DIY Electric bike conversion kit User Manual
Contents
1. Step 2 Transfer your tyre amp tube amp install the motor wheel You will need to transfer your existing tyre and tube or a new tyre and tube to hand built motor wheel Rim tape is highly advisable If you re existing wheel has rim tape simply transfer the tape across to the new motor wheel Otherwise rim tape is inexpensive and available from any decent local bike shop That will minimize the risk of puncture Front motor wheel disk OR caliper brakes 1 Take out the original bicycle wheel and release the caliper tool No 1 tool No 1 2 dismantle the original disc and install it on the motor wheel when tightening the screws for the r J R A SS AN N 3 Fit the spacers close to motor XK spacers quantities depend on your bicycle S when we watch the motor from the back J e EA W when we watch the motor from the back of bicycle these two spacers are on the A i of bicycle these two spacers are on left of the fork s dropout the right of the fork s dropout W i i 5 the dropouts position is spacer ts on the left side of dropout Rear disc V brake motor 1 000W 1 Take out the original bicycle wheel from the bike 2 Install the brake disc and freewheel on the motor when tightening the screws on the disc tighten them diagonally 7 amp d 3 Install the motor wheel and tight it This image below on the right shows the tab washers on the outside of the2. introducton 10 aseenhlo it Removable PAS 7 Display Presi of to adjust PAS class 1 1 7 3 Please refer LCD manual for its function introduction with normal cable Please reter LOO maeual for ite tenotion introduction with walerprool cable normal cate waterproct cable Pieese refer coniroiler cables Daada te wanennne i Picoso roter commrotor cabies imroduation Gim walking Sutten to sxeemnble i Battery power display LED display LCD display 8 Removable motor cable Some motor lines are not removable please refer to packing list 9 One cable system 4 1 cable system controller plug When you assemble please notice the corresponding plug colours Installation Guide Controller cables introduction 2 brakelevers 3 motor line 1 throttle ine i A 4 battery 5 display 6 motor hall All controllers with normal cables please refer this diagram no matter the controller shape Please notice the cable colours must mirror same colours 2 waterproof 1 PAS one cable system i 3 battery 4 motor All controllers with complete waterproof cables please refer this diagram no matter what controller shape is please notice the cable colours must mirror same colours 9 Tools A NO1 No2 a No 4 No5 No6 5mm 4mm in 17mm 10mm 8mm 15mm No7 1 No 8 No 9 No 10 17mm i 36mm _ q V You are able
3. forks facing inwards It s also possible to turn the tabbed washers around the other Step 3 Install display 1 Release the screws on the back of the display and fit it on the handle bar 2 Adjust the display location and tighten the screws Step 4 Install the brake levers amp throttle amp handle bars 1 Take out the original brake levers and grips left amp right 2 Insert the brake lines to new electric brake levers 3 Fit the electric brake levers on the bike and tight the screws left amp right 4 Fit the throttle generally right side and fit the new grips left amp right you may to warm the grips if they are hard to fit If you have rapid fire twist grip hydraulic brakes or any other sort of integrated shifter or hydraulic brake setup please see the last page of this manual Step 5 Install PAS pedal assist system sensor Removable PAS installed on the left side of the bicycle crank arm removal not required EA ka 1 Fit the disc on the crank axle Step 6 Install battery and controller Tube canister water bottle battery 1 Remove the bottle cage on the bicycle 2 Insert the bracket of tub battery tight the screws may look different to photo 3 Fit the tube battery lock it turn off the battery 4 Connect all controller plugs to the corresponding terminals on the wiring loom Seat post battery 1 Dismantle the controller box Please carefully keep these screws
4. ion c Make sure the tyre pressures are at optimum d Pedal harder when taking off and select the right gear for assisting up hills Trouble shooting If you have any problems with the kit the best way to find out what is causing the problem is to do the following Disconnect all components then connect the battery battery cable controller throttle display and motor In this basic installation mode you will more than likely have full function Then go through one by one plugging in the other components such as the PAS or the e brake handles to see which is the problem If there is a problem with the basic kit setup check that the plugs are all correctly touching and that there is a good solid connection at each junction Check the fuses in the battery Check the wires as they go into the motor axel for any signs of wear or tear If you cannot isolate the problem you may have to return the problem components to our factory Zo Maintenance We recommend to have the spoke tension of the motor wheel and the torque of all screws checked after the first 50km In order to ensure extended use of the electric system all plug in contacts of the system should be checked every two to three months and cleaned with a wire brush if necessary Cleaning Never use a high pressure washer or a garden hose to clean the e bike system The force of a water jet could damage the electrical components of the propulsion system Do not use water to c
