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Kit instruction guide 2012 proper.indd Last modifed July 13, 2012 2:50 PM
Installation Guide
Currie Electro-Drive Conversion Kits
2, 3, & 4
2
82
101
142
48
40
36
82
101
142
48
40
36
Before you start...
Drawing
Ref.
Area
Dimension
Kit 2
Dimension
Kit 3
Dimension
Kit 4
Fork
Leg clearance (inside to inside) Please evaluate based on drawings below
(circles indicate common areas with clearance issues)
1
Dropout surface area (minimum)
Diameter of axle nut. Make sure the nut will clear
any dropout safety tabs.
16mm 25mm 16mm
2
Fork spacing 100mm
Wheel size 26 or 700c (depending on kit version)
Brake compatibility Disc or rim Rim only Disc or rim
3
Dropout thickness (minimum)
Clearance for anti-torque hardware
5mm
Rack
Rack eyelets (rear dropout) Must be present
Seatstay type
May not ft wishbone stays
(Bikes with wishbone stays must have seatstay rack
eyelets)
Misc
Motor wire length
When installed, runs from halfway up the front fork
leg, along a frame tube, to about 5 inches behind
the saddle.
~160cm
Throttle wire length
~150cm
2
3
82
101
142
48
40
36
82
101
142
48
40
36
1
Use this information to determine whether one of our kits will ft your bike
82
101
142
36.5
48
40 36
35.5
60
73
100
41 38
1
8
0
163.5
1
5
6
9
8
5
6
H
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b

c
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45.5
Kit 3
82
101
142
36.5
48
40 36
35.5
60
73
100
41 38
1
8
0
163.5
1
5
6
9
8
5
6
H
u
b

c
e
n
t
e
r
l
i
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e
H
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c
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45.5
Kit 2 & 4
Use these measurements to make sure the hub
motor will be able to ft in your bicycles fork.
Kit instruction guide 2012 proper.indd
Last modifed July 13, 2012 2:50 PM
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Kit instruction guide 2012 proper.indd Last modifed July 13, 2012 2:50 PM
Required Tools
(Not provided with kit)
Allen wrenches
2.5mm, 3mm, 4mm, 5mm, 6mm
Phillips-head screwdriver
Wrenches
10mm, 17mm, 18mm
Bicycle tire levers
Bicycle tire pump
This guide covers the installation of Currie power kits 2, 3, and 4
Chainstay
Seatstay
Dropout (front/fork)
Dropout (rear)
Fork
Eyelets
Kit 2 250w hub motor Li-Ion 24V
Kit 3 500w hub motor Li-Ion 36V
Kit 4 250w hub motor SLA 24V
Important safety information
To install this kit properly, youll need to understand how to work on bicycle wheels, brakes, and other components that af-
fect the safety of the rider. If you are not comfortable installing this kit yourself, or you dont have the necessary skills and
experience, we recommend having your local bike shop do the work for you.
Because of the many differences between bicycle and fork models, this kit may not be suitable for all applications. It is the
assemblers responsibility to judge whether the Electro-Drive kit can safely be installed on his or her bicycle. Suggestions
made herein cannot account for all possible confgurations. If you are unsure of ft, or have a question related to safety,
function, or compatibility, please ask a mechanic at your local bike shop for assistance.
Contents

Before you start... (Kit ftment) . . . . . . . . . . . . . 2
Tools, safety, & terminology . . . . . . . . . . . . . . . 3
Wheel prep. . . . . . . . . . . . . . . . . . . . . . . . 4
Wheel installation (Kits 2 & 4) . . . . . . . . . . . . . . 4
Wheel/torque arm installation (Kit 3) . . . . . . . . . . . 5
Throttle Installation & cable routing . . . . . . . . . . . 6
Rack installation (Kit 2). . . . . . . . . . . . . . . . . . 7
Rack installation (Kit 3). . . . . . . . . . . . . . . . . . 8
Rack installation (Kit 4). . . . . . . . . . . . . . . . . . 9
Wiring diagram (Kits 2 & 3). . . . . . . . . . . . . . . .10
Wiring diagram (Kit 4) . . . . . . . . . . . . . . . . . . 11
Basic operation. . . . . . . . . . . . . . . . . . . . 12-13
Troubleshooting . . . . . . . . . . . . . . . . . . . . .14
There may be minor cosmetic differences between the parts included with your kit and the parts shown in photographs/
illustrations in this guide.
