Varstrom 125EVH Electric Bike Hub Motor Conversion Kit

1. Introduction

Thank you for choosing the Varstrom 125EVH Electric Bike Hub Motor Conversion Kit. This kit is designed to transform your standard bicycle into a powerful and efficient e-bike, suitable for various uses including daily commuting, food delivery, and recreational riding. This manual provides essential information for the safe installation, operation, and maintenance of your new e-bike system. Please read it thoroughly before proceeding with installation or use.

Figure 1: Varstrom 125EVH Hub Motor Conversion Kit components, including the motor wheel, display, controller, throttle, headlight, and brake sensors/levers.

2. Safety Information

Your safety is paramount. Please observe the following warnings and guidelines:

• Always wear a helmet and appropriate safety gear when riding your e-bike.
• Familiarize yourself with local e-bike regulations regarding speed limits and usage.
• Perform regular safety checks on your bicycle and the e-bike components, especially brakes, tires, and electrical connections.
• Do not operate the e-bike if any components are damaged or not functioning correctly.
• Exercise caution when riding in wet conditions, as braking distance may increase. The motor is IPX5 waterproof, but prolonged heavy rain is not recommended for all components.
• Ensure all electrical connections are secure before riding.
• Always follow the instruction manual for charging and storage of the battery (if applicable, battery not included in this kit but is a critical component of an e-bike system). Mind potential fire risks associated with improper battery handling.

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

3. Package Contents

The Varstrom 125EVH Hub Motor Conversion Kit includes the following components:

• 1 x VARSTROM 125EVH Hub Motor Wheel Kit (pre-assembled with motor in rim)
• 1 x Chosen Display (VD03 Mini Display, EKD01, or VD04)
• 1 x Controller
• 1 x Controller Box
• 1 x Throttle (Thumb Throttle or Half-Twist Throttle, depending on selection)
• 1 x Headlight
• 1 x Set of Brake Levers or Brake Sensor (depending on selection)
• 1 x PAS Sensor (Pedal Assist Sensor)
• All necessary cables & connectors
• Zip ties for cable management

Note: Battery is not included in this kit and must be purchased separately.

4. Installation Guide

The Varstrom 125EVH kit is designed for easy DIY installation. Follow these steps carefully:

4.1. Pre-Installation Checks

• Wheel Size Compatibility: Ensure the motor wheel matches your bicycle's wheel size. Refer to your tire's sidewall for markings (e.g., 26x1.95). The kit supports 20", 26", 27.5", 28"/29"/700C wheel sizes.
• Brake Type: Determine if your bike uses Disc Brakes or V-Brakes. The kit offers options for both.
• Dropout Spacing:
  • Rear Hub Motor: Compatible with 135-145mm rear dropout spacing.
  • Front Hub Motor: Compatible with 100mm front dropout spacing.
• Cassette Type: Rear hub motors are compatible with ≤10-Speed cassettes.

Figure 2: Guide for selecting the correct wheel size for your conversion kit.

Figure 3: Illustration of Disc Brake and V Brake compatibility. The kit supports both types.

Figure 4: Rear Hub Motor dimensions and compatible dropout spacing (135-145mm).

Figure 5: Front Hub Motor dimensions and compatible dropout spacing (100mm).

4.2. Component Installation

1. Install the Motor Wheel: Replace your bicycle's existing wheel with the Varstrom hub motor wheel. Ensure it is securely fastened and aligned.
2. Mount the Controller: Find a suitable location on your bike frame for the controller box, typically near the battery or motor. Secure it firmly.
3. Install Display: Mount your chosen display (VD03, EKD01, or VD04) on the handlebars.
4. Install Throttle: Mount the throttle (thumb or half-twist) on the handlebars.
5. Install Brake Levers/Sensors: Replace your existing brake levers with the provided e-bike specific levers, or install the brake sensors onto your existing levers. Ensure they are correctly positioned to activate when braking.
6. Install PAS Sensor: Mount the Pedal Assist Sensor on the crank arm near the bottom bracket. Ensure the magnet disc and sensor are correctly aligned and spaced.
7. Install Headlight: Mount the headlight in a suitable position, usually on the handlebars or front fork.

4.3. Wiring Connections

The kit features plug-and-play wiring with color-coded connectors to simplify the process. Refer to the wiring diagram below:

Figure 6: Detailed wiring diagram showing connections between controller, motor, PAS sensor, battery, brake levers/sensors, throttle, display, and headlight.

• Connect the motor cable to the controller.
• Connect the PAS sensor cable to the controller.
• Connect the brake lever/sensor cables to the controller.
• Connect the throttle cable to the controller.
• Connect the display cable to the controller.
• Connect the headlight cable to the controller.
• Finally, connect your 48V battery (not included) to the controller. Ensure polarity is correct.
• Secure all cables with zip ties to prevent snagging or damage.

