1. Introduction
This manual provides essential information for the installation, operation, and maintenance of your BAFANG BBS02 48V 750W Mid Drive Ebike Conversion Kit. Please read this manual thoroughly before attempting installation or operation to ensure proper function and safety.
Image 1.1: Overview of the BAFANG BBS02 48V 750W Mid Drive Ebike Conversion Kit components, including the motor, display, and various accessories.
2. Product Overview and Components
The BAFANG BBS02 48V 750W Mid Drive Ebike Conversion Kit is designed to transform a standard bicycle into an electric pedal-assist bicycle. It features a powerful mid-drive motor and comes with a comprehensive set of accessories for conversion.
Key Features:
- Powerful and Reliable Motor: The BBS02 750W motor delivers up to 120 N.m of torque, suitable for climbing and achieving speeds over 25mph.
- Smooth, Controlled Starts: The upgraded BBS02B motor features a slow start function and throttle-responsive acceleration.
- Multiple Riding Modes: Supports E-bike (throttle only), Pedal Assisted, and Push Assist modes.
- Universal Compatibility: Designed for bikes with a standard 68-73mm bottom bracket length and 34-36mm internal diameter.
- Comprehensive Accessory Kit: Includes motor, brake levers/sensors, thumb throttle, chainring, crank, LCD display, speed sensor, wiring harness, locknuts, wrench, and an ebike headlight.
Included Components:
- BAFANG Mid-drive motor (BBS02B 750W)
- Brake lever or hydraulic brake sensor cables (optional)
- Thumb throttle
- Chainring wheel (e.g., 44T)
- Crank arms
- LCD display (e.g., SW102)
- Speed sensor
- 1T4 wire harness
- Locknuts and wrench
- Ebike headlight (default inclusion)
- Optional Ebike Battery (not included by default)
Image 2.1: Visual representation of the motor's performance characteristics, such as torque, maximum speed, and waterproof rating.
3. Compatibility Guide
Before installation, it is crucial to verify that your bicycle frame is compatible with the BAFANG BBS02 mid-drive motor kit. Incorrect fitment can lead to damage or unsafe operation.
Bottom Bracket Requirements:
- Inner Diameter: Between 33.5mm and 36mm.
- Length: 68mm to 73mm.
Image 3.1: Instructions for checking bottom bracket inner diameter and length, and ensuring chainring clearance.
Unsuitable Bicycle Types:
The BAFANG BBS02 motor is not compatible with all bicycle types. Avoid installation on:
- Bicycles with belt drive chainrings.
- Coaster brake bicycles.
- Bicycles with bottom brackets outside the specified dimensions (e.g., less than 68mm or greater than 73mm).
- Bicycles where the sprocket will hit the chain stay.
Image 3.2: Examples of incompatible bicycle configurations for the BAFANG BBS motor.
Battery Compatibility (Optional):
If you are purchasing an optional battery, ensure it fits your bike frame. Templates for checking fitment are often available in product documentation.
Image 3.3: Guide for checking downtube battery compatibility.
Image 3.4: Guide for checking rear rack battery compatibility.
4. Installation
The BAFANG BBS02 kit is designed for relatively straightforward installation. An installation video and detailed instruction manual are typically provided to assist with the process. Basic mechanical skills and tools are required.
General Steps (Consult provided video/manual for details):
- Remove existing crankset, bottom bracket, and pedals.
- Install the BAFANG mid-drive motor into the bottom bracket shell.
- Secure the motor with the provided locknuts and mounting plate.
- Install the chainring and crank arms.
- Mount the LCD display on the handlebars.
- Install the thumb throttle and brake levers/sensors.
- Attach the speed sensor to the rear wheel and frame.
- Connect all components using the 1T4 wire harness and other cables. Ensure all connections are secure and waterproof.
- Install the ebike headlight.
- If using an optional battery, mount it securely and connect it to the motor system.
Image 4.1: Visual representation of the complete packing list for the conversion kit.
Brake Lever or Sensor:
The kit typically includes brake levers with integrated motor cut-off switches. If your bike uses hydraulic brakes or shift-integrated brake handles, you may need to request brake sensors instead of levers.
