Introduction
This manual provides essential information for the safe and efficient installation, operation, and maintenance of your Varstrom 250W Ebike Conversion Kit. Please read this manual thoroughly before attempting installation or use. Proper understanding and adherence to these instructions will ensure optimal performance and longevity of your ebike conversion kit.
1. Setup and Installation
1.1 Package Contents
Verify that all components are present in your package:
- 36V 250W Rear Hub Motor (for 26", 27.5", 28"/29"/700C wheel sizes)
- Controller with Control Box
- DZ40 Display
- Mechanical Brake Levers (pair) or Brake Sensor (optional)
- Thumb Throttle
- 1T4 Cable
- PAS Sensor (Left side by default, Right side optional)
- Downtube Battery 36V 13Ah (or other specified capacity)
1.2 Compatibility Requirements
Before installation, ensure your bicycle meets the following criteria:
- Rear Dropout (OLD): Your bicycle's rear dropout must be between 135 mm and 142 mm.
- Brake Type: The motor is compatible with bicycles equipped with disc brakes.
- Wheel Size: The kit is available for 26", 27.5", 28"/700C/29" wheel sizes. Ensure you have the correct kit for your wheel size.
1.3 Wiring Diagram
Follow the diagram carefully for correct component connection. All cable connectors are waterproof for durability.
2. Operating Instructions
2.1 Riding Modes
Your ebike conversion kit supports three distinct riding modes:
- Pure Electric Mode: Engages the motor directly via the thumb throttle, providing propulsion without pedaling.
- Pedal Assist Mode (PAS): The motor provides assistance as you pedal. The level of assistance can typically be adjusted via the display.
- Physical Riding Mode: The motor is disengaged, and the bicycle operates as a standard pedal bike.
2.2 DZ40 Display Operation
The DZ40 display provides crucial information and control over your ebike system.
- Screen: 1.3-inch LCD for clear visibility, even in direct sunlight.
- Information Displayed: Speed, battery status, headlight indicators, PAS level (0-5).
- Holder Size: Designed for handlebars with a 22.2 mm diameter.
3. Maintenance
Regular maintenance ensures the longevity and safe operation of your ebike conversion kit.
- Battery Care: Charge the battery regularly, even when not in use, to maintain its health. Avoid fully discharging the battery. Store in a cool, dry place.
- Motor Inspection: Periodically check the motor and wheel spokes for any damage or loose connections. The brushless motor is designed for low maintenance.
- Cable Connections: Ensure all waterproof connectors are securely fastened and free from dirt or moisture.
- Brake System: Regularly inspect brake levers and pads for wear and proper function. Adjust as necessary.
- General Cleaning: Keep the components clean, especially the motor and battery housing, using a damp cloth. Avoid high-pressure washing directly on electrical components.
4. Troubleshooting
If you encounter issues, refer to the following common troubleshooting steps:
- No Power to Display/Motor:
- Check if the battery is fully charged and properly seated.
- Ensure all cable connections are secure, especially the main power cable from the battery to the controller.
- Motor Not Assisting:
- Verify that Pedal Assist Mode (PAS) is enabled on the display and the PAS sensor is correctly installed and functioning.
- Check if the brake levers are fully released, as some systems cut motor power when brakes are applied.
- Inconsistent Power/Jerking:
- Inspect all wiring for damage or loose connections.
- Ensure the PAS sensor magnet ring is correctly positioned and not obstructed.
- Display Not Functioning Correctly:
- Check the display's cable connection to the controller.
- Ensure the battery voltage is within the applicable range for the display (24V/36V/48V).
For persistent issues, please contact customer support.
5. Specifications
5.1 Motor Specifications
- Type: Brushless Rear Hub Motor
- Voltage: 36V
- Power: 250W
- Maximum Torque: 35 Nm
- Maximum Speed: Up to 30 km/h
- Efficiency: ≥80%
- Controller: 36V 250W with 14A maximum current
5.2 Battery Specifications (36V 13Ah Downtube Battery)
- Voltage/Current: 36V 13Ah
- Energy: 468 Wh
- BMS: 30A
- Weight: 3 kg
- Install Position: Downtube
- Battery Cell: 18650-26E 2600mAh
- Cycle Life: 1000 times
- Dimensions: 368mm (14.5") x 90mm (3.5") x 89.5mm (3.52")
5.3 General Specifications
- Compatible Wheel Sizes: 26", 27.5", 28"/700C/29"
- Rear Dropout Compatibility: 135-142 mm
- Brake Compatibility: Disc Brakes
- Display: DZ40 LCD (1.3 inch)
- Included Components: PAS Sensor, Controller, Mechanical Brake Levers, Mini DZ40 Display, Thumb Throttle, 1T4 Cable.
6. Warranty Information
Varstrom products are covered by a limited warranty against manufacturing defects. The warranty period typically begins from the date of purchase. Please retain your proof of purchase for warranty claims. This warranty does not cover damage resulting from improper installation, misuse, neglect, accidents, or unauthorized modifications. For specific warranty terms and conditions, please refer to the documentation provided with your purchase or contact customer support.
7. Customer Support
If you have any questions, require technical assistance, or need to report an issue with your Varstrom Ebike Conversion Kit, please contact our customer support team. You can typically find contact information on our official website or through your retailer. When contacting support, please have your product model number and purchase date ready to expedite assistance.
