Surly Big Easy - User Manual

24213 5/18 † 85-000800_INST_A
HEY YOU
surlybikes.com
BIG EASY FRAMESHEET
RETAILER: This framesheet MUST BE provided to the end user.
Thanks for spending your hard-earned money on a Surly Big Easy. Seriously, we really appreciate it. You could’ve picked something
else but you didn’t, and that means a lot to us. We’ve put a lot of work into making a great-riding bike that you’ll enjoy for a long time.
Before you read any further take a minute and write down this frame’s serial number. If you should ever experience a problem with
it, the serial number will help us get things sorted, and if your bike is ever stolen the serial number is undeniable proof that
it’s yours. So take a minute and write it down. Your frame’s individual serial number is located on the top of the motor mount.
SERIAL NUMBER:______________________________
WARNING:
• Cycling can be dangerous. Bicycle products should be installed and serviced by a professional mechanic. Never modify your
bicycle or accessories. Read and follow all product instructions and warnings including information on the manufacturer’s
website. Inspect your bicycle before every ride. Always wear a helmet
• Do not use rigid forks exceeding 420mm axle-to-crown. Doing so will void the frame warranty and may result in damage
or failure of the frame, and possible serious injury
• Always check for 6mm of clearance between the front tire and/or fender and any accessory fitted to the accessory mounts
located on the underside of the downtube. Check the entire steering range
For additional product and safety information, Surly owner’s manuals, or Bosch component manuals, please visit surlybikes.com/safety.
Please note that the specifications and information in this particular framesheet are subject to change for product improvement.
For the latest information, go to surlybikes.com or Bosch-ebike.com.
FRAME COMPATIBILITY
Tubing: 4130 CroMoly, Natch tubing, double-butted main traingle, TIG welded
Rear hub compatibility: 10 x 135mm
Brake compatibility: 51mm I.S. disc; 203mm max rotor size
Water bottle mounts: One to three (depends on frame size and battery configuration)
Fender mounts: Yes (only compatible with quick-release fenders)
Rack mounts: Yes (Surly Dummy Cargo accessories)
Other accessory compatibility: Rohloff rear hub (OEM2 mounting plate), internal dropper post cable routing
Seatpost: 30.9mm
Seatpost clamp: 33.1mm
Headset/Steerer tube: EC34/28.6 upper, EC34/30 lower
Tire clearance: 26 x 2.5˝, individual tire and rim combos affect tire clearance
INTENDED USE
CONDITION 2
This is a set of conditions for the operation of a bicycle that includes Condition 1 as well as unpaved and gravel roads
and trails with moderate grades. In this set of conditions, contact with irregular terrain and loss of tire contact with the
ground may occur. Drops are intended to be limited to 15cm (6˝) or less. Please see link to Bike Owner’s Manual
on surlybikes.com/safety for complete list of riding condition descriptions.
MAXIMUM WEIGHT LIMIT
Rider: 300 lb (136kg)
Cargo: 200 lb (90kg)
Max Combined: 400 lb (181kg)
AB 1096 CALIFORNIA E-BIKE CLASS: CLASS 1, MOTOR: 250W, SPEED LIMIT: 20 MPH
WARNING: Your e-bike is intended for use by persons 16 years of age and older. Riders must have the physical coordination,
reaction, and mental capabilities to control a bike and manage traffic, road conditions, and sudden situations, and also to respect
the laws and instructions governing bicycle use.
NOT INTENDED
This bike is only intended to be operated on maintained roads that are legally open to bicycles with pedal-assist motors. The bicycle
is not intended for mountain biking, jumping, or racing. Although weather can be unpredictable, try to avoid riding this bicycle
in rain as water can damage electrical components.
2
ASTM F2043
Drops are
intended to be
limited to 15cm
(6
″) or less.

Summary

Big Easy Framesheet Overview

Frame Compatibility Specifications

Details on tubing, hub, brake, tire clearance, and accessory compatibility.

