Woosh Hub Kit Assembly instructions

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Tel: [phone] — E-mail: [email protected]
Important: For your own safety you must read this man-
ual before attempting to fit any part of the motor kit to
your bike. You must also ensure that you fit the kit in
strict accordance with the instructions in this manual.
Hub Kit Fing Guide
36V/HL

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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 tools to complete any of the procedures in
this manual, you should seek the advice of a professional who can t the kit for you. If necessary, call us
on 01702 684444 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.
There are several dierent types of pedelec sensor, we would normally have determined which type is
suitable for your bike before you nalised your order. If we didn’t, please contact us before aempng
to t your kit.
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 listed below before going any further, if there are any missing parts,
contact us on 01702 435566.
The motor kit comprises of a motor wheel with hub motor, a baery cradle with integral controller, a
baery, a charger, modular one-cable system, pedal-assist disc and sensor, speed sensor (and magnet) ,a
thumb throle, brake levers and KingMeter J-LCD. Ensure that you have all of these items, a photo of the
items is show below so you can easily idenfy each of the parts. Not shown in the photo below are the
baery itself and the motor wheel (which will dier depending on the type ordered), ensure you have the
complete kit before you start.
Modular cable
Baery cradle/controller
Thumb-throle
Brake levers
Speed sensor and magnet
Pedelec sensor
KingMeter LCD

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Installaon of the various Pedelec Sensor types
There are three types of sensor kit that can be used, two that t on the right side of the bike between the
chain-ring and frame, and the other le-side sensor which slots into the end of the boom bracket.
The standard right-side pedelec kit consists of two parts, these are the sensor itself and the PAS disc. You
will need to remove the boom bracket and then slide the sensor ring into place as shown below. With
the sensor in posion, you can ret the boom bracket. With the boom bracket re-installed, slide the
PAS disc over the spindle so that it is as close as possible to the sensor, without actually touching it.
You need to ensure that the disc is the correct way around on the spindle, otherwise you will nd that the
motor kicks in when you pedal backwards! The disc should be ed such that the arrows on the disc are
on the le side.
The supplied sensor/disc may dier slightly from the one shown above, but the installaon procedure will
be the same.
A variaon of this same arrangement is shown below, it sll uses a PAS disc much like the above, but uses
a sensor which is mounted onto the downtube instead.
Sensor To controller

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Le-side pedelec sensor
The le slide sensor slides over the spindle and into the toothed part of the boom bracket. It is not com-
pable with all boom brackets however. Some that aren’t compable include the boom brackets with
the plasc cups. Although they look very similar, the le-side PAS will not slot into these. It must be a
boom bracket with a metal cup—see pics below. In some cases you may nd that you cannot slide the
sensor down far enough, if this is the case, you can either swap the boom bracket for a dierent model
(we can advise you on a suitable unit), or contact us to see if a right-side PAS is a possibility for you. The
space between the rear face of the crank and the boom bracket needs to be around 5mm or more, if it
is less, you may need to shave a lile o the rear face of the crank to avoid crushing the PAS when you re-
t the crank.
Ensure that your boom bracket is similar to the one shown below, and then slide the sensor into posi-
on. It may need a reasonable amount of force to push it all the way on.

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Le-side pedelec sensor cont.
Slide the larger rubber washer over the spindle and then re-t the crank.

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Pedelec Sensor for Octalink type crank sets:
The diameter of the Octalink axle is greater and so the regular pedelec disc cannot be used. We are how-
ever able to provide a soluon for this type of boom bracket. We supply a modied pedelec disk which
has a larger hole in the centre which can be used, it needs to be secured to the back of your smallest
chain-ring in the case of double or triple rings. The sensor itself is then aached to the base of the seat
tube.
Pedelec disc
With the sensor in place as per the photo above, it now needs to be secured, the way you achieve this
may vary depending on your specic bike. In this example, we’re just using some cable-es.
The sensor is mounted at the base of the seat tube. The sensor is supplied with a single cable-e which is
use to secure the sensor to the seat tube.
Sensor To controller
Cable-e for
securing to
seat tube.

