The Naples E-Bike User's Guide

About Daymak

DAYMAK INC. is a developer, importer, and distributor of alternative energy and fuel-efficient vehicles. The company operates a distribution network of 10 retail stores, two of which are corporately owned, and 50 dealers primarily in Ontario. Daymak possesses the expertise and knowledge to manage all aspects from "Concept" to "Commercialization", including designing, testing, manufacturing, and selling its products. The company is currently developing and launching its proprietary Daymak Drive™ Technology. For more information, visit www.daymak.com.

Copyright 2008, Daymak Inc. All materials in this guide are the copyright property of Daymak, Inc. Reproduction requires written permission from Daymak.

Introduction

E-Bikes

Riding an electric bicycle is a convenient and affordable way to travel around town, representing a natural progression in urban transportation. E-bikes use minimal electricity, significantly reducing urban pollution and noise. They are easy and often free to park, making them unobtrusive and practical additions to the urban landscape. E-bikes are also inexpensive, currently requiring no registration, insurance, or license, and incurring no parking charges. Compared to internal combustion engines, electric motors have fewer moving parts and require less maintenance.

Your Daymak e-bike is the result of Daymak's extensive experience, skilled staff, and careful engineering design. We hope you enjoy using this product and welcome your feedback.

New Laws

Many Canadian provinces, U.S. states, the United Kingdom, and European countries have introduced laws permitting electric motors to assist bicycle operation. It is recommended to check with your provincial or state government for local laws. This manual includes a synopsis of common Canadian provincial regulations governing e-bikes.

This Guide

Information in this guide is subject to change without notice. For the latest details, contact your local Daymak dealer or visit the website. While every effort has been made to ensure accuracy and completeness, please inform Daymak of any missing, incomplete, or incorrect information.

Liability

Daymak is not liable for damages, loss of profits, or third-party claims arising from improper use of the product. Daymak is also not liable for damages resulting from service performed by unauthorized third parties.

Bicycle Components

Diagram 1: The Naples E-Bike

This diagram illustrates the various parts of the Naples E-Bike. Note that many components, especially electrical and mechanical systems, are not user-serviceable and require professional repair.

• 1. Seat
• 2. Rear Compartment
• 3. Taillight
• 4. Rear Mudguard/Fairing
• 5. Rear Wheel
• 6. Rear Shock Absorber
• 7. Hub Motor
• 8. Controller (inside)
• 9. Kickstand
• 10. Battery (inside)
• 11. Battery Carrier (with lock)
• 12. Battery charger slot
• 13. Front Shock Absorber
• 14. Wheel Rims
• 15. Tire
• 16. Front Mud Guard
• 17. Headlight
• 18. On / Off key switch
• 19. Handlebars
• 20. Pedals
• 21. Seat Compartment

Diagram 2: The Handlebars and Controls

This diagram shows the control mechanism and display. Features may parallel those on the Naples e-bike.

• 1. Accelerator (throttle)
• 2. Front brake controller
• 3. Rear brake controller
• 4. Speedometer
• 5. Horn
• 6. Blinker lights
• 7. Headlight Switch
• 8. Battery indicator
• 9. Power indicator

Riding Instructions

This guide assumes familiarity with riding a standard bicycle. Ensure you are comfortable with controlling and balancing a regular bicycle before riding an electric bicycle.

Caution

An e-bike is too dangerous for individuals without cycling experience. Do not use an e-bike to learn how to ride a bicycle.

Important Notes

• E-Bikes are Fast! E-bikes can reach higher speeds than many cyclists are accustomed to. Exercise caution, especially in mixed traffic, and always consider driving and traveling conditions.
• Obey the Law. Adhere to all provincial and city traffic laws, including obeying stop signs, signaling turns, and riding defensively. An e-bike is a motorized vehicle, even if classified as a bicycle.
• Stay Sober. Never ride while intoxicated. E-bikes are faster than regular bicycles, and maintaining control is paramount.
• Share the Road. Be courteous to others on bicycle paths, near pedestrians, and on recreational trails. E-bikes are relatively new, and other users may not be familiar with them. E-bike riders act as "ambassadors" for this new transportation method.

