1. Introduction
This manual provides comprehensive instructions for the installation, operation, maintenance, and troubleshooting of your Varstrom TSDZ2B Ebike Conversion Kit. This kit is designed to transform your standard bicycle into a powerful and efficient electric bicycle with a natural riding feel, thanks to its advanced torque sensor system.
Please read this manual thoroughly before installation and use to ensure safe and optimal performance of your ebike conversion kit.
Video: Overview of the Tongsheng TSDZ2B Ebike Conversion Kit, demonstrating installation and riding experience.
2. Safety Warnings and Disclaimer
⚠ 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 your ebike.
- Ensure all components are securely fastened before each ride.
- Do not modify the motor or battery system. Unauthorized modifications can lead to serious injury or damage.
- Keep the battery away from heat sources and direct sunlight.
- Use only the charger provided or recommended by the manufacturer.
- Do not immerse the motor or battery in water. The system is IP65 waterproof, meaning it is protected against dust and low-pressure water jets, but not submersion.
- Regularly inspect your ebike for any signs of wear or damage, especially to the electrical components and brakes.
3. Product Overview
The Varstrom TSDZ2B Ebike Conversion Kit is a mid-drive motor system designed for easy conversion of most standard bicycles into electric bikes. It features an integrated torque sensor for a natural and responsive pedaling experience.
3.1 Kit Components
Image: Main components of the Varstrom TSDZ2B Ebike Conversion Kit, including motor, display, battery (optional), and accessories.
- Mid-drive motor unit with integrated torque sensor
- Installation hardware and tools
- Optional display (EKD01 Bluetooth, DZ40, SW2-M58)
- Thumb throttle
- Brake levers or brake sensors (optional, depending on selection)
- Speed sensor
- Cranks
- Battery (optional, if selected)
3.2 Technical Specifications
| Feature | Specification |
|---|---|
| Motor Type | TSDZ2B Torque Sensor Mid-Drive Motor |
| Wattage | 250W (36V) / 500W (48V) |
| Max Torque | 80 N.m |
| Max Speed (36V250W) | 25-32 KM/H |
| Max Speed (48V500W) | 38-45 KM/H |
| Bottom Bracket Compatibility | 68-73mm length, 33.5-36mm inner diameter |
| Waterproof Rating | IP65 |
| Design | Brushless, Side Hung Motor |
| Certification | CE, UL |
| Weight (Motor) | 3.6KG / 7.9LB |
| Wheel Size Compatibility | 20"/26"/27.5"/700C |
3.3 Display Options
Image: Comparison of DZ40, SW2-M58, and EKD01 displays.
| Feature | DZ40 | SW2-M58 | EKD01 Bluetooth |
|---|---|---|---|
| Screen | 1.7" LCD | 3.8" LCD | 2.4" TFT Screen |
| Holder (mm) | Ø22.2mm | Ø22.2/25.4/31.8mm | Ø22.2/25.4mm |
| Password | None | 1919 | 2020 |
| PAS Mode | 5 | 5 | 5 |
| Output Port | None | None | Type-C |
| Language | English | English | EN, DE, NL, FR, IT, ES, PL, CZ |
Note: EKD01 and VD18MT displays offer Bluetooth connectivity and mobile app integration for advanced features.
3.4 Battery Specifications (Optional)
Image: Specifications for 36V 13Ah, 15.6Ah, 24Ah, and 20.8Ah batteries.
Image: Specifications for 48V 13Ah, 16Ah, and 20Ah batteries.
