Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your BAFANG Mid Drive Kit. This kit is designed to convert standard bicycles into electric bikes, offering enhanced performance and riding experience. Please read this manual thoroughly before beginning installation or operation to ensure safe and correct usage.
The BAFANG Mid Drive Motor is available in 500W, 750W, and 1000W variants, compatible with various bottom bracket sizes (68-73mm, 100mm, 120mm length, and 33.5-36mm inner diameter). It features upgraded current output stability, dual Hall speed sensors, and battery communication functions (requires a compatible battery). The kit includes essential components such as the motor, display (optional), sprocket, speed sensor, brake levers/sensors, crank, cables, throttle, locking nuts, installation tools, and a headlight.
Setup and Installation
Proper installation is crucial for the safe and efficient operation of your BAFANG Mid Drive Kit. Follow these steps carefully.
Video: BAFANG BBS Mid Drive Motor for eBike - Installation Guide. This video provides a visual guide to the installation process.
1. Package Contents
Before starting, verify all components are present in your package:
- BAFANG BBS01/BBS02B/BBS-HD Mid Drive Motor
- Ebike Display (Optional: VD03, EKD01, VD618, VD61, DPC010, DPC080)
- Sprocket (Chainwheel)
- Dual Hall Speed Sensor and Magnet
- Mechanical Brake Lever or Brake Sensor
- Crank Arms
- 1T4 EB-BUS Cable
- Thumb Throttle
- Locking Nuts
- Installation Tool (Wrench)
- Headlight
- Battery (Optional, if purchased with kit)
Image: Overview of the BAFANG Mid Drive Kit components, including the motor, display, battery, and various accessories for installation.
2. Removing the Crankset
Begin by removing the existing crankset from your bicycle. This typically involves:
- Remove the left crank arm using a crank arm puller.
- Remove the chainwheel from the drive side. A puller tool may be needed again.
- Use a bottom bracket extractor tool to remove the existing bottom bracket.
- Clean the bottom bracket shell thoroughly. Apply a thin layer of lubricant to remove any dirt or debris.
3. Mid-Drive Motor Installation
Install the BAFANG mid-drive motor into the bottom bracket shell:
- Attach the 44-tooth chainwheel to the BAFANG motor. Ensure the M6 bolts are tightened securely.
- Carefully push the motor into the bottom bracket shell of your bike frame.
- Secure the motor using the Y-shaped motor mount bracket on the left-hand side of the bike.
- Install and tighten the M6 bolts using a 5mm Allen wrench.
- Install the grey lock nut with the flat side facing the bike. The indicator arrow should go clockwise. Tighten with the provided wrench.
- Install and tighten the outer black lock nut with the same wrench.
4. Speed Sensor Installation
The speed sensor is essential for accurate speed readings and motor function:
- For longer bikes, a cable extension may be required for the speed sensor.
- To find the correct mounting spot, use the small red LED indicator light on the sensor. When the sensor detects the magnetic field from the wheel magnet, the light will blink.
- Securely attach the speed sensor and its magnet to the rear wheel area, ensuring proper alignment for detection.
5. Display Mount and Controls
Mount the display and other controls on the handlebar:
- Mount the display unit securely on the handlebar. For custom frames, a custom bracket may be needed to position the display correctly.
- Tighten the controller and the thumb throttle on the handlebar.
- Install the brake levers. BAFANG kits come with brake levers that have motor inhibitors, cutting off motor power when brakes are applied. If your bike has hydraulic brakes, brake sensors can be installed instead.
- To install brake sensors, add the provided magnet inside the brake lever and adjust its position until the brake signal is shown on the main display when the brake is engaged.
6. Cable Management and Headlight
Connect and organize all cables for a clean and safe setup:
- Connect all motor, display, sensor, and battery cables. Ensure all connections are secure.
- Organize the cables neatly along the bike frame using the provided zip ties.
- Install the bright LED headlight (often included as a gift). The installation is straightforward, and the light provides excellent illumination.
Image: A BAFANG Mid Drive Kit fully installed on a custom bicycle, showcasing the motor, battery, and display integration.
Operation
Once installed, operating your BAFANG e-bike is intuitive:
- Power On/Off: Use the power button on the display unit to turn the system on or off.
- Pedal Assist System (PAS): The motor provides assistance as you pedal. Most displays offer multiple PAS levels (e.g., 3, 5, or 9 levels) to adjust the level of assistance.
- Thumb Throttle: The thumb throttle allows for motor-only propulsion without pedaling.
- Display Functions: Your chosen display will show key information such as speed, battery level, assist level, and trip data. Refer to your specific display's manual for detailed functions and parameter modification (some BAFANG displays allow parameter changes via the display or BAFANG GO+ APP).
- Brake Cut-off: The motor will automatically cut off power when the brake levers/sensors are engaged, ensuring safety.
Maintenance
Regular maintenance ensures the longevity and optimal performance of your BAFANG Mid Drive Kit:
- Cleaning: Keep the motor, battery, and display clean. Avoid high-pressure washing directly on electrical components.
- Connections: Periodically check all electrical connections to ensure they are secure and free from corrosion.
- Chain and Sprocket: Keep the chain clean and lubricated. Inspect the sprocket for wear and replace if necessary.
- Battery Care: Follow the battery manufacturer's guidelines for charging and storage. Avoid fully discharging the battery and store it in a cool, dry place.
- General Bike Maintenance: Continue regular maintenance of your bicycle's mechanical components, including brakes, tires, and gears.
Troubleshooting
Here are some common issues and their potential solutions:
- Motor Not Assisting:
- Check battery charge level.
- Ensure all cables are securely connected.
- Verify the display is powered on and the assist level is not set to zero.
- Check brake levers/sensors; ensure they are not engaged, cutting off motor power.
- Inaccurate Speed Reading:
- Check the alignment of the speed sensor and its magnet. Ensure the magnet passes close enough to the sensor.
- Inspect the speed sensor cable for damage.
- Display Not Turning On:
- Check battery connection and charge.
- Inspect the display cable for damage.
- Unusual Noises from Motor:
- Ensure the motor is securely mounted and all nuts are tightened.
- Check for any foreign objects near the motor or chainwheel.
If you encounter persistent issues, please refer to the detailed troubleshooting section in the full user manual or contact BAFANG customer support.
Specifications
| Feature | Detail |
|---|---|
| Brand | BAFANG |
| Motor Type | Mid Drive Motor (BBS02B CAN Bus) |
| Power Options | 500W, 750W, 1000W |
| Torque (approx.) | 500W: 100 N.m, 750W: 120 N.m, 1000W: 160 N.m |
| Bottom Bracket Compatibility | 68-73mm, 100mm, 120mm length; 33.5-36mm inner diameter |
| Display Options | VD03, EKD01, VD618, VD61, DPC010, DPC080 (CAN protocol) |
| Battery Compatibility | 48V 13Ah/17.5Ah/19.2Ah/20Ah, 52V 20Ah (XT60 connector) |
| Color | Black |
| Model Number | US JJ DZ 500/750/1000W Mid Drive Kit |
Image: Detailed motor specifications for 500W, 750W, and 1000W variants, including torque, weight, and max speed.
Image: Comparison table of various BAFANG display options, highlighting screen size, voltage compatibility, and features like USB port and light sensor.
Warranty and Support
Your BAFANG Mid Drive Kit comes with a warranty covering manufacturing defects. The warranty description states: 30 days return, 365 days repair or replace.
For any missing components, technical assistance, or warranty claims, please contact BAFANG customer support. Ensure you have your product model number and purchase details ready for faster service.
