Pre-Conversion Planning

Confirm Compatibility

Before starting, double-check these measurements:

• Frame type: Ensure adequate clearance for motor and battery
• Wheel size: Verify kit matches your wheel diameter
• Dropout width: Measure rear axle spacing (usually 135mm or 142mm)
• Bottom bracket: For mid-drive motors (typically BSA 68mm threading)
• Brake style: Rim brakes, mechanical disc, or hydraulic disc

Gather Required Tools

• Allen key set (2mm-8mm)
• Torque wrench (recommended for proper tightening)
• Cable ties and electrical tape
• Wire strippers (for custom connections)
• Crank puller (for mid-drive installations)
• Basic bike maintenance tools

Step-by-Step Conversion

Step 1: Prepare Your Bike

1. Clean thoroughly - Remove dirt and grease from areas where components will mount
2. Inspect frame - Check for cracks, damage, or excessive wear
3. Remove existing parts - Take off the wheel (hub motor) or crankset (mid-drive)
4. Document setup - Take photos of cable routing and component positions

Step 2: Install the Motor

For Hub Motors:

1. Remove existing wheel - Release brakes and shift to smallest cog
2. Transfer components - Move tire, tube, cassette/freewheel to motor wheel
3. Install motor wheel - Ensure proper chain alignment and secure axle
4. Adjust brakes - Realign brake pads for new wheel position

For Mid-Drive Motors:

1. Remove crankset - Use crank puller to remove pedal arms
2. Prepare bottom bracket - Clean threads and apply grease if needed
3. Mount motor unit - Thread motor into bottom bracket with proper torque
4. Install new crankset - Use motor manufacturer's crankarms

Step 3: Mount the Battery

1. Choose location - Down tube, rear rack, or frame triangle mounting
2. Install mounting hardware - Use provided brackets and secure firmly
3. Test fit - Ensure battery locks securely and releases smoothly
4. Check clearance - Verify no interference with pedaling or steering

Step 4: Install Controls and Sensors

1. Mount display - Position for easy viewing while riding
2. Install throttle (if applicable) - Right side grip or thumb position
3. Add sensors - PAS sensor on crank or torque sensor per instructions
4. Route cables neatly - Avoid cable rub and stress points

Step 5: Connect Wiring

1. Follow wiring diagram - Match connector colors and types carefully
2. Secure connections - Ensure all plugs click firmly into place
3. Protect cables - Use protective tubing in high-wear areas
4. Test connections - Gently tug each connection to verify security

Step 6: Install Brake Sensors (If Equipped)

1. Mount brake levers - Position sensors to cut motor when brakes applied
2. Adjust sensitivity - Test that light pressure stops motor assistance
3. Verify operation - Motor should stop immediately when braking

Step 7: Initial Testing

1. Charge battery fully - Ensure proper voltage before first test
2. Power on system - Check display functions and shows correct information
3. Test throttle (if equipped) - Should provide smooth power delivery
4. Check pedal assist - Motor should engage when pedaling begins

Post-Conversion Setup

Fine-Tuning

1. Adjust brake pads - Account for any wheel position changes
2. Tune derailleur - Ensure smooth shifting with added motor weight
3. Set assistance levels - Configure power settings through display menu
4. Calibrate speedometer - Enter correct wheel circumference

Safety Verification

1. Test e-brake cutoffs - Motor must stop when brakes are applied
2. Verify speed limits - Ensure assistance stops at legal speed for your class
3. Check all bolts - Torque to manufacturer specifications
4. Inspect cable routing - No sharp bends or potential rub points

First Test Ride

Pre-Ride Checklist

• Battery charged and securely mounted
• All connections verified
• Brakes functioning properly
• Tires properly inflated
• No loose cables or components

Initial Ride Protocol

1. Start slowly - Begin in lowest assistance mode
2. Test in safe area - Empty parking lot or quiet street
3. Check motor engagement - Should be smooth and predictable
4. Test braking - Verify e-brake cutoffs work immediately
5. Monitor for issues - Listen for unusual noises or vibrations

After First Ride

1. Retighten bolts - Check all connections after initial use
2. Inspect for wear - Look for cable rub or component movement
3. Note any issues - Address problems before longer rides

Break-In Period

First 100 Miles

• Check bolts and connections after every few rides
• Monitor battery performance and charging behavior
• Watch for cable wear or component loosening
• Fine-tune assistance levels and settings

Ongoing Maintenance Schedule

• Weekly: Clean and inspect key components
• Monthly: Detailed bolt and connection check
• Seasonally: Complete system inspection and battery care

Safety Reminders

• Always wear a helmet - Essential for any bike, especially e-bikes
• Follow traffic laws - E-bikes must obey same rules as regular bicycles
• Start conservatively - Learn your e-bike's behavior before aggressive riding
• Respect others - Be courteous to pedestrians and other cyclists

Try This

Perform a short 5-10 minute test ride to ensure everything works properly before planning longer trips. Pay special attention to cable routing - make sure nothing rubs or catches during normal steering and pedaling.