Items to Carry with the E-Bike

• The charger (for recharging the battery)
• A lock (to secure the e-bike when parked)
• A helmet (as required by safety laws)

Inspecting your E-Bike

Always inspect your e-bike before riding to ensure safety features are operational. Routine inspections can prevent accidents. Pay attention to any changes in how the e-bike feels or sounds, as these may indicate mechanical or power issues requiring examination.

Holding the Handlebars

Place fingers over the brake levers and wrap hands around the grips, with thumbs underneath. This allows for easy brake activation for quick stops, ensuring safe control.

Turning your E-Bike On and Off

To turn on, insert the key into the "ignition" below the dashboard and turn right. The power indicator will light, and the battery charge indicator will show the power level. To turn off, turn the key left and remove it.

Warning

Activating the e-bike makes the electrical system live. Do not attempt to modify or repair any part of the e-bike while it is activated. Turn the e-bike off and remove the key before accessing electrical components. The battery carries a significant electric charge and can cause injury if not handled properly.

Accelerating and Decelerating

The throttle is on the right-side handlebar grip. Turn it forward (away from you) to accelerate. Release the grip (turn it towards you) to decelerate. Avoid over-rotating the accelerator, as this can damage the battery and electrical components.

Warning

Do not activate the accelerator until you are seated and ready to move. The e-bike can easily escape control, potentially causing injury to yourself or others, or damage to the e-bike if dropped.

Stopping

The e-bike has front and rear drum brakes, activated by levers on the handlebars. Pull levers towards you to brake. Using both brakes provides quicker stopping; one brake allows for a gentler stop. When brakes are activated, engine power is automatically cut off until the brakes are released, ensuring safe stopping.

Safety Tips

• In wet weather, water can reduce brake efficiency by decreasing friction. Slow down and allow more stopping distance.
• Regularly check brakes and brake pads. Brake pads wear down and will require replacement after significant use.

Signalling

You can signal and warn others using sound and light signals.

• The Horn: The horn button is on the left handlebar. Press it to activate.
• Turning Signal Lights: The turn signal activator is on the left handlebar. Push left or right to indicate turns; press the middle to turn them off. Note: Turn signals emit an audible sound to alert others.
• Lights: Headlight and taillight improve safety in dark conditions. The switch is on the left handlebar. Note: Lights consume electricity, potentially reducing travel distance by about 5%.

Riding Conditions

Pedaling

This e-bike is motor-assisted. While the motor can be used alone, pedaling alongside the motor increases travel distance by reducing battery draw.

Riding in Wet Weather

The e-bike is designed for wet conditions, but the rear-mounted motor can cause slipping at high speeds. Avoid high speeds in very wet conditions. Water can also reduce brake efficiency; slow down and allow more room for stopping.

The Motor and Water

The e-bike is not designed for immersion in water. Ensure water levels do not exceed the middle of the tire to prevent water from entering the motor, which can cause short-circuits and damage electrical systems.

Riding in Cold Weather

The e-bike operates year-round. However, in very cold conditions or snow/slush, the motor may get wet, and brakes may be less efficient. Batteries perform less effectively below 10°C. Both Lithium-Ion and Lead-Acid batteries experience reduced performance in cold temperatures. Cold weather riding may also shorten battery lifespan.

Operating Instructions

Using the Rear Storage Compartment

The rear storage compartment is opened with the provided key. Turn the key right to open, and left to lock. It can store the charger, cables, or a U-lock for security.

Opening the Seat Trunk

Insert the key into the lock below the seat and turn right to open the seat trunk. Push down firmly to close; a "click" indicates it is properly shut. The seat trunk will not open if you are sitting on it.

