Assembly Instructions for the Xplorer E-bike

Xplorer Assembly Manual

Assembly Instructions for the Xplorer Plus E-bike

Xplorer Plus Assembly Manual

Assembly Instructions for the Xplorer Sport E-bike

Xplorer Sport Assembly Manual

Display Operation Instructions for the Xplorer E-bike

Xplorer Display Operation Manual

Instructions to unlock power, speed, and throttle for the Xplorer E-bike

How to unlock Power, Speed and Throttle - Xplorer models

All our bikes are carefully assembled and thoroughly tested with multiple test rides at the manufacturer to ensure they are properly set up, so any significant issues, like those mentioned by the local bike shop you visited, are highly unlikely. If t

All our bikes are carefully assembled and thoroughly tested with multiple test rides at the manufacturer to ensure they are properly set up, so any significant issues, like those mentioned by the local bike shop you visited, are highly unlikely. If the brake disc is not bent inside the caliper and can be aligned properly within the gaps, some friction noise is normal during the first 20-30 km as the pads and rotor bed in. To adjust the caliper and brake disc alignment:<img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025020701-5b52ade6-945c-44d1-8dd9-b75bf6c5b60d-001.jpg" style="width: 540px;" class="fr-fic fr-dib"> <ol><li>Loosen the bolts highlighted below to adjust the caliper position.</li><li>Align the caliper so the disc runs freely between the brake pads without significant rubbing.</li><li>Retighten the bolts once the alignment is correct.</li></ol>If you find that the brake disc cannot be properly aligned within the caliper and there is always a slight angle causing it to rub on one side:<img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025020701-59b45c62-1738-4f84-a73e-5370fa2daa30-002.jpg" style="width: 491px;" class="fr-fic fr-dib"> <img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025020701-c93639ed-01af-46c4-a9cb-5a2100ae4bd7-003.jpg" style="width: 517px;" class="fr-fic fr-dib"> <img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025020701-d2fc0d02-11a7-439e-bacf-a83c618ec952-004.jpeg" style="width: 528px;" class="fr-fic fr-dib"> <ol><li>Remove the front wheel.</li><li>Loosen the bolts shown below that secure the fork leg (caliper side).</li><li>Gently twist the fork leg (caliper side) slightly to correct any misalignment.</li><li>Reinstall the front wheel and check if the brake disc and caliper are now properly aligned.</li><li>Spin the wheel to ensure there is no excessive rubbing noise.</li><li>Once everything looks aligned, securely tighten the front wheel axle and caliper bolts.</li></ol> <h3 id="better-to-adjust-the-fork-leg">Better to adjust the fork leg</h3>There is actually a better way to adjust the fork leg, start by flipping your bike upside down, just like in the photos. Loosely put the front wheel back on, but don&#x2019;t fully tighten anything just yet. On the side with the brake caliper, carefully adjust the fork leg to get the angle just right. Once it looks good, give the wheel a spin to check for any excessive friction. Just be careful while the wheel is spinning &#x2013; brake discs can be really sharp! If you&#x2019;re feeling unsure or not too confident, it&#x2019;s totally okay to ask someone experienced with bike repairs for help or stop by your local bike shop. Once everything is aligned properly, go ahead and tighten all the bolts and the front-wheel axle.&#xA0; <h3 id="tips-to-fix-the-caliper-shift-when-the-wheel-is-tightened">Tips to fix the caliper shift when the wheel is tightened</h3>I noticed that you also mentioned the caliper shifts slightly when the wheel is tightened, causing the brake disc to sit too close to one side again. To address this, I recommend positioning the brake disc slightly closer to the opposite side before tightening the axle. This way, when the caliper shifts during tightening, the brake disc will end up properly centered.

