Swytch Universal eBike Conversion Kit User manual

1
www.swytchbike.com/instructions
Instruction Manual

Contents
1. Safety Warnings 4
2. Quick Start Guide 6
3. Tools Required 8
4. What’s in the Box 10
5. Installation 14
5.1 Motor Wheel 15
5.2 Universal Pedal Sensor (PAS UNI) 19
5.2.1 Easy Fit Regular/Thin Magnet Disk 20
5.2.2 Universal Magnet Disk 22
5.2.3 Pedal Sensor Alignment 24
5.3 Quick Connect Handlebar Mount 26
6. Brompton Specific Instructions 30
6.1 Brompton Motor Torque Washer 31
6.2 Brompton Pedal Sensor 32
6.2.1 Brompton Pedal Sensor Alignment 34
6.3 Brompton Peg 35
6.4 Brompton Front Luggage Block Adapter (BRO BLOCK) 36
6.5 General Tips 41
7. Accessories 42
7.1 In-Line Brake Sensors 43
7.2 Hydraulic Brake Sensors 46
7.4 Universal Torque Arm 47
7.5 Torque Narrow 48
7.6 Twist Throttle 49
7.7 Thumb Throttle 49
8. Operation 50
8.1 Power Pack Removal 51
8.2 Power Pack Charging 52
8.3 Power Pack settings 54
9. Troubleshooting 56
9.1 Error Codes 57
9.2 Motor Wheel isn’t spinning freely 58
9.3 Pedal Sensor Magnet doesn’t fit my bike 59
9.4 Motor Starts and Stops when using Pedal Assist 60
9.5 Handlebar Mount moves up 61
9.6 Handlebar Mount pointing down 61
9.7 Power Pack is difficult to remove from bike 61
9.8 Operation Troubleshooting 62
9.9 Motor Starts and Stops when using Pedal Assist 63
10. Maintenance 64
Page No.

5
To ensure a safe and trouble-free experience when using your
Swytch Conversion Kit please follow the guidelines below:
Fully charge before first use
After receiving your kit and before fitting to your bike or
doing anything else fully charge the Power Pack until the
charger light goes from red to green.
Never leave on charge
The Power Pack is perfectly safe for home use, but the
charger and battery will naturally and gradually heat up
when it is plugged in.
Avoid leaving on charge for longer than necessary. Extended
periods left on charge can lead to reduced life of the
battery.
Hear the “Click” when attaching the Power Pack
to the Handlebar Mount.
Make sure that the Power Pack clicks into place when
attaching onto the handlebar mount. If you don’t hear the
click, give it a firm push – the Power Pack must be fully
pressed down on the mount to ensure correct operation.
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 during riding - please be careful. Every 100km,
do tighten your wheel spokes back up if loose to ensure the
wheel remains secure.
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3
4
Safety Warnings
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7
Is everything in your box?
Before starting, make sure everything is in the box that should
be, and double check the parts match with your order (see next
section).
Then, if you know what you’re doing, crack on!
Check our YouTube channel for a full video on the conversion
process. If you know your way around bikes you may prefer to
crack on and follow the video to get up and running.
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2
3
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Fit the Motor Wheel
Motor cable on the left of the bike.
Re-adjust the brakes if necessary.
Tighten wheel nuts.
Fit the Pedal Sensor
Magnet disk on left of the bike.
Mount sensor close to the magnets.
Smooth side facing the sensor.
Fit the Handlebar Mount
Tilt Mount 45° upwards when fitting
the strap so it is in tension when
horizontal.
Connect and Go!
Firmly press connectors together.
Secure cables to bike frame.
The process can be summed up in four
simple steps:
Quick Start Guide
2

8 9
Allen Key Set Tyre Levers Bicycle Pump
Elbow GreaseAdjustable Spanner Scissors
Tools Required
3

10 11
Check everything is there before you start! Once you’ve
unpacked and started fitting it’s easy for things to go missing.
Please keep the original packaging until you’ve fitted the kit.
Every kit should have the following parts:
What’s in the Box
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12 13
All kits should contain the following parts, please check them off
before starting the conversion.
Hub Motor Wheel
Quick Connect
Handlebar Mount
Swytch Power Pack
(ECO/PRO)
2A Standard Charger
(UK, EU, US)
Cable Ties x10
Universal Pedal Sensor /
Brompton Pedal Sensor
3A High-Power Charger
(Optional add-on)
Brompton Extension Peg
(16” Brompton Kits Only)
Brompton Block
(Optional add-on)
T-shirt
(Optional add-on)
In-line Brake Sensors /
Hydraulic Brake Sensors
(Optional add-on)
Thumb or Twist Throttle
(Optional add-on)
Torque Arm
(Optional add-on)