Intended Use and Riding Conditions

Defines acceptable riding conditions, weight limits, and e-bike classification.

Maximum Weight Limits

Specifies maximum rider, cargo, and combined weight capacities.

California E-Bike Class and Rider Requirements

Outlines e-bike class, motor specs, speed limits, and rider capabilities.

Not Intended Use Restrictions

Details activities and conditions the bicycle is not designed for.

Special Legal Requirements

Bicycle Regulation Compliance

Highlights adherence to local laws and the necessity of professional installation.

Operation Guidelines

Provides instructions for using the electric assist system and general riding advice.

Battery Upgrade Information

Guidance on battery compatibility and authorized service for upgrades.

Carrying Passengers and Cargo

Rules and recommendations for safely transporting passengers and cargo.

Electrical Component Safety

Storage and Transportation Warnings

Safety precautions for storing and transporting the bicycle's electrical components.

Care and Maintenance

Instructions for cleaning and maintaining the bicycle and its electrical parts.

Inspection and Limited Warranty

Pre-Ride Inspection Checklist

Essential checks before riding to ensure safety and proper function.

Modification Warning

Advises against modifying the frame, fork, or components to prevent damage or injury.

Limited Warranty Terms

Details the duration and limitations of the product warranty.

Overview

1. Important Technical Specifications
2. Usage Features
3. Maintenance Features
4. Safety Warnings
5. Warranty

This document is a framesheet for the Surly Big Easy, an electric pedal-assist cargo bicycle. It serves as a comprehensive guide for retailers and end-users, covering product specifications, safety warnings, operational instructions, maintenance, and warranty information.

The Surly Big Easy is designed as an electric pedal-assist cargo bicycle, featuring a 4130 CroMoly, Natch tubing, double-butted main triangle, TIG welded frame. It is equipped with a Bosch electric pedal-assist drive system, which includes a drive unit, battery, computer control, and various electronic components. The assist system engages only when the rider is pedaling, with power output dependent on pedaling force and the selected assistance mode. Pedal assist reduces as the bicycle approaches 20 mph and cuts off at speeds above that. The bicycle is classified as a Class 1 e-bike under AB 1096 California E-Bike Classifications, with a 250W motor and a speed limit of 20 MPH.

Important Technical Specifications:

• Frame Material: 4130 CroMoly, Natch tubing, double-butted main triangle, TIG welded.
• Rear Hub Compatibility: 10 x 135mm.
• Brake Compatibility: 51mm I.S. disc, 203mm max rotor size.
• Water Bottle Mounts: One to three (depends on frame size and battery configuration).
• Fender Mounts: Yes (only compatible with quick-release fenders).
• Rack Mounts: Yes (Surly Dummy Cargo accessories).
• Other Accessory Compatibility: Rohloff rear hub (OEM2 mounting plate), internal dropper post cable routing.
• Seatpost: 30.9mm.
• Seatpost Clamp: 33.1mm.
• Headset/Steerer Tube: EC34/28.6 upper, EC34/30 lower.
• Tire Clearance: 26 x 2.5" (individual tire and rim combos affect clearance).
• Maximum Weight Limit: Rider: 300 lb (136kg), Cargo: 200 lb (90kg), Max Combined: 400 lb (181kg).
• Fork Compatibility: Do not use rigid forks exceeding 420mm axle-to-crown to avoid voiding the warranty and potential serious injury.