5. Operating Instructions

Once installed, operating your Varstrom e-bike is straightforward:

5.1. Powering On/Off

• Ensure your battery is charged and properly connected.
• Press and hold the power button on your display to turn the system ON.
• To turn OFF, press and hold the power button again.

5.2. Display Functions

Your chosen display provides various information and control options:

Figure 7: Features and specifications of VD03, EKD01, and VD04 displays.

5.3. Riding Modes

• Pedal Assist System (PAS): The PAS sensor detects your pedaling and provides motor assistance. You can adjust the assist level (typically 1-9) using the display buttons. Higher levels provide more power.
• Throttle Mode: Use the throttle to engage the motor without pedaling. This is useful for quick starts or when you need an extra boost.
• Quick-Switch to 25 km/h Street-legal Mode: For compliance with certain regulations, you can quickly limit the maximum speed to 25 km/h by holding the "+" and "-" buttons on your display simultaneously. Repeat the action to revert to full power.

6. Maintenance

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

• Cleanliness: Keep the motor, controller, and display clean. Wipe down components with a damp cloth. Avoid high-pressure washing directly on electrical parts.
• Electrical Connections: Periodically check all electrical connections for tightness and corrosion. Ensure they are free from dirt and moisture.
• Motor Inspection: The helical gear design is known for reduced wear and low maintenance. However, inspect the motor for any unusual noises or vibrations.
• Water Protection: The system has an IPX5 waterproof rating, meaning it is protected against low-pressure water jets. While it can handle rain, avoid submerging the components or prolonged exposure to heavy downpours to maximize lifespan.
• Brakes: Regularly check your brake pads and cables/hydraulic fluid. Ensure the brake levers/sensors are functioning correctly to cut off motor power when applied.
• Tires: Maintain proper tire pressure and inspect for wear or damage.
• Battery Care: Follow the manufacturer's instructions for your e-bike battery regarding charging, storage, and temperature conditions to ensure safety and extend battery life.

7. Troubleshooting

If you encounter issues with your Varstrom e-bike kit, refer to the following common troubleshooting steps:

• No Power to Display/Motor:
  • Check if the battery is charged and properly connected.
  • Ensure all main power cables are securely connected to the controller and motor.
  • Verify the display cable is firmly connected.
• Motor Not Assisting:
  • Check the PAS sensor installation; ensure the magnet disc and sensor are correctly aligned and not obstructed.
  • Verify the PAS sensor cable is connected to the controller.
  • Ensure the assist level on the display is set above zero.
• Throttle Not Working:
  • Check the throttle cable connection to the controller.
  • Ensure the system is powered on and not in a restricted mode.
• Brakes Not Cutting Power:
  • Verify the brake lever/sensor cables are correctly connected to the controller.
  • Ensure the brake sensors are properly installed and activated when the brakes are applied.
• Unusual Noises from Motor:
  • Stop riding immediately.
  • Inspect the motor for any loose parts or obstructions.
  • If the noise persists, contact Varstrom support.

For persistent issues or error codes displayed on your screen, consult the specific display manual or contact Varstrom customer support.

8. Specifications

Detailed specifications for the Varstrom 125EVH Hub Motor Conversion Kit:

Note: Controller specifications vary by rated power. For 36V250W: Limit Current 15±1A, Rated Current 7±1A, Under-Voltage Protection 29±1V, Over-Voltage Protection 46.6V. For 48V750W: Limit Current 22±1A, Rated Current 11±1A, Under-Voltage Protection 39±1V, Over-Voltage Protection 62.4V.

9. Warranty and Support

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

9.1. Warranty Period

Under Warranty Conditions:

• If there is any quality problem within 6 months (Based on Delivery Date), all warranty costs (repair cost, material cost, shipping cost, etc) are responsible by the seller.
• If there is any quality problem more than 6 months, not more than 12 months (Based on Delivery Date), the repair cost and material cost are responsible by the seller, the shipping cost is responsible by the buyer.

Out of Warranty Conditions:

If the warranty period is exceeded, for products from our store, we can continue to provide after-sales service, but the cost will be responsible by the buyer. The exact cost depends on the specific issue.

Figure 8: Summary of Varstrom warranty periods and conditions.

9.2. Local Expertise and Support

Varstrom has a network of certified service centers in Poland, England, Spain, and America to ensure prompt repairs and support. For any technical assistance or warranty claims, please contact Varstrom customer service.

10. User Tips

• Cable Management: Take extra time to neatly route and secure all cables using the provided zip ties. This prevents damage, ensures safety, and gives your e-bike a clean look.
• Initial Test Ride: After installation, perform a short test ride in a safe, open area to ensure all components are functioning correctly, especially the brakes and motor assist.
• App Connectivity: If your display supports Bluetooth, download the "BIKEGO+" app to unlock remote locking/unlocking features and advanced ride data tracking.
• Regular Checks: Before each ride, quickly check tire pressure, brake function, and ensure all connections are secure.