TerraTrike Rover and Rover Tandem Boost Kit Instruction Manual

TerraTrike Rover and Rover Tandem Boost Kit

Product Information

Rover and Rover Tandem Boost Kit with Bosch Active Line Plus The Rover and Rover Tandem Boost Kit is an electric assist system designed to be mounted on a TerraTrike. It comes with a cable guide, speed sensor, battery, lock, magnet, key, clamp, display mount, computer sensor bracket, M5 Nyloc Nut, M5x70 BHCS, M8x20 SHCS, and a 34t chainring. The Boost Kit is compatible with the Bosch Active Line Plus system and can be used on the Rover Tandem model.
It is important to ensure that the Boost Kit serial number matches the order and specifications of the trike it is to be mounted. Failure to match the Boost Kit and trike specifications could result in an error code, improper operation of the Boost Kit, and voiding of the warranty.
Please note that TerraTrike Comfort Pedals or clipless pedals are highly recommended, specifically with the use of the Rover Tandem Boost Kit. Installing a Boost Kit on the Rover Tandem will eliminate the independent pedaling system (IPS) of the captain crankset.

Product Usage Instructions

1. Remove the pedals from the stock boom and break the chain before removing the stock boom.
2. Insert the Boom to the desired length and replace frame set screws with M8x20 SHCS bolts. Tighten bolts to 15-16Nm. For Rover Tandem models, after the boom is secured, replace the stock 44t chainring with the provided 34t chainring. Be careful not to change alignment while doing so.
3. Install the battery plate with the rear mounting bracket located behind the furthest frame set screw. Mount the battery plate to the frame using the M5x70 bolts and M5 nuts. Use red positions. Secure the battery to the frame using the included battery strap. Refer to charging instructions on TerraTrike’s website.
4. Apply cable guide to the bottom side of the left outrigger. Route wires according to the diagram on the following page. Using zip ties, secure excess wires under the mainframe, display wire to brake cable housing, speed sensor wire, and display wire to outrigger cable guide. Do not over-tighten zip ties. Affix Class 1 Sticker to the mainframe. For Rover models or trikes equipped with Sliding/EZ seats, affix behind seat clamp near chainstays.
5. Reconnect tie-rod with the wiring between the tie-rod and the frame. Reinstall the chain and pedals.
6. Assemble display mount. Attach the display mount to the left handlebar. Mount Purion display and secure. Mount the speed sensor on the computer sensor bracket. Refer to the diagram in Step 5 for proper wire routing. Install the magnet on the spoke and align it with the marking on the speed sensor. If your current computer sensor bracket does not have a mounting hole, replace it with the one included in the Boost Kit. Ensure that the speed sensor wire is clear of the brake rotor and any steering parts that could cause damage.

• Ensure Boost Kit serial number (located on the inside of the boom tube) matches the order and the specifications of the trike it is to be mounted on.
• Warning: Failure to match Boost Kit and the trike specifications it is programmed for could result in an error code, will cause the Boost Kit to not operate properly, and will void the warranty for the Boost Kit.

PLEASE NOTE

• TERRATRIKE COMFORT PEDALS OR CLIPLESS PEDALS ARE HIGHLY RECOMMENDED, SPECIFICALLY WITH USE OF THE ROVER TANDEM BOOST KIT.
• Installing a Boost Kit on the Rover Tandem will eliminate the independent pedaling system (IPS) of the captain crankset.

Perform the following before installing the Bosch Boost Kit:

• Remove pedals from stock boom.
• Break chain.
• Remove stock boom.

Boost Kit Hardware

1. Using caution to not stress wires, insert boom to desired length and replace frame set screws with M8x20 SHCS bolts. Tighten bolts to 15-16Nm.
   • Rover Tandem models:
   • After boom is secured, replace the stock 44t chainring with provided 34t chainring.
2. Being careful not to change the alignment, disconnect the tie-rod on one side.
3. Install the battery plate with the rear mounting bracket located behind the furthest frame set screw. Mount the battery plate to the frame using the M5x70 bolts and M5 nuts.

Frame placement – Rover

Frame placement – Rover Tandem

• Apply cable guide to bottom side of left outrigger.
• NOTE: MODIFICATION OF WIRES WILL VOID WARRANTY.
• DO NOT CUT AND SPLICE TO SHORTEN WIRES.
• Route wires according to the diagram on the following page. Using zip ties, secure excess wires under the mainframe, display wire to brake cable housing, speed sensor wire, and display wire to outrigger cable guide. Do not over tighten zip ties.
• Reconnect tie-rod with the wiring between the tie-rod and frame.
• Reinstall the chain and pedals.
• Assemble display mount.
• Attach display mount to left handlebar. Mount Purion display and secure.
• Mount speed sensor on computer sensor bracket.
• Refer to the diagram in Step 5 for proper wire routing.
• Install magnet on spoke.
• Align magnet and marking on speed sensor.
• Please note: If your current computer sensor bracket does not have a mounting hole, replace it with the one included in the Boost Kit.
• Ensure the speed sensor wire is clear of the brake rotor and any steering parts that could cause damage.
• Affix Class 1 Sticker to the mainframe. For Rover models, or trikes equipped with Sliding/EZ seats, affix behind seat clamp near chainstays.
• Charge the battery pack completely.
• Secure the battery to the frame using included battery strap.
• Instructions for charging are located on
• TerraTrike’s website at: www.terratrike.com/manuals
• Remember to double-check your work.
• Test-ride the finished product.
• Final step: Watch your customers smile with excitement as they test the intuitive power of the Boost Kit with the Bosch Active Line Plus motor.

• 4460 40th St SE Grand Rapids, MI 49512 www.TerraTrike.com  800.945.9910
• TerraTrike.com  800.945.9910

Documents / Resources

| TerraTrike Rover and Rover Tandem Boost Kit [pdf] Instruction Manual
Rover, Rover Tandem, Rover and Rover Tandem Boost Kit, Boost Kit, Rover Boost Kit, Rover Tandem Boost Kit
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References

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