Installation Guide Currie Electro-Drive Conversion Kits 2, 3, & 4 1
Before you start... Use this information to determine whether one of our kits will fit your bike Drawing Ref. Fork Area Leg clearance (inside to inside) Dimension Kit 2 Dimension Kit 3 Please evaluate based on drawings below (circles indicate common areas with clearance issues) Dimension Kit 4 1 Dropout surface area (minimum) 100 Diameter of axle nut. Make sure 41the nut 38will clear 16mm 25mm 16mm any dropout safety tabs. 2 Fork spacing 100mm Wheel size 26 or 700c (depending on kit version) Brake compatibility Disc or rim Rim only Disc or rim 3 Dropout thickness (minimum) Clearance for anti-torque hardware Rack Rack eyelets (rear dropout) Seatstay type 180 163.5 Misc Motor wire length When installed, runs from halfway 35.5up the front fork leg, along a frame tube, to about 60 5 inches behind the saddle. 73 Throttle wire length Hub centerline 156 98 56 5mm Must be present May not fit wishbone stays (Bikes with wishbone stays must have seatstay rack eyelets) ~160cm ~150cm Kit 2 & 4 Kit 3 82 163.5 100 41 38 48 Hub centerline 40 36 180 Hub centerline 156 98 56 45.5 36.5 2 2 3 1 101 142 Use these measurements to make sure the hub motor will be able to fit in your bicycle s fork. 35.5 60 73 Kit instruction guide 2012 proper.indd Last modified July 13, 2012 2:50 PM
This guide covers the installation of Currie power kits 2, 3, and 4 Kit 2 250w hub motor Li-Ion 24V Kit 3 500w hub motor Li-Ion 36V Kit 4 250w hub motor SLA 24V Contents Before you start... (Kit fitment) 2 Tools, safety, & terminology............... 3 Wheel prep........................ 4 Wheel installation (Kits 2 & 4).............. 4 Wheel/torque arm installation (Kit 3)........... 5 Throttle Installation & cable routing........... 6 Rack installation (Kit 2).................. 7 Rack installation (Kit 3).................. 8 Rack installation (Kit 4).................. 9 Wiring diagram (Kits 2 & 3)............... 10 Wiring diagram (Kit 4).................. 11 Basic operation....................12-13 Troubleshooting.....................14 Required Tools (Not provided with kit) Allen wrenches 2.5mm, 3mm, 4mm, 5mm, 6mm Phillips-head screwdriver Wrenches 10mm, 17mm, 18mm Bicycle tire levers Bicycle tire pump Important safety information To install this kit properly, you ll need to understand how to work on bicycle wheels, brakes, and other components that affect the safety of the rider. If you are not comfortable installing this kit yourself, or you don t have the necessary skills and experience, we recommend having your local bike shop do the work for you. Because of the many differences between bicycle and fork models, this kit may not be suitable for all applications. It is the assembler s responsibility to judge whether the Electro-Drive kit can safely be installed on his or her bicycle. Suggestions made herein cannot account for all possible configurations. If you are unsure of fit, or have a question related to safety, function, or compatibility, please ask a mechanic at your local bike shop for assistance. There may be minor cosmetic differences between the parts included with your kit and the parts shown in photographs/ illustrations in this guide. Parts of a bicycle frame Eyelets Seatstay Fork Dropout (rear) Dropout (front/fork) Chainstay 3
Prepare the kit wheel for your bike. Remove the tire, tube, and rim strip from your bike s original front wheel, then install them onto the kit wheel. If you plan to use a disc brake (kits 2 and 4 only), you should also install the rotor now. Kit 4 Kits 2 & 3 Test-fit the new front wheel in your bicycle s fork. Pay special attention to areas that might cause rubbing or improper fit. Check the dropouts to make sure the hub motor s axle is fully seated; you may need to file away the paint from the inside surface of the dropout to get a perfect fit. When you re satisfied with the fit of the wheel in the fork, you can install the wheel: Wheel Installation: Kit 2 & 4 (250w hub motor): Seat the wheel in the fork dropouts, then tighten the nuts on each side securely. Make sure to follow the proper hardware order (same for left and right sides): Tighten axe nuts to 390 in-lb/44nm (Fork dropout) Axle nut Split washer Washer Hook washer (align to fork dropout) Thin washer (Axle) Axle hardware is the same on both sides 4! Please note that the 250w hub motor uses acorn type nuts, and you must be sure they tighten properly against the fork dropout without bottoming out (minimum fork dropout thickness is 5mm, when using the included washers). Cutaway view of acorn nut. A nut installed on too thin a dropout will bottom out before tightening securely.
