acc 2014 integratedlightkit g2 en v1 - gocycle...gocycle g2 2014 integrated light kit assembly guide...

GOCYCLE G2

2014 INTEGRATED LIGHT KIT ASSEMBLY GUIDE (PRODUCT CODES 6102 & 6103)

Version 1.0

Assembly of the Gocycle G2 2014 Integrated Light Kit

Assembly Guide: Gocycle G2 2014 Integrated Light Kit

© Karbon Kinetics Limited. All Rights Reserved. i

CONTENTS Overview............................................................................................................1

Parts List............................................................................................................1

Tool List.............................................................................................................2

1. Gocycle Model Identification ............................................................................ 2

2. Battery Removal ............................................................................................. 3

3. Installing the 2014 Lighting Harness <240000 .................................................. 6

4. Installing the 2014 Rear Light <240000.......................................................... 16

5. Installing the 2014 Front Light >240000 ......................................................... 23

6. Installing the 2014 Rear Light >240000.......................................................... 28

7. Installing the Rear Reflector .......................................................................... 32


© Karbon Kinetics Limited. All Rights Reserved. 1

OVERVIEW

This document details assembly of the Gocycle G2 2014 Integrated Light Kit. Due to the inclusion of the light harness at production in Gocycles with frame numbers >240000, the light kit is assembled differently according to model type.

Product Code Part Description Go To

6102 Integrated Light Kit for Gocycles <240000 Section 2

6103 Integrated Light Kit for Gocycles >240000 Section 5

PARTS LIST

To successfully complete the procedure you will require the following parts. Note: You may be able to reuse parts on your Gocycle and as such only need to order parts specific to your repair:

4161 4128 4032

4125 4129

Part Code Part Description Quantity

4032 Reflector Kit 1

4161 Front Light 1

4128 Rear Light 1

4129 Rear Light Bracket 1

4125 Front Light Bracket 1

4037 Frame Plug – Modified 1

4132 Lighting Harness with Connector 1

2452 M5 x 10mm SH 4A S/S 2

4040 M6 x 20 BH SH A4 1

4041 M6 WS S/S 0.8 x 12mm 2

4042 M5 NY S/S thin 1

2383 M6 NY A4 S/S thin 1



TOOL LIST

To successfully complete this procedure, you will require the following tools. You can purchase special KKL tools by their tool number detailed below.

Part Code Tool Description

3mm Allen key

T-15 Torx

8mm spanner

If you have any questions, or require any further assistance, please contact [email protected].

1. GOCYCLE MODEL IDENTIFICATION

1.1. Locate the Gocycle unique frame number. The frame number can be found on a label on the left side of the Cleandrive, circled.

Note: If a frame number is not present please contact

Gocycle Technical Support at [email protected]

for further assistance.

1.2. For Gocycle frame numbers (greater than) >240000 please proceed to step 5.

For Gocycle frame numbers (less than) <240000 please proceed to step 2.

Note: Ensure correct frame number

identification prior to

commencing.



2. BATTERY REMOVAL

2.1. For ease, invert the Gocycle so that it rests on its handlebars and saddle.

Note: Ensure the battery pack is in

sleep mode. Consult your Owner’s Manual

for information.

2.2. Use a 3mm Allen key to undo the battery securing screw, as shown.

2.3. Now remove the screw and battery splash cap.



2.4. Locate the black and red Anderson connectors (shown) from within the frame.

2.5. Disconnect each one at a time.

2.6. Ensure all cables are out of the frame and are free to move.



2.7. Completely remove the battery from the frame.

WARNING! CONSULT YOUR GOCYCLE OWNER’S MANUAL REGARDING THE CARE AND MAINTENANCE OF GOCYCLE LITHIUM BATTERIES.



3. INSTALLING THE 2014 LIGHTING HARNESS ON <240000

3.1. Place your Gocycle G2 into the folded position, as demonstrated.

3.2. Make a loop in the red cable provided. Remove the hole plug and insert the red wire into the frame as shown.

3.3. Insert a hooked rod into the frame, through the battery aperture. Ensure that it travels beneath the battery rub strip, as shown.



3.4. Use a torch to illuminate the internal battery void. Hook the red cable and pull this through the frame towards the rear of the Gocycle, as shown.

Ensure the red cable travels under battery

rub strip as

demonstrated.

3.5. Pull the red cable through the frame, leaving a tail at both ends of the Gocycle as shown.

3.6. Locate the end of the lighting harness, shown, with the electrical connector. Thread the end of the red wire that exits the rear of the Gocycle (Read wire end A) through the black cables at the base of the connector as shown.

Red wire

end A

Red wire end B



3.7. Tie a knot in the red cable as shown.

3.8. Align the red cable exiting the frame along the edge of the connector as shown.

3.9. Use electrical tape to secure the red cable to the connector. This will aid pulling the cable harness through the frame.



3.10. Unfold the Cleandrive as shown. This will ensure the internal cables are taut, aiding the cable routing process.

3.11. Carefully pull the red wire end B, which will in turn pull the one end of the lighting harness through the Gocycle frame.

3.12. Pull the red cable until the end of the lighting harness is completely through the Gocycle frame and exposed at the front as demonstrated.



3.13. Locate the rubber fork boot.

3.14. Use a pair of sharp scissors to carefully cut the rectangular panel out of the boot.

3.15. Completely remove the panel from the boot, as shown.



3.16. Push the fork boot down and around the front fork race.

3.17. Feed the light harness cable underneath the fork boot and around the fork as shown.

3.18. Locate the front light bracket. Spread the bracket open to locate on to the fork boot.



3.19. Position the bracket on to the top groove of the fork boot, as shown.

3.20. Use a 4mm Allen key to sufficiently tighten the bracket bolt.

NOTE: DO NOT TRAP THE LIGHT HARNESS IN THE LIGHT BRACKET

3.21. Select the female front light securing bolt



3.22. Insert the female front light securing bolt into the front light bracket as shown.

3.23. Position the front light on to the bracket as shown.

3.24. Insert the male front light securing bolt to fix the light in place.



3.25. Connect the light connector to the light harness connector as shown.

3.26. Make sure the connectors are fully inserted.

3.27. Push the connectors up and into the Fork Boot as shown.



3.28. Check that the front light is positioned in the centre of the wheel.

This shows CORRECT alignment.

