Kit - Heavy Duty Recumbent

The Heavy-Duty Recumbent Trike Conversion System is engineered for riders who need the increased durability of a direct-drive motor and the long-term reliability of a 48V lithium-ion battery. It is ideal for recumbent trikes that regularly carry heavier riders or cargo.

• Special components selected for recumbent trike applications
• Top speed approximately 20 mph at 48V
• Estimated 15–45 mile range depending on rider, terrain, and usage
• Supports pedal-assist and throttle-on-demand

Heavy-Duty Power: The 500–1000W direct-drive hub motor used in this kit is a must for applications where total system weight (trike + rider + cargo) is 300 lb or more. This configuration prioritizes torque and reliability at lower speeds, making it well-suited for loaded touring, hauling, and demanding recumbent use.

Direct-drive motors are simple, robust, and long-lasting, with no internal gears to wear out. Unlike cheaper or oversized DD motors that can feel “draggy,” this E-BikeKit direct-drive hub is designed for smooth, efficient pedaling when unpowered and excellent thermal stability under load.

Recumbent Heavy-Duty Kit Extras:

• Pedal-assist extension cable
• Locking parking brake levers

Core Conversion Kit Components:

• USA hand-built rear wheel with 500W direct-drive hub motor (disc-brake compatible)
• 48V compatible 22A 12FET controller
• Programmable LCD dashboard
• 12-magnet PAS split disc
• PAS sensor, left-side mount (right-side mount available by request)
• Thumb throttle
• Left and right e-brake levers
• Main motor cable
• Accessory cable (3-to-1 or 4-to-1 depending on configuration)
• Battery wire harness (included only when a battery is not ordered)
• Battery and charger (only when a battery option is selected)
• Zip ties, C-washers, and torque arms

Battery mounting hardware is not included. Mounting solutions vary by recumbent frame — use an appropriate rack, plate, or battery mount.

Motor Specifications

• Brand: EBikeKit LLC
• Type: Direct-drive (brushless, disc-brake compatible)
• Power: 500W nominal / >1000W peak @ 48V
• Max Torque: 46 Nm @ 48 V
• Max RPM: ~259 RPM @ 48 V
• Cable Exit: 8″ axle exit, 3-phase / 5 Hall sensors
• Connector: Round 8-pin (10.4 mm)
• Weight: 12.8 lb (5.8 kg)
• Rear Dropout Spacing (OLD): ~135 mm with 7-speed freewheel & 15 mm disc offset
• Freewheel Compatibility: 7-speed standard (8/9/10-speed increases OLD by ~3.5 mm per additional cog)

This heavy-duty recumbent kit may be ordered with or without a 48 V 15 Ah lithium-ion battery pack and charger.

• Range: 15–45 miles (depending on rider, terrain, and assist level)
• Charging Time: ~5 hours (15 Ah pack with 3 A charger)
• Nominal Voltage: 48 V
• Nominal Capacity: 15 Ah (0.2 C)
• Energy: ~720 Wh
• Dimensions: 14″ × 3.5″ × 5″ (356 mm × 89 mm × 127 mm)
• Total Weight: 10.1 lb (4.6 kg)
• Cell Assembly: 18650-3.6 V, 13S4P
• Life Cycles: ~500–800 charge cycles
• Max Continuous Discharge: 16 A
• BMS Protection Current: 20 A
• Discharge Cut-Off Voltage: 37.5 V
• Max Charge Voltage: 54.6 V
• Internal Resistance: ≤230 mΩ
• Operating Temp (Charge): 0 °C–113 °F
• Operating Temp (Discharge): −68 °F–140 °F
• Storage Temp: 0 °C–104 °F (59 °F–77 °F recommended)
• Case Material: Plastic
• Certifications: UN38.3; MSDS; cells UL1642/2580-listed

If ordered without a battery, the kit does not include a battery or charger.

This Heavy-Duty Recumbent Kit is a proven solution for high-load recumbent trikes and has been successfully installed by many dealers in demanding real-world applications.

How to use this system in your shop:

• Recommend for riders or applications where total system weight will meet or exceed ~300 lb
• Ideal for touring trikes, cargo trikes, and utility recumbents
• Emphasize durability, smooth power delivery, and low maintenance vs. geared options

Dealer Support Commitment:

• Real-time support via text, phone, and email during installations
• Direct access to system builders and wheel technicians for detailed technical questions
• Guidance on freewheel selection (7/8/9/10-speed) and OLD spacing adjustments
• Help with torque-arm placement, dropout spreading, and chainline tuning
• Quick responses to keep your mechanics productive and installs on schedule

Our mission: Make sure every dealer can confidently deliver safe, high-load recumbent conversions that reflect well on your shop and on the E-BikeKit brand.

This system is designed for rear-drive recumbent trikes that use standard rear dropouts and have sufficient space for a 20″ or 26″ rear wheel with a 500 W direct-drive hub motor.

Frame & Drivetrain Requirements:

• Rear dropout spacing around 135 mm (can be slightly adjusted to accommodate wider freewheels)
• Threaded freewheel compatibility (not cassette-only hubs)
• Steel or robust aluminum dropouts capable of handling motor torque

Not Recommended For:

• Frames with rear thru-axles or proprietary dropout designs
• Recumbents using internal geared hubs that cannot be replaced
• Frames that cannot safely accept minor dropout spreading (when using 8/9/10-speed freewheels)

If you are unsure whether a particular recumbent trike is a good candidate, contact us with photos of the rear dropouts, brake mounts, and drivetrain so we can help evaluate compatibility.

The Heavy-Duty Recumbent Kit installs with common bike tools, but is best handled by an experienced mechanic due to the torque and weight involved.

• Remove the existing rear wheel and install the 500 W direct-drive wheel into the rear dropouts
• Confirm and adjust OLD spacing for 7/8/9/10-speed freewheel selection
• Install and tighten torque arms on both sides of the axle
• Mount the controller securely and connect all harness leads (motor, PAS, throttle, display, e-brakes, battery)
• Install the PAS disc and sensor on the crank (left-side standard, right-side possible where needed)
• Mount and secure the battery and route cables to avoid moving parts and pinch points

Correct spacing, precise torque-arm installation, and clean cable routing are essential to safe, long-term operation of this heavy-duty system.