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Swytch eBike Conversion Kit Instruction Manual

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Summary of Contents for Swytch eBike Conversion Kit

  • Page 1 Installation Instruction Manual...
  • Page 2 Got an accessory? Scan here for instructions.
  • Page 3 Introduction Introduction These are the original instructions for the Swytch eBike Conversion Kit. This is the Swytch Manual Version 007. The most up-to-date version of this manual can be found here and this should be consulted for any changes. swytchbike.com/manual.
  • Page 4 Before you ride your Swytch Bike for the first time, please be sure that it has been cor- rectly assembled. You’ll find step by step instructions in this manual. For further help and support visit our help centre - support.swytchbike.com...

  • Page 5: Table Of Contents

    Table of Contents Installation Brompton In the Box Kit Checklist p.10 p.33 Swytch Motor Wheel Torque Washer Magnetic Disc(s) p.15 Magnetic Disc(s) p.34 Tools Required Pedal Sensor p.23 Pedal Sensor p.36 Mount & Bracket p.25 Mount Placement p.37 Base Display p.28...

  • Page 6: In The Box

    In the Box Swytch Help Centre 1. Kit Checklist 2. Tools Required...

  • Page 7: Kit Checklist

    In the Box Kit Checklist Use this list to get all the parts ready before you start. Power Pack Motor Wheel Mount Base Display Magnetic Disc(s) Bracket, Spacers & Screws Pedal Sensor Charger Cable Ties *Please note that this doesn’t include any accessories.

