BAFANG 48V 500W Front Hub Motor Electric Bike Conversion Kit

1. Introduction

Thank you for choosing the BAFANG 48V 500W Front Hub Motor Electric Bike Conversion Kit. This kit is designed to transform your standard bicycle into a powerful electric bike, enhancing your riding experience with reliable performance and efficiency. This manual provides essential information for the safe installation, operation, and maintenance of your new e-bike system. Please read it thoroughly before beginning installation or use.

2. Important Safety Information

WARNING: Please mind potential fire risk and strictly follow the instruction manual for charging and storage of the battery.

• Always wear a helmet when riding your e-bike.
• Ensure all connections are secure and properly insulated to prevent electrical shorts.
• Do not modify the motor, controller, or battery components. Unauthorized modifications can lead to serious injury or damage and will void the warranty.
• Keep the battery away from heat sources, direct sunlight, and flammable materials.
• Do not immerse electrical components in water. The system has an IPX5 waterproof rating, but it is not designed for submersion.
• Regularly check brakes, tires, and all fasteners for proper function and tightness.
• Familiarize yourself with local regulations regarding e-bike use.

3. Package Contents

Your BAFANG Electric Bike Conversion Kit includes the following components:

Please check all items against the packing list to ensure everything is present and undamaged.

4. Specifications

4.1 Motor Specifications

4.2 Battery Parameters (Optional)

4.3 E-bike Display Details (Optional)

5. Setup and Installation

This section guides you through the installation process of your BAFANG e-bike conversion kit. Ensure you have all necessary tools and refer to the diagrams carefully.

5.1 Choosing the Correct Wheel Size

It is crucial to select the correct wheel size for your conversion kit. Refer to the table and instructions below to determine the appropriate size.

1. Check Tire Marking: Locate the size marking on your bicycle tire (e.g., 26x1.95).
2. Determine Rim Size: Use the provided table to match your tire size to the correct rim diameter.
3. Confirm Compatibility: Ensure the chosen kit wheel matches your bike's rim size and brake type (Disc Brake for this kit).

5.2 Measuring Dropout Width

Accurate measurement of your bike's dropout width is essential for proper motor fitment.

For the Front Hub Motor, the Front Drop Out Size should be 100mm.

5.3 Component Overview and Wiring

Familiarize yourself with the main components and their connections before starting the installation.

The following diagram illustrates the general wiring connections for the e-bike kit. Ensure each component is connected to its corresponding port on the controller.

The controller is the central unit for managing power and signals. Refer to the controller details for specific current ratings and connection types.

1. Install Hub Motor: Replace your bike's front wheel with the BAFANG front hub motor wheel. Ensure it is securely fastened and the dropout width is 100mm.
2. Mount Controller: Secure the controller box to your bike frame in a protected location.
3. Install Battery: If applicable, mount the battery securely to the frame (e.g., downtube or rear rack).
4. Install PAS Sensor: Attach the Pedal Assist System (PAS) sensor to your bike's bottom bracket area.
5. Install Display: Mount the LCD display on your handlebars.
6. Install Throttle & Brake Levers: Replace your existing brake levers with the e-bike specific ones (or install brake sensors) and mount the thumb throttle.
7. Connect Wiring: Carefully connect all components to the controller according to the wiring diagram. Ensure all connectors are fully seated and secured. Use plastic straps to manage cables neatly and prevent snagging.
8. Install Headlight (Optional): Connect the headlight to the designated port on the controller.

6. Operating Instructions

6.1 E-bike Display Functions

The optional LCD display provides crucial information and allows you to control your e-bike's settings.

Depending on your display model (e.g., EKD01, DPC18, 500C, DZ40 Mini), you can access various functions:

• Power On/Off: Typically a long press of the power button.
• Assist Level Adjustment: Use the '+' and '-' buttons to change the pedal assist level (0-9 levels).
• Information Display: View current speed, battery level, trip distance, total mileage, and error codes.
• Headlight Control: Some displays allow direct control of the headlight.
• Settings Menu: Access advanced settings for wheel size, speed limit, and battery parameters.

6.2 Riding Modes

Your e-bike kit supports multiple riding modes to suit different preferences and terrains.

• Exercise Mode (No Electric Riding): Pedal without motor assistance.
• Electric Assist Riding (Pedal Assist): The motor provides assistance based on your pedaling input and the selected assist level.
• Pure Mode (Throttle Only): Use the thumb throttle to engage the motor without pedaling.
• Walk Assist Mode: Provides low-speed assistance for walking the bike.

6.3 Battery Charging

Always use the charger provided with your battery. Connect the charger to the battery and then to a power outlet. The charger will indicate when the battery is fully charged. Do not overcharge the battery.

7. Maintenance

• Regular Cleaning: Keep the motor, controller, and battery clean and free from dirt and debris. Use a damp cloth; avoid high-pressure washing.
• Check Connections: Periodically inspect all electrical connections for corrosion or looseness.
• Brake Inspection: Ensure your brakes are functioning correctly. Adjust or replace brake pads as needed.
• Tire Pressure: Maintain correct tire pressure for optimal performance and safety.
• Battery Care: Store the battery in a cool, dry place when not in use. If storing for extended periods, charge it to 50-70% capacity every few months.
• General Bike Maintenance: Perform regular maintenance on your bicycle's mechanical components (chain, gears, bearings) as you would with a non-electric bike.

8. Troubleshooting

If you encounter issues with your e-bike kit, refer to the display for error codes or check the following common problems:

• No Power: Check battery connection, ensure battery is charged, and verify all main power cables are securely connected.
• Motor Not Assisting: Check PAS sensor alignment and connection. Ensure the assist level is not set to '0'.
• Display Not Working: Check display cable connection to the controller.
• Intermittent Power: Inspect all wiring for loose connections or damage.

For more complex issues or if troubleshooting steps do not resolve the problem, please contact customer support.

9. User Tips

• Cable Management: Use zip ties or cable wraps to secure all wires neatly along the bike frame. This prevents snagging and protects the cables from damage.
• Battery Security: Always ensure your battery is locked or securely fastened to prevent theft or accidental dislodgement during rides.
• Display Protection: Consider a screen protector for your LCD display to guard against scratches and impacts.
• Regular Software Updates: If your display or controller supports firmware updates, check the manufacturer's website for the latest versions to ensure optimal performance and new features.

10. Warranty and Support

All BAFANG products come with a one-year warranty. In case of any issues or technical questions, please contact our customer service. We have professional technicians in the EU who can provide technical support and assist you with problem resolution.

Maintain Points: France, Poland, Spain, UK

11. Product Video

Watch the official product video for a visual guide on the BAFANG e-bike system and its features.