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2000W+ E-BIKE CONVERSION
latest high power 2000 watt kit comes with a new OzEbikes
water proof 40A controller with LCD display screen! This controller is small
and robust, programming is via the screen, 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.
Plugs!! We are 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.
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! Running at
2000w means the motor is never overloaded and thermal cutout
is almost never experienced!
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
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.
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.
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
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
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.
40A LCD DISPLAY SPEED CONTROLLER
controller supplied is our OzEbikes sensored brushless 40A controller with LCD DISPLAY
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. Better is to
monitor the consumption, for example a 12Ah battery pack should not be
discharged more than 10Ah if you want to get long service life from the cells.
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 wire for the main power input.
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 1/8th
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 your 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.
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.
shows our optional LUNA frame bag fitted up, this bag will carry up to four
12Ah Lithium Polymer battery packs, and will easily carry a 48v 15-16Ah 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.
You can also use Lithium Polymer battery packs similar to what people 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, and will endeavour to keep 12Ah and/or 14Ah packs on hand
for new installs. We always have chargers available for charging two LiPO 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.
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
• OzEbikes 40A
LCD (60A burst) waterproof Speed controller with XT90 AntiSpark plugs.
• 44/44/32T Alloy/Steel/Alloy Crankset with freewheel hub, Black anodized. (48T
• Sealed 68-73mm triple bearing ISIS Bottom Bracket with extended LH Axle.
• 170mm Left & Right light Forged
Alloy ISIS Crank Arms black
• 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.
will need a rack or our LUNA bag to hold your battery pack.
TERMS & CONDITIONS:
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 AND
YOUR LEGAL RESPONSIBILITY:
This 2000 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.