Woosh HL30 Instructions de montage
1
Important: For your own safety you must read this
manual before attempting to fit this kit. You must also
ensure that you fit the kit in strict accordance with the
instructions in this manual.
Fing Guide for
HL/G30 Hub Kits
2
Before you start the installaon 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 435566 or email us at [email protected] and we will try and put you in touch with
someone in your area that has the necessary experse 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.
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 installaon, or the kit has been used improperly, the warranty will be voided.
3
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 baery cradle with integral controller, a
baery, a charger, modular cable/loom, pedal-assist sensor, a thumb throle, brake sensors and a King-
Meter KM529 LCD. Ensure that you have all of these items, a photo of the items is show below so you can
easily idenfy each of the parts. Not shown in the photo below are the baery itself , the charger, and the
motor wheel (which will dier depending on the type ordered), ensure you have the complete kit before
you start.
KM529 LCD
Thumb-throle
Controller/
Baery cradle
Inline brake
sensors
Loom/Modular
cable
Pedelec sensor
HL Kit
G30 Kit
As above but with dierent
baery and cradle
4
Installaon of the various Pedelec Assist Sensor (PAS) types
There are three types of PAS that can be used, two that t on the right side of the bike between the chain
-ring and frame, and the le-side sensor, which slots into the end of the boom bracket.
The right-side PAS kit consists of two parts, these are the sensor itself and the PAS disc. There are two
dierent opons for the disc/magnet-ring part of the PAS kit (see below-right), depending on whether
you have a square taper boom bracket or something else. In all cases, the sensor ring is mounted be-
hind the lip of the xed cup, or behind the right bearing shell (in the case of a BB with external bearings).
The PAS disc for square taper boom brackets is simply slid down the axle so that it is close to, but not
touching the sensor. For all other types of boom bracket, you would need to use the alternate disc
which comes in three parts—the two halves of the magnet ring, and the support/mounng plate. Ideally,
the mounng plate is cable-ed to the smallest chain ring (using the loops around the outside of the
plate), and the two halves of the magnet ring are then glued to the plate. In some cases, there is not al-
ways enough room to do this, and the ring needs to be bonded directly to the smallest chain ring and/or
you may need to use the seat-post mounted sensor instead—see next page.
Installaon Notes:
You need to ensure that the disc is the correct way around on the axle. The disc should be ed such that
the arrows on the disc are on the le side (facing the sensor). For other non-square taper boom
brackets, the two halves of the magnet ring only t on the mounng plate one way, so you can’t get it
wrong.
With external bearing shells, it is somemes necessary to t a spacer behind the shell, we can supply
these, but in many instances, you can just take one from the le side and move it over to the right.
5
Le-side pedelec assist sensor (PAS):
The le-side PAS slides down the axle on the le side of the boom bracket and meshes with the splines.
This PAS is not suitable for all square-taper boom brackets, if you have a plasc cup (as opposed to a
metal cup), the le-side PAS will likely not be suitable. Although they look very similar, the le-side PAS
will not mesh with the plasc cup.
The le-side PAS requires a gap of 7mm between the rear face of the le crank and the boom bracket. if
it is less, you may need to shave a lile o the rear face of the crank to avoid crushing the PAS when you
re-t the crank. Alternavely, we usually have in stock 127mm boom brackets that in most cases would
give you the space you require.
Sensor To controller
Seat-post mounted PAS:
The seat-post mounted sensor is shown below and is simply cable-ed to the lower part of the seat tube.
If the sensor isn’t sing back far enough, it is possible to remove one of the plasc spacers on the rear of
the mounng buy simply undoing the bolt and then removing the lower of the two spacers. The sensor
should be posioned as shown below-right, so that the magnets pass by the correct part of the sensor.
6
HL Baery/Controller
The HL baery-cradle/controller included with this kit mounts on your down-tube, where your bole
holder would normally be. If the bike does not have these xings or they are not in a suitable posion, you
will need to t riv-nuts (supplied) to allow you to mount the baery cradle. Ensure that you mount the
cradle high enough along the down-tube so that the cradle doesn’t foul on the chain-ring. You will also
need to ensure that there is sucient clearance at the top end of the baery, the baery needs to be slid
upwards a lile when removing it. Be careful not to mount the cradle too low, or you may nd that the
baery hits the seat-tube before it’s fully engaged on the cradle. The space required is 38cm x 10cm.
Don’t forget to use the supplied washers and rubber supports (shown below). If you bolt the cradle to
the frame without using the washers/supports, the plasc will deform and eventually break.
