E-Bike Owner’s Manual

Even if you have ridden a bike for years, it is important for you and every rider to read this manual before riding this . Keep for reference. 1 HELMETS

Correct Fitting - Make sure your helmet covers your SAVE forehead.

LIVES! Incorrect Fitting - Forehead Always wear a properly fitted is exposed and vulnerable to helmet that complies with CPSC or serious injury. CE safety standards when you ride your bicycle.

WARNING As with all mechanical components, the bicycle is subjected to wear and high stresses. Different materials and components may react to wear or fatigue in different ways. If the design life of a component has been exceeded, it may suddenly fail possibly causing injuries to the rider. Any form of crack, scratch or change of colouring in highly stressed areas indicate that the life of the component has been reached and it should be replaced. Do not ride in an abusive manner.

CAUTION WARNING In this manual, the CAUTION sign Great care should be taken when shows a hazardous situation which, locking the quick release levers on the if not avoided, could cause minor or bicycle. If you do not fully understand moderate injury. how to operate the quick release levers, ask a bicycle dealer for assistance, or call Montague’s WARNING Customer Support Team at +1 617-491-7200. In this manual, the WARNING sign shows a hazardous situation which, DO NOT RIDE YOUR BICYCLE if not avoided, could cause death or WITHOUT ALL QUICK RELEASES serious injury. SECURELY LOCKED.

2 TABLE OF CONTENTS

Warnings 2 Section Two Section One Assembling your Bicycle 26 Introduction 4 Packing List 26 Record Your Serial Number 4 Installing the Handlebars 27 Register Your Bicycle 4 Installing Display and Lights 28 Owner’s Responsibility 5 Attaching Front Brake 29 Bicycle Type and Use Conditions 6 Installing Front QR 29 E-Bike Classes 7 Installing Front Wheel 30 Product Symbols 7 Installing Front 32 Introduction to E-Bikes 8 Attaching Steering Damper Spring 33 Difference Between E-Bikes and Installing the 33 Conventional Bikes 8 Installing Pedals 34 and Cargo Rack 10 Inflating 35 Child Seats and Trailers 10 Folding your Bicycle 36 Supplementary Manuals 10 Folding the Pedals 38 Parts of your Bicycle 11 Rolling the Bike 39 Unfolding your Bicycle 40 Before your First Ride 12 Adjusting the Frame Quick Release 41 Sizing and Weight Limit 12 Electric Assist Operation 12 Drive Assist System 43 Check your Brakes, Steering, Rechargeable Battery 43 and Quick Releases 13 Charger and Power Supply 44 Prevent Toe Overlap 13 Tips for Getting the Most Range 46 Moving Parts and Pinch Points 14 Cleaning, Storing, and Transporting 47 Frame or Fork Problem 14 Keys 49 Life Span of a Bicycle 14 Disposal 49 Section Three Before Every Ride 15 Mechanical Checklist 15 Proper Maintenance Drive-Assist System Checklist 15 and Adjustment 50 Carbon Fiber Composite 15 Specifications 50 Examine the Frame, Fork, & 17 Handlebars 50 Inflation 17 51 Examine the Brakes and Steering 18 Seat (Saddle) Adjustments 52 Saddle and Seatpost 19 Pedals 53 Suspension and Quick Releases 19 Control Cables 53 Lights and Reflectors 19 Rear Adjustment 53 Front Derailleur Adjustment 54 Riding Safely 20 Brakes 55 Caution: Wet Weather Riding 21 Wheels 56 Be Seen (Especially at Night) 21 Fitted Accessories 58 Think Safety 22 Bearing Adjustments 59 Lubrication 59 Riding Instructions 23 Using your Brakes 23 Maintenance Schedule 62 Changing Gears Correctly 23 Warranty 63 Descending 24 Registration Card Insert Obstacles and Impacts 25 3 IMPORTANT: KEEP FOR FUTURE REFERENCE INTRODUCTION

This manual is designed to give you Your bicycle’s serial number is stamped the information you need for the safe on the seat tube of the frame, on the operation and maintenance of your new drive side of the bike (Fig. 1). Record bicycle. Please read it thoroughly before the serial number in this manual below riding your bicycle. in the event that your bicycle is lost or stolen. You may also want to register your serial number with your local police WARNING department. Make sure to read this complete manual before riding your bike. Failure to do Register Your Bicycle so, or failure to follow its guidelines, Bicycle could lead to serious injury or death. Serial Number registration is Location the only record Section One of this manual involves we have of who safety and bicycle care. Understanding owns this bicycle. and following this information will help Registration and you and your Montague bicycle avoid proof of purchase Fig. 1: The serial number is injury or damage. are necessary to located on the seat tube of make a warranty the frame on the drive-side. Section Two of this manual covers claim. There are specific operating instructions for your two easy procedures to complete the Montague bicycle. Even if you’re an registration (mail or email): experienced rider, you should review this section before your first ride. • Fill in the registration form in the back of this manual and mail it to us. Section Three of this manual gives basic instructions for making small • Go to www.montaguebikes.com/ adjustments to your bicycle and register and submit the registration performing regular maintenance. form to us via the internet.

Record Your Serial Number

Model Name: Serial Number: Key Serial Number: Date of Purchase: Place of Purchase:

4 INTRODUCTION CONTINUED

The frequently updated website also gives you a link to new instructions. If Note: Montague does not make you make a decision not to complete intended for children. Please the registration, make sure you visit the make sure all riders are adults. website frequently. Bicycle riding can be a hazardous Since the components on your activity even under the best of Montague are industry standard, repairs circumstances. Proper maintenance of or replacements may be performed at your bicycle is your responsibility as it virtually any retail bicycle dealer. helps reduce the risk of injury.

If you have any questions about your All quick releases must be securely Montague after reading this manual, or fastened before riding any Montague encounter any problems when . The quick releases are pictured or unfolding your bike, please visit the on page 11 in Fig. 2. They are: the front support section of our website at wheel quick release (#25), the seat www.montaguebikes.com/support or call post quick release (#8), the frame quick Montague’s Customer Support Team release (#9), the rear wheel quick release at +1 617-491-7200. A knowledgeable (#32), and the stem quick release (#4). representative will be happy to answer For instructions on operating the quick any questions and help you to fully enjoy release levers, read Assembling Your your new Montague. Montague Bicycle and Folding Your Montague Bicycle on pages 26-38. Owner’s Responsibility Double check to ensure all bolts and are tightened to the correct WARNING torque specifications.

Make sure to read this complete manual Make sure anyone to whom you loan before riding your bike. Failure to do your Montague understands how to work so, or failure to follow its guidelines the quick release levers and how to fold could lead to serious injury or death. and unfold your Montague bike properly.

Before riding your Montague, carefully The owner is responsible for required follow all assembly instructions. normal maintenance services, such Ensure your bike is the correct size for as those listed in the “Maintenance your comfort and safety. When standing Schedule” section of this booklet (page over the frame (straddle frame) you 62) in order to keep the bicycle in good should have a minimum of 1.0” clearance operating condition. between the top tube and your body. See page 12 for more information.

5 INTRODUCTION CONTINUED

Damage or injury resulting from condition 1 with the addition of gravel negligence, improper operation, improper roads and groomed off-pavement trails. or unauthorized repair or maintenance, environmental influences, or improper Condition 2 bicycles typically feature use are not warranted by Montague flat handlebars and 700c or 26” wheels. Corporation. Montague Corporation These bicycles have “semi slick” tires excludes incidental and consequential with light knobs on them and direct pull damages. brakes.

Bicycle Type and Use Condition 3 Conditions Condition 3 bicycles are made to cover There are many types of bicycles. Each all the riding conditions expressed by bicycle type is made for a specified use conditions 1 and 2 with the addition of or use condition. If your use of a bicycle rough trails, small obstacles, smooth applies more stress than its condition technical areas, and areas where tires limit specifies, this could cause a failure are momentarily not on the ground; of the bicycle (or a part of the bicycle). NOT FOR JUMPS. These bicycles are typically referred to as Mountain Bicycles This section shows the use condition for or Cross Country Mountain Bicycles. different types of bicycles. If you are not sure of what condition(s) apply to your Condition 3 bicycles typically feature bike, consult your Montague dealer or flat handlebars and 26” or 27.5” wheels. call Montague for more information. These bicycles have wider tires with large knobs on them and direct pull or Condition 1 disc brakes.

These bicycles are made to ride on a paved surface where the tires are always WARNING on the ground. If your use of a bicycle applies more stress than the specified use condition Condition 1 bicycles typically feature of the bicycle, the bicycle or its parts flat or drop style handlebars and 700c can be broken or damaged. Riding wheels and smooth tires. These bicycles a bicycle that is damaged could may have accessories such as a rack, decrease your control and cause you fenders, or kickstand attached. to fall. Do not ride in use conditions that apply more stress than the limits Condition 2 of the bicycle. If you are not sure of the limits of the bicycle, consult your Condition 2 bicycles are made to cover dealer. all the riding conditions expressed by

6 INTRODUCTION CONTINUED

E-Bike Classes batteries with this marking at suitable collection points for environmentally In the US, e-bikes can be categorized friendly recycling. by a three-class system based upon their speed, wattage, and operation. In Marking for materials that are some regions, the class of your e-bike hazardous to the environment. can determine which types of bicycle Take particular care when infrastructure it can be ridden on. handing products with this marking. Observe disposal regulations. Class 1: E-bikes that are pedal-assist only, with no Marking for recyclable throttle, and have a maximum materials. Sort packaging and assisted speed of 20 mph. dispose of separately. Dispose Your Montague e-bike falls of cardboard along with waste paper and under Class 1. film in your recycling collection. For reference: Class 2: E-bikes that also have a Marking for products that must maximum speed of 20 mph, but are only be used indoors. throttle-assisted. Class 3: E-bikes that are pedal-assist only, with no throttle, and a maximum Europe: The 230 V~/50 Hz assisted speed of 28 mph. mains power supply has a class II protection rating. Product Symbols USA: The 120 V~/60 Hz mains power supply has a class II protection rating. The following symbols are shown on packaging, the rechargeable battery, or Symbol for direct current (DC). the charger.

Marking for electrical devices that must not be disposed of in Symbol for alternating current household or non-recyclable (AC) waste. Dispose of electrical devices with this marking at suitable collection points for environmentally friendly recycling. Only applicable for Europe: Products marked with this Marking for single-use and symbol meet all applicable rechargeable batteries that European Economic Community must not be disposed of in regulations. household or non-recyclable waste. Dispose of single-use and rechargeable

7 INTRODUCTION CONTINUED

Introduction to E-bikes The electric drive and increased speed requires practice and care while braking. Electric bikes, known as “e-bikes” or Braking while steering may reduce the Pedelecs, are electric power-assisted ability to control your bicycle. bicycles (EPACs) which have an electric motor and battery operated drive system Due to the increased speed, braking to provide pedal assistance up to a may require more distance to stop. Pay maximum of 20 mph (25 km/h) when attention to road conditions as sand, the rider is pedaling and the bicycle is in leaves, rain or other materials on the motion. road may impact your ability to brake quickly. The Montague ME-1 is a Class-1 e-bike which has a power rating of 250 • E-bikes require more braking force. Watts and provides assistance up to This can increase wear on the a maximum speed of 20 mph. In most brakes. countries, Class-1 e-bikes are legally • Reduce pedal force before initiating classed as bicycles. Please familiarize a gear shift to reduce drivetrain yourself with the legal regulations and wear. laws regarding e-bikes in your country, • Pay attention to your speed going state and/or city and maintain a current into a corner and be sure to stop knowledge as these regulations and laws pedaling before entering the corner. are subject to change. Otherwise, you may carry too much speed when entering a corner. • Shift gears regularly to stay in WARNING an optimal cadence range and downshift before coming to a stop. Please read all warnings carefully. • Always keep both hands on the Failure to operate the e-bike safely may handlebars when riding the e-bike. result in serious injury or death to you Failure to do so may cause you to and others. lose control of the e-bike and crash. • Due to the greater acceleration of an electric bicycle, you should also Differences between E-bikes pay particular attention to terrain and Conventional Bicycles conditions as you may approach obstacles faster than expected. E-bikes ride differently from conventional bikes due to increased Riding faster increases the risks of weight and speed. In addition to the serious accidents. Watch out for other list below, please review the Sections vehicles, cyclists, pedestrians, and Before Your First Ride and the Riding animals where you ride. Always operate Instructions in this manual. under control and at a safe speed.