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5.1 Motor Wheel
Remove your old tyre + front wheel from your bicycle
- Swap the inner tube and tyre from the old wheel to
your new Swytch motor wheel.
- If your tyre tread is directional, make sure to face it the
correct way. Pump the tyre to the manufacturer’s suggested
pressure.
Fit disc brake disc (optional)
If you have disc brakes, move the disc from your old wheel
to your new Swytch motor wheel.
1
2
Note: Screws should have an 8mm thread length. If they are
longer they may cause the motor to stop spinning. If they are
shorter, you may strip the thread of the motor wheel.
Installation
5

16 17
Check orientation of motor
- The motor cable should be on the left of the bicycle
(opposite side to the chain).
- Ensure the motor cable is pointing down towards the
ground when the bike is upright. If the motor cable exits the
other way around it can get squashed and damaged.
Check the axle goes in all the way
The flat sides of the axle should fit within the forks. If it
does not fit, please check the troubleshooting section.
3
4
Motor cable
on this side
Slot size
10mm
Fit the torque washer “lips” into the fork slot
Assemble the motor wheel to the forks with the torque
washers installed as shown. The torque washer protrusion
should fit snugly inside the gap in the fork.
Tighten the Wheel Nut
Assemble both axle nuts tightly with a spanner.
5
6
Torque Washer
facing this
direction
Motor cable comes
out in direction of
fork slot.

18 19
5.2 Universal Pedal Sensor (PAS UNI)
There are 4 different configurations for the Universal Pedal
Sensor. Which one you should use depends on the size of gap
between pedal arm and bike frame, and the shape of your
pedal arm.
How big is the
gap between
pedal arm and
frame?
What shape
is the inside
of your
pedal arm?
Photo example Use this
configuration
Pg.
4mm + -
Easy Fit Regular
20
2mm – 4mm -
Easy Fit Thin
20
Less than
2mm
Round Universal Regular
22
Indented Universal Indented
22
Check motor spins correctly
- Spin the motor wheel with your hand to check it can
spin freely and isn’t touching the forks. If it is touching,
please check the troubleshooting section.
- The wheel should be harder to turn backwards than
turning forwards. If it is the opposite, then the motor
has been installed backwards.
Adjust brakes
If necessary, adjust the brakes so that they contact the rim
of the wheel. When adjusting the brakes follow the bicycle
manufacturer’s instructions.
7
8
Add spacers if
the motor casing
touches the forks
INDENTED
For Brompton Pedal Sensor, go to page 32

20 21
5.2.1 Easy Fit Regular/Thin Magnet Disk
Magnet disc
- Fit the magnet disk either side of the crank axle.
- The side of the bike should be opposite the side
with the chain.
- The smooth side of the magnet disk must be
facing the sensor.
Fit Retention Ring
Fit the retention ring around the magnet disk to secure it
in place. It’s easiest to start on one side and work the ring
around until you get to the other end.
Check Correctly Installed
Below is how the magnet disk should look once properly
fitted:
Troubleshooting
If the magnet disk doesn’t fit, check the troubleshooting section.
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2
3

22 23
5.2.2 Universal Magnet Disk
When switching between the different sides, you will need to
unscrew the arm and reassemble it flipped around so that the
working surface of the magnet disk remains facing the same way.
Before starting, clean your pedal arm of any dirt and debris.
This will allow the pedal disk arm to fit securely to the surface.
Loosely cable tie the magnet disk arm to the inside of your
pedal arm in at least 2 points. Reposition the magnet disk
so that it is close to the sensor and aligned. Check that the
alignment is correct by rotating the pedal arm backwards
and watching for any movement. After this check, tighten
the cable ties completely.
1
Once aligned in position, tighten the screws to lock the disk
arm into place.
For small pedal arms, thread the cable ties through the holes
to improve the grip.
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4
2

24 25
5.2.3 Pedal Sensor Alignment
Attach Pedal Sensor to bike
- Remove the pedal sensor adhesive cover.
- Attach the pedal sensor to the frame of the bike
close to the magnet disk.
Line up sensor to magnet arc
- Make sure that the centre of the sensor is aligned
to the magnets.
- Point the sensor away in a straight line from the
centre of the disk.
- As the magnet disk spins the magnets need to pass
close to the sensor for it to detect your pedalling.
Check correct installation
- The photo below shows a correctly fitted pedal sensor.
Adjust the pedal sensor to minimise the gap between the
sensor and the magnet. Tighten the screw to prevent it from
moving.
Cable tie in place
- Once fitted correctly, use the cable ties provided to secure
the pedal sensor to the frame. Route the wire along the
down-tube of the bike up to the handlebars, using the cable
ties to secure to the frame.
Make sure magnet
disc passes close
to sensor
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3
4

26 27
5.3 Quick Connect Handlebar Mount
Add rubber spacers to handlebars
- Fit the rubber handlebar spacers onto the handlebars.
(22mm diameter handlebars only).
- For larger sized handlebars (e.g. on mountain bikes) they
are not required.
Place mount onto handlebars angled upwards 45°
- Fit the Quick Connect Handlebar Mount over the spacers
onto the handlebar.
- Tilt the mount up approximately 45°, this is necessary to
ensure correct final installation.
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1
Fit the Anti-Twist Strap
- Pass the Anti-Twist Strap underneath the handlebar stem.
Tighten strap in place
- Secure the strap on to the other arm of the mount. Use the
closest holes possible with the mount tilted upwards. Fold
the strap back on itself to increase its strength and keep it
looking tidy. Tighten the screws.
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4