5. they are a unique thread type 2 Apply the rubber o ring around the opening hole of controller box insert the saddle seat stem adjust the box location and tighten the screws tool No 4 No 6 10mm 3 Connect all cables with controller 4 Place the controller into the box reassemble the box tool No 4 5 Insert the seat post battery Z 0 Step 7 Make final adjustments Make sure the brakes are adjusted the wheel is secure screws are tightened and everything is functioning as expected Charging Charging plug to connect local power Charging port to connect battery 1 Insert charging port on battery first then insert charging plug to mains socket 2 The charging signal is red during charging it turns to green when fully charged Cearyeng plug cosrect Deyrate es toca powe Al REQOREEN Charger pori dupara i bettery body The charge light will glow red whilst charging and then green when charged Some charger have 2 lights 2 lights red is charging 1 red 1 green means fully charged Load Unload the batteries 1 Please turn the keys left right to lock or unlock the batteries Tan ome tub wher ete ce breug j f as Cheers mri aAa ee eet to lock the battery and ignite the power for some units not others Tue cnet Costraitier box Installation of torque arm Torque arms are recommended for 1 000W front wheel kits They re provided for this kit but
6. DIY Electric bike conversion kit User Manual Please read the user manual carefully before starting the conversion Please convert the bicycle on the basis of a full understanding of the manual Contents Brief Introduction 3 User Precautions 4 Parts Introduction 5 Installation Steps 9 Final notes on installation MUST READ 24 Maintenance warranty and spare parts 26 Brief Introduction To create an electric bicycle is a rewarding project but caution is advised Customers converting their own bike are responsible for the safe operation and installation of the kit Please kindly read the user manual carefully before starting the conversion We disclaim any responsibility injury damage or other consequences arising from the use of this product User Precautions Even if you are an experienced rider take the opportunity to familiarise yourself with this conversion kits before you take your first trip Read all of the enclosed installation and operating instructions and follow the instructions prior to first use The e bike kit has lots of sealed electronic parts do not dismantle the parts let them fall or punctured them The electric
7. get the required range out of your kit The pedal assist modes only work for pedal assist input not throttle The throttle is awesome to use but even moderate use of the throttle with pedaling is still going to burn through the juice a lot faster than on a low medium pedal assist setting LED indicator lights full charge a The LED and LCD battery level displays are a basic indication of battery charge but the only indication of a full charge is having charged the battery and the battery charger lights glowing green to indicate that the battery is fully charged LED indicator light running low a Some customers find that the LED charge lights can lead them astray in terms of how far the bike will go on low power You don t risk damaging the system by riding all the way to the controller low voltage cutoff Keep riding on pedal assist even after the last LED light starts blinking Hills riding style other factors a The ranges quoted are from real world testing with some hills and some flat areas If your commute involves a lot of hills that s going to impact on the range of the kit 1 000W kits are especially susceptible to being zapped a lot more on hills than 250 s anyway If you need to purchase a second charger to charge the battery at half way or if you need an additional battery they will be available for purchase online General tips a Make sure the wheels are running free b Keep the battery topped up between uses if Li
8. lean electric components Use a wet rag or similar For practicality the warranty period commences from the purchase date All warranty details are available online Visit our website for all kit information order FAQ and enquiries Full range of accessories and replacement parts can be found on our website
9. ns connect w charger be charge it Lead acid battery 3 Controller Caties imrodectios phase refer alectronic map Normal controllers D Tub battery controtier with onal cabees complete wwterpeoct cablex This picture with normal cables please refer controller cattes Introduction to assarmite it Tube battery controller 4 Brake levels aa Regular brake levels Charging plug connect Signats local power A REOVGREEN Charging port comnect battery body Smart charger New Teb battery conmrolier with normal cables completo waterproot cables This picture with complete wwtergroc cables plaane refor controtlor cables intreduction to aanembte it Frame battery controller Water proof plug brake levels 5 Throttles throttle generaly mount on the right side Regular thumb throttle handie bars throttle turn onloff Regular twist throttle 6 PAS pedal assisted system sensor Horta PAS with normal cable manerproof cable This gioture wilh monnat cabis piossa reter comtrofer cables introduction te ancereiie it Regular PAS Sii Waterproof thumb throttle waterproof cable connect waterproof one cable system A handie bars throttle tern onvodf throttle switch working style bam on by throtile only tern off by PAS onty Waterproof twist throttle Removable PAS with orma cable walerproo cable Passe relor controller cables