8 INTRODUCTION CONTINUED

Other road users such as drivers, Intended Use pedestrians and other cyclists may need to adjust to the higher speed of the Your Montague e-bike is intended, e-bike and may not be aware of you. It is designed, and tested for riding on paved your responsibility to anticipate and react surfaces, smooth gravel roads and to avoid accidents. improved trails with moderate grades where the tires do not lose ground contact. WARNING Find out before your first ride whether IT IS YOUR RESPONSIBILITY TO your e-bike is equipped in accordance OPERATE YOUR E-BIKE IN A SAFE with requirements for use on the AND RESPONSIBLE MANNER. road. Note that national and regional regulations may vary. Always ride your e-bike under control and at a safe speed. Be Items that may have special aware of all other users of the road requirements: such as pedestrians, other cyclists, • Brakes motorcycle, scooter, automobile and • Lighting and reflectors truck drivers and animals. Note that • Bell or other approved warning they may not see you due to their line device of sight, or be expecting and able to react to the increased speed of the Familiarize yourself with the legal e-bike depending on the weight and regulations and laws regarding e-bikes in type of vehicle. Be especially cautious your country, state and/or city. while riding at night. For example: • Minimum rider age E-bikes are Heavier than • Compulsory insurance or if your Ordinary Bicycles insurance policy must provide Always park the bike in a suitable safe coverage for accidents involving area away from children, cars or animals use of this e-bike. You should that may come into contact with it. In contact your insurance agent to order to prevent possible injuries and determine if you need additional damage to the e-bike, park it so that coverage. it cannot fall over. Use caution when • Operating licenses or whether handling the e-bike (including, but not registration of your e-bike is limited to parking, lifting, pushing, loading required it into a car or onto a bicycle carrier and • Compulsory helmet use unloading it). • Use restrictions on public roads, cycling paths and/or trails

9 INTRODUCTION CONTINUED

Child Seats and Trailers WARNING WARNING It is your responsibility to know and follow all local laws and regulations No child seats or trailers are allowed regarding use of your e-bike. for use with this electric bicycle.

Use of the Kickstand Drive System and Supplementary Manuals The kickstand is not designed to support the weight of a person sitting on Your e-bike includes additional user the e-bike. Make sure the kickstand is up manuals for the various components before riding. Park your e-bike on a level, on your bike. For full instructions on firm surface for the best support of your the operation and configuration of the e-bike. drive-assist system and associated electronics, please read the included Rear Cargo Rack drive-assist manual.

• The rear rack is designed to carry Please familiarize yourself with the cargo secured in or other manufacturer’s instruction for intended containers. use or limitation. You are required to use • Never carry a passenger on the your e-bike responsibly. rack. • The maximum allowable cargo WARNING weight for the rear rack is 55 pounds (25kg). Do not exceed this Do not ride this e-bike through deep weight as it could cause a weight water or submerge any part of it. If imbalance and could result in a loss you do so, you could lose control of of control and injury. the e-bike or the drive system can become disabled or damaged. WARNING

The weight carried on your rack WARNING can affect the handling of a bicycle by altering the center of gravity, Understand your e-bike, drive-assist weight and balance. Using your rack system and the intended use of both. incorrectly can result in a loss of Using your e-bike the wrong way is control, resulting in serious injury and/ dangerous and can lead to serious or death. injury or death to you and others.

10 PARTS OF YOUR BICYCLE 33 25 17 10 3 12 1 19 2 31 16 13 4 30 6 20 11 9 14 28 7 21 13 5 24 8 27 31 10 26 15 22 29 12 32 18 23 17 Fig 2. Parts of your e-bike and location quick releases 1. shift levers 2. handlebar 3. brake lever 4. stem 5. saddle 6. head set 7. seat post 8. seat post quick release 9. frame quick release 10. reflectors (front & rear) down tube 11. 12. reflectors (front & rear) 13. tire (front & rear) 14. rechargeable battery 15. seat tube 16. control unit 17. lights (front & rear) 18. rear disc brake 19. front disc brake 20. drive unit (motor) 21. crank arm 22. seat stay 23. cassette 24. chain guard 25. front wheel quick release 26. chain 27. chainstay 28. chain wheel 29. rear derailleur 30. pedal 31. (front & rear) 32. rear wheel quick release or nut 33. wheel

11 BEFORE YOUR FIRST RIDE

• The arms are relaxed and bent WARNING slightly outwards • The back is leant slightly forward, A bicycle that does not work properly not vertical to the seat post. can cause you to lose control and fall. Inspect the entire bicycle thoroughly You can adjust the saddle (pages before every ride, and do not ride it 33 and 52) and handlebar (pages until any problem has been corrected. 27 and 50) to offer the best comfort and performance. Before you make these adjustments, refer to the Proper Make Sure your Bicycle is the Maintenance and Adjustments section Correct Size beginning on page 50. For a safe and comfortable ride, it is important to buy an e-bike with the right Maximum Gross Weight Limit height and length of frame for the rider. The right frame height depends on the Montague bicycles are designed for rider’s inside leg (inseam) measurement. a maximum total weight of rider plus It is important to take the inside leg luggage of 250lbs or a maximum total measurement into account so that it weight of rider plus luggage plus bicycle is possible to quickly and safely stop of 300lbs. the cycle and dismount in dangerous situations. Consult a dealer about the Know How your Bike Operates right frame size. The elements of your e-bike, if not used The optimum seating position depends correctly, can decrease your control on the size and shape of the cycle of the e-bike. Before you ride fast or frame, the size of the rider, and how the outside a controlled environment, learn handlebars and saddle are adjusted. the operation and performance of all the Optimum seating position adjustments mechanisms of your e-bike. Practice require expertise. The optimum seating using the various features of your e-bike position can also depend on how the at slower speeds in a flat, open area cycle is used, e.g. primarily for sports. before taking the bike on public roads. The main characteristics of an optimum If your e-bike does not operate correctly seating position are: or as expected, or if different parts are necessary for the safe operation of • When one pedal is up, the arms your e-bike, speak to your dealer or call and the top knee are all at a 90° Montague Corporation +1 617-491-7200. angle. • The lower leg is slightly bent. Electric Assist Operation • When one pedal is forward, the knee is over the of the front Familiarize yourself with all aspects pedal. of the e-bike that are specific to electric

12 BEFORE YOUR FIRST RIDE CONTINUED bicycles. Read the supplementary Review Riding Safely on page 20 and manuals to understand the power- Riding Instructions on page 23 before assisted drive system and other attempting to ride your Montague e-bike. components. Check the steering as shown in Fig. 5, Before your first ride, you should page 18. use the lowest power ECO mode and become familiar with the operation of Prevent Toe Overlap the electric bicycle by practicing starting Some frame sizes, especially smaller and stopping, cornering and navigating sizes, use a short-wheelbase design obstacles in a safe environment away with the front wheel close to the pedals. from other bicycles, pedestrians, and/ Increasing the or vehicles. Learn about the e-bike’s distance between controls and digital data/messaging. the front wheel and the pedals could place the handlebar WARNING too far away or Failure to practice riding your e-bike make the steering in a safe environment prior to riding unwieldy. On on a public road or pathway with other bicycles where this users of the road may result in serious distance is short, Fig. 3. Toe overlap. injury or death to you or other users of when the handlebar the road. is turned during very slow speeds your foot or toe-clip could overlap or touch the front wheel or fender (Fig. 3). Check your Brakes, Steering, and Quick Releases WARNING Press each hand lever to ensure the brakes are moving freely and stop the If your foot or toe-clip touches the front bike. Braking performance changes with wheel or fender, this could decrease riding conditions. Practice braking at low your control and cause a fall. Do not speeds before taking your e-bike out into pedal when you turn at slow speed. high traffic areas or trails. If your brakes This overlap is affected by the size of are not working properly, DO NOT ride your feet, the length of the crankarms, your e-bike. Take the e-bike to your local and the pedals you choose. At usual dealer for service. speeds, the handlebar does not turn Check that all quick releases (front suffiently for overlap to occur. When wheel, frame, stem, seatpost, and rear you ride slowly, do not pedal when the wheel) are fastened. Nothing should handelbar is turned. rattle or be loose.

13 BEFORE YOUR FIRST RIDE CONTINUED

Hot Spots, Moving Parts, Sharp range of operating conditions, so it is not Areas, and Pinch Points possible to provide a precise schedule Some parts of your e-bike can injure for replacement. Any cracks, scratches, you if mishandled. Sharp areas include or significant color changes indicate that chainring teeth, pedals, and brake discs. a component’s life has been reached and Brakes and their parts get hot. Moving should be replaced. Consult your dealer parts can cut skin and even break bones. if you have any areas of concern. Clamps and pivoting parts such as brake Good maintenance practices and levers can pinch, as can the chain where frequent inspections will ensure that you it runs over teeth. get the most out of your investment.

WARNING WARNING A frame or fork problem can decrease E-bikes are subjected to wear and control and cause a fall. If your e-bike high stresses. Different components gets a shimmy or any other issue, react to these stresses differently. decrease speed immediately and take If the design life of a component is it to your dealer for service. exceeded, it may suddenly fail and cause injury to the rider. Frame or Fork Problem Frame problems are uncommon, but an early warning sign can be the presence of a shake or shimmy while riding at some speeds. If you experience this, or any other problem, decrease speed immediately and do not ride the e-bike. If your e-bike behaves in an unusual manner or makes excessive noise, take the e-bike to your dealer for service.

Life Span of an Electric Bicycle E-bikes and the components that comprise them are not indestructible. Depending on the riding forces, conditions, and mileage endured, you should replace your e-bike or its parts at an appropriate frequency. The safe life of a part is determined by its construction, materials, and wide

14 BEFORE EVERY RIDE

WARNING

This is not a comprehensive maintenance program. Montague recommends that you have your e-bike tuned and safety checked by a bicycle technician familiar with e-bikes on a regular basis but no less than annually. If you notice any irregularities in your bike and/or its performance take it to a bicycle dealer before attempting to ride. Overuse of any brake system may cause loss of control resulting in personal injury.

Ensure that your e-bike is in proper before each ride. Perform inspection working condition each and every time and review the items on the following you ride. If a part of the e-bike does not checklist. function correctly, consult this manual and bring the e-bike to your local dealer Before Each Ride Drive Assist for repair. System Checklist • Check battery charge level WARNING • Check the lock for the battery to An e-bike that does not work properly ensure it is secured in the dock can cause you to lose control and fall. • Visually check the rechargeable Do not ride an e-bike with a part that battery for damage is damaged; replace the part before • Visually check the drive train for riding. damage and check the operation of the system Before Each Ride Mechanical • Visually check whether cables and Checklist connectors are securely in place • Frame and Fork and look for damage • Wheels • If you discover any missing or • Tire Inflation damaged parts, do not use the • Brakes e-bike. Have an authorized dealer • Handlebar and Stem repair your e-bike • Saddle and Seatpost • Suspension Carbon Fiber Composite • Quick Releases Some models have carbon fiber • Lights & Reflectors components. Pound for pound, • General carbon fiber is stronger than steel or aluminum. But it behaves differently E-Bike Drive System and when it is overloaded in an accident Battery or impact. An overloaded metal part It is important to thoroughly inspect will bend or deform before it breaks, the drive-assist system and electronics showing evidence of the load (Fig. 4).

