Woosh SWX02 48V Assembly instructions

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Sales: 01702 435566 — Support: 01702 684444 — 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.
SWX02 48V (REAR)
Hub Kit Fing Guide

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Before you start the installaon of your kit, please read the following:
This kit is intended to be fied by someone who is competent and experienced at fing electric kits to
bikes. If you are not experienced and/or lack the necessary tools to complete any of the proceduresin
this manual, you should seek the advice of a professional who can fit the kit for you. If necessary, call us
on 01702 684444 or email us at [e-mail] and we will try and put you in touch with
someone in your area that has the necessary experse to properly fit 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 different types of pedelec sensor, we would normally have determined which type is
suitable for your bike before you finalised your order. If we didn’t, please contact us before aempng
to fit your kit.
Warranty Terms:
If your kit is fi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 first need to have the person that installed your kit con-
firm 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 andsend it
back to you at our expense. If the kit was not fi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, a baery cradle with integral controller, a baery, a charger,
modular cable, pedal-assist disc and sensor, a throle, brake levers and an 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, and the pedelec sensor (as this differs from
kit to the next), ensure you have the complete kit before you start.
Baery cradle/controller
Modular cable
Thumb throle
Brake levers
KM529 LCD
Note: The speed sensor is internal to the motor on this unit, and so there is no separate sensor/magnet to
be fied.

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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 fit 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 refit 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 find that the
motor kicks in when you pedal backwards!The disc should be fied such that the arrows on the disc are
on the le side.
The supplied sensor/disc may differ 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 sensorwhich is mountedonto the downtube instead.
Sensor To controller

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Le-side pedelec sensor
The le side sensor consists of the sensor itself, two rubber washers, and the magnet-ring—see below.
Remove the le crank, and then fit the thinner of the two rubber washers into the rear of the sensor.
Ensure that your boom bracket matches the one shown below, and then slide the sensor into posion.
Fit the plasc ring that incorporates the magnets. The silver magnets should face inwards.

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Le-side pedelec sensor cont.
Slide the larger rubber washer over the spindle and then re-fit 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 modified 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 specific 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.
The sensor needs to line up with the magnets embedded in the disc, so that it can detect the magnetsas they pass by.
Sensor To controller
Cable-e for
securing to
seat tube.

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Baery Cradle/Controller
The HL baery/controller kit included with this conversion kit mounts to your down-tube where your
bole holder would normally be. If the bike does not have these fixings, you can fit the supplied riv-nuts
to allow you to mount the baery cradle. Ensure that you mount the cradle high enough up the frame so
that the baery/cradle does not foul on the chain-ring. You will also need to ensure that there is sufficient
clearance at the top end of the baery/base, the baery needs to be slid upwards and towards the front
of the bike a lile when removing it.
Once the base has been secured to the frame, fit 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-fit the baery when all leads have been correctly terminated/secured
and the kit installaon is complete. If you leave the baery aached, you may accidentally short some-
thing and cause damage to the baery and/or kit components.
Truing your wheel:
The wheel will come with a spoke tool, it will likely be necessary foryou to true your wheel. You should
ensure that the spokes are all sufficiently ght, then adjust the tension of the spokes to ensure the wheel
runs true. It may be necessary to adjust the alignment of the wheel, this is also done by adjustmentof the
spokes. If you’re not sure how to do this, you should ask your local bike shop to do this for you.

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Motor Wheel
Remove the exisng rear wheel and swap the tyre, tube and freewheel to the new motor wheel. If you
had a cassee previously, you should have ordered a suitable freewheel from us at the same me you or-
dered your kit, we will normally have fied the freewheel to the motor before despatching your kit.
If you have purchased this kit and cannot carry out one or more of the procedures in this manual ordo
not have the necessary tools to complete these procedures, you should seek the advice of a professional
who can fit the kit for you.
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 fi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 tothe
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 fi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 edges where the cable exits the motor.
The red arrow on the diagram above shows the usual route for the motor cable, with the quick-release
connector (in the cable) indicated by the solidred box.

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Handlebar Components:
The thumb-throle, brake levers and LCD need to be mounted to the handlebars. The installaon proce-
dure for these parts may vary a lile from bike to bike, but follow the guide below for a general overview.
The LCD would normally be fi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 your thumb. To fit the thumb-throle, slide the grip off 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) back in posion.
Depending on the configuraon of the bike, it may be more praccal to mount the throle and display in
slightly different locaons or on opposite sides. The next step is to run the modular cable (for the LCD,
throle and brake cut-outs) from the front of the bike, along the down-tube and back to the controller.