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E-bike with electric bike kit almost done, but..

E-bike with electric bike kit almost done, please help with final issue: Throttle

Q:I am almost done with electric bike kit, everything is ok except the throttle is not working. I connected the old throttle from my old e-bike, it’s connections fits the lcc-001 controller.But as I connect it, the motor doesn’t run at all.
What kind of throttle is to be connected to this controller to achieve speed control from 0 to full speed: potentiometer type or Hall Effect type?
My current throttle is 3 wired connected to a very small chip, which is moving along a magnet.

Answer 1:Pls check three-pin throttle connector.

Answer 2:Disconnect and re-connect these two connectors.Check male-female connector and pins.
If still not work,buy a new throttle or use a potentiometer to replace.

Answer 3:Make your electric bike kit wheel in the air,short red and green wires(3-pin throttle connector on controller).
Power on battery,motor will run as the fastest speed at once.
If not,it’s not throttle issue.

Answer 4:Yeah,jump red and green wires.If your system is no problem,e-bike can run at once.
Make sure your electric bike kit wheel in the air.

Answer 5:You had better to cut off three-pin throttle connector.Then connect wires as below:
Throttle —– Controller
red —– red
black —– black
white —– green

If you have volt-meter,pls power on,then test voltage from controller throttle connector.
1.red and black is about 4.5V
2.green and black is about 2.3V

Make a jumper between red and green,the electric bike kit wheel will run at once.

Done following above,if no any voltage and still no work.Pls replace controller.

Q:Thanks all,I dis-connected throttle connector and found green and white wires didn’t touch well.Re-made a new throttle connector,supply power,electric bike works without any noise.Prefer leafmotor’s electric bike kit.

How to make a hub motor for electric bike?

How to make a hub motor for electric bike?
Motorized hub motor can drive your e-bike.Everyone know motor controller,battery,throttle,brake lever etc other accessories.
But for motor,it seams a little mystic.Actually it’s not.
Because of hub motor doesn’t have two carbon brush inside motor,so called brushless. If have,it’s brushed hub motor.
Now we talk about brushless hub motor.
This hub motor is made of copper coil, aluminium / or steel rotor bracket,three hall sensors,

Needs below stuff:
1.1 pcs of Al motor hub and 2 pcs of Al motor covers (made by foundry);
2.1 pcs of axis (fix on rotor);
3.2 pcs of bearings (fix on each cover);
4.magnet (distribute inside hub);
5.copper coil;
6.aluminium / or steel rotor bracket (made by foundry);
7.three hall sensor.
8.six screw or more;
9.insulating paper;
10.A-B glue water (fix hall sensors on rotor)
11.8-pin cable (Yellow,blue and green three wires are used for motor phase A,BC…the other five wires are for hall sensor,red is supplied +5V,black to ground.Yellow,blue,green three wires are connected to separate three hall sensors.

Needs tools:
1.screw driver;
2.rubber / or wood hammer;

The important and complicated step of make a hub motor is circle coil.It’s made by machine or handwork.If magnet no change, just change the gauge of the coil wires and/or the turns number of the coils so that change hub motor ‘s power and speed.

After circle coil,then use A-B glue water to fix three hall sensors to each rabbet.Connect 8-pin cable to hall sensor and motor phase A,B,C

Install rotor inside hub,mount each cover.Use bldc motor controller to test hub motor.

20 inch 36V 250W front hub motor – electric bike conversion kit

Q: We are interested in leaf 20 inch 36v 250w front hub motor – electric bike kit. Item ID #LBCK2036250F
When I buy this electric bike conversion kit . I saw picture full Twist (Twist throttle No battery gauge), please can you change to half Twist? I want this Half Twist. My DAHAN will work match washer + front hub the 100mm fork and disk? See link info the DAHAN how look Hope help.

A: This bike conversion kit doesn’t need battery gauge, because LCD can display battery gauge, we can ship you a half twist throttle to replace this full twist.
If the spacing of your fork is 100mm (picture enclosed),this #LBCK2036250F can work with disk brake.