28 29
Align Mount horizontally
- Turn the Mount to face horizontally. This will put tension in
the Twist Strap and keep the Mount from turning any further.
If in the future the Mount sags, simply adjust to a new hole
on the Twist Strap.
Connect accessories
- Connect the PAS to the Quick Connect Handlebar Mount.
- 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.
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6
Connect motor
- Connect the motor to the Quick Connect Handlebar
Mount. Secure the motor wire to the fork with the cable ties
provided. Leave enough slack for the handlebars to turn.
- If the motor cable is not long enough, you may need an
extension cable.
Ensure the motor is fully connected – hear the “click”
- To connect the waterproof connector, align the arrows and
push together until the arrow on the motor wire connector
is touching the Mount connector. The photo below is not
properly connected.
- The photo below shows the motor connected correctly. You
will hear and feel a “click” once it is pushed in all the way.
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8
BAD – not fully connected
GOOD – fully connected

31
Brompton Specific
Instructions
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6.1 Brompton Motor Torque Washer
To fit the Brompton Torque Washer, first make sure to thread
the motor cable through the keyhole in the washer.
Remove any of the existing wheel hardware.
If you have a mudguard, assemble it underneath the
locking nut.
1
2
3
Be careful not to damage the motor
cable when tightening the nut

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6.2 Brompton Pedal Sensor
Assemble the Brompton Pedal Sensor by screwing the 2-part
clamp over the pedal arm. Use the Brompton plastic insert to
make sure the disk does not slip up the length of the arm.
Check which pedal type you have
1
How big is the
gap between
pedal arm and
frame?
What shape is
the inside of
your pedal arm?
Photo example Use this
configuration
Pg.
2mm - 4mm -
Easy Fit Thin Easy Fit Regular
20
Brompton pre
2013 PAS-BRO-A
32
Less than
2mm
Brompton post
2013 PAS-BRO-B
32
Non-Brompton
aftermarket
UNIVERSAL
22
Assemble these parts onto the pedal arm
This is how it should look when finished
When installing the sensor, an alternative mounting location
is directly on the bottom bracket block. Use cable ties as
shown to secure it into place. Route the cable around the
seat post and follow the existing cables.
If you have an after-market pedal arm, you will need to use the
Universal Magnet Disk or Easy Fit Magnet Disk.
2
3
4
Type A (indented) Type B (Not indented)

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6.2.1 Brompton Pedal Sensor Alignment
Fit the sensor onto the small frame tube of the Brompton.
Angle the sensor and add a spacer to move the sensor
within range. The spacer can be the supplied foam or a piece
of inner tube. Tighten the sensor screw to lock it in position
and add cable ties to secure it to the frame.
Alternative mounting location: Install the pedal sensor onto
the lower part of the frame. Remove the hinge mechanism
so that it can fit under the pedal sensor.
6.3 Brompton Peg
Follow the installation instructions for the standard kits.
Remove the existing peg from the Brompton frame and
attach the extended peg that is provided in the kit. Screw
the peg on by hand until it turns no further.
2
2
BROMPTON INCORRECT MOUNTING METHOD 1
Mounted onto incorrect tube. Magnets must pass from left
to right of the sensor.
BROMPTON INCORRECT MOUNTING METHOD 2
Mounted onto correct tube but gap is too big
1
1

36 37
6.4 Brompton Front Luggage Block Adapter
(BRO BLOCK)
The Brompton Block Adapter allows the Power Pack to be
mounted directly to the frame.
These parts are included in the Bro Block Kit:
Cable ties x10
M5x12 Cap Screws x2
M5 Locking Washers x2
M5 Large Washers x2
Brompton Carrier Adaptor x1
Pedal Sensor Extension Cable x1
Fasten the mount to the front carrier mount attachment
at the front of the Brompton using the screws provided. Be
sure to assemble the screws in the order shown below.
Attach the Handlebar Bracket to the adapter.
Don’t use the spacers or the twist strap.
1
2
Assemble in
this order

38 39
Connect your Pedal Sensor, Brake Sensors and Throttle to
the bracket. You will need to use extension cables to reach
the new position.
Shorten the motor cable by folding it back on itself and
securing it with a cable tie. Make the loop back the same
length as the length of the Brompton Block Adapter.
3
4
Use 2 extension cables to reach
handlebar addons e.g. Throttle
and Brake Sensors
Tie the cables to the
existing Brompton
cables to allow the
bike to fold
Use 1 extension cable
to reach the PAS
Thread the motor cable through the hole in the Brompton
Block Adapter to hide the excess cable.
You might find this step easier with the bracket removed
from the Block.
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