  • Page 8: Tools Required

    In the Box Tools Required You’ll need to use the following tools to install your Kit. Please note that these are not provided. Allen Key Set Tyre Levers Scissors Ruler Bicycle Pump Adjustable Spanner...
  • Page 9 Installation Swytch Help Centre 1. Swytch Motor Wheel 2. Magnetic Disc(s) 3. Pedal Sensor 4. Mount & Bracket 5. Base Display 6. Connecting Up 7. Routing Cables...
  • Page 10 Installation Swytch Motor Wheel Your Swytch motor wheel has been built to the size and colour you specified in the Order Portal. The wheel incorporates the 250W motor hub which is used to power your bike so it’s important to assemble it securely into your forks.
  • Page 11 Installation 2. Prepare your Swytch motor wheel Fit your Swytch motor wheel with a Pump up the tyre to the new tyre and inner tube. For support manufacturer’s suggested tyre and advice on which tyre you should pressure. This is printed on the use visit support.swytchbike.com.
  • Page 12 Installation 3. Fit the Swytch motor wheel onto your bike Slot the Swytch motor wheel into the dropouts of the forks. The motor cable should be on The motor cable should face the the opposite side to the chain. ground when the bike is upright.
  • Page 13 Installation Fit the torque washer, flat washer, Ensure the torque washer is and axle nut as shown. Your bike fitted correctly. forks should fit snugly around the lip of the torque washer. Fork drop out Flat washer Torque washer Using a large spanner, tighten the Fit the rubber cover over the nuts on nuts on both sides of the motor both sides of the motor.
  • Page 14 Installation Adjust your brakes (if necessary) If you have rim brakes, check the Note pads contact the new rim correctly. When adjusting the brakes follow The brake pads should only touch the bicycle manufacturer’s the rim and not the tyre. instructions.
  • Page 15 Installation Magnetic Disc(s) The magnetic disc is used to help detect when you pedal. There are several different types of magnetic discs with variations to fit each style of bike. Follow steps 1 and 2 to identify which is the correct magnetic disc for your bike.
  • Page 16 Installation Check the table below Complete steps one and two then use the table below to determine which magnetic disc you’ll need. Skip to the associated page number to continue fitting your disc. Distance Between Pedal Pedal Arm Shape Magnetic Disc Page Arm and Frame (cross section view)
  • Page 17 Installation Easy Fit Regular & Easy Fit Thin Magnetic Disc Retention ring Magnetic disc 1. Fit the magnetic disc Push together the four magnetic disc pieces. Fit the magnetic disc around the crank axle on the side of the bike opposite the chain.
  • Page 18 Installation 2. Fit the retention ring Fit the retention ring around the magnetic disc to secure it in place. Note Check that the alignment of the magnetic disc is parallel with the frame by rotating the pedal arm backwards and watching for any movement.
  • Page 19 Installation Universal Magnetic Disc Regular Bolt Magnetic disc Retention ring 1. Check your pedal arm Determine which way round you’ll need to fit your magnetic disc arm based on the shape of your pedal arm. Round or Flat pedal arm Indented pedal arm The magnetic disc arm curves The magnetic disc arm matches the...
  • Page 20 Installation 2. Fit your universal magnetic disc together Loosely tighten the bolt onto the arm using a 2.5mm Allen key, using the diagram below. Round or flat pedal arm configuration Allen key Inner curved arm Rough side of disc (side without writing) Indented pedal arm configuration Allen key...
  • Page 21 Installation 3. Fit the universal magetic disc Fit the magnetic disc around the Push and click together the two halves crank axle, behind the pedal arm, of the magnetic disc. on the side of the bike opposite the Note chain. If there is enough The side of the disc with ‘Working room, add the...
  • Page 22 Installation 5. Secure the arm with cable ties Make sure your pedal arm is clean. Loosely cable tie the magnetic disc arm to the inside of your pedal arm in at least two points. Reposition the magnetic disc so that it is aligned as seen in the picture.
  • Page 23 Installation Pedal Sensor The pedal sensor detects when you start to pedal, using the magnetic disc to determine your cadence. It then sends a signal to power the motor controller. The LED flashes red to indicate when it’s working. 1. Peel back the adhesive layer Peel back the red cover to show the adhesive layer.
  • Page 24 Installation 2. Line up sensor, stick and secure Stick the sensor to the side of your Ensure that the centre of the sensor down tube on the frame as seen in is aligned with the magnets on the the image below. disc.
  • Page 25 Installation 4. Mount & Handlebar Bracket The mount connects the Power Pack to the rest of the Swytch Kit system. It contains the controller and has a quick-release handle. The bracket secures the mount to the handlebars. There are alternative brackets available that secure the mount to other parts of the bike.
  • Page 26 Installation 1. Place the mount under the handlebar Position the mount on the centre Route any brake or gear cables of the handlebars, horizontal to the behind the mount. Check your floor. brakes still work as normal. 2. Find the correct spacers size (optional) Spacer Options: Without a spacer, the bracket has a 31.8mm diameter.
  • Page 27 Installation 3. Assemble the bracket Position together the lower and upper bracket halves, placing the spacers inside if they are required. 4. Screw the assembly together To secure the mount in place screw Note the two bracket halves together Tighten the screws with 2-3 Nm of using a 3mm Allen key.
  • Page 28 Installation Installing the Base Display The base display allows you to control the Kit’s power. You can also use it to access the settings. To fit the base display simply open Tighten the screw on the back of up the clasp and fit around your the display using a 3mm Allen key.
  • Page 29 Installation Connecting Up The mount has six cables coming out of it, each with a different purpose. Display Pedal sensor Throttle Brake sensors Motor wheel...
  • Page 30 Installation Connect the pedal sensor and base display To connect the waterproof connector, find the arrow on each connector and align. Once aligned, push the connector pair together until no colour is visible. The cable connectors are colour coded. The tall end of the connector connects with the short end.
  • Page 31 Installation 7. Routing the Cables When routing cables to the mount, Loop any extra length of cable back follow the existing cable routing on itself. of your bike. Allow some slack for Using the cable ties provided, se- turning of the handlebars. cure everything to your bike.
  • Page 32 Brompton Swytch Help Centre 1. Torque Washer 2. Magnetic Disc(s) 3. Pedal Sensor 4. Mount Placement 5. Cable Routing...
  • Page 33 Brompton Specific Torque Washer To fit the Brompton torque washer, first thread the motor cable through the keyhole in the washer. Angle the washer with the lip facing towards the forks. Remove any of the existing wheel hardware. Tighten and secure the nut, being Slot the torque washer into the careful not to pinch the motor cable.
  • Page 34 Brompton Specific 2. Magnetic Disc(s) 1. Choose the correct pedal type Determine which magnetic disc you need by finding your pedal arm shape in the table below. What shape is the inside of your pedal arm? Use this configuration Brompton PRE 2013 Brompton PAS type A Back of the pedal arm has a concave...
  • Page 35 Brompton Specific Assemble the parts Screw the two-part clamp over the Tighten the screws with a 2.5mm pedal arm. Note, you don’t need to Allen key. remove the pedal arm to do this. Screws Retention ring Magnetic disc Check This is how it should look when installed correctly.
  • Page 36 Brompton Specific 3. Pedal Sensor Stick the sensor onto the down tube of the Brompton. Angle the sensor so it’s sitting within 3mm of the magnetic disc, using spacers if needed. 2 x spacers 3mm gap Angle the pedal sensor by loosening the bolt and pointing the sensor target towards the magnetic disc.
  • Page 37 Brompton Specific 4. Mount Placement When securing the handlebar mount and bracket to a Brompton, please make sure that it’s positioned with the Power Pack facing the seat posts, as shown in this picture. This allows the Brompton to fold without damaging the Power Pack.
  • Page 38 Brompton Specific 5. Cable Routing Follow the existing cable routing on Using the cable ties provided, your bike. Allow some slack so you secure everything to your bike. can still turn the handlebars and fold your bike with ease. Make sure the cables aren’t in the way when pedaling.

