NOTE: These instructions, while similar to the instructions supplied by BionX , recommend construction in a different order.
Remove the wheel from packaging and install the tire. Screw the freewheel, counterclockwise, onto the threads.
Holding the wires tight, make sure the slot is vertical and slide the blocker unto the shaft.
The key must be in the groove of the dropout and the slot must be pointing straight down. In bicycles with vertical dropouts, the key and slot should be parallel, both pointing straight down. The wheel installation is the most difficult part of the installation. If you are unsure, it may be a good idea to bring the wheel, the bicycle, and the installation manual to a bike shop where they can install the wheel for you. If the dropouts of your bicycle are not vertical, you will need a special tool called a puller, to adjust the key and slot for your bicycle. The puller is available from NYCE Wheels, contact us for pricing and availability.
Install the wheel on the bicycle, making sure that the key is between the dropouts and adjust so that the slot is facing downward.
Place the bicycle on the ground and then tighten the bolts securing the wheel.
Take the wires from the motor and position them along the part of the frame leading from the rear wheel hub to the bottom bracket (part of frame where pedal cranks attach.) Secure the wires using the shorter piece of included velcro. Spin the rear wheel and make sure the wires do not conflict with the rear wheel or the rear brakes.
Use the M5x16 screws to attach the battery support bracket to the frame. One some kits there are eight holes. The extra holes have been added to aid the installation of the system on smaller framed bicycle. The original holes should be used whenever possible as they provide better support.
Using the two supplied screws, fasten the screws into the threaded holes in the frame.
Insert the three wires from the battery support through the frame behind the pedal.
Out of the three wires, take the longest (console wire) and thread the wire up the bottom of the lower frame piece and secure it to the handlebars with a piece of tape. Then position the two small pieces of grooved plastic (two sided tape on the bottom and groove for wire on the top) on the bottom of the frame without removing the tape. Move around the wire and the two plastic wire holders so that they are positioned where they adequately support the wire along the length of the frame.
After pealing the two sided tape and installing on the bike, push the wires into the grooves and tighten the zip ties around the wires.
The next step is to mount the console. In the kit there is a round plastic holder and a curved piece of rubber tape on the inside. Remove the piece of rubber and unscrew the screw.
Then remove the screw and nut, place them carefully on the side and make sure not to misplace them.
Then gently open the holder, at the point where it is cut, and place it around the handlebar. Make sure in doing so that the small tab on the flat piece of the holder is pointing towards the back of the bike.
Then attach the console to the holder by sliding the console down the groove from the top to the back of the bike. Then move the console around until it is positioned on the handlebars so that you can easily see the screen and reach the throttle. Remove the console without disturbing the position of the holder and put a piece of tape on the side of the holder to mark the place.
Remove the holder and then remove the tape on the piece of rubber and reinsert the rubber in the holder. Make sure the sticky side is inward. Then using the tape as a marker, reinstall the holder and rubber. Do not worry about the inclination angle (tilt) this can be adjusted afterwards. Then insert the nut into the whole facing upward and turn the screw from below, tightening the holder onto the handlebars.
Install the console. In the kit there is a length of wire with a foam covering on one end. This is the magnetic brake sensor which monitors when the brakes are applied. The sensor should be installed on the underside of the handlebars, on the brake handle support which does not move when the brakes are applied. The magnet should be installed 2mm from the end of the wire on the actual brake handle in a position which pivots away from the sensor when the brakes are applied.
This is one of the only tricky parts of the installation which requires a good deal of adjustment to work perfectly. Secure the magnet and foam in place with a piece of scotch tape, DO NOT UNPEAL THE DOUBLE SIDED TAPE yet. You can wait until the bike is fully operational and tested before permanently attaching the brake sensor and magnet. The picture below is a sensor on a bike with hydraulic brakes. The brakes work the opposite of regular brakes, pushing fluid, instead of pulling wire. So the sensor was mounted differently; however, the sensor is still 2mm from the magnet. The sensor wire can be adjusted by sliding through the foam after it has been attached.
Attach all the wire connections. The brake sensor wire attaches directly to one of the wires from the console by simply inserting. The wires from the console to the battery must have the white arrow lined up with the white mark on the other connector. Gently pull back on the housing of the connector with the white arrow, and insert the plugs and then release the housing you had pulled back. Repeat this connection on the wire from the motor to the batter. The power wires from the battery to the motor are two pronged and they connect by simply pushing together.
At this point, make sure all the wires are out of the way of the wheels and other moving parts. Then install the battery by inserting the key, turning clockwise and pulling out. Then place the battery on the frame of the support, and slide it down until it clicks, the handle will pop out. Push the handle back in to lock the battery down and push the key inward to lock. Make sure the battery is securely connected. Then push the power button and wait for the bike to power up. Resist the temptation to ride the bike and instead check to see whether or not the brake sensor is working. When you apply the brakes, look to see if the G symbol appears on the lower left. If it does not, the sensor is too close to the magnet. If the G sign remains even when the brake is not applied, then the sensor is too far from the magnet. Spend some time adjusting the sensor and magnet until they G appears consistently when the brake is applied and disappears when the brake is not applied. When you have reached a good setup, remove the two sided tape and re-attach the magnet and sensor. Spin the wheels and shift the bicycle making sure that the wires do not obstruct normal bicycle operation. Now take the two long zip ties and attach the wire the frame directly after the bracket and before the motor connections. Take the two smaller zip ties and secure the wires to the handlebars. Make sure that there is no pressure on the wires when the bike turns from side to side and the wires are out of the way when picking up the bike.
Once the wires have been connected, follow the instructions in the link below for choosing mph or kmh and setting up your wheel size. Once you have done this, read your owners manual, and take your bike for a spin.