Kit 3 (500w hub motor): Seat the wheel in the fork dropouts, tightening the right-side axle nut first. Add the torque arm (see instructions below), then tighten the left-side axle nut. Make sure the wheel sits evenly in the dropouts and is not tilted or shifted to one side. Make sure that both axle nuts are seated squarely against either a spacer washer, the torque arm, or the fork dropout surface. The entire face of each axle nut should be contacting one of those surfaces. You may need to add more spacer washers to safely install the wheel. Tighten axe nuts to 390 in-lb/44nm Fork dropout Axle nut Fork dropout Hook washer (align to fork dropout) Spacer washers (as needed) Axle (right) Axle nut Torque arm Spacer washers (as needed) Hook washer (align to fork dropout) Thin washer Axle (left) Wrap hose clamp in heat-shink tubing Torque arm assembly (Kit 3 only) Kit 3 s 500 watt motor can produce enough torque to potentially bend or break the fork it s mounted in, if the included torque arm is not installed. For this reason, it s very important that you follow these instructions to make sure the torque arm is secured completely! Please assemble the arm as shown in the diagram. You may need to slightly change the order of pieces to fit your specific fork. To avoid scratching your fork, put the included piece of heatshrink tubing around the hose clamp, then cut it to length and shrink it to fit. If your fork dropout surfaces are deeply inset (most aluminum suspension forks), you will need to use the included spacer washers (shown in diagram above) between the dropout and the torque arm to allow the torque arm to clear the fork leg. The portion of the torque arm that grabs the axle must sit flush and flat against either the dropout face itself or a spacer washer, and the axle nut must be tightened fully (390 in-lb/44 Nm) Must sit flush against dropout surface or spacer washer 5
Throttle Installation (all kits) Install the throttle on the handlebars in a position where it is easy to reach, and where it does not interfere with the brake or shift levers. The throttle should always be mounted to the inside of the brake as shown, so it does not move the brake lever into an unsafe position. Brake Throttle Shifter Grip Cable routing throttle and motor (all kits) Begin by attaching the female plug of the motor extension cable to your fork leg, using the rubber block and three cable ties as shown. Only the female plug is attached to the block; the male plug hangs freely below so the wheel can be easily removed without cutting any cable ties. String the motor extension cable up the leg of the fork, then along either the top tube or downtube of the bicycle, depending on what is most convenient. Be sure you leave enough slack to allow the handlebars to turn freely in both directions, and that the cable does not interfere with steering or braking. Route the throttle cable similarly, tying it to a brake or shifter housing, then following the same path as the motor extension cable. Both cables should end up near the seat of the bike, where they will be plugged into the controller later. After installing, check that the throttle and motor cables do not interfere with braking or shifting. Example path of throttle cable (red) and motor extension cable (green) 6
Installing the rack Please note that because bicycle designs vary widely, the rack may not fit all configurations without some modification. Kit 2 Bolt the rack to the bicycle frame. If your bicycle does not have eyelets provided on the seatstays for the rack s upper struts, you can use the included metal brackets instead. You can adjust the rack struts in several places (see pictures below). Once the rack is installed, adjust it until it is level with the ground, and as low as possible over the rear tire. Once the rack is attached, you ll need to connect the throttle and motor cables to the controller. Slide the bottom cover off of the rack s controller compartment, connect the cables, put any extra cable slack inside the compartment, then slide the bottom cover back on. See the wiring section of this guide for a full wiring diagram. Wiring fit into controller box Controller compartment bottom cover 7
Kit 3 Bolt the rack to the bicycle frame. If your bicycle does not have eyelets provided on the seatstays for the rack s upper struts, you can use the included metal brackets instead. You can adjust the rack struts in several places (see pictures). Once the rack is installed, adjust it until it is level with the ground, and as low as possible over the rear tire. Once the rack is attached, you ll need to connect the throttle and motor cables to the controller. Remove the two screws holding the bottom cover onto the rack s controller compartment (see photo below), connect the cables, put any extra cable slack inside the compartment, then screw the bottom cover back on. See the wiring section of this guide for a full wiring diagram. 8 Wiring fit into controller box Controller compartment bottom cover
