Varstrom TSDZ16 Ebike Kit User Manual

1. Introduction

Welcome to the Varstrom TSDZ16 Ebike Kit! This manual provides essential information for the safe and efficient installation, operation, and maintenance of your new electric bicycle conversion kit. The TSDZ16 mid-drive motor features advanced torque sensor technology, offering a natural and responsive riding experience by providing power assistance proportional to your pedaling effort. Convert your standard bicycle into a powerful and smooth-riding e-bike with ease.

2. Safety Information

Your safety is paramount. Please read and understand all safety warnings and instructions before installing or operating the e-bike kit.

• Disclaimer: ⚠️Please mind potential fire risk and strictly follow the instruction manual for charging and storage of batteries.
• Always wear a helmet and appropriate safety gear when riding.
• Ensure all components are securely installed and tightened before each ride.
• Regularly check brakes, tires, and all electrical connections.
• Familiarize yourself with local laws and regulations regarding e-bikes.
• Avoid riding in extreme weather conditions (heavy rain, snow, ice) to prevent damage to components and ensure rider safety.
• Do not modify the motor or battery system. Unauthorized modifications can lead to serious injury or product failure.
• Keep children and pets away from the e-bike during operation and charging.

3. Package Contents

Please verify that all items listed below are included in your package. If any items are missing or damaged, contact customer support immediately.

• Mid-drive motor unit with integrated torque sensor
• Installation hardware (bolts, nuts, washers)
• Cranks
• Speed sensor
• Thumb throttle
• Brake levers or brake sensors (depending on selection)
• Optional Display (DZ40, SW2-M58, or EKD01)
• Optional Battery (Downtube or Rear Rack, various capacities)
• Battery Charger (if battery included)
• User Manual (this document)

4. Specifications

4.1. Motor Specifications (TSDZ16 1000W)

4.2. Battery Specifications (Optional)

4.3. Display Specifications (Optional)

5. Compatibility

The Varstrom TSDZ16 kit is designed for broad compatibility with most standard bicycles. Please check the following dimensions to ensure a proper fit:

• Bottom Bracket: Your bicycle's bottom bracket shell must have a length of 68-73mm and an inner diameter between 33.5-36mm.
• Brake System: The kit is compatible with both disc brake and V brake systems.
• Frame Compatibility: The kit fits approximately 95% of standard bicycle frames.

Important: The kit is not compatible with belt drive chainrings or coaster brake bikes.

6. Setup and Installation

Installing the Varstrom TSDZ16 kit requires mechanical aptitude. If you are unsure about any steps, it is highly recommended to seek professional assistance from a qualified bicycle mechanic.

General Installation Steps:

1. Prepare Your Bicycle: Remove the existing bottom bracket, crankset, and chain. Clean the bottom bracket shell thoroughly.
2. Install the Motor: Insert the TSDZ16 mid-drive motor into the bottom bracket shell. Secure it according to the provided hardware and torque specifications.
3. Install Cranks and Chainring: Attach the new crank arms and chainring to the motor spindle.
4. Mount the Display: Secure the chosen display (DZ40, SW2-M58, or EKD01) to your handlebar.
5. Install Thumb Throttle: Mount the thumb throttle on the handlebar, ensuring comfortable access.
6. Install Brake Levers/Sensors: Replace your existing brake levers with the provided e-bike specific levers, or install brake sensors if using your original levers.
7. Install Speed Sensor: Attach the speed sensor to the chainstay and the magnet to a spoke on the rear wheel, ensuring proper alignment and gap.
8. Mount the Battery: Install the battery (downtube or rear rack type) securely to your bicycle frame.
9. Connect Wiring: Refer to Figure 6.1 for the detailed wiring connections. Connect the motor, display, throttle, brake components, and speed sensor to the main wiring harness. Ensure all connections are firm and waterproof.
10. Cable Management: Route and secure all cables neatly using zip ties or cable clips to prevent snagging or damage.
11. Final Checks: Double-check all connections, ensure the chain is properly installed, and test the brakes before your first ride.

7. Operating Instructions

Once installed, operating your Varstrom TSDZ16 e-bike is intuitive. The torque sensor system provides a natural boost to your pedaling.

7.1. Power On/Off

• To power on the system, press and hold the power button on your display unit.
• To power off, press and hold the power button again until the display turns off.

7.2. Display Functions

Your display provides crucial information and control over your e-bike system. The specific functions may vary slightly depending on your display model (DZ40, SW2-M58, or EKD01).

