Belize Bicycle BUDDY TRIKE Instruction Manual

BELIZE BICYCLE
36/48V BRUSHLESS FRONT HUB MOTOR KIT- BUDDY TRIKE
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INSTALLATION & USER MANUAL
Correct installation is critical to prevent the motor from spinning in the fork. Please
review these instructions BEFORE starting the installation and refer to them during
the installation process.
1. FRONT WHEEL ASSEMBLY ORIENTATION
Refer to photographs (1, 2 and 3)
1.1. Use a stand to support the trike so that the front fork is off the ground and the
bike is stable during the motor installation process. Place the front wheel / motor
assembly just under the front fork and rotate the axle so that the flats on the axle are
aligned vertically.
1.2. There is a left and a right side to the motor. The motor cable exits on the right-
hand side. The disc brake mounting interface is on the left-hand side. Installing the
wheel backwards will result in the front wheel spinning the wrong way.
1.3. The right-hand side of the motor axle is also slotted on one side. This slot
MUST be oriented downwards. This will result in a looped cable near the dropout
and facilitate wheel removal for maintenance or adjustment.
2. FRONT WHEEL ASSEMBLY SPACING
Refer to photographs (1, 2 and 3)
2.1. Visually check the fork axle spacing against the motor. In some cases, the fork
will need to be spread to accommodate the inner thrust washers already mounted on
the hub motor axle. These MUST go inside the fork to provide a solid mounting
interface.
2.2. If the fork needs to be spread, a tool can be easily fabricated using a rear axle,
three axle nuts and washers. Two nuts are used on one side to lock the axle to the
fork and the fork is spread from the other side using the third axle nut. The washers
are used between the fork and the axle nuts to protect the paint.
2.3. There are several items of required hardware on each side of the hub motor
axle. On the right-hand side there MUST be a thrust washer, a shaped split washer,
a large slotted washer, an axle nut and a rubber end cap. On the left-hand side there
MUST be a thrust washer, a shaped split washer, a torque arm, an axle nut and a
rubber end cap.

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36/48V BRUSHLESS FRONT HUB MOTOR KIT- BUDDY TRIKE
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3. FRONT WHEEL ASSEMBLY INSTALLATION
Refer to photographs (1, 2 and 3)
3.1. Install the hub motor assembly with the thrust washers on the axle INSIDE the
fork arms and the tabs pointing DOWN. The tabs will line up with the axle opening.
3.2. Install the shaped split washers on the axle OUTSIDE the fork arms. The open
side MUST face downwards. The shaped split washers will slide into the dropout
recess.
3.3. On the right-hand side install the large slotted washer and slide it against the
shaped split washer. On the left-hand side install the two-piece torque arm and slide
it against the shaped split washer.
3.4. Install both axle nuts and torque to a minimum of 40Nm. Confirm that the tire is
centered inside the fork and that the shaped split washers have both properly
installed themselves in the dropout recesses.
3.5. Install the protective rubber end caps, form a loop with the hub motor wire and
anchor the wire to the right-hand side fork arm using the tie wraps provided. (This
wire will be later bundled with the throttle cable and / or any other cables sharing a
similar routing using a spiral wound plastic cable wrap.)
3.6. Complete the left-hand side torque arm installation by installing and tightening
the stainless-steel band clamp around the left fork arm. Then tighten the nut and bolt
that the two parts of the torque arm pivot on. The stainless-steel band clamp is NOT
optional. It MUST be installed.
4. COMPONENT INSTALLATIONS
Refer to photograph (4)
4.1 CONTROL BOX
The recommended installation location for the control box on a trike is on the
seat stays behind the seat. From this location the wires can be easily routed to reach
the battery, throttle and hub motor. Use 4 of the tie wraps provided to securely
anchor it in place. Orientation is a personal preference –leads can come out the top
or bottom.
Required connections are the throttle interface, the power leads and the 3
motor phase wires. The 5-lead Hall sensor connector is easy to connect but is
optional with the controller provided.

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36/48V BRUSHLESS FRONT HUB MOTOR KIT- BUDDY TRIKE
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All other connections are not required and can be ignored. That includes the
connector leads for the pedal assist and brake cut-off levers. They can be safely and
neatly hidden behind a Velcro wrap. (Not provided)
4.2 THROTTLE
Install the twist throttle on the handlebar on the right-hand side. The wire
should be bundled with the right-hand brake cable and the hub motor cable and / or
any other cables sharing a similar routing using a spiral wound plastic cable wrap.
Leave a little extra looseness around the steering stem to allow for the turning of the
front wheel/fork.
A second grip is optionally provided for the left-hand side. This cannot be used
if a twist shift is installed.
4.2.1. THROTTLE / SHIFTER COMPATABILITY ISSUES
Twist shifters are NOT compatible with a twist throttle
installation. The solution with a single twist shifter is to move the
shifter to the left-hand side and install it upside-down. It will still
be fully functional in this orientation but will still not permit the
use of the left-hand side grip provided. Refer to photo (7)
Alternatively, twist shifters can be replaced with thumb shifters.
4.3 BRAKE CUT-OFF SWITCHES
Brake cut-off switches have been provided with your Belize Bicycle Front
Hub Motor Kit –Trike. Before you decide to install them please understand that you
will be losing the parking brake that is integrated into the current brake lever. The
choice is yours. Brake cut-off levers or parking brakes. Unfortunately, we can’t offer
you both.
4.4 PEDAL ASSIST (Missing from this kit)
A two-piece Pedal Assist assembly is part of the Standard Belize Bicycle
Hub Motor Kit. However, it is NOT shipped with the Belize Bicycle Front Hub
Motor Kit –Trike to simplify your experience. The Pedal Assist is not compatible
with the one piece crank found on your trike so we want to save you the headaches
of trying to install something that just won’t fit !!
5 BATTERY
5.1.1 BATTERY INSTALLATION –BUDDY TRIKE
Refer to photograph (5 and 6)

