How to Install an Electric Bike Conversion Kit – Add Motor DIY

In the modern-day, people want to have things that are more convenient for them to use. Due to the advancement of technology, gas and petrol cars are being replaced by new inventions like hybrid and electric cars. Similarly, traditional bikes demand has been replaced by electric bikes, which is one of the recent inventions.

However, instead of buying a new budget electric bike, you can transform your old traditional bike into an electric one with the proper conversion kit. In this review, I will show you how to install the electric bike conversion kit, which is a much cheaper option than buying a new one. Creating an electric bike can be an exciting project, but it is essential to be cautious for safer operation when installing the conversion kit.

How To Install An Electric Bike Conversion Kit

Preparation And Tools

Before starting the installation process, cover the area with paper or cardboard so that the floor does not get messy when you take the bicycle’s wheel and chain off. Often the bike’s chain has lube oil with which your hands might get dirty. So I suggest you wear latex gloves to prevent your hands from getting dirty.

You can either get a specialized tool kit or find similar tools to assist you in the installation process. Standard tools which you will need are screwdrivers, wrenches, pliers, etc. however, the tools should be compatible with the bike’s configuration.

Selection Of Battery Pack

With all the different battery pack products available in the market, the selection of battery packs can be frustrating. Battery packs feature different forms and functions such as amp-hour ratings, cell manufacturers, voltages, etc. the motor specifies the voltage range allowed. So the battery pack you buy must fall under this range. The amp-hour rating of the battery pack decides the strength of battery power on a single charge and how much it can carry out the load.

An efficient battery charger is crucial. Nonetheless, the battery packs offer a battery charger with them, but it is better to have an additional one. I recommend battery packs such as Samsung and Panasonic battery packs with 52V ( voltage ) and 13.5ah (amp-hour rating). If you are not fond of the battery being so noticeable, you can buy a Panasonic NCRB bottle battery pack. This battery pack has the shape of a drink bottle, which you fix in the bike’s frame.

Removal Of Rear Wheel For Installation

After you have ensured the availability of tools and selected the battery pack with good range, now it is time to start installing. The first step of installation requires the removal of the rear wheel to set up the wheel motor. Start by unclasping first, the brake cables. After that, loosen the wheel’s quick-release lever. You can do the above process by holding the rear derailleur down and raising the wheel to remove it.

Installing The Tire And New Wheel

Next, remove the existing freewheel with the help of the freewheel remover tool. Along with the freewheel or gear cassette, you also need to remove the tube and tire as well. If your existing tire is in good condition, you can reuse it on the new wheel with a hub motor. The process of removing the tire from the old wheel is to deflate the tire. Then remove the existing tire and tube from the old wheel with caution of not harming the valves.

You can use some tire levers for popping off the tire without any issues. Inflate the tire after placing the tube and tire over the new wheel. The further step is now to install the new wheel on the bicycle. When installing back the new rear wheel, make sure you place the freewheel or gear cassette. Do not forget to mount the disc brakes on the wheel hub motor.

Furthermore, the hub motor supplying cable to the rear wheel must be on the left, while cables supplied from the hub motor to the front wheel should be on the right side. Another to check is the proper setting of a chain on the gear cassette of the rear wheel.

Installing The Controller And Pedal Assist System

An ideal place to set a controller can reach all the cables of the Pedal Assist System, battery, motor, display, and brake levers. Your fast pedaling is determined by a magnetic ring and a magnetic sensor that a Pedal Assist System utilizes, also known as PAS. The controller processes the data and depends on the level of assistance you have to opt for the power required by the wheel.

To install PAS, start with taking off the hub of the left pedal. You will be able to notice the lock ring with which a pedal hub is mounted on the frame usually. Remove the lock ring. Place and install the sensor and set the lock ring back on, and tighten it up. On the hub, install the magnetic ring. The wire of the Pedal Assist System should be on the right side. The last step is to fasten the pedal back on.

Installation Of The Display And Brake Levers

Remove the handlebar grips by using an air compressor and unclasp the shifters and brakes. Before the installation of brake levers, install the display right to the center of the handlebar. Whereas, on the left handlebar, install the throttle and e-brakes along with the display’s controls. To ensure smooth operation of pedals, test them by turning them with hand and also shifting gears.

Installing The Battery

If you use a bottle-type battery, you can set it up where the bottle holder is mounted. Or, if you are using rack batteries, you need to place a rack to mount the battery. Once the place you install the battery is ready, you will be ready to mount the battery.

After installing the battery and checking the necessary cable connections, now it is time to see if your hard work has paid off. Clean out the bike before taking it out. Test out the transformed electric bike with the help of a conversion kit and ensure its efficient performance. During the run test, check out the brakes, display, and motor functioning.

Related Bike Guides: How to install Shimano gear shifter | How to reset Bosch Electric Bike


It is an excellent idea to transform your manual bike into an electric bike. However, you must have the necessary information required for the installation and knowledge about conversion kit products such as the battery, voltage, PAS, etc. The installation process is time-consuming compared to buying a new electric bike. But it allows you to save money. Be mindful of whatever conversion kit you are buying because there are different electric bike conversion kits and traditional bikes. So for good results and better compatibility, follow the steps mentioned above.

Photo of author
Sonia Seale loves to take her bike to the mountains near her place, the bike track has provided her the opportunity to go mountain biking since she was a child. That's where she developed a great deal of interest in cycling, no matter if it's electric or mountain bike, she's all over the place and loves to fix her own bikes along with exploring the new features coming along in the industry. That's why she's here, sharing her experience and learnings with you guys.