Category Archives: bike conversion kit - Page 5

How-to-build-a-freewheel-hub-motor-for-electric-bike-conversion-kit

Posted by on March 12, 2025 No comments

These days 250w hub motor wheels are popular with European. Nearly all of hub bike motor are brushless geared. Because there are several gears inside hub. It has more powerful than 250w brushless geared motor.
Order 1 set 12″ 14″ 16″ 18″ 20″ 24″ 26″ 700c 27.5(650) 27″ 28″ 29 inch hub motor electric bike conversion kit , convert your common bike to e-bike is so easy. Directly front or rear drive your bike.
The important part is an engine -hub motor. How to build this? There are some differences with brushless freewheel hub motor.

Step 1: winding
Calculate motor power, speed RPM and confirm what type of copper wire would you use, wind copper wires by handwork or machine, each notch should be separated by insulating paper so that not shot circuit between the coil. It takes about 1 hour to done it by handwork. And should use rubberized fabric to wrap your fingers. Nipping copper wires will break your fingers.

Step 2: fix axis into motor
Put axis into rotor winding and use a key to fix axis. Use A-B glue to paste three hall sensors on hub motor rotor, put 9-pin (three pin/each hall) into PCB and use insulated wire to fix it. Put 8-pin cable inside the axis and heavy yellow, blue, green wires to connect the three copper wires(Phase A,B,C) separately. Thin red, black wires are be weld to PCB + and – .

Step 3:soak paint
After winding should soak paint in order to be insulated. Use brush to put the insulated paint on the winding and make sure be soaked everywhere. It takes about 24 hours.

Step 4:press gear into hub
Use presser to press steel 90-gear into hub. This hub with one side cover.

Step 5:fix three gears
Use retainer ring and key to fix three white nylon gears on one steel 21-gear.

Step 6:fix magnet
Fix magnet inside the hoops.

Step 7:install rotor winding into this magnet hoops.

Step 8:install there gears on the axis of this rotor winding and put inside of hub with 90-gears.

Step 9:install the other cover.
Use screw driver to tight screw nuts. Done it.

Power on battery and use bldc motor controller to drive this hub motor. If no any strange noise. It’s okay.Then according as the size of your bike to fit this geared spoke hub motor to 20″ 24″ 26″ 27.5″ 700c 27″ 28″ and 29 inch bike kit wheel.

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

Leaf hub motor bike kit is working

Posted by on March 11, 2025 No comments

Q: The bike conversion kit system is now working.
Still have some questions. It is about the brakes.
If we take the red and black wires from the scooter brakes and connect in parallel to the connection of the new hub motor controller, will this have a negative effect on the controllers? My friend thinks that this should not be a problem since this only brakes a circuit.

A: About that brake has two types.ONE is high voltage to brake.The other is low voltage to brake.
Ours is low voltage to brake,you should check your old hub motor controller whether that is low voltage to brake.
If you have volt-meter,you could get about 5V from red and black wires from your old hub motor controller.If it’s 5V. That’s no problem.

Q: We finally got the chance to try the new bike conversion kit wheel after doing all the modifications except for the front brake which we still have to modify.

We have a new problem and I need your expertise. I tested the bike conversion kit wheel up the hill and on its own (without using the rear wheel motor). It went up the hill at about 17 km/hr……..which I think it is satisfactory.

However when I took it up a steeper but very short incline which is on my way home, the fuse connected to the batteries got blown and lost power (no electricity).

The fuse is gauged at 10A. What should I do to avoid blowing out the fuse? If I change the fuse to a different amperage, will this have negative consequences for the rear motor? Do you suggest anything different?

As always, appreciate your assistance.

A: When up the hill,the current will reach about 15A.If too steep hill,it will reach more than 20A.
20A-30A current is easy to break controller.
Sometimes 15A continuous current for about half an hour also can break controller that’s because of too hot will break hub motor controller’s MOSFET.

We suggest:
* Cool controller is important.
* When you up hill,use two hub motors.On the flat road,use one motor.

Our hub motor bike conversion kit can’t get any problem when your up any hill.But should cool controller.

Use 15A-20A fuse.Had better to use 15A.But if use 20A fuse,climb hill has more power.But we worry controller.

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

Posted by on March 11, 2025 No comments

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 okay 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: meter 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:Please 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 meter 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.Please 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.

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

Posted by on March 11, 2025 No comments

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?

issue about electric bike kit battery

Posted by on March 10, 2025 No comments

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

Posted by on March 10, 2025 No comments

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

Posted by on March 10, 2025 No comments

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 ?

Posted by on March 10, 2025 No comments

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

Posted by on March 10, 2025 No comments

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.

Some issues about front hub motor electric bike kit system

Posted by on March 9, 2025 No comments

DIY 1 set of 26″ 36V 750W front hub motor electric bike kit from Internet shop,waited for a couple days,at last received it.
Checked packing box,it’s okay.Disconnected package,there were all goods inside box:

1.1 set of 26″ 36V 750W front hub motor wheel without tyre
2.1 set of 36V 750W bldc motor controller with LCD
3.1 set of twist throttle with battery gauge
4.1 set of brake lever with low voltage to brake
5.1 set of three-button switches(control horn,led lights,cruise..)
6.1 set of 36V 16Ah LiMn2O4 electric bike battery with 110~230AC charger
7.some zip ties(fix wires)
8.1 set of instruction manual and wiring diagram

Was told to prepare below tools to install electric bike kit:
1.open-end wrench(loose/tight screw nuts)
2.philips screwdriver(fix LCD)

By now,install electric bike kit seems very easy.But for a newer,first time to install electric bike motor (hub motor) wheel and need to connect various unknown wires that is still a little difficult.
Leafmotor will share some install experience with every DIY bike kit rider.Some issues you will meet:
1.You are going to install hub motor wheel,you should find out the motor’s direction of rotation first.Please read install instruction manual;
2.Install tyre according as flower pattern of tyre;
3.Fix 26” front hub motor wheel on front fork.If your front fork is 100mm,no problem.After installed,sometime you will find the wheel isn’t in the middle of fork,now you should use some washers to adjust.If still can’t solve it,the problem come from spoke rim should re-fit this rim;
4.Fix bldc motor controller,LCD,electric bike battery and install throttle,brake lever,three-button switches.This step is easy;
5.Make the electric bike motor wheel in the air, power on li battery and test bike kit system.If it works normal.Please use zip ties to fix wires.If not,re-check wire connecting according as wiring diagram.

This fifth step is the most important.When you power on battery,you may meet below issues:
1.The electric bike kit system can’t work.When you turn throttle,nothing is happened.Now you should check battery power connector and three-pin throttle connector;
2.The electric bike kit system works as the fastest speed suddenly.The problem is the black ground wire from throttle isn’t connected well;
3.The hub motor shake,please check motor phase wires;
4.All leds light,but electric bike kit still can’t work.Check motor wires;
5.The electric bike kit works,but just wok less than 3 seconds,all lights on throttle are off.Loose throttle,be on and the bike kit system still works less than 3 seconds.This is battery issue,use volt-meter to measure it.Full charged 36V limno4 battery is 42V and dis-charged it is 34V.The volt of your new battery can’t less than 34V.If it’s under 34V,please return it to your supplier.
6.LCD doesn’t display speed.Solve: the sensor should be closed to the detector.

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