Q: We will buy this bike conversion kit later. LCD display have MPH? I see this youtube for full max speed 21.7mph which is 36V 10Ah Rack lithium ion OR 36V 8Ah bottle lithium battery?
I think will buy any online for 36V 10Ah Li-ion Water bottle Battery, will super up hall and super run road full 21.7mph?

A: This LCD display KMH, can’t display MPH now. One week later, we will have new LCD controller. This hub motor controller has more function:
 Cruise
 Reverse
 Regen brake
 Mph / kmh
 Pedal assist ( 1 – 5 )
 …

This old hub motor controller work with this 20 inch 36v 250 front hub motor wheel. Max speed:21.7mph (We test use 36v lead acid battery)
36V 10ah Rack lithium or 36V 8ah bottle lithium ion battery both can reach max 21.7mph.

We have 36V 11ah lithium-ion water bottle battery in stock, but we haven’t updated it to leaf site. The difference between them is the bottle size of 36V 11ah higher than 36V 8Ah bottle.

When you use 36V 10ah lithium-ion water bottle battery and ride it, full speed is about 18mph.(21.7mph is no load)

Sure if I would buy the 36V 8ah bottle lithium ion battery can work with 20 inch 36V 250W front hub motor max full 21.7mph and or 24 inch 36V 250W front hub motor max full 26mph? (LBCK2436250F)

My DAHAN Typhoon twin Brake right please find attach see picture, if this e-bike right brake cable can off one, or get right twin brake e-bike?

Leaf New 48V LCD brushless motor controller

48V 1000W Electric Bicycle Brushless Motor Controller For E-bike & Scooter — 12-MOSFET

Features:
Suitable for Electric for electric bike & scooter
Rated Voltage: DC 48 Volts
Min. Voltage: DC 40 ± 0.5 V
Rated power: 1000 Watts
Casing material: aluminium
Maximum Current: 26 A ± 1 Amps
Thermal: aluminum shell and the substrate

3 phase 120° brushless motor
Operating Conditions: -20~45 °C
Waterproof design
Size: 171 mm L × 82 mm W × 42 mm H
Weight: 0.66 kg

Working with LCD
Display: speed, mileage, battery gauge…

Functions:
Mute when start
Speed limit
Power cut brake
Blockage protection
Current limit protection
E-ABS brake
Short circuit protection
Avoid out of control
1:1 pedal assist function
Under voltage protection

Additional features:
* Cruise
* Reverse
* Regen brake
* Pedal assist ( 1 – 5 )
* Mph / kmh
* ….

Error 4 stop hub motor working

Q: I bought a hub motor few months ago. Display error 4 is your brushless controller LCD? And I have a problem in the moment, because I install it and when I start to move the quad appears all the display the error 04 and a symbol of a tool, I had seen at the forum what’s the error meaning, but I think it’s something different because it had full charged electric bike battery pack.

A: How long did you use this electric bike battery pack ?

Q: It’s new. I have used ones for test the hub motor. It start full at the display but 100 meter later appear the error, hold on, then when appears the error, 10 minutes later in the display appear again full the electric bike battery that I use is a 4 lead batteries of 12V 45 Ah

A: Is your electric bike battery is 48V? That’s correct. The issue is battery. Do you have volt meter?

Q: Yes. I can find one.

A: Ride this bike and use volt meter to test the voltage of electric bike battery. If the voltage will drop down. The problem comes from electric bike battery. If the voltage drop down to 42V, the error will appears. If you don’t ride, the will display appear full.

Q: I’m trying to start the hub motor without any load. It works for 6 hour more or less.

A: How many current does your electric bike battery can offer? 10A , 20A or larger. You should use volt meter to measure the voltage when you load this hub motor.

Q: I bought 4 batteries of 12 V 45 Ah

A: Sometimes new electric bike battery is in stock for a long time. Even if No use. Also can need this issue. If you don’t load our hub motor, is there no error display?

Q: No, if it start to work freely, it work for 6 hours. How I use the volt meter to measure the electric bike battery? Working the hub motor ?

A: Connect red, black wires of volt meter to the positive and negative when the engine works,
watch the voltage on volt meter.

Q: Let me prove it, so I have to connect the positive of the battery to the positive of the engine and as well to the positive of the volt meter, and the same thing whit the negative ones, then star to work the quad watching the volt meter and if the voltage goes down the issue is in the battery.