  • Page 39: Using Your Kit

    Using Your Kit Swytch Help Centre 1. Power Pack Introduction 2. Starting Your Ride 3. Power Pack Settings 4. Checking Your Battery 5. Ending Your Ride 6. Charging Your Kit...

  • Page 40: Power Pack Intro

    Using Your Kit Power Pack Introduction This is the Swytch Power Pack. It has Li-ion cells inside that provide the energy for the Kit. On the top, you’ll find the connector for the handlebar mount and the battery level indicator.

  • Page 41: Starting Your Ride

    Using Your Kit Starting Your Ride 1. Connect the Power Pack Lift up the mount handle so that it’s Push down the mount handle until fully open. it’s fully engaged. Fit the bottom of the Power Pack Avoid trapping anything in the into the mount alignment block.
  • Page 42 Using Your Kit 2. Setting your power level Press down the middle button on Check your wheel size is correct the display to turn it on. before your first ride, don’t ride your kit with the incorrect wheel Select your power level by size configured.

  • Page 43: Power Pack Settings

    Using Your Kit 3. Power Pack Settings This is how to access and adjust the settings in the Power Pack. Press and hold the up and down arrows together to access the settings. Once activated, the battery indicator will start flashing. In the settings mode, use the up and down arrows to change the...
  • Page 44 Using Your Kit These are different values available for each setting. Factory reset Click the middle button when ‘yes’ is highlighted to perform the reset. PAS direction Backwards Forwards Power limit 100% Top speed Please note the default setting is 15mph, which is the legal limit for eBikes in the UK/EU.

  • Page 45: Checking Your Battery

    Using Your Kit Checking Your Battery Press the battery button located on The LEDs will light up to indicate the top of the Power Pack. your battery percentage. Five lights show when its fully charged. Battery button Note The battery LEDs will remain on when connected in the mount.

  • Page 46: Ending Your Ride

    Using Your Kit Ending Your Ride To disconnect the Power Pack, lift the mount all the way up. Remove the Power Pack. Note To increase battery life remove your Power Pack from the mount when you’re not using it.

  • Page 47: Charging Your Kit

    Using Your Kit Charging Your Kit To charge your Power Pack plug the charger into the yellow connector block as shown. When the light on the charging brick changes from red to green the Power Pack is fully charged and should be unplugged.

  • Page 48: Troubleshooting

    Troubleshooting Swytch Help Centre 1. Error Codes 2. Motor Wheel 3. Pedal Sensor 4. Magnetic Disc(s) 5. Mount & Bracket...
  • Page 49 Troubleshooting Error Codes - Base Display These are some of the most common error codes you may encounter when using the base display. Error Lights Problem Action Required Code Flash at PAS Motor current abnormality Contact customer service Level 1 Flash at PAS Motor phase abnormality Contact customer service...

  • Page 50: Torque Washer

    Troubleshooting Motor Wheel isn’t Spinning Freely Ensure that the brakes are adjusted correctly and aren’t touching the rim. Washer fitted Next, check if the motor casing is inside fork touching the forks. If it is, you need to increase the gap between the forks.
  • Page 51 Troubleshooting Pedal Sensor Magnetic Disc Doesn’t Fit My Bike If there isn’t enough space, remove the plastic hinge and mount the pedal sensor directly to the frame using the cable ties provided.
  • Page 52 Troubleshooting Motor Starts and Stops When Using Pedal Assist If the pedal assist power is intermittent, make sure that the magnetic disc isn’t wonky. Straighten it and adjust the sensor so that it’s closer to the magnetic disc. Handlebar Mount Moves Check that the screws are tight.

  • Page 53: Kit Care

    Kit Care Swytch Help Centre 1. Maintenance 2. Warranty Terms...
  • Page 54 Kit Care Maintenance Interval (whichever is first) Swytch Kit Bike Every ride - Recharge the Power Pack - Tyre pressure -If installed, test the brake - Check tyres for debris/ sensors operate normally thorns - Check brakes Monthly - Top up battery charge if...
  • Page 55 This guarantee doesn’t necessarily cover transport costs and risks associated with the transport of your product to and from Swytch Bike. This Guarantee is exclusive to the pur- chaser and is dependent on the customer providing relevent proof of purchase.
  • Page 56 Swytch Bike’s only obligation under this guarantee is to repair or replace products subject to these guarantee terms and conditions. Swytch Bike is not liable for any loss or damage relating to products, service, this guarantee or otherwise, including – economic or intangible losses – the price paid for the product – loss of profits, revenue, data, enjoyment or use of the product or any associated products –...
  • Page 59 Installation Swytch Technology Ltd, Unit 10, One Dye House 455 Wick Lane London E3 2TB...
  • Page 60 Installation Watch the installation video! Scan here.

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