1. Introduction
This manual provides comprehensive instructions for the installation, operation, and maintenance of your Varstrom TSDZ8/TSDZ16 Torque Sensor Mid Drive Motor Kit. This kit is designed to convert standard bicycles into electric bicycles, offering enhanced power and a natural riding experience through its torque-sensing technology. Please read this manual thoroughly before installation and use to ensure proper function and safety.
2. Product Overview
The Varstrom TSDZ8/TSDZ16 Mid Drive Motor Kit integrates a powerful motor with a torque sensor for responsive pedal assistance. It is suitable for both mountain and road bicycles with 68-73mm bottom brackets.
Key Features:
- 750W/1000W Power Output: Provides robust assistance for varied terrains, including uphill sections.
- Torque Sensor Technology: Detects pedaling effort for a smooth, intuitive, and natural riding experience.
- Mid-Drive Motor Configuration: Positioned at the bike’s bottom bracket for balanced weight distribution, improved handling, and better efficiency.
- Universal Fit: Compatible with 68-73mm bottom bracket lengths and 34-36mm inner diameters.
- Durable Construction: Designed for long-lasting performance in various riding conditions.
What's in the Box:
The standard kit includes the following components:
Image: A visual representation of the components included in the Varstrom TSDZ8/TSDZ16 Mid Drive Motor Kit. This includes the TSDZ8 motor, DZ40 display, optional battery, brake levers or sensors, 1T4 cable, speed sensor, thumb throttle, ebike crank arms, cable ties, wrench, washers, and an installation manual.
- Varstrom TSDZ8/TSDZ16 Mid Drive Motor (48V 750W or 1000W)
- DZ40 Display (Upgradable)
- Battery (Optional, sold separately or as part of a kit variant)
- Brake Levers (Default) or Brake Sensors
- Thumb Throttle
- Cranks and Chainwheel (44T/46T)
- Speed Sensor & Magnets
- 1T4 Wiring Harness
- Lock Nuts (1 set)
- Installation Manual
3. Specifications
Detailed specifications for the Varstrom TSDZ8/TSDZ16 Mid Drive Motor Kit are provided below:
Image: A table comparing the specifications of TSDZ2B, TSDZ8, and TSDZ16 mid-drive motors, including rated voltage, power, max torque, max speed, weight, BB width, and waterproof grade.
| Specification | TSDZ8 | TSDZ16 |
|---|---|---|
| Voltage | 48V | 48V |
| Wattage | 750W | 1000W |
| Motor Type | Brushless Geared Motor | |
| Motor Position | Mid Mounted | |
| Controller | Integrated, inside the Motor | |
| Shaft Standard | JIS | |
| Operating Temperature | -10 to 45 ℃ | |
| Display | DZ40 Display (Upgradable) | |
| Chainwheel | 44T/46T | |
| Max Torque | 120 N.m | 160 N.m |
| Max Speed | 50-55 KM/H | 55-60 KM/H |
| Weight | Approx. 4.7 KG | Approx. 6 KG |
| BB Width Compatibility | 68-73mm | |
| Waterproof Grade | IPX5 | IPX6 |
Battery Parameters (Optional):
If an optional battery is purchased, refer to the following general parameters. Specific battery models may vary.
Image: A detailed table outlining parameters for various Varstrom battery options, including voltage, capacity (Ah), watt-hours (Wh), cell type, BMS, charge voltage, weight, USB port availability, cycle life, and protection functions.
4. Setup and Installation
Proper installation is crucial for the performance and safety of your e-bike conversion kit. It is recommended that installation be performed by an experienced bicycle mechanic if you are unfamiliar with bicycle component installation.
Motor Compatibility:
The TSDZ8/TSDZ16 motor is designed for bicycles with a bottom bracket shell width of 68-73mm and an inner diameter of 34-36mm. Verify your bicycle's bottom bracket dimensions before proceeding with installation.
Image: A diagram illustrating the dimensions of the TSDZ8 motor and a bicycle frame's bottom bracket area, highlighting the compatible 68-73mm bottom bracket width and 33.5-36mm inner diameter.
Wiring Diagram:
Follow the wiring diagram carefully to connect all components correctly. Ensure all connections are secure and waterproof where applicable.
Image: A detailed wiring diagram showing how the TSDZ8/TSDZ16 mid-drive motor connects to various components including the speed sensor, battery, shift sensor (optional), brake levers/sensors, thumb throttle, 1T4 E-BUS cable, and DZ40 display. Each connection point is clearly labeled.
- Motor Installation: Mount the mid-drive motor into the bottom bracket shell according to the specific instructions provided in the separate installation manual.