A: Connect wires as before. Just add two wires from voltage meter. Red wire of voltage meter is connected to the positive of battery. The black wire is connected to the negative of battery. Make sure it on the VDC voltage position (=200VDC or ..)

Q: How volts it has to show to work properly? More than 48V ?

A: 42-60V

Q: Ok, so if the battery is full it has to show around 60V?

A: No, that depends on what type of battery. If LiMn2o4 is about 54V, LiFepo4 is about 58V. Lead acid is about 54V. When you test, the voltage will drop down. This electric bike battery is not good.

Q: I let you know if something different happen.

issue about electric bike kit battery

We purchased an electric bike kit including motor controller, hub motor wheel, throttle, brake lever and with 36V 10AH bottle style Lithium Ion electric bike battery that used for testing 36V solar charger from one supplier, not from leaf motor. After charging this electric bike battery for 10 hours by better solar power, full charged, we rode the bike, but hub motor wheel only run about 8km.

We use a ampere meter in series to electric bike kit system, powered on and rode it. We got the current is about 5A. The speed is 257RPM.We use 26” hub motor wheel.

We calculate the speed is about 32Km/per hour.
See below formula:
(3.14×26”×0.0254)× 257RPM × 60 minutes ÷ 1000 (m-Km)=32km

If this is 10Ah battery, per hour lost 8ah.We can use 1.25 hours.
See below formula:
10Ah ÷ 8ah/per hour= 1.25hours

We think full charge this electric bike battery per time, the hub motor wheel can run about max 40 km. 32km/per hour × 1.25 hours = 40 km

There is definitely a problem with this electric bike battery, I’m not sure whether electric bike kit is because of the solar charging or our testing, or if it has a fault. But I need a replacement electric bike battery asap, because we don’t have any more 36v electric bike battery, and we sold 1 set of electric bike kit with lithium battery last week. I think BMS inside this electric bike battery no problem. The problem comes from the li battery cells. Maybe this electric bike battery had stayed in warehouse for a long time and haven’t charged it. It will make the electric bike battery cut down the achieve distances and use life.

So if solve this problem and let my hub motor to work asap, only replace all cells or replace new electric bike battery.

How connect electric hub motor controller wires

Q: Now that I understand the purpose of these wires, I need to know exactly how to connect bike conversion kit wires.
1. “you could use a switch(on/off)to short pink and black”
1.1 What kind of switch? Is it included this bike kit or I have to buy it?
1.2 If I have to buy a switch, what are the characteristics of it? How do I connect pink/black wires to the switch?
1.3 If so, do I need to buy additional wires to connect pink/black to the switch? If so – what are the characteristics of it, wire resistance/diameter?
1.4 These pink/black wires are connected to a plastic connector
Do I need to buy another connector to connect my new hub motor ?

2 “use yellow and brown wires coming from the throttle to control your bike kit cruise.”
2.1 Again-how would I do that? Do I need to connect yellow/brown wires somewhere on the hub motor controller, is so – how?
2.2 Please note that these wires don’t have any kind of connector attached – am I suppose to connect them ?

3 “put the green wire to “+” and the grey to “-“, your LED on your throttle will light”
3.1 Where are the “+” and “-” you are referring to? Is it on the battery itself, or controller, or elsewhere? (for example: battery itself doesn’t seem to have open +/- sockets – other than the one used by the supplied cable)
3.2 Can I connect green/grey permanently (so that LED always shows the battery status), if so – how would I connect? Where would I connect them to exactly – controller or battery?
3.3 Again please note that green/grey wires are not attached
to any connector, just “bare” wires, so I don’t understand how can I connect them?
If you have any additional photographs and/or drawings, please share them also. If I need to buy
additional parts – please let me know what they are.

