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Swytch Brompton eBike Conversion Kit, Instruction Manual

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Swytch Brompton eBike Conversion Kit Instruction Manual Download Page 22

42

43

Accessories

7

7.1 In-Line Brake Sensors

Without the brake sensors the motor will still turn off a moment 

after the pedals stop turning or the throttle is disengaged.

Brake sensors provide an additional level of control and safety by 

turning off the motor immediately when the brakes are applied – 

they are an optional addition to your kit.

Fitting the brake sensors requires the brake cable to be removed 

and replaced. If this is not done properly then the brakes may 

not function correctly which can cause a serious accident. If 

you are not confident with working on your bike’s brakes, then 

we recommend taking the bike to your local bike shop or bike 

mechanic for help fitting the sensors.

If you’re going to attempt to fit the brake sensors with no 

previous experience with working on brakes, fit only one brake 

sensor on to the rear brake and leave the front brake without a 

sensor as a backup.

Summary of Contents for Brompton eBike Conversion Kit

Page 1: ...1 www swytchbike com instructions Instruction Manual ...

Page 2: ...r BRO BLOCK 36 6 5 General Tips 41 7 Accessories 42 7 1 In Line Brake Sensors 43 7 2 Hydraulic Brake Sensors 46 7 4 Universal Torque Arm 47 7 5 Torque Narrow 48 7 6 Twist Throttle 49 7 7 Thumb Throttle 49 8 Operation 50 8 1 Power Pack Removal 51 8 2 Power Pack Charging 52 8 3 Power Pack settings 54 9 Troubleshooting 56 9 1 Error Codes 57 9 2 Motor Wheel isn t spinning freely 58 9 3 Pedal Sensor Ma...

Page 3: ...ed periods left on charge can lead to reduced life of the battery Hear the Click when attaching the Power Pack to the Handlebar Mount Make sure that the Power Pack clicks into place when attaching onto the handlebar mount If you don t hear the click give it a firm push the Power Pack must be fully pressed down on the mount to ensure correct operation Tighten up before riding Whether it s your firs...

Page 4: ... on and follow the video to get up and running 1 2 3 4 Fit the Motor Wheel Motor cable on the left of the bike Re adjust the brakes if necessary Tighten wheel nuts Fit the Pedal Sensor Magnet disk on left of the bike Mount sensor close to the magnets Smooth side facing the sensor Fit the Handlebar Mount Tilt Mount 45 upwards when fitting the strap so it is in tension when horizontal Connect and Go...

Page 5: ...8 9 Allen Key Set Tyre Levers Bicycle Pump Elbow Grease Adjustable Spanner Scissors Tools Required 3 ...

Page 6: ...s there before you start Once you ve unpacked and started fitting it s easy for things to go missing Please keep the original packaging until you ve fitted the kit Every kit should have the following parts What s in the Box 4 ...

Page 7: ...ck ECO PRO 2A Standard Charger UK EU US Cable Ties x10 Universal Pedal Sensor Brompton Pedal Sensor 3A High Power Charger Optional add on Brompton Extension Peg 16 Brompton Kits Only Brompton Block Optional add on T shirt Optional add on In line Brake Sensors Hydraulic Brake Sensors Optional add on Thumb or Twist Throttle Optional add on Torque Arm Optional add on ...

Page 8: ...sure to face it the correct way Pump the tyre to the manufacturer s suggested pressure Fit disc brake disc optional If you have disc brakes move the disc from your old wheel to your new Swytch motor wheel 1 2 Note Screws should have an 8mm thread length If they are longer they may cause the motor to stop spinning If they are shorter you may strip the thread of the motor wheel Installation 5 ...

Page 9: ...e flat sides of the axle should fit within the forks If it does not fit please check the troubleshooting section 3 4 Motor cable on this side Slot size 10mm Fit the torque washer lips into the fork slot Assemble the motor wheel to the forks with the torque washers installed as shown The torque washer protrusion should fit snugly inside the gap in the fork Tighten the Wheel Nut Assemble both axle n...

Page 10: ...Universal Regular 22 Indented Universal Indented 22 Check motor spins correctly Spin the motor wheel with your hand to check it can spin freely and isn t touching the forks If it is touching please check the troubleshooting section The wheel should be harder to turn backwards than turning forwards If it is the opposite then the motor has been installed backwards Adjust brakes If necessary adjust t...

