E-bike DIY USER MANUAL
Contents
1. C rims are double walled The rims are double walled to be able to with stand the powerful torque from the motor Page 7 Preparing and installing the Front Wheel 1 Remove your front wheel 2 Insert the motorised wheel insuring that the cables running to the motor are on the right hand side in normal driving direction Otherwise the wheel will run backwards Please orient yourself using the following pictures Page 8 Installing the Wheel Place the hub of your motor between the dropouts of your bike frame Firmly seat the axle into the dropouts to gain a good fit Tighten the nuts very firmly This is a crucial step in building a good electric bike as the motor provides a very large torque which may otherwise loosen your nuts Page 9 Installing Brake Levers Slide the hand brakes into both sides of the handlebar Find a comfortable position Then tighten using a 5 0mm Allen Wrench Installing the Thumb throttle Twist throttle A Thumb throttle F Slide the thumb throttle into either side of the of the handlebar that you feel comfortable with B Twist throttle Ee Slide the Twist throttle into the right side of the handlebar and get a feel of twisting the throttle E Place your hand on the bar and find the position Where your thumb feels most comfortable pressing down on the throttle When you feel comfortable with the position use position use the 3 0mm Alle2. to tie them so that they are almost invisible Remember however to check if they impede the movement of the handlebars Also secure the brake cables running to your front and back brakes accordingly B Note As a suggestion after you tied your cables rotate your handlebars to see if the movement is smooth and undisturbed Finishing the fight Checklist Turn off the battery 1 Wheel is secured in place 2 Back wheel is vertically aligned with front wheel 3 Wheel has no loose parts 4 All components on the handlebar have been secured tightly 5 You are comfortable with the throttle brakes etc 6 The handlebar is able to rotate freely 7 The mechanical brakes work properly 8 The battery cannot slide off without unlocking it 9 Check that the battery poles are connected correctly E Page 17 Motion Dynamics Australia Pty Ltd Website www motiondynamics com au Add 3 Rosehill Street Parramatta NSW 2150 Tel 61 2 96879187 Fax 61 2 80048232
3. E bike DIY USER MANUAL Contents Gene Started serisi e aE page 2 4 TOOLE esre page 5 Preparing the Rear Wheel 0 cece ee eee ees page 6 MOUNT the Tyi 6 so veestntdemceseaws dan doneseenis Page 7 Preparing and installing the Front Wheel cece cece eee Page 8 Installing the Wheel cece cece eee eee page 9 Installing Brake Lever and Throttle 00 cece cece ees page 10 Installing LED or LCD Meter 0 00 cee eee eee page 11 PAS Installation 00 00 cece cece eee eens page 12 Installing Vehicle Speed Sensor 0 cece eee e ee eee page 13 Installing a Bottle Battery 0 cece cece cece page 13 Installing the Controller Bag cece cece eee eens page 14 250W 500W Controller wiring instruction page 15 750W 1000W Controller wiring instruction page 16 Cabe C8 i 5st bat E page 17 Page 1 The simplest E bike conversion kits 4 styles of Lithium battery for selection Bottle style Rear rack style y Frog style 5 F t Page 2 Getting Started First open up the box and lay out the contents inside Check that you have 1 A large motor wheel or 2 A mini motor wheel 3 The controller 4 A pair of power brakes 5 Twist throttle or Thumb throttle 6 PAS system Page 3 Optional Items 1 Lithium Batter
4. n Wrench and secure It into place Page 10 Installing LED Display A lt ag Slide the LED display on either side of the steering bar so you feel comfortable Installing Multifunction LCD Display lO Slide the display on either side of the steering bar so you feel comfortable Page 11 Installing Pedal Assistance System PAS The Pedal Assistance System also known as pedal system is a compulsory component of an electric vehicle in European countries The system controls the amount of electricity supplied to the motor proportional to the angular velocity of the pedal i e the faster you pedal the faster the motor turns Remove the pedal crank arm Place the sensor ring to the bottom bracket and Place the outer magnetic ring next to the sensor ring Secure it in position using washers or superglue Make sure they do not have any contact by spacing them apart using washers Detail of sensor ring and magnetic ring Screw back the pedal into place connect the PAS wire with the controller and you are ready to ride legally in Europe Page 12 Installing Vehicle Speed Sensor When the LCD instrument matches the high speed motor without signal for speed output with built in clutch it requires and external vehicle speed sensor The installation method of the external vehicle speed sensor refers to the pictures below AAYY a Mount the sensor to the fork using the rubber M
5. ount the magnet to the spokes using a Philips bands screwdriver Installing the Bottle Battery Use the screws to fix the battery holder to the frame Put the battery into the case And connect the battery to the controller Page 13 Installing the Controller Bag The controller bag kit includes one bag a mounting plate a clip plate two screws and nuts one Allen key e Slip the mounting plate under the saddle Fasten the clip plate to the mounting support plate using both screws and nuts Clip on the controller bag Put the controller in the bag and connect The cables Page 14 250W 500W Controller wiring instruction yellow yellow A green a green 2 J bue E le n red 5W yellow yellow green blue black 5V blue black 5V black GND iggy C5 red VDD ll blue signal Controller brown GND black VDD yellow signal Page 15 750W 1000W controller wiring instruction yellow my yellow A green mae green B blue blue C Pal red 5V red 5V MOTOR J yellow yellow w green blue blue black 5V black 5V red VDD Eisai blue signal Controller brown GND black VDD ao yellow signal Page 16 Cable Tying It is advisable to use cable ties to secure the cables to your bicycle frame Perhaps you find a way
6. y 2 Controller s Bag 3 LED Meter or 4 Multifunction LCD meter Val a th i aii te a P i BERG T j a ae j 880 ER i Boal T Electric bicycle Different types of lithium batteries Bottle style Rear rack style Frog style Saddle tube style Page 4 Basic Tools List P At least 6 Zip Ties For holding wires firmly to your bicycle frame Q 3 Allen Wrench with diameters 2 5mm 3 0mm 5 0mm R Adjustable wrench S Philip Screwdriver Locating the parts on the bike 30V 250W Rear wheel kit with 36V 10AH Bottle style lithium Battery Page 5 2 36V 250W Controller with mounting box This E bike equiped with folowing parts 1 36V 250W Rear whee motor 3 36V 10AH Bottle style Lithium Battery k Y B i 4 Pedal assist sensor 5 Low level brake handlebar T 6 LCD display panel ga 7 Twist throttle eS 8 7 speeds freewheel se Preparing the Back Wheel Includes Gear and Disc Brake 1 Installing the gear freewheel on the back wheel Page 6 Mounting the Tire First confirm the direction of the thread pattern of your tires Turn the wheel around and insert the tube s valve into the opening of the wheel s rim Place the rest of the tube between the rim and the tire and pull the tire over the rim Then pump it up check for leaks and you are done assembling the wheel Important Note Please choose a tube with a longer valve as M amp
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