Parts of a bicycle frame
4
Prepare the kit wheel for your bike. Remove the tire, tube, and rim strip from your bikes original front
wheel, then install them onto the kit wheel. If you plan to use a disc brake (kits 2 and 4 only), you should also install the
rotor now.
Axle nut
Split washer
Washer
Hook washer (align to fork dropout)
Thin washer
(Axle)
(Fork dropout)
Test-ft the new front wheel in your bicycles fork. Pay special attention to areas that might cause rubbing or improper ft.
Check the dropouts to make sure the hub motors axle is fully seated; you may need to fle away the paint from the inside
surface of the dropout to get a perfect ft.
When youre satisfed with the ft of the wheel in the fork, you can install the wheel:
Wheel Installation:
Kit 2 & 4 (250w hub motor): Seat the wheel in the fork dropouts, then tighten the nuts on each side securely. Make
sure to follow the proper hardware order (same for left and right sides):
Tighten axe nuts to 390 in-lb/44Nm
Axle hardware is the same on both sides
Please note that the 250w hub motor
uses acorn type nuts, and you must
be sure they tighten properly against
the fork dropout without bottoming
out (minimum fork dropout thickness
is 5mm, when using the included
washers).
!
Cutaway view of acorn nut. A nut installed
on too thin a dropout will bottom out before
tightening securely.
Kit 4 Kits 2 & 3
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Kit instruction guide 2012 proper.indd Last modifed July 13, 2012 2:50 PM
Axle nut
Spacer washers (as needed)
Hook washer (align to fork dropout)
Fork dropout
Fork dropout
Axle (right)
Axle (left)
Thin washer
Hook washer (align to fork dropout)
Spacer washers (as needed)
Torque arm
Axle nut
Wrap hose clamp in
heat-shink tubing
Must sit fush against
dropout surface or spacer
washer

Kit 3 (500w hub motor): Seat the wheel in the fork dropouts, tightening
the right-side axle nut frst. Add the torque arm (see instructions below), then
tighten the left-side axle nut. Make sure the wheel sits evenly in the dropouts
and is not tilted or shifted to one side. Make sure that both axle nuts are
seated squarely against either a spacer washer, the torque arm, or the fork
dropout surface. The entire face of each axle nut should be contacting one of
those surfaces. You may need to add more spacer washers to safely install
the wheel.
Torque arm assembly (Kit 3 only)
Kit 3s 500 watt motor can produce enough torque to poten-
tially bend or break the fork its mounted in, if the included
torque arm is not installed. For this reason, its very im-
portant that you follow these instructions to make sure the
torque arm is secured completely!
Please assemble the arm as shown in the diagram. You may
need to slightly change the order of pieces to ft your specifc
fork.
To avoid scratching your fork, put the included piece of heat-
shrink tubing around the hose clamp, then cut it to length
and shrink it to ft.
If your fork dropout surfaces are deeply inset (most alumi-
num suspension forks), you will need to use the included
spacer washers (shown in diagram above) between the
dropout and the torque arm to allow the torque arm to clear
the fork leg. The portion of the torque arm that grabs the
axle must sit fush and fat against either the dropout face
itself or a spacer washer, and the axle nut must be tightened
fully (390 in-lb/44 Nm)
Tighten axe nuts to 390 in-lb/44Nm
6
Throttle Installation (all kits)
Install the throttle on the handlebars in a position
where it is easy to reach, and where it does not
interfere with the brake or shift levers. The throttle
should always be mounted to the inside of the brake
as shown, so it does not move the brake lever into
an unsafe position.