Page 11: ...the magnet disk must be facing the sensor Fit Retention Ring Fit the retention ring around the magnet disk to secure it in place It s easiest to start on one side and work the ring around until you get to the other end Check Correctly Installed Below is how the magnet disk should look once properly fitted Troubleshooting If the magnet disk doesn t fit check the troubleshooting section 1 2 3 ...

Page 12: ... to fit securely to the surface Loosely cable tie the magnet disk arm to the inside of your pedal arm in at least 2 points Reposition the magnet disk so that it is close to the sensor and aligned Check that the alignment is correct by rotating the pedal arm backwards and watching for any movement After this check tighten the cable ties completely 1 Once aligned in position tighten the screws to lo...

Page 13: ... spins the magnets need to pass close to the sensor for it to detect your pedalling Check correct installation The photo below shows a correctly fitted pedal sensor Adjust the pedal sensor to minimise the gap between the sensor and the magnet Tighten the screw to prevent it from moving Cable tie in place Once fitted correctly use the cable ties provided to secure the pedal sensor to the frame Rout...

Page 14: ...he Quick Connect Handlebar Mount over the spacers onto the handlebar Tilt the mount up approximately 45 this is necessary to ensure correct final installation 2 1 Fit the Anti Twist Strap Pass the Anti Twist Strap underneath the handlebar stem Tighten strap in place Secure the strap on to the other arm of the mount Use the closest holes possible with the mount tilted upwards Fold the strap back on...

Page 15: ... 5 6 Connect motor Connect the motor to the Quick Connect Handlebar Mount Secure the motor wire to the fork with the cable ties provided Leave enough slack for the handlebars to turn If the motor cable is not long enough you may need an extension cable Ensure the motor is fully connected hear the click To connect the waterproof connector align the arrows and push together until the arrow on the mo...

Page 16: ...the Brompton Torque Washer first make sure to thread the motor cable through the keyhole in the washer Remove any of the existing wheel hardware If you have a mudguard assemble it underneath the locking nut 1 2 3 Be careful not to damage the motor cable when tightening the nut ...

Page 17: ...t Thin Easy Fit Regular 20 Brompton pre 2013 PAS BRO A 32 Less than 2mm Brompton post 2013 PAS BRO B 32 Non Brompton aftermarket UNIVERSAL 22 Assemble these parts onto the pedal arm This is how it should look when finished When installing the sensor an alternative mounting location is directly on the bottom bracket block Use cable ties as shown to secure it into place Route the cable around the se...

Page 18: ...ll the pedal sensor onto the lower part of the frame Remove the hinge mechanism so that it can fit under the pedal sensor 6 3 Brompton Peg Follow the installation instructions for the standard kits Remove the existing peg from the Brompton frame and attach the extended peg that is provided in the kit Screw the peg on by hand until it turns no further 2 2 BROMPTON INCORRECT MOUNTING METHOD 1 Mounte...

Page 19: ...10 M5x12 Cap Screws x2 M5 Locking Washers x2 M5 Large Washers x2 Brompton Carrier Adaptor x1 Pedal Sensor Extension Cable x1 Fasten the mount to the front carrier mount attachment at the front of the Brompton using the screws provided Be sure to assemble the screws in the order shown below Attach the Handlebar Bracket to the adapter Don t use the spacers or the twist strap 1 2 Assemble in this ord...

Page 20: ...oop back the same length as the length of the Brompton Block Adapter 3 4 Use 2 extension cables to reach handlebar addons e g Throttle and Brake Sensors Tie the cables to the existing Brompton cables to allow the bike to fold Use 1 extension cable to reach the PAS Thread the motor cable through the hole in the Brompton Block Adapter to hide the excess cable You might find this step easier with the...

Page 21: ...pton and check that the new cables do not interfere with the fold 6 5 General Tips Check your brake pads are not touching your tyre Adjust them to be lower and straight if necessary Make sure your motor wheel is assembled fully into the forks Replacing your brake pads can help with clearing the tyre Follow the existing cable routing of your bike to enable it to fold like normal Tie the PAS cable a...