This shows INCORRECT alignment.

3.29. The front light installation is now complete.



4. INSTALLING THE 2014 REAR LIGHT <240000

4.1. Remove the M5 nut and spring washer from the rear light.

4.2. Locate the rear light and the rear light bracket. Align as demonstrated.

4.3. Install the spring washer and M5 nut and tighten fully using an 8mm spanner.



4.4. Locate the end of the lighting harness with two connectors.

4.5. Ensure that the cable with two connectors exits the rear of the Gocycle frame threaded over the internal lug as demonstrated.



4.6. Remove the frame trim, as shown.

4.7. Now thread the two connectors through as demonstrated.

4.8. Reinstall the frame trim with the two connectors protruding as demonstrated.



4.9. Hold all the internal cabling that protrudes form the frame as demonstrated, and carefully insert the battery ensuring that it does not catch the cable that is routed through the frame trim.

4.10. The lighting harness has two sets of Anderson connectors.

First connect side-by-side the Anderson connectors for the battery and the internal Gocycle power cable.

Ensure red is connected to red and black to black.

Lighting harness connectors.

Black = negative

Battery and

Internal Power (Red)

Lighting harness connectors.

Red = positive

Battery and Internal Power

(Black)



4.11. With the Anderson connectors arranged appropriately, connect the lighting harness Anderson connectors to the internal Gocycle Anderson connectors as shown.

NOTE. Ensure that all connectors are properly connected, with a “click!”l

4.12. Insert the connectors back into the frame cavity, before reinstalling the battery splash cap and securing screw, as shown.

4.13. Use a 3mm Allen key to tighten the securing bolt.

“Click!”



4.14. Now locate the assembled rear light and the two connectors. The cable with a white stripe is positive (+) and needs to be plugged into the rear light as shown.

Note: The positive terminal will be denoted by a

‘plus, +’ sign or a ‘lightning bolt’.

4.15. The plain black cable is negative and has to be plugged into the opposite terminal of the rear light.

Note: The negative terminal will be denoted by a ‘minus,-’ sign or

an ‘earth’ sign.

4.16. Push the Lockshock to its normal position.



4.17. Locate as shown, pressing firmly on the Rear Light Bracket to secure in place with a “click”.

4.18. The rear light is now fitted.

Proceed to step 7 for installing the rear reflector.

“Click!”



5. INSTALLING THE 2014 FRONT LIGHT >240000

5.1. Locate the front light bracket. Spread the bracket open to locate on to the fork boot.

5.2. Position the bracket on to the top groove of the fork boot as shown.

5.3. Use a 4mm Allen key to sufficiently tighten the bracket bolt.

NOTE: DO NOT TRAP THE LIGHT HARNESS IN THE LIGHT BRACKET.



5.4. Select the female front light bolt

5.5. Insert the female front light bolt in to the front light bracket as shown.

5.6. Position the front light on to the bracket as shown.



5.7. Insert the male front light bolt to secure the light in place.

5.8. Connect the light connector to the light harness connector.

5.9. Make sure the connectors are fully inserted.



5.10. Push the connectors up and in to the Fork Boot as shown.

5.11. The front light installation is now complete.

5.12. Check that the front light is positioned in the centre of the wheel.

This shows CORRECT alignment.



This shows INCORRECT alignment.



6. INSTALLING THE 2014 REAR LIGHT >240000

6.1. Remove the M5 nut and spring washer from the rear light.

6.2. Locate the rear light and the rear light bracket. Align as demonstrated.

6.3. Install the spring washer and M5 nut and tighten fully using an 8mm spanner.



6.4. Locate the end of the lighting harness with two connectors.

6.5. Remove the frame trim of the Gocycle.

6.6. Now thread the two connectors through as demonstrated.



6.7. Reinstall the frame trim with the two connectors protruding as demonstrated.

6.8. Locate the assembled rear light and the two connectors. The cable with a white stripe is positive (+) and needs to be plugged into the rear light as shown.

Note: The positive terminal will be denoted by a

‘plus, +’ sign or a

‘lightning bolt’.

6.9. The plain black cable is negative and has to be plugged in to the opposite terminal of the rear light.

Note: The negative terminal will be denoted by a ‘minus, -’ sign or

an ‘earth’ sign.



6.10. Push the Lockshock upwards to its normal position.

6.11. Locate as shown, pressing firmly on the Rear Light Bracket to secure in place with a “click”.

6.12. The rear light is now fitted.

“Click!”



7. INSTALLING THE REAR REFLECTOR

7.1. Invert the Gocycle to the correct orientation and ensure your saddle height is correctly adjusted. Locate the rear reflector bracket as shown.

7.2. Attach the bracket using a 2.5mm Allen key. (There is an Allen key supplied with the kit.)

7.3. Attach the reflector as demonstrated. Note the correct orientation.



IMPORTANT NOTE: THE ABOVE ASSEMBLY STEPS MUST BE CARRIED OUT IN ORDER. FAILING TO DO SO MAY RESULT IN DAMAGE TO THE GOCYCLE.

If you have any further queries or comments, please contact Gocycle Technical Support:

[email protected]

7.4. Use the 2.5mm Allen key to tighten the reflector securing clamp.

Completed installation

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