BAFANG BBS02 48V 750W Mid Drive Ebike Conversion Kit User Manual

1. Introduction

This manual provides comprehensive instructions for the installation, operation, and maintenance of your BAFANG BBS02 48V 750W Mid Drive Ebike Conversion Kit. Please read this manual thoroughly before beginning installation or operation to ensure proper function and safety. This kit is designed to transform a standard bicycle into a powerful electric bicycle, offering enhanced riding experience and versatility.

2. Key Features

• Universal Compatibility: Designed to fit standard 68-73mm (length) and 34-36mm (internal diameter) bottom brackets.
• Powerful and Reliable Motor: BBS02 750W motor with up to 120N.m torque, suitable for climbing and reaching speeds over 25mph.
• Easy Installation: Comes with an installation video and instruction manual for straightforward setup.
• Multiple Riding Modes: Supports E-bike, Pedal Assisted, and Push Assist modes.
• Complete Accessories: Includes motor, brake levers/sensors, thumb throttle, chainring, crank, LCD display, speed sensor, wiring, and headlight.
• New Upgraded Motor: Features smooth, controlled starts and speed limitation settings for both Pedal Assist and Throttle modes.

Figure 2.1: Comparison of New Upgraded BBS02B Motor Features.

Figure 2.2: BAFANG BBS02B Motor Specifications and Performance.

3. What's in the Box

Your BAFANG BBS02 kit includes the following components:

• BAFANG Mid-drive motor (for BB68-73mm)
• Brake lever or hydraulic brake sensor cables (default is brake lever)
• Thumb throttle
• Chainring wheel (various sizes available)
• Crank arms
• LCD display
• Speed sensor
• 1T4 wire harness
• Locknuts
• Wrench
• Ebike headlight (in default)
• Installation Screws
• Sticker
• Crank Removal Tool
• Cable Ties
• BBS Wrench
• Centre Shaft Removal Tool
• Optional Ebike Battery (not included in this kit)

Figure 3.1: Contents of the BAFANG BBS02 Ebike Conversion Kit.

4. Setup and Installation

4.1. Bike Compatibility Check

Ensure your bicycle's bottom bracket meets the following specifications for compatibility:

• Bottom Bracket Length: Standard 68-73mm. (For 100MM bottom bracket, a different ASIN is required: B0CL912Y72)
• Bottom Bracket Internal Diameter: 34-36mm.

Also, verify that the chosen chainring will not interfere with your bike's chain stay.

Figure 4.1: Checking Bike Bottom Bracket and Chainring Compatibility.

Figure 4.2: Measuring Bottom Bracket for Motor Fit.

4.2. Chain Wheel Options

The kit offers various chain wheel sizes. Select the appropriate size based on your riding needs and bike's compatibility.

4.3. Brake Lever or Brake Sensor

The kit comes with brake levers by default. If your bike requires brake sensors (e.g., for hydraulic disc brakes or integrated shift/brake handles), please contact customer service to request the appropriate sensor cables.

Figure 4.3: Brake System Compatibility.

4.4. Battery Compatibility (Optional)

If you are purchasing a battery separately, ensure it is compatible with your bike frame. For downtube shark batteries, use the provided size guide to check fitment. For rear rack batteries, verify installation screw holes and rear fork size (150-160mm).

Figure 4.4: Checking Downtube Shark Battery Fit.

Figure 4.5: Checking Rear Rack Battery Fit.

4.5. General Installation Notes

Refer to the included installation video and detailed instruction manual for step-by-step guidance. Ensure all connections are secure and waterproof. The entire ebike kit is designed with waterproof wiring to ensure safety and extend service life.

Figure 4.6: Installation Process.

Figure 4.7: IP65 Waterproof Wiring Diagram.

5. Operating Instructions

5.1. Riding Modes

The BAFANG BBS02 kit offers three primary riding modes:

• E-bike Mode (Rapid Climb): Full electric power, ideal for steep inclines or effortless cruising.
• Pedal Assisted Mode (Exercise Mode): Motor provides assistance as you pedal, balancing workout intensity with support.
• Push Assist Mode (Save Effort): Provides low-speed assistance for walking the bike, useful when pushing uphill or through crowded areas.

Figure 5.1: Riding Modes for Different Terrains.

5.2. LCD Display Usage

The LCD display provides essential information and allows for customization of settings. Features may vary slightly depending on the specific display model included with your kit (e.g., 500C, EKD01, DPC010.CB, etc.).

• Color Screens: With backlight settings for clear visibility in various conditions.
• Adjustable Speed Limits: Customize speed limits to suit different terrains or regulations.
• Dual Interface Themes: For customizable display appearance.
• PAS Levels: Nine levels for versatile speed adjustments.
• USB Charging Port: For emergency smartphone charging (Type-C or USB-A depending on model).
• Automatic Light Sensor: Activates headlight in dark environments (on some models).

Figure 5.2: Smart Digital Display Features.

Figure 5.3: Various High-Tech Ebike Display Options.

6. Maintenance

Regular maintenance is crucial for the longevity and optimal performance of your BAFANG ebike conversion kit. While the kit is designed for durability and features waterproof components, general care practices should be followed:

• Keep the motor and electrical connections clean and free from debris.
• Periodically check all bolts and fasteners for tightness, especially after initial rides.
• Inspect wiring for any signs of wear or damage.
• Ensure the chain and chainring are clean and lubricated.
• Avoid submerging the motor or electrical components in water, despite their waterproof rating.
• Store the ebike in a dry place when not in use.

Figure 6.1: Regular Maintenance is Key.

7. Troubleshooting

If you encounter any issues with your BAFANG BBS02 kit, consider the following general troubleshooting steps:

• No Power/Display Not Turning On: Check all electrical connections, especially the battery connection. Ensure the battery is charged.
• Motor Not Assisting: Verify that the PAS level is set above zero on the display. Check if brake levers are engaged (they cut motor power). Inspect speed sensor for proper alignment and connection.
• Unusual Noises: Stop riding immediately. Check for loose components, chainring alignment, or foreign objects near the motor.
• Error Codes on Display: Consult the specific display manual for interpretation of error codes.

For persistent issues, refer to the detailed user guide PDF available online or contact customer support.

8. Specifications

8.1. Battery Specifications (Optional)

If you are using a BAFANG compatible battery, refer to the following general specifications. Note that actual performance may vary based on battery model and usage.

Figure 8.1: Various Durable Ebike Battery Specifications.

9. Warranty and Support

BAFANG offers a one-month return service. If any quality problem arises within one year of purchase, our North American after-sales service center is available to provide technical support and maintenance.

For assistance, please contact our North American service center. Local warehouses in US/UK/CA/EU are available for support.

Figure 9.1: Dedicated Customer Support.