The TerraTrike EVO is an electric vehicle option designed to enhance the riding experience of TerraTrike recumbent trikes. This manual provides detailed build notes for assembling and integrating the EVO system, focusing on the electrical components, steering, and chain systems.

Function Description:

The TerraTrike EVO system integrates an electric motor and control unit into a standard TerraTrike, providing pedal assistance to the rider. This "Electric Vehicle Option" (EVO) is designed to make riding easier, especially on inclines or over long distances, by augmenting the rider's pedaling power. The system includes a Bosch Kiox display for monitoring ride data and controlling the electric assist, a speed sensor for accurate speed measurement and motor control, and a battery pack (charging instructions for which are available on the TerraTrike website). The overall design ensures that the electric components are seamlessly integrated into the trike's frame, maintaining the TerraTrike's stability and comfort.

Important Technical Specifications:

While specific power output (e.g., motor wattage) and battery capacity are not detailed in this document, the manual highlights several key components and their specifications:

Kiox Display: The system utilizes a Bosch Kiox display, which is a common and advanced e-bike display known for its robust features and clear interface. The display bracket uses M4x.7 x 6mm SBHCS SS and M5x.8 x 18mm SBHCS SS screws, and a M4x0.7x6mm Flat Head SS screw for mounting.
Speed Sensor: A speed sensor magnet (x1) is installed on a spoke, and the speed sensor itself is mounted on a computer sensor bracket.
Lock Keys: The system includes two lock keys (x2), likely for securing the battery or other components.
Boom and Main Frame: The boom and main frame are connected by the battery wire, emphasizing the importance of careful handling to avoid damaging the wire during assembly.
Axle Torque: The axle should be torqued to 23-25Nm during the Hybrid Steering Stack Assembly.
Alignment: The recommended alignment measurement for the front wheels (center tread to center tread) is approximately 29 5/8 inches.
Chain System Components: The chain system includes various components such as Chain Tube, 56 LDPE (TT000548), Chain Tube Clamp (GT - TT000697, Traveler - TT000422), Spacer (GT Chain Tube - TT000700), M5x35 SHSCS SS (TT000436), Idler Wheel Spacer (TT000262), M8x30mm BHCS SS (TT000280), M5x18mm PHSS (N/A), Idler, 10t Deluxe (TT000261), Idler "L" Bracket (TT000263), and M8x35mm BHCS SS (TT000279).
Hybrid Steering Stack Components: Key components for the steering stack include M6x30 Bolt (TT000576), Hybrid Top Cap (TT000506), Trigger Handlebar (RH - TT000649, LH - TT000650, Pair - TT000514), M5x20 Bolt - 2qty (TT000301), Hybrid Headset Spacer (TT000520), Hybrid Headset Cap (TT000505), Bushing (pre-installed - TT000809), Hybrid Headset Cup (pre-installed - TT000602), Hybrid Headset Bearing (TT000600), Rapid Axle Hubmount (RH - TT000713, LH - TT000714, Pair - TT000516), Rapid Axle (RH - TT000717, LH - TT000718, Pair - TT000563), and Axle Spacer (TT000568).

Usage Features:

The TerraTrike EVO is designed for ease of use and integration with existing TerraTrike models.

Pedal Assist: The primary usage feature is the electric pedal assist, which reduces the effort required to pedal, making the trike accessible to a wider range of riders and suitable for various terrains.
Kiox Display Interface: The Bosch Kiox display provides an intuitive interface for riders to monitor speed, battery level, assist mode, and other ride metrics. The display is mounted on the left handlebar for easy access and visibility.
Boom Adjustment: The boom can be inserted to a desired length, allowing for rider-specific adjustments to optimize pedaling position and comfort.
Cable Routing: The manual emphasizes proper cable routing for the Kiox cable (following brake cable routing) and the speed sensor cable (clear of brake rotor and steering parts), ensuring safe and reliable operation.
Battery System: The system is powered by a battery pack, which needs to be charged completely before use. Charging instructions are provided separately on the TerraTrike website.

Maintenance Features:

The manual provides several key maintenance guidelines during the assembly process, which are crucial for the long-term performance and safety of the EVO system.

Wire Management: A critical maintenance aspect is the careful handling and routing of wires. The manual explicitly warns against stressing wires when inserting the boom and advises securing excess wires with zipties using the cable housing guide under the center lug of the frame. This prevents damage to the electrical system and ensures reliable operation.
Greasing Components: During the Hybrid Steering Stack Assembly, it is recommended to grease the steerer tube before inserting it into the head tube and to remove any excess grease before installing the handlebar. The axle should also be greased before installing the wheel. Proper lubrication is essential for smooth steering and wheel rotation, reducing wear and tear.
Torque Specifications: Adhering to the specified torque of 23-25Nm for the axle is vital for the structural integrity and safety of the steering system.
Alignment Check: Regular alignment checks, with a recommended measurement of approximately 29 5/8 inches (center tread to center tread), are important for maintaining stable handling and even tire wear. The manual notes that slight variance is possible and emphasizes checking alignment with a rider seated in the trike.
Pre-Ride Checks: The manual advises a thorough double-check of all work after assembly and a test ride of the finished product. This ensures all components are correctly installed and functioning safely before regular use.
Battery Care: While not detailed in this document, the mention of charging the battery pack completely and referring to the TerraTrike website for charging instructions highlights the importance of proper battery maintenance for longevity and performance.
Component Replacement: The parts list for the Hybrid Steering Stack Assembly indicates that components can be purchased individually or in pairs, facilitating easy replacement of worn or damaged parts.

In summary, the TerraTrike EVO is a well-integrated electric assist system designed to enhance the TerraTrike riding experience through thoughtful engineering and clear assembly instructions, ensuring both performance and durability.

TerraTrike EVO - Page 4

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