500W EBIKE CONVERSION INTERNAL CONTROLLER

BUILT IN CONTROLLER 500W E-BIKE CONVERSION

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 built in sensored speed controller, designed to run on Lithium battery packs that measure 25v fully charged. The motor runs through a sealed planetary gearbox. The output shaft runs a standard pitch sprocket that matches most bike chains, and features a 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.

CRANK SET

The supplied crank-set is the top model available and is a double chainwheel 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 cranksets. 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 once the front one has been adjusted to suit 2 sprockets, the only difference is the front gears will only change between 2 sprockets, small and large.

Note: Buying a kit with a single crank sprocket for the front really limits your power as you have no small sprocket to drop down to when climbing steep hills. This is why we don’t even have the option of single chainwheel crank set. Of course on bikes which can only have one front chainwheel we can assemble custom cranks to suit!

 We supply a sealed bottom bracket with an extended axle so that your left pedal clears the back of the motor housing. The bottom bracket is standard 68mm cups and will fit most older bikes and many newer bikes that have a regular screw in bottom bracket.

THROTTLE CONTROL

The throttle is a twist grip much like a motorbike and comes with matching rubber grips for your handlebars. All the wiring is pre terminated and simply plugs together. There is a power switch on the throttle assembly so that you can switch the system off and a 3 stage LED light system to show the battery capacity. 

 With our 22.2v 12Ah battery pack we can maintain 25-30kmh genuine speed with light pedalling along level surfaces and get well over an hour of constant running from the system. 

Photo shows complete bike, note the bag under the seat is not included in the kit and is no longer available, we have the LUNA triangle bag that goes inside the frame now.

Our hi powered 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 quality Electric Assist setup like this you will never go back to a regular bike! The 500w motor will peak at around 750 watts power consumption under full load to get the rated 500+w output.

BATTERY REQUIRED:

One of our 22.2v 14Ah EXTREME POWER Lithium-Polymer battery packs (22.2v is nominal rating used by most factories, fully charged is 25v) will give you good range with a 500w system, the 500w motor will pull around 32 amps max at full load and usually sits around 10 amps when used liberally with light pedalling. At 10 amps you will get around 70 minutes continuous running with a safe reserve in the battery, usually this will equate to 30-40km distance, often more when it’s largely flat terrain, its very dependant on your use of throttle! You can carry 2 or even 3 batteries on your bike and simply swap over as your current battery gets low. Our LUNA battery bags are designed to carry 2-3 packs and our batteries are affordable as they don’t run internal balancers or output regulation, our chargers do all the balancing and maintenance of the battery.

INSTALLATION

We fit plugs for the battery connections, assemble the motor mount to your bikes BB width, and test the complete set on the bench before shipping. The motor mount for all our kits 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. You will need some simple bike tools, a crank puller, a chain press, and a bottom bracket spanner. We usually stock these tools, and all are available at your local bike shop.

WHAT YOU GET IN THIS KIT:

• 500 Watt 3 Phase BRUSHLESS Motor with inbuilt hall sensored speed controller.

• Sealed Planetary Gearbox & 14T Freewheel sprag clutch sprocket (factory assembled and tested).

• New Bottom Bracket mounting kit, much simpler mounting!

• 44/44/34T Alloy Chain-wheel Crankset with built in Freewheel sprag clutch.

• 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 drive chain for connecting motor drive to cranks.

• Custom Throttle with LED voltage display. (throttle type may vary depending on stock)

• Pre-terminated wiring with XT90  plugs pre-fitted.

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:

250w is the PEDELEC legal power limit that can be ridden on public roads. Ride at your own risk. This kit is sold as an offroad kit only. 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 installation. 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.