Parking and Locking your E-Bike

1. Stop the e-bike and position it.
2. Get off, ensuring the e-bike remains balanced.
3. Stand slightly to the side and rear.
4. Hold the kickstand with one foot and grip the rear basket bracket.
5. Pull the back of the seat up and towards you; the e-bike will move backward, supported by the kickstand.
6. Lock the e-bike to a secure object (e.g., post) through the rear wheel frame or a metal frame component.

Warning

Do not let your e-bike drop or fall, as the exterior and internal components may be damaged.

Maximum Load

Do not exceed the e-bike's maximum load capacity (refer to technical specifications). Exceeding the limit can reduce performance, damage shocks, the mechanism, frame, or motor.

Disconnecting the Circuit Breaker

To disconnect power from the battery, follow these steps:

1. Open the seat compartment.
2. Locate the circuit breaker switch.
3. Activate the switch to disable power.

Long-Term Storage of your E-Bike

For long-term storage, disconnect the circuit breaker to prevent accidental activation. The circuit breaker is located within the battery case, between the battery and the controller. Refer to "Your Battery" for maintenance during storage.

The Battery

Battery Power

The dashboard features a battery charge indicator. If the power level drops significantly, recharge the e-bike.

Distance and Power

The battery typically provides a range of 35 to 50 km. Range depends on rider weight, wind resistance, driving habits, terrain (hills), and tire pressure.

Saving Power

To maximize range:

• Coasting: Utilize momentum on downhill or flat surfaces without drawing motor power.
• Stopping and Starting: Minimize stop-and-go movements, as starting from a full stop consumes more power.
• Weight: Remove unnecessary weight to reduce motor load.
• Air Pressure: Ensure tires are properly inflated to reduce drag and increase efficiency.
• Head and Tail Lights: Turn off lights when safe to conserve power (may reduce range by ~5%).
• Pedaling: Assist acceleration from a stop by pedaling.

Charging your E-Bike

You will need the e-bike's charger and a 110V household electrical outlet.

Charger Warning

Use only the supplied charger. Using an incompatible charger can irreparably damage the e-bike's battery and electrical systems, and may cause injury.

Charging Steps:

1. Turn off the e-bike and remove the key from the ignition.
2. Plug the charger cable into the e-bike's charging slot (located on the outside casing, in front of and below the seat).
3. Plug the charger into a 110V wall socket or a portable generator providing 110V current.
4. Allow the e-bike to charge for 3-8 hours. A musical tune indicates charging has started.
5. Disconnect the charger when the LED light turns green, indicating a full charge.

If charging the battery separately, follow the same procedure, plugging the battery directly into the power supply.

Note

If the charger's LED light remains red for over 14 hours, and the battery becomes very hot, the battery or charger may need replacement. Stop charging and contact your Daymak dealer immediately.

Battery Care

Follow these suggestions for optimal battery performance and lifespan:

• Charge it: Charge your battery immediately after riding.
• Full Charge: Do not store the battery completely depleted. This significantly reduces lifespan and can cause damage.
• Keep it Charged: When stored, charge the battery occasionally (e.g., once every 21 days) to prevent power depletion.
• Storage Conditions: Store the battery on a flat, cool, dry surface. Avoid temperatures below 10°C for extended periods.

Warning

DO NOT place your Lead-Acid battery on concrete. Concrete drains battery power and neutralizes lead-acid. Storing the battery on concrete will likely result in power loss and reduced storage capacity.

Cold Weather and your Battery

Batteries perform less effectively below 10°C. While Lithium-Ion batteries are better in temperature extremes than Lead-Acid, both experience reduced performance in cold. Riding in cold temperatures may also necessitate earlier battery replacement.

Handling the Battery

Use caution when handling the battery, as it contains significant electrical power. Failure to follow instructions can result in serious injury.

• WARNING! Follow these instructions closely.
• Always lift and carry the battery with both hands. Never drop it. Damaged cases may leak contents.
• Never puncture or open the battery case. Contents are dangerous. Do not touch leaking battery contents; seek immediate help.
• Do not touch both metal poles on the battery box simultaneously, as this can cause a short-circuit, injury, or damage to the e-bike's electrical systems.
• Do not handle the battery or yourself if wet. Water conducts electricity and can cause shocks or injury.

