ASSEMBLY MANUAL SE-4S35

CONTENTS

INSTALLATION CONDITIONS

INSTALLATION METHOD

2

2

2

3

3

3

3

1. Installing the battery box

4

2. Installing the right-side brake lever

4

3. Installing the operating panel

4

4. Installing the speed sensor

5

5. Installing the motor unit to the hub (rear wheel)

6

6. Installing the hub (rear wheel) to the frame

6

7. Installing the batteries

8

CHANGING THE INITIAL SETTINGS

(FOR BICYCLE RETAILER)

Selecting the setting to be changed

9

10

Changing the wheel size setting

Recalibrating the motor unit

10

Selecting mph or km / h

10

Operating panel

1

WARNING

Battery box

Speed sensor

Cable lengths and diameters

Motor unit

Be sure to observe the following when using the Auto-D. If this is not done, incorrect operations such as unwanted gear shifting may occur while riding, and this might lead to your feet coming off the pedals and the bicycle falling over.

Check that the motor unit and the connector are securely installed with the connector fixing bolts so that there is no gap between them.

If there is a gap between the motor unit and the connector, vibration may occur or water may get inside, and this may cause incorrect signals to be output.

Motor unit

Motor unit cable

WARNING

1)

Check that the motor unit cable does not come into contact with parts such as the chain or the wheel, and that there are no other places where the cable may become damaged.

2) AI-4S41 JAPAN AUTOMATIC-DRIVE AI-4S41 JAPAN AUTOMATIC-DRIVE

There should be no gap

The cable should be routed so that it is not loose and does not come into contact with parts such as the chain and wheel.

Connector

INSTALLATION CONDITIONS

Necessary length for straight section of handlebar: Grip length + 65 mm

Install the battery box to the chainstay.

Spoke diameter should be 2.3 mm or less

Find a place which meets these conditions.

22.2 mm

Operating panel

Battery box

Speed sensor

If the mudguard cross-section has a radius of more than 30 mm, it will be necessary to increase the dimensions for C.

The bridge / lug should be less than 3.0 mm, including the weld. 64 66 68

A

B

C

3mm 19.3mm 38. 1 mm

30 mm radius (mudguard cross-section shape)

23 mm or more Bridge 52 mm or less 80 mm or more 95 mm or more 49 mm or less 77 mm or more 92 mm or more 47 mm or less 75 mm or more 90 mm or more Size Lug A B C Note: 28 mm or more (inside width of chainstay)

Minimum distance should be within 22 – 27 mm

Diameter of chainstay should be 19 – 23 mm

Km-Mile/h D Ds AUTOMATIC-DRIVE AI-4S41 JAPAN

The shapes of the lead tubes should be hooking types rather than pass-through types. Ideally there should be three lead tubes attached to the down tube and two attached to the right-side chainstay.

Cable lengths and diameters

Note:

Cable cover: length 1,040 mm, diameter 5.4 mm Cable: length 1,200 mm, diameter 3.7 mm

Dimension A:

B: Motor unit cable

(attached to right-side chainstay)

(attached to left-side chainstay)

C: Speed sensor cable

A: Operating panel cable

Cable: length 400 mm, diameter 5.2 mm

Dimension B:

Cable: length 250 mm, diameter 3 mm

(Any excess cable running from the speed sensor should be tucked inside the battery box.)

Dimension C:

Note:

Motor unit

Frame

When designing the frame, make sure that there are no obstructions between the frame, motor unit and hub.

Motor unit Operating panel

connector

Operating panel

Operating panel

cable cover _{Lead tubes}

Battery box

Lead tubes

Motor unit

Motor unit connector Speed sensor Note: Dimension E: 31.8 mm Dimension F: 29.0 mm Front chainwheel: 31T / 32T / 33T For 26 / 27 inches Rear sprockets: 20T / 21T / 22T / 23T

Width between cones: 130 mm No. of spoke holes: 36H / 28H Spoke hole P.C.D.: 83.5 mm Dimension G: 54.8 mm Dimension H: 3.7 mm F E Frame center G A B B D A C 1.1 mm Section A Section B Section C 2.6 mm 1.6 mm Section D 2.0 mm

Hub shell dimensions

Recommended gear ratios

Motor unit

Leave a gap Gap _53.2 mm 76.7 mm C D

The cable lengths are the lengths from the exit points for each connector to the exit/entry points at the battery box.

