Varstrom-125XVH Electric Bike Hub Motor Conversion Kit

1. Introduction

Thank you for choosing the Varstrom-125XVH Electric Bike Hub Motor Conversion Kit. This kit is designed to transform your standard bicycle into a powerful and efficient electric bike, offering enhanced performance for various uses, from daily commuting to delivery services. This manual provides essential information for the safe and effective installation, operation, and maintenance of your new e-bike system.

Figure 1: Overview of Varstrom-125XVH Hub Motor Conversion Kit Components

2. What's Included

Your Varstrom-125XVH kit includes the following components:

• 1 x 125XVH Hub Motor (pre-laced to your chosen wheel size)
• 1 x Motor Controller
• 1 x Controller Box (for mounting the controller)
• 1 x Display (Optional, specific model depends on selection)
• 1 x 1T4 Cable (main wiring harness)
• 1 set x Thumb Throttle
• 1 set x PAS Sensor (Pedal Assist System) with magnet
• 1 set x Brake Lever or Brake Sensor (Optional, depending on selection)

Free Gifts:

• 1 x 36-60V Front Light
• 1 x 36V 250W Sticker (for compliance in some regions)
• 1 set x Cable Ties

3. Specifications

3.1 Motor Specifications

Figure 2: Varstrom 125XVH Motor Specifications

3.2 Controller Specifications

• Max Current of Controller: 18A (for 500W), 22A (for 750W)
• Controller Low-Voltage Protection: 39±1V
• 125RX-500W Controller Size: 109.9*60.8*30mm
• 125RX-750W Controller Size: 116.9*64*31.3mm

3.3 Battery Specifications (Optional)

Figure 3: Hailong 13Ah 624Wh Battery Dimensions and Specifications

Additional battery options include:

• 48V20Ah 960Wh Hailong MAX Battery: Sa-m*sung 21700 5000mah 13S4P 52PCS (4A Charger)
• 48V20Ah 960Wh VoltzX Battery: Sa-m*sung 21700 5000mah 13S4P 52PCS (4A Charger)
• 48V17.5Ah 840Wh Rear Rack Battery: Grade A 18650 2600mah 13S7P 91PCS (4A Charger)

All batteries feature comprehensive protection functions including over-current, over-voltage, overload, over-charging, over-discharge, temperature control, short circuit protection, and cell voltage balance.

4. Setup and Installation

4.1 Choosing the Suitable Wheel Size

Before installation, ensure you select the correct wheel size for your bicycle. The kit supports 20/26/27.5/700C (28/29) inch wheels. To determine your tire size, locate the marking on your tire sidewall (e.g., 26x1.95). This indicates a 26-inch tire.

Figure 4: How to Choose Suitable Wheel Size

4.2 Brake Type Compatibility

The Varstrom-125XVH hub motor is compatible with both Disc Brake and V-Brake systems. Ensure your bicycle's rear dropout spacing is 135-145mm for proper fitment.

• If your bike has a mechanical brake system, you can choose our Brake Lever option.
• If your bike has a hydraulic brake system, you should choose our Brake Sensor option. The Brake Sensor can also be used with mechanical brakes if you prefer not to change your existing brake levers.

Figure 5: Brake Type Options

4.3 Wiring Diagram and Component Overview

The installation process is designed for ease with color-coded connectors. Follow the diagram below for proper connection of all components.

Figure 6: Wiring Diagram and Component Layout

1. Rear Hub Motor Wheel: Install the motor wheel into your bike's rear dropout (135-145mm spacing).
2. Controller & Box: Mount the controller securely, preferably within the provided controller box, on your bike frame.
3. Battery: Install the battery in its designated position (e.g., downtube for Hailong, rear rack for rack-type batteries).
4. Display: Mount the display on your handlebars.
5. Thumb Throttle: Install the thumb throttle on your handlebars.
6. Brake Lever or Brake Sensor: Install the chosen brake component.
7. PAS Sensor: Install the PAS sensor and magnet on your pedal crank.
8. 1T4 Cable: Connect all components to the 1T4 main cable according to the color-coded connectors.
9. Headlight: Connect the headlight to the appropriate port on the 1T4 cable.

4.4 Battery Installation (Hailong Type)

For Hailong-style batteries, follow these steps for secure mounting:

Figure 7: Hailong Battery Installation

1. Attach the battery base plate to your bike's downtube bottle cage mounts.
2. Slide the battery onto the base plate until it clicks securely into place.
3. Ensure the battery is locked to prevent theft and accidental detachment.

4.5 Rear Rack Installation (for Rear Rack Battery)

If you have chosen a rear rack battery, install the rear rack first. The rack is made of high-quality aluminum alloy and can carry items up to 15KG.

Figure 8: Rear Rack Battery Installation

5. Operation

5.1 EKD01 Display Functions

The EKD01 display provides essential information and control over your e-bike system. It supports remote locking and unlocking via the 'BIKEGO+' app and features a quick-switch street-legal mode.

Figure 9: EKD01 Display Features

• 2.4" TFT Screen: Clear display of speed, battery level, trip distance, and more.
• IP67 Waterproof: Durable for various weather conditions.
• Bluetooth & App Connectivity: Connects to the 'BIKEGO+' app for remote functions and advanced ride data tracking.
• 9 PAS Level: Adjust pedal assist levels for different riding preferences.

