KINETICS Brompton Hub User manual

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Tel: [phone] — E-mail: [email protected]
Brompton Hub Kit
Installaon Manual
Important: For your own safety you must read this manual in
full before attempting to fit the kit to your bike. You must also
ensure that you fit the kit in strict accordance with the
instructions. If you are unsure of any of the procedures, have
the kit fitted by a professional.

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Before you start the installaon of your kit, please read the following:
This kit is intended to be ed by someone who is competent and experienced at ng electric kits to
bikes. If you are not experienced and/or lack the necessary skills or tools to complete any of the proce-
dures in this manual, you should seek the advice of a professional who can t the kit for you. If necessary,
call us on 01702 435566 or email us at [email protected] and we will try and put you in touch
with someone in your area that has the necessary experse to properly t your kit. You will of course
need to pay for the technician to install your kit, these costs are not covered by Woosh Bikes.
Warranty Terms:
If your kit is ed by a professional installer, it will be covered by our standard one year warranty, which
means that in the event of a failure, you would rst need to have the person that installed your kit con-
rm the issue and likely cause, then you (or the installer) would need to contact us and provide us with
the details of the fault. If the issue cannot be resolved over the phone or via email, then you would need
to return the faulty part to us at your expense. We will then repair or replace the faulty part and send it
back to you at our expense. If the kit was not ed by a professional and/or the failure that has occurred
is due to poor/incorrect installaon, or the kit has been used improperly, the warranty will be voided.

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What’s in the box
Ensure that you have all the parts shown below before going any further, if there are any missing parts,
contact us on 01702 435566.
The kit comprises of a motor wheel, controller, pedelec sensor, display, frog-baery and baery-mounts.
As well as the items shown below, you will also have a selecon of bolts/xings, a motor wheel and a
baery charger—not pictured.

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BEFORE ng the kit to the bike
Plug everything in on your workbench and power up the kit, this will help to familiarise you with the vari-
ous parts that make up the kit, and also to ensure it works before ng it to your bike. Refer to the in-
strucons later in this manual to see which connecons go where.
If the kit does not power up, contact us straight away on 01702 435566 or send an email (preferably with
pictures) to [email protected]
Assuming the kit powers up and the display comes on, you can then proceed to install the kit.
Fit the motor wheel rst—this is normally very straighorward, but if there are any issues ng the mo-
tor wheel, it’s best to discover them before installing the other parts of the kits.

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Motor wheel
Remove the exisng wheel and then t the new motor wheel in it’s place. The wheel should be ed such
that the cable from the motor is on the le side of the bike.
Ensure that the cable exits from the aperture on the motor downwards towards the ground. This cable is
then looped upwards towards the handlebars, where it will meet a matching connector coming from the
controller.
Pedelec sensor
Use a crank puller to remove the right crank. Undo the boom bracket cup and then t the pedelec
sensor behind the lip of the cup, and then re-t the cup.
Next, slide the PAS along the axle as far as it will go and then ret the crank.

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Baery mounng
The mounng for the baery ts where the luggage block would normally be. If you have a luggage block,
remove it before you go any further.
The parts shown below-le must be ed rst. Use the two M5 buon bolts to secure both of the parts
to the frame of the bike, as shown below-right.
The parts to be ed next are shown below-le. Drop the white into the rear of the black casing, and feed
the four M5 cross-head bolts through the metal support from the other side, and then secure it to the
bike. The round opening in the side of the black plasc should be on the le as you look at the bike (the
right side if you were sing on the bike).
When ghtening these four bolts, ghten them a lile each and go around each of them unl they are all
ght. Don’t ghten one fully and move on to the next, ghten each of them gradually.

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Baery mounng cont…
The next part of the baery mounng is now bolted to the other half already on the bike. There six nuts
and bolts for this, that are ed along the top and boom edge, bolts through the front, nuts on the
back.
The lock that is ed to this has been deliberately le loose as it’s easier to t this part of the casing with
it like this. Don’t forget to ghten the two bolts to properly secure the lock in place when you’re done
ghtening the other six nuts/bolts.
Ensure that the moulded plug it sing in the correct posion before ng the two halves together—see
below-right.
Display
The LCD would normally be ed on the le as shown below. Use a 3mm allen key to release the clamp,
and then ghten to secure in posion. The bolt is accessed from the underside of the display.
DO NOT FIT THE BATTERY AT THIS STAGE

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Controller
You can now aach the display, motor cable and pedelec sensor and baery leads to the controller. The
leads coming form the controller match the leads from the other components, it’s not possible to plug
them into the wrong connectors, but pay close aenon and ensure that the arrows on each of the black
connectors line up before pushing them together.
The power leads are black and red, and should be mated with the matching leads from the baery-
mount/controller.
To pedelec
To display
To baery
To motor
The cables should be run alongside the exisng cables already on the bike as much as possible, and
Shrink the supplied heat-shrink
sleeving over the baery cable
connectors, and then use the
ribbed cable-dy to secure/hide the
cables.
You will need to purchase a pouch
of some sort like the one shown to
the le to protect the controller
from the elements, we don’t supply
these currently. This ideally should
be ed just below/behind the
handlebar clamp.

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Using the kit
Slide the baery in place (from le to right) on to the baery mount, and then use the key turning it
clockwise to lock it in posion. Make sure the baery is properly secure before riding the bike.
The on/o switch for the baery is located at the top-rear of the unit.
The charging socket is also on the rear of the unit, on the opposite side to the on/o switch. The baery
can be charged on or o of the bike
The baery has a meter showing the remaining capacity, and a light which would normally be used when
the baery is ed to the rear of a bike. To see the state of the baery, press the ‘Voltage’ buon, and to
switch the light on/o, press the light buon. The light will cycle from O > On > Flashing > O.
The meter showing the remaining baery capacity is made up of several LED’s, they are mostly green but
there is a single red LED. This red LED is always red and cannot change colour. It is like this to indicate that
if the red LED is the only one lit, the baery is almost completely at, and requires charging.

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Baery care:
Some care is needed to ensure that the baery performs at its best and lasts as long as possible. All
baeries age over me, and the way that they age is that the range you can achieve will gradually de-
crease. Follow the instrucons below to ensure your baery performs as well as possible for as long as
possible. Charge the baery once or twice per week or more as needed.
Do NOT charge the baery in extremely cold condions. The baery can be easily removed from the bike
and charged whilst o the bike.
If the baery is not in regular use i.e. over the winter, you should charge the baery to around two thirds
full, and then charge it for 5-10 minutes every three to four weeks. When the bike is to be put back into
service, fully charge the baery as normal. General baery care:
Do not aempt to open the outer casing of the baery.
Do not aempt to repair the baery.
Do not immerse the baery in water.
Keep the baery away from children.
Do not drop, pierce or otherwise damage the baery.
Ensure the baery is not exposed to temperatures above 55 degrees Celsius or extreme humidity.
Do not use the bike in an environment where temperatures are below -5 degrees Celsius.
Lithium baeries do not perform at their best during the winter months, and so the range may vary from
one season to another.
Charging the baery:
Plug the charger lead into the socket on the rear of the baery, then plug mains cable into the socket and
switch it on. While the baery is charging, the LED on the charger will glow RED, when charging is com-
plete, the LED will go GREEN. If the charger is on but not aached to the baery, the LED will also be
GREEN. If you experience a sudden drop in capacity, run the baery down quite low, then fully charge it.
Once full, leave the charger switched on and connected to the baery for a further two hours. This will
help to balance the cells internally and restore normal operaon.