M

Km-Mile/h D

M Ds

INSTALLATION METHOD

Use a 5 mm Allen key to install the brake lever installation band to the handlebars.

To seat tube

To rear wheel

1. Installing the battery box

3. Installing the operating

panel

Installation band Installation bolt 5 mm Allen key Chainstay Fixing plate

Battery box fixing screw Spring washer

4 mm Allen key

Battery box

Operating panel

Connector fixing screw

Operating panel cable

Operating panel fixing screw Brake lever bracket

Operating panel Operating panel fixing screw

Place the battery box on the chainstay between the seat tube and the rear wheel. Next, place the fixing plate against the bottom of the chainstay, and then use a 4 mm Allen key to tighten the battery box fixing screws to secure the battery box to the chainstay.

SE-4S40

JAPAN22.2

The upper cover fixing screws are tapping screws, so be careful not to over-tighten them.

The connector fixing screws are tapping screws, so be careful not to over-tighten them. Tightening torque: 4 – 5 Nm {40 – 50 kgfcm} Tightening torque: 6 – 8 Nm {60 – 80 kgfcm} Tightening torque: 0.1 Nm {1 kgfcm} Tightening torque: 1 – 1.5 Nm {10 – 15 kgfcm}

1.

Attach the connector at the operating panel end of

the cable to the operating panel, and then use a Phillips screwdriver to tighten it into place.

2.

Check that there is sufficient length of cable, and

then use a Phillips screwdriver to install the operating panel to the brake lever bracket, while being careful of the cable..

22.2 mm

Install the speed sensor to the left-side chainstay of the rear wheel, in a position as close to the hub as possible.

Gently wrap the speed sensor cable twice around the stay so that the cable then points toward the front of the bicycle. Next, place the pad in between the speed sensor and the chainstay, and then tighten the speed sensor fixing bolt so that the speed sensor will not turn.

Install the speed sensor close to the hub.

Installation position

Installing the speed sensor

Installing the magnet

Spoke side

2 lines

Leave a clearance of 2 – 6 mm between the speed sensor and the magnet.

Install the magnet to one of the wheel spokes so that the magnet is aligned with one or other of the two lines on the speed sensor. Install the magnet so that there is a clearance of 2 – 6 mm between the magnet and the speed sensor at this time.

Tightening torque: 1 Nm {10 kgfcm}

Tightening torque: 1 Nm {10 kgfcm}

Do not forget to install the spacer, otherwise the magnet fixing bolt will loosen and the magnet will fall off the spoke.

Note:

SENSOR

SENSOR Speed sensor fixing bolt

Cable Chainstay Speed sensor Pad Speed sensor Magnet

Magnet fixing bolt

Spacer

Spoke

Magnet

Speed sensor

Magnet

5. Installing the motor unit

to the hub (rear wheel)

6. Installing the hub (rear

wheel) to the frame

1.

Mount the chain on the sprocket, and then set the

hub axle into the fork ends.

1.

Check that the rubber seal is attached. If the rubber

seal is not attached, attach as shown in the illustration.

2.

Install the motor unit to the hub so that the mark

(yellow) on the motor unit is aligned with the mark (yellow) on the hub lock spacer. After this, gently push the motor unit while turning it slowly to set it correctly until it stops turning on the hub axle. Next, secure the motor unit by tightening right-hand lock nut B.

When tightening right-hand lock nut B, hold the two bevelled surfaces of the hub axle (8-mm wide) with a spanner to stop the hub axle from turning.

Right-hand lock nut B mark (yellow)

on lock spacer

mark (yellow) on motor unit Note:

Check that the guide of right-hand lock nut A is seated securely in the guide hole on the front of the motor unit.

