There are many options and what you want will vary depending on your goals and the bike itself.
We will start by measuring the bike, then go over the options available and finally, installation instructions.
Measurement
We will not cover disassembly or other topics that can be researched elsewhere, if you need this info please see this link.
Start by measuring the width of the bottom bracket shell, from face to face. Do not measure any bearings or other pieces, you are looking for the bottom bracket shell width only. Measure it twice. 99.9% of you will have a measurement between 68mm and 120mm. If its not, then it is an install that is outside the scope of this article.
Remove the bottom bracket from the bottom bracket shell using the appropriate tools, this is a job for your local bike shop if you don't have the tools, patience or knowhow. Even if you do have the tools, some of them can be very stubborn to come out even if the bike is brand new.
If your bottom bracket shell has threads on the inside this is great news, it means your style of bottom bracket will likely take the BBS motor without needing an adaptor. Threaded bottom bracket shells are called JIS or BSA standard and this is what the Bafang motor kit was designed to work with. The inside diameter of your JIS-BSA shell should be 33.8mm +/- .2mm. Check it. Twice.
If your bottom bracket does NOT have threads, but has pressed in bearings, don't panic. Yet.
There are adaptors for some of the most common press fit style bottom brackets, not all but some. There is an article discussing adaptors and press fit bottom brackets here, to determine what kind of non-threaded BB you have and if you can get an adaptor or if you are out of luck.
At this point you have a bike with a bottom bracket shell between 68 and 120mm and it is a JIS-BSA type or you have to use an adapter to make it standard BSA diameter.
Next thing you need to do is determine which size (length) bottom bracket you should order. The following compatibility chart shows where you should START, do not skip ahead and order yet! Match your width with the BB type to tell you what bottom brackets you can use.
At this point you should know what BB will fit.
Motor types
Essentially we have three different Cyclone versions. The 3000, the Mini, and the Monster. The 3000 is by far the most popular.
The Mini is more lightweight and lower powered while also being a bit more stealthy. The monster is very large and heavy and can only be used with a 120mm since it needs at least this width for the cranks to clear the motor, as well as needing a special battery for all the current it pulls. The 3000 strikes the best balance between power and size.
For this guide we will assume your choice is the 3000w version.
Options
Chainrings
Now that you know the motor you want you likely have the choice of ISIS or square taper BB. The ISIS BB is well made with good tolerances and uses the latest bicycle crankset standard. However the square taper BB is required for use with the Luna-tic crankset, which is a heavy duty crankset with an especially heavy duty freewheel specifically designed to handle high power. It is by far the most durable crankset on the market for cyclone.
Many people choose one or the other, ISIS with one of the standard cranksets or square taper with the Luna-tic crankset. If you truly wanted the best of both worlds you could modify it to combine an ISIS BB with the Luna-tic chainwheel.
Next option is the triple chainring, this is a good option for folks that do not want to compromise by optimizing their bike for torque or speed, but instead want both. With a triple chainring you essentially double your gear range. You have one gear going from the motor to the chainring, and the other two are going to the rear cassette on your bike. So if you have a 9 speed rear, instead of having a 9 speed ebike this triple chainring gives you an 18 speed ebike. All of the chainrings will give very good torque but this may be a good option if you still want to go 40+ MPH while you have that much torque, and while still maintaining peak efficiency.
Please note that if you use the triple chainring you cannot use a front derailleur to change between the rings, you will need to manually take the chain with your fingers and move it to the other chain ring.
Included controller
We currently have two options, either stock or ASI. Stock is 40A, easily replaceable, and usable with all accessories such as PAS sensor and 3-speed switch. ASI is sinewave, which is both a significant increase in efficiency as well as quieter operation and more durability. There are two different versions of the ASI programming we offer on this controller for the 3K, one that is 2000W and the other at 4000W. Both the stock controller and the 4000W ASI should be used with a high power battery but this is especially so with the 4000W ASI. For the 2000W version you can use a battery with a lower constant discharge rate.
