Conversion of Normal Cycle to Electric Cycle
The full build video for this conversion — the steps below follow it in the same order.
What you need before starting
- 24V E-Bike Conversion Kit: 24V DC motor, motor controller unit, twist throttle with integrated key ignition & battery indicator, electronic cut-off brake levers, headlight and horn module, secondary freewheel, extended rear axle, and motor chain
- Batteries: 2x 12V Lead-Acid batteries (Amaron Quanta 12V batteries wired in series for a 24V output)
- Charger: 24V AC-to-DC external battery charger with 3-pin connector
- Mounting Supplies: Rear bicycle rack/carrier, battery housing box, zip ties, and mounting hardware
The full build video for this conversion — the steps below follow it in the same order.
Replace the rear axle and install dual freewheels
Remove the rear wheel and replace the original stock axle with a longer replacement axle. Install the secondary motor freewheel alongside the stock pedaling freewheel so both the pedal chain and motor drive chain can operate independently.
Mount the motor and motor drive chain
Attach the 24V DC motor to the rear frame or rack mounting bracket. Align the motor drive sprocket with the secondary rear freewheel and connect them using the motor drive chain.
Prepare and wire the 24V battery pack
Position the two 12V lead-acid batteries inside a protective battery box on the rear rack. Wire the positive terminal of one battery to the negative terminal of the second battery to output 24V power to the controller.
Install the controller and handlebar controls
Mount the main controller unit onto the frame or under the rear rack. Replace the stock brake levers with the electronic cut-off brake levers, mount the twist throttle with its key ignition and LED battery indicator on the handlebar, and attach the combined headlight/horn module.
Wire system inputs into the controller
Plug the battery leads, key ignition, twist throttle, motor power cables, e-brake levers, headlight, and horn into their corresponding matching wiring harnesses on the motor controller unit.
Charge and test the e-bike
Plug the 24V charger into the controller's charging port and connect it to a wall socket (the indicator turns red while charging and green when complete). Turn the key switch to ON, check the LED battery display, and twist the throttle to verify motor operation.
If something does not work
Motor spins but bike doesn't move: Check motor chain alignment and ensure the secondary freewheel engages properly.
Throttle does nothing: Check key switch position and verify e-brake levers are fully released, as engaged brakes cut motor power.
Charger light remains green on low battery: Inspect charging port terminals and main battery connections for open circuits or loose wires.
Short runtime: Charge batteries fully for a complete cycle and confirm series wiring (positive to negative) maintains a full 24V output.