Replacement and Disposal

Lead-acid batteries typically need replacement after ~300 charges; lithium-ion batteries after ~1500 charges. Reduced charge capacity indicates replacement is needed. Contact your local Daymak dealer for a new battery.

Dispose of used batteries at a municipal battery recycling facility. If unavailable, contact your local Daymak dealer.

Warning

Ensure replacement batteries are identical or very similar. Changing battery format or power levels requires advanced electrical knowledge and can cause irreparable damage if done improperly. Be certain of your actions before using a different battery type, as it will void your warranty.

Technical Data

The Motor and Wheel Assembly

The Naples e-bike features a 500 Watt magnetic DC brushless motor on the rear wheel hub, offering excellent low-end torque and high efficiency. The motor is quiet but produces some noise. The rear hub also includes a speed reduction gear and a speed free clutch.

The Freewheel

The wheels have freewheels, meaning the drive train is not fixedly geared. This allows the e-bike to continue moving without slowing when coasting or traveling downhill, even with the engine off. This feature enables higher speeds when coasting, moving downhill, or with the wind, and conserves electrical power by allowing the motor to rest.

The Controller

Daymak pioneered intelligent component control in e-bikes. The "D-Drive" technology is the e-bike's "brain", enabling faster acceleration, climbing steeper hills, and saving energy. Future versions may support solar or wind power recharging. The electronic controller, located under the seat assembly, regulates speed and functions, offering stepless speed adjustment, motor shut-off when brakes are applied, low voltage protection, and fuses for overcurrent protection.

The Governor

A key controller component, the Governor regulates speed, preventing motor assistance above 32 km/h. Its primary function is to ensure efficient motor operation. Governor malfunction can significantly reduce mileage and performance. Disabling the governor voids the warranty and may damage the controller.

The 32 km/h speed limitation is a government regulation. Exceeding this speed via motor power alone is illegal in Canada without proper insurance, registration, and licensing.

The Brakes

The e-bike uses drum brakes, similar to those on gas scooters and motorcycles, providing fine stopping and control. While a tested technology, brakes require periodic servicing and tension adjustment.

How the Brakes Work

Unlike external friction-grip brakes, drum brakes clamp from the inside. Activating the brakes increases tension, engaging the clamps for effective stopping. They are contained within a sealed unit and finely adjusted.

The Chain and Pedals

Pedals connect to the rear wheel via the chain, forming a human-powered "drive train". Pedals are not removable.

Shock Absorbers

The e-bike is equipped with Monoshock shock absorbers to absorb bumps and dips. While resilient, sharp shocks (e.g., drops from 15 cm or more) can damage them. Replacement is complex and time-consuming.

Basic Statistics

Electrical System Statistics

Motor Statistics

• Rated Power: 500W
• Voltage: 48V
• Rated rolled speed: 200 RPM
• Working efficiency: 70-80%
• Torque: 32-55 Nm
• Max. Climbing Angle: 12-15 Degrees

Controller Statistics

• Model: D-125
• Input voltage: 48V
• Low Protective Voltage: >43.5V
• Excess Current Protection: <17A

Charger Statistics

• Charger Input: AC 100 – 240V
• Standard Input voltage: 110V +/- 10%
• Output: DC 48V, BM-online
• Charger output voltage: 43.8 +/- 10%, 50Hz
• Power Rated: 80W
• Voltage Charge: 43.2 – 44.2V
• Charge Current: 2.5A +/- 0.02A
• Charge Time: 3-8 hours

Battery Statistics

• Type: Sealed Lead Acid Battery
• Rated Voltage: 48V
• Rated Power: 20AH
• Battery Life: 300 charges
• Number: 4 battery units in series
• Dimensions: 17cm x 9.8cm x 11cm
• Weight: 6 kg each, total 24 kg
• Standard Capacity: 12V x 17 AH
• Rated Total Capacity: 500Wh

Wiring Diagram

The wiring diagram shows a 110V/220V AC Charger connected to a 20A fused Battery. The Battery powers a Controller, which is connected to a Hub Motor. A Switch and Brakes are also connected to the Controller, with the Brakes designed to cut motor power when engaged.

