2000-3000w EBIKE CONVERSION

2000+W E-BIKE CONVERSION

NEWS!! Our latest high power 2000 watt kit comes with a new OzEbikes water proof 40A BLUETOOTH speed controller! This controller is small and robust, much smaller than the old brick style pre-programmed units. Programming is via smart phone, this allows you to set your cut-off voltage easily for various 36-48v battery packs and also adjust power levels for extended range when you don’t need the full capability of 2+Kw. You can run a 36v pack, our 44.4v LiPO packs, or our 48v LiIon packs without issue, all that is required is the cut off voltage reset.

NEW Plugs!! We are now running a compact waterproof motor connector plug that houses both the main power phase wiring as well as the hall sensor wiring, this has added to the price but the kit is now much more waterproof and less chance of damaging the fine sensor wiring.

All new motor design with completely redesigned winding layout and much larger diameter rotor has resulted in a unit that can handle up to 3000 watts  (subject to ambient temp and load) and produces more torque at less amp draw!

Our test figures using our 44.4v (50v fully charged) lithium polymer batteries show 1960 watts max load with 20% more torque than the old Headline motor produced at 2500 watts! New gearbox design with Nylon planetary gears reduces noise to a new low, very quiet running system!

Our kit comes with everything you need to convert a regular Diamond framed bike to electric power. We use a custom 3 phase brushless in-runner motor with external sensored speed controller, designed to run on Lithium battery packs. The motor runs through a sealed planetary gearbox. The output shaft runs a standard pitch sprocket that will take 8-9spd chains, and features a freewheel sprag clutch built in, this allows the motor to drive the bikes gear system without you pedalling, or sit idle with no load on the gear system while you pedal.

 The combination of high torque 3 phase brushless motor, planetary reduction gearbox, and the direct drive through the bikes own gear system results in a bicycle that is very versatile and has very hi torque, able to climb steep hills through the low gears or cruise along  on the flats at a rapid pace with only light pedal input! Overall power is many times more than any hub motor setup can produce, and that power runs through your gears, unlike a hub motor that has a single geared speed.

New 3Kw hi torque motor with black ISIS crank set, 40A controller and new LED throttle.

CRANK SET

The supplied crank-set is the top model ISIS DRIVE available and is a double chain wheel plus drive sprocket for the motor. The outer sprocket is spaced further than a regular crank set and runs the drive chain from the motor. The second and third sprockets are the main gear sprockets and carry your existing main chain to the back gear cluster. Our outer and inner sprockets are the more expensive heat treated alloy, saving almost 500g in weight over the regular steel crank sets.

So what you end up with is 2 main sprockets at the front much like your original gear system, your derailers will operate all the gears as normal, the only difference is the front gears will only change between 2 sprockets, small and large. Our cranks feature a freewheel sprag clutch as well, this allows you to pedal the bike as a regular bike without any interference from the motor, or let the motor run without having to pedal.

NOTE: Our standard 2000W Crankset is built with 44T chain wheels for both motor and main drive, this gives us the best ratio between the motor and the cranks for a good balance between torque and speed, this setup can reach 60+kmh on the flat when fitted to a regular 26” mountain bike, a hybrid or flat bar road bike will usually be faster. My 26” test bike has done 64kmh into a strong headwind running the 14/44 ratio. We can also build custom cranks with various combinations of chainwheel.

Note: Buying a kit with a single sprocket for the front really limits your climbing ability as you have no small sprocket to drop down to when climbing very steep hills. This is why we don’t bother to offer a basic crank set that other sellers include as standard.

MOTOR DRIVE SPROCKET

We supply a new custom made 14 tooth sprocket on this motor, this is a new freewheel with stronger pawl mechanism forged in chromalloy and with the screw on cover spot welded to ensure it cannot unscrew. 14T is a good balance between speed and torque, and with the rear gearing you get the best of both worlds.