5.2 Street-Legal Mode

To comply with local regulations (e.g., EU/UK 25 km/h limit), you can quickly switch to street-legal mode by holding the "+" and "-" buttons on the display simultaneously. For off-road or private land use, the full performance of the motor can be unlocked.

5.3 Battery Operation

Figure 10: Battery Details

• Battery Indicator: Press the button on the battery to check the remaining power. (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%).
• Charging Port: XLR Type. Use the provided charger only.
• Power Switch: Turn the battery ON or OFF.
• Taillight Switch: Turn the taillight ON or OFF (if equipped).
• XT60 Port: Red "+" (Positive Electrode), Black "-" (Negative Electrode).

5.4 Rear Rack Features (if applicable)

Figure 11: Rear Rack Features

• Rear Rack: Easy to install, high-quality aluminum alloy, max loading is 15KG.
• Taillight: Press the "-" button to turn the taillight on, press the "o" button to turn it off.
• USB Port: 5V 1A Output, can be used for charging cell phones and other devices.

6. Maintenance

Regular maintenance ensures the longevity and optimal performance of your e-bike conversion kit.

• Motor: The motor features advanced helical gearing for superior wear resistance and a longer lifespan. Keep the motor clean and free from debris. While the motor is IPX5 waterproof, it is not recommended for prolonged heavy rain exposure.
• Battery: Always use the provided charger. Store the battery in a cool, dry place. Avoid fully discharging the battery frequently. If storing for an extended period, charge it to about 50-60%.
• Connections: Periodically check all electrical connections (especially the 1T4 cable and motor connections) to ensure they are secure and free from corrosion.
• Brakes: Regularly inspect your brake pads and rotors/rims for wear. Ensure brake levers/sensors are functioning correctly.
• Tires: Maintain proper tire pressure as recommended by your bicycle manufacturer.
• General Cleaning: Clean your e-bike regularly with a damp cloth. Avoid using high-pressure washers directly on electrical components.

7. Troubleshooting

Here are some common issues and their potential solutions:

• No Power to Display/Motor:
  • Check if the battery is charged and turned ON.
  • Ensure all electrical connections, especially the 1T4 cable, are firmly seated.
  • Inspect the main power cable from the battery to the controller for any visible damage.
• Motor Not Assisting:
  • Verify the PAS sensor is correctly installed and the magnet is aligned.
  • Check if the throttle is functioning (if installed).
  • Ensure the display is not showing any error codes. Consult the display manual for specific error code meanings.
  • Confirm the brake levers/sensors are not engaged, as they cut motor power.
• Intermittent Power:
  • Loose connections are a common cause. Re-check all plugs.
  • Inspect wiring for any cuts or pinches.
• Unusual Noises from Motor:
  • While the helical gears are designed for quiet operation, excessive noise might indicate an issue. Ensure the motor is securely mounted and nothing is rubbing against it.
  • If noise persists, contact support.

If you encounter issues not listed here or cannot resolve a problem, please contact customer support for assistance.

8. User Tips

• Daily Commuters: The high efficiency and robust design make this kit ideal for daily commutes. Ensure your battery is fully charged for longer trips.
• Delivery Professionals: The powerful motor and durable helical gears are well-suited for high-intensity use, such as food delivery. Regular checks of connections and tire pressure are recommended due to frequent use.
• Hill Climbing: Users have noted the excellent torque for tackling hills. Utilize the PAS levels to manage your effort and battery consumption effectively.
• Installation Time: Many users report quick installation times, often under an hour, thanks to the color-coded connectors. Take your time and follow the wiring diagram carefully.

9. Safety Information

⚠️ Disclaimer: Please mind potential fire risk and strictly follow the instruction manual for charging and storage of batteries.

• Always wear a helmet when riding your e-bike.
• Familiarize yourself with local e-bike regulations, especially regarding speed limits and motor wattage. Use the street-legal mode when required.
• Perform a pre-ride check before each use: inspect brakes, tire pressure, and ensure all connections are secure.
• Do not operate the e-bike in conditions beyond its IPX5 waterproof rating (e.g., submerging in water).
• Ensure the battery is securely mounted and locked to prevent accidental detachment during riding.
• Keep children and pets away from the e-bike during charging and operation.

10. Warranty and Support

10.1 Warranty Periods:

10.2 Warranty Terms:

• Within 6 Months (from Delivery Date): If any quality problem arises, all warranty costs (repair cost, material cost, shipping cost, etc.) are covered by the seller.
• Between 6 and 12 Months (from Delivery Date): If a quality problem arises, the repair cost and material cost are covered by the seller, but the shipping cost is the responsibility of the buyer.
• Out of Warranty: If the warranty period is exceeded, we can continue to provide after-sales service, but all costs will be the responsibility of the buyer. The exact cost depends on the specific issue.

10.3 Local Support:

Our network of certified service centers across Poland, England, Spain, and America ensures prompt repairs and support. For assistance, please contact our customer service team.

Figure 12: Warranty Service Overview