For example, with stock you may be able to use our shark pack with 30A continuous/50A peak BMS, but this would not be enough for the 4000W ASI as it can peak higher than 50A and may be higher than 30A continuous depending on riding conditions. For a controller pulling that much power we would typically recommend one of our high power softpack batteries with 50A continuous/ 70A peak BMS. But if you select the 2000W version or even the 3000W stock controller, a pack with 30A BMS (i.e., most of the batteries we sell) should be fine under most circumstances.
This is not a typical controller where power is measured based on current, it is based on wattage. So if you have a lower voltage, it's going to pull more amperage. Wattage is peak rating on these option descriptions, not continuous. So a 4000W is programmed to run for up to 4000W, 2000W is programmed to run for up to 2000W.
Warning about options for ASI controller
No extra accessories currently work with ASI. No PAS sensor, 3 speed switch, or ebrakes. If these options are important to you, select stock controller.
Bluetooth controller: Sometimes we have BT controller option. If upgrading to the Bluetooth controller or needing info on it, see the controller's listing for documentation. If using bluetooth controller option it has a smartphone app to use phone as display. This app is on the controller listing. 40A version here ... 60A version here
Display
The kit will function perfectly with no display. However if you want a full featured display we recommend the Batt-Man.
This shows power being used, has a programmable gauge, speedometer and is easy to use. Click the image above for more details.
Custom Mount
These custom mounts are offered due to customer requests for a more robust mount solution than the default mount provided with the kit. It can also be custom strengthened for even more rigidity if you so choose, see this link.
Throttle Options
Click the image to see full description on each throttle. Much of this is down to personal preference. The Oro throttles do not have keyed on/off switch, if this is a priority then you want one of the other types.
Crank Arm Set
This one is fairly straightforward. If you have selected a an ISIS BB you need an ISIS crankset. If you have selected the Luna-tic crankset you need square taper.
Ebrake Cutoff Sensors
This is a standard safety power cutoff sensor. It is set up in such a way that pulling the lever pulls the magnet away from the sensor. Once the magnet/sensor is far enough away, power cuts on the throttle. Often this is positioned using epoxy adhesive to affix the sensor and magnet in the proper position. Note: If the throttle does not work when this is plugged in you have the magnet too far from the sensor.
Cadence Sensor for Pedal Assist
Standard PAS sensor. Please note this is only compatible with stock controller.
Motor sizing
This is the latest cyclone kit with new and improved mounting brackets that mimimize frame flex and eliminate the need for the janky looking Hose clamp. The picture below illustrates the difference between the 68mm and fat bike kits. We ship whichever mount corresponds with the bottom bracket you select in the order.
Installation
Click here to go to the beginners guide to Cyclone installation, or simply scroll down to post #5 on this page
Other components
Another optional component on this kit is the 3 speed switch, available here. Confirmed usable with stock and bluetooth controller, please contact support for confirmation on its use with other controllers.
FAQ
What sort of chain do I need?
Different sized chain depending on whether it is going to the motor or the rear. Single speed going to motor and regular chain going to rear.
Does the Cyclone 3000 offer multiple levels of pedal assist?
No, the PAS is only at full power same as throttle. unless you can install a 3 speed switch to it.
Details on wiring: Wiring diagram
How to adjust a 68mm square taper Cyclone BB for more width with a spacer
Legacy installation instructions
These instructions were written for previous versions and as such are obsolete. They may still be useful if you would like to be more familiar with how Cyclone works.
We will start by measuring the bike, then go over the options available and finally, installation instructions.
Measurement
We will not cover disassembly or other topics that can be researched elsewhere, if you need this info please see this link.
Start by measuring the width of the bottom bracket shell, from face to face. Do not measure any bearings or other pieces, you are looking for the bottom bracket shell width only. Measure it twice. 99.9% of you will have a measurement between 68mm and 120mm. If its not, then it is an install that is outside the scope of this article.
Remove the bottom bracket from the bottom bracket shell using the appropriate tools, this is a job for your local bike shop if you don't have the tools, patience or knowhow. Even if you do have the tools, some of them can be very stubborn to come out even if the bike is brand new.
