1. Introduction and Overview
Thank you for choosing the Varstrom Electric Bicycle Conversion Kit. This kit is designed to transform your standard bicycle into a powerful electric bike, offering enhanced performance and versatility. Featuring a brushless direct-drive hub motor, this system provides efficient and reliable power for various riding conditions.
The Varstrom kit is available in 1000W and 1500W options for both front and rear wheel installations, supporting multiple wheel sizes including 26'', 27.5'', 29'', and 700C. It is built with durability in mind, boasting an IPX5 waterproof rating and CE/EN14764/ROHS certifications for safety and quality.
This manual provides essential information for the safe and effective installation, operation, and maintenance of your new electric bicycle conversion kit. Please read it thoroughly before beginning installation or operation.
2. Safety Information
⚠️ Please mind potential fire risk and strictly follow the instruction manual for charging and storage of any battery used with this kit. Batteries are not included with the kit and must be purchased separately.
- Always wear a helmet and appropriate safety gear when riding.
- Ensure all connections are secure and properly insulated before riding.
- Do not operate the kit in conditions beyond its specified waterproof rating (IPX5).
- Regularly inspect your bicycle and the conversion kit components for any signs of wear or damage.
- Familiarize yourself with local regulations regarding electric bicycles.
3. Package Contents
Your Varstrom Electric Bicycle Conversion Kit may include the following components, depending on your specific order configuration:
Packing list for 1500W Rear Motor kit
Packing list for 1000W Front Motor kit
- Hub Motor (Front or Rear Wheel, 1000W or 1500W)
- Motor Controller
- Controller Box
- Thumb Throttle
- 1T4 Cable
- Brake Levers or Brake Sensors (depending on selection)
- Left PAS Sensor
- Display (Optional, various models available: Mini DZ40, VD18 MT, DPC18, SW-M58, EKD01 Bluetooth)
- Headlight (Optional)
- Battery (Optional - not included in standard kit)
- Motor Extension Cable (for Front Motor kits)
- BPM500V/600W Label
- Zip Ties
4. Specifications
Detailed specifications table for Varstrom Hub Motors, including dimensions and performance metrics.
| Feature | 1000W Front/Rear Hub Motor | 1500W Rear Hub Motor |
|---|---|---|
| Rated Voltage | 48V | |
| Rated Power | 1000W | 1500W |
| No-load Current | ≤1A | ≤1.8A |
| Rated Current | ≤28A | ≤38A |
| Max Speed | 55 KM/H | 70 KM/H |
| Max Torque | 66 N.m | 78 N.m |
| Efficiency | ≥82% (Rear), ≥78% (Front) | ≥82% |
| Noise Grade | <55 dB | |
| Waterproof Grade | IPX5 | |
| Operating Temperature | -20 to 45 ℃ | |
| Installation Widths (OLD) | Front: 100mm, Rear: 132-138mm | Rear: 135-148mm |
| Max Current (Controller) | 15A | 30A |
| Weight | 5.8KG (Rear), 6.17KG (Front) | 7.16KG |
| Certification | CE / EN 14764 / ROHS | |
Controller Specifications
Varstrom Controller dimensions (162x57x32mm) and specifications.
| Feature | Value |
|---|---|
| Rated Voltage | 48V |
| Rated Power | 1500W |
| Rated Current | 18A |
| Low Voltage Protection | 39±1V |
| Maximum Current | 35A |
| Size (mm) | 162*57*32 |
5. Compatibility
Compatibility diagram showing rear (138-148mm) and front (100mm) hub motor dropout measurements.
Guide on how to choose the correct wheel size for your hub motor.
Motor Position and Dropout Widths:
- Rear Hub Motor: Fits bicycles with 138-148mm rear dropout size. Designed for Cassette Flywheel.
- Front Hub Motor: Fits bicycles with 100mm front dropout size.
Wheel Diameter and Tire Compatibility:
- Rim Diameter Options: 26 inch (570mm / 22.4"), 27.5 inch (600mm / 23.6"), 28 inch / 29 inch / 700C (630mm / 24.8").
- Compatible Tire Widths:
- For 26"-27.5" wheels: 1.5"-2.4" width.
- For 700C wheels: 32C-50C width.
- Spokes: 12G*36H
Brake Type:
- This kit is designed for Disc Brake systems. It does not support V-brake systems.
Bicycle Types:
The Varstrom motor is versatile and suitable for various bicycle types, including:
- Mountain Bikes
- Road Bikes
- City Bikes
- Tricycles
- Cargo Bikes
- And other DIY electric mobility solutions.
Varstrom Motor Endless DIY Possibilities, suitable for various terrains.
6. Setup and Installation
6.1 Determining Wheel Size:
To ensure proper fit, find the tire size marked on your bike's tire. Check the label number (e.g., 26x1.95). This will help you determine the correct wheel size for your conversion kit.
6.2 Measuring Dropout Width:
Measure the internal width of your bicycle's rear or front dropout to ensure it matches the motor's installation width. Rear dropout should be 138-148mm for rear hub motors, and front dropout should be 100mm for front hub motors.
6.3 Rear Wheel Hub Installation (Gasket Tutorial):
The rear wheel hub installation may require the use of gaskets to ensure proper fit and alignment. There are two common methods:
Visual guide for internal and external gasket installation for rear wheel hub.