10. parts should NEVER be submerged in liquid or left in a wet state Storage temperature of lithium ion battery is 20 60 C e Batteries should be charged immediately after every use and never be stored for long periods of time without maintenance charging if you have to store them for a long period of time please remember to charge once at least every two months The bike should be checked carefully after a long time idle Spoke tension should be checked after the first 50km and adjusted where necessary Make sure the tyres have proper pressure before riding Make sure the brakes are operating properly before riding Always wear a helmet when riding an electric bicycle for your own safety Adhere to all valid traffic regulations Adhere to all national state and local council laws Keep in mind that other traffic participants may underestimate the speed of an electric bicycle Ride with both hands on the handlebars when riding your electric bicycle Parts Introduction When you open the carton please find the components as below 1 Hand Built motor wheel motor line 2 Battery amp Charger a Turn onon Battery power display aad w _ 2w Tum owon N Turn ontott u battory on the side Tube battery Rear rack battery Power display Charging port USS socket Tum osoli battery Tum ofall coniroller brocket Tum onoff i Controtier box Frame battery Seat post battery tis cable should take ou a
11. there is the option of purchase them for any of the kits 250W front rear and even 1 000W rear They look fiddly to put on but actually aren t that difficult Your torque arm might go together on a slightly different angle depending on the angle of the dropout slots AA e brake power cutoff If the standard e brake handles aren t going to work for your installation please check out our e brake sensors online They re available separately and aren t exchangeable for the standard e brake handles Here are a couple of photo to illustrate 1 way they can be installed ZO Additional points on the installation Motor orientation Different series of kits have the cable coming out on different sides The foolproof way to orientate the motor correctly is to make sure that the disk brake side of the motor is on the left So when you re sitting on the bike the disk brake holes should always be facing towards the left Spoke adjustment The spokes used on the e bike hubs are very heavy duty Because of the rigidity of the harder heavier gauge spokes they may have a tendency to come loose more often than a regular bike wheel spokes That means that it s a good idea to check the spoke tension after the first 50km and then every 100km or so If you break a spoke we have spares available via our website 48V bottle battery charging specific to the 48V battery only Ensure that when you plug the black 4 pin battery cable pl
12. to use similar tools or you could buy specialized tool kits from our website Step 1 Check that your bike is suitable for conversion Our e bike kit is universal and can be used to convert most conversional bicycles however there are criteria which much be meet first Your front forks and rear dropouts must be wide enough to accept hub motor Front fork dropout MUST BE at least 98 102mm for regular bicycles For regular bicycles the dropout of front folk require 100mm more or less Rear conversions require 133 137mm at least for regular bicycles Assprrnnpoqenseperrapeponsepegeaney 12345 For regular bicycles the dropout of rear folk require 135mm more or less Bromton bicycle s front fork dropout is 80mm please order special motors to convert Bromton bicycles or 20 folding bicycles The opening on the fork or rear frame must be suitable to fit hub motor axles too wide is not acceptable XK generally the diameter of motor axle is 10mm You may have to remove a layer or 2 of paint for the axels to fit in the dropout They re designed to be a very tight fit You re better off to remove a layer of paint to make the fit reasonable You should have to exert a lot of force to get the axels to go in If you use too much force instead of filing back a layer of paint you risk damage to the fork and also that could result in a dropout failure due to Stress fractures Damage to forks is not covered by warranty
13. ug into the base of the 48V bottle battery that the battery is turned off The plug has a groove to prevent the it from going in incorrectly but because of the high voltage it s still possible for the plug to get close enough that it can ark out and short against the wrong terminals on the base of the battery melting the plug and doing damage to the battery that is not covered under warranty Vibration The motor hubs can at times be under quite a lot of load which can result in mild vibrations when accelerating or going up an incline If there is a loose item anywhere on the bike quite often that can exacerbate the moderate motor vibration into an almighty drone of a vibration giving the rider the impression that the bike is about to come apart If this happens to you you have to look for anything that could be loose Sometimes it might be an unused disk brake bolt or even something loose on the rear rack of the bike If there s something wrong with a component on the kit like a motor it won t be that subtle Integrated controllers on parts lists When you open up the carton of a 250W bottle battery or frame battery kit don t despair the controller isn t missing it s integrated into the battery 24 Range extension If you re not getting the approximate quoted range out of your e bike system take the following Steps l Pedal assist sensor a If you haven t installed the pedal assist sensor you might not
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