10/23/2015

ElectroCycleE4KitforRecumbentBikes:InstallationInstructions

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ElectroCycleE4KitforRecumbentBikes:InstallationInstructions
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ElectroCycleE4KitforRecumbentBikes:InstallationInstructions

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10/23/2015

ElectroCycleE4KitforRecumbentBikes:InstallationInstructions

ThetwowheeledEZ1isthemostpopularrecumbentonthemarket,largelyduetoits
excellentreputationandlowprice.Thisone(left)hasbeenmodifiedwithblacksprocketcover,
rearrackandChristmastreelights.
ThethreewheeledEZ3(above)providesthesamegreatfeatureswithastable,no
balancingrequiredconfiguration.

Thebracketassembly
includesaderaileurand
cableend(arrow).The
cableendisunnecessary
andmustberemovedtodo
thenextstep.
Notethe2washerstie
wrappedtotheupperbolt
hole.You'llusethoselater
inmountingthemotorto
thebracket.
Removetheboltbehind
thederaileur.You'llneedto
flexthederaileuroutofthewayto
extractthebolt.Withinthebracket
andunderthebike'sframeisaclear
plasticsleeve(showninrightphoto).

Wheninstallingthebracket,ensurethatthecablesrunningalongtheframeare
outsidethebracketwheretheycanmoveeasily.
Next,thechainmustbe"broken"andremoved.HereaParkToolsCT5chain
toolisabouttopressaconnectingpinoutofthechain.
(Althoughthesephotosshowthebracketinstallationbeforethechainremoval,
eitherwayworks.)
TheCT5
toolis
designedto
pressthe
connectingpin
onlysofarto
theinneredge
oftheoutside
link.Atthat
point,I
removedthe
"presser"anditshandlefromthe
bodyofthetool,soIcouldunscrew
thetip2turns.Whenthetoolis
reassembled,thetipisnowlong
enoughtopresstheconnectingpin
allthewayout.
Oncethechainisoff,it'stimetoremovetheidlerwheelassembly.Startbyremovingtheidlerwheelusingan8mmwrenchanda
3mmhexdriver.Nowthe4mmhexswivelboltcanberemoved.Ifakickstandismountedhere,removeit.
InstalltheE4bracketusingtheboltandclearplasticsleeve(mentionedabove).Then,replacethekickstandandboltwhichholds
thebracketinplace.
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10/23/2015

ElectroCycleE4KitforRecumbentBikes:InstallationInstructions

Nowisthetime
tousethose2
washerstie
wrappedtothe
upperbolthole.
Theygobetween
themotorandthe
bracketonthe
upperrightmotor
bolt.Usethethree
lockwashersand
nutstosecurethe
motortothe
bracket.Ensure
thatthemotor
wirespointtothe
rearofthe
bike/trike.
Standardgearingis14Tfortheinner(withchaininstalledinphotobelow)and16Tforthe
outer(pedalchain).