AI-4S41

JAPAN

Motor unit Rubber seal

Motor unit guide hole Right-hand lock nut A guide Motor unit Front Right-hand lock nut A Right-hand lock nut B Reverse side of motor unit

Tightening torque: 15 – 20 Nm {150 – 200 kgfcm} Hub axle Fork end Motor unit Motor unit Fork end Hub axle

Turn the motor unit slightly

For reversed fork end

When mounting the chain on the sprocket, remove the chain from the chainring in order to protect the motor unit. After mounting the chain on the sprocket and setting the hub axle into the fork ends, place the chain back onto the chainring.

AI-4S41

JAPAN

For standard fork end

The motor unit may be obstructed by the frame in this case, which can cause difficulties in setting the hub into the fork ends. Turn the motor unit slightly as shown in the illustration before setting the hub into the fork ends. At this time, do not tighten the brake unit fixing nut of the Inter-M brake so that the Inter-M brake can rotate on the hub axle during installation.

AUTOMATIC-DRIVE

AI-4S41

JAPAN

2.

Install the non-turn washers onto the right side and the left side of the hub axle. At this time, turn the motor unit until it is almost parallel to the chainstay so that the projecting parts of the non-turn washers fit into the grooves of the fork end.

3.

Install the brake arm of the Inter-M brake to the

chainstay with the brake arm clip, provisionally tighten the clip bolt and clip nut, and then tighten the brake unit fixing nut.

Non-turn washer (for left side)

Chainstay

Mark

Motor unit

Non-turn washer (for right side)

This surface should be almost parallel to the chainstay

Section B Section A

The projecting parts should be on the fork end side.

Install the non-turn washers so that the projecting parts are securely in section A or section B of the fork end grooves.

If inserting the projecting parts into section B, insert the hub axle as far as possible into the fork ends so that the projecting parts are not too close to the groove openings.

Fork end Non-turn washer Standard Reversed 6R / Silver 7R / Black 6L / White 7L / Gray Mark / Color Left Size Right

Different types of left and right non-turn washers are provided for use with standard and reversed fork ends. Use whichever non-turn washers are suitable.

20 38 = 0 6R AI-4S41 JAPAN 7R Groove of

fork end

4.

Take up the slack in the chain and secure the wheel

to the frame with the hub nuts. Chainstay

Brake arm

Brake unit fixing nut

Non-turn washer Hub nut Washer Carrier stay Mudguard stay Hub nut Hub nut

Non-turn washer (for right side) Brake arm clip

Note: Note:

Right side

Tightening torque: 20 – 25 Nm {200 – 250 kgfcm} Tightening torque: 30 – 45 Nm {300 – 450 kgfcm}

When installing a part such as a mudguard stay to the hub axle, install in the order shown in the illustration below.

If the brake arm is in the incorrect position as shown in the illustration so that it cannot be provisionally installed to the chainstay, loosen the brake unit fixing nut and turn the brake arm. Then, after provisionally securing the brake arm to the chainstay, tighten the brake unit fixing nut.

Non-turn washer (for left side) Washer

Hub nut

Carrier stay Mudguard stay

Stand

Because a non-turn washer is used, the chain tension may become too loose if the slot in the stand is too short in length. A stand with a slot length of 31 mm or more and a height of 10 mm should be used. 31 mm or more Loosen 10 mm Chainstay Brake arm Brake arm clip

Clip nut Brake arm clip

Brake arm

5.

6.

Attach the connector at the motor unit end of the

cable to the motor unit, and then tighten the bolts to secure it in place.

If excessive force is applied to the brake arm, the wheel will become difficult to turn. Make sure that you don't apply excessive force when installing.

Note:

When installing the brake arm clip, securely tighten the clip bolt while holding the clip nut with a 10 mm spanner.

After installing the brake arm clip, check that the clip bolt protrudes about 2 – 3 mm from the surface of the clip nut.

Clip bolt (M6 x 16 mm) Tightening torque: 2 – 3 Nm {20 – 30 kgfcm} Tightening torque: 0.5 – 1 Nm {5 – 10 kgfcm} About 2 – 3 mm 6 L

Left side

Slot in stand Motor unit

Motor unit cable

Battery cover

Lithium battery (CR-P2) Battery cover fixing screw

1.