- Chainwheel and Cranks: Install the chainwheel and crank arms onto the motor's shaft.
- Display Installation: Mount the DZ40 display on the handlebar.
- Brake Levers/Sensors: Replace existing brake levers with the provided ones or install brake sensors.
- Thumb Throttle: Install the thumb throttle on the handlebar.
- Speed Sensor: Attach the speed sensor to the chainstay and the magnet to a spoke on the rear wheel. Ensure proper alignment.
- Battery Installation: Securely mount the battery (if included) to the bicycle frame.
- Wiring Connections: Connect all components to the 1T4 wiring harness and then to the motor, following the color-coded connectors as shown in the diagram. Ensure all connections are tight and protected from moisture.
5. Operation
The Varstrom TSDZ8/TSDZ16 kit offers multiple riding modes and features controlled via the DZ40 display.
Image: A comparison chart detailing features of three e-bike displays: EKD01, M58, and DZ40. The DZ40 display, included with this kit, features a 1.68" IPS screen, 22.2mm handlebar diameter, 24V/36V/48V/52V operating voltage, and English language support. It supports speed limit and battery percentage display but lacks a USB port, boot password, and light sensor.
DZ40 Display Functions:
- Screen: 1.68" IPS display.
- Operating Voltage: 24V/36V/48V/52V.
- Information Displayed: Speed, battery percentage, and assistance level.
- Controls: Buttons for power on/off, changing assistance levels, and accessing basic settings.
Riding Modes:
Image: A graphic highlighting the features of the Varstrom TSDZ8 48V 750W mid-drive motor, including Electrical Throttle mode, Pedal Assist mode, and Walk Assist mode, along with a torque curve and specifications like IPX5 waterproof rating and 4.7KG weight.
- Pedal Assist Mode: The motor provides assistance based on your pedaling effort, detected by the torque sensor. This offers a natural and intuitive riding feel. Adjust assistance levels via the display.
- Electrical Throttle Mode: Use the thumb throttle to engage motor power independently of pedaling. This mode is typically used for quick acceleration or maintaining speed without pedaling.
- Walk Assist Mode: Provides low-speed motor assistance to help push the bicycle when walking alongside it.
Refer to the detailed display manual for specific instructions on navigating menus, adjusting settings, and understanding error codes.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your Varstrom e-bike conversion kit.
- Cleaning: Keep the motor, battery, and display clean. Use a damp cloth to wipe surfaces. Avoid high-pressure washing directly on electrical components.
- Connections: Periodically check all electrical connections for tightness and corrosion. Ensure waterproof connectors are properly sealed.
- Cables: Inspect all cables for wear, cuts, or damage. Replace damaged cables immediately.
- Motor Mount: Ensure the motor is securely mounted to the bottom bracket. Check mounting bolts for tightness.
- Chain and Drivetrain: Maintain your bicycle's chain and drivetrain (chainwheel, cassette, derailleur) as you would a regular bicycle. Keep the chain clean and lubricated.
- Battery Care: Follow the battery manufacturer's instructions for charging, storage, and temperature guidelines to maximize battery life. Avoid fully discharging the battery.
- General Bicycle Maintenance: Continue with regular maintenance of your bicycle's brakes, tires, and other components.
7. Troubleshooting
This section addresses common issues you might encounter. For more complex problems, contact Varstrom customer support.
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor not providing assistance | Battery low or off Loose electrical connection Speed sensor misalignment Display error | Check battery charge and ensure it's powered on Inspect all cable connections, especially to the motor and battery Verify speed sensor and magnet alignment Check display for error codes and consult display manual |
| Display not turning on | Battery off or discharged Loose display cable connection | Ensure battery is charged and powered on Check the connection between the display and the main wiring harness |
| Assistance feels inconsistent or jerky | Torque sensor calibration issue Loose motor mount Chain/drivetrain issue | Consult display manual for torque sensor calibration Check motor mounting bolts for tightness Inspect chain and drivetrain for wear or damage |
| Unusual noises from motor | Loose components Internal motor issue | Check all external components for tightness If noise persists, discontinue use and contact support |
8. Warranty and Support
Varstrom products are designed for reliability and performance. In the event of an issue, please refer to the warranty information below.
Warranty Information:
- Return Policy: 30 days from the date of purchase.
- Repair or Replacement: 365 days from the date of purchase for manufacturing defects.
Please retain your proof of purchase for warranty claims.
Customer Support:
For technical assistance, troubleshooting beyond this manual, or warranty claims, please contact Varstrom customer support through the retailer where the product was purchased or visit the official Varstrom website for contact information.
