1. Introduction
Welcome to the Varstrom 125XVH Hub Rear Motor Electric Bike Conversion Kit user manual. This manual provides essential information for the safe installation, operation, and maintenance of your e-bike conversion kit. The Varstrom 125XVH motor is engineered for exceptional efficiency, power, and reliability, featuring advanced helical gearing and robust internal design for high-intensity use.
2. Safety Information
⚠️ Please mind potential fire risk and strictly follow the instruction manual for charging and storage.
- Always wear a helmet and appropriate safety gear when riding.
- Ensure all connections are secure before riding.
- Do not operate the e-bike in prolonged heavy rain, despite its IPX5 waterproof rating.
- Regularly inspect your e-bike for any signs of wear or damage.
- Follow local regulations regarding e-bike usage and speed limits.
3. Product Features
3.1. High Efficiency & Durability
- Rated Efficiency: Over 78%, ensuring optimal energy conversion from your battery to power.
- Optimized Internal Design: Every component is refined for strength and efficiency, providing reliable power and extended motor lifespan.
- Advanced Helical Gearing: Features a precision-engineered helical nylon gear for superior wear resistance and smoother operation compared to standard spur gears. This significantly reduces maintenance needs.
- Waterproof Connectors: Enhanced splash and weather resistance with plug-and-play connections for ease of installation. Note: Not recommended for prolonged heavy rain.
3.2. Personalized Display Options
The kit offers various display options, each with unique features:
- EKD01 Display:
- 2.4" TFT Screen
- φ22.2/25.4mm Holder
- IP67 Waterproof
- 9 PAS Levels
- Bluetooth & Navigation Function
- Multi-language support: English, French, Spanish, Italian, German, Polish, Dutch, Czech, Chinese
- Supports remote locking & unlocking via “BIKEGO+” APP
- Quick-switch to 25 km/h street-legal mode (hold “+” and “-” buttons together) - VD03 Display (Mini):
- 1.5" LED Screen
- φ22.2mm Holder
- IP67 Waterproof
- 9 PAS Levels
- Bluetooth Function
- English Version
- Supports remote locking & unlocking via “BIKEGO+” APP
- Quick-switch to 25 km/h street-legal mode (hold “Power” and “.” buttons together) - VD04 Display:
- 3.5" IPS Screen
- φ22.2/25.4/31.8mm Holder
- IP67 Waterproof
- 9 PAS Levels
- Bluetooth & Navigation Function
- Multi-language support: English, French, Spanish, Italian, German, Polish, Dutch, Czech, Chinese
- Supports remote locking & unlocking via “BIKEGO+” APP
- Quick-switch to 25 km/h street-legal mode (hold “+” and “-” buttons together)
4. Specifications
| Attribute | 500W Version | 750W Version |
|---|---|---|
| Model | 125XVH | |
| Type | Gear Drive Brushless Motor | |
| Installation | Rear Hub Motor | |
| Rated Voltage | 48V | |
| Rated Power | 500W | 750W |
| Peak Power | 864W | 1056W |
| Max Speed | 45-50 KM/H | 55-60 KM/H |
| Max Torque | 65Nm | 80Nm |
| Controller Limited Current | 18±1 A | 22±1 A |
| Controller Rated Current | 9±1 A | 11±1 A |
| Under-Voltage Protection | 39 ±1 V | |
| Over Voltage Protection | 62.4V | |
| Waterproof | IPX5 | |
| Rated Efficiency | More than 78% | |
| No load noise | <60db | |
| Suitable Bike Cassette | Less than 11 speeds | |
| Spoke Hole | 36H * 12G | |
| Brake Type | Disc Brake / V Brake (depending on kit selection) | |
| Operation Temperature | -20 °C ~ 45 °C | |
| Rear Dropout Size | 135-145mm | |
4.1. Wheel Size Compatibility
| Rim Size | Rim Diameter | Compatible Tire Width |
|---|---|---|
| 20" | 420mm (16.5") | 1.5"-2.4" |
| 26" | 570mm (22.4") | 1.5"-2.4" |
| 27.5" | 600mm (23.6") | 1.5"-2.4" |
| 29" / 700C | 630mm (24.8") | 700C: 32C-50C Width |
5. Package Contents
Your Varstrom 125XVH conversion kit typically includes the following components. Specific items may vary based on your selected options (e.g., brake type, display model).
- Hub Motor Wheel (pre-assembled with chosen rim size and brake type)
- Controller & Controller Box
- Display (EKD01, VD03, or VD04)
- Brake Levers or Brake Sensors (optional, depending on selection)
- Thumb Throttle
- PAS (Pedal Assist System) Sensor
- 1T4 Cable (main wiring harness)
- Headlight (optional)
- Battery (optional, typically sold separately)
- Small accessories (e.g., cable ties, mounting hardware)
6. Installation and Setup
This section provides a general guide for installing your e-bike conversion kit. Professional installation is recommended if you are unfamiliar with bicycle mechanics or electrical wiring.