Use a Phillips screwdriver to remove the four battery

cover fixing screws, and then open the battery cover.

2.

Insert the new lithium battery (CR-P2), making sure

that its polarity is correct.

3.

After inserting the battery, close the battery cover

and tighten the battery cover fixing screws.

CR-P2 LITHIUM

7. Installing the battery

Fix the brake arm of the Inter-M brake securely to the chainstay with the brake arm clip.

Connector

Make sufficiently sure that the cable is not loose and does not come into contact with parts such as the chain and wheel.

CHANGING THE INITIAL SETTINGS

Check that the battery has been inserted. If the battery has not been inserted, refer to "Installing the battery" on page 8.

If the battery has been inserted correctly, a beep will sound, the LED will illuminate red and will illuminate in the digital display (for about 1 second). After this, will illuminate in the digital display.

AUTOMATIC DRIVE

Note:

Beep

FOR BICYCLE RETAILER

If the above does not appear even after the battery has been replaced, remove and re-insert the battery.

Note: If you lose your place at any time during the above procedure, or if you make a mistake in operation, wait 10 seconds or more without pressing any of the operating keys. The digital display will return to , and you can then start the procedure again from step 2.

D Ds Km-Mile/h M D Ds Km-Mile/h M

Changing the settings is not possible in "M" mode.

D Ds

Km-Mile/h M

Scroll using the (left) key The Auto-D system is ready to run as soon as the CR-P2

battery is installed.

The initial settings are as follows: Speed units: km / h

Wheel size: 27"

If necessary, modify the initial settings to properly suit the bicycle dimensions or rider preferences.

1.

Move the mode

select switch to the

"D" or "Ds"

position.

3.

... Ready for –

... Change the wheel size setting ... Select mph or km / h

... Recalibrate the motor unit

Km-Mile/h M

D Ds

2.

4.

Press the (right) key to select the

setting to be changed.

will illuminate in the digital display.

Press the and

keys

simulta-neously for 3

seconds or more.

D Ds Km-Mile/h M

2.

Check that is flashing

in the digital display.

4.

Press the (right) key.

Changing the wheel size

setting

3.

Km-Mile/h M D Ds D Ds Km-Mile/h M D Ds Km-Mile/h M

The wheel size setting will then be accepted. Example:

The digital display switches each time the (left) key is pressed.

(27˝) (26˝) (28˝) (700C) (650BA) (24˝) (22˝) (20˝) (18˝) (16˝)

Scroll using the (left) key

Press the (left) key to

scroll the digital display

in order to select the

desired wheel size

setting.

Setting the wheel size to 27".

1.

Follow steps 1 to 4 on page 15 to select .

Note: If you carry out the recalibration operation by mistake, it will not cause any problems.

1.

Follow steps 1 to 3 on page 15 to select .

1.

Follow steps 1 to 4 on page 15 to select .

Note: If you lose your place at any time during the procedure for changing the speed units, or if you make a mistake in operation, wait 10 seconds or more without pressing any of the operating keys. The digital display will return to , and you can then start the procedure again from step 2 on page 9.

Note: If you lose your place at any time during the procedure for changing the wheel size, or if you make a mistake in operation, wait 10 seconds or more without pressing any of the operating keys. The digital display will return to , and you can then start the procedure again from step 2 on page 9.

2.

km / h mph

4.

2.

Press the (right) key.

At the same time that the key is pressed, the motor unit will start moving and recalibrate automatically.

If the rear wheel, internal hub mechanism or the motor unit has been replaced, then the motor unit should be recalibrated as follows to ensure optimal shifting performance.

Check the current speed unit setting by

checking whether or is flashing in

the digital display.

Km-Mile/h M D Ds Km-Mile/h M D Ds or Km-Mile/h M D Ds D Ds Km-Mile/h M

3.

Press the (left) key to

select either km / h

or mph.

The digital display switches between and each time the (left) key is pressed.

Recalibrating the motor

unit

Press the (right) key.

The speed unit setting will then be accepted. Example:

The speed unit is km / h.

R