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How to Install Electric Bike Kit


How to Install an Electric Bike KitOur electric bike kits are easy to install and allow you to convert your standard bicycle into an fun and eco-friendly e-bike. Since every model is different and components will vary, it's your responsibility to determine the best way to install an electric bike kit on your bike. Although most of the steps are similar from install to install, the following instructions should only be used as a guideline to convert your bicycle. If you do not have the mechanical ability to correctly and safely install an electric bike kit on your bike, you should contact a local bike shop or a professional bike mechanic for help.

General Installation Instructions

Step 1 - Choose Your Bike

Before you purchase or install an electric bike kit, make sure you have a suitable bike for the job. In particular, we recommend installing a front hub motor on a bike with steel forks. Since an alloy fork may not be able to handle the torque produced by a hub motor, test the fork with a magnet to ensure it's made of steel. If the magnet isn't attracted, we highly suggest replacing it with a steel fork instead. Although rear wheel kits are OK on aluminum, front hub motors can easily tear off an alloy fork and cause injury.

It's also important to ensure the fork (or frame for rear mounts) is large enough to accommodate the hub motor and axle. All our kits fit a standard 100mm bike dropout in the front, and 135mm in the rear. If necessary, forks (without suspension) may be spread using a threaded stud with two bolts that are turned evenly on each side.

Step 2 - Remove the Wheel

Once you've chosen your bike, it's time to remove the wheel. Turn the bike upside-down and let the air out of the tire. Then unhook the brakes to remove the wheel from the forks (or frame for rear mounts). If your kit does not include a tire and inner tube, remove them from the old wheel and install them on your new e-bike rim. If the old tire is worn, cracked or damaged in any way we suggest purchasing a new tire.


Step 3 - Install the Hub Motor

Take the new rim and place it between the forks to make sure it fits correctly. To ensure the wheel rotates in the right direction, see the detailed instructions that came with your kit. For the E-BikeKit™ and Amped conversion kits, the wires should exit on the right hand side of the bike - the Crystalyte RoadRunner and Phoenix kits exit on the left. Make sure you secure the bolts tightly and use the torque arm (if applicable) 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. Double check - and triple check that the bolts are tight! Inflate the tire, secure the brakes and flip the bike back over.

Step 4 - Install the Throttle

Next, remove the grips from the handle bars to replace the brakes (dependent on kit) and install the throttle. As a safety feature, some kits include brake inhibitors which cutoff power and deactivate the throttle when braking. After installing the brakes (if applicable), install and connect the throttle. If you have a twist throttle, simply slide it onto the handlebars. If you have a thumb throttle, secure it to the handlebars and then slide the handle grip back on.


Step 5 - Add Battery Rack

There are several options for mounting batteries. The most common option is a rear mounted rack behind the seat. It’s a little different for each bike, but generally you'll use the axle for the lower support and the seat post for the upper support. It may be necessary to bend or grind a little off the upper supports of the rack to fit some bikes.

Step 6 - 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 7 - 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. 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 8 - Hook Up the Electronics

Connect all of the wires to the controller. All the wires are color coded to make the process simple and many components have special fittings. However, keep in mind that some kits will require special connections (see specific kit instructions). 

When all connections are correctly and securely attached, plug your battery into the controller. If you're using your own battery and not one supplied with the kit, you'll need to follow the specific wiring instructions provided.

Step 9 - Make Final Adjustments & Enjoy

Finally, make sure the brakes are adjusted, gears are tuned and everything is ready to go. That's it! Now you're ready to ride. Be careful and take it slow until you get the feel. Ride for a few miles and then come back to check everything over. Give the bolts a good tightening one more time. You should check all the components often to make sure all connections are secure, especially near the hub and at the motor.

* See examples of different electric bike kit installations.
 

Detailed Assembly Instructions

Crystalyte Electric Bike Kit Instructions >>>
-  Amped Electric Bike Kit Instructions >>>

Installation Videos 1-7 (Provided by E-BikeKit)


 

This article is copyrighted work owned by eCo Wheelz, Inc. You may not copy, reprint, distribute, create derivative work of, or use this content in any way without citing eCo Wheelz (with link to website). For example: "Article by <link>eCo Wheelz - Electric Bikes</link>"

 

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