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    Cycle Analyst / Batt-Man installation (without a direct CA plug)

    Here is a quick tutorial on how to install a Batt-man or CAv2 (or V3) on any controller that has no factory direct plug (DP)

    I will only show you the Cycle Analyst installation but it's similar for the Batt-Man

    For the Cycle Analyst you will need the "Shunt Option" that is the part that will measure the current passing through.

    UPDATE: Luna no longer sells the Cycle analyst.


    For the Batt-Man, no shunt is required because it's included.

    Batt-Man



    First you will need all these tools and accessories to do a good job; Click image for larger version  Name:	DSC00024.jpg Views:	1 Size:	209.6 KB ID:	22619



    Heat shrink butt connectors 10-12AWG 4x
    1 set of XT-90 S (spark arrestor if possible) Make it 2 sets if you don't have a XT-90 plug on your controller and battery, or you could use the type of connectors that you prefer.
    Heat Shrink tubing (better if they are 3:1 with adhesive)
    Heat gun, torch or lighter (for the heat shrink)
    Crimping tool or a plier (even a cutter if you are careful)
    Liquid tape (not mandatory but nice to seal up were the speed sensor wire is coming out.

    Ok this is what you get when you order a CA with shunt : Click image for larger version  Name:	Screen Shot 2016-11-18 at 3.47.13 PM.png Views:	1 Size:	783.8 KB ID:	22620
    Click image for larger version  Name:	Screen Shot 2016-11-18 at 3.46.33 PM.png Views:	1 Size:	121.0 KB ID:	22621


    I will not show you how to install the Cycle Analyst on the handle bar or show you how to connect it, you can't miss it!


    The Shunt, there is a battery side and controller side,

    The controller side will be attached to the female XT-90 and the battery side to the male XT-90

    I did shorten the wires of the shunt and on the XT-90 pigtails to have the smallest possible length

    Start by cutting the wires to the desired length (not too short you won't be able to crimp them),

    This next part is not necessary if you use butt connector like I do, but I tend to always go over the top to never have to worry about it.....
    Cut the small heat shrink tubes to the desired length (photo is an uncut XT-90). Make sure you have all the small heat shrink cut to the right length then crimp the red and black on one side and put the heat shrink in each wires (like this picture). now take the shunt and put heat shrink tubes on to the wires of the shunt.

    Make sure it's the right side to the right connector gender. Click image for larger version  Name:	DSC00008.jpg Views:	1 Size:	177.5 KB ID:	22622




    And crimp them Click image for larger version  Name:	DSC00032.jpg Views:	1 Size:	146.9 KB ID:	22623
    Last edited by Sebz; 04-06-2017, 06:21 AM.

    #2
    Repeat for the other side! and you should have already have a working shunt.

    You can go ahead and test it on your battery to check if all works fine

    If you did wire it correctly you can now cover it with heat shrink, I used 2 pieces of HS for the DP plug and overlapped them.

    I also used Liquid tape around the wire so no water can get in it (not shown in the pictures)

    After a few minutes you should have something like this: Click image for larger version

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    Click image for larger version

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    Click image for larger version

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    Now just install the Shunt in between the battery and the controller (taken you have replaced the connector to XT-90s)

    install the CA to the handle bar, place the wire were you can!

    And now you have a speed sensor that is too short to go to the back wheel.... and like me you have a front fork... well this is how I managed to install it :

    I just used the hydraulic line as support for the wire and put the wire on the inside of the fork to protect it against the elements and used 2x 50lbs HD zipties. Click image for larger version

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    BATT-MAN VS CAv2 for size : Click image for larger version

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    Don't worry I know the voltages are not the same they were connected to 2 different packs!


    Hope that helps

    Seb
    Last edited by Sebz; 11-18-2016, 12:32 PM.

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