Use the round top screws to attach the battery bracket to the frame. Do not use the countersunk screws without supporting the bracket from below. Support from below will prevent the bracket from flexing as you tighten the counter sunk screws. Keep in mind the best practice is to use the round top screws when possible.
Note: The following cable routing guide applies to standard bicycles only. It will not be an exact guide for recumbent or other specialized bikes. If your bike is not exactly standard, read it anyway so you get a general idea.
There are two wires coming from the back of the bracket: the thin one that goes to the console, and the thick one (a bundle of two) that goes to the motor. Run all wires from the back of the battery bracket along the frame toward the motor. Bring them around the right side of the seat tube, and then through the gap just behind the cluster of tubes that holds the pedals (bottom bracket). Make sure the no wires come close to touching the gears or the tire because that could damage them.
To put the battery onto the bracket, set it on top of the bracket, with the back of the battery about 1 inch from the plug on the bracket. Line up the battery parallel with the bracket so that the rail of the bracket sits into the slot on the battery. Slide the battery onto the bracket so that the plastic plug at the base sits into the back of the battery.
To lock the battery in place first press down on the lever on the front of the battery. When the lever is flush with the battery case, press the round lock button into the battery. When it clicks you've locked the battery in place.
To unlock the battery and remove it, press down on the lever on the front of the battery. This releases pressure from the lock. Then insert your key and turn it. The lock will pop out. Now you can open the lever and slide the battery off.
Remove your regular bicycle wheel and take off the tire and tube. You can most likely reuse these, unless the tube is flat or the tire too thin for the BionX wheel.
Remove the BionX wheel from its packaging and install your tube and tire. If using a disc brake, install the disc rotor using the screws provided with your BionX kit. Screw the freewheel onto the motor.
Note: Be careful not to force the freewheel on!! It should screw on smoothly and easily. If you are forcing it, back out and try again.
Slide the axle of your BionX wheel into the drop outs of the frame (the space where the axle slides into). Make sure that the key'd washer on the left side of the wheel is facing the open end of the drop out.
There is a slot in the tip of the axle on the left side. This slot must be pointing straight down (to 6:00) before tightening the axle nut. To rotate the slot to the 6:00 position you can use a large, flat-head, screw driver.
Once you have that slot facing downwards, tighten the axle nuts. BionX recommends a tightness of 30 ft/lbs. This means that on a one foot long wrench you should push down with a force of 30 lbs. Most people don't have the kind of wrench that can measure values like this, so just make it good and tight without going so hard that you're killing yourself. The key is to keep the axle from rotating in the frame while not being so tight that you strip the threads or break the axle.
Take the bundle of 2 wires from the motor and connect them to the bundle of 2 wires coming from the battery. Start by plugging the larger flat connector together and then the smaller round one. When connecting the smaller round one, be sure to line up the little white arrow on one plug with the little white dot on the other plug.
Now that they are connected, wrap these bundled wires against the frame using the shorter piece of velcro/neoprene included with your kit. Do not use a zip tie to secure the wires coming directly from the motor. You may need to unplug and remove these if you have to change a flat tire. The velcro/neoprene should do the trick just fine.
Spin the rear wheel and make sure the wires do not come too close to the rear wheel or the rear brakes. Any contact of the wires with the wheel or a disc brake could damage them beyond repair.
Note: It is always best to have the wires tight against the frame. This makes it look neater and prevents them from being caught or pulled while pedaling.
Follow the appropriate instructions depending on whether you have a G1 or G2 console. Not sure which you have? Check here.
Note: This is one of the only tricky parts of the installation which requires a bit of adjustment to work perfectly. Be patient, a good adjustment here will save you time/headache later.
There is a short length of wire with a plug at one end and a black cylinder on the other end. Sometimes a piece of foam will be covering the cylinder at the end or sometimes the foam will be separate. This is the magnetic brake sensor which detects when the brake are applied.
The sensor wire should be installed on the underside of your brake lever (the part that doesn't move when you pull the brakes and clamps onto the handlebar). The magnet should be installed on the actual brake lever, 2mm from the fat end of the wire. It is critical that, when installed, the magnet pivots away from the sensor when the brakes are applied.
Once you've got these items set in place generally with tape, turn your BionX on by pressing the power button (for G1 consoles) or either of the left/right top buttons (for G2 consoles).
Resist the urge to ride your now electrified bike! It will be super fun but first you should follow our BionX Brake Sensor Adjustment instructions. After you've made a good adjustment and things are working properly you can go for your first ride!
You should now be ready to take your BionX out for a spin! Congratulations, you did a great job. One of the best things about installing the kit yourself is you now know how everything connects and how everything fits together to produce the incredible sensation of riding your BionX bike!
If your BionX is not performing as you think it should you may have made some small mistake in the installation. 99% of issues people report with their BionX can be traced back to connection issues or installation problems. These issues are easily fixed by following our BionX troubleshooting resource. Start with the basic issues and go deeper if needed. Be patient, the feeling of the wind in your face as your BionX cruises you down the road is worth it!
Thank you for following our installation instructions. Please contact us if you feel they could be made more clear or concise!