| Battery Model | 36V 13Ah | 36V 15.6Ah | 36V 24Ah | 36V 20.8Ah (Rear Rack) | 48V 13Ah | 48V 16Ah | 48V 20Ah |
|---|---|---|---|---|---|---|---|
| Battery Cell | DNEGC 18650 - 26E 2600mAh | FEB 18650 2600mAh | L-G INR21700M50LT 4800mAh | FEB 18650 2600mAh | DMEGC 18650-26E 2600mAh | CMICR 18650 F9M 3200mAh | SAM-SUNG INR21700 - 50E 5000mAh |
| BMS Max Protection Current | 30A | ||||||
| USB Port | ❌ | ✅ | ✅ | ✅ | ✅ | ✅ | ✅ |
| Weight | ~3kg | ~3.9kg | ~4.82kg | ~5.1kg | ~4.25kg | ~4.23kg | ~4.7kg |
| Cycle Life | 1000 times | ||||||
| Battery Charger | 42V 2A/3A | 42V 3A/4A | 42V 4A | 42V 4A | 54.6V 2A | 54.6V 3A/4A | 54.6V 3A/4A |
Note: Battery is optional and must be selected at the time of purchase. If "Not Battery" is chosen, only the motor kit components are included.
4. Installation Guide
The TSDZ2B kit is designed for ease of installation, compatible with most standard bicycle frames. Professional installation is recommended if you are unfamiliar with bicycle mechanics.
4.1 Pre-Installation Checklist
- Ensure your bicycle's bottom bracket is 68-73mm in length and has an inner diameter between 33.5-36mm.
- Confirm compatibility with your brake system (Disc Brake or V Brake).
- Gather necessary tools: crank puller, bottom bracket tool, hex keys, cable ties, etc.
4.2 Installation Steps
Image: Diagram showing the ease of installation for the TSDZ2B motor kit.
- Remove Existing Components: Remove your bicycle's existing crankset, bottom bracket, and any other components that interfere with the motor installation.
- Install Mid-Drive Motor: Slide the TSDZ2B motor unit into the bottom bracket shell. Secure it using the provided locking nuts and washers. Ensure it is tightly fastened to prevent rotation.
- Install Cranks: Attach the new cranks to the motor spindle.
- Install Speed Sensor: Mount the speed sensor on the chainstay and attach the magnet to a spoke on the rear wheel. Ensure proper alignment and gap (typically 5-10mm) between the sensor and magnet.
- Connect Display: Mount your chosen display (EKD01, DZ40, or SW2-M58) on the handlebar. Connect the display cable to the main wiring harness.
- Connect Throttle: Mount the thumb throttle on the handlebar and connect its cable to the main wiring harness.
- Connect Brake Levers/Sensors:
- Brake Lever Option: Replace your existing brake levers with the provided BAFANG Electric Bicycle Brake Levers. These levers have integrated motor cut-off switches.
- Brake Sensor Option: Attach the Electric Bicycle Brake Sensors to your existing brake levers (compatible with hydraulic and mechanical brakes). Connect the sensor cables to the main wiring harness.
Image: Illustration of BAFANG Electric Bicycle Brake Lever and Electric Bicycle Brake Sensor options.
- Connect Battery (if applicable): Mount the battery securely on your bike frame (e.g., downtube or rear rack, depending on battery type). Connect the battery cable to the motor's main power cable.
- Cable Management: Route all cables neatly along the bike frame using cable ties. Ensure cables are not pinched or interfere with moving parts.
- Final Checks: Double-check all connections, ensure the motor is secure, and test the brakes and throttle before riding.
5. Operating Instructions
5.1 Powering On/Off
- To Power On: Press and hold the power button on the display unit for a few seconds until the screen illuminates.
- To Power Off: Press and hold the power button again until the display turns off.
5.2 Display Functions
Your display provides essential riding information and allows you to control assistance levels. Refer to the specific display model's section for detailed features.
Image: EKD01 Bluetooth Display showing speed, battery, and assistance levels.
- Assistance Levels (PAS): Use the '+' and '-' buttons on the display or handlebar remote (if applicable) to cycle through 5 fixed assistance levels. Higher levels provide more motor assistance.
- Information Display: The display shows current speed, battery level, total mileage, single mileage, power display, and real-time speed.
- Backlight: Some displays (e.g., EKD01) offer a manual backlight switch.
- Bluetooth Connectivity (EKD01/VD18MT): Connect your smartphone via Bluetooth to access additional features and settings through the dedicated mobile app.
5.3 Riding with Torque Sensor
The TSDZ2B's torque sensor provides a highly intuitive riding experience. The motor output is proportional to your pedaling force, making it feel like your own strength is amplified.