15 BEFORE EVERY RIDE CONTINUED

An overloaded carbon fiber part will not Carbon Fiber Test bend or deform, so a damaged carbon part (with reduced strength due to the To examine for surface problems damage) may look normal - even after 1. Clean the part fully with a moist cloth. the same load that bent the metal part. But when the sum of the forces finally 2. Look carefully for problems. These exceeds the strength limit of the carbon include scratches, gouges, cracks, fiber, the carbon fiber part breaks, it does discoloration, loose fibers, or other not deform (Fig. 4). surface imperfections. In an accident or impact that does not break the carbon fiber, the carbon fiber To examine for a change of the rigidity could have internal or hidden damage (flex test): but appear normal. If that occurs, please carefully read these instructions and Do not ride, but use the part in the examine the carbon fiber. These tests usual manner while someone carefully are not conclusive: If you are not sure a examines the part for movement or unusual noise. part is safe, replace it. Fig. 4. To examine for delamination (tap test): Overloaded forks: • The metal fork 1. Clean the part fully with a moist cloth. on the left bent when overloaded 2. With a coin, tap near the area you • The carbon fiber suspect damage. fork on the right failed at a much 3. Listen carefully for variations in higher load, but sound. Tap on the part where it is separated. in good condition (or use a part that is almost the same). Compare the sound. Anything unusual, especially WARNING a hollow sound, indicates a problem. A carbon fiber part that has damage can break suddenly, causing serious Protect from Extreme injury or death. Temperatures Carbon fiber can conceal damage Protect carbon composite components from an impact or crash. If you from extreme temperatures when storing suspect your bicycle has had an or transporting your bike. impact or crash, immediately stop Allow carbon composite components to riding the bicycle. Replace the part cool off or warm up before you ride. Do not before riding, or take to your dealer for store a bike with carbon components in places where the temperature will exceed service. 66.5°C (150°F). For example, do not

16 BEFORE EVERY RIDE CONTINUED leave your bike lying flat in a black pickup there is any movement or irregularity in truck bed in the desert sun or under the the wheel do not ride your bike. Take it to glass of a hatchback auto. your local dealer for service. Excessive heat, such as that used in When the quick release lever is powder coating, or any open flame, may properly adjusted and in closed position damage the adhesive which joins carbon you should not be able to rotate the lever composite parts. Do not exceed 180°F (82°C) exposure to your frame. in a circular motion (parallel to wheel). This is different from the “flipping” motion, used to open and close the quick Examine the Frame and Fork release lever (Fig. 16b page 30). Repeat Before and after each ride, examine the same steps to check the rear wheel. your e-bike for signs of fatigue and stress. Such signs may manifest WARNING themselves in the form of: A wheel quick release that is not • Dents properly adjusted or closed can cause • Cracks the wheel to loosen or come off, • Scratches suddenly stop its rotation, or decrease • Deformation your control, causing you to fall. Make • Discoloration sure the wheels are correctly attached • Unusual Noises before riding your bicycle.

If your bicycle receives a high force Note that different systems attach load or impact, fully examine all the bicycle wheels to the frame: threaded parts of your bicycle. High force loads axle nuts, and multiple styles of a lever include crashes and strong impacts that actuated quick-release system. do not cause you to crash. If you are Make sure the wheels are straight. Turn unsure whether or not to replace a part, each wheel and look at the rim when speak to your local dealer. it goes through the brake pads or the frame. If the rim wobbles up and down or from side to side, repair the wheel. Examine the Wheels Check the attachment of both wheels. Examine Tire Inflation With the quick release lever in the “close” position, pick the front wheel off WARNING the ground and apply force to the wheel in a downward motion (Fig. 17 page 31). Excess air pressure can cause the tire The wheel should remain securely in to explode off the rim, causing hearing place. Grab your wheel and try to move loss or, if riding, a loss of control. Use it from side to side. Check the rims for a hand pump with a reliable pressure cracks, discoloration, and trueness. If gauge and do not overinflate.

17 BEFORE EVERY RIDE CONTINUED

Inflate the tires to the air pressure Pull the brake lever to make sure recommended on the sidewall of the the brake moves freely and stops the tire. Improper tire pressure will cause bicycle. If the brake lever can be pulled excessive wear, causing premature to the handlebar, the brake is too loose. replacement. Pressurized, unregulated When brakes are not applied, the brake pumps should not be used for this task. pads should be .25-.75mm away from The tire should be properly seated in the disc. If the pads are too near to the the rim and the fitting of the tire bead and disc, the brake is not in line or it is too rim bead should be checked. If the tube tight and the brake should be adjusted. is pinched between the tire and the rim, it can explode when inflated. Ensure that Examine the Steering the tire is not cracked or unevenly worn. Check for bulges. Check that the valve is straight in the rim. Irregular tires should WARNING be replaced immediately. Never ride a bike with an improperly adjusted handlebar or stem as this Examine the Brakes can cause you to lose control of the bike, leading to serious injury or death. WARNING Also, handlebar ends that are not plugged or covered can cut in a crash. A brake system that has damage or is not adjusted properly could decrease Make sure the stem is in line with the your control and cause you to fall. front wheel and correctly attached to the Inspect brakes fully before each ride, fork and handlebar. and do not ride if brakes are not To examine the connection to the operating correctly. Make adjustments fork, try to turn the handlebar from side as needed or take to your local dealer to side while you hold the front wheel for service. between your knees (Fig. 5).To examine

Your Montague e-bike is equipped with Fig. 5: disc brakes The hand lever causes Try to turn the the brake to apply pressure to a handlebars while disc attached to the hub. Follow the holding the front inspection instructions for disc brakes. wheel between your knees. CAUTION Disc brakes and discs get very hot during use and could burn skin. Also, the disc edges can be sharp and could cut skin. Do not touch the disc or disc brake when it turns or when hot.

18 BEFORE EVERY RIDE CONTINUED the connection of the handlebar, try to Your Montague e-bike comes equipped twist it in the stem. The handlebar should with front and rear lights powered from not move or be loose. Make sure that the main e-bike battery. For additional no cables are pulled or caught on the information regarding operation, please bicycle when you turn the handlebar. refer to the supplemental drive system If the handlebar or stem is loose to manual. turn, bring the bike to a local dealer for inspection. General Check to make sure nothing seems Saddle and Seatpost loose or rattles. Check that both pedals Make sure the saddle is correctly are properly threaded into the crank arm. attached and the minimum insertion line on the seatpost is not showing. Try to turn the saddle and seatpost in WARNING the frame, and try to move the front of Without correct lights and reflectors, the saddle up and down. The saddle it will not be easy for you to see or for should not move or be loose. If the other people to see you. If you cannot saddle is loose try adjusting it using the see, or other people cannot see you, instructions on pages 33 & 52. you could have an accident. Use a Suspension front light, a rear light, and reflectors when you ride in low visibility On select models, adjust your conditions. suspension for your use, and make sure that no suspension component can “bottom-out”, or be fully compressed while riding. Refer to the enclosed supplementary manual for the suspension fork equipped on your bike.

Quick Releases Check that all quick releases (front wheel, frame, seatpost, rear wheel, stem) are fastened. Nothing should rattle or be loose.

Lights & Reflectors Make sure lights operate correctly and are turned on. Make sure all reflectors are clean and in their correct position.

19 RIDING SAFELY

The first rule in safe e-bike riding is • Give pedestrians the right of way. to use common sense. An e-bike is Do not ride too close to pedestrians vulnerable; it cannot protect you in a and alert them if you intend to pass crash, impact, or loss of control the from behind. way a car can. An e-bike can tip over sideways or pitch you over the front • Slow down at all street intersections wheel. It does not have bumpers or and look to the left and right before airbags as a car does. This section is crossing. a guide of safe riding practices for on- and off-road operation. Make sure you are using your e-bike for the proper use WARNING condition (page 6) as it relates to off-road Proper use of your front brake is vital riding. to ensure safe, efficient stopping. To avoid misuse and potential injury, do Different localities and countries have not apply sudden or excessive force to different laws governing e-bike riding your front brake. Doing so may cause on public roads, and you should check your rear wheel to lift off the ground with local officials to make sure you are and/or your front wheel to slip from complying with these laws. under you. Apply both brakes at the same time and shift your weight back- • For your safety, always wear a ward on the e-bike while braking. helmet that meets CPSE or CE safety standards. In the event of • Always use proper hand signals for an accident a helmet can protect turning and stopping. Give signals you from serious injury and even 100 ft. before stopping or turning death. A bicycle dealer will be happy and always return both hands to to assist you in the selection of a the handlebars before stopping or helmet and other useful accessories. turning.

• Obey all local traffic laws. Obey red • Watch for cars pulling out into traffic and green lights, one-way streets, and for the sudden opening of car stop signs, etc. doors.

• Ride with the traffic, not against it. • Avoid potholes, drainage grates or Ride single file in a straight line. other road surface hazards. Cross railroad tracks at a right angle. Be • Have a satisfactory signaling careful when riding on soft road device (bell, horn, etc.), to warn of edges, gravel, sand and uneven approach. Ride defensively (expect surfaces. Ride slowly and avoid quick the unexpected). turns when riding on these surfaces.

20 RIDING SAFELY CONTINUED

• Never hitch on to other vehicles, do Be Seen (Especially at Night) not “stunt” ride or race in traffic. Do not weave in and out of the traffic or Your e-bike comes equipped with front swerve from side to side. and rear lights that are powered from the main e-bike battery. These lights • A crash can put extraordinary are not designed to improve your vision stress on bicycle components, when riding at night, but can help with causing them to fatigue prematurely. being seen by others. Please refer to the Components suffering from stress supplementary drive-assist manual for fatigue can fail suddenly, causing full instructions on operating the lights. loss of control, or serious injury. For more information and a guide for Your e-bike has a full set of reflectors. safe on-road and off-road riding, see Make sure the reflectors are clean and www.montaguebikes.com/support. in the correct position. As useful as these reflectors are, they do not help Caution: Wet Weather Riding your vision. They do not make you easy to see unless light is pointed at them. Brakes do not work as well under You should see and be seen. If you wet conditions as they do when dry. In ride at dusk, at night, or in low-visibility wet weather, special precautions must conditions, speak to your dealer to find be taken to ensure safety in stopping. equipment or materials to help your Proper adjustment and cable lubrication vision and make you easier to see. will help, but the major precaution rests with you, the rider. Increased brake pressure is needed in wet or rainy weather and care must be taken to WARNING maintain safety in these conditions. When you ride in low-visibility condi- tions such as fog, dusk, or night, you WARNING might be difficult to see, which could lead to a collision. Your bicycle is Wet or inclement weather can make equipped with reflectors. In addition an e-bike difficult to control. Decrease to keeping your reflectors clean, and your speed and use extra caution, or properly affixed to your bicycle, use a use other types of transportation. front light and rear light when you ride in conditions with low light or low vis- Ride slower than normal and apply your ibility. Wear bright, reflective clothing brakes sooner than regular conditions when riding in poor lighting conditions. would require. Consult your local bike shop to find When wet surfaces freeze, traction is accessories and clothing appropriate further decreased. Brake power could for your riding needs. decrease. Adjust your speed.

21 RIDING SAFELY CONTINUED

Think Safety • Ride carefully when off-road, staying Think about safety when you ride. You on trails, and not riding over rocks, can prevent many bicycle accidents if branches, or depressions. you think about safety. For example: • When approaching a descent, • Check your e-bike before every ride, decrease speed, move your weight making sure that your brakes are to the rear, and use the rear brake operating effectively and everything more than the front. is in perfect working condition. • Do not ride abusively, ride within the • Do not ride ‘no hands.’ Use Conditions specified for your bicycle type. • Do not ‘ride double.’ • Avoid riding in large groups, as this can force you to ride too close to WARNING other riders, making it difficult to see other vehicles and road hazards. You add to your risk of injury when When another rider is close, a sud- you use your e-bike incorrectly, for den change in direction or speed can example when you: cause you to lose control. • Jump your e-bike • Do not ride above your skill level. • Ride over sticks, debris, or other • Do not ride too fast - with increased obstacles speed comes increased risk. Higher • Do stunts speed causes small bumps to create • Ride in severe, off-road terrain large impact forces on your forks and • Ride fast, in competition, or frame, and results in higher forces “downhill” and risk of injury if a crash occurs. • Ride in an unusual manner

• Do not ride with loose objects Such examples add to the stress on attached to the handlebar or other each part of your e-bike. High stress parts of the bicycle, for example with can cause the frame or a part to break a pet or its leash. and increase your risk of injury. To decrease your risk of injury, use your • Never carry other riders or packages, e-bike correctly. as they may obstruct vision or proper control of the bicycle.

• Do not ride while intoxicated or while taking medications which can make you drowsy.

22 RIDING INSTRUCTIONS

Using Your Brakes the front brake, and the right brake lever operates the rear brake (note: bicycles Always ride with a safe distance manufactured for the United Kingdom between you and other vehicles or and some other countries switch these objects. Use your brakes. Adjust speed, and the left brake lever operates the rear braking distances, and braking force brake and the right brake lever operates based on the conditions you ride in. the front brake).

