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Swytch Universal eBike Conversion Kit Instruction Manual

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Instruction Manual
www.swytchbike.com/instructions
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Summary of Contents for Swytch Universal eBike Conversion Kit

  • Page 1 Instruction Manual www.swytchbike.com/instructions...

  • Page 2: Table Of Contents

    Contents Page No. 1. Safety Warnings 2. Quick Start Guide 3. Tools Required 4. What’s in the Box 5. Installation 5.1 Motor Wheel 5.2 Universal Pedal Sensor (PAS UNI) 5.2.1 Easy Fit Regular/Thin Magnet Disk 5.2.2 Universal Magnet Disk 5.2.3 Pedal Sensor Alignment 5.3 Quick Connect Handlebar Mount 6.

  • Page 3: Safety Warnings

    To ensure a safe and trouble-free experience when using your Swytch Conversion Kit please follow the guidelines below: Fully charge before first use After receiving your kit and before fitting to your bike or doing anything else fully charge the Power Pack until the charger light goes from red to green.

  • Page 4: Quick Start Guide

    Is everything in your box? Before starting, make sure everything is in the box that should be, and double check the parts match with your order (see next section). Then, if you know what you’re doing, crack on! Check our YouTube channel for a full video on the conversion process.

  • Page 5: Tools Required

    Allen Key Set Tyre Levers Bicycle Pump Tools Required Adjustable Spanner Scissors Elbow Grease...

  • Page 6: What's In The Box

    Check everything is there before you start! Once you’ve unpacked and started fitting it’s easy for things to go missing. Please keep the original packaging until you’ve fitted the kit. What’s in the Box Every kit should have the following parts:...
  • Page 7 (Optional add-on) Hub Motor Wheel Brompton Extension Peg (16” Brompton Kits Only) Quick Connect Handlebar Mount Brompton Block (Optional add-on) Swytch Power Pack (ECO/PRO) Torque Arm (Optional add-on) Universal Pedal Sensor / Brompton Pedal Sensor Thumb or Twist Throttle (Optional add-on)

  • Page 8: Installation

    Fit disc brake disc (optional) If you have disc brakes, move the disc from your old wheel to your new Swytch motor wheel. Note: Screws should have an 8mm thread length. If they are longer they may cause the motor to stop spinning. If they are...
  • Page 9 Check orientation of motor Fit the torque washer “lips” into the fork slot - The motor cable should be on the left of the bicycle Assemble the motor wheel to the forks with the torque (opposite side to the chain). washers installed as shown.

  • Page 10: Universal Pedal Sensor (Pas Uni)

    5.2 Universal Pedal Sensor (PAS UNI) Check motor spins correctly - Spin the motor wheel with your hand to check it can spin freely and isn’t touching the forks. If it is touching, please check the troubleshooting section. - The wheel should be harder to turn backwards than turning forwards.

  • Page 11: Easy Fit Regular/Thin Magnet Disk

    5.2.1 Easy Fit Regular/Thin Magnet Disk Fit Retention Ring Fit the retention ring around the magnet disk to secure it in place. It’s easiest to start on one side and work the ring around until you get to the other end. Magnet disc - Fit the magnet disk either side of the crank axle.

  • Page 12: Universal Magnet Disk

    5.2.2 Universal Magnet Disk Once aligned in position, tighten the screws to lock the disk arm into place. When switching between the different sides, you will need to unscrew the arm and reassemble it flipped around so that the working surface of the magnet disk remains facing the same way. Before starting, clean your pedal arm of any dirt and debris.

  • Page 13: Pedal Sensor Alignment

    5.2.3 Pedal Sensor Alignment Check correct installation Attach Pedal Sensor to bike - The photo below shows a correctly fitted pedal sensor. - Remove the pedal sensor adhesive cover. Adjust the pedal sensor to minimise the gap between the - Attach the pedal sensor to the frame of the bike sensor and the magnet.

  • Page 14: Quick Connect Handlebar Mount

    5.3 Quick Connect Handlebar Mount Fit the Anti-Twist Strap Add rubber spacers to handlebars - Pass the Anti-Twist Strap underneath the handlebar stem. - Fit the rubber handlebar spacers onto the handlebars. (22mm diameter handlebars only). - For larger sized handlebars (e.g. on mountain bikes) they are not required.
  • Page 15 Align Mount horizontally Connect motor - Turn the Mount to face horizontally. This will put tension in - Connect the motor to the Quick Connect Handlebar the Twist Strap and keep the Mount from turning any further. Mount. Secure the motor wire to the fork with the cable ties If in the future the Mount sags, simply adjust to a new hole provided.

  • Page 16: Brompton Specific Instructions

    6.1 Brompton Motor Torque Washer To fit the Brompton Torque Washer, first make sure to thread the motor cable through the keyhole in the washer. Remove any of the existing wheel hardware. Brompton Specific Instructions If you have a mudguard, assemble it underneath the locking nut.

  • Page 17: Brompton Pedal Sensor

    6.2 Brompton Pedal Sensor Assemble these parts onto the pedal arm Assemble the Brompton Pedal Sensor by screwing the 2-part clamp over the pedal arm. Use the Brompton plastic insert to make sure the disk does not slip up the length of the arm. How big is the What shape is Photo example...

