THIN has arrived! We’re so excited to see happy owners out riding their THINs, but first: let’s get it put together correctly! If you are unfamiliar with bike assembly, it is strongly recommended that you take your THIN to a local bike shop for assistance. Most shops will be able to assemble and make any necessary […]
The post THIN Assembly Instructions appeared first on Sondors.
THIN Assembly Instructions
THIN has arrived! We’re so excited to see happy owners out riding their THINs, but first: let’s get it put together correctly!
If you are unfamiliar with bike assembly, it is strongly recommended that you take your THIN to a local bike shop for assistance. Most shops will be able to assemble and make any necessary adjustments to your bike for a small fee.
If you are confident with doing the bike assembly on your own, please watch the following video as a guide for assembly of your SONDORS THIN>>
The following is a transcript of the video, to help guide assembly.
INCLUDED PARTS & TOOLS:
Box#1 = L&R pedals, included tools, reflectors & mounts, battery charger, (2)4mm allen bolts, (2) phillips head screws, aluminum ferrule, small black rubber button
Box #2=battery & battery lock keys
Included w/ your bike is a set of 5 allen wrenches (6mm, 5mm, 4mm, 3mm, 2.5mm), a stamped steel multi-wrench tool, and a T25 Torx Wrench
Phillips screwdriver required but not included.
We suggest that you start the initial charge as the first step so the battery can be charging while the bike is being assembled.
BATTERY CHARGE:
Position rocker to ‘off’ position
Open the charging port cap and insert the battery charging cable into the port
Plug charger into standard grounded household outlet or surge protector
When the charging unit is correctly connected the LED will show GREEN briefly and then it will switch to RED while the battery charge cycle is underway
When the battery is fully charged teh LED light will change from RED back to GREEN
When the battery is fully charged disconnect the charge from the wall socket, and then remove the charging cable from the battery
To charge on the bike, first positionthe battery rocker in the ‘off’ position
Open the battery compartment, unscrew and disconnect the metal socket from the battery
Cover the battery discharge port with the rubber cap
Open the charging port cap and insert the battery cable into the port
Plug the charger unit into a standard grounded household outlet or surge protector
When the battery is fully charged, disconnect the charger from the wall socket, and then remove the charging cable from the battery
Reconnect the bike controller power cable
**Battery Notes**
- Do not interrupt the charging cycle until the battery is fully charged
- Always follow the correct battery connection sequence
- Do not exceed 8 hours charging time
- Do not store the battery connected to the battery charger
- Battery must be charged at least once every 3 months if it is not being used for extended periods of time
- Read & follow the additional instructions and cautions listed on the battery labels
STEM & FORK ALIGMENT
Loosen the (2) 4mm pinch bolts and 5mm cap bolt
Rotate the stem so it is aligned with fork (as shown in Video)
Re-tighten the 5 mm cap bolt and (2) 4mm pinch bolts
Repeat this procedure after the wheel and handlebars are installed to ensure proper alignment
Rotate both the stem and fork into the forward position
ATTACH HANDLEBAR & ALIGN CONTROLS
Remove the (4) 4mm bolts & faceplate
Rotate the handlebar assembly up into the stem
Be careful not to twist or kink the cables attached to the brake levels & throttle
Replace the faceplate & lightly tighten the (4) 4mm bolts
Double Check that the handle bar is L/R centered in the stem and the bar is rotated in the position that will be ideal for your riding comfort
Finish tightening down the Faceplate bolts
Loosen the 5 mm bolt on the bottom of the brake levers, rotate to the desired position and re-tighten
To adjust the throttle: loosen the throttles 2.5mm set crew, rotate unit to your preferred position and re-tighten
*Be careful not to over tighten as it can inhibit throttle operation & make sure the throttle operates freely & doesn’t bind on the grip
Loosen the 3mm bolts on the grip locks, rotate the grips into your preferred position & retighten
Insert rubber cap onto 5mm stem cap bolt
FRONT BRAKE CABLE ATTACHMENT
Loosen the cable clamp on the caliper arm using the 5mm allen wrench
Pull the brake cable up approx 9.5″ to provide slack to install the cable in the brake lever
Rotate the black ferrules to align their slots with the slot on brake’s forward edge
Pull brake lever in and swing the cable end basket out
Place cable in basket and move cable through the forward edge slot
Tighten black ferrules down to secure cable, being certain their slots no longer align with brake lever slot
Arrange and secure cables using the 3 black plastic clips that were attached to the bike cables during shipping
FRONT WHEEL ATTACHMENT
Remove the plastic foot from the axle dropouts in the front fork
Loosen the R&L side axle nuts until they are slightly beyond the outside ends of the axel
Pull the fishtailed washers up to the inside surface of the axle nuts
