1. Introduction
This manual provides comprehensive instructions for the installation, operation, and maintenance of the Varstrom TSDZ2B 48V 500W Mid Drive Ebike Conversion Kit with SW2-M58 Display. This kit is designed to convert standard bicycles into electric bikes, offering enhanced power and torque for various terrains. It is compatible with bikes featuring a 68-73mm bottom bracket.
2. Safety Information
Always prioritize safety when installing and operating your ebike conversion kit. Read all instructions carefully before beginning installation. Wear appropriate safety gear, including gloves and eye protection, during installation. Ensure all connections are secure and properly insulated. Regularly inspect your ebike for any signs of wear or damage, especially to electrical components and brakes. Adhere to local regulations regarding ebike usage and speed limits.
3. Package Contents
The Varstrom TSDZ2B Mid Drive Ebike Conversion Kit includes the following components:
- TSDZ2B Mid Drive Motor (with Integrated Controller)
- Brake Lever (Default) OR Brake Sensors (if requested)
- Thumb Throttle
- Chainwheel
- Cranks
- Speed Sensor & Magnets
- 1T4 Wireness (EB-BUS Waterproof Cable)
- Lock Nuts (1 set)
- Instruction Manual
- Wrench, Screws, Extension Cable
- LCD Display (SW2-M58)
Note: The battery needs to be purchased separately.
Figure 3.1: Overview of the TSDZ2B Mid Drive Ebike Conversion Kit components.
4. Compatibility
The TSDZ2B mid drive motor is compatible with bicycles that have a bottom bracket shell width of 68-73mm. It is suitable for various bike types including mountain bikes, city bikes, and tricycles. Ensure your bike's bottom bracket dimensions fall within this range for proper fitment.
Figure 4.1: Bottom bracket compatibility guide for the TSDZ2B motor.
5. Setup and Installation
This section guides you through the installation process of the TSDZ2B Mid Drive Ebike Conversion Kit. While the process is generally straightforward, careful attention to detail is crucial for safe and effective operation. For a visual guide, please refer to the installation video below.
Video 5.1: General installation guide for the Tongsheng Mid Drive Motor kit. This video demonstrates the overall process of converting a bicycle to an ebike using a similar mid-drive motor kit.
5.1. Removing the Crankset
- Remove the left crank arm using a crank arm puller.
- Remove the chainwheel from the drive side. A crank arm puller may be needed again.
- Remove the bottom bracket using a bottom bracket extractor tool.
- Clean the bottom bracket shell thoroughly to remove any dirt or debris.
Figure 5.1.1: Preparing the bottom bracket for motor installation.
5.2. Mid-Drive Motor Installation
- Attach the chainwheel (e.g., 44T) to the TSDZ2B motor using the provided M6 bolts. Ensure they are tightened securely.
- Carefully insert the motor into the bottom bracket shell from the drive side.
- Secure the motor using the Y-shaped motor mount bracket on the non-drive side.
- Install the M6 bolts using a 5mm Allen wrench to firmly attach the motor to the frame.
- Thread the gray lock nut onto the motor shaft from the non-drive side, with the flat side facing the bike. Tighten it using the provided wrench.
- Install and tighten the outer black lock nut with the same wrench.
Figure 5.2.1: TSDZ2B motor securely mounted to the bicycle frame.
5.3. Speed Sensor Installation
Attach the speed sensor to the chainstay, ensuring it is positioned correctly to detect the magnet on the wheel spoke. The distance between the sensor and the magnet should be 10-15mm. Use zip ties to secure the sensor cable along the frame.
Figure 5.3.1: Proper placement of the speed sensor and magnet.
5.4. Display and Controls Installation
- Mount the SW2-M58 LCD display securely on the handlebar.
- Install the thumb throttle and brake levers (or brake sensors) on the handlebar.
- Connect all cables from the display, throttle, brake levers/sensors, and speed sensor to the main 1T4 EB-BUS waterproof cable.
- Route and secure all cables neatly along the bike frame using zip ties.
Figure 5.4.1: SW2-M58 LCD Display on the handlebar.
Figure 5.4.2: Wiring diagram for the TSDZ2B Mid Drive Kit.
6. Operating Instructions
The TSDZ2B Mid Drive Ebike Conversion Kit offers three adaptable riding modes to suit various preferences and terrains:
- Pedal Assist Mode: The motor provides assistance based on your pedaling force, thanks to the high-precision torque sensor. This mode offers a smooth and intuitive riding experience, making pedaling easier and extending your range.
- Throttle Mode: Engage the thumb throttle for on-demand power without pedaling. This mode is ideal for quick acceleration or when you need a break from pedaling.
- Bike Mode: Ride your bicycle as a traditional unassisted bike, with the motor disengaged.
The SW2-M58 display provides real-time information such as speed, battery level, PAS level, total mileage, and single mileage. It also indicates error codes and low voltage warnings. The motor's output aligns with pedal movement, instantly ceasing upon pedal release for safety.
Figure 6.1: TSDZ2B Motor performance and riding modes.
7. Maintenance
Regular maintenance ensures the longevity and optimal performance of your TSDZ2B ebike kit. Keep the motor and electrical connections clean and dry. Periodically check all bolts and nuts for tightness, especially those securing the motor and cranks. Inspect cables for any signs of wear or damage. Ensure the chain is clean and lubricated. If you encounter any issues, refer to the troubleshooting section or contact customer support.
8. Troubleshooting
- Motor not fitting 68-73mm bottom bracket: Double-check your bike's bottom bracket dimensions. The TSDZ2B motor is specifically designed for 68-73mm bottom brackets.
- Need to switch brake levers to brake sensors: If your bike uses hydraulic brakes or integrated shifters, contact customer support with your order number to request replacement brake sensors.
- Battery not included: The battery is sold separately. Refer to the product page for compatible battery options.
- Display showing error codes: Consult the display's specific manual for error code definitions and troubleshooting steps.
9. Specifications
| Feature | Detail |
|---|---|
| Brand | Varstrom |
| Model Name | TSDZ2B |
| Voltage | 48V |
| Wattage | 500W |
| Motor Type | Brushless Geared Motor |
| Motor Position | Mid Crank |
| Controller | Integrated, inside the Motor |
| Shaft Standard | JIS |
| Operating Temperature | -10-45℃ |
| Display | SW2-M58 (Optional: 500C/B02N EKD01) |
| Chainwheel | Integrated |
| Max Torque | 100 N.m |
| Max Speed | 45 KM/H (on flat ground) |
| Motor Weight | 3.6 KG |
| Material | Aluminum |
10. Warranty and Support
The TSDZ2B Mid Drive Ebike Conversion Kit comes with a one-year warranty on the motor. Varstrom also provides lifetime technical support to ensure you have a smooth riding experience. If you have any questions, concerns, or require technical assistance, please do not hesitate to reach out to Varstrom customer support.
