BAFANG M615 MM G320.1000.C

BAFANG BBSHD 1000W Mid Drive Ebike Conversion Kit

User Manual - Model M615 MM G320.1000.C

1. Introduction

This manual provides essential information for the installation, operation, and maintenance of your BAFANG BBSHD 1000W Mid Drive Ebike Conversion Kit. This kit is designed to convert standard bicycles into electric bicycles, offering enhanced power and versatility for various terrains and riding styles. Please read this manual thoroughly before installation and use to ensure safe and optimal performance.

2. Safety Information

Always prioritize safety when operating an electric bicycle. Failure to follow safety guidelines can result in serious injury or damage to the product.

  • Wear a Helmet: Always wear an approved bicycle helmet when riding.
  • Pre-Ride Check: Before each ride, inspect brakes, tires, battery charge, and all connections.
  • Traffic Laws: Obey all local traffic laws and regulations.
  • Weather Conditions: Exercise caution when riding in wet or adverse weather conditions. The kit features IP65 waterproof wiring, but avoid submerging components.
  • Battery Handling: Handle the battery with care. Do not puncture, expose to extreme temperatures, or short-circuit. Use only the provided charger.
  • Professional Installation: If you are unsure about any installation steps, seek assistance from a qualified bicycle mechanic.

3. Package Contents

Verify that all components are present in your kit. The standard kit includes the following items:

  • BAFANG 1000W Mid-drive motor (48V or 52V)
  • Brake levers or brake sensors (for hydraulic brakes)
  • Thumb throttle
  • BAFANG chainring (e.g., 42T, 40T, 46T options)
  • Crank arms
  • LCD display (various optional models available)
  • Speed sensor and magnets
  • 1T4 wire harness
  • Mounting nuts and bolts
  • Battery (optional, if purchased with the kit)
  • Ebike headlight (1 pc)
  • Installation tools (2 pcs)
  • 250W stickers (4 pcs)
  • Installation accessories set
Diagram showing all components included in the BAFANG BBSHD 1000W Mid Drive Ebike Conversion Kit, such as the motor, battery, display, throttle, brake levers, chainring, cranks, speed sensor, and wiring.
Figure 3.1: Overview of included components in the BAFANG BBSHD 1000W Mid Drive Ebike Conversion Kit. This diagram illustrates the motor, optional battery, display, throttle, brake levers, chainring, cranks, speed sensor, and various wiring and installation accessories.

4. Compatibility Guide

The BAFANG BBSHD Mid Drive motor kit is compatible with most bicycles featuring a bottom bracket length of 68-73mm, 100mm, or 120mm, and an internal diameter of 34-36mm. This includes commuter bikes, fat bikes, mountain bikes, road bikes, and tricycles.

4.1. Confirming Bottom Bracket Fit

To ensure compatibility, measure your bike's bottom bracket shell width and internal diameter. The kit offers different motor shaft lengths (68-73mm, 100mm, 120mm) to match your bike's specifications.

Diagram illustrating how to measure a bicycle's bottom bracket for compatibility with the BAFANG mid-drive motor. It shows measurements for 68-73mm, 100mm, and 120mm bottom bracket lengths and a 33.5-36mm internal diameter.
Figure 4.1: Guide for measuring your bike's bottom bracket to ensure compatibility with the BAFANG mid-drive motor. This image details the required length (68-73mm, 100mm, or 120mm) and internal diameter (33.5-36mm) for proper fitment.

4.2. Confirming Battery Fit (Downtube Shark Battery)

If you opt for a downtube shark battery, it is crucial to verify it fits your bike frame. A size guide document is typically available for download to create cutouts for physical testing.

Instructions on how to check if a downtube shark battery fits a bicycle frame using a cutout template. The image shows a template being cut out and then placed on a bike frame to check for clearance.
Figure 4.2: Method for checking downtube shark battery compatibility with your bike frame. This involves using a downloadable size guide to create a cutout and physically test the fit on your bicycle.

4.3. Confirming Battery Fit (Rear Rack Battery)

For rear rack batteries, check for existing installation screw holes on your rear fork and measure the size of your rear fork to ensure the rack can be securely mounted.

Diagram showing how to check for rear rack battery compatibility by inspecting installation screw holes on the rear fork and measuring the fork width (A: 150-160MM).
Figure 4.3: Guide for verifying rear rack battery compatibility. This image highlights checking for existing screw holes on the rear fork and measuring the fork width (150-160mm) for proper rack installation.