WARNING Changing Gears Correctly The multi-gear system provides a means of maintaining a constant pedaling rate, regardless of road level conditions.

The gears are activated by cables connecting the shift levers located on the handlebar to the .

If your e-bike is equipped with twist shifters, rotating the twist shifters towards you moves the chain from one chainring (or sprocket) to the next larger chainring Fig. 6. Do not over-use the front-wheel brake; the (or sprocket). Rotating the twist shifters rear wheel can lift and cause you to lose control. away from you moves the chain from one chainring (or sprocket) to the next smaller Apply pressure to both brakes at the chainring (or sprocket). same time. Overuse or incorrect use of a front brake could cause the rear wheel to If your bicycle is equipped with shift lift from the ground which can cause an levers, pushing the thumb shift lever accident (Fig. 6). away from you moves the chain from one chainring (or sprocket) to the next larger Many models of modern brakes are chainring. Pulling the index finger shift very powerful; they are made to stop a lever towards you moves the chain to the bicycle in wet or muddy conditions. If you next smaller chainring (or sprocket). think your brakes are too powerful, or not powerful enough, transport your e-bike to The left controls the front your dealer for adjustment of the brake derailleur and the right shifter lever system. controls the rear derailleur. To shift, continue pedaling at a steady pace while Note: In most countries around the operating the shifters and engage the world, including the U.S.A., France, and gear you find most comfortable. Germany, the left brake lever operates 23 RIDING INSTRUCTIONS CONTINUED

like when braking. Keep your feet on For easiest pedaling (while going the pedals and keep the crank arms uphill), position the chain over the horizontal and parallel to the ground smallest chainring in front and the largest (unless you are cornering as you sprocket in back. For hardest pedaling descend; see the next section). Keep (while going downhill or quickly), position your knees and elbows bent to allow your the chain over the largest chainring in body to absorb some of the bumps and front and the smallest sprocket in back. impacts during the descent. For extra stability, squeeze the seat between your For models with an external derailleur, thighs (some folks even like to squeeze pedals and wheels must be turning the top tube with their legs). Avoid a forward while shifting gears. Never pedal “death grip” on your brakes, instead backward while shifting gears and never use them as outlined in the Using Your force the twist shifters or shift levers. Brakes section.

If your bicycle is shifting incorrectly, Steering control please review Derailleur Adjustment on pages 53-54 or take the bike to your When cornering, do the majority of your local dealer. braking before you make your turn, and stop pedaling before entering the corner. Descending Hard braking during the turn can cause The keys to safely and effectively your wheels to skid, which could cause descending a hill are speed control, you to lose control. Make sure your speed weight distribution, and steering control. is reasonable, then ease off the brakes when you’re about halfway through the Speed control turn.

Your speed is controlled through To avoid catching the inside pedal on the experience and good braking, (covered ground, make sure that your outside pedal earlier). Remeber that e-bikes require is down and your weight is on the outside more braking force than conventional pedal. Lean your e-bike in the direction bicycles due to increased speeds. of the turn, but slightly angle your upper body in the opposite direction, keeping your body and head more upright. Weight distribution

Keep your weight correctly in balance between the wheels on a steep downhill by moving your weight rearward on the e-bike and as low as possible, just

24 RIDING INSTRUCTIONS CONTINUED

Obstacles and Impacts Always look well down the road to help you anticipate upcoming obstacles. This distance will vary according to your speed, but remember that the closer you get to an obstacle, the less time you have to react to it. Due to the greater acceleration and speed of an e-bike, you may approach obstacles faster than expected.

Use caution when you encounter obstacles in the road, whether it’s a sewer grate, speed bump, gravel, or any other hazard. If you are going fast, even a small obstacle can create a significant impact to your bicycle. If you are unsure of your ability to safely ride over an object, it is best to either ride around it or dismount and walk around it.

Your body and bicycle will have a natural tendency to go where you are looking. If you focus on an obstacle, you may go through it when you really wanted to avoid it. Focus on the part of the road where you want to go, not on the obstacles.

25 ASSEMBLING YOUR MONTAGUE BICYCLE

Your new e-bike was assembled and Carefully remove the e-bike and all ac- tuned in the factory and then partially cessories from the box to avoid scratch- disassembled for shipping. You may ing the frame. Cut all zip ties, and re- have purchased the e-bike already move all packing materials from the bike fully assembled and ready to ride OR in the shipping carton in the partially Check the carton for loose parts before disassembled form. discarding. Locate the included set of keys. Record the key identification num- If you have questions or concerns about ber stamped on the metal portion of the any of these steps, please see a bicycle key. Be sure they are not discarded with dealer or contact Montague’s Customer the packaging. These keys allow you to Support Team at +1 617-491-7200. remove the battery from the bike. Carefully follow the Final Assembly Instructions attached to your bike. Once you have completed the assembly, read the remainder of this Owner’s Manual.

Packing List Inside your box you will find: • 1 Mostly Assembled Bicycle Assembly • 1 Front Wheel Note: Depending on the model year and • 1 Front Fender design, your e-bike may be assembled • 1 Saddle with seat post differently. Refer to the Final Assembly • 1 Small Parts Box which includes: Instructions attached to your bike for the • Tools for assembly most up to date information. • 1 set of Folding Pedals For additional manuals, please visit • 1 Front wheel quick release montaguebikes.com/online-owners- • 1 Steering damper spring manual/. • 1 Spring bracket • Instructions and manuals Begin by pushing the kickstand down to • 1 Battery (some models) the lowered position, so that the bike is • 2 Keys for battery (some models) resting on the kickstand and rear wheel. This will keep the bike stable during WARNING assembly. Never attempt to ride a bicycle that is not properly assembled.

26 ASSEMBLING YOUR MONTAGUE BICYCLE CONTINUED

Installing the Handlebars 3. Tighten with the provided hex For some models, the handlebars are (Fig. 9) to proper torque (page 49). shipped off the bike. If so: Make sure that the gap between the stem is roughly the same on 1. Using the provided hex wrench, the top and bottom (Fig. 10, a), and remove the two screws (or four, the handlebars are at a comfortable depending on model) holding the riding angle (Fig. 10, b). stem clamp in place (Fig. 7).

Fig. 9: Tighten screws. Fig. 7: Remove the stem clamp.

2. Place and center handlebars within the stem (some have centerline marks), and replace screws (Fig. 8). B

A Fig. 10: Set at comfortable angle.

cables hidden To complete the assembly of your Mon- for clarity tague bicycle, continue with the instruc- tions provided in the next sections.

Fig. 8: Replace and center handlebars.

27 ASSEMBLING YOUR MONTAGUE BICYCLE CONTINUED

Install Display Screen Install Front Light

Your e-bike includes a handlebar Your e-bike includes front and rear mounted LCD display, which provides lights that are powered from the main a visual output of ride data, and an battery. To install: interface for changing settings. To install: 1. Remove the cover from the mount 1. Plug the power cable into the display area on the arch of the suspension screen. It can be found dangling from fork. The mounting screws are the main cable at the front of the located on the back side. Turn them bike. Insert it into the port closest to counterclockwise to loosen. Remove the display clamp (Fig.11a). he screws and cover, and discard (Fig. 12).

Fig. 11a: Plug the power cable into the display. Fig. 12: Remove cover from front light mount area. 2. Attach the display to the handlebars to the right of the stem. Remove the 2. Slide the light into the mounting bolt from the display clamp and wrap area on the fork arch, and insert the clamp around the handlebar. the mounting screws into the holes Re-insert the clamp bolt and turn on the back side. Turn clockwise to clockwise to tighten (Fig. 11b). tighten (Fig. 13).

Fig. 11b: Clamp the display screen to the bars. Fig. 13: Install the front light.

28 ASSEMBLING YOUR MONTAGUE BICYCLE

Attaching the Front Brake The front brake caliper needs to be secured to the front fork. To install: 1. Align the brake caliper bolts with the mounting holes on the non-drive side fork leg. Turn bolts clockwise to Fig. 15a: Remove end nut and first spring. attach the caliper to the fork. Tighten to a torque of 6 - 8 Nm (Fig. 14). 2. Slide the into the hollow axle of the front wheel hub, with the quick release lever located on the side opposite the disc brake rotor. The lever being on the correct side is important to ensure the bike can fold completely.

3. The end of the skewer should stick out from the opposite side of the hub. Slide the spring that was removed Fig. 14: Attach the front brake caliper. in step 1 back onto the end of the skewer, and thread the end nut back 2. Remove the plastic shipping spacer onto the skewer, turning it clockwise wedged between the brake pads. (Fig. 15b). You can see the layout and order of parts in Fig. 16 on the Additional adjustment of the brake align- following page. ment may be necessary after the front wheel is installed. See pages 55 - 56 for adjustment instructions.

Installing Front Wheel Quick Release

The front wheel quick release skewer is shipped separately and can be found in the small parts box. To install it in the front wheel: Fig. 15b: Slide skewer into wheel and replace nut. 1. Remove the quick release adjustment nut by rotating it counter- WARNING clockwise to loosen. Remove the first spring next to the adjustment nut, Never attempt to ride a bicycle that is and set both pieces aside (Fig. 15a). not properly assembled.

29 ASSEMBLING YOUR MONTAGUE BICYCLE CONTINUED

Closed Quick release Spring Hub axle lever

Hub

Mid

Quick release skewer Adjustment Spring Open nut Fig. 16a: Traditional quick release; diagram of parts. Fig. 16b: Positions of a quick release.

Installing the Front Wheel WARNING The front wheel of your new bicycle DO NOT change or swap wheels be- attaches to the fork with a traditional tween different bicycles. Your wheels wheel quick release. may not engage the other bicycle’s fork correctly causing an accident. WARNING 3. Move the quick release into the Improper installation or improper use closed position (Fig. 16b) with the of the quick release system can allow palm of your hand. the wheel to WOBBLE or DETACH from the bicycle causing you to crash. 4. A properly closed quick release lever Read and follow these instructions to should leave a mark on the palm of properly install and use this product your hand from closing. Check that to reduce your chance of SERIOUS the word “Close” is visible and that INJURY or DEATH. the lever is pushed fully to the closed position. Make sure that the lever is To install a wheel with a traditional positioned adjacent to the fork blade quick-release so it will not catch on any passing objects.

1. Move the quick release lever to the 5. If you can lock the lever with little OPEN position (Fig. 16b) and set the or no resistance, the clamp-force is wheel so it fully engages the frame not sufficient. Go back to step 2 and dropouts. tighten the adjustment nut 1/4 turn and return to step 3. 2. With the lever in the MID position (Fig. 16b), tighten the adjusting nut 6. Examine for correct quick release (Fig. 16a) until it is slightly tight. adjustment. With the quick release

30 ASSEMBLING YOUR MONTAGUE BICYCLE CONTINUED

closed, lift the If your front or rear disc brake needs to bicycle and hit the be adjusted or does not apply adequate top of the tire with a stopping power to the wheel, it may need solid blow (Fig. 17). to be adjusted. Be sure to squeeze the The wheel should brake levers to ensure that the brakes are not come off, be secured in place and functioning properly loose, or move before riding. For adjustment instruction, from side to side. please see Brakes on pages 55-56.

Note: Assembly instructions continue on Fig. 17: Strike the wheel the following page. in a downward motion.

Disc Brake (Fig. 18): To attach the front wheel on a disc brake equipped bike, align the wheel rotor with the slot in the disc brake caliper attached to the left hand fork stanchion.

Rotor Cable barrel adjuster Disc brake rotor bolts

Wheel quick Caliper release Cable clamp bolt

Fig. 18: Disc Brake. Once the rotor is aligned with the caliper slot, review Installing the Front Wheel on page 30 in order to properly secure the front wheel quick release.

Note: When installing the front wheel on a disc brake equipped model, the disc brake rotor is lined up between the brake pads in the caliper slot. If the pads are knocked out of place, the rotor may not go into the caliper slot. Reset the pads before attempting to install the wheel.

