1. Introduction
Welcome to the Varstrom x SUTTO 250W Rear Hub Motor Kit. This kit is designed to transform your standard bicycle into an electric bike, offering seamless pedal assistance for an enhanced riding experience. This manual provides essential information for the safe installation, operation, and maintenance of your new e-bike conversion kit.
The 250W rear hub motor ensures quiet operation and consistent torque, making it easier to tackle inclines and extend your rides. It is compatible with most standard bicycles and is suitable for urban commuting, leisure rides, and adventurous journeys.
Image: SUTTO Hub Motor E-Bike Conversion Kit overview.
2. Safety Information
⚠ Disclaimer: Please mind potential fire risk and strictly follow the instruction manual for charging and storage of the battery.
- Always wear a helmet and appropriate safety gear when riding your e-bike.
- Ensure all connections are secure and properly insulated before operating the e-bike.
- Do not operate the e-bike in adverse weather conditions without proper precautions.
- Keep the battery away from heat sources, direct sunlight, and flammable materials.
- Use only the provided charger for the battery.
- Do not modify the motor, battery, or controller in any way.
- Regularly check brakes, tires, and all components for wear and tear.
3. What's Included
Your Varstrom x SUTTO 250W Rear Hub Motor Kit package includes the following components:
Motor Kit Components:
- 1 x SUTTO Hub Motor Wheel
- 1 x Controller
- 1 x Controller Box (Note: Battery is not included in this box)
- 1 x Display (Optional, specific model depends on selection)
- 1 x 1T4 Cable
- 1 x Thumb Throttle
- 1 x PAS Sensor (Small One - Left)
- 1 pair Brake Levers or Brake Sensor (Optional, depending on selection)
Free Gifts:
- 1 x Headlight
- 1 set Plastic Straps
- 1 x Manual
Battery Kit Components (if purchased with battery):
- 1 x Battery (Optional, specific type depends on selection)
- 1 x Battery Charger
- 1 x Battery Manual
- 1 x XT60 Port Motor Battery Connector Cable
- 1 set of Screws
- 1 set Rear Bracket (Only for Rear Rack Battery)
- 1 x Backup Battery Fuse (Only for Rear Rack Battery)
- 2 pcs Battery Keys
Image: Visual representation of the 250W Hub Motor Kit packing list.
Image: Visual representation of the Battery Kit packing list.
4. Specifications
Motor Specifications:
| Feature | Specification |
|---|---|
| Brand Name | varstrom |
| Motor Type | Brushless Gear Hub Motor |
| Wattage | 201 - 300w (250W) |
| Voltage | 36V |
| Design | Brushless |
| Max Torque | 35N.m |
| Max Speed | 25Km/H |
| Rear Drop Out size | 136-142MM |
| Compatible Wheel Sizes | 26"/27.5"/700C |
| Construction | Gear drive |
| Compatible Brake System | Disc Brake |
| Operation Temperature | -20℃ ~ 45℃ |
| Waterproof Grade | IP X5 |
| Controller Max. Current | 15A |
| Controller Rated Current | 7A |
| Certification | CE |
| Origin | Mainland China |
Battery Specifications (Optional):
| Feature | 36V13Ah Hailong Battery | 36V17.4Ah Hailong Battery | 36V24Ah Hailong MAX Battery | 36V22.5Ah Rear Rack Battery |
|---|---|---|---|---|
| Battery Cells | Grade A 18650 2600mah 10s5p 50PCS | Grade A 18650 2900mAh 10s6p 60PCS | L-G 21700 4800mah 10s5p 50PCS | Grade A 18650 2500mah 10s9p 90PCS |
| BMS | 30A | |||
| Charge Voltage | 42V | |||
| Discharge Cut-off Voltage | 28V | |||
| USB Port | YES | |||
| Cycle Life | 1000 times | |||
| Charging Current | 2A - 4A | |||
| Charge Temperature | 0℃ ~ 45℃ | |||
| Discharge Temperature | -15℃ ~ 65℃ | |||
| Way of Charge | CC/CV | |||
| Protection Function | Over charge, Over discharge, Over current, Short circuit, Balance | |||
Image: Wheel size compatibility and rear dropout dimensions.
Image: E-bike display details and specifications.
Image: Battery specifications and dimensions.
5. Installation Guide
This section outlines the general steps for installing your SUTTO 250W Rear Hub Motor Kit. Always ensure the power is OFF before making any connections.
5.1 Pre-Installation Checks
- Verify your bicycle's rear dropout size is between 136mm and 142mm.
- Confirm your bike uses a disc brake system.
- Ensure you have all components listed in the "What's Included" section.
Image: Bike front & rear dropout size compatibility.
5.2 Hub Motor Wheel Installation
- Remove your existing rear wheel.
- Install the SUTTO Hub Motor Wheel into the rear dropout. Ensure it fits securely within the 136-142mm range.
- Secure the wheel with appropriate fasteners.
5.3 Controller and Wiring
- Mount the controller box in a suitable location on your bike frame, typically near the battery or motor.
- Connect the motor extension cable from the hub motor to the controller.