- Plan A: Internal Installation Gasket - Follow steps 01-04 in the diagram to install gaskets internally.
- Plan B: External Installation Gaskets - Follow steps 01-04 in the diagram to install gaskets externally.
DIY selection of gasket installation position and quantity should be based on your bicycle fork size to achieve optimal alignment and security.
6.4 Wiring Diagram:
Refer to the diagram below for proper connection of all components. Ensure all connectors are firmly seated and secured.
Wiring Diagram for 1500W Rear Hub Motor kit, showing connections for all components.
- Brake Lever or Brake Sensor (Optional)
- Thumb Throttle
- Display (Optional)
- 1T4 Cable
- Headlight (Optional)
- Controller & Box
- PAS Sensor
- Motor Extension Cable (Optional)
- Rear Hub Motor Wheel (Optional)
- Battery (Optional)
Connect the 9-Pin Motor Interface, Yellow Circular 3-Pin, 8-Pin 1T4 Cable Interface, Red Taillight Interface, Black Headlight Interface, and XT60H Battery Interface as shown in the diagram.
7. Operating Instructions
7.1 Intelligent Motor Control System:
The Varstrom kit features an intelligent motor control system with various riding modes:
Overview of the Intelligent Motor Control System modes.
- Throttle Electric Mode (100%): Provides full electric power via the thumb throttle.
- Pedal Assisted Mode (70%): Provides electric assistance proportional to your pedaling effort.
- Walk Assisted Mode (20%): Provides low-speed assistance for walking the bike.
- Manual Mode (0%): No electric assistance, operates as a regular bicycle.
7.2 Ebike Display Details:
Your kit may come with one of several display models, each offering unique features:
Details and features of various Ebike Display models.
- EKD01 Bluetooth: PAS 0-9 levels, USB output for phone charging, Bluetooth connectivity.
- P860ML: PAS 0-9 levels, USB output for phone charging, supports dual interface show.
- DPC18: PAS 0-9 levels, USB output for phone charging, ECO/Sport mode.
- T1Touch: Touch screen control, USB output for phone charging, supports 6 languages.
- 800S: Black and white screen, adjustable backlight, ergonomic button design.
- 500C: Adjustable backlight, USB output for phone charging, ECO/Sport mode.
- DM03 Mini: Minimized display, supports 5 PAS levels.
- DZ40 Mini: Comprehensive data display, IPX5 waterproof.
Refer to your specific display's mini-manual for detailed operation and settings.
8. Maintenance
The Varstrom brushless, gearless hub motor is designed for low maintenance and high durability. Its direct-drive design minimizes wear and tear, requiring virtually zero maintenance for tens of thousands of kilometers.
- Regular Cleaning: Keep the motor and controller clean from dirt and debris. The IPX5 rating protects against water jets, but avoid submerging the components.
- Cable Inspection: Periodically check all electrical cables and connectors for any signs of damage, fraying, or loose connections.
- Fastener Check: Ensure all bolts and fasteners, especially those securing the motor to the dropout, are tight.
- Brake System: As this kit uses disc brakes, regularly check your brake pads and rotors for wear and ensure proper braking function.
- Tire Pressure: Maintain correct tire pressure for optimal performance and motor efficiency.
9. Troubleshooting
If you encounter issues with your Varstrom Electric Bicycle Conversion Kit, consider the following common troubleshooting steps:
- No Power/Motor Not Responding:
- Check battery connection and ensure it is charged.
- Verify all electrical connections are secure, especially the main power cable from the battery to the controller, and the motor cable.
- Check the display for any error codes. Consult the display's manual for specific code meanings.
- Motor Cutting Out:
- This could indicate an overheating issue. Allow the motor to cool down.
- Check for loose connections or damaged wires.
- Ensure the battery has sufficient charge.
- PAS Not Working:
- Check the PAS sensor installation and ensure it is correctly aligned and free from obstructions.
- Verify the PAS sensor cable is securely connected to the controller.
- Check display settings for PAS level.
- Throttle Not Working:
- Ensure the throttle cable is securely connected.
- Check display settings to ensure throttle function is enabled.
If problems persist, please contact Varstrom customer support for assistance. Provide detailed information about the issue and any error codes displayed.
10. User Tips
- Battery Selection: The kit does not include a battery. Ensure you select a 48V battery with sufficient capacity (Ah) and discharge rate (A) to match your motor's power (1000W or 1500W) and desired range.
- Brake Compatibility: This kit is designed for disc brake systems. If your bicycle has V-brakes, you will need to upgrade to disc brakes for compatibility.
- Gasket Installation: Pay close attention to the gasket installation steps for rear hub motors. Proper gasket placement is crucial for correct wheel alignment and motor performance.
- Display Customization: Explore the settings on your chosen display model. Many displays offer customizable parameters like PAS levels, speed limits, and unit preferences to tailor your riding experience.
11. Warranty and Support
Varstrom provides a 1-year warranty for the Electric Bicycle Conversion Kit, covering defects in materials and workmanship from the date of purchase.
Customer Support:
For technical support, troubleshooting assistance, or warranty claims, please contact Varstrom customer service. We have dedicated service and repair centers in Europe to provide timely support.
Bafang's global service locations, including Europe.
Our main service points are located in France, Poland, and the UK, ensuring quick processing times for your requests and access to professional technical assistance.
