The Ultimate Beginner’s Guide to Cargo Bike Spare Parts and Accessories

Freya
2025-07-07
Knowledge

Cargo bikes are transforming how we move goods and people in urban environments. But unlike a regular bike, cargo bikes—especially electric ones—consist of dozens of purpose-built components, each playing a critical role in functionality, safety, and usability.

Whether you’re a first-time buyer, an urban logistics planner, or a business owner looking into fleet procurement, this guide offers a complete walk-through of the key components of a cargo bike. We’ll explain what each part does, how it fits into the big picture, and what to consider when choosing or maintaining one.

💡 Want to reduce maintenance costs through smarter component choices? Check out our guide on modular part selection.

Labeled diagram of a Regen front-loading electric cargo bike, showing key components including the bike frame, handlebar grip, display/dashboard, brake lever, steering linkage, rigid front fork, cargo box chassis, mid motor, torque sensor, chainring, pedal cranks, spoke, hub, and seat post clamp.

1. Structural Components (Designed In-House)

These components form the cargo bike’s physical structure and are often custom-engineered by manufacturers like Regen to ensure strength, safety, and compatibility with diverse use cases.

Frame

The foundation of any cargo bike. Our frames are typically made from 6061-T6 aerospace-grade aluminum or reinforced steel, offering high strength-to-weight ratio.

Long John: Front cargo box between handlebars and front wheel
Longtail: Extended rear rack
Trike: Two front or two rear wheels for balance

📚 Learn more:
Why 6061-T6 Aluminum is the Best Material for Cargo Bike Frame？

1.2 Rigid Front Fork

The fork connects the front wheel to the frame. Rigid forks are strong, light, and require no maintenance—ideal for load-bearing bikes. Some cargo bikes use suspension forks to improve ride comfort.

1.3 Cargo Rack

Attached over the rear wheel or in the front section, the cargo rack supports panniers, delivery boxes, or seats.

1.4 Basket

Lighter and smaller than cargo boxes, baskets are perfect for personal items. Usually mounted at the front.

1.5 Cargo Box Chassis

This underframe reinforces the box and connects it to the main frame. Must be sturdy to absorb road vibrations.

1.6 Cargo Box

Your main cargo space. Materials range from marine-grade plywood to injection-molded plastic.

Family Use: Often includes seats and safety belts
Business Use: Can be branded, insulated, or refrigerated

📦 Read: How Custom Cargo Boxes Enhance Brand Recognition

1.7 Cargo Seat

Optional seating within the cargo box, especially for children. Should include harness points and weather-resistant materials.

1.8 Steering Linkage

A key system in Long John cargo bikes. The linkage connects the handlebars to the front wheel via rods or cables.

Not sure how it works? Our explainer on steering mechanisms breaks it down

1.9 Canopy Frame

This supports weatherproof covers for the cargo box—essential for comfort in rainy climates.

1.10 Handlebar Tube

Connects the handlebar to the front fork or steering linkage. Adjustable designs support ergonomic riding.

1.11 Rain Cover

Clear, flexible PVC or fabric canopy that keeps passengers and goods dry. Modular options improve flexibility and reduce replacement cost.

Only 20 MOQ Bikes to Get Started

Customizable E-Cargo Bike - RS01

Whether you’re a growing brand or a neighborhood store, our heavy-duty cargo bikes are your ticket into the booming world of eco-friendly delivery. Let’s roll!

Request A Quote

2. Electrical Components (Power and Control)

Electric cargo bikes depend on a well-coordinated electronic system that helps move heavy loads with ease and efficiency. Below is a breakdown of the core electrical parts, their function, and how they support the bike’s overall performance:

Part	Name	Definition & Role in Cargo Bike
2.1	Motor	Converts electrical energy into mechanical power to assist pedaling. Provides torque needed to move heavy loads.
2.2	Controller	The central processing unit of the motor system. Regulates power based on inputs from sensors and user settings.
2.3	Display / Dashboard	Mounted on the handlebar, shows real-time ride data like speed, power mode, battery status, and fault alerts.
2.4	Battery	Stores energy for the motor and accessories. Determines the range and power reserve of the cargo e-bike.
2.5	Sensors	Detect pedal input to regulate motor assistance. Torque sensors measure pedaling force; cadence sensors detect pedal rotation.
2.6	Front Light	Illuminates the road ahead for visibility and safety during night riding.
2.7	Tail Light	Increases visibility from behind. Often integrated with brake or turn signals.
2.8	Turn Signals	Optional safety feature to indicate direction change. Useful in dense traffic.
2.9	Wiring Harness	Electrical cable network connecting all components. Needs to be waterproof and well-routed.
2.10	Integrated Switch	Button or panel used to turn the bike on/off and control lights, power mode, or boost.
2.11	DC Converter	Converts high-voltage battery output to 5V/12V for USB ports, phone charging, or IoT systems.

2.1 Motor

The motor is the engine of an electric cargo bike. It boosts the rider’s pedaling power and is essential for carrying heavy cargo or climbing hills. Two types are common:

Mid-drive motor: Located near the crank, transfers power directly to the drivetrain. Provides better hill-climbing and load distribution.
Hub motor: Built into the front or rear wheel. Quieter and simpler but less efficient under high loads.