How to adjust front disc brakes and caliper - Xplorer

Tools Required:. - To make the entire process easier, it is best to flip the bike onto it's handlebars before trying to remove the rear wheel. Use a carton or soft barrier to prevent scratching or damaging the bike frame. Use the size 22 wrench to re

Tools Required:<ul><li>Size 22 Wrench</li><li>Cable Cutters</li><li>Screwdriver (flathead preferred)</li><li>4mm Hex Key&#xA0; </li></ul>- To make the entire process easier, it is best to flip the bike onto it&apos;s handlebars before trying to remove the rear wheel. Use a carton or soft barrier to prevent scratching or damaging the bike frame. Use the size 22 wrench to remove the outer wheel nuts from each side of the bicycle. Note:&#xA0;The drive-side (the side with the derailleur) may be harder to access due to the derailleur guard. In this case, work slowly and carefully with small turns, as there&#x2019;s limited space. Avoid stripping the nut by keeping the wrench aligned.&#xA0;<img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032404-ca54956e-e2d9-4bdf-a08d-d181ceb6c926-654ddfe2-ad79-403b-9fd7-f1ef1816f139.png" style="width: 300px;" class="fr-fic fr-dib fr-fil" data-first-enter-image="true"> - Once the wheel nuts have been removed, use the 4mm hex key to loosen and remove the bolts securing the torque arms on both sides of the wheel. On the drive-side, the derailleur guard must be pulled downward and off the axle first to access the torque arm bolt. After removing the torque arm bolts, you can now take off: torque arms, outer wheel nuts (if not already removed), derailleur guard, spacers. Leave the locking washers in place on the inside of the dropouts (these are small toothed washers that help keep the axle aligned).<img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032404-2ac25e6d-1801-4f75-9f71-2be72ece8a3d-6174d06d-03b7-4afe-b8b2-49c005a520ac.png" style="width: 300px;" class="fr-fic fr-dib fr-fil"> - Locate the motor cable connection on the non-drive side of the rear wheel, near the brake rotor. Use cable cutters to snip the zip ties that are holding the cable in place along the frame. Gently unscrew and pull apart the two ends of the motor cable connector. This will fully disconnect the motor from the controller.<img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032405-88367762-9751-42e7-acce-f95dc88a2b03-b47b237e-ba8b-404c-9d86-e718469eee97.png" style="width: 300px; height: 265px;" class="fr-fic fr-fil fr-dii"><img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032405-915f8599-fa44-4a3c-b5ca-03e66a1d61a3-8e9611c0-583f-4152-a752-b333fe521a3c.png" style="width: 300px;" class="fr-fic fr-fil fr-dii"> - Now that the motor cable is disconnected and all hardware is removed from the axle:&#xA0;<ul><li data-end="2506" data-start="2404" id="isPasted" style="font-size: 16px;">Hold the derailleur with one hand and gently pull it backward to create space for axle removal.</li><li data-end="2605" data-start="2507" style="font-size: 16px;">With your other hand, grip the wheel by the rim, inserting your fingers between the spokes.</li><li data-end="2690" data-start="2606" style="font-size: 16px;">Pull upward firmly but steadily&#x2014;the axle should pop out of the dropout slots.</li><li data-end="2778" data-start="2691" style="font-size: 16px;">Once the axle clears the frame, remove the chain by lifting it off the cassette.</li><li data-end="2845" data-start="2779" style="font-size: 16px;">Carefully slide the wheel out and away from the bike frame.</li></ul><img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032405-bcfcbbb7-93c8-4001-8d7a-7bc0895ce8ee-21bd017a-e11b-4b2c-8be9-570de5710ba9.png" style="width: 300px;" class="fr-fic fr-dib fr-fil" data-first-enter-image="true"> &#x1F4A1; Tip: Lay the wheel flat on a clean surface for the next steps.&#xA0; Removing the inner tube and tyre:&#xA0;- Once the wheel is removed, lay it down on a clean, dry surface and use a flathead screwdriver, tyre lever or other suitable tool to press the valve core and release most of the air from the tube. The valve stem will start to descend into the space created by the air leaving the tube, try not to let it fall all the way through at this stage of the process.