MOTOR MOUNT & BOTTOM BRACKET

We supply a special triple bearing sealed cartridge bottom bracket with an extended axle so that your left pedal clears the back of the motor housing. The bottom bracket is standard English fitment and is adjustable 68-82mm long via a new long left hand cone to support the motor mounting plate. It will fit all older bikes with an English BB and many newer bikes that have an external bottom bracket that screws into the frame, 68-82mm is easily covered.  We also have custom bottom brackets with 170 and 190mm long axles that are suitable for most Downhill frames and even FatBike frames which have very wide 120mm BB’s! The motor mount for the 2000W kit is a new design that hangs off the bottom bracket and helps to reduce the issue of mount and frame flex from the high torque our motors produce. It also allows fitment to many suspension bikes and bikes with odd shaped frame tubes that would normally not accept the alloy clamp mount. The chain tensioner is a new design with a coil spring that is easier to install and adjust the chain alignment.

 

NOTE: We assemble all motor mounts before shipping, when you are ordering from us you will be asked questions about the width of your bikes BB frame tube, and for photos of your bike so we can make sure the motor assembly is a drop in fit. There are a couple of hours of work involved in setting up each kit but I feel this is necessary in order to offer the customer a tailor made conversion that requires minimal work to install.

BLUETOOTH SPEED CONTROLLER

The speed controller supplied is our OzEbikes sensored brushless 40A BlueTooth controller rated at 40A continuous with an 80A burst rating. This new controller is waterproof and can be set for voltage cut off inside. It has no power ramp down as your batteries get low like some controllers; it will provide full power right up to cut off. We recommend the cut off be set to 43v minimum with 12s lipo, this helps to protect our battery packs while still allowing you to use 85% of available capacity. It is very important you do not drain your lithium batteries too low, you can damage the cells, as soon as you hit cut off the first time you should stop using the motor.

Again we do the hard work, your Controller comes pre-wired with new WATERPROOF connector for motor and an XT90-s Anti-Spark plug for battery connection, you will receive a series harness for your batteries if you are ordering batteries with the kit. All unused connections are insulated out of the way, connection is simple. We suggest using one bolt to one of the drink bottle mounts on your frame with a tie strap at the other end of the controller. We remove unnecessary plugs and use quality  silicon wire for the main power input.

DRIVE CHAIN

We supply a YBN Heavy duty MACK Half Link chain for your motor to crank drive, these chains are very strong and long lasting, the half link allows more accurate adjustment of chain slack and is much stronger than the best conventional chain available. Our chain is the compact 8spd 3/32 size not the wide heavy 1/8^th BMX chain.

THROTTLE CONTROL

The throttle is thumb operated and will work with your existing grips. All the wiring is pre terminated and simply plugs together. There is a key switch so that you can switch the system off and an LED readout showing battery voltage. This new throttle makes it easy to know where you batteries are at, once your batteries drop to 43-44v under load you should stop using them and swap over or recharge. Pushing them lower in voltage risks damaging cells.

NOTE: Most electric throttle housings interfere with Shimano gear levers, we recommend swapping your shifters to our Sunrace rapid fire as both levers are at the back, we have 6, 7, 8 and 9spd available. If you have SRAM shifters you are usually good to go, all that is needed is to trim the raised section of plastic off the top of the large lever so it better clears the  throttle casing.

With 44.4v 12Ah battery packs the 2000W bike below has reached 64kmh on the flat with a 100kg rider! Due to the high torque and power full throttle is not needed as much with this setup, I have calculated that riding around 25-30kmh average speed with pedalling our 12Ah battery set will get 35km range, maybe even more, its very hard to predict due to rider style and terrain, wind direction etc.

TEST RIDE DATA

Our 2000w test bike, full throttle settled power recorded on the Batteryman meter is 1960 watts when running our 16Ah 12c 44.4v lithium polymer batteries. One of my harder tests is a 16km run that has long steep climbs in both directions, I do this ride using the motor almost the entire time, usually at full throttle with light pedalling. With the new setup I managed 30mins and 7500mah consumed from the battery packs, a very impressive real world result.

