1. Safety Warnings
⚠ Please mind potential fire risk and strictly follow the instruction manual for charging and storage.
2. Introduction
Congratulations on your purchase of the Varstrom 125XVH 500W Rear Wheel Hub Motor E-bike Conversion Kit. This kit is designed to transform your regular bicycle into a powerful electric bicycle, offering enhanced performance and versatility. This manual provides essential information for the proper installation, operation, and maintenance of your new e-bike conversion kit.
3. Package Contents
The Varstrom 125XVH 500W Rear Hub Motor Conversion Kit typically includes the following components:
- Pre-built motor wheel with internal controller
- Left PAS sensor (Right sensor option available)
- Brake lever (default, brake sensors available upon request)
- Front light
- Thumb throttle
- Waterproof connectors & tools
- Optional smart display (VD03/VD04/EKD01)
Note: Battery is not included with the kit. If ordered, it will be shipped separately.
4. Specifications
4.1. Motor Specifications
| Feature | Specification |
|---|---|
| Rated Power | 500W |
| Peak Power | 864W |
| Max Speed | 45-50 KM/H |
| Max Torque | 65 N.m |
| Rear Dropout Size | 135-145mm |
| Waterproof Rating | IPX5 |
| Design | Brushless Gear Hub Motor (Helical Gear Drive) |
| Certification | CE, UL |
4.2. Battery Specifications (Optional)
Various battery options are available. Below are common specifications:
| Battery Model | Voltage/Current/Energy | Battery Cell | BMS | Weight | Cycle Life | Cell Configuration | Charger | Usage Cut-off Voltage |
|---|---|---|---|---|---|---|---|---|
| Downtube Battery | 48V 13Ah 624Wh | 18650 2600mAh | 30A | 4.25KG | 1000 times | 13S5P 65PCS | 54.6V 2A | 36.4V |
| Downtube Battery | 48V 20Ah 960Wh | SAM-SUNG 21700 5000mAh | 30A | 4.7KG | 1000 times | 13S4P 52PCS | 54.6V 3A /4A | 36.4V |
5. Setup and Installation
5.1. Pre-installation Tests
Before installing the hub motor on your bicycle, it is crucial to perform a pre-installation test. Connect the motor, the battery (if purchased separately), and all other accessories according to the wiring diagram provided below. Power on the system and test the motor to ensure it functions correctly. If the motor operates as expected, proceed with the installation on your bike. If not, please contact customer service for assistance.
5.2. Recommended Tools
The following tools are recommended for installation. You may not need all of them, use what is necessary for your specific setup:
- M2.5, M3, M4, M5, M8 Allen wrenches (for meter, handlebar sleeve, brake lever, stem screw, thumb shifter, central shaft screw)
- No. 15 open-end wrench (for pedal)
- No. 18 open-end wrench (for hub motor flange nuts)
- Crank disassembling tool (for cranks and chain wheel)
- Central shaft tool (for central shaft)
- Cross screwdriver (for controller box)
5.3. Choosing the Correct Wheel Size
Ensure you select the correct wheel size for your bicycle. Refer to the markings on your tire to determine the size (e.g., 26x1.95 indicates 26 inches).
| Rim Size | Rim Diameter | Compatible Tire |
|---|---|---|
| 28"/29"/700C | 630mm (24.8") | 700C 32C-50C Width |
| 27.5" | 600mm (23.6") | 20"/26"/27.5"/28"/29":1.5"-2.4" Width |
| 26" | 570mm (22.4") | 20"/26"/27.5"/28"/29":1.5"-2.4" Width |
| 20" | 420mm (16.5") | 20"/26"/27.5"/28"/29":1.5"-2.4" Width |
5.4. Brake Type Compatibility
The kit supports both V-Brake and Disc Brake systems. Ensure you select the appropriate motor wheel type for your bicycle's brake system.
5.5. Torque Arm Recommendation
Hub wheel motors can generate substantial torque, potentially causing the motor to rotate within the bike frame's dropouts. This can lead to damage or motor detachment. For your safety, it is strongly recommended to purchase and install a torque arm. A torque arm helps distribute torque forces to the bicycle frame, preventing rotational movement and ensuring the motor remains securely attached.
