Electric Bicycle Course

Lesson 1 • E-Bike History and Market Overview

This module traces the evolution of electric bicycles from early prototypes to modern mass-market products. It establishes industry context essential for understanding current technology choices.

Lesson 2 • How Electric Assist Works

This module explains the sensor-to-controller-to-motor signal chain that produces pedal assist. Students trace power flow from battery to wheel under various assist levels.

Lesson 3 • Core Components at a Glance

This module identifies every major subsystem: motor, battery, controller, display, and drivetrain. It provides a shared vocabulary used throughout the entire course.

Lesson 1 • Motor Physics and Fundamentals

This section covers torque, RPM, efficiency curves, and winding configurations relevant to e-bike motors. It grounds later motor selection decisions in measurable performance data.

Lesson 2 • Hub Motor Architecture

This section examines front and rear direct-drive and geared hub motor designs, including internal components. Students evaluate trade-offs in weight, drag, and maintenance access.

Lesson 3 • Mid-Drive Motor Architecture

This section analyzes crank-mounted motor systems that leverage the bicycle's existing gear ratios. Students compare mid-drive advantages in climbing and weight distribution against hub motors.

Lesson 4 • Motor Performance Metrics

This section teaches how to read and interpret motor specification sheets, including peak versus continuous power ratings. Students apply metrics to real-world range and hill-climb calculations.

Lesson 1 • Charging Systems and Protocols

This section covers CC/CV charging stages, charger ratings, and smart charging features that extend battery life. Students select appropriate chargers and configure charge limits for longevity.

Lesson 2 • Battery Pack Construction

This section explains cell-to-pack assembly using series and parallel configurations to achieve target voltage and capacity. Students interpret pack specifications and identify cell arrangement from labels.

Lesson 3 • Battery Management Systems

This section details BMS functions: cell balancing, over-current protection, temperature monitoring, and state-of-charge estimation. Students diagnose common BMS fault codes and understand protection thresholds.

Lesson 4 • Range Estimation and Energy Planning

This section applies Wh/km consumption modeling to predict range under varying rider, terrain, and assist conditions. Students build a range estimation worksheet used in later practical chapters.

Lesson 1 • Communication Protocols

This section covers UART, CAN bus, and proprietary protocols used between battery, controller, motor, and display. Students trace data flow and identify protocol mismatches causing system errors.

Lesson 2 • Sensors and Feedback Devices

This section details torque sensors, cadence sensors, speed sensors, and throttle inputs that feed the controller. Students test sensor output signals and identify faulty sensor behavior.

Lesson 3 • Controller Programming and Tuning

This module guides parameter adjustment using PC-based software tools to optimize assist feel and motor protection. Students tune current limits, assist curves, and wheel circumference settings.

Lesson 4 • Display Units and User Interfaces

This section examines display types, menu navigation, and configurable parameters accessible to riders and technicians. Students adjust assist levels, wheel size, and speed limits through display menus.

Lesson 1 • Motor Inhibitor Integration

This section explains how brake levers with motor-inhibit switches cut motor power during braking for safety. Students wire, test, and verify inhibitor function across different controller platforms.

Lesson 2 • Hydraulic and Mechanical Disc Brakes

This section covers brake system selection, rotor sizing, and pad compound choices appropriate for heavier e-bike loads. Students bleed hydraulic systems and adjust mechanical cable brakes to spec.

Lesson 3 • Suspension and Wheel Systems

This section evaluates fork and rear suspension tuning for added e-bike mass and hub motor wheel builds. Students true wheels, set sag, and verify spoke tension on motor-laced wheels.

Lesson 4 • Frame Design for Electric Assist

This section analyzes how motor torque, battery weight, and rider load influence frame geometry and material choices. Students evaluate frame ratings and identify stress points unique to e-bikes.

Lesson 1 • Pre-Delivery Inspection Protocol

This section applies a structured 30-point PDI checklist covering mechanical, electrical, and safety items before customer handover. Students complete and sign PDI documentation as a professional quality record.

Lesson 2 • Workshop Setup and Tool Requirements

This section identifies specialized tools, torque wrenches, and diagnostic equipment needed for e-bike assembly. Proper tool selection prevents component damage and ensures repeatable assembly quality.

Lesson 3 • System Power-On and Initial Configuration

This module guides the first power-on sequence, display pairing, and baseline parameter entry for wheel size and assist levels. Students confirm motor direction, sensor response, and display communication.

Lesson 4 • Electrical Harness Routing and Connection

This section routes motor cables, battery leads, and sensor wires to avoid pinch points and frame abrasion. Students connect all harness plugs, verify polarity, and secure cables with proper clips.

Lesson 1 • Diagnostic Methodology and Workflow

This section introduces a structured fault-finding process: symptom collection, hypothesis testing, and root-cause confirmation. Systematic workflow prevents misdiagnosis and unnecessary part replacement.

Lesson 2 • Error Code Interpretation

This section decodes manufacturer error codes from display units and PC diagnostic software across common platforms. Students map error codes to probable causes and confirm with physical testing.

Lesson 3 • Software and Firmware Fault Resolution

This section addresses controller firmware corruption, failed updates, and parameter reset procedures. Students perform firmware reflashing and restore factory defaults safely.

Lesson 4 • Mechanical Fault Identification

This section identifies noise, vibration, and resistance faults originating in motor internals, bearings, and drivetrain. Students differentiate mechanical from electrical symptoms using isolation techniques.

Lesson 1 • Battery Safety and Storage Protocols

This section covers safe charge state for storage, temperature limits, and transport regulations for lithium packs. Students apply hazard identification and emergency response steps for battery incidents.

Lesson 2 • Service Records and Documentation

This section establishes digital and paper service record standards for warranty compliance and resale value. Students complete a full service record entry and understand data retention requirements.

Lesson 3 • Customer Education and Handover Briefing

This module structures a rider briefing covering assist modes, charging habits, and basic safety checks. Effective handover reduces warranty claims and builds long-term customer trust.

Lesson 4 • Cleaning and Corrosion Prevention

This section specifies safe cleaning methods that protect electrical connectors, motor seals, and display units. Students apply dielectric grease, corrosion inhibitors, and protective coatings correctly.