Usage Features:

The Big Easy is intended for use on unpaved and gravel roads and trails with moderate grades, as well as maintained roads legally open to bicycles with pedal-assist motors. It is not intended for mountain biking, jumping, or racing. Drops are intended to be limited to 15cm (6") or less. The bicycle comes stock with one battery mounted to the downtube but is capable of a dual battery upgrade, with a second battery mounted under the frame behind the motor. All components for dual battery setup are included, but the second battery must be purchased separately and installed by a Bosch-certified e-bike dealer. The Big Easy is designed for carrying passengers and cargo. It includes two Rail Collars, with up to four compatible for use with Surly Dummy Deck, Rails, and Bags, or when carrying passengers. Child passengers must use seat pads unless secured in a child carrier, and Big Dummy bags or a compatible foot retention system must be installed for all passengers. Surly recommends the Thule Yepp Maxi seat for carrying children, noting that other child seats are not endorsed. Riders are advised to practice handling the bike with additional loads in low-traffic areas to familiarize themselves with turning, stopping, and maneuvering. The device is intended for use by persons 16 years of age and older, who possess the physical coordination, reaction, and mental capabilities to control a bike and manage traffic, road conditions, and sudden situations, while respecting laws and instructions governing bicycle use.

Maintenance Features:

• General Cleaning: Keep the frame clean to prevent oxidation, fading, and abrasion. Use a damp sponge or soft brush with a mild soap and water solution; do not spray water.
• Storage: Store the bicycle where it is protected from rain, snow, and sun to prevent corrosion. Apply J.P. Weigle's Frame Saver to the inside of the tubes before assembly.
• Moisture Management: If exposed to moisture, thoroughly dry the bicycle before storing. If water enters the frame, tilt the bicycle to drain, removing the seatpost and turning upside down if necessary. Freezing water inside the frame can crack and rupture the structure.
• Pre-Ride Inspection: Carefully inspect the frame for signs of fatigue before every ride. Consult a dealer or replace the frame if any damage or fatigue is observed.
• Electrical Components: Follow all storage and transportation requirements outlined by Bosch for the battery and charging manuals. Always remove the battery before storing or transporting the bike to prevent accidental activation of the drive system. Avoid riding in rain as water can damage electrical components.
• Professional Service: All service and maintenance should be coordinated through an authorized Surly Dealer to ensure correct servicing and to protect applicable warranties.
• Torque Values: Do not exceed specified torque values for bolts. Periodically inspect and retighten bolts.
• Car Rack Transport: Only use an e-bike-approved car rack for transport, ensuring compatibility with the rack manufacturer and avoiding overloading.

Safety Warnings:

• Cycling can be dangerous. Bicycle products should be installed and serviced by a professional mechanic.
• Never modify the bicycle or accessories. Read and follow all product instructions and warnings, including information on the manufacturer's website.
• Inspect the bicycle before every ride and always wear a helmet.
• Do not use rigid forks exceeding 420mm axle-to-crown.
• Always check for 6mm of clearance between the front tire/fender and any accessory fitted to the accessory mounts located on the underside of the downtube, across the entire steering range.
• It is the rider's responsibility to know and follow all local laws and regulations regarding bicycle use, including any special licensing, permits, or helmet requirements.
• Always remove the battery before working on the bicycle to prevent accidental activation of the drive system.
• An improperly modified frame, fork, or component can cause loss of control and falls. NEVER MODIFY THE FRAMESET.
• Attaching incompatible clamping devices to a fork can lead to fork breakage.
• Improper installation of bolts may lead to product failure.
• Failure to follow passenger and cargo carrying requirements may lead to instability, crashes, and serious injury.
• Follow all storage and transportation requirements for e-bike components outlined by Bosch.
• Only use an e-bike-approved car rack for transport.

Warranty:

The Surly Big Easy product is warranted against defects in materials and workmanship for three years from the date of retail purchase. This limited warranty does not cover damage due to improper assembly, lack of maintenance, modifications, neglect, competition use, commercial use, misuse, abuse, accidents, or anything other than normal use. It also excludes installation of incompatible components, damage to paint/surface finish, normal wear and tear, and labor for removal/refitting/readjustment. The warranty is limited to repair or replacement of a defective product at Surly's option and applies only to the original purchaser through an authorized dealer or distributor.

Surly Big Easy Specifications

General

Brand	Surly
Model	Big Easy
Category	Bicycle
Language	English