- Connect the 1T4 cable to the controller. This cable will branch out to connect the display, throttle, and brake levers/sensors.
Image: Easy installation guide and wiring diagram for the Hub Motor Kit.
5.4 Display, Throttle, and PAS Sensor Installation
- Mount the display (if included) on your handlebars. Connect it to the 1T4 cable.
- Install the thumb throttle on your handlebars and connect it to the 1T4 cable.
- Install the PAS (Pedal Assist Sensor) on the left side of your crank arm. Ensure the magnets are correctly aligned with the sensor. Connect it to the 1T4 cable.
Image: PAS Sensor installation details and specifications.
5.5 Brake System Integration
- If your bike has mechanical brakes, install the provided brake levers and connect them to the 1T4 cable.
- If your bike has hydraulic brakes, you can choose to install the brake sensors on your existing brake levers and connect them to the 1T4 cable.
Image: Brake lever and brake sensor options.
5.6 Battery Installation (if applicable)
- Mount the battery securely on your bike frame (for Hailong type) or on the rear rack (for Rear Rack type).
- Connect the XT60 Port Motor Battery Connector Cable from the battery to the controller.
- Ensure the battery is locked in place with the provided keys.
Image: Hailong battery installation and features.
Image: Rear Rack battery installation and features.
Important: Before installing the motor, please follow the steps in the manual to connect the motor to see if the motor can work normally. Please DO NOT remove any connection while the power supply is on.
6. Operation Guide
6.1 Powering On/Off
Locate the power switch on the battery (if applicable) or the display. Press and hold the power button to turn the system ON or OFF.
6.2 Battery Indicator
Press the button on the battery to check the remaining power level. The indicator lights typically show:
- 1 Red 0 Green: 0%
- 1 Red 1 Green: 1%-25%
- 1 Red 2 Green: 26%-50%
- 1 Red 3 Green: 51%-75%
- 1 Red 4 Green: 76%-100%
Image: Battery details including indicator, charging port, and switches.
6.3 Pedal Assist System (PAS)
The PAS sensor detects your pedaling motion and provides motor assistance. Use the display to adjust the PAS level (0-9 or 0-5 depending on display model) to control the amount of assistance you receive.
6.4 Thumb Throttle
The thumb throttle provides on-demand power, allowing you to accelerate without pedaling. Use it cautiously, especially when starting from a standstill.
6.5 Headlight and Taillight (Optional)
If included, the headlight can be turned on/off via a switch, often located on the battery or controller. Some batteries also feature a taillight switch.
7. Maintenance
- Battery Care:
- Charge the battery regularly, even when not in use, to maintain its health.
- Store the battery in a cool, dry place, away from direct sunlight and extreme temperatures.
- Avoid fully discharging the battery.
- Motor Care:
- Keep the motor clean and free from dirt and debris.
- Avoid submerging the motor in water, despite its IPX5 waterproof rating.
- Wiring and Connections:
- Periodically check all cables and connectors for damage or loose connections.
- Ensure all connections are dry before use.
- General Bike Maintenance:
- Regularly inspect tires, brakes, chain, and other bicycle components for wear and tear.
- Lubricate the chain as needed.
8. Troubleshooting
If you encounter issues with your e-bike kit, please refer to the following common problems and solutions:
- No Power / System Not Turning On:
- Check if the battery is charged and properly connected.
- Ensure the power switch on the battery or display is ON.
- Inspect all cable connections for looseness or damage.
- Motor Not Assisting:
- Verify the PAS sensor is correctly installed and aligned with the magnets.
- Check the display for error codes.
- Ensure the PAS level is set above 0.
- Display Not Working:
- Check the display cable connection to the 1T4 cable.
- Ensure the battery has power.
- Unusual Noises from Motor:
- Stop riding immediately and inspect the motor for any obstructions.
- Contact support if the noise persists.
If problems persist after checking these points, please contact customer support for technical assistance.
9. User Tips
- Battery Life: To maximize battery life, avoid storing it in extremely hot or cold conditions. Charge it to about 60-80% for long-term storage.
- Installation: Some users find it helpful to watch online video tutorials for visual guidance during installation, especially for wiring and PAS sensor alignment.
- Compatibility: Double-check your bike's rear dropout size (136-142mm) and brake type (disc brake) before purchasing to ensure compatibility.
- Package Contents: If you receive multiple packages, they might arrive at different times. If you believe a part is missing, contact customer service before assuming the package is incomplete.
- Initial Motor Test: Before fully installing the motor, connect it according to the manual to ensure it functions normally. Avoid disconnecting any parts while the power is on.
10. Warranty & Support
Varstrom provides comprehensive warranty and support for your SUTTO E-Bike Conversion Kit:
- Motor & Battery: 12 months quality warranty.
- Accessories & Parts: 30-day warranty for quality assurance.
Our network of certified service centers across the EU and UK ensures prompt repairs and support. For any issues or technical assistance, please contact our customer service team.
Image: Warranty service details.
Image: Global warehouse and repair point locations.
11. Statement of Compliance
This product is CE certified, ensuring it meets European safety, health, and environmental protection requirements.
Image: Motor and Battery Certificates.
