HOW WE BUILD YOUR CUSTOM EBIKE

Follow the steps below to see what is involved in building your custom ebike

1. Inspect, clean, repair, prep

We will inspect your bike for free and make sure it is a good candidate for conversion. A few things we will examine: 1) is the frame solid and in good condition 2) are the brakes suitable for the extra weight of an ebike 3) are the wheels true and tires in good shape 4) does the bottom tube measure between 68-73mm or 102mm (required for the Bafang motor to fit) 5) Are there sturdy mounting points for the battery 6) will the battery fit in the frame 7) is the drive train in good condition (cassette, derailleur, and chain). Once you decide to proceed with the conversion, we will thoroughly clean and lube your bike. Next, we will repair any issues we see. Finally we will prep the bike for conversion.

2. Motor Installation

The Bafang motor is installed in the bottom bracket tube. First, we remove the existing front crankset and bottom bracket cartridge. We clean and grease the bottom tube and insert the Bafang motor. We check and adjust chainring clearance against the chainstays to about 2mm. We then torque the retaining nut to 80nms to make sure the motor stays tight to the frame during rough riding.

3. Cockpit Installation

On the handlebars, we will install the 500c display. If the brakes are cable-actuated, we will swap out the levers with the Bafang-provided levers that automatically shut off the motor when they are squeezed. If the bike has hydraulic brakes, we can install an optional hydraulic level with built in motor cut-off switch. We will install the throttle switch and grips and make sure everything is adjusted to the rider’s preference.

4. Battery Installation

The battery installation can be one of the most challenging steps of the install. Typically, the battery is installed on the downtube and secured with the insert nuts in the frame. However, depending on the bike, the battery mounting plate doesn’t always line up with the frame inserts. In that instance, we will add custom rivnut mounting points to securely attach the battery mount. We strongly recommend the use of a Titan strap around the battery to absorb the bumps of the road. We carry these straps in stock as an option.

5. Shift Sensor Installation

The shift sensor is a highly encouraged option and installs in-line with the rear derailleur shift cable. It detects when the rider is changing gears and momentarily cuts off power to the motor to protect the drive train and make for smoother shifts. It essentially acts like the clutch in a transmission.

6. Speed Sensor Installation

The speed sensor installs on the left chainstay tube, detects the rate of wheel rotation, and sends an electronic signal of the bike speed to the motor controller and display.

7. Cable Management

eBikes require a fair number of wires to connect the motor, battery, display, throttle, controller, and various sensors. The wire harness is shipped from the factory as “one-size-fits-all” so often there is excess lengths of wire once all the connections have been made. This is where cable management comes into play. Cable management is more art than science and we take it very seriously. We carefully figure out the most esthetically pleasing method of cable routing for your bike. We use the existing cables and lines on the bike to conceal the motor and battery wires. Casual observers will be hard pressed to notice any additionally cabling on our ebike installations.

8. Final Tune-up and Test Ride

Once all the ebike components are installed and connected, we make sure the bike is properly tuned to ensure smooth shifting and confident braking. We configure and customize the motor controller and display to your particular bike and riding preferences. We then take the bike on a test ride to make sure everything is working as designed. When you pick up your bike, we will accompany you on a test ride to answer questions and make sure you fully understand how you new ebike functions.