Cable routing throttle and motor (all kits)
Begin by attaching the female plug of the motor extension cable to your fork leg, using the rubber block and three cable
ties as shown. Only the female plug is attached to the block; the male plug hangs freely below so the wheel can be easily
removed without cutting any cable ties.
String the motor extension cable up the leg of the fork, then along either the top tube or downtube of the bicycle, depend-
ing on what is most convenient. Be sure you leave enough slack to allow the handlebars to turn freely in both directions,
and that the cable does not interfere with steering or braking.
Route the throttle cable similarly, tying it to a brake or shifter
housing, then following the same path as the motor extension
cable. Both cables should end up near the seat of the bike, where
they will be plugged into the controller later.
After installing, check that the throttle and motor cables do not
interfere with braking or shifting.
Grip Shifter
Brake
Throttle
Example path of throttle cable (red) and motor extension cable (green)
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Kit instruction guide 2012 proper.indd Last modifed July 13, 2012 2:50 PM
Installing the rack
Please note that because bicycle designs vary widely, the rack may not ft all confgurations without some modifcation.
Kit 2
Bolt the rack to the bicycle frame. If your bicycle does not have eyelets provided on the seatstays for the racks upper
struts, you can use the included metal brackets instead.
You can adjust the rack struts in several places (see pictures below). Once the rack is installed, adjust it until it is level
with the ground, and as low as possible over the rear tire.
Once the rack is attached, youll need to connect the throttle and motor cables to the controller. Slide the bottom cover off
of the racks controller compartment, connect the cables, put any extra cable slack inside the compartment, then slide the
bottom cover back on. See the wiring section of this guide for a full wiring diagram.
Controller compartment bottom cover Wiring ft into controller box
8
Kit 3
Bolt the rack to the bicycle frame. If your bicycle does not have eyelets provided on the seatstays for the racks upper
struts, you can use the included metal brackets instead.
You can adjust the rack struts in several places (see pictures). Once the rack is installed, adjust it until it is level with the
ground, and as low as possible over the rear tire.
Once the rack is attached, youll need to connect the throttle and motor cables to the controller. Remove the two screws
holding the bottom cover onto the racks controller compartment (see photo below), connect the cables, put any extra
cable slack inside the compartment, then screw the bottom cover back on. See the wiring section of this guide for a full
wiring diagram.
Controller compartment bottom cover Wiring ft into controller box
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Kit instruction guide 2012 proper.indd Last modifed July 13, 2012 2:50 PM
Kit 4
Bolt the rack to the bicycle frame. If your bicycle does not have eyelets provided on the seatstays for the racks upper
struts, you can use the included metal brackets instead.
You can adjust the rack struts in several places (see pictures). Once the rack is installed, adjust it until it is level with the
ground, and as low as possible over the rear tire.
Once the rack is attached, youll need to connect the throttle and motor cables to the controller. Remove the four screws
holding the top cover onto the racks controller compartment (see photo below), connect the cables, put any extra cable
slack inside the compartment, then screw the bottom cover back on. See the wiring section of this guide for a full wiring
diagram.
Controller compartment screws
Controller compartment wiring
10
Throttle
Battery
Hub motor
Controller
+ -
+ -
Motor Extension
Cable
ON/OFF switch
Throttle signal and lights
Be careful that you dont accidentally plug the throttle (5-pin connector)
into the motor hall sensor (6-pin connector with 5 wires). This could
permanently damage the controller! Always double check the labels
near each connector before plugging them in.
Check the polarity of the 4-prong battery connector before connecting
the battery for the frst time! Both the male connector on the rack and
the female connector on the battery are labeled with + and - signs to
indicate their polarity, and these must match to avoid damaging the
controller.
!
!