Maintenance and Troubleshooting

Tire Pressure

Maintain proper tire pressure for optimal performance and to prevent damage. Low pressure reduces performance and increases damage risk. Cold weather lowers pressure; warm weather increases it.

Procedure for Adding Air:

1. Check the tire sidewall for the recommended pressure.
2. Locate the air valve on the inner rim.
3. Remove the valve cap.
4. Place an air pump nozzle over the valve.
5. Inflate the tire to the recommended pressure, avoiding over-inflation.
6. Remove the pump nozzle carefully to minimize air loss.
7. Replace the valve cap.

Proper tire pressure allows for longer travel distance as the motor works less.

Replacing Flat Tires

Replacing flat tire tubes on e-bikes is more complex than on regular bicycles, requiring specific tools, skill, and patience. The front wheel is easier to service than the rear, which is connected to the hub motor and other mechanical parts. Attempting rear wheel repairs without familiarity with these components can cause serious problems. Contact your Daymak dealer for instructions or assistance with tire replacement.

The Brakes

Drum brakes are a critical safety feature. Test them regularly and consult your Daymak dealer if they feel loose or lose stopping power. Brake pads require replacement typically after 1-1.5 years, and brake cables may need tension adjustment. Servicing drum brakes requires extensive experience; do not attempt if unsure.

Adjusting the Brake Cable Tension

To adjust brake cable tension, locate the small wing nut near the drum brake where the cable joins. Turn the wing nut clockwise to tighten brakes, counter-clockwise to loosen. Adjust until brakes provide proper safety but allow the wheel to spin freely when not engaged.

Warning

Brakes are critical. Do not excessively loosen them; failure to maintain proper tension can lead to brake failure and inability to stop.

Servicing the Battery

Refer to the "The Battery" section for information on servicing or handling your battery.

The Battery Fuse

A fuse protects the e-bike's electrical systems from over-use and power surges. It is located on the battery where the power cable attaches.

Total Loss of Power

If the fuse blows, all electrical input to the e-bike ceases, and the battery will not recharge, though the charger light may show "green".

Procedure to Replace the Fuse:

1. Turn off the e-bike.
2. Remove the battery.
3. Turn the fuse case clockwise near the battery plug to remove it.
4. Replace the old fuse with a new 30A cylindrical fuse (check the old fuse for specific markings).
5. Replace the battery.
6. Restart the e-bike.

Note

Carry a spare 30A fuse.

The Motor

Do not service the motor yourself. Bring the e-bike to your Daymak dealer for service, as motor repair requires significant expertise. Maintenance is suggested every 100 running hours.

The Chain

Ensure the chain is well-oiled and lubricated for proper function.

Shock Absorbers and Comfort

If your ride feels bumpier than usual, check tire pressure first, as low pressure can cause discomfort. If the problem persists, take your e-bike to your Daymak dealer for servicing.

Bringing in your E-Bike for Service

Do not attempt to service electronic or mechanical parts unless you are certain of your actions and have a solid understanding of electrical and mechanical equipment. If the e-bike malfunctions, disconnect the circuit breaker and bring it to your local Daymak dealer. Do not store the e-bike without disconnecting the circuit breaker.

Liability

Daymak is not responsible for damage or injuries resulting from errors due to improperly serviced parts.

E-Bikes and Canadian Law

Canadian Jurisdictions

Eight Canadian jurisdictions (British Columbia, Alberta, Saskatchewan, Manitoba, Quebec, Nova Scotia, Newfoundland and Labrador, and Yukon Territory) have legalized power-assisted bicycles for public road use, treating them as conventional bicycles, not motor vehicles. They do not require insurance, registration, or licenses, provided technical specifications meet certain parameters. Rules are generally consistent across provinces, with minor variations. Consult your local transportation ministry for guidelines.