Kit 4 Bolt the rack to the bicycle frame. If your bicycle does not have eyelets provided on the seatstays for the rack s upper struts, you can use the included metal brackets instead. You can adjust the rack struts in several places (see pictures). Once the rack is installed, adjust it until it is level with the ground, and as low as possible over the rear tire. Once the rack is attached, you ll need to connect the throttle and motor cables to the controller. Remove the four screws holding the top cover onto the rack s controller compartment (see photo below), connect the cables, put any extra cable slack inside the compartment, then screw the bottom cover back on. See the wiring section of this guide for a full wiring diagram. Controller compartment screws Controller compartment wiring 9
Wiring Diagram IZIP Kit 2 & 3 2012 Battery!! Be careful that you don t accidentally plug the throttle (5-pin connector) into the motor hall sensor (6-pin connector with 5 wires). This could permanently damage the controller! Always double check the labels near each connector before plugging them in. Check the polarity of the 4-prong battery connector before connecting the battery for the first time! Both the male connector on the rack and the female connector on the battery are labeled with + and - signs to indicate their polarity, and these must match to avoid damaging the controller. Hub motor + - Motor Extension Cable + - Throttle Controller Throttle signal and lights ON/OFF switch 10
2 3 1 Wiring Diagram IZIP Kit 4 2012! Be careful that you don t accidentally plug the throttle (5-pin connector) into the motor hall sensor (6-pin connector with 5 wires). This could permanently damage the controller! Always double check the labels near each connector before plugging them in. Left side + Right side + Wiring Harness, RMB Switch Harness Wiring Harness, RMB Terminal-to-Switch Motor Wire Extension Harness Switch, ON/ON ON 1a 1 Hub motor ON 1b Battery (SLA) BA-PK24-005 WIRE HARNESS, BATTERY CASE CHARGER PORT Controller ON/OFF switch Throttle With on/off switch FUSE BATTERY BATTERY Throttle signal and lights 11
Basic operation Install the battery into the rack Kit 2 Kit 3 Lock the battery into the rackv Kits 2, 3, 4 Before riding, you should lock the battery into the bike s rack. This prevents the battery from falling out of the bike as you ride, and helps maintain a steady electrical connection at the battery terminal. For kits 2 and 3, the lock is attached to the battery itself, near the rear reflector. For kit 4, the locks are bolted to the rack on both sides, near the top. Turn on the bicycle Kits 2 & 3 Use the ON/OFF switch on the throttle to power up the bike. The indicator lights on the throttle will illuminate and the bike will be ready to ride. Push the throttle paddle down with your thumb to start the motor. Kit 4 Find the battery selector switch at the back of the rack, behind the rear reflector. Toggle the switch to the left or right, depending on where your battery is installed. After selecting your battery location, you can use the ON/OFF switch on the throttle to power up the bike. The indicator lights on the throttle will illuminate and the bike will be ready to ride. Push the throttle paddle down with your thumb to start the motor. Kit 4 Kit 4 battery selector switch Throttle ON/OFF switch 12
Battery indicator lights Capacity Fully charged < 3/4 full < 1/2 full Empty, or very low Battery Voltage (± 10%) Kit 3 >39V 37.5V - 39V 35V - 37.5V <35V Kit 2 >26V 24.7V - 26V 23.7V - 24.7V <23.7V Kit 4 >24.8V 23.3-24.8V 22.6-23.3V <22.6V The four lights on the throttle indicate current battery voltage. Because of the way battery voltage rises and falls depending on the current load, it is best to take a battery reading after reaching cruising speed on level ground. Before your first ride... Familiarize yourself with the operation of your bicycle s electrical system (previous page). Be sure your tires are inflated to the pressure indicated on the sidewall. Double-check the tightness of any nuts or bolts affected by the installation of this kit. Check your brakes. Read the included battery care guide. Troubleshooting Are all your controller connections made correctly? Double-check based on the wiring diagrams provided in this guide. Check each plug for broken or pushed-out connector pins. Check the controller and component wiring for damage. If the motor won t run, but the lights on the throttle illuminate when the bike is switched on... Is the motor s quick-disconnect plug (attached to the leg of your bicycle s fork) connected fully? Try pushing the plug halves together forcefully, and massaging them together. If the lights on the throttle will not illuminate (the bike will not turn on)... Is the battery coming fully into contact with the input terminal? (Kit 4) Do you have the correct battery selected, using the switch on the back of the rack? See the Basic operation section of this manual for more info. (Kit 4) Is the rear selector switch reversed? Try flipping the rear selector switch to the opposite side. If the switch works in reverse, you ll need to reverse the two plugs labeled Wiring Harness, RMB Terminal-to-Switch in the wiring diagram on page 11. Please call the Currie Tech technical and customer service department at 1-800-377-4532 if you need additional assistace. 13