If your bottom bracket shell has threads on the inside this is great news, it means your style of bottom bracket will likely take the BBS motor without needing an adaptor. Threaded bottom bracket shells are called JIS or BSA standard and this is what the Bafang motor kit was designed to work with. The inside diameter of your JIS-BSA shell should be 33.8mm +/- .2mm. Check it. Twice.
If your bottom bracket does NOT have threads, but has pressed in bearings, don't panic. Yet.
There are adaptors for some of the most common press fit style bottom brackets, not all but some. There is an article discussing adaptors and press fit bottom brackets here, to determine what kind of non-threaded BB you have and if you can get an adaptor or if you are out of luck.
At this point you have a bike with a bottom bracket shell between 68 and 120mm and it is a JIS-BSA type or you have to use an adapter to make it standard BSA diameter.
Next thing you need to do is determine which size (length) bottom bracket you should order. The following compatibility chart shows where you should START, do not skip ahead and order yet! Match your width with the BB type to tell you what bottom brackets you can use.
| 68-73mm | ~83mm | 100mm | 120mm | |
|---|---|---|---|---|
| BSA | Standard Square Tapered BB 68-83mm, ISIS BB 68-73mm | Standard Square Taper BB 83-100mm, Square taper 68-83mm (use a spacer bearing), ISIS BB 83mm | Standard Square Taper BB 83-100mm, ISIS BB 100mm | Standard Square Taper BB - 120mm, ISIS BB 120mm |
| (Pressfit) BB30 | BB30 Adapter required | BB30 Adapter required | BB30 Adapter required | BB30 Adapter required |
| (Pressfit) PF30 | PF30 Adapter required | PF30 Adapter required | PF30 Adapter required | PF30 Adapter required |
| (Pressfit) PF41 | PF41 Adapter required | PF41 Adapter required | PF41 Adapter required | PF41 Adapter required |
| Eccentric (Old-style American aka Ashtabula) | Eccentric Adapter required | Eccentric Adapter required | Eccentric Adapter required | Eccentric Adapter required |
| Anything else | Not likely | Not likely | Not likely | Not likely |
At this point you should know what BB will fit.
Motor types
Essentially we have three different Cyclone versions. The 3000, the Mini, and the Monster. The 3000 is by far the most popular.
The Mini is more lightweight and lower powered while also being a bit more stealthy. The monster is very large and heavy and can only be used with a 120mm since it needs at least this width for the cranks to clear the motor, as well as needing a special battery for all the current it pulls. The 3000 strikes the best balance between power and size.
For this guide we will assume your choice is the 3000w version.
Options
Chainrings
Now that you know the motor you want you likely have the choice of ISIS or square taper BB. The ISIS BB is well made with good tolerances and uses the latest bicycle crankset standard. However the square taper BB is required for use with the Luna-tic crankset, which is a heavy duty crankset with an especially heavy duty freewheel specifically designed to handle high power. It is by far the most durable crankset on the market for cyclone.
Many people choose one or the other, ISIS with one of the standard cranksets or square taper with the Luna-tic crankset. If you truly wanted the best of both worlds you could modify it to combine an ISIS BB with the Luna-tic chainwheel.
Next option is the triple chainring, this is a good option for folks that do not want to compromise by optimizing their bike for torque or speed, but instead want both. With a triple chainring you essentially double your gear range. You have one gear going from the motor to the chainring, and the other two are going to the rear cassette on your bike. So if you have a 9 speed rear, instead of having a 9 speed ebike this triple chainring gives you an 18 speed ebike. All of the chainrings will give very good torque but this may be a good option if you still want to go 40+ MPH while you have that much torque, and while still maintaining peak efficiency.
Please note that if you use the triple chainring you cannot use a front derailleur to change between the rings, you will need to manually take the chain with your fingers and move it to the other chain ring.
Included controller
We currently have two options, either stock or ASI. Stock is 40A, easily replaceable, and usable with all accessories such as PAS sensor and 3-speed switch. ASI is sinewave, which is both a significant increase in efficiency as well as quieter operation and more durability. There are two different versions of the ASI programming we offer on this controller for the 3K, one that is 2000W and the other at 4000W. Both the stock controller and the 4000W ASI should be used with a high power battery but this is especially so with the 4000W ASI. For the 2000W version you can use a battery with a lower constant discharge rate.