New Ontario Regulations

Ontario is piloting regulations for e-bike road use, with decisions expected after the program ends in 2009. This manual provides a synopsis of current regulations, which are similar to those in other Canadian provinces. Keep a printed copy of the "TPS Training Bulletin" for reference when traveling; it may help clarify regulations with traffic authorities.

Definition of an E-Bike

An e-bike is a bicycle with a battery-powered electric motor (not exceeding 500 watts) that assists pedaling up to 32 km/h. It can also be ridden without motor assistance. The power assist aids in pedaling, increases distance, and helps with hills and headwinds. E-bikes are similar to conventional bicycles in size, weight, speed, and required skills. A power-assisted bicycle is an e-bike that meets the Motor Vehicle Safety Act requirements.

Traveling by E-Bike

Power-assisted bicycles can travel anywhere bicycles are permitted, including trails and paths where municipal by-laws allow. They are prohibited on controlled-access highways (e.g., 400 series highways, Queen Elizabeth Way) and municipal roads where bicycles are banned, including sidewalks.

Who Can Ride an E-Bike

Anyone 16 years of age or older wearing an approved bicycle helmet may ride an e-bike.

Specific Riding Requirements

Power-assisted bicycles are treated as bicycles, meaning:

• No driver's license is required.
• No written test is required.
• No vehicle registration or license plate is required.
• No motor vehicle liability insurance is required.
• Operators must be 16 years of age or older.
• All persons must wear an approved bicycle helmet.
• Only electric bicycles conforming to the federal Motor Vehicle Safety Act and labeled as "power-assisted bicycle" are eligible for the pilot program.

Equipment

A power-assisted bicycle (e-bike) must have:

• Steering handlebars and pedals.
• A design for primary propulsion by muscular power, with not more than three wheels.
• An electric motor with a power output of 500W or less, incapable of propelling the cycle at 32 km/h or greater on level ground without pedaling.
• A label indicating it is a "Power-Assisted Bicycle".

Safety Equipment

E-bikes require the same safety equipment as bicycles under the Highway Traffic Act:

• Proper lights
• Proper brakes
• Proper bell

Bicycle Helmets

Wearing an approved bicycle helmet is mandatory for all e-bike operators, with no age exemptions.

Fines and Penalties

Standard fines for bicyclist violations apply. Offences related to the pilot program (e.g., riding under 16, no helmet) may incur higher fines ($250 to $2,500).

Drinking and Driving

Operating an e-bike while intoxicated is a Criminal Code offense. While the Highway Traffic Act may not apply to e-bikes as motor vehicles, the Criminal Code definition of "motor vehicle" could include an e-bike, leading to impaired driving charges, fines, jail time, and driving prohibitions.

TPS Training Bulletin

Attention Traffic and Training Sergeants:

This bulletin addresses confusion regarding the definition of a Power Assisted Bicycle (e-bike). According to Ontario Regulation 473/06, an e-bike meeting the definition is not considered a motor vehicle under the Highway Traffic Act and is treated as a bicycle. Persons 16 years and older wearing a bicycle helmet may ride an e-bike on the highway without a driver's license, permit, or insurance.

Key requirements for an e-bike designation include being "capable of being propelled by muscular power" and bearing a "permanently affixed manufacturer's label stating that the vehicle is a power assisted bicycle". Pedals must be attached and functional during operation. O. Reg 473 references federal Motor Vehicle Safety Regulations for definitions.

Contact Information:

Rick Line, TC 4365,
TPS Training & Education Unit,
Traffic & Provincial Statutes Section,
C.O. Bick College,
4620 Finch Ave. E.,
Scarborough, On, M1S-4G2
Ph: 416-808-4877
"Committed to Lifelong Learning"