31 ASSEMBLING YOUR MONTAGUE BICYCLE CONTINUED

Installing the Front Fender The front fender mounts to three points on the fork: the arch, and a mount near the bottom of each fork leg. To install the fender: 1. Slide the fender into place so that the top bracket is directly behind the fork arch, and the mounting arms are on Fig. 20b: Slide bolt through fender bracket. either side of the wheel (Fig. 19). 3. An additional L shaped bracket, found in the small parts box, mounts on the back side of the fender bracket. Slide the L shaped bracket over the fender mounting bolt, and thread the end nut back onto the bolt, turning clockwise to tighten. The fender should be sandwiched between the L shaped bracket and the fork arch (Fig 21).

Fig. 19: Front fender in place

2. The top fender mounting bolt is found in the small parts box. Remove the end nut from the bolt by turning counter-clockwise, and slide the bolt through the hole in the fork arch (Fig. 20a), and through the bracket on the Fig. 21: Install L shaped brcket and attach end nut. fender (Fig. 20b). 4. Remove the two mounting bolts on the fork lowers by turning them counter-clockwise to loosen (Fig 22, page 33).

5. Pass the bolts through the eyelets on the ends of the mounting arms, and re-attach them to the fork. Turn them counterclockwise to tighten (Fig 22, Fig. 20a: Install the top fender mounting bolt. page 33).

32 ASSEMBLING YOUR MONTAGUE BICYCLE CONTINUED

A

B Fig. 22: Mounting bolt on fork lower Fig. 23: Steering damper spring Attaching the Steering Damper Spring Installing the Seatpost A steering damper spring is included to keep the fork and handlebars from Closed turning on their own and falling to one side when the bike is parked. It does not Adjustment affect handling of the bike while riding. Nut Open The spring can be found in the small parts box. To attach it: 1. Loop the hook on one end of the spring through the eyelet on the L Fig. 24: Opening and adjusting a quick release. shaped bracket that was installed on the fork arch during fender attachmnet (Fig. 23, a). WARNING A seatpost that is too high can cause 2. Using a pair of pliers to grip the hook damage to your e-bike or decrease on the opposite end of the spring, your control and cause you to fall. stretch the spring back toward the Make sure the minimum-insertion line downtube of the frame. This requires is in the frame (Fig. 25). considerable force, so be sure the pliers have a secure grip on the 1. Open the seatpost quick release spring. lever (Figs. 24 & 25).

3. Insert the hook end into the eyelet 2. Insert the seatpost into the seat on the underside of the frame’s down tube to a sufficient depth so that the tube (Fig. 23, b). minimum insertion line is no longer showing (Fig. 25).

33 ASSEMBLING YOUR MONTAGUE BICYCLE CONTINUED

3. When you are when you can sit on the saddle, and satisfied with with your knee only slightly bent the height of Minimum (approximately 15º), reach the pedal insertion the seatpost, line “OPEN”at its lowest point with the ball of your close the foot. seatpost Open OPEN seatpost quick release quick Installing the Pedals lever. The release tightness of Fig. 25: Insert seatpost You will find both pedals in your small the lever is beyond minimum line. parts box. The pedals are marked and adjusted by stamped “R” for Right, and “L” for Left. rotating the adjustment nut opposite The crank arms are also clearly marked the quick release lever. Turn the nut Saddle-clamp“R” and “L” to to differentiate between by hand to adjust the tension while boltright and left.closed holding the lever stable (Fig. 24). Each pedal can only be installed on 4. The lever is securely tightened when the corresponding side of the bike, as it leaves an imprint on the palm of they thread on in opposite directions. your hand from pushing it closed. The right pedal threads on clockwise, as normal. The left pedal threads on by 5. Once the lever is securely closed, turning it counter-clockwise. you should not be able to move it RT PO AN unless you open it again. If you can IM T move the seat up and down or side L Counter- to side with the quick release lever clockwise on Left Pedal Only in the closed position, repeat the seatpost installation process from step 3. Repeat until the seat cannot be moved when the quick release RT lever is closed. PO AN IM T Clockwise on 6. If you have adjusted the nut too R tightly and cannot push the lever Right Pedal Only to the “close” position, open the Fig. 26: Install the pedals. quick release lever again and turn the adjusting nut 1/4 turn counterclockwise. Continue with CAUTION Step 3. Do not try to insert the wrong pedal into the crank, as it will strip the crank 7. Adjust the height for comfort of the threads. Always check that the pedals rider. The saddle is properly adjusted are securely tightened before riding.

34 ASSEMBLING YOUR MONTAGUE BICYCLE CONTINUED

1. Align the right pedal axle into the Inflating Tires and Checking threaded hole in the right crank arm Pressure and secure it in the crank by hand. The right hand side of the bicycle is Your Montague e-bike is shipped the side of the bicycle with the chain. with the rear tire deflated for packing purposes. 2. The right pedal is installed by turning the pedal axle clockwise (Fig. 26). 1. Remove the cap, and using a standard pump, 3. Align the left pedal axle into the inflate the rear tire. Refer to the threaded hole in the left crank arm instructions for your pump to ensure and secure it in the crank by hand. proper use. The recommended The left hand side of the bicycle is pressure for your bike is specified on the side of the bicycle opposite the the sidewall of the tire. chain. 2. Since bicycle tires can lose pressure 4. The left pedal is installed by turning over time, the front tire may also the pedal axle counter-clockwise require inflation. Check the tire (Fig. 26). pressure and add air if necessary to reach the recommended pressure for 5. When both are hand-tight, use the your tires. 15mm pedal wrench (in small parts box) to tighten the pedals to 350-380 lb•in (40.2-42.9 N•m). Each pedal should be tight against the crank arm.

35 FOLDING YOUR MONTAGUE BICYCLE

Your Montague e-bike is designed to 3. Open the frame quick release by fold quickly without the use of tools. lifting up on the lever (fig 30).

To Fold Your Bike:

1. Lower the kickstand. Lift the rear end of the bike to allow it to fully straighten. Your bike should now be held up by the kickstand and balancing on its own (Fig. 28).

Fig. 30: Open the frame quick release.

4. Press straight down on the center of the frame quick release. The skewer should depress and will release the quick release clamp on the Fig. 28: Lowering the kickstand. underside of the frame (Fig 31).

2. In order to fold the frame completely, the crank arms must be positioned properly. Grasp the pedal and turn the crank arms counter-clockwise until the non-drive side crank arm is at its lowest point. It should be perpendicular to the ground with the pedal at the bottom (Fig. 29).

Fig. 31: Press down the frame quick release to al- low the frame to fold.

5. While holding the quick release down, fold the bike in half (Fig. 32, page 37).

Fig. 29: Reposition non-drive side crank arm

36 FOLDING YOUR MONTAGUE BICYCLE

Fig. 32: Fold the bike frame in half. Fig. 34: Lock the folded bike together with hook.

6. Where the two halves of the bike 8. Open the seat post quick release come together, the front wheel quick and slide the seatpost down until the release end nut should nestle inside saddle is completely lowered. an opening on the rear axle. Ensure the end nut is fully seated inside the 9. Open the quick release lever on the opening. (Fig. 33). handlebar stem (Fig. 35).

Fig. 33: Front wheel quick release end nut entering Fig. 35: Open the handlebar stem quick release. rear axle opening. 10. Pivot the handlebars to the down 7. The two halves of the frame can be position. (Fig 36, page 38). The locked together with a hook located saddle should be nestled in the on the front fork, which grasps a post middle of the handlebars (Fig. 37, on the rear rack. Press the hook into page 38) the post on the rear rack until it clicks into place. (Fig. 34).

37 FOLDING YOUR MONTAGUE BICYCLE

Folding the Pedals Your Montague e-bike is equipped with folding pedals to provide a more compact size when folding the bike. To fold the pedals: 1. Grasp the outside edge of the pedal, insert your fingers into the center of the pedal body, and squeeze (Fig. 38).

Fig. 36: Fold down the handlebars.

Fig. 38: Folding the pedals

2. The inner spring loaded portion of Fig. 37: Folded bike. the pedal body should compress, unlocking the folding hinge.

3. Fold the pedal 90 degrees so it lays parallel with the crank arm (Fig. 38).

38 ROLLING YOUR FOLDED BICYCLE

Rolling the Bike 4. With the motor side of the bike raised, release the brakes, and the Your Montague bicycle is designed bike should now easily balance. You to be rolled while folded to make can now roll the bike in front of you transportation easier. In order to roll while walking (Fig. 39). the bike, the frame must be folded and locked together, with the handlebars 5. In order to set the bike down, press in the upright position. Keeping the both brake levers to activate the handlebars in the upright position brakes, and pivot the bike away from provides a place to hold the bike while you until it rests on the kickstand. Be rolling. careful not to drop the weight of the 1. Follow steps 1 through 8 in “Folding bike onto the kickstand as it could Your Montague Bicycle” (pages 36 - cause damage. 38). Do not fold down the handlebars or open the handlebar stem quick release.

2. Grasp the handlebars with the drive unit of the bike facing away from you.

3. Press down both brake levers with your thumbs, and tilt the bike toward you. Activating the brakes will lock the wheels and allow you to pivot the bike to a balanced position (Fig. 39).

Fig. 39: Rolling the bike while folded.

39 UNFOLDING YOUR MONTAGUE BICYCLE

Since your Montague e-bike relies on quick releases for folding and adjustment, it is crucial that you fully Quick release understand how to operate the quick lever release levers. Upper clamp

Wedge

WARNING Lower clamp Failure to properly lock the quick re- lease levers for the wheels, seatpost, Fig. 40: Parts of the frame quick release. frame, or brakes can result in loss of To Unfold your Bike: control and may result in serious injury or death. 1. Pivot the stem and handlebars to the upright position (Fig. 41). Great care should be taken when locking the quick release levers on the e-bike. After reading this manual if you do not fully understand how to operate the quick release levers, ask a bicycle dealer for assistance, or call Montague’s Customer Support Team at +1 617-491- 7200. Do not ride your e-bike without all quick releases securely locked.

There are 5 different types of quick Fig. 41: Folding stem pivot releases found on your Montague e-bike They are as follows: 2. Flip the stem quick release lever to the closed position, and push it tight • The front wheel quick release lever. against the stem. You should feel the See Installing the Front Wheel, lever snap into place, and hear an page 30. audible click. (Fig. 42). • The frame quick release. See Adjusting the Frame Quick Release, page 41. • The seatpost quick release. See page 33 - 34. • The rear wheel quick release. See pages 30 (same as front wheel). • The handlebar stem quick release lever. See Fig. 42. Fig. 42: Left: open position. Right: closed position 40 UNFOLDING YOUR MONTAGUE BICYCLE CONTINUED

3. Once the lever is securely closed, you should no longer be able to pivot the stem along the hinge, and you should not be able to move the stem relative to the front wheel.

4. Ensure the frame quick release is in the open position (Fig. 30 page 36).

5. Unlock the two halves of the frame by detaching the fork latch from the Fig. 44: Close the frame quick release post on the rear rack (Fig. 34, page 37). Note: When closing, if the quick release lever does not leave an imprint on the 6. Unfold the frame, pivoting the front palm of your hand, refer to Adjusting the half of the frame until it is aligned Frame Quick Release below (Fig. 45). straight with the rear half (Fig. 43).

9. Raise the seatpost to the desired position (Fig. 24 and 25, pages 33 - 34).

Adjusting the Frame Quick Release If the frame quick release becomes loose or does not leave an imprint on your palm when closing the lever, the quick release may need to be adjusted. Fig. 43: Unfold the frame

7. Make sure the Wedge is completely engaged. It should hold the Upper and Lower Clamps together, and the frame should no longer fold (Fig. 40).

8. Secure the frame quick release lever by closing the quick release. It should point straight down and lay flat against the frame when closed. (Fig. 44) Fig. 45: Tighten frame quick release adjusting nut 41 UNFOLDING YOUR MONTAGUE BICYCLE CONTINUED

1. Make sure your e-bike is in the Unfolding the Pedals unfolded position with the frame quick release Wedge properly seated If the pedals were folded down for a over the Lower Clamp (Fig. 40). more compact folded bike size, they must be unfolded before riding 2. Open the quick release lever so the lever is pointing upward. Tighten 1. Pivot the pedal body 90 degrees, so the adjusting nut by turning it it is perpendicular to the crank arm. clockwise by 1/4 turn (Fig. 45). (Fig. 46)

3. Close the lever. If there is too much 2. The pedal should should snap resistance for you to be able to into place and you should hear an close the lever, open, and turn the audible click. The inner spring loaded adjusting nut counter-clockwise 1/4 portion of the pedal body should lock turn and try to close again (Fig. 45). into the spindle.

