EV Depot Crystalyte Assembly Manual Download Page 18

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Connect the Battery Pack to the Controller

22.

Connect the battery pack to the. If your keyswitch is on when you make the
connection, you will hear a “pop” and maybe see a spark. This is normal
behavior. It will not hurt you or the system.

Enjoy your first E-Ride!

Crystalyte Hub Motor Kit Home Assembly Guide



2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company

18 of 20

Summary of Contents for Crystalyte

Page 1: ...t Fork Width 4 About Dropout Diameter 4 About Torque 5 Phoenix Front Wheel Torque Arm 5 Install the Rack 5 Mount the Controller 6 Mount the Throttle 6 Run the Wire 7 Wire the Batteries 8 About Batteries 8 Connect the Battery Pack to the Controller 18 Enjoy your first E Ride 18 Disclaimers 19 Warranty 19 Upgrades Parts and Accessories 20 Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a ...

Page 2: ...op now along with these instructions The charge is minimal 35 60 and it will take a professional less than an hour to do the job correctly If you cannot assemble a battery pack per these instructions you must order a pre wired kit We have prepared these instructions to make the installation of your hub motor conversion kit as fast and worry free as possible If you are not confident in your ability...

Page 3: ...flate to 20 lbs pressure and repeat 5 Inflate to the full pressure specified on the sidewall of your tire About tires The higher the pressure the less rolling resistance Tires capable of higher pressure will give you better range and speed The smoother the tire the less rolling resistance Slicks give you better range and speed than knobbies Install the Wheel 6 If you don t have a bike stand turn t...

Page 4: ...er If necessary use a die grinder to enlarge dropouts to the 9mm diameter of the axle Any means of filing can be employed The fit should be snug For Phoenix systems we recommend steel forks with large dropouts usually found on less expensive bikes 10 Put the wheel onto the frame making sure that the channel through which the wires run faces downward when the bike is upright This will help protect ...

Page 5: ...nces are good that the new rim and the old one aren t exactly the same so adjust the shoes so that they engage the rim with full contact Adjust the cable for just enough free play to keep the shoes off the wheel during rotation Remember you will be asking more from your brakes when riding at electric bike speeds Install the Rack 13 Install the rack It s a little different for each bike but general...

Page 6: ...the bike frame Doing this will allow you to leave throttle motor and optional cruise control with inhibits connected to the controller as a part of the bike To remove the battery pack you only have to disconnect one connector from controller to batteries Mount the Throttle 15 Remove the right handlebar grip and shifter if there is one present Push the throttle onto the handlebar and tighten using ...

Page 7: ...ve the color coding and join the same color wires Phoenix RoadRunner Sparrow 17 Connect the throttle wire to the controller There is only one plug on the controller that fits the throttle connector All of our throttles fit all of our controllers Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distribution LLC Company 7 of 20 ...

Page 8: ...two types of battery packs supplied with EV Depot hub systems 36 volt 3 batteries and 48 volt 4 batteries Please see the detailed instructions for how to wire your batteries Batteries contain a lot of energy You can vaporize light metal with a single battery About Batteries Your hub motor system uses sealed lead acid SLA batteries The acid is fully absorbed into a glass mat and the batteries are t...

Page 9: ...ponent failure Particularly susceptible to failure is the charger If you have your pack wired incorrectly your charger is likely to blow If you have a Soneil charger the fuse will blow but the charger will survive 1 Set your batteries on a non metallic workbench as shown Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distribution LLC Company 9 of 20 ...

Page 10: ...he batteries and a large connector that goes to the control unit There are also two long wires and a fuse holder with wires 3 Using scissors or wire cutters cut the shrink tubing into 8 pieces Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distribution LLC Company 10 of 20 ...

Page 11: ... the end of each wire before soldering to the battery terminal 5 Push one piece of heat shrink tubing up the wire a few inches far enough to prevent being heated Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distribution LLC Company 11 of 20 ...

Page 12: ...wire onto the battery terminal Touch the soldering iron to the wire The drop of solder on the tip will facilitate rapid heat transfer into the wire then onto the battery terminal As soon as the solder begins to flow on the terminal remove the iron Too much heat on a terminal will destroy your batteries Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distributi...

Page 13: ...y terminal 9 Continue to solder or use push on tabs until your battery pack looks like the picture above If you number the battery terminals 1 to 8 here is where they connect 1 to 8 2 to negative black side of key switch harness 3 to positive red side of key switch harness 4 to 5 6 to 7 Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distribution LLC Company 1...

Page 14: ... appearance of red hot on the battery surface around the wire is a reflection of light not heat It doesn t take much to shrink the tubing A match or lighter will work very well 11 This is what solder joints should look like when complete Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distribution LLC Company 14 of 20 ...

Page 15: ...ft and right 13 For each pair turn one battery so the leads are opposite the other then set them top to top on each other Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distribution LLC Company 15 of 20 ...

Page 16: ... result could smoke from melting insulation severely degraded performance and one or more ruined batteries 15 Put each pair of batteries in a side of the pannier bag The key switch and charger port normally go on the left side Close the zippers with the cross connect wires that run to the opposite side pannier to the front of the bag Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Pri...

Page 17: ...16 Left side 17 Right side Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distribution LLC Company 17 of 20 ...

Page 18: ...eyswitch is on when you make the connection you will hear a pop and maybe see a spark This is normal behavior It will not hurt you or the system Enjoy your first E Ride Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distribution LLC Company 18 of 20 ...

Page 19: ...s We will not cover abuse That is we expect our customers to realize their light electric vehicles have limits Most of the same kinds of rules apply to electric vehicles as gas powered vehicles You can t hold the throttle and brake at the same time for very long or something is going to break In the case of a car it will probably be the transmission In the case of an electric vehicle it will proba...

Page 20: ...and or farther From faster chargers to batteries to beefed up motors they will try to satisfy your electric transportation needs Crystalyte Phoenix RoadRunner and Sparrow are distributed in the US by EV Depot and are sold at EV specialty stores bike shops and a several online stores Crystalyte Hub Motor Kit Home Assembly Guide 2006 EV Depot a Priority Fulfillment and Distribution LLC Company 20 of...

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