<img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032405-6f3f7715-dcf4-4119-8e34-849c62dfc69f-7d9cc824-399d-4d27-85c6-cd8cc5bb18a3.png" style="width: 300px;" class="fr-fic fr-dib fr-fil"> - Once mostly deflated, pinch the tyre sidewalls inward to loosen the bead from the rim. Using your hands or tyre levers, work one side of the tyre bead over the rim edge. Do this incrementally around the wheel. Once one side is free, lift out the inner tube, starting from the valve stem. Use your thumb to push the valve stem fully through the rim. Now you can either remove the tyre entirely (by pulling the other bead off the rim), or leave it partially on if you&apos;re just replacing the tube.&#xA0;<img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032405-e0291ba1-f8cd-44d3-95ed-79a977ce9634-3e90bc68-b9b1-43d8-81d4-dbbe667b90f2.png" style="width: 300px;" class="fr-fic fr-dib fr-fil"><img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032405-0753600a-5cd7-43a3-8b28-868e57627812-cec25510-5628-498a-b11e-516715f00bd1.png" style="width: 300px;" class="fr-fic fr-dib fr-fil"><img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032405-24d48305-45ef-4462-8126-b6fd7ef5cc1a-c552fdad-4f17-4449-9992-88a5ace5beb2.png" style="width: 300px;" class="fr-fic fr-dib fr-fil"> Installing the new tube and/or tyre:- If installing a new tyre, fit one bead of the tyre fully onto the rim first. Lightly inflate the new inner tube just enough to give it shape. Insert the valve stem through the rim hole, then carefully tuck the rest of the tube inside the tyre, making sure it&#x2019;s not twisted or pinched.&#xA0;<img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032806-790fca41-8328-447d-8ad1-58ba33461b41-8079d0be-c063-4e12-9a21-c18ce812e963.png" style="width: 300px;" class="fr-fic fr-dib fr-fil"> - Starting near the valve, work the second tyre bead onto the rim, moving around the wheel with your thumbs or tyre levers.<blockquote data-end="1959" data-start="1871">&#x26A0;&#xFE0F; Be cautious not to pinch the tube between the rim and tyre bead during this step.</blockquote><img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032806-b64bbcfe-3bde-471f-84d3-0556082bd218-e0e8ea36-38f5-4ca7-9fae-f8ef7a9ffa34.png" style="width: 300px;" class="fr-fic fr-dib fr-fil"> - Once the tyre is fully seated, check around both sides to ensure the tube isn&#x2019;t sticking out and the bead is evenly positioned all the way around.&#xA0;<img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032806-47f97420-89e8-4efa-82d1-2260a567930c-dcdd763c-c3ed-4be5-bd35-0e6d125845af.png" style="width: 300px;" class="fr-fic fr-dib fr-fil"> Reinstalling the rear wheel:- Slide the chain back onto the smallest cog on the cassette. Guide the axle back into the dropout slots, gently pulling the derailleur back to create space. Ensure that the locking washers are on the inner part of the frame and positioned correctly.<img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032806-dc0c6305-a0ae-45c4-822f-722c3b29a2b7-395e6c53-4963-4f49-b922-8cfb2d21ff2b.png" style="width: 300px;" class="fr-fic fr-dib fr-fil"><img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032806-5bca05f2-d054-4245-b407-04c0c3b030da-2ad77741-2d3c-4c42-8348-074d3097a2e1.png" style="width: 300px;" class="fr-fic fr-dib fr-fil"> - Reconnect the motor cable and use new zip ties to secure it along the frame. Reinstall in reverse order:&#xA0;<ol><li>Torque arms (secure with 4mm hex bolts)&#xA0;</li><li>Spacers/washers and derailleur guard&#xA0;</li><li>Wheel nuts (tighten securely with the 22mm wrench)</li></ol><img src="https://attachments.gorgias.help/1QNmd2YbR4A79XA0/hc/GyBLV6kNwrxNbQkK/2025032806-51bd3608-5c78-4b5c-a296-1f4cb2812cac-c62c6dd8-b96e-4409-964d-4494b89c2d73.png" style="width: 300px;" class="fr-fic fr-dib fr-fil">&#x26A0;&#xFE0F; Double-check everything is tightened and aligned correctly before riding.&#xA0; Attached are some links to useful videos that may help with this tricky process:<a href="https://youtu.be/FNVKIOSWuAE" id="isPasted" rel="noopener noreferrer" target="_blank">How To Change Rear eBike Tire: Aventon Aventure</a><a href="https://youtu.be/mzew9CrXixQ" id="isPasted" rel="noopener noreferrer" target="_blank">HOW TO CHANGE A FATBIKE TYRE - EASY FAT TYRE CHANGE&#xA0;</a>

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