4.4. Brake System Compatibility

The kit supports mechanical disc brakes and rim V-brakes. If your bike uses shift-integrated brake handles or hydraulic disc brakes, you may need to use brake sensors instead of the default brake levers. Contact support if you require brake sensors.

Comparison of different brake types and their compatibility with the ebike conversion kit. It shows mechanical disc brakes and rim V-brakes as compatible, and shift-integrated brake handles and hydraulic disc brakes as potentially requiring brake sensors.
Figure 4.4: Brake system compatibility guide. This image illustrates which brake types (mechanical disc, rim V-brake, shift-integrated, hydraulic disc) are compatible and when brake sensors might be necessary.

5. Setup and Installation

Converting your pedal bike into an electric bike with the BAFANG BBSHD kit involves several steps. A detailed installation video is typically available to guide you through the process. Ensure you have the necessary tools and follow all instructions carefully.

5.1. General Installation Steps

  1. Remove existing bottom bracket and crankset.
  2. Install the BAFANG mid-drive motor into the bottom bracket shell.
  3. Secure the motor with the provided nuts and bolts.
  4. Install the chainring and crank arms.
  5. Mount the display, throttle, and brake levers/sensors on the handlebars.
  6. Install the speed sensor on the rear wheel.
  7. Connect all components using the 1T4 wire harness.
  8. Mount the battery securely (if included).
  9. Perform a functional test before riding.
Image showing a person working on a bicycle, likely installing or maintaining the mid-drive motor, with tools visible in the background.
Figure 5.1: Illustration of a bicycle being worked on, representing the installation or maintenance process of the ebike conversion kit.

5.2. Waterproof Wiring

The entire ebike kit is designed with IP65 waterproof wiring to ensure safety and extend the service life of the components. All joints are waterproof, fitting tightly to effectively achieve waterproofing. Seal interfaces to prevent water droplets from entering.

Diagram showing the waterproof wiring connections of the BAFANG ebike kit, highlighting the motor, battery, display, throttle, brake levers, speed sensor, and headlight connections.
Figure 5.2: Wiring diagram illustrating the IP65 waterproof connections for the BAFANG ebike kit components, including the motor, battery, display, and various sensors.

6. Operating Instructions

The BAFANG BBSHD kit offers multiple riding modes and an intelligent display for a customizable experience.

6.1. Riding Modes

Choose from three primary riding modes:

  • E-bike Mode: Full electric power, no pedaling required.
  • Pedal Assisted Bicycle Mode: Motor provides assistance as you pedal.
  • Push Assisted Bike Mode: Provides low-speed assistance for walking the bike.
Images depicting different riding modes and terrains for the BAFANG ebike kit, including Rapid Climb (Ebike Mode), Exercise Mode (Pedal Assistance Mode), Save Effort (Push Assistance Mode), and Bike Mode (no assistance).
Figure 6.1: Visual representation of the different riding modes available with the BAFANG ebike kit, suitable for various terrains and preferences.

6.2. Digital Display

The intelligent T1 Touch display (and other optional displays) allows you to monitor and adjust various parameters. Features include:

  • Real-time speed display (KM/H or MPH)
  • Battery power indicator
  • Ride time and trip distance
  • PAS (Pedal Assist System) level setting (0-9 levels)
  • Headlight indicator and brake indicator
  • Error code display for diagnostics
  • Adjustable speed limits
  • USB charging port for mobile devices (on some models)
  • Automatic light sensor for headlight activation (on some models)
Various optional digital displays for the BAFANG ebike kit, showing different screen sizes and features like speed, battery level, PAS level, and USB charging ports.
Figure 6.2: Examples of optional digital displays available for the BAFANG ebike kit, showcasing their features and interface.

6.3. CAN Protocol Advantage

The kit utilizes a CAN (Controller Area Network) protocol, offering advantages over older UART systems:

  • Tune via Display/App (no extra programming cable needed)
  • Car-Grade Stability (anti-interference)
  • See Battery Health (real data & cycles when using BAFANG battery)
  • 30W Lights + Protection
  • Protected Display Circuit (prevents burn-out)
  • 60V Tough Circuit (handles surges)
Infographic comparing the advantages of the new CAN protocol over the old UART protocol for BAFANG ebike systems, highlighting features like tuning via app, stability, battery health monitoring, and circuit protection.
Figure 6.3: Comparison illustrating the benefits of the CAN protocol used in the BAFANG BBSHD kit compared to older UART systems.

