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Hub Kit Fitting Guide
36V/HL
Important: For your own safety you must read this man-
ual before attempting to fit any part of the motor kit to
your bike. You must also ensure that you fit the kit in
strict accordance with the instructions in this manual.
Tel: 01702 435566 — E-mail: support@wooshbikes.co.uk
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Summary of Contents for Woosh Hub Kit
- Page 1 Hub Kit Fitting Guide 36V/HL Important: For your own safety you must read this man- ual before attempting to fit any part of the motor kit to your bike. You must also ensure that you fit the kit in strict accordance with the instructions in this manual.
- Page 2 You will of course need to pay for the technician to install your kit, these costs are not covered by Woosh Bikes. There are several different types of pedelec sensor, we would normally have determined which type is suitable for your bike before you finalised your order.
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Page 3: Thumb-Throttle
What’s in the Box Ensure that you have all the parts listed below before going any further, if there are any missing parts, contact us on 01702 435566. The motor kit comprises of a motor wheel with hub motor, a battery cradle with integral controller, a battery, a charger, modular one-cable system, pedal-assist disc and sensor, speed sensor (and magnet) ,a thumb throttle, brake levers and KingMeter J-LCD. - Page 4 Installation of the various Pedelec Sensor types There are three types of sensor kit that can be used, two that fit on the right side of the bike between the chain-ring and frame, and the other left-side sensor which slots into the end of the bottom bracket. The standard right-side pedelec kit consists of two parts, these are the sensor itself and the PAS disc.
- Page 5 Left-side pedelec sensor The left slide sensor slides over the spindle and into the toothed part of the bottom bracket. It is not com- patible with all bottom brackets however. Some that aren’t compatible include the bottom brackets with the plastic cups. Although they look very similar, the left-side PAS will not slot into these. It must be a bottom bracket with a metal cup—see pics below.
- Page 6 Left-side pedelec sensor cont. Slide the larger rubber washer over the spindle and then re-fit the crank.
- Page 7 Pedelec Sensor for Octalink type crank sets: The diameter of the Octalink axle is greater and so the regular pedelec disc cannot be used. We are how- ever able to provide a solution for this type of bottom bracket. We supply a modified pedelec disk which has a larger hole in the centre which can be used, it needs to be secured to the back of your smallest chain-ring in the case of double or triple rings.
- Page 8 Battery/Controller The HL battery cradle/controller included with this kit mounts on your down-tube, where your bottle holder fixings would normally be. If the bike does not have these fixings or they are not in a suitable posi- tion, you can fit riv-nuts (supplied) to allow you to mount the battery cradle. Ensure that you mount the cradle high enough up the down-tube that the cradle doesn’t foul on the chain-ring.
- Page 9 Motor Wheel Remove the existing rear wheel and swap the tyre, tube and freewheel/cassette to the new motor wheel. You must ensure that the motor cable where it exits the spindle, points downwards towards the ground, see below for photos showing how the wheel should be fitted and the correct orientation of the cable. Once the wheel is properly installed, slide the rubber covers in place and secure the motor cable to the frame using cable–ties.
- Page 10 Handlebar Components: The thumb-throttle, brake levers and display unit need to be mounted to the handlebars. The installation procedure for these parts may vary a little from bike to bike, but follow the guide below for a general overview. The display would normally be fitted to the left side of the handlebars just to the right of the grip, this way the buttons can be easily reached with a thumb .
- Page 11 Handlebar Components cont. You must ensure that there is enough play in the cables so that they do not get stretched or pulled when the handlebars are rotated. The throttle cable and LCD connectors are colour coded and should be mated with the matching colours on the modular cabling.
- Page 12 Fitting the Speed Sensor: The speed sensor consists of two parts, the sensor itself and a magnet that is attached to one of the spokes. The sensor is normally fitted at the rear. The speed sensor is mounted approximately half-way along the inside of the chain stay as shown in the diagram below (in Red).
- Page 13 Controller Connections: Exiting from the bottom of the battery base/cradle are four cables, these are for the speed sensor, the motor wheel, the pedelec sensor and the modular cable. The modular cable runs up to the handlebars and connects to the display unit, the thumb-throttle and the brake levers. All of the connectors have ar- rows on them that need to be correctly aligned before pushing the connectors firmly together.
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Page 14: Lcd Control Panel
LCD—Control Panel The display has many advanced features and modes, these include back-lit display (for night riding), indi- cator options for max speed, average speed and current speed and a battery power indicator. It also fea- tures a walking mode which is used when you want to wheel/push the bike, this is basically a very low speed mode which is activated by pressing and holding the minus (-) button, this can also be used as a start-aid. - Page 15 Battery care: Some care is needed to ensure that the battery performs at its best and lasts as long as possible. All batteries age over time, and the way that they age is that the range you can achieve will gradually de- crease.
- Page 16 Battery operation: The HL batteries come in two slightly different variants. Battery Type 1 The first battery-type is always on, and when the button is pressed, it just shows current state of the battery—the more lights illuminated, the more full the battery is. Battery Type 2 The second type, while physically identical, the button on this one is a multi-function button.
- Page 17 Support staff are not available at the weekends, though if you send an email, it will normally be read and replied to on the following Monday (except on bank holidays). Email: kits@wooshbikes.co.uk Telephone: 01702 435566 Support staff are available 10am to 5pm Monday to Friday. © 2018 Woosh Bikes Limited...
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