2.2 Controller

This component acts like a brain, taking signals from the pedals, throttle, and sensors to manage how much power the motor delivers. It ensures smooth acceleration and efficient energy use.

2.3 Display / Dashboard

Your cockpit interface. It provides real-time data on speed, battery level, distance, assist mode, and diagnostics. Advanced displays may include GPS or Bluetooth.

2.4 Battery

Typically lithium-ion, batteries are mounted in the frame or on the rear rack. A high-capacity battery (e.g., 720Wh) can support over 60 km of assisted riding. Regen uses batteries certified to EU/CE standards from brands like LG and Panasonic.

2.5 Sensor

Two main types:

Torque sensor: Measures force applied to pedals. Offers a natural, responsive feel.
Cadence sensor: Measures if and how fast you’re pedaling. Simpler but less intuitive.

2.6–2.8 Lights

Front and rear lights are required in most regions. Advanced models feature automatic headlights, brake lights, and handlebar-mounted turn signals. These improve safety in high-traffic areas.

2.9 Wiring Harness

This is the nervous system of the electrical setup. A well-designed harness ensures stable connections, avoids shorts, and resists water and corrosion.

2.10 Integrated Switch

Many Regen cargo bikes use thumb switches integrated into the handlebar grip for quick toggling between power levels, lights, or horn.

2.11 DC Converter

Useful for delivery fleets or urban riders who rely on smartphones or IoT devices. Converts battery power to usable voltages for charging accessories or powering auxiliary devices.

3. Standard Bike Components (Interchangeable)

These parts are commonly used in regular bicycles but are often reinforced or adapted in cargo bikes to accommodate additional weight, stress, and functionality.

Part	Name	Definition & Role in Cargo Bike
3.1	Fork	Holds the front wheel and connects it to the frame. Suspension forks add comfort; rigid forks are stronger for heavy loads.
3.2	Stem	Connects the handlebar to the fork and determines rider posture.
3.3	Handlebar	Enables steering and often houses control systems and grips.
3.4	Grip	Rubber or foam handles for comfort and anti-slip control.
3.5	Headset	Bearing system that enables smooth handlebar rotation.
3.6	Crank	The arm connecting the pedal to the bottom bracket. Transfers power.
3.7	Bottom Bracket	Houses the axle and bearings. Needs to be reinforced for cargo applications.
3.8	Pedal	Where the rider applies force. Larger pedals offer better stability.
3.9	Saddle	The seat. Wide, padded saddles are ideal for longer rides.
3.10	Seatpost	Connects the saddle to the frame. Height-adjustable.
3.11	Seat Clamp	Secures the seatpost in position. Quick-release clamps help shared riders.
3.12	Chainring / Crankset	Main front gear. Affects pedaling torque and speed.
3.13	Freewheel / Cassette	Rear gear cluster. Defines gear range.
3.14	Internal Gear Hub	Enclosed rear gear system. Low maintenance and weatherproof.
3.15	Hub	Wheel center that may contain gears, motor, or brake parts.
3.16	Brake Lever	Handlebar-mounted lever to activate brakes.
3.17	Brake Caliper	Applies pressure to brake disc for stopping power.
3.18	Brake Disc	Rotating disc that the caliper clamps onto. Found in disc brake systems.
3.19	Speed Sensor	Measures wheel speed to help regulate pedal assist.
3.20	Wheel	The rotating element. Cargo bikes use stronger rims and higher load tires.
3.21	Inner Tube	Inflatable tube inside the tire.
3.22	Tire	External rubber covering. Must support heavy loads and resist punctures.
3.23	Shock Absorber	Reduces vibration and improves comfort. Found in high-end models.
3.24	Air Spring	Suspension element using pressurized air. Lighter than coil springs.
3.25	Reflector	Enhances visibility. Required in many regions.
3.26	Mudguard	Blocks splashes from water and mud. Keeps rider and cargo clean.
3.27	Lock	Prevents theft. Frame locks are common on European cargo bikes.
3.28	Spoke	Connects hub to rim. Must be reinforced in cargo wheels.
3.29	Chain	Transfers power from crank to rear wheel. Must withstand tension and load.
3.30	Fasteners & Hardware	Includes nuts, bolts, clamps, and hinges essential for structural integrity.

Recommended: Hydraulic vs. Mechanical Brakes – Which is Right for Cargo Bikes?
See also: How Cargo Bike Tires Differ from Standard eBikes

How These Parts Work Together

When well-integrated, these components create a safe, comfortable, and efficient cargo vehicle. An unbalanced system (e.g., weak brakes or underpowered motors) compromises performance.

Final Thoughts

Cargo bikes are not just oversized bicycles—they’re mobile systems designed for utility, efficiency, and safety. Whether you’re customizing your first family bike or managing a logistics fleet, understanding the components empowers better decisions.

👨‍🔧 Want to speak to our engineers about your build? Book a free consultation