Installing my BionX Electric Motor Kit

by BionX Electric Motor on June 19, 2010

BionX Kit Installation

David converts his BionX bike

My BionX electric drive kit arrived in a neat square box about 2 feet high.  In the background, you can see the bike to be converted, a Specialized Hard Rock mountain bike. I opened the box and removed the contents.  Here’s what I found inside: There was a rear wheel, a freewheel, a battery, a battery charger and a bag containing some smaller items. Inside the bag was a one-page instruction sheet.  One page?  All these parts and only one sheet of instructions?  I was a little worried, but I moved ahead.

BionX kit laid out

David's BionX kit before installation

The instructions told me to remove the existing real wheel from my bike, then dismount the tire, and mount it on the new wheel containing the BionX hub motor. It took about five minutes to remove the tire from the old wheel and mount it on the BionX wheel.  After inflating the tire, it was time to thread the new freewheel onto the wheel, then replace the wheel on the bike. The new wheel looked so neat, with its sealed hub motor and little pig tail sticking out.  I slipped the axle into the dropouts on the rear fork of the bike.  A small tab on the axle fits into the dropout to lock the axle in place so that the motor can safely provide power to the rear wheel.

After I completed the installation of the rear wheel, the next step was to begin attaching the battery mount. The first step is to install some protective tape over the frame to protect it from the metal edges of the mount. The battery mount attaches with two Allen screws. The battery mount contains two cables, a thick one for the hub motor, and a thin one for the control console. I ran the hub motor cable back along the rear fork and plugged it into the motor. Then I secured it with tie wraps (cable ties) to make sure that the wire does not get snagged or accidentally caught in any of the bike’s moving parts.

David installs his BionX kit

Installing the BionX bracket

The longer wire goes up the frame, where it will attach to the control Console, mounted on the handlebars. I secured this wire to the frame with cable ties, being careful to place the ties underneath the brake and derailleur cables which run along the frame. Now it was time to attach the BionX Control Console. There’s a mounting bracket that attaches to the handlebars, and then the Console slides into the bracket.

I couldn’t believe how easy this installation was.  Here I was almost finished, and I wasn’t even breaking a sweat!

There’s a small switch which needs to be attached to the handbrake lever to shut off the motor when you brake. Before attaching the switch, the instructions call for cleaning and de-greasing the brake. Isopropyl alcohol or acetone can be used for this.

Wipe all grease and dirt off the brake lever. Now you can attach the shutoff switch to the part of the brake that doesn’t move. The little round magnet sticks onto the lever, right next to the switch. It’s like the door switch on a burglar alarm. When you pull the brake, it moves the magnet and opens the circuit.

Finally you can attach the wire from the shutoff switch to the control console. It looks like a bit of a tangle. The important thing is that the handlebars can move from freely from side to side without pulling or snagging any cables. Take your time with this. Here’s how my handlebars looked when I was done. Order out of chaos!

David instlls his BionX kit

BionX handlebars

I suddenly realized I was near the end. There was only one more step left to go, installing the BionX battery. Simply place the battery on top of the mount about two inches from the bottom, and gently slide it into place. Push down on the locking tab, and push in the lock button. That’s it! Installation complete!

Install a BionX electric motor kit on your own bike!

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