Motor Wheels:
There are several dierent opons for the motor wheel, front, rear, 26”, 700c, cassee hubs, freewheel
hubs etc. We would normally have idened the motor/wheel that would best suit your bike before the
order was placed.
Once the cradle has been secured to the frame, t the baery in place and check that it ts correctly.
Next, remove the baery from the cradle and connue on with the installaon of the kit. Do NOT conn-
ue the installaon with the baery in place. You should only re-t the baery when all leads have been
correctly terminated/secured and the kit installaon is complete. If you leave the baery aached, you
may accidentally short something and damage the baery and/or kit components.
7
G30 Baery/Controller
The G30 baery-cradle/controller included with this kit mounts on your down-tube, where your bole
holder would normally be. If the bike does not have these xings or they are not in a suitable posion, you
will need to t riv-nuts (supplied) to allow you to mount the baery cradle. Ensure that you mount the
cradle high enough along the down-tube so that the cradle doesn’t foul on the chain-ring. The baery re-
quires a space of 18cm x 7.5cm
Don’t forget to t the rubber spacers/supports (shown below).
Once the cradle has been secured to the frame (using the supplied bolts), t the baery in place and
check that it ts correctly and that the lock is funconing. Next, remove the baery from the cradle and
connue on with the installaon of the kit. Do NOT connue the installaon with the baery in place.
You should only re-t the baery once all of the cables have been correctly terminated/secured and the
installaon of the kit is complete.
Motor Wheels:
There are several dierent opons for the motor wheel, front, rear, 26”, 700c, cassee hubs, freewheel
hubs etc. We would normally have idened the motor/wheel that would best suit your bike before the
order was placed.
8
85SX
Important note for purchasers of the 85SX motor wheel
You must NOT use rotor bolts longer than 10mm. Longer
bolts will protrude too far into the motor housing and will
damage the motor.
9
Motor Wheel
Swap the tyre, tube and freewheel/cassee (in the case of a rear wheel) from your original wheel over to
the motor wheel.
The wheel comes with the nuts and washers that you will need, they should normally be ed in the or-
der shown below, but somemes it is necessary to re-arrange them, or to t addional washers to ensure
the wheel is correctly aligned. The an-rotaon washer for instance, can be ipped around and ed on
outside of the drop-outs if necessary. If you have disc brakes, loosen the two bolts indicated below-le
before ng the wheel to the bike. This will allow you to make any minor adjustments immediately. If
you are experienced, you can remove the callipers if you prefer and re-t them later. Don’t forget to ght-
en the calliper bolts aer the wheel is correctly ed and the rotor correctly aligned.
The normal order for the nuts/washers is as below-le, but as menoned above, it may be necessary to re
-arrange them to suit your parcular bike. On the drive-side, try to leave enough space so that if the chain
were to come o, it won’t get jammed between the frame and cassee/freewheel.
Ensure that the motor cable exits downwards, and also ensure that the metal coil is far enough down the
cable so that it protects the cable from the edges where it exits the spindle. It can be slid down further by
hand if it’s not in the correct posion.
Thick washer Torque washer
Thin washer Nut
There is a cut-out where the cable exits the axle.
This cut-out and the cable should face downwards
towards the ground. In the case of a front wheel,
the cable should also exit downwards before loop-
ing back up towards the fork. This is to prevent wa-
ter collecng at the aperture.
10
Motor Wheel cont…
To complete the installaon of the wheel, t the nut covers. The le side cover simply pushes on, the
drive side cover should be slid down the cable and ed as shown below-right.
The red arrow on the diagram above-right shows the typical route for the motor cable (in the case of a
rear hub conversion), with the quick-release connector (in the cable) indicated by the solid red box. Re-
member to properly secure these cables to the frame using cable-es before riding the bike.
Cable orientaon:
It is possible to t the front motor wheels the wrong way around, and so to avoid any mishaps, please re-
fer to the table below, and ensure that the wheel is ed correctly. For all XF07 front hub installaons,
the wheel should be ed such that the motor cable exits the hub on the right side.
Motor Wheel Orientaon
XF07 Front Hub Cable exits the right side of the hub
XF08 Rear Hub Cable exits the right side of the hub
SWX02 Rear Hub Cable exits the right side of the hub
DGW22C Rear Hub Cable exits the right side of the hub
SX85 Rear Hub Cable exits the le side of the hub
G060500DC Rear Hub Cable exits the right side of the hub
Q70 Front Hub (Brompton Kit) Cable exits the le side of the hub
Ce manuel convient aux modèles suivants
1
Table des matières
Autres manuels Woosh Accessoires pour vélos
