KG4 Routine Maintenance Guide and Schedule

Below is a list of regular maintenance activities you need to perform in order to keep the ebike running well.

Routine Maintenance Guide

1. Inspect the bike
   1. Check the bike components for signs of improper alignment, safety and function.
2. Clean the bike
   1. It is very important to clean the ebike often with a moist rag and non-corrosive biodegradable cleaners. Do not use pressure washers or hose to clean the bike. This can cause water damage to electrical components and will likely void the warranty. Keeping the ebike clean will help avoid and discover other maintenance needs.
3. Check brake pads
   1. Ebikes travel at higher speeds and have more momentum because of the weight of the powered components, so brake pads normally wear down faster than a traditional non-powered bike. Make note of any changes in brake stopping power or uneven brake wear. Brake pads must be replaced when the amount of pad material is less than 1 mm.
4. Check wheel set
   1. Ebikes can travel at high speeds, causing the tires to be consumed quicker than a normal bike, so we must check all wheel parts.
   2. Check if the inner tube has folded in the insert or doesn’t inflate properly.
   3. Check tire pressure and visually inspect.
   4. Follow the wheel maintenance guide for more details
5. Inspect the paint
   1. Visually inspect the paint on the frame. If the paint has become scratched or chipped in the metal, use touch-up paint to prevent rust. Clear nail polish can also be used as a preventative measure.
6. Function check
   1. Check that all the functions of the ebike are as expected, both electronical and mechanical
      1. Electronical:
         1. Front / rear light
         2. Motor power
         3. Display
         4. Throttle
         5. Horn
         6. Brake cut-off signal
         7. Error code check
         8. Power pedaling for each PAS level
      2. Mechanical:
         1. Brake
         2. Wheel smoothness
         3. Pedaling smoothness
         4. The handlebar should turn smoothly

Routine Maintenance Schedule

Below is a list of maintenance schedule you need to expect, this list is the items that need to check and maintenance at that time or ondograph.

Every 300 km Maintenance Requirement

1. Check
   1. Check hardware for proper torque—see “KG4 torque setting”
   2. Check drivetrain for proper alignment and function (including chain, freewheel, chainring, and chain tensioner).
   3. Check wheel trueness and spoke tension, and check for quiet wheel operation (without spoke noise)
   4. Check the frame for any damage.
2. Service
   1. Clean frame by wiping frame down with damp cloth.
   2. Clean and grease the chain.
3. Replace
   1. Replace any components confirmed to be broken or damaged beyond repair.

Every 1000 km Maintenance Requirement

1. Check
   1. Check brake pad wear, alignment, and the brake lever tension.
   2. Check chain stretch.
   3. Check brake cables for corrosion and fraying.
   4. Check wheel trueness and spoke tension, and check for quiet wheel operation (without spoke noise)
2. Service
   1. Clean and lubricate the drivetrain.
   2. Check crankset and pedal torque.
   3. Tension spokes and true wheels if any loose spokes are found.
3. Replace
   1. Replace brake pads if necessary (typically when the pad material is thinner than the backing plate).

Every 6 months or 2000 km Check and Maintenance Requirement

1. Check
   1. Check drivetrain (chain, chainring, freewheel, and chain tensioner).
   2. Check all cables and housings.
2. Service
   1. Standard tune-up.
   2. Grease bottom bracket and drivetrain.
3. Replace
   1. Replace brake pads.
   2. Replace tires or inner tube if necessary.
   3. Replace cables and housings if necessary.