5.6. Detailed Installation Resources
For detailed installation instructions and videos, please refer to the following resources:
- Hub Wheel Detailed Manual: bit.ly/bf-03
- Hub Wheel Installation Video: bit.ly/bfhub-in, youtu.be/qvXNjlTcldc
- Torque Arm Installation Video (Optional): https://bit.ly/ta-i
You can also find a user manual in PDF format for additional guidance: User manual (PDF)
6. Operating Instructions
6.1. Smart Display Functions
Your kit may include one of several smart display options (VD03, VD04, EKD01), each offering various features:
| Feature | VD03 Display | EKD01 Display | VD04 Display |
|---|---|---|---|
| Screen Type | 1.5" LCD | 2.4" TFT | 3.5" IPS |
| Holder Size | φ22.2mm | φ22.2/25.4mm | φ22.2/25.4/31.8mm |
| PAS Level | 9 | 9 | 9 |
| Waterproof Rating | IP67 | IP67 | IP67 |
| Bluetooth Function | No | Yes | Yes |
| Navigation Function | No | Yes | Yes |
| Remote Locking & Unlocking (On "BIKEGO+" APP) | No | Yes | Yes |
| Quick-Switch to 25 km/h Street-legal Mode | Yes (Holding "+" and "-" Button Together) | Yes (Holding "+" and "-" Button Together) | Yes (Holding "+" and "-" Button Together) |
6.2. Battery Operation Details
- Discharge Port: Equipped with a 6-pin interface for increased conductivity and improved heat dissipation.
- XT60 Connector: The discharge interface features an XT60 female connector, complemented by an XT60 male connector for linking up your electric bicycle seamlessly.
- Power Switch: Switch the battery power on and off. "O" represents turning the power off, while "I" indicates turning the power on.
- USB Port: Delivers a steady 5V and 1A output for charging phones or other gadgets.
- Battery Indication: A simple press of the button illuminates the light to show battery level.
- Anti-Theft Lock: Ensures utmost safety for your battery, providing theft prevention and guarding against unintentional drops.
7. Maintenance
Regular maintenance is crucial for the longevity and optimal performance of your e-bike conversion kit. Always ensure all connections are secure and free from corrosion. Keep the motor and battery clean and dry. Avoid exposing the battery to extreme temperatures. Refer to the specific component manuals for detailed maintenance schedules.
8. Troubleshooting
If you encounter any issues with your e-bike kit, first check all connections according to the wiring diagram. Ensure the battery is charged and properly connected. If the display is not turning on, check the power switch on the battery. For persistent issues, refer to the detailed manual or contact customer support.
9. User Tips
- Always perform the pre-installation test to ensure all components are working before final assembly on your bike.
- Consider installing a torque arm to protect your bike frame from potential damage due to motor torque.
- Familiarize yourself with your display's functions, especially the quick-switch to 25 km/h mode for legal compliance in certain regions.
- Regularly check battery charge and connections to prevent unexpected power loss during rides.
10. Warranty & Support
10.1. Warranty Activation
To ensure your satisfaction, Varstrom offers a warranty covering defects in materials and workmanship. To activate your warranty, please refer to the warranty card included in your package (pages 21-22 of the PDF manual). You will need to fill in the necessary information using the provided link or QR code. Once activated, your warranty record will be stored in our system.
10.2. Warranty Coverage and Limitations
The warranty covers material and manufacturing defects from the date of purchase. It does NOT cover:
- Normal wear and tear.
- Damage caused by accident, abuse, misuse, or failure to use the product according to the manual.
- Negligence, improper assembly or maintenance, or modifications to the product.
- Damage or malfunction caused by the use of non-genuine parts or accessories.
If your product breaks down within 15 days of receipt and is not covered by the above exclusions, you may be eligible for a free return, replacement, repair service, or free delivery of the part to be replaced. After 15 days, an inspection and repair service will be provided, or in exceptional circumstances, a full kit replacement.
The warranty is valid only if registered and within its active period. Defects due to private modifications or unauthorized repairs without contacting customer service are not covered.
10.3. Warranty Claims
To make a warranty claim, please contact your seller directly. Alternatively, you can contact Varstrom customer service. You will need to provide proof of purchase and a detailed description of the problem. Customer service will provide instructions for returning the product for repair or replacement.
10.4. Service Centers
For support and service, you can contact the following regional service centers:
- Poland Service Center: Warehouse Department, Nowa Wieś Wrocławska, Poland, 55-080
- British Service Center: Pro ebike, North Lanarkshire, Scotland, UK, ML2 9EP
- French Service Center: Teddy Bike, Sonnay, Isere, France, 38150
- US Service Center: Varstrom Group US, Las Vegas, Nevada, 89102
When contacting customer service, please include your order number/invoice, product name, and a description of the problem. You can reach them via:
- E-mail: service@varstrom.com
- Website: www.varstrom.com
- Facebook: www.facebook.com/groups/bafangkits
- Whatsapp: +48 571478352
10.5. Privacy Regulations
Varstrom is committed to protecting your privacy. Your personal details will not be shared with third parties without your consent. The warranty card is solely for after-sales service and does not contain marketing content or solicit positive feedback or promotions on social media platforms.