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Dillenger CONVERSION KIT, User Manual, Page: 7 / 27

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Dillenger CONVERSION KIT User Manual Download Page 7

7

INSTALLATION INSTRUCTIONS

The installation instructions for this kit are show in this video:

https://www.youtube.com/watch?v=Arg5zSV3Cl8

Cassette and Disk Brake Install

Once you’ve taken your old wheel out of your bike and put the tube and tyre on the new 
motor wheel, you can install the gear cluster on the motor.

Unlike our previous rear wheel hub motors, this motor uses a splined cassette. You can use 
your current cassette (up to a 9 speed), or get a new cassette for the wheel. 

 
For those with disk brakes, the disk brake rotor installs onto the side of the motor hub just 
like a regular hub. 

Tighten the bolts to maximum 5Nm (40 lbs) tightening torque. If you overtightened these 
bolts, you may risk stripping the hub which is not covered by warranty. Make sure that the 
bolts aren’t too long, otherwise they’ll interfere with the internal parts of the motor.

If you don’t have disk brakes, you can leave this side of the hub untouched.

 

In this manual we will describe the main steps in the installation process, but we strongly 
recommend use the video as well. Seeing the steps in the video will help you to understand 
each step and make the process a lot easier.

Summary of Contents for CONVERSION KIT

Page 1: ...CONVERSION KIT Please read through carefully before beginning your conversion User Manual Dillenger Premium Off Road Kit Samsung Powered English ...

Page 2: ... pick an area away from cars other cyclists obstacles or other hazards to become familiar with the controls features and performance of your new electric bike We highly recommend the purchase of the Dillenger hub motor conversion kit It will make your installation and ongoing maintenance much easier This can be purchased online Thank you for purchasing your new Dillenger conversion kit We know you...

Page 3: ...tall 8 Battery Cradle Install 10 Battery Install 11 Handlebar Controls Install 11 Display Install 12 Thumb Throttle Install 13 E Brake Sensors Install 14 Removable Pedal Assist Sensor RPAS Install 15 Wiring Install 16 Tidy Up 17 Battery Operation 18 Turning Your Bike On Off 18 Charging 19 Maintenance and Care 20 Trouble Shooting 21 Specifications 25 Contact Us 27 ...

Page 4: ...er on your bicycle Before you begin your conversion it can be helpful to lay everything out first and make sure all the parts are there Something missing Double check the box even under the flaps Those small parts can be sneaky If you still can t find it let us know and we ll assist you ASAP In the box you ll find Motor wheel Battery with keys and cradle PAS throttle and e brake sensors LCD displa...

Page 5: ...g into the frame Then move on to the battery cradle controller and handlebar controls 3 Ride Once the battery is fully charged you ve checked your tyre pressures and fasteners you re now ready to go 5 Prepare you bike Make sure you have measured your dropout slot widths approx 10mm and the clearance between your dropouts approx 135 140mm for the rear of the frame Remove your current wheel remove t...

Page 6: ...nstalling the wheel The easiest way to take off your wheel is to turn your bike upside down so that your bike rests on the handlebars and the seat Your seat height may need to be adjusted to ensure the bike will be stable when upside down Take off your disk brake caliper from the frame or release your V brakes if you have not done so already For disk brake users it s much easier to fit the motor w...

Page 7: ...el For those with disk brakes the disk brake rotor installs onto the side of the motor hub just like a regular hub Tighten the bolts to maximum 5Nm 40 lbs tightening torque If you overtightened these bolts you may risk stripping the hub which is not covered by warranty Make sure that the bolts aren t too long otherwise they ll interfere with the internal parts of the motor If you don t have disk b...

Page 8: ...ashers provided or if you need to space the hub evenly over to the disk brake side you can rearrange the fasteners to achieve this The distance between your dropouts should be around approx 135 140mm Your rear dropouts chain stays will flex in and out a certain amount without causing any structural issues The dropout axle slots should be approx 10mm however you may need to file off a thin layer of...

Page 9: ...t slots this could cause failure of the dropouts or cause the electric hub axle to become unsecured Tighten to approx 30 40Nm 250 350 in lbs If you would like to install the torque arm on the rear wheel please see the manual for the Arc torque arm on the website Your rear derailleur and disk brake callipers can now by reinstalled if they were removed prior to the installation of the rear wheel 9 W...

Page 10: ... screws and tightening them up Be careful not to over tighten your bolts screws as drink bottle mounts and threads are only nutserts If installed correctly the battery and cradle should feel very secure and not bounce over bumps If drink bottle mounts aren t an option there are plenty of battery attachment options other than the method above such as 1 Install the battery on a rear rack contact Dil...

Page 11: ... in order to remove the battery from the cradle you need to turn the key and gently slide the battery out of the cradle With the motor battery and cradle controller mounted it s time to move on to the easy part Firstly remove the packaging from the Display Thumb Throttle and E Brake Sensor kit Your handlebars should be just about bare ready to accept your new controls ...

