Swytch eBike Conversion Kit User manual

Installation
1
Instruction
Manual

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3
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.
Please read this manual as it contains important safety information and guidelines for how
to get the most out of our Swytch Kit.
Safety Warnings
To ensure a safe and trouble-free experience when using your Swytch Conversion Kit
please follow the guidelines below:
Kit intended use
The Swytch Kit is designed for roads and well-made paths. It’s not intended for drops of
more than 10cm, stunts, cross-country riding, or extreme sports. Misuse may lead to the
failure of some components and void your warranty.
The product must be used in compliance with your local laws and legislation.
Fully charge before first use
As soon as you receive your kit fully charge your Power Pack, the light will go from red to
green. Do this before you start fitting the Kit.
Never leave on charge for longer than necessary
The Power Pack is perfectly safe for home use, but the charger and battery will
gradually and naturally heat up when it’s plugged in. Avoid leaving your Power Pack on
charge for longer than necessary as this can lead to reduced battery life.
Power Pack Warnings
When using, please follow the manual instructions. The battery must not be
exposed to temperatures below -10°C or above 40°C. The battery contains
dangerous substances, and you must not disassemble, impact, or soak it in water. Only use
the charger provided to charge the battery and when in storage you must charge every 90
days.
The handlebar mount handle must be fully engaged with the Power Pack
The Power Pack must be fully connected within the mount for correct operation. The Power
Pack should sit vertically within the mount with the logo facing forwards and the yellow
connector at the top.
Introduction

4
Tighten up before riding
Whether it’s your first ride or your hundredth ride, please ensure all nuts, screws and bolts
are tight before taking off on the road. Any loose parts could result in the motor wheel
coming off while riding - please be careful. Every 100 km, check your wheel spokes are
tight to ensure that the wheel remains secure.
Maintain your bike
For a safe ride on any bicycle, it’s important that the bike is well-maintained and in good
working order. Regularly check and maintain the condition of your bike.
Placing any metallic or conductive objects into the charge port other than the
charger may cause electric shock, fire or other injury. Don’t connect the charger if water,
ice or condensation is in the charge port.
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
Spares
Only genuine replacement parts for safety-critical components must be used. There are no
consumables or lubricants necessary for the Swytch Kit. Please contact our help centre for
more information about spares.
Warnings
Throughout the manual these callouts warn about situations that could cause death,
serious injury and/or heavy material damage if you don’t follow the safety
instructions.
Get in touch
Before you ride your Swytch Bike for the first time, please be absolutely sure that it has
been correctly assembled. You will find step-by-step instructions in this manual. For
further help and support visit our help centre here - support.swytchbike.com.
!
Introduction

5
00
Table of Contents
01
In the Box
04
Using Your Kit 05 Troubleshooting
02
Installation
06
Kit Care
03
Brompton
Kit Checklist
Tools Required
p.7
p.8
Error Codes
Motor Wheel
Pedal Sensor
Magnetic Disc(s)
Mount & Bracket
Swytch Motor Wheel
Magnetic Disc(s)
Pedal Sensor
Mount & Bracket
Base Display
Connecting Up
Routing Cables
Power Pack Intro
Starting Your Ride
Power Pack Settings
Checking Your Battery
Ending Your Ride
Charging Your Kit
p.10
p.15
p.23
p.25
p.28
p.29
p.31
p.40
p.41
p.43
p.45
p.46
p.47
p.49
p.50
p.51
p.52
p.54
p.54
p.55
p.33
p.34
p.36
p.37
p.38
Maintenance
Warranty Terms
Torque Washer
Magnetic Disc(s)
Pedal Sensor
Mount Placement
Cable Routing

Swytch Help Centre
01
In the Box
1. Kit Checklist
2. Tools Required

7
Kit Checklist
In the Box
Power Pack Motor Wheel Mount
Bracket, Spacers & Screws Base Display Magnetic Disc(s)
Pedal Sensor Charger Cable Ties
Use this list to get all the parts
ready before you start.
*Please note that this doesn’t include any accessories.
1.

8
In the Box
Tools Required
Allen Key Set Tyre Levers Scissors
Bicycle Pump Adjustable Spanner Ruler
You’ll need to use the following tools
to install your Kit. Please note that
these are not provided.
2.

Swytch Help Centre
02
Installation
1. Swytch Motor Wheel
2. Magnetic Disc(s)
3. Pedal Sensor
4. Mount & Bracket
5. Base Display
6. Connecting Up
7. Routing Cables

10
Installation
1.
1. Remove your front wheel
Swytch Motor Wheel
1.1
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.
Turn your bike upside down.
Loosen your existing front wheel
and remove it.
Note
These steps depend on the brand
and type of bike you have. Please
see the manufacturer’s instructions
or visit support.swytchbike.com for
support.