For example, with stock you may be able to use our shark pack with 30A continuous/50A peak BMS, but this would not be enough for the 4000W ASI as it can peak higher than 50A and may be higher than 30A continuous depending on riding conditions. For a controller pulling that much power we would typically recommend one of our high power softpack batteries with 50A continuous/ 70A peak BMS. But if you select the 2000W version or even the 3000W stock controller, a pack with 30A BMS (i.e., most of the batteries we sell) should be fine under most circumstances.
This is not a typical controller where power is measured based on current, it is based on wattage. So if you have a lower voltage, it's going to pull more amperage. Wattage is peak rating on these option descriptions, not continuous. So a 4000W is programmed to run for up to 4000W, 2000W is programmed to run for up to 2000W.
Warning about options for ASI controller
No extra accessories currently work with ASI. No PAS sensor, 3 speed switch, or ebrakes. If these options are important to you, select stock controller.
Bluetooth controller: Sometimes we have BT controller option. If upgrading to the Bluetooth controller or needing info on it, see the controller's listing for documentation. If using bluetooth controller option it has a smartphone app to use phone as display. This app is on the controller listing. 40A version here ... 60A version here
Display
The kit will function perfectly with no display. However if you want a full featured display we recommend the Batt-Man.
This shows power being used, has a programmable gauge, speedometer and is easy to use. Click the image above for more details.
Custom Mount
These custom mounts are offered due to customer requests for a more robust mount solution than the default mount provided with the kit. It can also be custom strengthened for even more rigidity if you so choose, see this link.
Throttle Options
Click the image to see full description on each throttle. Much of this is down to personal preference. The Oro throttles do not have keyed on/off switch, if this is a priority then you want one of the other types.
Crank Arm Set
This one is fairly straightforward. If you have selected a an ISIS BB you need an ISIS crankset. If you have selected the Luna-tic crankset you need square taper.
Ebrake Cutoff Sensors
This is a standard safety power cutoff sensor. It is set up in such a way that pulling the lever pulls the magnet away from the sensor. Once the magnet/sensor is far enough away, power cuts on the throttle. Often this is positioned using epoxy adhesive to affix the sensor and magnet in the proper position. Note: If the throttle does not work when this is plugged in you have the magnet too far from the sensor.
Cadence Sensor for Pedal Assist
Standard PAS sensor. Please note this is only compatible with stock controller.
Motor sizing
This is the latest cyclone kit with new and improved mounting brackets that mimimize frame flex and eliminate the need for the janky looking Hose clamp. The picture below illustrates the difference between the 68mm and fat bike kits. We ship whichever mount corresponds with the bottom bracket you select in the order.
Installation
Click here to go to the beginners guide to Cyclone installation, or simply scroll down to post #5 on this page
Other components
Another optional component on this kit is the 3 speed switch, available here. Confirmed usable with stock and bluetooth controller, please contact support for confirmation on its use with other controllers.
FAQ
What sort of chain do I need?
Different sized chain depending on whether it is going to the motor or the rear. Single speed going to motor and regular chain going to rear.
Does the Cyclone 3000 offer multiple levels of pedal assist?
No, the PAS is only at full power same as throttle. unless you can install a 3 speed switch to it.
Details on wiring: Wiring diagram
How to adjust a 68mm square taper Cyclone BB for more width with a spacer
Legacy installation instructions
These instructions were written for previous versions and as such are obsolete. They may still be useful if you would like to be more familiar with how Cyclone works.
- How to Cylone 3000: Table of Contents
- This electricbike.com article: https://www.electricbike.com/cyclone...-build-report/
- Electric-fatbike.com did an article on building up the wide bottom bracket version of the kit (click here)
- On endless-sphere you can get in depth information on the cyclone drive on this thread.
- Cyclone 3000 Knowledge Base
- Read our in depth article which explains what your up against when taking on the Cyclone.
- You can also find various threads on endless-sphere.com where several DIY builders have bought cyclone drives and are dong build threads.
- We also have a quickstart guide on our forum
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