Next,installthechains.FortheEZ1,Istartedwiththerearonestartingwiththefrontchainworkstoo.
Ifthechainistoolong,itwillrubagainsttherearbrakearmasshowninthisphoto(arrow).Ifitistooshort,youwon'tbeabletouse
1st(lowest)gear.
MylocalbikeshopcarriedtheSRAMPowerChain8speedMTB/Roadchainwith
powerlinksilverconnectorincluded(SRAMPC48)forlessthan$20.It's56.5"long.
TofittherearoftheEZ1,itmustbeshortenedby4.5"toalengthof52"withoutthe
masterlink.(Thephotomarksoff8connectingpinsintheremainerpiece.)
Theoriginalchainmustbeshortenedtoalengthof62.5"asshowntotheright.The
photoalsoshowspartsofalink.
IfyouputyourE4kitonanEZ3,thechainmeasurementsaredifferent!
HerearethechainmeasurementsfortheEZ1:56"fortherear,65"forthefront.
(Formodelsbefore2005,use52"fortherear,63"forthefront.)
HerearethechainmeasurementsfortheEZ3:48.5"fortherear,56.5"forthefront.
NoticethattheSRAMPowerChain8speedMTB/Roadchainfitsthefrontwithout
needforshortening.
Here'saproperlengthrearchainin1st(low)gearontheEZ1.Noticethatitdoesn't
touchthebrakearm.
Here'saproperlengthrearchainin7th
(high)gear.
Thesephotosshowthefrontchainbeing
preparedforthe"masterlink",thechainon
thelargestsprocket(above),andthechain
onthesmallestsprocket(left).
Hereareproperlengthchainsonthe
smallestsprocketsontheEZ3.
Hereareproperlengthchainsonthe
largestsprocketsontheEZ3.
WiththeE4'suniquemiddrivemotorassist,all21gearsareavailable(withnodrag)whentheriderwantstopedalwithout(orwith)themotor
assist.Thedoublesprocketonthemotorshaftincludesthenecessaryfreewheelmechanismtoallowmotoronlydrive,pedalonlydriveand
combineddrive.
TheElectroCycleE4kitcomeswitha1.5A24voltchagerwithindustrystandardXLRconnector.Alsoincludedaremotorcutoffbrakes
which,whensqueezed,immediatelyshutoffthemotor.Althoughthesearerequiredinsomejurisdictionsanddesiredforindividualswhomight
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10/23/2015

ElectroCycleE4KitforRecumbentBikes:InstallationInstructions

notreleasethethrottleinapanicstop,manyuserselectnottousethem.Thestockbrakes
thatcomewiththeEZ1andEZ3workeasierwiththeE4throttle.Ifthecutoffbrakesare
used,youmaywanttoextendthestockhandlebarontherightsideusingapairofshort
aluminumtubesone2.5"longthat'sthesamediameterasthehandlebaranda5"piece
tofitinsidethehandlebarandtheshortextension.Withinstallationofthemotorassembly,
theEZ1/EZ3idlerwheel(leftphoto,upperrightcorner)isnolongerneeded.
Thesephotosshowthestockbrakelevers.OntheEZ3,theleftbrakeleverincludesa
buttonthatlocksthebrakeahandyfeaturethatkeepsthebikefromrollingawaywhenit's
parked.TherightphotoshowstheE4'svariable
speedthumbthrottlewithon/offswitchand
batterylevelindicator.
Onemethodofmountingthebatteryonthe
EZ1isvertically,attachedtotheseat
supports.TheVelcrostraps(indicatedbythe
whitearrows)makeiteasytomountboth
verticallyandhorizontally(e.g.lyingonthe
rack).TheE4kitalsoincludesakeyedswitch
(2keys)andchargingport.
[Editor'sNote:Whenyougetoffyourbike,
plugthechargerintothechargingportyour
batterieswilllastlongerwhenpromptly
chargedaftereachride.]
Thebatterypackcanbeplacedinarearbasket,mounted
ontherearrack,ortiedtotheseatsupportswithbungee
cordsasshownhere.The37"rubberbungeecordhooksto
theseatsupport(asshownbythearrow)andsupportsmost
ofthebatteryweight.TherestissupportedbytheVelcro
strapsthatarepartofthebatterypack.Insteadofusinga
19"bungeearoundthebatterypackandseatsupports(as
shownhere),aVelcrostrapfromthehardwarestoremight
workbetter.FortheEZ3SX,acustombatterydeckis
available.(Editor'snote:ifyouplantousearearrack,be
suretogettheonespecficallydesignedfortheEZ1whichis
sizedfora20"wheelunlikestandardbikerackssizedfor26"
wheels.)
Clickhereforideasoncustomizingyourbetterbike.
ReturntoE4descriptionandpricing.

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10/23/2015

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ElectroCycleE4KitforRecumbentBikes:InstallationInstructions

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10/23/2015

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ElectroCycleE4KitforRecumbentBikes:InstallationInstructions

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