Step by Step Custom MADSEN Electric Assist Installation

Step by Step Custom MADSEN Electric Assist Installation

Step by Step Custom MADSEN Electric Assist Installation

Custom MADSEN E-Assist Installation (we highly recommend taking your MADSEN to a local bicycle shop for installation of the MADSEN e-assist)

  1. Remove bucket.
  2. Remove chain guard & chain guide.
  3. Remove pedals, crank arms & bottom bracket.
  4. Shift MADSEN to the smallest gear.
  5. Remove shift cable.
  6. Cut shift cable casing (center of water bottle bolts), and remove 53mm piece out of the short end of casing.
  7. Install new shift cable & gear shifting sensor onto cable.
  8. Slide motor assembly into bottom bracket. DO NOT BOLT IT ON YET. Install motor by sliding it into the bottom bracket, and tuck wire harness under bottom bracket.
  9. Bolt battery bracket onto frame using the 4 - M5 Bolts (M5x15).
  10. Bolt on U-shaped bracket around bottom bracket onto motor, using 2 - M6 Bolts (M6x10). Make sure the bumps are facing towards the frame. Loosely tighten each bolt, going back and forth at first. Then tighten all the way, going back and forth between bolts.
  11. Install motor bottom bracket nut using a spanner wrench. Tighten to 60 NM.
  12. Install top aluminum bottom bracket nut using a ***BBT-9 Tool. Tighten to 25-30 NM. (***We are now including a custom laser-cut tool in your kit, to replace the BBT-9 Tool.)
  13. Remove chainring from old crank. Bolt chainring onto spider bracket plate.
  14. Install chainring assembly onto motor using 5 - M5 Bolts (M5x8). Loosely tighten bolts. Perform final tightening of bolts, moving in a star pattern.
  15. Install chain on to chainring. Open up chain guard mount to thread chain under chain guide wheel and into chain guard mount.
  16. Install chain guard onto chain guard mount.
  17. Install crank arms -  make sure L is on left side and R on right side.
  18. Install Pedals - again, make sure L is on left side and R is on right side.
  19. Remove grips and brake cable from levers. Remove levers.
  20. Install speed sensor and magnet on rear wheel.
  21. Slide on heat shrink tubing over cables.
  22. Install new brake levers.
  23. Connect brake cables to new levers.
  24. Plug in all wires:  2 - Brake, 1 - Display, 1 - Y-splitter, 1 - Gear Sensor.
  25. Zip tie cable and wires.

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