Photo above shows our optional LUNA frame bag fitted up, this bag will carry up to four 12Ah Lithium Polymer battery packs, and will easily carry our 48v 16Ah pack as well as water bottle and other things, it’s the best value bag on the market and gives great balance to the bike as well as looking good. You can find the bags on our bag page.

BATTERY REQUIRED

Our new LiIon NMC 48v 16Ah battery pack is made for this kit! With a 40A constant BMS built in, the new battery offers a compact hi capacity solution that will actually handle the power of our mid drive kit. Of course you can still damage a battery, running the bike at full power ouput constantly will risk tripping the BMS and in severe cases you could burn out the output stage of the BMS. There is very little chance of this happening, but we like to be informative and have seen users do all sorts of crazy things with batteries over the years!

You can also use Lithium Polymer battery packs similar to what the use in large drones and UAV. You might already have our old setup for these. Two 6 cell batteries are connected in series for 44.4v nominal, 50v fully charged. We are happy to source replacement batteries for those who have this setup and the charger/s to suit, but we wont be selling them as a general stock item anymore as we are invested in the new technology of our NMC LiIon battery packs.

Our bikes will climb steep fire trails on their own in low gear, or you can power up a trail by pedalling and running at full electric power, once you have experienced a high power Electric Assist setup like this you will never go back to riding off road without it! Our system will peak at around 2000 input watts on 44.4v batteries, we have measured this in real time with our E-meter equipment, unlike other sellers we deal in electronics daily and have an extensive workshop for testing and fabrication.

Longevity: The freewheel clutches in our cranks and motor drive are good quality and made in Taiwan, don’t be scared off by talk that these clutches fail quickly, my own has been running for over 2 years regularly, and these clutches stand up to the torque of the 2000W system without trouble. In the event you manage to wear or break one of the free wheels they are available as spare parts for an enormous $33.00 each! J

WHAT YOU GET IN THIS KIT:

• 2000 Watt 3 Phase BRUSHLESS inrunner Motor. (This kit set up for 44.4v 2000w).

• Sealed Planetary Gearbox (motor and gearbox assembled and tested).

• 14T heavy duty welded motor sprocket for best balance of performance.

• BB Motor Mounting Bracket with coil spring chain tensioner, bracket is assembled ready to install.

• OzEbikes 40A BT (70A burst) waterproof Speed controller with XT90 AntiSpark plugs.

• 44/44/32T Alloy/Steel/Alloy Crankset with freewheel hub, Black anodized. (48T available)

• Sealed 68-73mm triple bearing ISIS Bottom Bracket with extended LH Axle.

• 170mm Left & Right light Forged Alloy ISIS Crank Arms black anodized.

• YBN heavy duty MACK Half Link drive chain for connecting motor drive to cranks.

• Custom 30-72v thumb Throttle with LED voltage display and key switch.

NOTE: You will need a rack or our LUNA bag to hold your battery pack.

TERMS & CONDITIONS:

Riding an Electric bicycle can be a dangerous activity, OZ-eBikes cannot be held responsible for accidents or injury caused by your use of these products. It is your responsibility to ride in a safe manner using appropriate safety gear and to follow your states road laws for bicycles. Our warranty responsibility is limited to the products supplied only, and warranty is provided for the supplied products only if they are used as intended. Any modifications of the equipment, use of incorrect batteries or chargers etc will void the warranty. By purchasing any kit or parts from us you agree to all our terms and conditions. For the full terms and conditions please go to our TERMS & CONDITIONS page.

YOUR LEGAL RESPONSIBILITY:

This 1800 watt kit is sold for offroad use only, as it is above the 250w legal power limit it can not be ridden on public roads. Ride at your own risk, please read our terms and conditions and follow your local state and country laws regarding electric bicycle use. NOTE: We cannot be held liable for any issues that may arise during installation and operation as this is a kit intended to be installed by the end user, we cannot control the installation process and can only offer technical support to aid in instllation. We wire up and bench test every kit before shipping out to ensure every component works correctly and is ready to use. The onus to meet Australian Road legal requirements falls upon the user of the product.