Image: Diagram illustrating motor output response to pedaling force via torque sensor.
- Zero-Start: The motor provides assistance from a complete stop as soon as you apply pressure to the pedals.
- Smooth Power Delivery: The power assistance is smooth and natural, avoiding jerky movements often associated with cadence-sensor-only systems.
- Throttle Use: The thumb throttle can be used for additional boost or to propel the bike without pedaling (check local regulations for throttle use).
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your ebike conversion kit.
6.1 Motor Maintenance
- Cleaning: Wipe down the motor casing with a damp cloth. Avoid high-pressure washing directly on the motor or electrical components.
- Inspection: Periodically check the motor mounting bolts for tightness. Ensure all cables are securely connected and free from damage.
- Gear Inspection: The 2025 upgraded design features enhanced gear positioning for better sealing. However, if you notice unusual noises, consult a professional for internal gear inspection.
6.2 Battery Care
- Charging: Use only the specified charger. Charge the battery in a well-ventilated area, away from flammable materials. Do not overcharge or leave charging unattended for extended periods.
- Storage: If storing the battery for an extended period, charge it to 50-60% and store in a cool, dry place. Recharge every 2-3 months to prevent deep discharge.
- Temperature: Avoid exposing the battery to extreme temperatures (hot or cold).
- BMS Protection: The built-in BMS (Battery Management System) provides protection against over-current, over-voltage, over-load, over-charge, over-discharge, temperature control, short-circuit, and cell voltage balancing.
Image: Diagram illustrating the protective features of the built-in Battery Management System (BMS).
6.3 General Ebike Maintenance
- Keep your chain clean and lubricated.
- Regularly check tire pressure.
- Inspect brake pads and cables for wear.
- Ensure all nuts and bolts on your bicycle are tight.
7. Troubleshooting
This section covers common issues and their potential solutions.
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor not providing assistance | Battery low or disconnected; Brake levers engaged; Speed sensor misaligned; Display error. | Check battery charge and connection. Ensure brake levers are fully released. Verify speed sensor alignment. Check display for error codes and restart. |
| Display not turning on | Battery low or disconnected; Loose display cable; Faulty display. | Check battery charge and connection. Ensure display cable is securely plugged in. If issue persists, contact support. |
| Inconsistent power delivery | Torque sensor calibration issue; Loose motor mounting. | Ensure motor is securely mounted. If the issue persists, a torque sensor recalibration might be needed by a professional. |
| Unusual noises from motor | Loose components; Internal gear issue. | Check for any loose external components. If noise persists, contact support for internal inspection. |
| Battery not charging | Charger not connected properly; Faulty charger or battery. | Ensure charger is correctly plugged into both the battery and power outlet. Check charger indicator lights. Try a different outlet. If still not charging, contact support. |
If you encounter issues not listed here or if the suggested solutions do not resolve the problem, please contact customer support.
8. User Tips
- Optimal PAS Usage: For a more natural and efficient ride, start with lower PAS levels and increase as needed for hills or acceleration. This also helps conserve battery life.
- Battery Longevity: Avoid fully discharging the battery regularly. Charge it after each ride, even short ones, to maintain battery health.
- Display Password: Remember the default passwords for your display (SW2-M58: 1919, EKD01: 2020) if you need to access advanced settings.
- Cable Management: Proper cable routing not only looks cleaner but also prevents damage and ensures safe operation. Use zip ties to secure loose cables.
- Regular Cleaning: Keep the motor and battery housing clean, especially after riding in wet or dusty conditions, to prevent dirt buildup from affecting performance.
9. Warranty and Support
Your Varstrom TSDZ2B Ebike Conversion Kit comes with a 12-month warranty from the date of purchase. This warranty covers manufacturing defects and malfunctions under normal use.
For warranty claims, technical support, or any questions regarding your product, please contact the seller or manufacturer directly. Provide your purchase details and a clear description of the issue to expedite the support process.
Seller: Greenergy Choice Store
Contact Information: Refer to your purchase receipt or the seller's store page for contact details.