4. The quick release is securely closed when it leaves an imprint on the palm of your hand from moving the lever into the closed position. Make sure the word “close” is visible and that the lever is pushed fully to the closed position.

WARNING Fig. 46: Pivot folding pedals to riding position Great care should be taken when locking the quick release levers on your e-bike. If you do not fully under- stand how to operate the quick release levers, ask a bicycle dealer for assis- tance, or call Montague’s Customer Support Team at +1 617-491-7200.

DO NOT RIDE YOUR E-BIKE WITHOUT ALL QUICK RELEASES SECURELY LOCKED.

42 DRIVE-ASSIST SYSTEM

Rechargeable Battery • Only operate the battery between the temperature range of 14◦F (-10◦C) Your Montague e-bike is equipped with and + 122◦ F (+50◦C). a rechargeable lithium ion battery. Please follow the below guidelines for battery • Only use the original battery included longevity and safe operation. with your Montague e-bike. Do not use the included battery with any other bicycle, or any other battery WARNING with your Montague e-bike, even if it fits. Failure to follow the instructions in this section may result in damage to • Always turn the e-bike’s drive-assist electrical components on your e-bike system off before connecting or dis- and will void your warranty, but most connecting the battery.’ importantly, may result in serious per- • Do not modify, open or disassemble sonal injury or death. If your battery or the battery or charger. Modification charger exhibits any signs of damage, or disassembly may result in a short do not use it and immediately bring it circuit, fire or malfunction and will to an authorized retailer for inspection. void your warranty.

• The battery is heavy. Be careful WARNING when handling it and do not drop it. • Do not allow any nails, screws or Failure to observe these warnings can other small, sharp and/or metallic result in electrical fires, explosion, or objects to come in contact with the severe burns or electrocution. battery or the battery’s charging socket.

Even if all safety precautions are • Do not allow the battery to overheat. observed, the rechargeable battery can Protect the battery from excessive still become dangerous, such as if it sun exposure. catches fire. • Do not expose the battery to open In an emergency, make sure that fire or radiator heat. your actions do not put you or other Do not submerge the battery in people in danger at any time. Read • water. these instructions so that you can be focused and prepared when reacting to • Keep the battery away from metal an emergency. Refer to and follow the objects such as paper clips, coins, enclosed system manuals. nails, screws or keys that can cause a short-circuit.

43 DRIVE-ASSIST SYSTEM CONTINUED

• Do not use a battery that shows any Particularly high and particularly low signs of damage, or is leaking any ambient temperatures can permanently fluids. Battery liquid can cause skin speed up battery wear or even irritation, burns and respiratory tract damage the rechargeable battery. The issues. In the event of damage that rechargeable battery is subject to a results in skin or eye contact with certain degree of wear. Refer to the any liquid from the battery, immedi- manufacturer’s warranty terms for exact ately flush with water and seek medi- charge/discharge cycle specifications cal assistance. and corresponding power loss figures.

Maintain the battery and the charger WARNING as directed by the manufacturer’s instructions. Do not use a battery that shows any signs of damage, or is leaking any fluids. Contact with battery liquid can cause serious personal injury. WARNING In the event of a malfunction of the drivetrain and/or battery, the compo- • Turn off the battery and remove it nents may be come hot. Shut off the before performing work of any kind, e-bike or charger and do not touch such as installation, maintenance, any of the components until they have cleaning and/or repair. Touching the cooled down. contacts when the e-bike is ON can result in electric shock and/or injury.

Disconnect the battery from the charger Charger and Power Supply unit when fully charged. Do not leave a fully charged battery connected to the charger. Unplug the charger from the WARNING wall outlet when not in use. Store the battery in an area where it Failure to follow the instructions in will not become wet or damp and do not this section may result in damage to spray any liquid on the battery. Store the electrical components on your bicycle battery in a safe place out of the reach of and will void your warranty, but most children and pets. importantly, may result in serious per- If the battery has been stored for an sonal injury or death. If your battery or extended period of time, even if it has charger exhibits any signs of damage, been periodically charged, it should be do not use it and immediately bring it fully charged before using it in the e-bike. to an authorized retailer for inspection.

44 DRIVE-ASSIST SYSTEM CONTINUED

When charging the battery, place • Confirm that the charger and A/C the charger and battery on a stable, outlet are the same voltage and use level surface unaffected by heat. You the appropriate plug for each coun- should charge the battery in a dry, try’s electrical standards. well-ventilated area and make sure the charger is uncovered during the • While charging the battery, do not charging process. Ensure that the battery leave it unattended. and charger are not exposed to any • When removing the battery charger flammable or dangerous substances. power plug from the outlet or the Plug the charger into an outlet (100- charging plug from the battery, do 240V), using the appropriate plug for the not pull it out by the cord. country’s standards, then connect the charging plug with the charging socket • Store the charger in an area where it on the battery. will not become wet or damp and do not spray any liquid on the charger. Montague recommends charging the battery in an area with a working smoke • Do not modify, open or disassemble detector. the charger. Modification or disas- sembly may result in a short circuit, • Inspect the charger regularly for fire or malfunction and will void your damage prior to using. Do not use a warranty. charger that appears damaged. • Verify that the charger and battery WARNING are clean and dry before charging the battery. Do not modify the drive system, bat- tery, or charger in any way for any • Charge the battery on a fire-proof reason. Doing so will void the warran- material in a dry, well-ventilated area ty and can result in severe damage, with a smoke detector. Make sure faulty or dangerous operating condi- that the battery and charger are un- tions, and/or violation of local laws. covered during the charging process. Do not charge near any flammable or dangerous substances. Please review the enclosed supplementary drive-assist manual for • Charge the battery at an ambient additional information about the charger temperature between 32◦F and and the battery. 104◦F (0◦C and 40◦C). If outside temperatures are too hot or too cold, Dealers and Owners MUST NOT charge the battery inside. For safety change, alter, or modify in any way the reasons, if the battery is too hot or original components of the bicycle or too cold, it will not charge. drive-assist system (e.g the specified

45 DRIVE-ASSIST SYSTEM CONTINUED sizing of the attached gear ratios (front/ In general however, the higher the rear chain rings)). Attempts to “hot- power mode, more resistance created rod” or “improve” the speed of the bike by inclines, terrain, wind and weight on are dangerous to the rider. Use only the e-bike, and frequent stopping and specified manufacturer drive-assist starting will consume more energy and service and replacement parts. will reduce the range of the battery.

To improve range from your battery:

WARNING • Shift to a lower or higher gear before inclines and descents to avoid ex- Allow the drive system and recharge- cessively fast or slow cadences. able battery to cool before touching to prevent risk of being burned. • Operate the gear shifting system as if you were riding without assistance.

• Use the lower gears in your gear WARNING shifting system on inclines, in head- winds and with heavy loads. Do not leave the battery connected to When starting from a complete stop, the charger for extended periods after • begin in the lowest gear. the battery is charged. • Always ride in a low gear and pedal Tips for Getting the Most as hard as possible to use less bat- Range from Your Battery tery power. • Shift down to a lower gear before The drive is an auxiliary motor and reaching an incline. works most efficiently at a cadence of 50-80 crank revolutions/minute. You can • Look ahead and anticipate while rid- get the most mileage out of a new and ing so that you can avoid unneces- fully charged battery. sary stops. Because the range is dependent on a variety of factors such as the level of • Where possible, ride on surfaced assistance, speed, shifting behavior, tires roads and paths. and tire pressure, age and condition of • Do not transport unnecessary loads. the rechargeable battery, route profile and conditions, headwind and ambient • Take care of the e-bike on a regular temperature as well as the weight of basis and check the tire pressure the e-bike, rider and luggage, it is not regularly. possible to accurately predict the range before setting off or during a ride. • Observe maintenance periods.

46 DRIVE-ASSIST SYSTEM CONTINUED

• Continually test the functionality of • If any part of any component of the e-bike and check for wear, and the drivetrain is wet, allow it to dry refer to all notes on the rechargeable completely before connecting the battery in this user manual and the charger. drive system manual. • Do not use a pressure washer or dry • Keep the e-bike and components with compressed air. This will force clean. contaminants into sealed areas, electrical connections/components • Store the battery at room tempera- promoting corrosion, immediately ture prior to riding. damaging, or result in accelerated wear. • Follow the instructions regarding the temperature range for storage of the • Do not use alcohol, solvents or abra- battery. sive cleaners to clean the battery or charger. • Do not insert the battery into the cas- ing until just before you ride. • For instructions on how to clean drivetrain components, please refer to the supplementary drive-assist Cleaning, Storing, and manual for the drivetrain manu- Transporting your E-bike facturer’s instructions. Make sure connectors are dry and clean before When not riding, turn the drive system reconnecting and riding. off and remove the battery to prevent unauthorized use. Remove the battery and key when the bike is parked for long WARNING periods of time. Remove the battery from the e-bike Cleaning before cleaning. Make sure no electri- cal component is connected or on as you may be injured. WARNING Keep water away from the electrical components. WARNING

Use a damp sponge with only a mild Make sure the bike is secured upright soap and water solution. Rinse the and can not fall over accidentally sponge often. Do not spray water directly while you are cleaning it. Don’t rely on on controls or drive system components. the kickstand. Use a sturdy wheel stand to hold the bike • Use a soft brush to remove dry con- upright. tamination. 47 DRIVE-ASSIST SYSTEM CONTINUED

Storage Transportation • Store your e-bike in a dry, well venti- lated area. Only store the battery at WARNING an ambient temperature below +95◦F (+35◦C). Always remove the battery before transporting your e-bike. The battery is • Clean your e-bike prior to storing for considered dangerous and is subject an extended period of time and pro- to hazardous materials regulation. tect it from moisture, dirt, dust and It will require special packaging and other contaminants during storage. labeling for certain forms of transpor- tation and may be limited as to how it • If the bicycle or battery are stored may be transported. and not in use for extended periods of time, be sure to charge the battery at least every three (3) months so at You are responsible for knowing least 3 LEDs (60%) are glowing blue. and following the legal requirements If the battery is not charged over a of transporting your battery. Consult period longer than three months, it shipping experts to determine the can cause damage to the battery. appropriate methods of shipping your battery and e-bike including any legal • If the battery has been stored for insulation or packaging requirements. an extended period of time, even if it has been periodically charged, it should be fully charged before using CAUTION it in the e-bike. Use caution when handling the bicycle • Store the rechargeable battery out of (including, but not limited to parking, reach of children and animals, and in lifting, pushing, loading it into a car or such a way that it cannot fall down. onto a bicycle carrier and unloading). • Do not expose your bicycle to pro- longed excessive heat (e.g. direct • If you use a bike carrier, confirm that sunlight) such as inside a car parked it is able to carry your e-bike. in the sun or near a heat source such as a radiator. • When carrying the battery outside the frame, consider using an ap- • If your bicycle is exposed to cooler proved battery transport box. Make temperatures, keep the bicycle sure the battery is secured while stored indoors until just before riding. transporting to prevent damage to the battery or collision with other items.

48 DRIVE-ASSIST SYSTEM CONTINUED

• Avoid transporting the rechargeable Disposal battery by car in high outdoor tem- peratures. Ensure that you park the Do not dispose of the battery or charger car in the shade when transporting in your household waste. All parts the rechargeable battery by car. of the e-bike must be disposed of in accordance with the laws and regulations If traveling by rail, air or ferry, confirm in your country, state or municipality. It with the carrier well in advance of your is your responsibility to know and comply departure as to the legal requirements of with such laws and regulations. traveling with your e-bike. The lithium ion battery is considered hazardous goods. Lithium-ion rechargeable batteries are You may need to ship the battery or potentially dangerous and considered e-bike separately with legally appropriate hazardous waste and, as such, are packaging and labeling. subject to all country, state, regional and municipal laws and regulations Keys regarding their disposal. Familiarize yourself with the laws and regulations The rechargeable battery is unlocked and if appropriate, take it to a collection and removed using a key. Keys are location or a recycling center. identified by the serial number engraved on the key. Please record the key Do not dispose of your e-bike or serial number for future use and key charger in household waste. Once the replacement. If your keys are ever lost rechargeable battery has been removed, or stolen, or you would like additional due to the electrical components the spares, please contact the key provider. e-bike and charger may be considered After lots of rides and washing, the electrical waste or electronic equipment. battery lock can become dry and difficult As such, disposal may be subject to all to use. To maintain, whenever you country, state, regional and municipal lubricate your bike chain, place a few laws and regulations regarding disposal. drops of chain oil on the key insert the Familiarize yourself with the laws and key and operate the lock, then remove regulations and if appropriate, take it to a and wipe the key clean. collection location or a recycling center.

