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Installation Manual

  • Loosen your brakes, turn your bicycle upside down and remove your front wheel. Put a tyre on the motorised rim, ensuring you have some rim tape on the new rim.
  • Put the motorised wheel in your forks, ensure that the motor axle slides deeply into the fork dropouts. Sometimes a little bit of filing is required to do this (about 5% of the time it's required), if you have to do over 5 minutes of filing then the fork strength will be compromised and you shouldn't continue and will be required to get a different set of forks.
  • Put the motor in the dropouts so that the cable runs down the right fork (if you are sitting on the bike and looking down). Make sure that the motor cable runs through the groove cut into the motor axle and down the fork, spin the motor half a turn otherwise.
  • Put one washer on the inside of the forks. Ensure that any lugs on the washers are facing the correct direction - on the mini motor the washers with lugs should go on the inside of the forks with the lug facing outwards. You may be required to undo the axle nuts and spin them around. Tighten nuts very well. Look from the front of the bike whilst spinning the wheel to ensure that the wheel is well centered. If not, then you can loosen the nuts and move some washers either side to make it very central.
electric kit cable
  • At this point, it is good to connect all components (throttle, battery, motor and controller) and ensure that the motor spins the correct direction and everything is functioning.
  • Install a torque bar. This can go on either axle. The one with the cable tends to be a bit longer on the mini-motors so tends to offer more room to tighten up the axle nuts. To see a video on torque bar installation click here.
  • Secure the motor cable to the forks to avoid damage during installaion with cable ties.
  • Adjust your brakes well. You will likely have to move the brake pads down a little. Centre your brakes by using the screws above the pads, they work like a fulcrum, as you tighten, the brake pads will move away from your rim (usually).
  • Spin the bicycle around the right way. Remove the hand grip of choice for throttle use. It's easy to remove the hand grip by lifting an edge with a flat edge screw driver and spraying any type of spray can up there. Do this a couple of time and twist and pull and it will come off.
  • Loosen brake and gear levers and slide up the handle bar. Put on the throttle of choice and tighten with an Allen key into a position so that it doesn't impede with any brake or gear levers and is in a comfortable position when riding full throttle. The choice of thumb throttle or twist grip throttle is generally made by one being better suited to the brake and gear levers on your bike. Make sure that the gear and brake levers have enough room to be used fully.
  • If using the water bottle style battery, then mount the battery holder and the controller bag onto the bicycle. If using the rear carrier rack battery, then remove the battery to avoid damage (and put it on the charger now) and secure the rack to the bicycle.
  • If using the water bottle battery, then run all cables into the controller bag and then connect to the controller. Put the controller in the controller bag and the battery in the battery holder. Secure all cables to the bicycle with cable ties very neatly and then put any excess cables into the controller bag.
  • If using the rear rack battery, then undo the screws of the controller box and connect all wires to the controller (one from inside the controller box that goes to the battery, one to the throttle and one to the motor). Run the throttle cable through the hole in the controller box and connect to the controller. Also, run the long cable on the controller out through the hole and connect to the end of the motor axle.
  • The controller sits tightly in the controller box and you must be careful to leave room behind where the switch sits so that the switch functions correctly when the controller box is sealed and tightened.
  • Cable tie the motor and throttle cables all the way along to the battery. Ensure there is enough loose cable for rotation of the handlebars. Tighten these cables neatly to the frame of the bike.
  • Sit the controller on the opposite side of where the switch will lie. Pull the motor and throttle cables through the hole in the controller box. Put all extra plugs and cables above the controller and then screw the face of the controller box on (begin with the bottom screws). Once again, be sure there is ample room for the switch when it is tightened - make sure the controller is not directly behind the switch.
  • Put the battery in the rack and lock into place so it doesn't move.
  • Cut all ends of the cable ties off and spin them around to face down or inwards. It can be a good idea to file any sharp edges from these for just a few seconds now too.
  • All ready to ride. Take the bike for a quick spin but then be sure to give the battery a full charge.
  • Make sure the battery charging light is functiong; red or orange when charging and green when fully charged (or not charging). The battery charger will switch itself off and the light will change to green when it's fully charged. At this point it's good practice to disconnect it. Turn the battery switch off when the bike is not in use.

HAPPY CYCLING

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