A: Don’t mistake with the positive and cathode of your bike kit battery to hub motor controller.(red and black battery wires).It doesn’t matter about making a mistake with other wires.
Don’t worry. Short any thin wires, it doesn’t burn your controller.
1.Cruise: when your motor is running, connect the pink wire to black wire(use a wire to connect pink and black wire) or you could use your brake lever to test this function. When your brake, it will cruise, when your loose your brake level, it will cancel cruise function.
2.This switch just have on/off function, you could buy other switches in your market
3.You should use a wire to connect bike conversion kit, it doesn’t matter about wire resistance / diameter, is this wire, no current.
4.You could use spare connector: yellow connect pink wire, brown connect black wire (C&Z),when your motor is running, press this red switch, your motor will cruise as the same speed.
Put the green wire to battery “+”
Put the grey wire to battery “-”
The Led will light, try it as I said, it doesn’t burn anything.
In fact, it’s very easy to do it, for example, you could use your
handle brake (two wires) to make a female connector connect any connector (white & black, pink & black)from hub motor controller.
If possible, you could use a software “e-drawing” to open our 3D about this hub motor controller.

The Displayer Operating Manual for LCD motor controller

When you received leaf motor’s bike motor kit with the LCD motor controller .Don’t know how to handle it.
For example: 36V LCD motor controller
1. Power switch
Supply battery, press power switch once, the LCD panel will display total mileage, speed , battery capacity and the time (time will be recounted once the power is on).
Voltage ≥ 36V four cells
36V > Voltage ≥ 34.5V two cells
33V > Voltage ≥ 31.5V one cell (flash every 0.5 second)
Voltage < 31.5V no cells (flash every 0.5 second) 2. → Next button Users may adjust freely between different levels of assistant functions by this button. 3. Set button 3.1 Press set button once, “KM” light is on. At this status, the single mileage will be shown in this area. You may reset it by → button.; 3.2 Press “SET” one time under the status of single mileage, total mileage will be shown. Press it again , it will display single mileage; 3.3 Press “SET” for 5 seconds, the light is on. At this status, you may set with → the size of wheel diameter from 10inch to 30inch in speed display area. 3.4 Fault code Eight status of fault instruction from 01~05, 07~09 will be displayed in speed area when the light is flashing. 01: Abnormal connection between LCD screen and controller; 02: Excessive current is detected in controller. If the status remains the same after restarting, it is certain that something is wrong with the controller internal power devices. 03: Motor three-phase power lines are fallen off, or motor is stocked for more than 2 seconds. If the status remains the same after restarting, it is caused by undesirable contact of three-phase lines. 04: Battery is at the status of voltage protection; 05: Hall cables are not connected, or incorrectly connected. 07: It is wrong with the brake lever cable when system is running. 08: The controller internal current will detect if the circuit element is damaged. The status will be displayed if it is abnormal. 09: The battery voltage is measured all the time under the working state. If it is > 47V,the system will enter into high-voltage protection mode, stop working.

Bike motor, motor controller supplier: Leaf Motor Technology Co., Ltd

How to build spokes on hub motor for electric bike ?

DIY electric bike conversion kit and convert your bike is funny. Sometimes we prefer to purchase spoke hub motor , bike rim and spokes. And build spokes on electric bike motor by ourselves.

If we want to convert 26inch front wheel, we should purchase 1 set of front spokes hub motor, 26inch rim and 36pcs of spokes. We can purchase them from leaf bike motor shop online.

Received goods and check them:
1. How many spokes you received. Generally we need 36 pcs spokes to built on hub motor and 12 gauge spokes for electric bike. 13, 14 gauge spokes are too thin, just for common bike.
2. There are 36 eyelet on bike rim and hub motor.
3. Check nipple and the dia. of eyelet on rim, make sure the nipple can put into eyelet.

Calculate the length of spoke :
If you use 205 leaf front hub motor, the eyelet to eyelet of rim is 511mm that is 26inch rim, spokes should be 155mm length.

You need below tools to install spokes on hub motor.
1.iron shelf
2.slotted screwdriver
3.nipple wrench
4.magnet
5.rubber hammer
6.tape measure
7.calipers

Done check, everything is okay. But we found the dia. of nipple is 4.5mm and the rim is also 4.5mm. These eyelets are too small. See pictures.