49 PROPER MAINTENANCE AND ADJUSTMENT

WARNING WARNING DO NOT attempt to perform any Incorrect torque can cause damage adjustments while riding your e-bike. or break a part. Use a torque wrench to correctly tighten a part, or transport This chapter lists instructions for the bicycle to your dealer for service. adjustment of some the parts of an e-bike. After a repair, examine the e-bike as shown in the Before Each Ride It is important to use only genuine Checklists on page 15. This manual is replacement parts with dimensions not intended to be a repair manual. If you identical to the original components on are unsure about adjusting your e-bike or your bike. The Montague frame quick have any questions about adjusting your release and the foldable stem assembly e-bike, transport it to your local dealer for are both safety-critical components. Only adjustments and repairs. replace the frame quick release and the foldable stem with a genuine part sourced from Montague. WARNING If you replace the crank or tires A bicycle that malfunctions could with different models, you should use decrease your control and cause you caution as there is a possible reduction to fall. Fully examine all parts of the of toe-clearance and the possibility of bicycle before each ride. If there is a pedal contact with the ground may be problem, do not ride the bicycle, but increased. take it to your local bike dealer for inspection and repair. Handlebars Torque Specifications Handlebar clamp Torque is a measure of the tightness bolts of a or bolt. Use a torque wrench to make sure you do not apply too much Handlebar torque, which can cause damage to or break the part. However, a fastener that is too loose can also cause damage. After you use the torque wrench, examine the function of the part with Fig. 47: Handlebar bolts on threadless stem the tests in this section. If a part does not have the correct function when it is To rotate the angle of your handlebar: tightened to the recommended torque, 1. Decrease the tightness of the tranport your e-bike to your dealer for handlebar clamp bolts on the stem repair. (Fig. 47). 50 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

2. Decrease the tightness of the 2. Twist the handlebar by rotating it expander bolt by two or three turns forward or backward. Make sure it (Fig 48). remains in the center of the stem (Fig. 10 page 27). 3. Decrease the tightness of all (4) set screws by two or three turns (Fig 48). 3. Tighten the handlebar clamp bolts on your type of stem: Welded stems: 4. Fold the handlebars back to the 100-120 lb•in (11.3-13.6 N•m). upright position, and close the stem Forged Stems: 150-180 lb•in (17- quick release. This will allow you to 20.3 N•m). properly align the stem with the front wheel. Stem 5. With the stem aligned parallel with Your Montague e-bike comes equipped the front wheel, apply a clamping with a stem that folds down to create the force between the top of the stem smallest folded bike size possible. The assembly and the fork crown. This mounting and adjustment of this stem will press the stem down onto the is unique to Montague. Please read bearings (Fig 49). the instructions below carefully before attempting to adjust the stem.

Expander bolt

Set screws

Stem wedge

Fig. 49: Apply clamping force to tension headset

Fig. 48: Stem mounting parts. 6. While applying the clamping force, To align or adjust headset tension: tighten all (4) set screws around 1. Open the stem quick release, and the bottom of the stem. This will begin to fold the handlebars down temporarily hold the stem in place (Fig. 36, page 38). This will provide until the expander bolt can be access to the expander bolt. tightened (Fig 48).

51 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

7. Open the stem quick release and 2. Move the lever back to the open begin to fold the handlebars down to position, and rotate the quick release provide access to the expander bolt. barrel adjuster clockwise (relative to the lever) 1/8 turn to tighten (Fig. 8. Tighten the expander bolt to 120 51). Close quick release lever again lb•in (13.6 N•m). to check tension, and repeat if necessary. 9. Fold the handlebars back to the upright position, and close the stem quick release. WARNING If you complete these adjustments and the quick release is tight, yet the handlebars feel loose, do not ride your bike. Take it to your local dealer for inspection and adjustment. Fig. 51: Turn barrel adjuster to tighten quick release

To adjust stem quick release: 1. Begin by checking the stem quick WARNING release tension. Move the handlebar quick release to the open position, If you complete these adjustments and check the tension by pushing it and the quick release is tight, yet the back to the closed position (Fig. 50). handlebars feel loose, do not ride A properly tightened quick release your bike. Take it to your local dealer lever should leave a mark on the for inspection and adjustment. palm of your hand from closing. If you can lock the lever with little or no resistance, the clamp-force is not sufficient.

Fig. 50: Left: open position. Right: closed position 52 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

Seat (Saddle) Adjustments 3. Adjust the saddle and tighten the saddle-clamp bolt for your type of seatpost: WARNING If you ride a saddle that is not adjusted • One bolt that uses a 13 or 14 mm correctly or one that does not correctly open-end wrench: 180-220 lb•in support your pelvic area, it can cause (20.3-24.9 N•m) injury to your nerves and blood • One bolt across the seatpost head vessels. If your saddle causes pain or that uses a 5mm allen wrench: 120- numbness, adjust the saddle position 130 lb•in (13.6-14.7 N•m) or speak to your dealer about a saddle • One bolt that uses a 6mm allen that is more comfortable. wrench: 150-250 lb•in (17-28.3 N•m) • Two bolts that use a 5mm allen wrench: 80-120 lb•in (9.6-14.1 N•m)

WARNING An incorrectly positioned seatpost can Saddle-clamp break the saddle rails or the seat-

bolt closed Seat post quick release clamp bolt, and cause you to fall. Only clamp the flat portion of the saddle Fig. 52: Saddle bolts and adjustments. rails in the seat clamp. Saddle angles can be adjusted to meet your preferences. It is recommended For saddle height adjustment and that you first try to ride with the top of the seatpost quick release usage, see page saddle parallel to the ground. The saddle 33, Installing the Seatpost. can also be moved forward or rearwards along the seatpost to adjust the distance from the handlebar. WARNING To adjust the angle of the saddle: A seatpost that is too high can cause 1. Decrease the tightness of the damage to the bicycle, decrease your saddle-clamp bolt (Fig. 52) until the control, and cause you to fall. Make saddle can be moved. sure the minimum-insertion mark (Fig. 25 page 34) is in the frame. 2. Put a straight edge, bubble level or ruler across the top of the saddle to better see the angle of the saddle.

53 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

Pedals Control Cables The right pedal (chainside) is threaded Examine all cables for kinks, rust, in the standard clockwise to tighten broken strands, or frayed ends. Also direction. The left pedal is threaded in examine the cable housing for loose the opposite direction (Fig. 26, page 34). wire strands, bent ends, cuts, and worn Tighten pedals into the crankarms to areas. If you think there is a problem with 350-380 lb•in (40.2-42.9 N•m). a cable or housing, replace the cable before riding. The adjustment of pedal bearings requires special tools and training. Only Rear Derailleur Adjustment a bicycle dealer should attempt these Pully Adjustment adjustments. Screw

H + + L +

Freewheel H + L +

Adjustment Screws

Cable Adjustment Barrel

Fig. 53: Rear derailleur parts. View from the rear. If the gear system is not functioning properly, check to ensure that the rear derailleur follows each shifting command of the right twist shifter/shift lever. Cable stretching could affect the function after some time, so that synchronization may no longer be assured. Position the bicycle in a stand and check and adjust as follows: 1. On models with a front derailleur, shift so that the chain is on the middle chainring, by turning the crank forward and shifting the left twist shifter/shift lever.

54 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

Front Derailleur Adjustment 2. Shift the chain to the outermost/ smallest rear sprocket by turning the right twist shifter all the way away H from you, or moving the right shift Cable + L lever all the way towards you. + Cable clamp bolt 3. While turning the crank forward, rotate the right twist shifter or push the right shift lever to the next Chain guide position. Adjustment Chainring Screws 4. The chain should move to the second sprocket quickly and easily. If it stays on the first sprocket, the tension of the shifting cable must be Fig. 54: Front Derailleur Adjustments. increased (proceed to Step 6). With bicycles that have more than one 5. If the chain jumps across the second chainring, the front derailleur makes gear sprocket or if it scratches the third changes. sprocket, the tension of the shifting cable must be decreased. To adjust the small-chainring position 6. Cable tension is adjusted by turning the Cable Adjusting Barrel, which is 1. Move the chain to the smallest front located at the junction of the cable chainring and the largest rear cog. and the shifter or rear derailleur (Fig. 53). To increase tension, turn 2. Decrease the tightness of the cable the knurled knob counterclockwise, clamp bolt (Fig. 54) until the cable is to decrease tension, turn the knob free. clockwise. Turn until the problem is corrected. 3. Turn the low-gear adjustment screw (identified with an “L”) until the If the tension is adjusted according to inner chain-guide of the derailleur the above steps, the chain should follow is approximately 0.5 mm from the all shifting commands on the shifters. chain. If the gear system still does not function properly, please contact a bicycle dealer 4. Pull on the cable end, and move the for assistance. left shift lever to the small chainring position.

55 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

5. On the shift lever, fully turn clockwise To adjust the middle-gear position the derailleur cable barrel-adjuster. with three chainrings

6. Put the cable in the groove found 1. Move the chain to the largest front near the derailleur-cable-clamp bolt, chainring and the smallest rear cog. pull the cable tight, and tighten the clamp bolt to 44-60 lb•in (5.0-6.8 2. Turn the cable barrel-adjuster (on the N•m). shifter) to change the cable tension and align the inner cage of the derailleur until it touches the chain. To adjust the large-chainring position 1. Move the rear derailleur to the 3. Change to all gear combinations to smallest rear cog. make sure the chain smoothly lines up with all the chainrings. 2. Turn the high-gear adjustment screw (identified with an “H”) Brakes counterclockwise until it cannot stop the movement of the derailleur. The brake system on your bike lets you slow and stop. The function of this 3. Turn the crankarms with your hand. system is crucial to your safety. It is Use the shifter to carefully move the strongly recommended that only your chain to the outside chainring. dealer adjust your brakes. Each month, examine the brake pads 4. Move the outer chain-guide for wear. approximately 0.5mm from the chain. To adjust disc brake caliper position: 5. Tighten the high-gear adjustment screw until it resists. 1. Loosen the brake caliper bolts by turning counter-clockwise (Fig. 14, If you have turned the screw too far, page 29). the front derailleur will move to the small chainring. 2. Engage the brake by squeezing the brake lever toward the handlebar. 6. Change gears to all the gear This will center the caliper on the combinations. Make sure the chain rotor. does not come off when you move the shift lever. Make sure the 3. While keeping the brake engaged, derailleur cage does not rub on part tighten the brake caliper bolts to a of the crankarms. torque of 6 - 8 Nm.

56 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

To adjust brake pads on a cable actuated disc brake WARNING First adjust the clearance between the When you apply the brake, the brake right (inside) brake pad and the disc. pads remove material from the disc rotor. If the brakes remove too much 1. Use a 5mm allen wrench to move the material, the rotor can become inside pad inward toward the disc weak and sudden failure can ensue. rotor till it touches the rotor. Examine the rotors regularly and replace them when they are worn. 2. Back off slightly until the pad does not touch the rotor surface. Wheels Next adjust the clearance between the left (outside) brake pad and the disc. Examine tires for worn areas, bulges, and damage. Make sure rims are clean. 3. Turn the barrel adjuster located on Make sure tires are inflated to proper the front brake lever clockwise to specifications as listed on the sidewall move the outside brake pad inward of the tire. If the wear-indicators on the until it touches the rotor. brake surface show the rim is worn, replace the rim. Make sure there are 4. Back off slightly (1/4 turn) until the no loose or damaged spokes. If loose pad does not touch the rotor surface or damaged spokes are found, do not and the wheel spins freely. ride the bicycle, take it to your local bike dealer for repair. If there is contact between the brake pads and rotor after performing the above steps bring your bike to your WARNING local dealer for adjustment. Riding with an improperly adjusted wheel quick release can allow the Hydraulic Disc Brake wheel to wobble or disengage from the bicycle, causing damage to the Maintaining hydraulic disc brakes bicycle, and serious injury or death to requires purpose built bleed kits and the rider. extensive training. Please bring your bike to a professional bicycle mechanic for hydraulic disc brake adjustment and repair.

