1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your Varstrom 26-inch Ebike Conversion Kit. This kit is designed to transform a standard bicycle into an electric bicycle, featuring a powerful 48V 1000W brushless geared rear hub motor, a 3-mode controller, an LCD display, and a Pedal Assist System (PAS).
Please read this manual thoroughly before attempting installation or operation to ensure safe and correct usage of the product.
2. Safety Information
- Always wear a helmet when riding your e-bike.
- Ensure all components are securely fastened before each ride.
- Do not operate the e-bike in adverse weather conditions without proper precautions.
- Familiarize yourself with local e-bike regulations and traffic laws.
- Keep hands and feet clear of moving parts, especially the motor and wheel spokes.
- Avoid submerging electrical components in water. The motor has an IPX5 waterproof rating, but other components may not.
- Always disconnect the battery before performing any maintenance or installation.
3. Package Contents
Verify that all components listed below are included in your package. If any items are missing or damaged, please contact customer support.
Image 3.1: Overview of the Varstrom Ebike Conversion Kit components, including the rear wheel motor, controller, display, throttle, brake levers, and wiring.
Image 3.2: Diagram illustrating the placement of various components on a bicycle, serving as a visual packing list.
The kit typically includes:
- 48V 1000W 26" Rear Hub Motor Wheel
- Controller
- Controller Box
- DZ40 Display (or other optional display)
- Brake Levers (or Brake Sensors)
- Thumb Throttle
- PAS Sensor (Left)
- 1T4 Cable
- Headlight
- Motor Extension Cable
- Essential Mounting Hardware
- (Battery and Taillight are NOT included)
4. Specifications
Image 4.1: Key features of the 1000W brushless geared hub motor, including rated power, voltage, max speed, and torque.
Image 4.2: A table detailing the technical specifications of the ebike conversion kit components.
| Feature | Specification | Feature | Specification |
|---|---|---|---|
| Brand Name | Varstrom | Style | DZ40 Display |
| Model No. | RW28-1 | Position | Rear Motor |
| Wheel Size | 26 inches | Rated Voltage | 48V |
| Rated Power | 1000W | Max Torque | 82 N.m |
| Max Speed | Up to 50 KM/H | Efficiency | >80% |
| Construction | Gear Drive | Brake Type | Disc Brake Compatible |
| Waterproof Grade | IPX5 | Installation Widths (OLD) | 142 ± 1mm |
| Spoke Specification | 36H * 12G | Operating Temperature | -20 - 45°C |
| Weight | 5.2 kg | Suggested Users | Unisex-adult |
5. Compatibility
This conversion kit is designed for specific bicycle types. Please ensure your bicycle meets the following criteria:
Image 5.1: Visual guide for checking bicycle compatibility, including rim diameter, tire size, and rear dropout width.
- Wheel Size: Compatible with 26-inch bicycle wheels. Verify your tire marking (e.g., 26*1.95) to confirm wheel size.
- Brake Type: Designed for disc brake bicycles.
- Cassette Freewheel: Suitable for 10-speed or lower cassette freewheels.
- Rear Dropout Width (OLD): Your bicycle frame must have a rear dropout width of 135-142mm.
- Tire Compatibility: Suitable for tires with a width between 1.5" and 2.4".
Note: Disc brake and cassette are not included with the kit.
6. Setup and Installation
The installation process involves replacing your bicycle's rear wheel with the motorized wheel and connecting the various electrical components. It is recommended to have basic bicycle maintenance knowledge or seek professional assistance if unsure.
6.1 Component Overview
Image 6.1: Diagram showing the main components of the kit and their general placement, including the controller box dimensions.
6.2 Wiring Connection Instructions
Follow the wiring diagram carefully to connect all electrical components. Ensure all connections are secure and waterproof where applicable.
Image 6.2: Detailed wiring diagram illustrating how to connect the display, throttle, brake sensors/levers, PAS sensor, battery, headlight, controller, and hub motor wheel.
- Install Rear Wheel: Replace your bicycle's rear wheel with the 48V 1000W hub motor wheel. Ensure it is properly seated in the dropouts and secured.
- Mount Controller: Secure the controller and controller box to your bicycle frame in a protected location.
- Install Display: Mount the DZ40 LCD display on your handlebars.
- Install Throttle and Brake Levers/Sensors: Mount the thumb throttle and brake levers (or brake sensors) on the handlebars.