Get a 4.8mm electric drill. Drill 36 pcs of eyelets. Adjust the iron shelf so that the dia. is 100mm. Because standard front fork is 100mm. Then put the rim inside the iron shelf, hold on the hub motor. Make the first spoke wear into hub from left side, the next from right side. One by one from left side to right side. Done install all 36 pcs of spokes, please check them whether correct. See pictures.

If no problem, we should hold spokes on rim by nipples First hold one spoke on left side, then cross to fix another spoke on left side. Next step, cross two spokes on rights side and fix them. Left side, right side, a group of four spokes. See pictures.

Fix all spokes, we should use wrench to tight spokes a little, please don’t be too tight. Use hand to turn wheel, make sure there is no noise from friction of rim and nipple. Use rubber hammer to knock rim when the wheel is running so that the rim will be not jumping up and down. Still to tight spokes a little. See pictures.

Turn wheel, you will find the rim from left side to right side. In order to make the wheel running in the middle. We use calipers to measure and get the data. Then use a magnet to hold a pin. See pictures. If rim to the left, we tight right side spokes or loose left side spokes. See pictures.

It takes about 1 hour to build an wheel.

Electric hub motor bike conversion kit for electric bike

Ride a bike everyday is good for health. It can help you lose weight and achieve healthier body. By the way,sometimes riding for a long trip or steep road that is too tired.Buy a new e-bike is too expensive.Why not place an order for bike conversion kit and convert your common bike to electric bike by yourself.

Standard bike conversion kit includes:
1.hub motor wheel (8″ 10″ 12″ 14″ 16″ 18″ 20″ 24″ 26″ 27.5″ 700c 28″ 29″ 27″)
2.motor controller(drive hub motor)
3.twist throttle or thumb throttle(default twist throttle)
4.brake lever with low voltage to brake
5.three-button switches(control horn,led lights,cruise..)
6.pas(for Europe)
7.battery with charger(optional)

1 set of bike conversion kit has three key products:hub motor,motor controller and electric bike battery.
Hub Motor:There are 8″ 10″ 12″ 14″ 16″ 18″ 20″ 24″ 26″ 27.5″ 700c 28″ 29″ 27″ hub motor,what inch would you choose depend on your common bike wheel size.Motor type:brushed hub motor or brushless hub motor also called BLDC hub motor.Now because the bldc hub motor has advantage of low noise,high efficiency that replace of brushed hub motor.
Leaf Motor has 36V 750W / 48V 1000W brushless gearless electric bike motors are popular with North America.The other 24V 250W / 36V 250W bldc geared hub motors,European prefer them.

Motor Controller:Bldc motor controller which is called a heart of bike conversion kit system.Generally 6-MOSFET controller drives 250W hub motor,9-MOSFET drives 500W,12-MOSFET drives 1000W bldc motor.
Leafmotor is selling a LCD motor controller that display speed,mileage,battery gauge.

Battery:In China,electric bikes still use lead-acid batteries,they’re much cheaper,but a little heavy.North America or Europe always use lithium batteries that are more environmental.
Leafmotor has three types of lithium batteries:high speed,frog and bottle electric bike batteries for customers to choose.We found most of issues from lithium batteries that were not used correctly.
Three are two advice about how to use lithium battery.
1.Please remove power connector. If you don’t ride your e-bike for a couple of days.
2.Charge your battery often,but please don’t overcharge it.

Received your bike conversion kit,please check packing box first,then disconnect it and check each product that make sure all goods are okay.Then prepare below tools to install bike kit.
1.open-end wrench(loose/tight screw nuts)
2.philips screwdriver(fix LCD)
3.some zip ties(fix wires)

Remove the front or rear wheel.Find out the motor’s direction of rotation.Fix this motorized hub motor wheel to your frame fork and use open-end wrench to tight both screw nuts.According as install instruction manual and wiring diagram to connect wires make sure your wheel in the air,power on your battery,test bike conversion kit system.Turn throttle,if motor works well without any noise.Then use zip ties to fix wires.If not,please re-check your wire connecting.

If everything is good,it will take about 10 minutes to done it.Just order 1 set of electric hub motor bike conversion kit,your common bike will become electric bike.Cost less,get more.Have you found some fun?

Hub motor,bldc motor,bike conversion kit supplier: Leaf Motor Technology Co.,Ltd.