Image 4.2: Guide for choosing between brake levers and brake sensors based on your bicycle's brake system.
5. Operating Instructions
Once installed, the BAFANG BBS02 kit offers various modes to enhance your cycling experience.
Riding Modes:
- E-bike Mode (Throttle Only): Provides motor power without pedaling, controlled by the thumb throttle.
- Pedal Assisted Bicycle Mode: The motor provides assistance as you pedal. The level of assistance can be adjusted via the LCD display.
- Push Assist Mode: Provides low-speed motor assistance for walking the bike.
Image 5.1: Features of the upgraded BBS02B motor, highlighting smooth starts and adjustable speed limits.
LCD Display Usage:
The LCD display provides essential information and allows you to control various settings of your ebike system.
- Power On/Off: Typically a long press of the power button.
- Assist Level Adjustment: Use the up/down buttons to change pedal assist levels.
- Information Display: View speed, distance, battery level, and other metrics.
- Settings: Access advanced settings like wheel size, speed limit, and backlight brightness.
Image 5.2: Features and benefits of various smart digital displays.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your BAFANG mid-drive kit.
- Keep Clean: Regularly clean the motor and electrical connections to prevent dirt and debris buildup.
- Check Connections: Periodically inspect all electrical connections for tightness and signs of wear or corrosion. The wiring is IP65 waterproof, but proper sealing is still important.
- Lubrication: Ensure the bicycle chain and other moving parts are properly lubricated.
- Battery Care: Follow the battery manufacturer's instructions for charging, storage, and temperature guidelines. Avoid fully discharging the battery.
- Professional Inspection: Consider periodic inspections by a qualified ebike technician.
Image 6.1: Overview of the IP65 waterproof wiring system.
7. Troubleshooting
If you encounter issues with your BAFANG mid-drive kit, refer to the following general troubleshooting tips. For complex problems, contact customer support.
- No Power/Motor Not Responding:
- Check battery connection and charge level.
- Ensure all electrical cables are securely connected.
- Verify the display is powered on and showing no error codes.
- Motor Cuts Out:
- Check brake levers/sensors; ensure they are not engaged.
- Inspect for loose connections.
- Monitor motor temperature; overheating can cause cut-off.
- Inconsistent Pedal Assist:
- Check speed sensor alignment and ensure it's clean.
- Verify pedal assist level on the display.
- Display Not Working:
- Check power cable to the display.
- Ensure battery is charged and connected.
If problems persist, contact the BAFANG service center for technical support.
8. Specifications
Motor Specifications (BBS02B 750W):
- Voltage: 48V
- Wattage: 750W
- Max Torque: Up to 120 N.m
- Max Speed: Approximately 45 km/h (28 mph)
- Waterproof Rating: IP65
- Net Motor Weight: Approximately 4.24 kg
- Bracket Bottom Length: 68mm (compatible with 68-73mm)
- Material: Aluminum
Image 8.1: Comparison of BAFANG BBS and HD motor specifications.
Display Specifications (Example SW102):
- Model Name: SW102 Small Stealthy Ebike Display
- Screen Size: 1.5 inch IPS
- PAS Level: 3/5/9
- Holder (mm): 22.2
- Navigation: Not available
- Speed Limit: 0-99km/h
- USB Charger: Not available
Image 8.2: Detailed display specifications for various BAFANG models.
Battery Specifications (Optional, various models):
Various battery options are available, typically 48V or 52V, with capacities ranging from 13Ah to 20Ah. Key features often include:
- BMS Max Protection Current: 30A
- Cycle Life: 1000 times
- Charging Time: 6-7 hours
- Protection Features: Overcharge, overdischarge, overcurrent, short circuit, overtemperature protection.
Image 8.3: Detailed battery specifications for various BAFANG models.
9. Warranty and Support
BAFANG provides customer support and warranty services for its products.
- Warranty: One month return service. For quality problems within one year, the North American after-sales service center provides technical support and maintenance.
- Service Center: Local warehouses and service centers are available in US/UK/CA/EU for technical support and maintenance.
For any quality issues or technical assistance, please contact the BAFANG North American service center.
Image 9.1: Certificate of Compliance for BAFANG products.
