Nukeproof MEGAWATT 297 - User Manual

How to remove and install your Nukeproof Megawatt battery
ITEMs required
• 4mm hex key
removal
1. Set your bike upright somewhere safe and look
under the downtube
2. Loosen the bottom left hand bolt on the battery door
1 full turn using your 4mm hex key
3. Loosen the bottom right hand bolt on the battery
door 1 full turn using your 4mm hex key
4. Fully remove the top battery door bolt

Summary

Items Required for Battery Service

Nukeproof Megawatt Battery Removal

Step 1: Bike Setup for Removal

Position the bike upright safely and inspect the downtube area for access to the battery.

Step 2: Loosen Bottom Left Bolt

Loosen the bottom left bolt on the battery door one full turn using a 4mm hex key.

Step 3: Loosen Bottom Right Bolt

Loosen the bottom right bolt on the battery door one full turn using a 4mm hex key.

Step 4: Remove Top Battery Bolt

Fully remove the top battery door bolt to allow detachment.

Step 5: Slide Battery Door Up

Carefully slide the battery door upwards to detach it from the frame.

Step 6: Release Battery Bolt

Turn the silver battery release bolt clockwise with a 4mm hex key to unlock.

Step 7: Battery Front Stop

The battery should slide forward and stop at the position shown in the photo.

Step 8: Release Silver Clip

Push the silver clip down to fully release the battery from its housing.

Step 9: Remove Battery

Lift the battery out of the frame carefully.

Nukeproof Megawatt Battery Installation

Step 10: Check Battery Holder

Inspect the battery holder for condition and any signs of damage before proceeding.

Step 11: Align Battery Mount

Rotate the battery to align the plastic locating part with the hole in the battery casing.

Step 12: Insert Battery

Line up the battery and push it into the frame.

Step 13: Seat Battery

Ensure the battery is fully seated; two clicks indicate proper engagement.

Step 14: Replace Battery Door

Slide the battery door back into its original position.

Step 15: Tighten Top Bolt

Tighten the top bolt first using your 4mm hex key.

Step 16: Tighten Bottom Left Bolt

Tighten the lower left bolt using your 4mm hex key.

Step 17: Tighten Bottom Right Bolt

Tighten the lower right bolt using your 4mm hex key.

Overview

1. Function Description
2. Usage Features
3. Removal Process
4. Installation Process
5. Maintenance Features

This document outlines the procedure for removing and installing the battery on a Nukeproof Megawatt electric bicycle. It serves as a comprehensive guide for users to safely and effectively manage their bike's power source.

Function Description

The Nukeproof Megawatt battery is an integral component of the electric bicycle, providing the necessary power for the motor to assist the rider. Its design allows for removal and reinstallation, which is crucial for charging, maintenance, or replacement. The battery is housed within the downtube of the bicycle frame and secured by a battery door, which is fastened with bolts. A specialized locking mechanism ensures the battery remains firmly in place during operation.

Usage Features

The removal and installation process is designed to be straightforward, requiring only a 4mm hex key.

Removal Process:

1. Preparation: The first step involves positioning the bike upright in a safe and stable location. This ensures easy access to the downtube area where the battery is housed.
2. Accessing the Battery Door: The battery door is secured by three bolts. The process begins by loosening the two lower bolts on the battery door. Each of these bolts should be turned one full turn using the 4mm hex key. This initial loosening prepares the door for removal without fully detaching the bolts at this stage.
3. Removing the Top Bolt: After loosening the lower bolts, the top battery door bolt is fully removed. This allows the battery door to be manipulated.
4. Sliding the Battery Door: Once the top bolt is removed and the lower bolts are loosened, the battery door can be slid upwards. This action disengages it from its position, allowing access to the battery compartment.
5. Releasing the Battery: With the battery door removed, the internal battery release mechanism becomes accessible. A silver battery release bolt needs to be carefully turned clockwise using the 4mm hex key. This action initiates the release of the battery from its secure position.
6. Sliding the Battery Forward: After turning the release bolt, the battery should slide forward slightly. This indicates that it has been partially disengaged from its mounting points.
7. Final Release: A silver clip, located near the front of the battery, needs to be pushed down. This action fully releases the battery from its locking mechanism within the frame.
8. Extracting the Battery: Once fully released, the battery can be carefully lifted out of the bicycle frame. It is important to handle the battery with care during this step to avoid any damage.

Installation Process:

1. Inspection: Before installing the battery, it is crucial to inspect the battery holder within the frame. The holder should be in good condition, free from any damage, to ensure a secure and proper fit for the battery.
2. Battery Orientation: The battery needs to be rotated to the correct orientation. There is a specific plastic locating part on the battery's mount that must align with a corresponding hole in the battery casing within the frame. This ensures the battery is inserted correctly and makes proper electrical contact.
3. Inserting the Battery: With the correct orientation, the battery is lined up with the frame's opening and pushed into the frame. It should slide smoothly into place.
4. Securing the Battery: The battery is fully seated when two distinct clicks are heard. These clicks confirm that the battery's locking mechanism has engaged, securing it within the frame.
5. Reattaching the Battery Door: Once the battery is securely in place, the battery door is slid back into its original position.
6. Tightening the Bolts: The bolts are tightened in a specific order to ensure even pressure and a secure fit.
   • First, the top bolt is tightened using the 4mm hex key.
   • Next, the lower left bolt is tightened.
   • Finally, the lower right bolt is tightened. It is important to tighten these bolts firmly but without over-tightening to prevent damage to the threads or the frame.

Maintenance Features

The design of the Nukeproof Megawatt battery system emphasizes ease of maintenance and replacement. The ability to remove the battery allows for:

• Off-bike Charging: Users can remove the battery to charge it indoors or at a convenient location, separate from the bicycle. This is particularly useful for those who store their bikes in areas without easy access to power outlets.
• Battery Replacement: In the event of battery degradation or failure, the modular design allows for easy replacement of the battery unit without needing specialized tools or extensive disassembly of the bicycle.
• Inspection and Cleaning: Removing the battery provides an opportunity to inspect both the battery and the internal battery compartment for any signs of wear, damage, or debris. This allows for cleaning of contacts and the compartment itself, which can help maintain optimal performance and longevity of the electrical connections.
• Frame Access: Removing the battery can also provide better access to internal frame components for other maintenance tasks or inspections, if necessary.

The clear, step-by-step instructions, accompanied by visual aids, make the process accessible even for users with limited mechanical experience. The requirement of a single common tool (4mm hex key) further simplifies the procedure, making battery management a user-friendly aspect of owning a Nukeproof Megawatt electric bicycle.

Nukeproof MEGAWATT 297 Specifications

General

Wheel Size	29" front, 27.5" rear
Motor	Shimano EP8
Fork Travel	170mm
Rear Shock Travel	160mm
Drivetrain	Shimano XT 12-speed
Brakes	Shimano XT 4-piston
Battery	630Wh
Head Angle	64°
Fork	Fox 38 Float Factory, GRIP2 Damper