EV Depot Crystalyte Assembly Manual

Electric bicycle hub motor conversion

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Overview......................................................................................................................... 2
Your safety.................................................................................................................. 2
Required tools ................................................................................................................. 2
Unpack ............................................................................................................................ 2
Kit Contents .................................................................................................................... 3
Install the Tire ................................................................................................................. 3
About tires................................................................................................................... 3
Install the Electric Wheel................................................................................................ 3
About Fork Width ....................................................................................................... 4
About Dropout Diameter ............................................................................................ 4
About Torque .............................................................................................................. 5
Phoenix Front Wheel Torque Arm ................................................................................. 5
Install the Rack ............................................................................................................... 5
Mount the Controller....................................................................................................... 6
Mount the Throttle .......................................................................................................... 6
Run the Wire ................................................................................................................... 7
Wire the Batteries ........................................................................................................... 8
About Batteries ........................................................................................................... 8
Connect the Battery Pack to the Controller .................................................................. 18
Enjoy your first E-Ride!................................................................................................ 18
Disclaimers ................................................................................................................... 19
Warranty ....................................................................................................................... 19
Upgrades, Parts, and Accessories ................................................................................. 20
Crystalyte Hub Motor Kit Home Assembly Guide
 2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company
Electric Bicycle
Hub Motor Conversion
Home Assembly Guide
1 of 20

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Summary of Contents for EV Depot Crystalyte

  • Page 1: Table Of Contents

    Electric Bicycle Hub Motor Conversion Home Assembly Guide  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company Overview......................... 2 Your safety........................2 Required tools ......................... 2 Unpack ..........................2 Kit Contents ........................3 Install the Tire ......................... 3 About tires........................
  • Page 2: 2006 Ev Depot, A Priority Fulfillment And Distribution, Llc Company

    Those items should have their own documentation. This guide covers installation and assembly of the equipment supplied by EV Depot with your hub motor system. Your safety If you are not confident of your ability to assemble a safe, properly adjusted bike, please take it to a bike shop now along with these instructions.
  • Page 3: Kit Contents

    Some brakes require that you loosen the cable. Others have a quick-release for the cable. Crystalyte Hub Motor Kit Home Assembly Guide 3 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 4: About Fork Width

    Please tighten the bolts! Crystalyte Hub Motor Kit Home Assembly Guide 4 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 5: About Torque

    For the rack you will need a Phillips-head screwdriver and an 11/32” or crescent wrench. Crystalyte Hub Motor Kit Home Assembly Guide 5 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 6: Mount The Controller

    There is a way on every bike; some just take a bit more creativity than others. Crystalyte Hub Motor Kit Home Assembly Guide 6 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 7: Run The Wire

    Connect the throttle wire to the controller. There is only one plug on the controller that fits the throttle connector. All of our throttles fit all of our controllers. Crystalyte Hub Motor Kit Home Assembly Guide 7 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 8: Wire The Batteries

    There are two types of battery packs supplied with EV Depot hub systems: 36- volt (3 batteries) and 48-volt (4 batteries). Please see the detailed instructions for how to wire your batteries.
  • Page 9 If you have a Soneil charger, the fuse will blow, but the charger will survive. Set your batteries on a non-metallic workbench as shown. Crystalyte Hub Motor Kit Home Assembly Guide 9 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 10 There are also two long wires and a fuse holder with wires. Using scissors or wire cutters, cut the shrink tubing into 8 pieces. Crystalyte Hub Motor Kit Home Assembly Guide 10 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 11 Push one piece of heat shrink tubing up the wire a few inches – far enough to prevent being heated. Crystalyte Hub Motor Kit Home Assembly Guide 11 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 12 As soon as the solder begins to flow on the terminal, remove the iron. Too much heat on a terminal will destroy your batteries! Crystalyte Hub Motor Kit Home Assembly Guide 12 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 13 1 to 8, 2 to negative (black) side of key switch harness, 3 to positive (red) side of key switch harness, 4 to 5, 6 to 7 Crystalyte Hub Motor Kit Home Assembly Guide 13 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 14 – not heat! It doesn’t take much to shrink the tubing. A match or lighter will work very well. This is what solder joints should look like when complete. Crystalyte Hub Motor Kit Home Assembly Guide 14 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 15 For each pair, turn one battery so the leads are opposite the other, then set them top-to-top on each other. Crystalyte Hub Motor Kit Home Assembly Guide 15 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 16 Close the zippers with the cross-connect wires that run to the opposite side pannier to the front of the bag. Crystalyte Hub Motor Kit Home Assembly Guide 16 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 17 Left side. Right side. Crystalyte Hub Motor Kit Home Assembly Guide 17 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 18: Connect The Battery Pack To The Controller

    “pop” and maybe see a spark. This is normal behavior. It will not hurt you or the system. Enjoy your first E-Ride! Crystalyte Hub Motor Kit Home Assembly Guide 18 of 20  2006 EV Depot, a Priority Fulfillment and Distribution, LLC Company...
  • Page 19: Disclaimers

    Here's how it works: Contact your dealer. He will listen to the symptoms you describe and contact EV Depot for a replacement part. If your dealer cannot be reached, call EV Depot at 785-749-0949. EV Depot’s policy is to give you a choice of: •...
  • Page 20: Upgrades, Parts, And Accessories

    From faster chargers to batteries to beefed-up motors, they will try to satisfy your electric transportation needs. Crystalyte Phoenix, RoadRunner, and Sparrow are distributed in the US by EV Depot and are sold at EV specialty stores, bike shops, and a several online stores.

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