6.1. Pre-Installation Checks
- Bike Compatibility: Ensure your bicycle's rear dropout size is between 135-145mm to accommodate the hub motor.
- Wheel Size: Verify the correct wheel size for your kit matches your bike. You can determine your bike's wheel size by checking the markings on your tire (e.g., 26x1.95 indicates a 26" wheel).
6.2. Component Installation
- Install the Hub Motor Wheel: Replace your bike's rear wheel with the new hub motor wheel. Ensure it fits securely within the 135-145mm dropout.
- Mount the Controller Box: Secure the controller box to your bike frame in a protected location.
- Install Display: Mount the display unit on your handlebars.
- Install Brake Levers/Sensors: Replace your existing brake levers with the e-bike specific brake levers, or install brake sensors if you are retaining your original levers.
- Install Thumb Throttle: Mount the thumb throttle on your handlebars.
- Install PAS Sensor: Attach the PAS sensor to your bike's bottom bracket area, ensuring proper alignment with the pedal crank.
6.3. Wiring Connections
Connect all components to the controller using the provided 1T4 cable and individual connectors. The waterproof connectors are designed for plug-and-play installation. Refer to the wiring diagram below for detailed connections:
- Connect the Hub Motor to the controller.
- Connect the Display to the controller.
- Connect the Brake Levers/Sensors to the 1T4 cable, then to the controller.
- Connect the Thumb Throttle to the 1T4 cable, then to the controller.
- Connect the PAS Sensor to the controller.
- Connect the Headlight (if included) to the designated port on the controller or 1T4 cable.
- Connect your 48V battery (sold separately) to the controller.
Ensure all connections are firm and correctly seated to prevent malfunctions.
7. Operating Instructions
7.1. Power On/Off
Refer to your specific display's manual for exact power on/off procedures. Generally, a long press on the power button will turn the system on or off.
7.2. Pedal Assist System (PAS)
The system offers 0-9 levels of pedal assist. Use the '+' and '-' buttons on your display to adjust the assist level. Higher levels provide more motor assistance.
7.3. Throttle Operation
The thumb throttle provides instant power without pedaling. Apply the throttle gently to control speed. Always be mindful of your surroundings when using the throttle.
7.4. Street-Legal Mode
To quickly switch to a 25 km/h street-legal mode:
- For EKD01 and VD04 Displays: Hold the “+” and “-” buttons together.
- For VD03 Display: Hold the “Power” and “.” buttons together.
7.5. Bluetooth & Navigation (EKD01 & VD04)
Displays EKD01 and VD04 feature Bluetooth connectivity and navigation functions. Download the “BIKEGO+” APP to your smartphone to:
- Remotely lock and unlock your e-bike.
- Track ride data and statistics.
8. Maintenance
- Regular Cleaning: Keep the motor, controller, and display clean from dirt and debris. Use a damp cloth; avoid high-pressure washing directly on electrical components.
- Connection Checks: Periodically check all electrical connections for tightness and signs of corrosion.
- Gear Inspection: While the helical gears are designed for reduced maintenance, occasional inspection for unusual noises or resistance is recommended.
- Water Exposure: Although rated IPX5, avoid prolonged exposure to heavy rain or submerging components in water. Dry any wet components thoroughly after exposure.
- Battery Care: Follow the battery manufacturer's instructions for charging, storage, and maintenance to ensure longevity and safety.
9. Troubleshooting
If you encounter issues with your Varstrom 125XVH kit, consider the following basic troubleshooting steps:
- No Power to Display: Check battery connection and ensure the battery is charged. Verify all cable connections to the controller and display are secure.
- Motor Not Assisting: Ensure the PAS sensor is correctly installed and aligned. Check if the brake levers/sensors are engaged, as they cut motor power. Verify the PAS level on the display is not set to 0.
- Unusual Noises from Motor: Stop riding immediately and inspect the motor for any obstructions or loose components. Contact support if the noise persists.
- Display Errors: Refer to your specific display's manual for a list of error codes and their meanings.
For persistent issues, please contact Varstrom customer support.
10. User Tips
- Battery Selection: The conversion kit does not typically include a battery. Ensure you purchase a compatible 48V e-bike battery with sufficient capacity for your intended range.
- Application: This kit is well-suited for various applications, including daily commuting, long-distance touring, city riding, and even demanding tasks like food delivery, thanks to its robust design and high torque output.
- App Integration: For EKD01 and VD04 display users, leverage the “BIKEGO+” APP for enhanced features like remote locking and detailed ride data tracking.
11. Warranty and Support
- Warranty Period: The Varstrom 125XVH Hub Rear Motor Electric Bike Conversion Kit comes with a 2-year warranty.
- Support & Repair Points: Varstrom offers global service with repair points located in Poland, France, and the UK. Professional technical support is available to assist with any issues.
- Customer Service: For any inquiries or technical assistance, please contact Varstrom customer service.
12. Certifications
The Varstrom 125XVH Hub Rear Motor Electric Bike Conversion Kit is certified to meet international safety and quality standards, including:
- CE
- RoHS
- UL
