1. Product Overview
This manual provides detailed instructions for the installation, operation, and maintenance of your BAFANG 48V 500W Rear Hub Motor Ebike Conversion Kit. This kit is designed to transform a standard bicycle into an electric bicycle, offering enhanced power and efficiency for various riding conditions.
The kit features a 500W rear-drive motor compatible with disc and V brakes, providing robust power for your vehicle. It is suitable for touring bikes, commuter bikes, and mountain bikes, offering a maximum speed of up to 38-40 KM/H.
An overview of the BAFANG 48V 500W Rear Hub Motor Ebike Conversion Kit, displaying the rear wheel with integrated motor, battery, controller, display, and various accessories.
2. Package Contents
Please verify that all components listed below are included in your package:
- Rear Wheel & Motor Assembly
- Controller
- Brake Levers (or Brake Sensors for hydraulic brakes)
- Thumb Throttle
- Controller Case
- BAFANG LCD Display (optional, DZ40 model)
- Extension Cable
- PAS (Pedal Assist Sensor)
- 1T4 Cable
- Battery and Charger (optional, if ordered)
- Headlight (optional)
- Sticker
- Plastic Straps
A visual representation of the packing list, detailing each component included in the BAFANG ebike conversion kit, such as the rear hub motor, controller, display, battery, and various sensors and cables.
3. Compatibility Requirements
Before installation, ensure your bicycle meets the following compatibility criteria:
- Rear Dropout Size: Your bicycle's rear dropout size must be between 135mm and 142mm.
- Cassette Flywheel: The kit is compatible with cassette flywheels of ≤9 speeds.
- Brake Type: Compatible with both disc brakes and V brakes.
This diagram shows how to check compatibility for the ebike conversion kit, specifically focusing on the rear dropout measurement (135-142mm), the type of gear shift (cassette vs. freewheel), and the axle length (138mm dropout).
3.1 Choosing the Correct Tire Size
The kit supports various wheel sizes. Refer to the image below to select the appropriate rim diameter based on your tire size.
A visual guide demonstrating how to choose the correct tire size for the conversion kit, showing double wall rim options for 20", 26", 27.5", and 700C wheels, along with their respective diameters, spoke counts, and compatible tire widths.
4. Installation Guide
This section outlines the general steps for installing your BAFANG ebike conversion kit. For detailed visual instructions, please refer to the provided diagrams.
4.1 Component Connection Overview
The kit utilizes durable waterproof connectors for easy and secure assembly. Each component connects to the controller, which acts as the central hub for the system.
A detailed wiring diagram illustrating the connections between the rear hub motor, controller, battery, display, brake levers, thumb throttle, PAS sensor, and optional headlight/taillight for the BAFANG ebike conversion kit.
4.2 Display Options
Your kit may include one of several display models. Each display offers different features and screen sizes.
A comparative table showcasing different BAFANG ebike display models (e.g., SW2-M58, DZ40, DM03, 500C, EKD01, P860ML, C18, 800S) with details on PAS levels, screen size, holder dimensions, advanced password, language support, and USB charging capabilities.
4.3 Battery Installation (Optional)
If your kit includes a battery, refer to the battery specification image for details on different battery types and their installation methods. Ensure the battery is securely mounted and connected to the controller.
An image detailing various BAFANG ebike battery types, including Shark Battery, G80 Shark Battery, Max Shark Battery, VoltzX Battery, and Rear Rack Battery, with specifications such as voltage, watt-hours, battery cell type, BMS, weight, and cycle life.
5. Operating Instructions
Once installed, your BAFANG ebike conversion kit provides multiple modes of operation to enhance your riding experience.
5.1 Power On/Off
To power on the system, press and hold the power button on your display unit. To power off, press and hold the same button.
5.2 Pedal Assist System (PAS)
The PAS provides assistance as you pedal. Use the display controls to adjust the level of assistance (typically 0-5 or 0-9 levels). Higher levels provide more motor power.
5.3 Throttle Operation
The thumb throttle allows for on-demand power without pedaling. Gently press the throttle to engage the motor. Release the throttle to disengage.
5.4 Display Functions
Your display provides real-time information such as speed, battery level, PAS level, and trip distance. Consult your specific display model's manual for detailed navigation and settings.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your ebike conversion kit.
- Motor: The rear hub motor is largely maintenance-free. Keep the motor housing clean and free from debris. Avoid submerging the motor in water.
- Battery: Charge the battery regularly, even when not in use, to maintain its health. Store the battery in a cool, dry place. Avoid fully discharging the battery.
- Connections: Periodically check all electrical connections for tightness and signs of wear. Ensure waterproof connectors are properly sealed.
- Brakes: Ensure brake levers are functioning correctly and cut off power to the motor safely when engaged. Adjust or replace brake pads as needed.
- General Bicycle Maintenance: Continue with regular bicycle maintenance, including tire pressure checks, chain lubrication, and gear adjustments.
7. Troubleshooting
This section addresses common issues you might encounter.
| Problem | Possible Cause | Solution |
|---|
| Motor not engaging/no power | Low battery; loose connection; brake lever engaged; display error. | Charge battery; check all cables are securely connected; ensure brake levers are fully released; check display for error codes. |
| Inconsistent pedal assist | PAS sensor misalignment or damage; dirty sensor. | Check PAS sensor position and ensure it's clean and unobstructed. |
| Display not turning on | Battery not connected; faulty display cable; low battery. | Verify battery connection; check display cable for damage; charge battery. |
| Unusual noise from motor | Loose spokes; internal motor issue; debris in motor. | Check spoke tension; if noise persists, contact customer support. |
If you encounter issues not listed here or require further assistance, please contact our global service center.
8. Specifications
Key technical specifications for the BAFANG 48V 500W Rear Hub Motor Kit.
| Feature | Specification |
|---|
| Brand | BAFANG |
| Model Name | RM G020.500.D/DC |
| Rated Power | 500W |
| Rated Voltage | 48V |
| Max Speed | Up to 38-40 KM/H |
| Max Torque | 65 N.m |
| Efficiency | ≥ 80% |
| Waterproof Grade | IPX5 |
| Installation Widths (OLD) | 138mm ± 1 |
| Compatible Wheel Sizes | 20", 26", 27.5", 700C |
| Material | Aluminum |
A table outlining the technical specifications of the BAFANG 500W rear hub motor, including max speed (40 KM/H), max torque (60 N.m), noise grade (<55 dB), waterproof grade (IPX5), and weight (3.5KG).
9. Warranty and Support
BAFANG offers a global service network to support its products.
If any quality problem arises within one year of purchase, our local after-sales service centers are available to provide technical support and maintenance.
For assistance, please refer to the contact information provided with your product documentation or visit the official BAFANG website.