• Assistance Levels: Use the '+' and '-' buttons on the display or handlebar control to cycle through the 5 fixed assistance levels. Higher levels provide more motor assistance.
• Backlight: The SW2-M58 display features a manual backlight switch. Consult your specific display manual for details.
• Information Display: Depending on your display, you can view current speed, average speed, max speed, trip distance, odometer, battery voltage, and power percentage.
• EKD01 Display: Offers advanced settings (password 2020) and Type-C USB for charging. It also supports Bluetooth connectivity for mobile app integration.

7.3. Riding with Torque Sensor

The TSDZ16 motor utilizes a torque sensor, meaning the motor's output is directly proportional to the force you apply to the pedals. This creates a very natural and intuitive riding feel, as if your own pedaling power is amplified.

• Zero-Start: The motor provides assistance from a complete stop, making it easy to get going.
• Throttle Mode: Use the thumb throttle for power without pedaling, if desired.
• Pedal Assist Mode: The primary mode of operation, where motor power is added to your pedaling.
• Push Assist Mode: For walking the bike, the motor can provide low-speed assistance.

8. Maintenance

Regular maintenance will ensure the longevity and optimal performance of your Varstrom TSDZ16 e-bike kit.

• Cleaning: Clean the motor, battery, and other components regularly with a damp cloth. Avoid high-pressure washing directly on electrical parts.
• Battery Care:
  1. Always use the original charger provided with your battery.
  2. Do not overcharge or completely discharge the battery.
  3. Store the battery in a cool, dry place, away from direct sunlight and extreme temperatures.
  4. If storing for an extended period, charge the battery to 50-70% capacity and check it periodically.
  5. As per safety disclaimer, strictly follow the instruction manual for charging and storage to prevent fire risk.
• Electrical Connections: Periodically check all electrical connections for corrosion, looseness, or damage. Ensure they are clean and dry.
• Mechanical Components: Lubricate the chain and inspect the crank arms, chainring, and bottom bracket for wear or damage.
• Brakes: Ensure brakes are functioning correctly and brake pads are not excessively worn.
• Firmware Updates: Check the Varstrom website or contact support for any available firmware updates for your motor or display.

9. Troubleshooting

If you encounter issues with your e-bike kit, try these basic troubleshooting steps:

• No Power/Display Not Turning On:
  1. Check if the battery is fully charged and properly seated.
  2. Ensure all electrical connections, especially the main power cable from the battery to the motor, are secure.
  3. Inspect the display cable for any damage.
• Motor Not Assisting:
  1. Verify that the system is powered on and not in '0' assistance level.
  2. Check the speed sensor and magnet alignment.
  3. Ensure the brake levers/sensors are not engaged, as they cut motor power.
  4. If using a throttle, ensure it's connected and functioning.
• Unusual Noises from Motor:
  1. Stop riding immediately.
  2. Check for any loose components around the bottom bracket or motor.
  3. Ensure the chainring is properly aligned and not rubbing.
• Error Codes on Display: Refer to your specific display manual for a list of error codes and their meanings.

If the problem persists after attempting these steps, please contact Varstrom customer support for further assistance.

10. User Tips

Here are some tips to enhance your riding experience and prolong the life of your Varstrom TSDZ16 e-bike kit:

• Start in Lower Assist Levels: Begin your ride in a lower pedal-assist level (e.g., Level 1 or 2) to conserve battery and get a smoother start.
• Shift Gears Smartly: Just like a regular bicycle, shifting gears appropriately for terrain and speed will make your ride more efficient and reduce strain on the motor.
• Monitor Battery Level: Keep an eye on your display's battery indicator to avoid running out of power unexpectedly. Plan longer rides accordingly.
• Regular Cleaning: Especially after riding in wet or dusty conditions, clean your motor and battery to prevent dirt buildup and corrosion.
• Secure Cables: Ensure all cables are neatly tucked away and secured to prevent them from getting caught or damaged during rides.

11. Warranty and Support

Varstrom is committed to providing high-quality products and excellent customer service.

• Warranty: Your Varstrom TSDZ16 Ebike Kit comes with a 12-month warranty from the date of purchase. This warranty covers manufacturing defects and malfunctions under normal use. Please retain your proof of purchase for warranty claims.
• Support: For technical assistance, troubleshooting, or warranty inquiries, please contact Varstrom customer support through the seller's platform or official website.
• Service Commitments: Varstrom offers various service commitments, including fast delivery and refunds for specific issues like delayed packages, damaged items, or non-delivery within 20 days. The product is also certified original.