Installation
11
Tyre levers
2. Prepare your Swytch motor wheel
Fit your Swytch motor wheel with a
new tyre and inner tube. For support
and advice on which tyre you should
use visit support.swytchbike.com.
If you don’t have a new tyre, use the
tyre and inner tube off the wheel
you just removed from your bike.
Pump up the tyre to the
manufacturer’s suggested tyre
pressure. This is printed on the
sidewall of the tyre.
If you have disc brakes, remove the
six screws and plastic spacer from
the motor wheel. Move the disc
rotor from your old wheel onto your
Swytch motor wheel.
2.1 2.2
2.3 2.4
8mm
Note
Tighten the screws with 2-3 Nm of
torque. If you’re unsure about
working on your brakes, visit
swytchbike.com/manual/3nm/ for
support.
Use the existing screws and
hardware you have. The screws
should have an 8mm thread length.

Installation
12
If it doesn’t fit, check the axle flats
are aligned with the fork dropouts.
10mm or 9mm
3. Fit the Swytch motor wheel onto your bike
3.1 Slot the Swytch motor wheel into
the dropouts of the forks.
Note
Most bikes have a 10mm dropout
slot width, so our standard motor
axle is 10mm wide. If the axle doesn’t
fit your bike, please get in touch at
support.swytchbike.com for support.
!Don’t file your forks or axle to
make the motor wheel fit.
!The motor cable should face the
ground when the bike is upright.
!The motor cable should be on
the opposite side to the chain.

Installation
13
3.3
3.2
3.4
Fit the torque washer, flat washer,
and axle nut as shown. Your bike
forks should fit snugly around the lip
of the torque washer.
Fork drop out
Torque washer
Lip
Flat
washer
Nut
Fit the rubber cover over the nuts on
both sides of the motor.
Rubber
cap
Motor cable
Using a large spanner, tighten the
nuts on both sides of the motor
wheel.
!Ensure the torque washer is
fitted correctly.
Ensure 45 Nm of torque is
used to tighten the axle nuts.
Unsure how to get 45 Nm? Visit
swytchbike.com/manual/45nm/
for support.
!

Installation
14
5.1 Spin the motor wheel by hand. The
wheel should spin freely.
Check the troubleshooting section
if your wheel doesn’t spin freely.
4.
5.
Adjust your brakes (if necessary)
Check your motor wheel
If you have rim brakes, check the
pads contact the new rim correctly.
The brake pads should only touch
the rim and not the tyre.
4.1 Note
When adjusting the brakes follow
the bicycle manufacturer’s
instructions.
If you’re unsure about working on
your brakes, visit swytchbike.com/
manual/adjustbrakes/ for support.
Tyre
Adjust if necessary
Rim

15
Installation
1.
Measure the distance
between your pedal arm
and bike frame
Use a ruler to measure the gap
between the end of the pedal arm
and the start of the bike frame on
the left side of the bike (opposite
to chain side).
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. Then use the table on
the following page to find the
relevant fitting instructions.
1.1
Magnetic Disc(s)
2.
If 2mm or less: check
the inside of your pedal
arm
If the distance measured in step 1.1
is 2mm or less then check the shape
of the inside of your pedal arm.
Depending on the shape of your
pedal arm, turning the magnetic
disc arm can get a better fit.
2.1
Pedal Arm
?
Indent Round or Flat
2.

Installation
16
3.
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.
3.1
Distance Between Pedal
Arm and Frame
Pedal Arm Shape
(cross section view)
Magnetic Disc Page
4mm or more Either Easy fit regular 17
2mm - 4mm Either Easy fit thin 17
2mm or less Round or flat inside arm Universal 19
2mm or less Indented inside arm Universal
(rotated arm to fit
pedal indent)
19
For Brompton riders go to the Brompton specific instructions on page 34.
Check the table below
ROUND
Pedal Arm
FLAT
Pedal Arm
INDENTED
Pedal Arm

Installation
17
1. Fit the magnetic disc
Easy Fit Regular & Easy Fit Thin 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.
The side of the disc with ‘Working
Surface’ written on must face the
bike frame.
1.1
1.2
Magnetic discRetention ring

Installation
18
2. Fit the retention ring
Fit the retention ring around the
magnetic disc to secure it in place.
2.1
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.
If the magnetic disc slides around
when rotating the arm you may
need to use the universal arm to
secure it in place. See the next page
for more information.

Installation
19
1. Check your pedal arm
Universal Magnetic Disc Regular
Determine which way round you’ll need
to fit your magnetic disc arm based on
the shape of your pedal arm.
1.1
A. B.
Magnetic disc
Arm
Bolt
Retention ring
Indented pedal arm
The magnetic disc arm matches the
curve of the indent.
Round or Flat pedal arm
The magnetic disc arm curves
around your flat or round pedal arm.
ROUND
Pedal Arm
INDENTED
Pedal Arm
INDENTED
Pedal Arm
FLAT
Pedal Arm
FLAT
Pedal Arm

Installation
20
2. Fit your universal magnetic disc together
Loosely tighten the bolt onto the arm
using a 2.5mm Allen key, using the diagram
below.
2.1
A.
B. Indented pedal arm
configuration
Round or flat pedal arm
configuration
Allen key
Rough side of disc
(side without writing)
Outer curved arm
Allen key
Rough side of disc
(side without writing)
Inner curved arm