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Baery/Controller
The HL baery cradle/controller included with this kit mounts on your down-tube, where your bole
holder xings would normally be. If the bike does not have these xings or they are not in a suitable posi-
on, you can t riv-nuts (supplied) to allow you to mount the baery cradle. Ensure that you mount the
cradle high enough up the down-tube that the cradle doesn’t foul on the chain-ring. You will also need to
ensure that there is sucient clearance at the top end of the baery, the baery needs to be slid up-
wards (towards the front of the bike) a lile when removing it. Also, be careful not to mount the cradle
too low, or you may nd that the baery hits the seat-tube before it’s fully engaged on the cradle.
Don’t forget to use the supplied washers, if you bolt the cradle to the frame without using the washers,
the plasc will deform and eventually break.
Once the cradle has been secured to the frame, t the baery in place and double-check that that you
have enough clearance at either end, and adjust the posion of the base if necessary. You should then
remove the baery and connue on with the installaon of the kit. Do NOT connue the installaon
with the baery in place. You should only re-t the baery when all leads have been correctly terminat-
ed/secured and the kit installaon is complete. If you leave the baery aached, you may accidentally
short something and damage the baery and/or kit components.
Motor Wheels:
There are several dierent opons for the motor wheel. The Front-BPM opons require torque arms to
be ed, and the rear wheel opons will need the cassee or freewheel from your exisng wheel to be
ed to the new motor wheel.

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Motor Wheel
Remove the exisng rear wheel and swap the tyre, tube and freewheel/cassee to the new motor wheel.
You must ensure that the motor cable where it exits the spindle, points downwards towards the ground,
see below for photos showing how the wheel should be ed and the correct orientaon of the cable.
Once the wheel is properly installed, slide the rubber covers in place and secure the motor cable to the
frame using cable–es. The rubber cover for the side where the cable exits the spindle will need to be slid
along the cable, and it should be ed in such a way that the hole in the rubber cover keeps the motor
cable poinng downwards as much as possible—see below. Also ensure that the metal coil/sheath is all
the way down the cable so that it protects the cable from the somewhat sharp edges where the cable ex-
its the motor.
The red arrow on the diagram above shows the typical route for the motor cable, with the quick-release
connector (in the cable) indicated by the solid red box.
FRONT Motor Wheel
Remove the exisng wheel and swap the tyre and tube to the new motor wheel. If you have purchased
this kit and cannot carry out one or more of the procedures in this manual or do not have the necessary
tools to complete the installaon, you should seek the advice of a professional who can t the kit for you.
You must ensure that the motor cable where it exits the spindle, points downwards before looping back
up, to form a drip –loop, this is to stop water running down the cable and collecng at the cable exit.
Once the wheel is properly installed, connect the motor cable and then secure the motor cable to the
fork using cable–es.

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Handlebar Components:
The thumb-throle, brake levers and display unit need to be mounted to the handlebars. The installaon
procedure for these parts may vary a lile from bike to bike, but follow the guide below for a general
overview.
The display would normally be ed to the le side of the handlebars just to the right of the grip, this way
the buons can be easily reached with a thumb . To t the thumb-throle, slide the grip o the right side,
loosen the exisng components such as the shier, brake lever etc. then slide the thumb-throle on and
then secure it (and the other components) in posion.
Depending on the conguraon of the bike, it may be more praccal to mount the throle and display in
slightly dierent locaons or on opposite sides.
If you have hydraulic brakes or brake levers which have an integral gear shier, you will need to use a
dierent brake sensor arrangement. The way these sensors work is that as the magnet is moved away
from the sensor, the brake cut-out is acvated. A typical installaon would look similar to the below.
The next step is to run the modular cable (for the LCD, throle and brake cut-outs) from the front of the
bike back to the controller .
Sensor
Magnet