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500W E-BIKE CONVERSION KIT

Our kit comes with everything you need to convert a regular Diamond framed bike to electric power. We use a custom 3 phase brushless in-runner motor with built in sensored speed controller, designed to run on Lithium battery packs that measure 25-26v fully charged. The motor runs through a sealed planetary gearbox. The output shaft runs a standard pitch sprocket that matches most bike chains, and features a sprag clutch built in, this allows the motor to drive the bikes gear system without you pedalling, or sit idle with no load on the gear system while you pedal.

 

The combination of high torque 3 phase brushless motor, planetary reduction gearbox, and the direct drive through the bikes own gear system results in a bicycle that is very versatile and has very hi torque, able to climb steep hills through the low gears or cruise along  on the flats at a rapid pace with only light pedal input! Overall power is many times more than any hub motor setup can produce, and that power runs through your gears, unlike a hub motor that has a single geared speed.

 

 

CRANK SET

The supplied crank-set is the top model available and is a double chainwheel plus drive sprocket for the motor. The outer sprocket is spaced further than a regular crank set and runs the drive chain from the motor. The second and third sprockets are the main gear sprockets and carry your existing main chain to the back gear cluster. Our outer and inner sprockets are the more expensive heat treated alloy, saving almost 500g in weight over the regular cranksets.

 

So what you end up with is 2 main sprockets at the front much like your original gear system, your derailers will operate all the gears as normal once the front one has been adjusted to suit 2 sprockets, the only difference is the front gears will only change between 2 sprockets, small and large.

 

Note: Buying a kit with the basic single sprocket for the front really limits your power as you have no small 34T sprocket to drop down to when climbing steep hills. This is why we don’t bother to offer the cheap 2 chainwheel crank set.

 

 

We supply a special triple bearing sealed cartridge bottom bracket with an extended axle so that your left pedal clears the back of the motor housing. The bottom bracket is standard 68mm fitment but is 73mm long in order to accept the motor mounting plates. It will fit all older bikes with an English BB and many newer bikes that have an external bottom bracket that screws into the frame.

We also have custom bottom brackets with 170 and 190mm long axles that are suitable for most Downhill frames and even FatBike frames which have very wide 120mm BB’s!

 

The motor mount for the 500W kit is a new design that hangs off the bottom bracket and helps to reduce the issue of mount and frame flex from the high torque our motors produce. It also allows fitment to many suspension bikes and bikes with odd shaped frame tubes that would normally not accept the alloy clamp mount.

NOTE: We assemble all motor mounts before shipping, when you are ordering from us you will be asked questions about the width of your bikes BB frame tube, and for photos of your bike so we can make sure the motor assembly is a drop in fit. There are a couple of hours of work involved in setting up each kit but I feel this is necessary in order to offer the customer a tailor made conversion that requires minimal work to install.

 

 

THROTTLE CONTROL

The throttle is a twist grip much like a motorbike and comes with matching rubber grips for your handlebars. All the wiring is pre terminated and simply plugs together. There is a power switch on the throttle assembly so that you can switch the system off and a 3 stage LED light system to show the battery capacity.

 

Please note Shimano shifters have a lot of trouble fitting under the throttle body, we stock Sunrace M80 and M90 shifter sets which are 8 or 9spd rapid fire thumb/thumb, these just clear the throttle body and allow all the controls to remain within normal reach, they are regular shimano compatible road and MTB. In fact we have 6, 7, 8, and 9spd available. You can also use SRAM X series shifters as they are thumb/thumb trigger as well, but you will need to use the SRAM rear derailleur. 2mm trimmed from the top of the large lever is all that’s needed for a perfect setup!

 

 

We also supply a tough nylon bag that straps under your seat and can carry up to two battery packs. The photo below shows the complete setup fitted to one of our bikes. With two 25v 12Ah battery packs we can maintain 35-40kmh with light pedalling along level surfaces and get almost 2 hours of constant running from the system (dependant on terrain and headwind).

 

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Our bikes will climb fairly steep trails on their own in low gear, or you can power up a trail by pedalling and running at full electric power, once you have experienced a quality Electric Assist setup like this you will never go back to riding on or off road without it! Our system will peak at 1 horsepower, around 750 input watts, we have measured this in real time with our E-meter equipment, unlike other sellers we deal in electronics daily and have an extensive workshop for testing and fabrication.

 

BATTERY REQUIRED

One EXTREME POWER 22.2v 12Ah or 16Ah Lithium Polymer battery pack is required. (22.2v is nominal rating used by most factories, fully charged is 25v). We recommend that you use two batteries if running 12Ah or less due to the higher load this power system presents when running at full power, ride time is short otherwise. By running two of our batteries you get double the run time and besides, our battery bags are designed to take 2 packs anyway!

 

INSTALLATION

Our Motor kit is easily mounted on most diamond frame bikes with the supplied mounting bracket set & hardware. The kit is supplied with all parts listed above, we are happy to help via email with any installation issues. We fit plugs for the battery connections and test the complete set on the bench before shipping.

 

You will need some simple bike tools, a crank puller, a chain press, and a bottom bracket spanner. We will be stocking these tools in the near future, all are available at your local bike shop.

 

WHAT YOU GET IN THIS KIT:

• 500 Watt (nominal rating) 3 Phase BRUSHLESS inrunner Motor with inbuilt sensored speed controller.

• Sealed Planetary Gearbox & 14T Freewheel sprag clutch sprocket (factory assembled and tested).

• NEW BB Mounting Plate system with spring loaded chain tensioner pulley, spacers & bolts.
• 44/44/34T Alloy Chain-wheel Crankset with built in Freewheel sprag clutch.
• Sealed bearing Bottom Bracket with extended LH Axle.
• 170mm Left & Right Crank Arms & bolts.

• Drive chain for connecting motor drive to cranks.
• Twist Grip Throttle with wiring loom.
• 2x Handlebar Grips.
• Battery connecting harness with heavy duty T plugs pre-fitted.

NOTE: You will need a rack or bag to hold your battery pack.

 

 

PRICE FOR KIT:     AUD$790.00 inc GST

 

 

TERMS & CONDITIONS:

Riding an Electric bicycle can be a dangerous activity, OZ-eBikes cannot be held responsible for accidents or injury caused by your use of these products. It is your responsibility to ride in a safe manner using appropriate safety gear and to follow your states road laws for bicycles. Our warranty responsibility is limited to the products supplied only, and warranty is provided for the supplied products only if they are used as intended. Any modifications of the equipment, use of incorrect batteries or chargers etc will void the warranty. By purchasing any kit or parts from us you agree to all our terms and conditions. For the full terms and conditions please go to our TERMS & CONDITIONS page.

 

YOUR LEGAL RESPONSIBILITY:

This 500 watt kit is sold for offroad use only, as it is above the 250w legal power limit it can not be ridden on public roads. Ride at your own risk, please read our terms and conditions and follow your local state and country laws regarding electric bicycle use.

 

 
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