Steps 1

  • Disconnect the power cable that connects the motor to the battery at the rear wheel.

Steps 1

Steps 2

  • Remove the chain, both wheels and the cranks to make it easier to work on the bike. Make sure not to lose the quick link in the chain when removing.

Steps 2

Steps 3

  • Remove the drive side bottom bracket cup using the Park tool BBT-19.2.
  • Removing this cup will make it a lot easier to route the power wire to the rear wheel.

Steps 3

Steps 4

  • Remove the headlight from the handlebar by removing the two 3mm bolts under the headlight and disconnecting the wire from the headlight.

Steps 4

Steps 5

  • Remove the grips from the handlebar, for this you may need to use compressed air to get them off. Once the grips are removed take the shifter and rear brake lever off the handlebar. 

Steps 5

Steps 6

  • Loosen the 4 4mm bolts on the face plate of the handlebar and remove the top cap. Then whilst holding the fork remove the handlebar allowing the fork to drop down and out of the bike. Be careful of the front brake hose as it is still attached. Set these parts carefully aside making sure not to damage them

Steps 6

Steps 7

  • Using a 2mm allen, Remove the 2mm bolt holding the power button in place on the top tube. Once removed pull the wire out of the frame carefully and disconnect it from the wire

Steps 7

Steps 8

  • One the bottom of the bike under the bottom bracket there is a hatch held in with a 2mm screw. Remove the screw and the hatch to reveal the wiring for the bike. Carefully remove the wiring so it is hanging out of the bike.

Steps 8

Steps 9

  • The first part to remove is the power controller for the lights. It consists of 4 wires, two in the middle for the taillights and one either side of them for the headlight and the power cable. Be very careful unplugging these as they are fragile.  Once removed set the power controller aside.

Steps 9

Steps 10

  • Now you have removed the power controller you will have the speed sensor wire, the charge port wire and the rear wheel power wire remaining in the frame. These are attached to the battery so will come out together once the battery is

Steps 10

Steps 11

  • On the underside of the down tube there are 3 3mm bolts that need to be removed. Be careful with them as they are soft and can round out. Once these three bolts are removed using the thicker wires pull the battery out of the frame via the hatch on the bottom of the bike. It can be tough to remove. The headlight wire will be loose in the frame as it is not attached to anything now. The power wire will be attached at the top of the battery once the battery is removed unplug the power wire and set the old battery aside.

Steps 12

  • Connect the female end of the power wire to the male end attached to the power controller. Also connect the female end of the headlight wire to the male end attached to the power controller.
  • LeMond bikes built before October 2021 may have the older version of the power controller installed. The old power controller has the headlight and power wire integrated into the power controller. The new version as seen in the picture above has quick disconnects for the headlight and power wires to make installing easier.
  • If your bike has the older version of the power controller, please refer to the Replacing Your Old Power Controller with The New Power Controller document.
  • If you do not have this document, please reach out to info@lemond.com.

Steps 12

Steps 13

  • Connect the male end of the power wire to the female end at the head tube end of the battery making sure the arrows line up.(Refer to picture above.)
  • Also make sure the male end of the headlight wire goes to the head tube end of the battery.

Steps 13
Steps 13

Steps 14

  • Using tape preferably masking tape. Tape the power wire and the headlight wire to the battery together and put it in the center of the battery. Also use some tape to tape the excess wire at the headtube end of the battery together to keep it out of the way.

Steps 14

Steps 15

  • To install the battery in the bike first slide the two cables on the headtube end of the battery into the frame and slide battery into the frame making sure the threaded inserts are facing down. It can be tight to get the battery in, but it will fit. Slide the battery all the way in until the final threaded insert lines up with the hole in the underside of the downtube.

Steps 15

Steps 16

  • Place a drop of blue Loctite on each of the 3mm battery bolts before installing. Once the battery is installed install the 3mm battery bolt in the bolt hole closest to the hatch. This will keep the battery secure but still easy to move. Once you have all the battery bolts installed tighten them down. DO NOT OVERTIGHTEN.

Steps 16

Steps 17

  • Once the battery is installed and secure, connect the taillight wires to the power controller. Make sure they are lined up correctly, do not force them. Next connect the charge port wire and the speed sensor wires that is all the wires connected.

Steps 17
Steps 17

Steps 18

  •  At the headtube of the bike route the wire for the button threw the hole for the button and connect it to the button. Once it is connected tuck the wire into the frame and secure the button to the frame with the 2mm bolt.

Steps 18

Steps 19

  • nsert the fork back into the headtube and have something under it to support it. Make sure the brake line, shift cable and headlight wire are behind the fork as shown in the picture, also make sure the

Steps 19

Steps 20

  • Feed the headlight wire through the upper headset bearing and the headset spacer making sure the headlight wire goes through the slot on the riders left of the spacer as shown in the picture. headlight cable is on the riders left side of the headtube.

Steps 20

Steps 21

  • Connect the headlight wire to the connection on the inside of the headlight.  Be careful when connecting as it can slip and snap the zip tie holding 

Steps 21

Steps 22

  • Reinstall the handlebar and tighten the top cap leaving the faceplate loose to straighten the handlebar once the bike is on the ground. Reinstall the right brake lever, Shifter and grips. Also attach the headlight under the handlebar with the 2 3mm bolts. Feed any excess

Steps 22

Steps 23

  • Feed the long power wire from the hatch through the non-drive side chainstay out of the large hole in the frame as shown. It can be difficult to get through as the brake line is in the same space but with some persuasion it will go through. Also make sure to route it around the bottom bracket not under it.

Steps 23

Steps 24

  • nstall the rear wheel into the dropout and tighten the rear axle bolts evenly on both sides to 20nm. Once installed connect the power wire from the rear wheel to the power wire you ran through the frame making sure the arrows line up. Once done zip tie the power wire to the brake mount bracket as shown to keep it out of the wheel.

Steps 24

Steps 25

  • Once the rear wheel is connected press the power button on the top tube and the bike will turn on. It will flash a couple times and then stay on a solid color. If it is flashing purple check all connections especially the speed sensor and headlight connections as they are the same connector and can sometimes get swapped around. 

Steps 25

Steps 26

  • Reinstall the drive side bottom bracket cup using the park tool bbt-19.2 making sure to torque It to 30nm. Next install the crank and tighten the pinch bolts evenly to 13nm and ensure the plastic clip is inserted. Finally install the chain making sure the lettering on the chain is facing out and the quick link is fully seated.

Steps 27

  • uck all the wires into the frame before installing the hatch. Make sure the wires coming from the power controller are not kinked or bent as they are fragile. Once all inside the frame reinstall the hatch and tighten the 2mm bolt. DO NOT OVERTIGHTEN

Steps 27
Steps 27

Steps 28

Reinstall the front wheel making sure to torque the front axle to 12nm DO NOT OVERTIGHTEN.

Steps 29

  • FINAL STEP. Put the bike on the ground and make sure the handlebar is straight. Also level the brake levers and shift lever to the customers desired position. Once straight tighten the 4 face plate bolts evenly in a star pattern to 5nm DO NOT OVERTIGHTEN. Once done, test ride the bike to make sure all assist modes are working, and all the lights come on. 
  • If for some reason the bike will not turn on or the light do not work don’t hesitate to reach out to us and we can assist with solving any issues.

Steps 29