BAFANG Ebike Conversion Kit User Manual

1. Introduction

Thank you for choosing the BAFANG Ebike Conversion Kit. This manual provides essential information for the proper installation, operation, and maintenance of your new ebike system. Please read this manual thoroughly before attempting installation or use to ensure safety and optimal performance.

This kit is designed to transform your standard bicycle into a powerful electric bike, offering enhanced mobility and an enjoyable riding experience. It features a robust rear hub motor, intelligent controller system, and optional battery and display components.

Image: Overview of the BAFANG Ebike Conversion Kit components, including the rear hub motor wheel, controller, display, battery, and various cables.

2. Packing List

Please verify that all components listed below are included in your package. If any items are missing or damaged, contact customer support immediately.

• BAFANG Rear Hub Motor (pre-installed in wheel, optional wheel size)
• Controller Box
• Motor Controller
• Optional Display (e.g., DZ40, DM03, 500C, EKD01, SWM58, C18, P860ML)
• PAS Sensor (Left)
• Thumb Throttle
• 1T4 Cable (main wiring harness)
• Headlight (included)
• Brake Levers (default, or brake sensor if requested)
• Plastic Straps
• Sticker (product information)
• Optional Battery (various models like Shark, Max Shark, Downtube Yingwu, Rear Rack)
• Optional Charger (for battery)

Image: Visual representation of the components included in the BAFANG Ebike Conversion Kit package.

3. Specifications

Motor Specifications

Image: Detailed comparison of 48V 750W and 48V 500W BAFANG Rear Hub Motors, including dimensions, performance metrics, and compatibility.

General Product Specifications

• Bike Type: Electric Bike
• Age Range: Adult
• Brand: BAFANG
• Number of Speeds: Up to 10-speed cassettes supported
• Color: Slivery
• Frame Material: Aluminum (for compatible bikes)
• Suspension Type: Dual (compatible with dual suspension bikes)
• Special Feature: Digital Display (optional), Durable
• Power Source: Electric motor
• Assembly Required: Yes
• Electric Assist Type: Pedal-assist

4. Compatibility

This BAFANG Ebike Conversion Kit is designed for broad compatibility with various bicycle types. Please ensure your bike meets the following requirements:

• Rear Dropout Width: Your bike's rear dropout width must be between 135mm and 142mm.
• Cassette Compatibility: Supports up to 10-speed cassettes. Note: Flywheel is not included.
• Brake System: Compatible with both V-brakes and disc brake systems.
• Wheel Size: Available for 20", 26", 27.5", and 700C wheel sizes. Ensure you select the correct kit for your bike's wheel size.

Image: Diagram illustrating rear dropout measurement (135-142mm), cassette compatibility, and brake system compatibility (disc brake and rim brake).

How to Choose the Correct Wheel Size

To determine the correct wheel size for your kit, check the label marked on your tire. For example, if it says "26 x 1.95", your tire is 26 inches. The kit is available for 20", 26", 27.5", and 700C (28"/29") rim diameters.

Image: Guide on how to identify your bike's tire size and corresponding rim diameter for selecting the correct conversion kit.

5. Installation

The BAFANG Ebike Conversion Kit is designed for user-friendly installation. Comprehensive manuals and video guides are available to assist you. Below is a general overview of the wiring connections.

Wiring Diagram (750W Rear Hub Motor)

Image: Detailed wiring diagram for the 750W BAFANG Rear Hub Motor kit, showing connections for throttle, brake levers, display, PAS sensor, battery, headlight, and taillight.

Wiring Diagram (500W Rear Hub Motor)

Image: Detailed wiring diagram for the 500W BAFANG Rear Hub Motor kit, showing connections for throttle, brake levers, display, PAS sensor, battery, headlight, and taillight.

Key Installation Steps:

1. Prepare Your Bike: Remove the existing rear wheel and any unnecessary components.
2. Install the Motor Wheel: Mount the BAFANG rear hub motor wheel into your bike's rear dropouts, ensuring proper alignment.
3. Mount Components: Install the controller box, display, throttle, and PAS sensor in their designated locations on the bike frame and handlebars.
4. Connect Wiring: Follow the provided wiring diagrams carefully. Use the 1T4 cable to connect the main components. Ensure all connections are secure and waterproof.
5. Install Battery (Optional): If you purchased a battery, mount it securely to your bike frame.
6. Cable Management: Secure all cables with plastic straps to prevent interference with moving parts and ensure a clean appearance.
7. Initial Test: Before riding, perform a static test to ensure all components are functioning correctly.

6. Operation

Your BAFANG Ebike Conversion Kit offers multiple riding modes for a versatile experience:

• Throttle Mode: Provides power on demand, similar to a motorcycle.
• Pedal Assist System (PAS) Mode: The motor provides assistance as you pedal. This system typically has multiple levels (e.g., 0-5 or 0-9) that can be adjusted via the display.
• Walk Assist Mode: Provides low-speed assistance for pushing the bike while walking.
• Pure Cycling Mode: The motor is off, and you pedal the bike like a traditional bicycle.

Smart LCD Display (Optional)

If you have an optional smart LCD display, it provides real-time insights and control over your ebike system. Features may include:

• Battery level indicator
• Current speed display
• Trip mileage and total odometer
• PAS level selection
• Error diagnostics
• Adjustable speed limits
• USB charging port for smartphones (on some models)
• Automatic light sensor for headlight (on some models)

Image: Overview of various BAFANG high-tech ebike display models (DZ40, DM03, 500C, EKD01, SWM58, C18, P860ML) with their features and specifications.

7. Maintenance

Regular maintenance ensures the longevity and optimal performance of your BAFANG Ebike Conversion Kit.

• Cleaning: Regularly clean the motor, controller, and battery with a damp cloth. Avoid using high-pressure water jets directly on electrical components.
• Water Resistance: The motor has an IPX5 waterproof design, protecting against splashes. However, avoid submerging the motor or other electrical components in water.
• Cable Inspection: Periodically check all cables and connectors for wear, damage, or loose connections. Ensure waterproof connectors are properly sealed.
• Battery Care:
  • Charge the battery regularly, even if not in use, to maintain its health.
  • Store the battery in a cool, dry place.
  • Avoid fully discharging the battery frequently.
  • The battery features an anti-theft lock and BMS security system for protection.
• Motor Inspection: Listen for any unusual noises from the motor during operation. The motor is designed for quiet operation (<55dB).
• General Bike Maintenance: Continue to perform regular maintenance on your bicycle's mechanical components (brakes, chain, tires, gears) as you would with a standard bike.

Image: Information on BAFANG ebike battery features, including 100% tested cells, 85% capacity after 1000 cycles, waterproof technology, BMS security system, anti-theft lock, and USB port connection.

8. Troubleshooting

This section provides solutions to common issues you might encounter. For more complex problems, please refer to the detailed video guides or contact customer support.

9. Warranty and Support

BAFANG is committed to providing high-quality products and excellent customer service.

• Warranty: This product comes with a one-year repair or replacement service from the date of purchase.
• Returns: A 30-day return policy is available for this product.
• Technical Guidance: We offer lifetime technical guidance service to assist you with any questions or issues you may encounter during the product's lifespan.
• Manufacturer: Bafang Electric (Suzhou) Co., Ltd.
• Seller: Greenergia

For any inquiries, technical assistance, or warranty claims, please contact the seller or BAFANG customer support through the platform where you purchased the product. Providing your order number and a detailed description of the issue will help expedite the support process.