Can I Fit The Kit Myself
YES - Our electric bike kits are designed for DIY fitting so most of our customers are able to fit a kit with the help of our comprehensive fitting instructions.The fitting instructions are listed on our website with each of the kits, but as a quick guide, the steps to fitting a kit are as follows (please note that there is no right or wrong order to fitting the different components - these guides below are the sequence that we adopted but documented instructions may be in a different order):
Front Hub Kit
- Take the front wheel off the bike and remove the tyre, tube and rim liner from the wheel. Fit the rim liner, tube and tyre to the motor wheel
- If you have disc brakes then remove the rotor from your existing wheel and fit to the motor
- Fit the motor into the bike forks. You may need to experiment with the order of the washers to find the correct spacing for your forks. Just be sure to fit the torque washers (with the lug) so that the lug is facing into the dropouts. You will need a 19mm spanner to tighten the wheel in place
- Fit the brake levers and handlebar pedal assistance controls. To remove the handgrip from the handlebars: loosen the brake lever and gear shifters and move them away from the handgrip. Push a flat blade screwdriver under the handgrip from the side of the brake levers. Squirt a small amount of WD40 along the screwdriver, under the handgrip. Twist the handgrip and slide off.
- Set up the brakes with the new levers and tighten the components on the handlebars. When fitting the pedal assistance display ensure that you don't over-tighten the clamp.
- Fit the battery holder in place (this will be the pannier rack for a pannier battery)
- Fit the pedal assistance sensor. Note that this needs to be fitted on the non-chain side of the bike and the disc can face either way when fitting the DIY set up. The marking on the sensor needs to align with the magnets on the split disc, no more than 2-3mm away.
- Connect the motor cable and system cable to the relevant components (push fit and colour coded so you can't get this wrong). When connecting the cables ensure that the arrows on the connectors align. When fitting the motor cable ensure that this is fully pushed into position.
- Run the cables from the front of the bike to the controller, picking up the pedal assistance cable as you go. With a frame mounted battery the controller will be housed in a black box that you mount to the frame. A pannier battery has the controller housing at the end of the rack. In both cases, connect the system cable, motor cable, pedal assist cable and battery terminals (again colour coded so you can't get this wrong).
- Ensure that all cables are clear of any moving parts including cranks, chain and your legs and feet!
- Finally put the battery onto the bike, turn it on test that the motor works when pedalling.
Rear Hub Kit
Exactly the same as above but between steps 2 and 3 you have the additional task of fitting your cassette/freewheel (depending on the type of motor) and resetting the gears.
When fitting a rear 500w or 1000w kit with disc brakes be prepared to have to experiment to find the best set up for gear selection and brake caliper positions. You may need to space out the rotor, adjust the caliper position and find the best combination of axle spacer washers to get the bike running as it should.
- Remove the cranks from your bike using a suitable crank arm removal tool
- Remove the bottom bracket by using a bottom bracket removal tool
- Remove the front derailleur from the bike. You'll need to split the chain to do this.
- Fit the chain wheel onto the motor and slide the motor into place. When fixing the motor into place the retaining bracket needs to be tightened first and should lock the motor so that it can't be moved by hand. If needed a spacer can be fitted to move the retaining bracket out slightly to achieve a tighter fit. Now fit and tighten the retaining nut
- Fit the controls on the handlebar. Tips on removing the handgrips are described in the hub motor fitting guide above
- Fit the speed sensor by clamping the sensor onto the frame and fitting the magnet onto the spokes
- Fit the battery. When connecting the battery cable you may need to change the connectors - some customers prefer to solder the connectors from the motor to the battery, other use crimped connectors. It's your preference and it doesn't affect your warranty if you change the connector type.
- Connect the cables. The cable lengths on the mid drive motors are "one size fits all" and so you can find that you have excess cable. Do not cut the cable to shorten! You will need to be creative with the cable runs to make the neatest job possible
- Refit the chain and test!