- Install PAS Sensor: Install the left PAS sensor on your bicycle's bottom bracket.
- Connect Wiring:
- Connect the motor cable to the controller.
- Connect the 1T4 cable to the controller.
- Connect the display, throttle, brake levers/sensors, and PAS sensor to the 1T4 cable.
- Connect the headlight to the designated port on the controller or 1T4 cable.
- Connect your 48V battery (not included) to the controller.
- Cable Management: Secure all cables with zip ties to prevent them from interfering with moving parts or getting damaged.
For an in-depth installation walkthrough, please refer to the support resources provided by Varstrom or contact their technical support team.
7. Operating Instructions
Your Varstrom Ebike Conversion Kit offers versatile riding modes and a smart display for an enhanced cycling experience.
7.1 Riding Modes
The kit supports three primary riding modes:
- Full Electric Assistance: Use the thumb throttle for propulsion without pedaling.
- Pedal-Assist System (PAS): The motor provides assistance as you pedal. The level of assistance can be adjusted via the display.
- No Assistance: Ride the bicycle as a traditional pedal bike with no motor assistance.
7.2 LCD Display Operation (DZ40 Example)
The DZ40 display provides real-time data and allows you to control various functions of your e-bike.
Image 7.1: The DZ40 LCD display showing speed and battery level, along with other optional display models.
- Power On/Off: Press and hold the power button on the display to turn the system on or off.
- PAS Level Adjustment: Use the '+' and '-' buttons to cycle through the Pedal Assist System levels (typically 3, 5, or 9 levels depending on configuration).
- Information Display: The 1.68" LCD screen shows essential information such as current speed, distance traveled, battery status, and PAS level.
- Speed Limit: The display may allow setting a speed limit (e.g., 0-61 km/h). Refer to the specific display manual for detailed settings.
- Headlight Control: Some displays allow control of the headlight directly.
For detailed instructions on your specific display model, please refer to the separate display manual or Varstrom's online resources.
8. Maintenance
Regular maintenance is crucial for the longevity and safe operation of your e-bike conversion kit.
- Regular Checks: Periodically inspect all bolts, nuts, and quick releases for tightness.
- Tire Pressure: Maintain correct tire pressure as recommended by the tire manufacturer.
- Brakes: Check brake pads for wear and ensure brake levers operate smoothly. Adjust as necessary.
- Chain and Drivetrain: Keep the chain clean and lubricated. Inspect gears for wear.
- Electrical Connections: Ensure all electrical connections are clean, dry, and securely plugged in. Avoid pulling on cables.
- Motor and Controller: Keep the motor and controller free from dirt and debris. Do not attempt to open the motor or controller housing.
- Battery Care: Follow the battery manufacturer's instructions for charging, storage, and maintenance.
- Cleaning: Clean the e-bike with a damp cloth. Avoid high-pressure washing directly on electrical components.
9. Troubleshooting
If you encounter issues with your e-bike kit, refer to the following common troubleshooting steps:
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor not assisting | Battery low or disconnected; PAS sensor not working; loose electrical connection; brake lever sensor engaged. | Check battery charge and connection. Inspect PAS sensor for proper alignment. Verify all cables are securely connected. Ensure brake levers are fully released. |
| Display not turning on | Battery disconnected or dead; loose display cable; faulty display. | Check battery connection and charge. Ensure display cable is firmly connected. If problem persists, contact support. |
| Inconsistent power delivery | Loose connections; PAS sensor issues; controller malfunction. | Check all electrical connections. Verify PAS sensor is clean and correctly positioned. Contact support if the issue continues. |
| Brakes not working effectively | Worn brake pads; misaligned calipers; air in hydraulic lines (if applicable). | Inspect and replace worn brake pads. Adjust brake calipers. Consult a bike mechanic for hydraulic brake issues. |
If you cannot resolve the issue using these steps, please contact Varstrom technical support for further assistance.
10. Warranty and Support
Varstrom is committed to providing quality products and customer satisfaction.
- Warranty: The motor comes with a one-year warranty for peace of mind.
- Return Policy: A one-month return period is offered.
- Service: One year repair or replacement service is available.
- Technical Guidance: Permanent technical guidance services are provided.
- Support Team: Our team of professional technicians based in the USA is available to provide technical support whenever needed.
For any questions, technical assistance, or warranty claims, please contact Varstrom customer service. Ensure you have your product model (RW28-1) and purchase details ready.