Wiring Diagram
IZIP Kit 2 & 3 2012
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Kit instruction guide 2012 proper.indd Last modifed July 13, 2012 2:50 PM
Be careful that you dont accidentally plug the throttle (5-pin connector)
into the motor hall sensor (6-pin connector with 5 wires). This could
permanently damage the controller! Always double check the labels
near each connector before plugging them in.
!
Throttle
With on/off switch
Hub motor
Controller
Motor Wire Extension
Harness
ON/OFF switch
Throttle signal
and lights
Wiring Harness,
RMB Switch Harness
1
2
3
CHARGER PORT
BATTERY BATTERY
WIRE HARNESS, BATTERY CASE
FUSE
Battery (SLA)
BA-PK24-005
+ +
Right side Left side
1a
1
1b
Switch, ON/ON
ON
ON
Wiring Harness,
RMB Terminal-to-Switch
Wiring Diagram
IZIP Kit 4 2012
12
Basic operation
Install the battery into the rack
Lock the battery into the rackv
Kits 2, 3, 4
Before riding, you should lock the battery into the bikes rack. This prevents the battery from falling out of the bike as you
ride, and helps maintain a steady electrical connection at the battery terminal. For kits 2 and 3, the lock is attached to the
battery itself, near the rear refector. For kit 4, the locks are bolted to the rack on both sides, near the top.
Turn on the bicycle
Kits 2 & 3
Use the ON/OFF switch on the throttle to power up the bike. The indicator lights on the throttle will illuminate and the bike
will be ready to ride. Push the throttle paddle down with your thumb to start the motor.
Kit 4
Find the battery selector switch at the back of the rack, behind the rear refector. Toggle the switch to the left or right,
depending on where your battery is installed. After selecting your battery location, you can use the ON/OFF switch on the
throttle to power up the bike. The indicator lights on the throttle will illuminate and the bike will be ready to ride. Push the
throttle paddle down with your thumb to start the motor.
Kit 4 Kit 2 Kit 3
Kit 4 battery selector switch Throttle ON/OFF switch
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Kit instruction guide 2012 proper.indd Last modifed July 13, 2012 2:50 PM
Capacity
Fully charged
< 3/4 full
< 1/2 full
Empty, or very low
Battery indicator lights
The four lights on the throttle indicate current battery voltage. Because of the way battery
voltage rises and falls depending on the current load, it is best to take a battery reading
after reaching cruising speed on level ground.
Before your frst ride...
Familiarize yourself with the operation of your bicycles electrical system (previous page).
Be sure your tires are infated to the pressure indicated on the sidewall.
Double-check the tightness of any nuts or bolts affected by the installation of this kit.
Check your brakes.
Read the included battery care guide.
Troubleshooting
Are all your controller connections made correctly? Double-check based on the wiring diagrams provided in this
guide. Check each plug for broken or pushed-out connector pins. Check the controller and component wiring for dam-
age.
If the motor wont run, but the lights on the throttle illuminate when the bike is switched on...
Is the motors quick-disconnect plug (attached to the leg of your bicycles fork) connected fully? Try pushing
the plug halves together forcefully, and massaging them together.
If the lights on the throttle will not illuminate (the bike will not turn on)...
Is the battery coming fully into contact with the input terminal?
(Kit 4) Do you have the correct battery selected, using the switch on the back of the rack? See the Basic opera-
tion section of this manual for more info.
(Kit 4) Is the rear selector switch reversed? Try fipping the rear selector switch to the opposite side. If the switch
works in reverse, youll need to reverse the two plugs labeled Wiring Harness, RMB Terminal-to-Switch in the wiring
diagram on page 11.
Please call the Currie Tech technical and customer service department at 1-800-377-4532 if you need additional
assistace.
Battery Voltage ( 10%)
Kit 3 >39V 37.5V - 39V 35V - 37.5V <35V
Kit 2 >26V 24.7V - 26V 23.7V - 24.7V <23.7V
Kit 4 >24.8V 23.3 - 24.8V 22.6 - 23.3V <22.6V