Lekkie Converted System Summit, Installation Instructions Manual

Page 1: ...WWW CONVERTED CO NZ SUMMIT INSTALLATION INSTRUCTIONS 2020 ...

Page 2: ...ars 8 4 KIT INSTALLATION 9 4 1 Bottom Bracket Preparation Motor Fit 9 4 2 Speed Sensor Fitting 11 4 3 Shift Sensor Fitting 13 4 4 Battery Mount Fitting 14 4 5 Fitting the Chainring 16 4 6 Fitting the Cranks 17 4 7 Wiring Harness and Handlebars 18 4 8 Cockpit Handlebars 19 4 9 Cable tidy up and check 20 5 SYSTEM TEST 21 5 1 Powering on and Charging 21 5 SYSTEM TEST 22 6 SAFETY CHECK 22 5 2 Power as...

Page 3: ...others and there are some which unfortunately won t convert Generally speaking a basic hard tail no rear suspension bike with a traditional tringle frame will be the easiest conversion If you have a bike already and are unsure or if would like to buy a bike for conversion please contact us and we can give guidance we have converted hundreds We have created printable templates as guides for battery...

Page 4: ...nstall the drive unit battery and associated wiring Tidy up clip all your cable ties get everything looking smart Safety Check Your bike is going to be fast so make sure everything is properly installed all bolts are tight brakes function cables are all secure but allow adequate steering movement but cant get caught etc Get riding While it is still your same beloved bike it will be faster than eve...

Page 5: ... pictured Converted System operation manual shipping boxes Battery and keys Motor unit Cranks optional Buzz bars pictured Charger with AU NZ mains cable Main EU BUS wiring harness Mounting hardware axle plate mounting bolts crank bolts Converted System 3 button display Universal throttle Speed sensor with magnet and small mounting screw Gear shift sensor Mechanical brake levers with e cutoff Chain...

Page 6: ...k cup socket 44mm 16 notch Half round file potentially depending on frame Consumables extras items you may consider Extra cable zip ties some bikes need more than others Shift cable core it can sometimes be difficult to a install shift sensor with an old cable especially with frayed end as you need to slide it onto the cable New chain We advise fiting a new chain remember you have just added more ...

Page 7: ...contact Converted System for further info as required 3 2 Cranks bottom bracket front derailleur Remove the pedals from the original cranks if you are planning to re use generally 15mm spanner or allen key Left pedal is reverse thread turn clockwise to loosen Remove cranks Remove the centre crank bolts normally 8mm Allen Key Using a crank extractor tool remove the cranks see manufacturer instructi...

Page 8: ...et up with cable brakes it is advised to replace with the included levers which incorporate cut out switches which cut motor power when the brake is operated Hydraulic brakes For bikes with hydraulic brakes you may wish to run your existing brakes without cut off Converted recommends running some form of motor cut off for safety We can provide Tektro E 350 hydraulic E bike brakes with built in sen...

Page 9: ...is clean free of weld debris you may need to file to get motor to slide in The motor should be able to swing up till it comes in contact with the downtube Ensure the motor can be inserted fully and sits with the drive side flat against the botom bracket shell without touching chain stays etc For rear suspension bikes ensure the pivots are clear of the casing for the full range of movement else spa...

Page 10: ...g a lock ring tool or C spanner see pic tighten both the M33 lockring 33 40Nm torque and the BB cup over the M33 20 30Nm torque Lock ring socket tools are available to purchase through Converted System Tighten the M6 bolts to final torque 34 40Nm 4 KIT INSTALLATION ...

Page 11: ... sensor and magnet is approximately 50mm from the rim The mount for the sensor has double sided tape but fasten further with two zip ties Install the magnet on a spoke For best practice ensure that the magnet passes within 5mm of the sensor The small black screw holds the mount in its horizontal position 4 KIT INSTALLATION ...

Page 12: ...W CONVERTED CO NZ Connect the speed sensor to the 3 pin plug running from the controller On some bikes like the one pictured you may require the Converted System speed sensor extension 4 KIT INSTALLATION ...

Page 13: ...the upper chainstay Feed the gear shift cable through the sensor There should be only a small amount of resistance Secure with zip ties Connect the shift sensor to the yellow plug which runs from the bottom of the controller The sensor will partially cut the motor power for one second when shifting 4 KIT INSTALLATION ...

Page 14: ...unt the battery cradle to the downtube ensuring that you have at least 2 bolts fixing the cradle in position Before completely tightening the bolts ensure that the battery has enough clearance from the seat tube and can be slid forward upwards on the rails for removal ...

Page 15: ... the motor controller There is only one connector this shape ensure connectors are pressed together as far as they can go Tidy up the wiring underneath the motor or behind the seat tube using zip ties so it can t catch on anything Routing will depend on frame With full suspension frames ensure cables do not get pinched or overly stressed pulled at any stage of travel 4 KIT INSTALLATION ...

Page 16: ...GRING Summit Pro Kit optional accessory Tighten the M5 x 10mm bolts to 25 30nm Ensure the chainring is free to turn and does not touch the chainstay else spacers or a smaller chainring may be required see www Converted System bike for available options Refit the chain ideally using a new chain Check chainline is good and there is no frame interference ...

Page 17: ... axle using a general lithium based workshop grease Fit the cranks note L and R sides as pedal threads are different directions Insert and tighten the M8 crank bolts to 40nm Note that the optional Converted System Buzz bar cranks which are self extracting are used in this example ...

Page 18: ...ng Harness and Handlebars Connect the main wiring harness to the motor ensuring the arrows on the connectors are aligned Secure with cable ties and neaten all wires Ensure cables ave adequate length to enable correct function of steering handlebars ...

Page 19: ...eft or right side of the handlebars Note As you may still have the rear gear shifter located on the right side this may interfere with easy operation Install the display close to he left hand grip and plug the cables together The connectors are colour coded for your convenience On the harness side there is one display plug green male 2x ebrake cutoffs yellow female and 1x throttle yellow male BRAK...

Page 20: ... on the bike use cable ties as necessary Ensure all cable connectors are fully inserted Ensure there is adequate length allowed for around moving parts steering suspension etc and cables are not strained at the full extent of movement Ensure cables cannot be caught or pinched between moving parts suspension tyres wheels cranks chain etc ...

Page 21: ...ystem is powered on and charged from the section of the battery shown below Switch the battery on before powering on the display For display operation please refer to the Converted System User Manual WARNING YOUR SYSTEM IS NOW LIVE KEEP HANDS AND FINGERS WELL CLEAR OF ALL MOVING PARTS FAILURE TO DO SO MAY RESULT IN INJURY 5 SYSTEM TEST ...

Page 22: ...actory settings Ensure brake function before riding If fitted ensure the ebrake cutoffs stop the motor power when applied READ THE SYSTEM USER MANUAL The system is very easy to use however for your own safety please ensure you read and undersand the manual and understand how the system works Remember your bike is faster than ever please take your time to learn it s new capabilities Have Fun keep s...

Page 23: ...WWW CONVERTED CO NZ WWW Converted System BIKE hello Converted System bike Petone New Zealand ...