Page 22: ...ng the brake sensors requires the brake cable to be removed and replaced If this is not done properly then the brakes may not function correctly which can cause a serious accident If you are not confident with working on your bike s brakes then we recommend taking the bike to your local bike shop or bike mechanic for help fitting the sensors If you re going to attempt to fit the brake sensors with...

Page 23: ...d to fit the rear brake use your rear brake cable to replace your front brake cable 2 1 Brake sensor goes in line with the brake cable which is fed through it Cable guide keeps it in line Connect the brake sensor to the Quick Connect Mount Repeat for the other brake Test by turning on the Power Pack and holding the button to activate the walk mode and check the brake sensor stops the motor turning...

Page 24: ...se when the brake lever is not used far when brake is engaged Test by turning on the Power Pack and holding the button to activate the walk mode and check the brake sensor stops the motor turning 1 2 Brake Sensor Magnet 7 4 Universal Torque Arm Fit the Universal Torque Arm Use the side opposite to the motor wire Use the C Washer or screw washers if necessary to help with the fit Tighten all screws...

Page 25: ...axle 2 1 7 6 Twist Throttle Fit the Twist Throttle to the handlebars Should be on the right hand side Cut hand grips shorter to accommodate the size of the throttle Ensure that the brake and gear shifters operate normally before riding 7 7 Thumb Throttle Fit the Thumb Throttle to the handlebars Should be on the right hand side Cut hand grips shorter to accommodate the size of the throttle Ensure t...

Page 26: ...nect Handlebar Mount and slide downwards pressing firmly until you hear a click Detachment To disconnect press the button on the Handlebar Mount and pull the Power Pack up with the handle If it is difficult to disconnect instead of pulling directly up wiggle the Power Pack side to side With the ECO and PRO Power Pack you can do this with one hand ...

Page 27: ...bol at the back of the Power Pack Alternatively use the back of the blade cleaning tool to flick the switch 2 1 To charge the Power Pack use the charge port in the rear of the pack 3 Battery level Press hold to turn on front light Press hold to turn on powerpack Press hold for walk mode Charge port battery on off switch is under the charge cover Power level Light Fixture ...

Page 28: ...what value that setting is being set to The flashing batterylight indicates what setting is being adjusted 1 2 3 4 8 3 Power Pack settings This is how to access and adjust the settings in the Power Pack For a video visit www swytchbike com instructions These are the different values available for each setting Please note the default setting is 15mph which is the legal limit for e bikes in the UK EU...

Page 29: ...mality Contact Customer Service 24 Flash at PAS Level 5 Motor Hall Signal Abnormality Fit the Hall Sensor Bypass Cable disconnect the hall sensor cable 25 Flash at PAS Level 3 5 Brake Abnormality Commonly happens when the brakes are engaged before the Power Pack is turned on Turn off the brake sensors before turning on the Power Pack Brake sensor light will indicate when it is on Alternatively tur...

Page 30: ...lternatively move the torque washer to the inside of the forks and use in place of a new washer 2 1 3 9 3 Pedal Sensor Magnet doesn t fit my bike If there isn t enough space remove the plastic hinge part and mount the pedal sensor directly to the frame using the cable ties provided The Pedal Sensor works with most bicycle types The easiest installation is to fit the magnet disk to the axle This re...

Page 31: ...eck that they have not moved to the side This can happen with the curved Brompton handlebars 9 6 Handlebar Mount pointing down If the handlebar mount appears loose or sags Adjust the twist strap to a higher closer hole Make sure to tilt the mount upwards 45 before tightening 9 7 Power Pack is difficult to remove from bike At the beginning of use there is a break in period where the Power Pack will...

Page 32: ...tions but not when you are riding sit on the bike and test all again for loading Front light isn t turning on Check the connector to the front light and controller This is a link to the troubleshooting video that summarises the steps https youtu be yTborNfH1wo 2 1 3 4 5 6 9 9 Motor Starts and Stops when using Pedal Assist To ensure the kit fulfils its complete working lifetime you can keep it in g...

Page 33: ...harge if storing over winter Check motor wheel nuts are tight Check pedal sensor is aligned Adjust brakes Lubricate Chain Check Tyre Wear 6 months 100 hours 3000 miles Check motor wheel spoke tension Check motor and sensor connectors Check throttle and PAS function normally Deep clean drive parts Check your rims are true without wobble 12 months 200 hours 6000 miles Check Motor wheel turns smoothl...

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