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36/48V BRUSHLESS FRONT HUB MOTOR KIT- BUDDY TRIKE
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This Belize Bicycle Front Hub Motor Kit –Trike has been shipped with
either (1) a track mounted lithium battery that can be bolted to the deck under the
rear seat. This involves drilling 4 holes in the frame and using low profile bolts to
anchor the battery mounting rail to the deck. (Holes are not predrilled)
The battery has a three-position lock with a pin that locks the battery to the rail.
The key can only be removed in the OFF position.
(2) a sealed lead acid battery pack stored in a heavy-weight cordoura carry
bag which will sit under the seat or in a basket. Velcro anchors (not included) may be
required for some installation to keep the bag from wandering.
5.1.2 BATTERY CHARGING AND STORAGE
Charge the battery using ONLY the battery charger supplied. It has been
selected to match the chemistry, voltage and polarity of the battery supplied
with the Belize Bicycle Hub Motor Kit.
The charger has two LEDs, one to indicate that the unit is plugged in and a
second that changes from RED to GREEN when the battery is fully charged.
For safety reasons, batteries and not shipped fully charged. The initial charge
may require 2 to 3 hours. Do NOT leave the battery charger attached and
unattended. Should the battery charger fail to shut off after the batteries are
fully charged, it will damage the batteries.
5.1.2.1 A sealed lead acid (SLA) battery is best stored FULLY CHARGED,
disconnected, and protected from both heat and from freezing. It should
NOT be permitted to be fully discharged for any extended period of time
as the lead plates may become permanently sulfated. If stored fully
charged it only needs a maintenance charge once or twice a year. A
well maintained sealed lead acid battery has an expected service life of
200 to 300 cycles and should be replaced every two years.
5.1.2.2 A Lithium battery (Lipo) (Li) (LiFePO4) battery is best long term
stored PARTIALLY CHARGED, disconnected, and protected from both
heat and from freezing. It should NOT be permitted to be fully
discharged for any extended period of time because if the voltage falls
too low the BMS will refuse to allow the battery to accept a charge. A
lithium battery is best stored at a 60% charge and maintained at that
point with a one hour charge every 3 months. Be sure to always turn off
the battery key when not in use as leaving the key on will eventually
discharge the battery.

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36/48V BRUSHLESS FRONT HUB MOTOR KIT- BUDDY TRIKE
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PHOTO (1)
Axle hardware

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36/48V BRUSHLESS FRONT HUB MOTOR KIT- BUDDY TRIKE
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PHOTO (2)
Left hand side axle
PHOTO (3)
Right hand side axle

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36/48V BRUSHLESS FRONT HUB MOTOR KIT- BUDDY TRIKE
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PHOTO (4)
Suggested component locations

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36/48V BRUSHLESS FRONT HUB MOTOR KIT- BUDDY TRIKE
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PHOTO (5)
Suggested rectangular battery location on floor deck
PHOTO (6)
Suggested left or right-side rail mounting for fish type battery

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36/48V BRUSHLESS FRONT HUB MOTOR KIT- BUDDY TRIKE
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PHOTO (7)
Twist shifter relocated to left hand side
OPERATING TIPS:
(A)Both the key in the battery and the key on the throttle must be turned ON for the
electric motor to receive power.
(B)Both the key in the battery and the key on the throttle must be turned OFF to avoid
draining the battery unintentionally.
(C)Do not immerse electrical components in water. The motor hub and controller are
well sealed units. The throttle and connectors are not.
(D)The motor operates most efficiently at higher RPM. Therefore assisting the motor
when starting from a dead stop or when climbing a steep hill will improve the range of
the battery.
(E) Maintain the recommended tire pressure indicated on the side of your tires.
Low tire pressure requires more energy from the battery and will result in a greatly
reduced range when using the hub motor.
(F) An electrically assisted 48V motor and controller can result in speeds much
higher than you are used to. Please drive safely and obey all laws.

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36/48V BRUSHLESS FRONT HUB MOTOR KIT- BUDDY TRIKE
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MAINTENAINCE TIPS:
(G) When stored outside, use a cover to protect the trike from sun and rain.
Prolonged exposure to the sun will fade the paint. Prolonged exposure to rain will
cause corrosion.
(H)Clean the bike with a cloth and mild soap and water. A good car wax will help
maintain its appearance.
(I) An electrically assisted vehicle travels at a higher average speed and
therefore needs more frequent maintenance. Inspect the bike for obvious safety
issues before every ride. Check fasteners regularly for looseness.
(J) Consult with your dealer to plan for scheduled maintenance