CycloTricity eKit User Manual Download Page 19 | Manualshive

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19

Copyright May 2020 Cycloricity Ltd.

3.

The fork drop-out must be 10mm wide.

10mm drop-outs are standard for the vast majority of forks. However, some drop-outs may
be 9mm wide. To enable the motor to fit inside, it is okay to use a metal file to scrape off
excess paint and widen the drop-outs to 10mm. Be EXTREMELY careful not to file too much.

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Summary of Contents for eKit

Page 1: ...1 Copyright May 2020 Cycloricity Ltd eKit User Manual Cyclotricity e bike Conversion Kit Assembly instructions May 2020...

Page 2: ...original CycloTricity eKit is constantly evolving based on your feedback and the improvements from the CycloTricity team the eKit is getting new features and re configuration of parts for easier asse...

Page 3: ...tructions should be considered as general guidelines only every electric bike conversion will be slightly different If you do not have the mechanical ability to correctly and safely install this elect...

Page 4: ...hing correctly and you ll have more clarity during the assembly process This will also help with any troubleshooting before you spend time assembling everything on your bicycle So let s get started 1...

Page 5: ...iquely shaped so you cannot go wrong Some cables have arrows on the connections If so make sure the arrows are aligned Push the connections firmly all the way in 3 Connect the Motor to the Motor Cable...

Page 6: ...hrottle Yours may look slightly different Match the Throttle to the Yellow branch of the System Cable Align the arrows and push them all the way in 5 Connect the E brakes to the System Cable The red b...

Page 7: ...een cap to connect to the System Cable instead Please look into your eKit box carefully In the absence of a Display this Cap is necessary for the eKit to function 7 Connect the Battery to the Controll...

Page 8: ...er PAS The Pedal Assistance System is an optional extra Ignore this step if you have not purchased this option Controller The yellow connection on the controller is for the PAS If you have not purchas...

Page 9: ...n using the ON OFF button on the battery If you have a Display connected switch it on by pressing and holding the ON OFF button If it does not come on please charge the battery If you do not have a Di...

Page 10: ...g and you have completed the first part of this project Great job Chapter 2 We are here for you Lost in the instructions Things didn t work Missing parts Let us know You can contact us via our website...

Page 11: ...pared to improvise and do your own tweaks if necessary This is a DIY conversion project after all Chapter 3 Tools As each bike is different and may require different tools no standard tools are suppli...

Page 12: ...ricity Ltd Chapter 4 Mounting the Front Hub Motor If your eKit comes with a Rear Hub Motor skip to the next chapter 1 Start by turning your bike upside down so it is resting on the saddle and handleba...

Page 13: ...tor to fit inside it is okay to use a metal file to scrape off excess paint and widen the drop outs to 10mm Be EXTREMELY careful not to file too much WARNING If you have a carbon fiber fork do NOT fil...

Page 14: ...ur fork is made of steel material WARNING Do NOT attempt to widen an Aluminum or Carbon Fiber fork It will compromise its structural integrity and will pose a safety risk Stretching the forks can only...

Page 15: ...em on the motor wheel instead This step is best described visually If you haven t replaced a tube tyre on your bike before you are recommended to watch one of the many video tutorials online 6 If your...

Page 16: ...l If the fork is resting upside down the motor cable must be pointing in the direction as the above picture 8 Torque Washer You will notice there is an unusual washer with a small flange sticking out...

Page 17: ...hten them against the outside of the fork drop outs 10 Your motor should now be securely tight and can spin freely Whether your bike is fitted with Disc brakes or V brakes you may need to adjust them...

Page 18: ...y Ltd Chapter 5 Mounting the Rear Hub Motor If your eKit comes with a Front Hub Motor this chapter does not apply to you 1 Start by turning your bike upside down so it is resting on the saddle and han...

Page 19: ...wide 10mm drop outs are standard for the vast majority of forks However some drop outs may be 9mm wide To enable the motor to fit inside it is okay to use a metal file to scrape off excess paint and...

Page 20: ...t May 2020 Cycloricity Ltd WARNING If you have a carbon fiber fork do NOT file it It will compromise its structural integrity Please return your hub motor kit and consider fitting a Crank drive motor...

