Instructions for How to Build an Electric Bike

Convert an upright or recumbent bicycle to electric.

Building your own electric bike gives you the option of selecting the type of drive system. Chain drive and friction drive systems are available in kits that include the primary components, such as the motor, battery and control lever. Most manufactured electric bikes include the manual drive as a pedal assist. Leaving the pedals, sprocket and chain intact makes the conversion to electric simpler and you'll have the pedal assist feature. Chain drive systems require a number of modifications to install. Friction drive systems are easily installed using basic hand tools.

Things You'll Need

• Allen wrench
• Box wrench
• Screwdriver

Instructions

1. Organize the components of the friction drive kit on a worktable. Secure the bicycle in a repair rack to elevate the rear wheel. Use an Allen wrench to loosen the compression bolts on the front brake lever. Remove the lever from the handlebars and let it suspend from the brake cable.

2. Slide the control lever assembly on the handlebars and tighten the compression bolts to hold it in place. Make sure to position the lever for convenient access. Reattach the front brake lever to the handlebars.

3. String the control lever cable along the underside of the upper frame tube. The end of the cable should easily reach the frame post in front of the rear wheel. Use the provided clips to hold the cable in place.

4. Align the control lever on the motor with the end of the control cable and mark the frame at this location. Attach the motor bracket to the frame using the provided u-bolts and tighten the nuts with a box wrench.

5. Position the motor perpendicular to the rear wheel with the side of the friction roller contacting the middle of the rear tire. Adjust the bracket if necessary for full contact and use the provided bolts to attach the motor to the bracket.

6. Insert the end of the control cable in the motor lever. Tighten the cable stay with a screwdriver to secure the cable.

7. String the wire harness from the motor and determine location for the battery. Use the provided u-bolts to attach the battery case to the bike frame. Place the battery in the case.

8. Insert the end of the wire harness into the port on the side of the battery case cover. Attach the red lead to the positive battery post. Attach the black lead to the negative post and tighten the connections with a screwdriver or small box wrench.

9. Put the cover on the battery case and close the latches to hold it in place. Move the control lever on the handlebars to the first position. The motor will start and the rear wheel should turn. Make any adjustments needed for maximum efficiency of the friction roller at the rear tire. Remove the bike from the repair rack and test drive the electric bike.

Tips & Warnings

• Refer to the model and size of your bike when purchasing a friction drive kit.

References

• USA Electric Bike: Friction Style Electric Bike Motor Kit
• Motorized Bicycles: Different Systems And Terms Used