6.4. Official Product Video

Video 6.1: This video provides an overview of the BAFANG BBS HD motor, demonstrating its integration with a bicycle, the functionality of the T1 Touch display, and its performance across various terrains. It highlights the motor's power transfer and versatility for different riding environments.

7. Maintenance

Regular maintenance ensures the longevity and safe operation of your BAFANG ebike conversion kit.

  • Cleaning: Clean the motor and battery regularly with a damp cloth. Avoid high-pressure washing directly on electrical components.
  • Battery Care: Store the battery in a cool, dry place. Charge it regularly, even when not in use, to maintain battery health. Avoid fully discharging the battery.
  • Connections: Periodically check all electrical connections for tightness and corrosion.
  • Mechanical Components: Maintain your bicycle's mechanical components (chain, gears, brakes) as you would a regular bike. Lubricate the chain regularly.
  • Professional Inspection: Consider annual professional inspection of the motor and electrical system.

8. Troubleshooting

This section addresses common issues you might encounter with your BAFANG ebike kit.

  • Motor Not Engaging: Check battery connection, ensure the display is on, and verify PAS level settings. Inspect for any error codes on the display.
  • Loss of Power: Check battery charge level. Ensure all motor and battery connections are secure.
  • Display Not Working: Check power cable connection to the display and battery.
  • Unusual Noises: Stop riding immediately and inspect the motor and drivetrain for any obstructions or loose parts.
  • Error Codes: Refer to your display's specific manual for a list of error codes and their meanings.

If you encounter persistent issues, contact customer support for assistance.

9. Specifications

Key technical specifications for the BAFANG BBSHD 1000W Mid Drive Motor Kit:

FeatureSpecification
BrandBAFANG
Model NameM615 MM G320.1000.C
Power1000 Watts
Voltage48 Volts (or 52 Volts with optional battery)
Controller Current30A
Efficiency>80%
Max Torque160 N.m
Maximum Speed50-60 km/h
Net Motor WeightApprox. 5.80kg (68mm), 5.93kg (100mm), 5.99kg (120mm)
Bottom Bracket Length Compatibility68-73mm, 100mm, 120mm
Bottom Bracket Internal Diameter34-36mm
MaterialAluminum
Item Weight (Kit)17.64 pounds (approx. 8 kg)
UPC053742479405
Table showing detailed motor parameters for the BAFANG BBS-HD CAN Version, including power, voltage, controller current, efficiency, max torque, maximum speed, net motor weight, and bracket bottom length for 68mm, 100mm, and 120mm versions.
Figure 9.1: Detailed motor parameters for the BAFANG BBS-HD CAN Version, outlining specifications for different bottom bracket lengths.

9.1. Battery Specifications (Optional)

Various battery options are available, each with specific characteristics:

TypeParameterWatt-hourBattery CellBMSWeightCycle Life
Shark Battery48V 13Ah624Wh18650 2600mAh30A4.25KG1000 times
Shark Battery48V 17.5Ah840WhSam*sung 21700 5000mAh30A4KG1000 times
Max Shark Battery48V 19.2 / 20Ah921.6 / 960WhL*G, Sam*sung 21700 4800mAh30A4.95 / 4.7KG1000 times
Downtube Yingwu52V 20Ah1040WhSam*sung 21700 5000mAh30A5KG1000 times
Rear Rack Battery48V 17.5Ah840Wh18650 2600mAh30A6KG1000 times
VoltzX Battery48V 20Ah960Wh30A5.2KG1000 times
Table and images detailing various ebike battery specifications, including voltage, capacity, watt-hours, cell type, BMS, weight, and cycle life for different battery models like Shark Battery, Max Shark Battery, Downtube Yingwu, Rear Rack Battery, and VoltzX Battery.
Figure 9.2: Overview of various optional ebike battery specifications, including their type, capacity, and physical dimensions.

10. Warranty and Support

BAFANG is committed to providing quality products and support. As an officially authorized shop, Greenergia ensures genuine products and offers cooperative service points in various countries.

  • Genuine Products: All motors are genuine BAFANG products.
  • Service Points: Cooperative service points are available globally.
  • Contact Support: For any questions, technical assistance, or warranty claims, please contact the seller or an authorized BAFANG service center.

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