Page 21: ...ndle sticks out you are required to fit a torque arm for your own safety more on this later 5 Remove your existing tyre air tube and protection tape Place them on the motor wheel instead This step is...

Page 22: ...22 Copyright May 2020 Cycloricity Ltd 6 If your bike is fitted with disc brakes remove the disc from your wheel and add it unto the motor 1 2 3 4...

Page 23: ...mpatible with Freewheels I e threaded cogs In other words if your bicycle is fitted with a Cassette you will need to purchase a Freewheel before you can proceed with installing this Rear Hub Motor If...

Page 24: ...td If you purchased a separate Freewheel together with your eKit you can mount it on the motor by hand without any specialist tools Although you are recommended to keep a Freewheel Remover as part of...

Page 25: ...necessary but not always Trial and error is the only way to perfect this part of the project A common issue is that your derailleur may be wider than usual This means your derailleur may rub against t...

Page 26: ...scover later that your derailleur is unable to reach the large cogs of your freewheel you can then experiment with spacers until you achieve perfect alignment 9 Lubricate the freewheel Before fitting...

Page 27: ...motor like so The Spindle of the motor has a flange This must not be below the edge of the freewheel This is likely to happen if you have a spacer behind the freewheel It may also happen if your free...

Page 28: ...May 2020 Cycloricity Ltd You may pancake one washer on top of the other until they exceed the edge of the freewheel This is to prevent the fork drop outs from rubbing against the freewheel 11 Add the...

Page 29: ...arm You are recommended to fit a torque arm for extra safety Remember this is a high torque motor and can be de restricted for even more power Depending on the type of bicycle you have your drop outs...

Page 30: ...orque arms are not provided with the eKit by default as not all bikes need them If you have an aluminum carbon fibre or a degraded steel frame you re recommended to fit a torque arm Also if you had to...

Page 31: ...ay 2020 Cycloricity Ltd The motor spindle must fit snugly all the way into the drop outs like so If your drop outs are not deep enough See Point 4 in this Chapter you MUST use a torque arm 14 Fitting...

Page 32: ...32 Copyright May 2020 Cycloricity Ltd 1 2 3 4 5 6 7 8 9...

Page 33: ...ailleur is best described visually If you are unsure of how to do that you are recommended to watch one of the many great video tutorials online If the derailleur rubs against the motor and cannot rea...

Page 34: ...loricity Ltd Chapter 6 Fitting the Bottle Battery Skip to the next chapter if you did not purchase this battery 1 Remove the Battery Holder First unlock it with the key 2 Fit the Battery Holder on the...

Page 35: ...t have provision for a water bottle a qualified bike mechanic can drill holes into the frame and install threaded rivet nuts This will enable you to fit the Battery Holder using screws 3 Slide the Bat...

Page 36: ...36 Copyright May 2020 Cycloricity Ltd Chapter 7 Fitting the Frame Battery Skip to the next chapter if you did not purchase this battery 1 Remove the Battery Holder First unlock it with the key...

Page 37: ...fferent the screws shown in this image typically come with your bike They are not provided with the battery If your down tube does not have provision for a water bottle a qualified bike mechanic can d...

Page 38: ...ber the battery lock is only meant to prevent it from falling off during cycling and should not be regarded as a security lock against theft We recommend you detach the battery and carry it with you w...

Page 39: ...t May 2020 Cycloricity Ltd Chapter 8 Fitting the Pannier Rack Battery Skip to the next chapter if you did not purchase this battery 1 Pannier Rack 2 Rack fittings 3 Rack rods 4 Battery Plate 5 Battery...

Page 40: ...ler inside the plastic compartment and connect the bullet connectors If you purchased the 500W Rear Drive Motor your controller may be too large to fit inside the plastic compartment In this case you...

Page 41: ...e Note Since each bike is different the screws or alternative fittings shown in this image typically come with your bike They are not provided with the battery If you do not have suitable screws for y...

Page 42: ...ht May 2020 Cycloricity Ltd Chapter 9 Plastic Controller Box If your kit did not come with the following plastic housing this chapter does not apply to you 1 Place the Controller inside the Plastic Bo...

Page 43: ...Connect the Battery bullet connectors Ensure the bullet connectors for the battery remain inside the housing 3 Close the lid of the plastic housing Ensure the bullet connectors for the battery remain...

