can be easily identified for assembly. inside frame downtube.

  • Page 42: Battery Cap

    1. Remove the right crank arm as described (C) to their mates from the switch module. in Chapter Five. The 3-pin connector (D) is not used in the 2. Remove the battery cap as described in A2B Metro. this chapter.

  • Page 43: Key Switch

    ELECTRICAL 3. Slide the switch module (A, Figure 3) into 8. Align the switch tabs (B, Figure 5) with the position noted during removal, and the cutouts in the frame, and press the press the wiring (B) into the battery com- switch into place.

  • Page 44: Electrical Troubleshooting

    Chapter Seven ELECTRICAL TROUBLESHOOTING Brake Switch Test Motor Input Voltage Test The A2B Metro has two brake switch con- nectors which are identical. Once the 1. Remove the heat shrink tubing, and dis- identity of a particular switch has been...
  • Page 45 ELECTRICAL 3. Check the continuity by performing the Motor Troubleshooting following: a. Connect one ohmmeter test probe to Perform the following if the motor does the red wire in port side of the charger-port not operate when the throttle is applied. connector, and connect the other test 1.
  • Page 46 Chapter Seven...
  • Page 48 ©Ultra Motor USA 45 Broadway Street, San Francisco, CA 94111 Tel: (415) 693-3110 Fax: (415) 693-3121...

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