BAFANG BBSHD Mid-Drive Motor Controller Instruction Manual

1. Introduction

This manual provides detailed instructions for the installation, operation, maintenance, and troubleshooting of your BAFANG BBSHD Mid-Drive Motor Controller. Please read this manual thoroughly before installation and use to ensure proper function and safety. This controller is designed for BAFANG BBSHD, BBS, and BBS03B mid-drive crank engine kits, compatible with 36V, 48V, and 52V systems, and power outputs of 500W, 750W, and 1000W.

2. Safety Information

• Always wear appropriate safety gear, including gloves and eye protection, during installation.
• Ensure the battery is disconnected before performing any installation or maintenance.
• Verify all connections are secure and properly insulated to prevent short circuits.
• Do not modify the controller or any kit components, as this may void the warranty and create safety hazards.
• Consult a professional bicycle mechanic if you are unsure about any installation steps.

3. What's in the Box

Your BAFANG Mid-Drive Motor Controller kit typically includes the following components:

• Controller (integrated inside the motor)
• Brake Levers (with motor inhibitor sensors)
• Thumb Throttle
• Speed Sensor and Magnets
• LCD Display (various models supported)
• Cables and Wiring Harness
• Chain Wheel
• Crank Arms
• Nuts and Mounting Hardware
• Instruction Manual
• Tools/Wrench (for installation)
• Battery and Charger (optional, depending on kit configuration)

Figure 3.1: Overview of BAFANG mid-drive motor kit components.

4. Specifications

Figure 4.1: BAFANG BBSHD Controller with key specifications.

5. Setup and Installation

This section guides you through the installation of the BAFANG mid-drive motor controller kit. For a visual guide, please refer to the embedded installation videos.

5.1. Pre-Installation Checks

• Ensure your bike's bottom bracket shell width is compatible (typically 68-73mm for standard kits).
• Gather all necessary tools, including a crank arm puller, bottom bracket tool, and Allen wrenches.

5.2. Removing the Crankset

1. Remove the left crank arm using a crank arm puller.
2. Remove the chainwheel from the drive side.
3. Use a bottom bracket extractor tool to remove the existing bottom bracket.
4. Clean the bottom bracket shell and apply a layer of lubricant to remove any dirt.

Figure 5.1: BAFANG mid-drive motor system overview.

5.3. Mid-Drive Motor Installation

1. Attach the chainring (e.g., 44T) to the BAFANG motor unit. Secure with M6 bolts.
2. Carefully push the motor unit into the bottom bracket shell.
3. Secure the motor with the Y-shaped motor mount bracket on the left-hand side of the bike, using M6 bolts and a 5mm Allen wrench.
4. Install and tighten the gray locknut with the flat side facing the bike, ensuring the indicator arrow goes clockwise.
5. Install and tighten the outer black locknut using the provided wrench.

Figure 5.2: Detailed view of the BBSHD controller and its connections.

5.4. Speed Sensor Installation

Attach the speed sensor to the rear chainstay. Use the small red LED indicator light on the sensor to find the correct position where it detects the magnetic field (the light will blink). Secure the sensor and magnet using zip ties or other provided fasteners.

5.5. Display and Controls Mounting

1. Mount the display unit (e.g., DPC 010, DPC 080, EKD01) securely on the handlebar.
2. Install the controller and thumb throttle on the handlebar, ensuring they are easily accessible.
3. Replace your existing brake levers with the provided brake levers that include motor inhibitor sensors. These sensors cut off motor power when the brakes are applied. If your bike has hydraulic brakes, use the provided brake sensors which can be installed on the existing levers.

5.6. Wiring and Cable Management

Connect all cables from the motor, battery, display, throttle, and brake sensors according to the wiring diagram in the separate BAFANG user manual. Use the provided zip ties to organize and secure all cables along the bike frame for a clean and safe setup.

6. Operating Instructions

Your BAFANG mid-drive system offers various operating modes and customizable settings for an optimized riding experience.

6.1. Display Functions

The LCD display (e.g., Bafang DPC 010, DPC 080, EKD01) provides real-time information and allows you to adjust settings:

• Speed Indication: Current, average, and max speed.
• Battery Level: Real-time battery charge indicator.
• Assist Level: Select from multiple pedal-assist levels (ECO, TOUR, SPORT, BOOST).
• Trip Information: Distance, time, and odometer.
• Error Codes: Displays diagnostic error codes.
• Bluetooth Connectivity: Some displays (e.g., DPC 010) offer Bluetooth for map navigation integration and motor settings customization via a smartphone app.

6.2. Riding Modes

• Pedal-Assist Mode: The motor provides assistance based on your pedaling input and selected assist level. Features a slow start function for smooth acceleration.
• Throttle Mode: Use the thumb throttle for instant power without pedaling.
• Walk Assist Mode: Provides low-speed assistance (e.g., 6 KM/H) for pushing the bike, useful for climbing inclines up to 15%.

6.3. Customizing Motor Settings

Depending on your display model, you can customize various motor parameters, including support level speed limits, max output power, start angle, and start acceleration. Refer to your specific display's manual or the BAFANG smartphone app for detailed instructions on these advanced settings.

7. Maintenance

Regular maintenance ensures the longevity and optimal performance of your BAFANG mid-drive system.

• Cleaning: Keep the motor, battery, and electrical connections clean and free from dirt and moisture. Use a damp cloth; avoid high-pressure washing directly on components.
• Connections: Periodically check all electrical connections for tightness and corrosion.
• Chain and Drivetrain: Keep your chain clean and lubricated. Inspect the chainring and other drivetrain components for wear.
• Battery Care: Follow the battery manufacturer's instructions for charging and storage. Avoid fully discharging the battery and store it in a cool, dry place.
• General Bike Maintenance: Perform regular checks on brakes, tires, and other bicycle components as you would with a standard bicycle.

8. Troubleshooting

If you encounter issues with your BAFANG mid-drive system, refer to the following common troubleshooting tips:

• No Power: Check battery connection, ensure the battery is charged, and verify all main power cables are securely connected.
• Motor Not Assisting: Check the selected assist level on the display. Ensure the brake levers are not engaged (motor inhibitor sensors). Verify the speed sensor is correctly aligned and functioning (LED blinks).
• Display Not Working: Check display cable connection to the controller. Ensure the main power is on.
• Error Codes: Consult the specific BAFANG display manual for explanations of error codes and recommended solutions.
• Unusual Noises: Inspect the motor and drivetrain for any loose parts or obstructions.

If the problem persists, contact BAFANG customer support or a certified e-bike technician.

9. Warranty and Support

BAFANG provides comprehensive warranty and support for its products:

• Warranty: All devices and parts are produced by OEM of BAFANG, reliable and in good compatibility. One year quality warranty.
• Returns/Replacements: One month free return, replacement, or maintenance if any quality problem within 1 year.
• After-Sales Service: North American after-sales service center provides technical support and maintenance.

For warranty claims or technical assistance, please refer to the contact information provided with your purchase or visit the official BAFANG website.