Page 44: ...44 Copyright May 2020 Cycloricity Ltd 4 Fasten the lid with screws 5 Use the brackets to mount the box on the Seat tube of your bike...

Page 45: ...2020 Cycloricity Ltd Chapter 10 Velcro Controller Bag If your kit did not come with the following Velcro bag this chapter does not apply to you 1 Open the bag and put the controller cables through the...

Page 46: ...pyright May 2020 Cycloricity Ltd 2 Ensure the bullet connectors for the battery remain on the inside to keep them protected 3 Use the Velcro strips to mount the bag on your frame as you see fit for ex...

Page 47: ...Ltd Chapter 11 Fitting the PAS Optional If you did not purchase a PAS with your kit skip to the next chapter 1 Prerequisites The PAS fits on the Bottom Bracket of your bike A Bottom Bracket is the sp...

Page 48: ...your Bottom Bracket before you can fit the PAS A bottom bracket is fairly inexpensive and simple to replace But requires specialist tools Therefore it is best to have this done by a qualified bike mec...

Page 49: ...49 Copyright May 2020 Cycloricity Ltd 1 Dismantle the Magnet Disc 2 Fit the magnet disc around the Bottom Bracket spindle...

Page 50: ...50 Copyright May 2020 Cycloricity Ltd 3 Fit the sensor on either the down tube or the seat tube pick the tube that allows the sensor to be positioned closer to the Magnet disc...

Page 51: ...will blink as you rotate the magnet disc passed it The adhesive on the sensor is not enough to cope with real life conditions Secure the sensor firmly with zip ties ATTENTION If the spindle of your b...

Page 52: ...hing up liquid Hairspray also works great as it acts as a lubricant when wet and as an adhesive when dry Perfect for working with grips 1 E brakes E brakes are like regular brake levers but with the a...

Page 53: ...ht May 2020 Cycloricity Ltd If you have regular mechanical brake levers you can swap them with the e brakes provided with your kit Remove the brake cable from your existing brake levers Remove the bra...

Page 54: ...2020 Cycloricity Ltd Fit the E brakes on the handlebar and hook the brake cables back Adjust the brakes as needed If you are unsure of how to do that you are recommended to watch one of the many video...

Page 55: ...tening the Throttle screw consider the positions of the brake levers and any gear shifters you may have Determine the best order in which these three items are mounted on the handlebar for best reach...

Page 56: ...intuitive ride It also provides various useful functions like speedometer odometer battery load etc The eKit comes with two different displays to choose from LED LCD The LCD is required if you need to...

Page 57: ...purchase a Display with your eKit remember to connect the green cap to the green connector of the system cable instead If you did not fit the e brakes seal the red connectors with electrical tape to...

Page 58: ...lectrical tape to keep it protected Or better still tuck it inside the controller housing Congratulations You have now built your own fully functional e bike Chapter 14 Testing Switch the Battery on S...

Page 59: ...sform your bike into a normal push bike 5 The LCD also provides other functions such as speed time distance of your journey etc see below 6 Please note that the battery bars on the LCD may not necessa...

Page 60: ...SW button To switch it off press and hold the SW button or the device will automatically switch off when the bike is left without use for 5 minutes Change level of assistance Under normal operating c...

Page 61: ...buttons at the same time for 3 seconds till you see a number flashing on the screen This will take you into the LCD setup view Adjust the maximum speed Note you cannot achieve speeds greater than 25km...

Page 62: ...We do not recommend you run on the throttle alone for long distances as this will impact the performance and lifecycle of the battery 7 The battery performs best with a payload less than 80Kg Heavier...

Page 63: ...save this setting and exit the setup state by holding down the MODE button Alternatively you can stay on the setup state and move on to configuring the wheel diameter by pressing the 6km h button Whee...

Page 64: ...ire heat sources acid or alkaline substances Keep it away from radiators 5 For best results always charge the battery at room temperature 6 Always make sure the battery is turned off before detaching...

Page 65: ...of and expressly excludes all other warranties not expressly set forth herein whether expressed or implied by law or otherwise including but not limited to any warranties for merchantability and or fi...

Page 66: ...f a Cyclotricity battery for best compatibility and performance Water Damage The warranty does not include damage from power surges use of improper charger improper maintenance or other such misuse or...

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