1. Introduction
Thank you for choosing the Varstrom Electric Bicycle Hub Motor Conversion Kit. This kit is designed to convert your standard bicycle into a powerful electric bicycle, offering enhanced performance and versatility for various terrains and riding styles. This manual provides essential information for the safe installation, operation, and maintenance of your new e-bike conversion kit.
The Varstrom hub motor is a brushless, gearless design, ensuring smooth operation, extended lifespan, and reliable performance even under demanding conditions. It is available in 1000W and 1500W power options, with compatibility for 26", 27.5", and 700C (28"/29") wheel sizes, and can be installed on either the front or rear wheel depending on the chosen model.
Image: Varstrom 1000W/1500W Hub Motor providing high power, speed, torque, and longevity for demanding terrains, harsh weather, and long-distance journeys.
2. Safety Information
⚠️️ Please mind potential fire risk and strictly follow the instruction manual for charging and storage of any associated battery (not included with this kit). Always wear appropriate safety gear, including a helmet, when riding your e-bike. Ensure all connections are secure and properly insulated before operation.
3. Package Contents
Your Varstrom Hub Motor Conversion Kit may include the following components. Please verify all items upon receipt:
- Hub Motor Wheel (Front or Rear, 1000W or 1500W, specific wheel size)
- Motor Controller
- Controller Box
- Display (Optional: DZ40 Mini, SW2-M58 Color Screen, VD18MT Touch Screen, EKD01 Bluetooth, Bafang DPC18)
- Left PAS Sensor
- Thumb Throttle
- 36-60V Headlight
- Brake Levers or Brake Sensors (selectable)
- 1T4 Cable
- Motor Extension Cable (typically for Front Motor 1000W parcel)
- Plastic Straps
- Decorative Stickers
Note: The battery and taillight are optional and typically not included in the standard kit. The Brake Lever and Brake Sensor can be selected based on your order. If a left-side PAS sensor with a larger hole is required, please contact the seller for replacement.
Image: Example packing list for a Rear Motor 1500W kit, showing the hub motor wheel, display, motor controller, controller box, PAS sensor, thumb throttle, headlight, brake levers/sensors, 1T4 cable, plastic straps, and decorative stickers.
Image: Example packing list for a Front Motor 1000W kit, showing the hub motor wheel, display, motor controller, controller box, PAS sensor, thumb throttle, headlight, brake levers/sensors, 1T4 cable, motor extension cable, plastic straps, and decorative stickers.
4. Specifications
| Feature | 48V 1000W (Front/Rear) | 48V 1500W (Rear) |
|---|---|---|
| Motor Type | Brushless Non-gear Hub Motor | |
| Rated Voltage | 48V | |
| Rated Power | 1000W | 1500W |
| Max Speed | 55 KM/h | 70 KM/h |
| Max Torque | 66 N.m | 78 N.m |
| No-load Current | ≤1A | ≤1.8A |
| Rated Current (Controller) | 15A | 18A |
| Max Output (Controller) | 30A | 35A |
| Efficiency | >82% | >85% |
| Noise Grade | <55 dB | |
| Waterproof Grade | IPX5 | |
| Certification | CE | |
| Wheel Diameter (Inch) | 26" / 27.5" / 700C (28" / 29") Optional | |
| Spoke Specification | 12G*36H | |
| Front Dropout Size | 100-106mm | |
| Rear Dropout Size | 132-139mm | 135-146mm |
Display Models Comparison
| Feature | DZ40 Mini | SW2-M58 | EKD01 | VD18MT | Bafang DPC18 |
|---|---|---|---|---|---|
| Screen | 1.7" LCD | 3.8" LCD | 2.4" TFT | 1.45" TFT | 3.5" TFT |
| Holder (mm) | 22.2 | 22.2/25.4/31.8 | 22.2/25.4 | 22.2 | 22.2/25.4/31.8 |
| Password | / | 1919 | 2020 | 1919 | 1919 |
| Pas Mode | 5 | 5 | 5 | 3/5 | 3/5/9 |
| Output Port | / | / | Type-C | / | USB Port |
| Language | EN | EN,DE,NL,FR,IT,ES,PL,CZ | EN | ||
Image: Detailed performance specifications for the Varstrom 48V 1000W and 1500W brushless non-gear hub motors, including rated power, max speed, max torque, dropout size, and waterproof grade.
Image: Comparison of various e-bike display models (DZ40, SW2-M58, EKD01, VD18MT, DPC18) showing screen type, holder size, password features, PAS modes, output ports, and supported languages.
5. Installation Guide
This section outlines the general steps for installing your Varstrom Hub Motor Conversion Kit. Ensure your bicycle is clean and stable before beginning installation. Professional installation is recommended if you are unfamiliar with bicycle mechanics or electrical wiring.
5.1. Choosing the Right Wheel Size and Dropout
Before installation, confirm your bicycle's wheel size and frame dropout dimensions are compatible with the kit. The kit supports 26", 27.5", and 700C (28"/29") rim sizes. Measure your bike's front or rear dropout width to ensure proper fitment.
- Front Dropout Size: 100-106mm
- Rear Dropout Size: 132-139mm (for 1000W motors), 135-146mm (for 1500W motors)
Image: Guide on how to choose the suitable wheel size and measure the frame dropout size for front and rear wheel installations, including rim diameter and compatible tire widths.
5.2. Component Identification
Familiarize yourself with the main components of the kit:
- Brake Lever or Brake Sensor (Optional)
- Thumb Throttle
- Display (Optional)
- 1T4 Cable
- Headlight
- Controller & Box
- PAS Sensor
- Motor Extension Cable (if applicable)
- Hub Motor Wheel (Front or Rear)
- Battery (Optional, not included)
5.3. Rear Hub Motor Installation (Example)
Follow the wiring diagram carefully. Connect each component to the controller as indicated. Ensure all connections are firm and waterproof.