Making sure the brake disc is on the left side of the wheel (same side as brake caliper) carefully place the axle in the front fork dropouts
The kickstand can now be lowered to stabilize the bike
On both the L&R sides: Insert the tail of the washers into the hole above the axle dropout slot on the fork
With the washers in the locked position, hand-rotate both nuts clockwise until they contact w/ the fork sides
*Make sure your wheel is centered, relative to the front fork
Tighten the axle nuts using the 15mm end of the stamped tool or a 15mm wrench
*after tightening, check again to make sure your wheel is still centered in the forks
FRONT BRAKE ADJUSTMENT
Use the 5mm allen key to loosen the clamp bolt on the brake caliper arm
Remove slack from the cable by pulling the inner cable into the brake caliper arm
Place metal end of cable jacket in the receivers of the lever unit and the upper end of the brake unit
Rotate the caliper arm upward approx 1/2″, hold the cable tightly below the caliper arm while tightening 5mm bolt
Loosen the rear facing upper and lower caliper attachment bolts using the 5mm allen key
when loosened, the brake caliper unit can move L/R over the disc rotor
Pull the brake lever to align the loosened brake unit over the disc rotor
With the brake lever still pulled, tighten both 5mm caliper attachment bolts on the brake caliper mount
Check for brake alignment and re-adjust brake cable in the caliper arm if needed
Front brake cable can be tripped with heavy wire cutters and the aluminum ferrule can be crimped on end of the cable
PEDAL ATTACHMENT
This bike includes a R&L pedal, they are marked with a “R” and an “L” on the end of the threaded post
The pedal orientation refers to the riders LEFT and RIGHT as you sit on the bike
Start w/ left pedal: Slowly rotate the threaded post onto the left side crank counter clockwise
It should turn easily into the crank by hand when aligned correctly
Tighten the pedal with a 15mm open-ended wrench or the included multi-tool
Right Pedal: Slowly rotate the threaded post onto the right side crank clockwise
It should turn easily into the crank by hand when aligned correctly
Tighten the pedal with a 15mm open ended wrench or the included multi-tool
REFLECTOR ATTACHMENT
The wheel reflectors have a vertical spoke slot through the side where the clip attaches
Position the reflector in the wheel and align the spoke in the reflector slot
Carefully push the clear connector button into the hole
Slowly slide reflector upwards until it fits snug between opposite spokes
Slide white reflector into handle bar mount until it clicks into place, repeat w/ red reflector & seat post mount
Spread the assembled white reflector and slip over handle bar
Insert included black phillips screw and tighten
Slide red reflector assembly up the seat post & insert the included black phillips screw and tighten when positioned in desired location
SEAT ATTACHMENT
Open the quick release seat tube clamp & insert the seat post
Close the quick release and finger-tighten the knurled nut
Open the lever & tighten the knurled nut an additional approx 180 degrees
The lever should now be somewhat difficult to close when the clamp pressure is correct
Adjust the seat height and alignment as needed
BATTERY INSTALLATION
Prior to installing, ensure the battery rocker power switch is in the “OFF” position
Open the battery compartment
Note the 2 slots in the bottom edge of the battery and their corresponding rails on the battery mount
Remove the rubber cap from the metal discharge port on the side of battery & insert battery key
While holding the frame, rotate key 1/4 turn counter clockwise and firmly push the battery until the lock clicks into place
Remove & secure battery key
The controller connection socket has a slot that is keyed to fit in the battery charge port
When aligned, it will fit easily into the port
Once inserted, slide the metal knurled collar towards the battery and rotate clockwise to secure the socket
Close the battery compartment and secure with the threaded toggle
POWER-ON AND POWER-OFF (NO LCD INSTALLED)
First, remove the rubber cap on the lower right side of the bike’s battery compartment to access the power switch
Put the power switch to the “ON” position and replace the cap
To power-on the bike, press the grey button on the throttle
The LEDs on the throttle will light up when powered-on
*The number of LEDs will vary depending on the battery charge level and the draw being applied to the system
To power-off the bike, press the gray button again and the LEDs on the throttle will turn off when the bike is powered-off
Then, remove the rubber cap, push the power switch to the “OFF” position and replace the cap
Anytime the battery is not being used, it is recommended the battery be in the “OFF” position
Congratulations on your SONDORS THIN & thanks for your support!
Warning: Do not replace SONDORS eBike original components with third-part “after-market upgrades” like controller, battery, LCD screen, throttle, motor, or charger sold from anywhere other than gosondors.com. Replacing parts with anything other than SONDORS genuine parts can cause serious damage to your SONDORS eBike.
The post THIN Assembly Instructions appeared first on Sondors.