Page 12: ...y can depend on the rider style or the shape of the handle bars Attached to the Display is also a Pedal Assist Controller This Controller also has the On Off button on it The way this controller works is that it has a number rating that will appear on screen The higher the number the more that the motor will assist with your riding or pedaling This pedal assist controller should be slid on to the ...

Page 13: ...ke sure the cable is not fouling the brake lever otherwise readjust Before sliding the grip handle onto the handlebars make sure you insert the small plastic bush you can see this in the third photo on this page This prevents the grip from rubbing against the throttle At this point your handlebar installation is completed and you should have everything in a comfortable position For users in states...

Page 14: ...n purposes The sensors magnets can also be installed underneath the brake levers so they are hidden making for a sleeker look The magnetic square and the sensor should be installed so that when the brake lever is realeased they contact each other When you pull on the lever to brake the sensor will register the proximity change and activate the e brake cut off This means that when you use your brak...

Page 15: ...k generate a changing magnetic field or a hall effect and this is picked up by the hall effect sensor which transmits a signal to the controller The pedal assist is the primary function of an electric bike and the level of assistance is adjustable on the handlebar LCD 1 The sensor will need to line up very closely under 5mm to the RPAS disk 2 Be sure to have the working side text facing the sensor...

Page 16: ...c You may be required to carefully remove a portion of the vanes if a larger diameter hole is required This would be done with a sharp pair of scissors or side cutters The level of assistance you receive is controlled by your handle bar display buttons which we already fitted with the display up and down buttons Wiring Install The wiring now has to be connected up so that everyhting has power and ...

Page 17: ...ug from the wiring loom joins with the wire coming from the LCD display Wiring Install Continued Tidy Up In the final stage of the installation it s time to tidy up the wires and make everything look nice and neat In the adjacent images you can see the provided zip cable ties being used to bundle and secure the cables coming from the base of the battery controller RPAS and anything else leading up...

Page 18: ...Dillenger to have the barrel replaced not ideal The battery should never be ridden or turned On without being locked into the rack It should also never be dropped or treated roughly If you re battery is returned to us and has signs of being dropped this will void the warranty Turning Your Bike On Off Once your bike and conversion kit have been properly assembled and wired you will obviously want t...

Page 19: ...The charger indicator lights should glow red whilst charging 5 Once the charger indicator lights change to 1 red and 1 green the battery is fully charged There is no way to over charge the battery When it is full the charger will stop charging the battery automatically Charging time can vary from 1 to 9 hours if completely empty The battery should be charged once every month as a minimum to mainta...

Page 20: ...on toolkit is ideal Check the tightness of each spoke ideally after the first 100km and then every 500km As well as caring for your spoke tension it s important to do a check on all of your fasteners every few months It never hurts to go over your bike with tools tightening and checking everything that can be checked This will ensure you have a safe and well serviced bike Keep your bike clean Ther...

Page 21: ...ckwards Remove the motor from the frame and switch the direction Motor feels like it has something caught inside or some kind of brake on inside Remove the disk brake bolts completely and see if this remedies the issue If the disk brake bolts are too long they will go too far into the housing and fowl against the internals A high pitched rattling noise can be heard when accelerating The vibration ...

Page 22: ...e side to achieve clearance Wiring to a part of the kit is not long enough For this problem we stock a wiring extension kit which can be purchased online This is usually recommended for rear rack versions of this kit Disk brake bolts won t tighten You may require some longer bolts but be careful they are not too long and foul against the internals of the motor Handlebar too crowded If for instance...

Page 23: ... out intermittently If the battery is low on power or you are going up a very steep hill with a load on the motor you will likely experience a voltage cut off if you have overloaded the controller or dropped the voltage below the low voltage cut off which is more prevalent at low power This isn t a fault with the kit it s just physics I would like my battery capacity tested Please contact Dillenge...

Page 24: ... Indicator Light Running Low Some customers find that the LED LCD charge indicator can lead them astray in terms of how far the bike will go on low power You don t risk damaging the system by riding all the way to the controller low voltage cutoff Keep riding on pedal assist even after the last battery indicator bar starts blinking 4 Hills Riding Style Other Factors The ranges quoted are from real...

Page 25: ...d Nominal Power 500W Peak Power 1 000W Max Speed 45km h Max Range 100km Average Range 50km Throttle Only Range 40km Throttle Type Thumb throttle Pedal Assist Levels 0 9 levels Handlebar Display C965 LCD Rims Double wall eyelet Spokes 12G stainless steel Wiring Type EB BUS Weight Total Weight No Battery 4 7kg Battery Weight 3 8kg Total Weight 8 5kg ...

Page 26: ...Battery Capacity 17 5Ah Nominal Battery Energy 840Wh Battery Removable Yes Batery Cell Type 18650 Cell Spec Samsung 35E Cell Configuration 13S P Motor Motor Brand Bafang Motor Model G360 Motor Voltage 48V Max Motor Power 1 000W Drive Type Geared reduction hub motor ...

Page 27: ...27 Dillenger HQ CONTACT US 3 13 Olympic Circuit Southport QLD 4215 AUSTRALIA Phone 1300 014 317 support dillenger zendesk com www dillengerelectricbikes com au Dillenger 2016 ...

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