Image: Detailed wiring diagram for installing the Rear Hub Motor kit, showing connections for brake levers, thumb throttle, display, 1T4 cable, headlight, controller, PAS sensor, motor extension cable, and the hub motor wheel.
5.4. Front Hub Motor Installation (Example)
Similar to the rear motor, connect all components to the controller according to the diagram. Note the inclusion of a motor extension cable for front wheel installations.
Image: Detailed wiring diagram for installing the Front Hub Motor kit, showing connections for brake levers, thumb throttle, display, 1T4 cable, headlight, controller, PAS sensor, motor extension cable, and the hub motor wheel.
5.5. Controller Interface Diagram
The controller is the central unit for managing power and signals. Refer to the specific diagram for your motor's wattage (1000W or 1500W).
Image: Controller interface diagram for a 1000W motor, detailing dimensions (159mm x 50mm x 29mm) and connections for battery, 1T4 cable, PAS sensor, taillight, headlight, and hub motor wheel. Specifications include 1000W compatible power, 30A max current, 15A rated current, 48V rated voltage, and 39±1 low-voltage protection.
Image: Controller interface diagram for a 1500W motor, detailing dimensions (162mm x 57mm x 32mm) and connections for battery, 1T4 cable, PAS sensor, taillight, headlight, and hub motor wheel. Specifications include 1500W compatible power, 35A max current, 18A rated current, 48V rated voltage, and 39±1 low-voltage protection.
6. Operation and Riding Modes
Your Varstrom e-bike kit offers multiple riding modes to suit your preferences and riding conditions.
Image: Graphic illustrating the four riding modes: Pedal Assisted Mode, Throttle Electric Mode, Manual Mode, and Walk Assisted Mode, with visual representations of their use cases.
6.1. Pedal Assisted Mode (PAS)
This mode activates intelligent motor support as you pedal. It seamlessly adapts to your riding style, offering a natural boost for hills, headwinds, or longer commutes. The level of assistance can typically be adjusted via the display.
6.2. Throttle Electric Mode
Simply twist the throttle for 100% electric power on demand. Enjoy effortless riding without pedaling, perfect for quick acceleration or relaxing when you're tired. This mode provides full power directly from the motor.
6.3. Manual Mode
Ride using only your own power. With the motor and battery disengaged, experience the classic, silent, and satisfying feel of a traditional bicycle. This mode is ideal for exercise or when you want to conserve battery life.
6.4. Walk Assisted Mode
Hold the lower button on your display or controller to activate a steady 6 km/h walking aid. This EU-compliant feature helps you push the e-bike safely up slopes or through crowded areas without having to pedal.
7. Maintenance
Regular maintenance will ensure the longevity and optimal performance of your Varstrom e-bike kit.
- Motor: The brushless, gearless hub motor is designed to be 100% maintenance-free. Keep it clean from dirt and debris.
- Connections: Periodically check all electrical connections for tightness and signs of wear or corrosion. Ensure they are securely fastened and waterproof.
- Cables: Inspect cables for any damage, fraying, or kinks. Replace damaged cables immediately.
- Display: Keep the display clean and protected from impacts.
- Water Exposure: While the kit has an IPX5 waterproof rating, avoid submerging the motor or controller in water. Wipe down any moisture after riding in wet conditions.
- General Bicycle Maintenance: Continue to perform regular maintenance on your bicycle's mechanical components, such as brakes, tires, chain, and gears.
Image: Features of the brushless, gearless hub motor, highlighting -70% noise & vibration, +18% power efficiency, and 100% maintenance-free operation due to its solid direct-drive design.
8. Troubleshooting
If you encounter issues with your e-bike kit, refer to the following common problems and solutions:
- No Power to Motor/Display:
- Check battery connection and charge level.
- Ensure all electrical connectors are fully seated and not damaged.
- Inspect the controller for any visible damage.
- Motor Not Assisting:
- Verify PAS sensor installation and ensure it's correctly aligned and not obstructed.
- Check if the display is showing an error code. Refer to your display's manual for specific codes.
- Ensure the brake levers/sensors are not engaged, as they cut off motor power.
- Inconsistent Power/Jerking:
- Check for loose wiring connections, especially to the motor and controller.
- Ensure the throttle is functioning correctly and not sticking.
- Display Not Turning On:
- Check the main power cable from the battery to the controller.
- Ensure the display cable is securely connected to the controller.
For persistent issues, please contact Varstrom customer support.
9. User Tips
- Battery Compatibility: Remember that the kit typically does not include a battery. Ensure you purchase a compatible 48V e-bike battery with sufficient capacity (Ah) for your desired range and power output.
- Brake Sensor/Lever Choice: The kit allows for selection between brake levers with integrated sensors or separate brake sensors. Choose the option that best suits your existing brake system and personal preference.
- PAS Sensor Placement: Pay close attention to the installation of the PAS sensor. Correct alignment and distance from the magnet disc are crucial for proper pedal assist functionality.
- Cable Management: Use the provided plastic straps to neatly secure all cables to your bike frame. This prevents snagging, damage, and ensures a clean aesthetic.
10. Warranty and Support
Varstrom is committed to providing high-quality products and customer satisfaction. Your e-bike conversion kit is covered by a warranty against manufacturing defects. For specific warranty terms and conditions, please refer to the product documentation or contact Varstrom customer service.
Customer Support: For technical assistance, troubleshooting, or warranty claims, please contact the seller or Varstrom support directly. Provide your order number and a detailed description of the issue for faster service.
Product Authenticity: This product is certified original, ensuring you receive a genuine Varstrom product.
