This document is an adjustment guide for the OSO Battery Mount, produced by Ibis Cycles. It outlines the tools required and a step-by-step procedure for adjusting the battery mount on an Ibis OSO bike.
Function Description:
The OSO Battery Mount Adjustment Guide provides instructions for properly securing and adjusting the battery within the bike's frame. The primary function of these adjustments is to ensure the battery is held firmly in place, preventing movement and ensuring proper electrical contact, while also allowing for removal and reinstallation. The guide details how to tighten various bolts that secure the battery cradle and mount, and how to verify that the battery interface is correctly aligned and contacting the foam for a secure fit.
Important Technical Specifications:
The guide specifies various torque values and tool sizes essential for proper adjustment:
- T20, T30 Torx key: Used for specific bolts, with a torque value of 2Nm for the lower battery cradle bolts.
- 2.5mm, 3mm, 4mm, and 6mm Allen keys: Used for different bolts throughout the adjustment process.
- Torque Wrench with T20, T30, 4mm, and 6mm Allen bits: Essential for applying precise torque values to prevent over-tightening or under-tightening, which could damage components or lead to an insecure battery.
- Loctite 243: Recommended for reapplication to bolt threads to ensure they remain secure and prevent them from loosening due to vibrations.
- Torque for lower battery cradle bolts: 2Nm (using a T20 key).
- Torque for bolts holding the lower battery cradle (depending on bolt type):
- 4mm Allen bolt head: 12Nm
- T30 Torx or 5mm Allen bolt head: 15Nm
- Torque for front battery mount: 12Nm (using a 6mm Allen key).
Usage Features:
The guide provides a clear, step-by-step procedure for adjusting the battery mount, making it accessible for users to perform maintenance or adjustments.
- Battery Removal: The first step involves removing the battery door and the battery itself, which is a prerequisite for accessing the mounting bolts.
- Lower Battery Cradle Adjustment: Users are instructed to ensure the bolts holding the lower battery cradle are tight, applying a specific torque of 2Nm.
- Front Battery Mount Initial Tightening: The front battery mount is initially tightened "snug" and then backed out 3/4 turn, suggesting a preliminary positioning before final torque.
- Downtube Guard and Motor Cover Removal: These components must be removed to access the bolts that secure the lower battery cradle.
- Loosening and Loctite Application: The two bolts holding the lower battery cradle are loosened, and Loctite 243 is reapplied to the threads to prevent loosening. This step emphasizes removing one bolt at a time to prevent internal components from falling into the frame.
- Battery Cradle Pressure Application: A long 6 or 8mm Allen key is used to apply moderate pressure to the center of the back of the battery cradle, which likely helps in seating the battery correctly before final tightening.
- Final Torque Application: The bolts are tightened to their specified torque values (12Nm for 4mm Allen head bolts, 15Nm for T30 Torx or 5mm Allen head bolts), ensuring the battery cradle is securely fastened.
- Front Battery Mount Final Tightening: The front battery mount is tightened to 12Nm with a 6mm Allen key.
- Battery Reinstallation and Alignment Check: The battery is reinstalled to verify correct alignment and fit.
- Visual Inspection for Gaps: A crucial step involves visually inspecting the interface between the battery cradle and the battery to ensure the foam contacts the battery, indicating a secure fit with "No Gap."
- Functionality Check: The bike is turned on to confirm that the battery system is functioning correctly after the adjustments.
- Reassembly: The downtube guard, battery door, and motor cover are replaced.
Maintenance Features:
The guide implicitly highlights several maintenance aspects:
- Regular Torque Checks: The emphasis on specific torque values suggests that these bolts may require periodic checking to ensure they remain tight, especially given the vibrations and stresses experienced by an e-bike.
- Loctite Reapplication: The instruction to reapply Loctite 243 indicates that this is a consumable item that should be used during maintenance to maintain bolt security.
- Component Inspection: The visual inspection for gaps and the functionality check are critical maintenance steps to ensure the battery is properly seated and operating.
- Troubleshooting Support: The note regarding 4mm Allen head bolts and the recommendation to contact
askchuck@ibiscycles.com for higher installation torque bolts or more information suggests a support channel for users encountering specific issues or needing specialized components for frequent adjustments. This indicates that Ibis Cycles provides ongoing support for their products.
- Preventative Measures: The instruction to remove one bolt at a time when reapplying Loctite is a preventative measure to avoid internal components from falling into the frame, demonstrating attention to detail in maintenance procedures.
The guide is designed to empower users to perform precise adjustments to their OSO battery mount, ensuring safety, performance, and longevity of the battery system.
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