  • Page 18: Brompton Pedal Sensor Alignment

    6.2.1 Brompton Pedal Sensor Alignment BROMPTON INCORRECT MOUNTING METHOD 1 Mounted onto incorrect tube. Magnets must pass from left Fit the sensor onto the small frame tube of the Brompton. to right of the sensor. Angle the sensor and add a spacer to move the sensor within range.

  • Page 19: Brompton Front Luggage Block Adapter (Bro Block)

    6.4 Brompton Front Luggage Block Adapter Fasten the mount to the front carrier mount attachment at the front of the Brompton using the screws provided. Be (BRO BLOCK) sure to assemble the screws in the order shown below. Assemble in this order The Brompton Block Adapter allows the Power Pack to be mounted directly to the frame.
  • Page 20 Connect your Pedal Sensor, Brake Sensors and Throttle to Thread the motor cable through the hole in the Brompton the bracket. You will need to use extension cables to reach Block Adapter to hide the excess cable. the new position. Tie the cables to the existing Brompton cables to allow the...

  • Page 21: General Tips

    6.5 General Tips This is how it should look once assembled. Check your brake pads are not touching your tyre. Adjust them to be lower and straight if necessary. Make sure your motor wheel is assembled fully into the forks. Replacing your brake pads can help with clearing the tyre.

  • Page 22: Accessories

    7.1 In-Line Brake Sensors Without the brake sensors the motor will still turn off a moment after the pedals stop turning or the throttle is disengaged. Brake sensors provide an additional level of control and safety by turning off the motor immediately when the brakes are applied – they are an optional addition to your kit.
  • Page 23 Fit the inline brake sensor to the brake cable Connect the brake sensor to the Quick Connect Mount - Thread the cable guide and inline sensor onto the bicycle - Repeat for the other brake. brake cable. - Test by turning on the Power Pack and holding the (-) - The sensor connector should be pointing away from the button to activate the walk mode and check the brake brake lever.

  • Page 24: Hydraulic Brake Sensors

    7.2 Hydraulic Brake Sensors 7.4 Universal Torque Arm Fit the hydraulic brake sensor to the outside of the brake lever. -Stick the sensor to the brake lever base. Fit the Universal Torque Arm -Stick the magnet to the brake lever. - Use the side opposite to the motor wire.

  • Page 25: Torque Narrow

    7.5 Torque Narrow 7.6 Twist Throttle Fit the Torque Narrow onto the RIGHT-HAND SIDE of the Fit the Twist Throttle to the handlebars. bicycle - Should be on the right-hand side. - Must be on RIGHT. - Cut hand-grips shorter to accommodate the size of the - Fit Torque arm over a tightly fastened axle nut.

  • Page 26: Operation

    8.1 Power Pack Removal Attachment To attach the Power Pack to the handlebars, align the back of the Power Pack with the Quick Connect Handlebar Mount and slide downwards, pressing firmly until you hear a *click*. Detachment To disconnect, press the button on the Handlebar Mount and pull the Power Pack up with the handle.

  • Page 27: Power Pack Charging

    8.2 Power Pack Charging To charge the Power Pack, use the charge port in the rear To set up the Power Pack, you must first turn on the battery. of the pack. The battery is shipped turned off for safety. Do this by pressing firmly on the (-) symbol at the back of the Power Pack.

  • Page 28: Power Pack Settings

    8.3 Power Pack settings These are the different values available for each setting This is how to access and adjust the settings in the Power Pack. 28 inch For a video, visit: www.swytchbike.com/instructions 26 inch 24 inch 20 inch 16 inch WHEEL SIZE PRESS and HOLD up and down...

  • Page 29: Troubleshooting

    9.1 Error Codes The display can sometimes show an error code. These are the most common that you may encounter with the corresponding solutions. For other error codes, check the LCD Display manual. Error Code Lights Problem Solution Flash at PAS Motor Current Contact Customer Level 1...

  • Page 30: Motor Wheel Isn't Spinning Freely

    9.2 Motor Wheel isn’t spinning freely 9.3 Pedal Sensor Magnet doesn’t fit my bike First check that the brakes are properly adjusted and are If there isn’t enough space, remove the plastic hinge part and not touching the rim. mount the pedal sensor directly to the frame using the cable ties provided.

  • Page 31: Motor Starts And Stops When Using Pedal Assist

    However, some bikes have a gap too small for the magnet disk to 9.5 Handlebar Mount moves up fit, like the one below! If the handlebar mount moves up when removing the Power Pack: - Check the screws are tightened. - Fit the rubber handlebar spacers directly underneath the handlebar mount arms, check that they have not moved to the side.

  • Page 32: Operation Troubleshooting

    9.8 Operation Troubleshooting 9.9 Motor Starts and Stops when using Pedal Assist To ensure the kit fulfils its complete working lifetime you can keep it in good shape by: This is a link to the troubleshooting video that summarises the steps: https://youtu.be/yTborNfH1wo - Attach the rain cover to the bracket when leaving outside - Wipe and dry the motor casing when wet to prevent rust Please follow this step by step process from start to finish if you...

  • Page 33: Maintenance

    Interval Swytch Kit Bike (whichever is first) Every Ride - Check battery charge - Tyre pressure level - Check tyres for debris/ - Re-charge after every ride thorns - If installed, test the brake - Check Brakes sensors operate normally...

This manual is also suitable for:

Brompton ebike conversion kit

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