57 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

Closed Quick release Spring Hub axle lever

Hub

Mid

Quick release skewer Adjustment Spring Open nut Fig. 55: Traditional quick release; diagram of parts. Fig. 56: Positions of a quick release.

Wheel installation 3. Move the quick release into the closed position (Fig. 56) with the palm of your hand. WARNING 4. A properly closed quick release lever DO NOT change or swap wheels be- should leave a mark on the palm of tween different bicycles. Your wheels your hand from closing. may not engage the other bicycle’s fork correctly causing an accident. 5. If you can lock the lever with little or no resistance, the clamp-force is Your Montague bicycle could use two not sufficient. Go back to step 2 and different types of wheel attachment tighten the adjustment nut 1/4 turn devices. Carefully read the instructions and return to step 3. for the devices on your bicycle. 6. Examine for correct quick release • Traditional quick-release adjustment. With the quick release • Threaded axle and nut closed, lift the bicycle and hit the top of the tire with a solid blow (Fig. To install a wheel with a traditional 17 page 31). The wheel should not quick-release come off, be loose, or move from side to side.

1. Move the quick release lever to the To remove a wheel with a traditional OPEN position (Fig. 56) and set the quick-release: wheel so it fully engages the frame dropouts. 1. Open quick release lever (Fig. 56). 2. Decrease the tightness of the 2. With the lever in the MID position adjustment nut; turn it approximately (Fig. 56), tighten the adjusting nut three full turns. (Fig. 55) until it is slightly tight.

58 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

3. Move wheel out of the fork or frame. Fitted Accessories (Racks and Fenders) To install a wheel with a threaded In addition to the parts already axle and nut: discussed in this chapter, your bicycle might have accessories such as fenders, Some rear wheels are attached with lights, racks, chain guard, or kickstand. nuts threaded on the axle. A toothed Each month, check the accessories to washer could be necessary between the make sure they are correctly attached. nut and . If the part is loose or not in alignment, adjust or tighten the part, or take your 1. Tighten the rear wheel axle nuts: bicycle to your dealer for service. 240-300 lb•in (27.1-33.9 N•m). If you are attaching additional 2. Make sure you have correctly aftermarket accessories to your e-bike, attached the wheel. Lift the bicycle, make sure your e-bike is suitable for the and hit the top of the tire with a solid attachment of those accessories. Read blow (Fig. 17, page 31). The wheel and follow the instructions that came with should not come off, be loose, or each accessory. move from side to side.

3. If the wheel connection fails the test, Only Install Compatible Accessories do these procedures again. If you Not all accessories are compatible or cannot correctly attach the wheel, safe, so only add accessories that have transport your bicycle to your dealer the approval of the manufacturer. As an for repair. example, some panniers or bags can put weight high on the e-bike. This can Cassette and Adjustments make your e-bike less stable. Although some bags are compatible with some Cassette and freehub adjustments of our e-bikes, always check with your require special tools and training and dealer before making any change to your should only be performed by your local e-bike. As another example, clamping bicycle dealer. anything on a carbon part can weaken or damage the part. Tighten freehub body: 354 lb•in (40 N•m). Tighten cassette sprocket lockring: 347 lb•in (39 N•m).

59 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

Stem WARNING Each year apply lubricant to the stem. Any modification can make your To apply lubricant to a direct-connect frame, fork, or part unsafe. Do not stem, adjustment of the headset sand, drill, file, remove redundant bearings is necessary. Only your dealer retention devices, install incompatible should do this. forks, or make other modifications. A component that is not approved or To apply lubricant to a quill stem: assembly that is not correct can put high stress on your e-bike or compo- 1. Remove the stem from the frame. nents. A frame, fork, or component with modifications could decrease your 2. Clean the used grease from the control and cause you to fall. Before stem. you add an accessory to your e-bike or change a part of your e-bike, speak 3. Apply a thin layer of grease to the to your dealer. section of the stem-quill that will be put into the frame. Also apply grease Bearing Adjustments to the stem wedge. Adjustments to bearing systems found 4. Install the stem. on your e-bike require special training. If your e-bike requires adjustment to the Seatpost bearings, take it to your local bicycle dealer. Each year apply lubricant. Use the procedure for your frame and seatpost Lubrication materials: This section shows the parts that For a metal seatpost in a metal frame you should lubricate, the frequency of service, and brief instructions. See your 1. Loosen the seatpost binder bolt, dealer for recommended grease or oil. or release the quick-release, and If more instructions are necessary, see remove the seatpost from the other sections of this manual or consult frame. your dealer. 2. Clean the used grease off the To service bearings, special tools and seatpost. training are necessary, so only your dealer should do this. Some bearings are 3. Apply a thin layer of grease to the permanently sealed and do not require section of the seatpost that will be new grease each year. in the frame.

60 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

4. Put the seatpost into the frame. 2. Apply a thin layer of grease on the threads. 5. Adjust the saddle to the correct height and align it. Tighten the 3. Install the pedals on the correct seatpost binder-bolt or lock the side; put the right pedal on the right quick-release. crankarm and the left pedal on the left crankarm. 4. Tighten the pedal-. Each year, replace the grease in the bottom bracket bearings. To service Derailleurs bearings, special tools and training are necessary, so only your dealer should do Each month, apply lubricant to all pivot this. points on the front and rear derailleurs, together with the derailleur pulleys on the Chain rear derailleur.

Each month, apply lubricant to the Headset chain. Always place a rag behind the chain to prevent lubricant on other parts Each year, replace the grease in the of the bicycle. After you apply lubricant, headset bearings. To service bearings, wipe off the excess with a rag. special tools and training are necessary, so only your dealer should do this. Pedals Brakes and Brake-levers Each year, replace the grease in the pedal bearings. To service bearings, Each three months apply lubricant to special tools and training are necessary, the brake-lever pivots and brake arm so only your dealer should do this. fixing pivots.

Each year replace the grease on the Wheels pedal axles where they thread into the crank arms. There are right and left Each year, replace the grease in the pedals, usually identified with a letter wheel bearings. To service bearings, on the end of the pedal axle or on the special tools and training are necessary, wrench flats. so only your dealer should do this.

1. Remove the pedal-axles from the Each year, apply lubricant to wheel crankarms; turn the right pedal-axle quick-releases. Apply two or three drops counterclockwise, but turn the left of synthetic lubricant or a light oil where pedal-axle clockwise. the quick-release lever turns in the quick- release body. 61 PROPER MAINTENANCE AND ADJUSTMENT CONTINUED

Suspension Forks 4. Turn the barrel-adjuster clockwise so that the threads on the barrel- Each month, lubricate your suspension adjuster do not show. • For a fork. Refer to the supplementary manual derailleur cable, put the shift-lever provided by the fork maker, or consult in the position with the least cable your dealer. tension. • For a brake cable, hold the brake closed while you do the Each year, replace the oil in your subsequent step. suspension fork. To replace the oil, special tools and training are necessary, 5. Tighten the cable-clamp bolt to 52- so only your dealer should do this. 69 lb•in (6-8 Nm).

Cables 6. Cut the cable so that no more than 2” (51 mm) extends through the Apply lubricant to a cable when you clamp-bolt. install it. 7. Put a metal cap or put a bit of To install a cable in a cantilever brake, solder on the end of the cable to special tools and training are necessary, prevent a frayed cable. so only your dealer should do this.

To install a cable

1. Before you remove the used cable, note its path on the frame. Loosen the cable-clamp bolt, and remove the worn cable.

2. Apply grease to the new cable where it passes through housing or guides. Install the new cable on the same path as the used cable.

3. Make sure the leaded end of the cable is installed correctly in the lever. Make sure the housing is correctly installed in the housing stop of the lever. • If necessary when you install a cable in a brake, adjust the brake again.

62 MAINTENANCE SCHEDULE

Many of the items scheduled on Every Month the maintenance list are described within this manual. Several items on • Examine the attachment of the this maintenance list require special handlebar and stem tools and training to complete. We • Examine the attachment of the recommend that you bring your and seatpost to your local bike dealer to ensure these • Examine the chain items are completed correctly. • Examine the cables for wear • Examine the operation of the shift Before Each Ride levers and derailleurs • Lubricate derailleurs • Examine the frame and fork • Examine headset bearing • Examine the wheels adjustment • Examine tire inflation • Examine brake pads • Examine the brakes • Examine attachment of brakepads • Examine the handlebar and stem • Examine chain tension • Examine the saddle and seatpost • Examine wheel bearing adjustment • Examine lights and reflectors • Examine rims and tires for wear • Ensure pedals are on tight • Lubricate brake levers • Ensure all quick releases are • Examine and bottom clamping properly bracket • Examine the attachment of • Check battery charge level accessories • Check the lock for the battery • Visually check the rechargeable Every Year battery for damage • Visually check the drive train for • Bring in bicycle for full inspection by damage and check the operation of your dealer the system • Lubricate handlebar stem • Visually check whether cables and • Lubricate seatpost connectors are securely in place • Replace grease in the pedal and look for damage threads and bearings • If you discover any missing or • Replace grease in the wheel damaged parts, do not use the bearings e-bike. Have an authorized dealer • Replace grease in the headset repair your e-bike bearings • Replace grease in bottom bracket Each Week • Lubricate wheel quick releases • Replace grease and oil in • Clean bicycle with a damp cloth suspension forks • Examine wheels for loose spokes • Apply lubricant to suspension forks 63 MONTAGUE CORPORATION LIMITED WARRANTY

Every new Montague bicycle comes with our industry leading warranty coverage. Once your bicycle is registered, Montague Corporation provides each retail purchaser a warranty against defects in workmanship and materials. For the full terms of your bicycle’s warranty, please visit www.montaguebikes.com/warranty- information/.

The bicycle’s warranty is not meant to suggest that the bicycle cannot be broken or will last forever. It only means that the bicycle is covered subject to the terms of the warranty.

Montague Corporation does not make any promise, representation or warranty regarding the use of this e-bike.

Failure to follow the instructions and warnings in this manual may invalidate the warranty. Improper maintenance, use of the e-bike, the battery or charger will invalidate the warranty(ies) provided

The applicable statutory warranty provisions will be those for the country in which the product was purchased.

Any modification or attempted modification of the drive train system power-output is prohibited and will void the warranty.

64 © 2020 Montague Corporation, Cambridge, MA 02141 USA. Montague is a registered Trademark of the Montague Corporation. Component specifications vary by country and are subject to change without notice. All Montague bicycles are cov- ered under one or more patents or patents pending. CLIX is a registered Trademark of CLIX Systems, Inc.

65 66 Montague Corporation P.O. Box 398032 Cambridge, MA 02139 Phone # +1 617-491-7200 www.montaguebikes.com © 2020 Montague Corporation, Cambridge, MA, USA

67 68 Serial Number Comments: Bicycle Color Age City First Name MONTAGUE IMPORTANT! How will you use your bike when folded? Street E-mail Car Trunk Boating Private Plane Train Public Transportation Home storage Date of purchase Month Please complete and return within the next 30 days OR register online at www.montaguebikes.com/register. Day 16 17 18 19 20 21 Frame Size At Work RV Airline Travel ® Year Bicycle Registration Card Name of store where purchased M.I. (circle) Last Name Bicycle Model Name $ Price Paid What most influenced your purchase? Weight Recommendation Good Fit / Comfort Ease of Use Bicycle Design Montague Reputation . State Male / Female Rider’s Sex Apt. No. ZIP Code Other Website Style Price Warranty Quality (circle) State income? Which group describes your household Montague Bicycles? How did you hear about What kind of riding do you do? $100-000 - $200,000 $75,000 - $100,000 $50,000 - $75,000 $25,000 - $50,000 Under $25,000 All of the above. Off Road / Mountain Biking Road / Fitness Commuting / Trekking Touring Urban / City Bike Trails / Paths Other: I’m a repeat customer! I saw an ad in a magazine. I found you by browsing online. A local bike shop recommended your bikes. A friend recommended your bikes. In a magazine/newspaper article.

$200,000 & Over

69 70 From:

MONTAGUE CORPORATION

Cambridge, MA 02139

P.O. Box 398032

71