Installation
E-BikeKit™ Owner's Manual
E-BikeKit™ Installation Video Series
The E-BikeKit™ electric bicycle motor kit is supplied as a set of do-it-yourself parts.
If you are not confident about installing the system yourself please consult your local bicycle shop for advice and service. If there is not an Authorized E-BikeKit Dealer near enough to you and your local bike shop is unable or unwilling to perform the installation then please visit E-BikeDealers.com to search for a local bike shop that will. Of course you can always contact customer service with any installation questions you may have.
Part 1 - Box Contents This video outlines the box contents of the electric bike conversion kit. |
Part 2 - The Front Wheel This video demonstrates how to install the front wheel and universal torque arm of the electric bike conversion kit. |
Part 3 - E-Brakes This video demonstrates the importance of e-brakes and how to install the e-brakes as part of the E-BikeKit electric bike conversion kit. |
Part 4 - The Throttle This video demonstrates the throttle and how to install a throttle as part of the E-BikeKit electric bike conversion kit. |
Part 5 - The Controller This video defines the wires and connectors of the controller and shows how to connect the controller as part of the E-BikeKit electric bike conversion kit. |
Part 6 - Running Wires This video demonstrates ways to run wiring from the components to the controller and battery as part of the E-BikeKit electric bike conversion kit. |
Part 7 - Mounting the LiFePO4 Battery This video explains how to properly use the mounting bracket and sliding plate to mount the e-bike battery to the rear rack as part of the E-BikeKit electric bike conversion kit. It also explains the locking mechanism and the on/off key positioning. |
Controller Wiring Diagram
Step by Step Installation Guide
IMPORTANT: You MUST only install a front hub motor on a bike with steel forks. NO ALLOY FORKS.
Alloy forks are NOT strong enough to support a hub motor. During installation and even worse during a ride, alloy forks can crack or break under the pressure of a wheel with a hub motor. It is important to tighten front wheels extremely tight when installing a hub motor and there is a strong likelihood of cracking alloy forks during installation. This could also be very dangerous if it happens while you are riding. Use your torque arms to eliminate the possibility of losing a wheel while riding and use steel forks to ensure your own safety. If you are unsure if your fork set is alloy or steel, test the fork with a magnet to ensure it's made of steel. If the magnet is NOT attracted to your fork it is an alloy fork and NOT steel. Replace your fork with a steel fork or find another bike with a steel fork to convert. E-BikeKit™ is not responsible for damages or injuries as a result of installing an E-BikeKit™ hub motor on alloy forks.
Step 1 - Make Sure Your Bike is Suitable for Conversion
The E-BikeKit™ is available in the following standard wheel sizes: 20", 26", or 28". What is important is the width of the space between your forks. You need at least 4 inches between the inside of the dropouts (where the axle fits into your forks) and you need at least 3.25 inches of width between the inside of the forks for 5 inches up the forks from the dropouts. You should also have 3/8" width in your dropouts (where the axle fits into the forks) which is the standard dropout width on most bikes.
Step 2 - Install the Hub Motor Wheel
Take the E-BikeKit™ hub motor wheel and place it between the forks to make sure it fits correctly. After making sure it fits you can secure the rim in place. Make sure you secure the bolts tightly and secure both torque arms to keep the motor from spinning within the fork. If you apply power and the axle is not secured tightly, the motor will try to turn inside the dropouts, permanently damaging the wires connecting the motor.
Torque arms should always be used. Tighten axle bolts and secure torque arm. Inflate the tire, secure the brakes and flip the bike back over.Re-install and adjust the brakes. Odds are good that the new rim and old rim are not 100% the same, so adjust the brake pads so that they engage the rim with full contact. Adjust the cable for enough free-play to keep the shoes off the wheel during rotation. Electric bikes require more attention and care to brakes since you will normally be riding at higher speeds.
Step 3 - Install the Throttle & Brake Handles
Next remove the grips from the handle bars to replace the brakes and install the throttle. The E-BikeKit™ includes two brake handles with internal magnetic switches that cutoff power and deactivate the throttle when braking. You will need to connect your existing caliper brake inner-wires to the E-BikeKit™ brake handles. After installing the brakes, install and connect the throttle. If you have a twist throttle, simply slide it onto you right side handlebar and tighten in place with the provided 3 mm hex wrench. If you are using a thumb throttle you will need to remove your right grip, slide the thumb throttle onto the handlebar, slide your right handle grip back into place and then secure the thumb throttle with the hex wrench.
Step 4 - Install the Rear Rack & Secure Battery Pack
It is a little different for each bike, but generally when installing a rear rack you'll use the axle for the lower support and the seat post for the upper support. If you are using the E-BikeKit™ 36v 10ah LiFePo4 battery pack it will come with a mounting plate that can be secured to your rack allowing you to easily slide your battery on and off and lock it in place when riding. Racks come in many styles so each installation will be different depending on the type of rack used. Make sure your battery is secure and snug so it will not move when riding. If you are unsure about how to secure the battery properly you should consult a professional.
Step 5 - Mount the Controller
Now you have to decide where you would like to mount the controller. The most common places are behind the seat or on top of the battery bag. Do not mount it inside the battery bag because the controller needs ventilation to prevent overheating.
Step 6 - Run the Wiring
For a clean install, route all of the wires toward the back of the bike and secure the wires with zip ties (included with the E-BikeKit™). Make sure you have full range of motion with the handlebars when tying back the wires and leave some slack at each zip tie.
Step 7 - Connect the Electronics
Connect the wires from the motor, brakes and throttle to the controller. The connectors from each component will only fit to the correct mate on the controller. Please consult the wiring diagram for further clarification. Please not that there is a black & white "European Suppressor Loop Wire" on the controller that limits power to the motor to 200 watts when connected. This will limit the top speed of the motor to approximately 200 watts(14 MPH). Simply disconnect the loop to enable full power and higher top speeds.
When all connections are correctly and securely attached, plug your battery into the controller. If you're using your own battery and not the E-BikeKit™ 36v 10ah LiFePo4 battery pack, you can use the wiring harness (included with the kit) to easily connect your battery pack.
