1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your BAFANG 48V 750W Rear Hub Motor Electric Bike Conversion Kit. Please read this manual thoroughly before attempting installation or operation to ensure safe and correct usage of the product.
Image 1.1: Overview of the BAFANG 48V 750W Rear Hub Motor Electric Bike Conversion Kit components.
2. Product Overview and Features
The BAFANG 48V 750W Rear Hub Motor Kit is designed to convert a standard bicycle into a powerful electric bike. It features a robust motor with high torque and an IPX5 waterproof rating for reliable performance in various conditions.
Key Features:
- Powerful 750W Motor: Delivers 80N.m of torque for strong acceleration and hill climbing.
- High Speed Capability: Achieves speeds up to 45 KM/H.
- Quiet Operation: Operates at a noise level of approximately 55dB.
- IPX5 Waterproof Rating: Motor and controller are protected against rain and splashes.
- Universal Fitment: Compatible with most 26", 27.5", and 700C (29") wheels.
- Dropout Spacing: Fits standard 135mm - 142mm rear dropout spacing.
- Brake Compatibility: Supports both V-Brakes and Disc Brakes.
- Cassette Compatibility: Designed for 10-speed cassettes.
- Intelligent Pedal Assist System (PAS): Offers 5 levels of pedal assistance.
- Flexible Power Options: Compatible with standard 48V/52V batteries (10Ah-20Ah) with a pre-installed XT60 connector.
Image 2.1: Internal structure of the BAFANG 48V 750W Rear Hub Motor.
3. Package Contents
The BAFANG 48V 750W Rear Hub Motor Conversion Kit includes the following components:
- Motor Wheel (26"/27.5"/700C options)
- Intelligent Controller
- PAS Sensor
- Throttle
- Brake Levers (or Brake Sensors)
- All necessary cables and connectors
- Installation tools
- Plastic straps
- 36V/250W stickers
- Headlight (Optional, may vary by kit)
- Ebike Display (Optional, sold separately)
- Ebike Battery (Optional, needs extra purchase)
Image 3.1: Packing list of the conversion kit components.
4. Compatibility
Ensure your bicycle meets the following compatibility requirements before installation:
- Wheel Size: Compatible with 26", 27.5", and 700C (29") wheels.
- Rear Dropout Spacing: Standard 135mm - 142mm.
- Cassette: Supports 10-speed cassettes. Not compatible with rotary freewheels.
- Brakes: Compatible with both V-Brakes and Disc Brakes.
Image 4.1: Wheel size and frame compatibility details.
Image 4.2: Cassette and brake system compatibility.
5. Setup and Installation
The installation process involves replacing your bicycle's rear wheel with the BAFANG motor wheel and connecting the various electrical components. It is recommended to have basic bicycle maintenance knowledge or seek professional assistance if unsure.
General Installation Steps:
- Prepare Your Bike: Ensure your bike is stable, preferably on a repair stand. Remove the existing rear wheel.
- Install Motor Wheel: Mount the BAFANG motor wheel into the rear dropout, ensuring proper alignment and securing it with the provided nuts.
- Install PAS Sensor: Attach the pedal assist sensor to your bike's bottom bracket area.
- Install Throttle and Brake Levers: Mount the throttle and brake levers (or brake sensors) onto the handlebars.
- Mount Controller: Secure the intelligent controller to your bike frame in a protected location.
- Connect Wiring: Follow the wiring diagram carefully to connect all components to the controller. Ensure all connections are secure and waterproof.
- Install Battery (Optional): If using a BAFANG compatible battery, mount it securely to the frame and connect it to the controller.
- Install Display (Optional): Mount the LCD display on the handlebars and connect it to the controller.
- Cable Management: Use plastic straps to neatly secure all cables along the frame, preventing interference with moving parts.
- Final Checks: Before riding, check all connections, ensure brakes are functioning correctly, and verify the motor engages properly.
Image 5.1: Detailed connection instruction diagram for the conversion kit.
Image 5.2: Brake lever and sensor options.
Installation Video:
Video 5.1: An instructional video demonstrating the installation process for a hub motor kit, providing visual guidance for assembly and connection.
6. Operating Instructions
Once installed, your e-bike conversion kit is ready for operation. The primary control is through the Pedal Assist System (PAS) and an optional LCD display.
Pedal Assist System (PAS):
The 5-level PAS provides automatic power assistance as you pedal, reducing effort and extending your range. The level of assistance can typically be adjusted via the control buttons on your LCD display or a separate control pad.
LCD Display (Optional):
If you have purchased a compatible LCD display (e.g., 500C, DPC18, EKD01, SW2-M25, DZ40), it will provide real-time information and control over your e-bike system. Common functions include:
- Current Speed
- Battery Level/Percentage
- Distance Traveled
- Assist Mode/Level
- Headlight Control (if connected)
Refer to your specific LCD display's manual for detailed operating instructions and advanced settings.
Image 6.1: Overview of compatible LCD display options and their features.
7. Maintenance
Regular maintenance ensures the longevity and optimal performance of your BAFANG conversion kit.
- Cleanliness: Keep the motor, controller, and connections clean. Avoid high-pressure washing directly on electrical components.
- Connections: Periodically check all electrical connections for tightness and corrosion.
- Cables: Inspect cables for any signs of wear, fraying, or damage. Replace damaged cables immediately.
- Battery Care: Follow the manufacturer's instructions for your specific battery regarding charging, storage, and temperature.
- General Bike Maintenance: Continue regular maintenance of your bicycle's mechanical components, including brakes, tires, and chain.
8. Troubleshooting
If you encounter issues with your BAFANG conversion kit, consider the following common troubleshooting steps:
- No Power: Check battery connection, ensure the battery is charged, and verify all electrical connections are secure.
- Motor Not Engaging: Ensure the PAS sensor is correctly installed and aligned. Check if the brake levers are fully released, as some systems have cut-off switches.
- Display Errors: Consult your display's specific manual for error codes and their meanings. Often, re-seating connections can resolve minor communication errors.
- Reduced Performance: Check tire pressure, battery charge level, and ensure no mechanical drag from brakes or drivetrain.
For persistent issues, contact BAFANG customer support or a qualified e-bike technician.
9. Specifications
Detailed specifications for the BAFANG 48V 750W Rear Hub Motor Kit:
| Feature | Specification |
|---|---|
| Brand Name | BAFANG |
| Model Number | US JJ CS G0900 Rear DZ 50 |
| Motor Type | Rear Hub Motor (Cassette) |
| Rated Voltage | 48V |
| Rated Power | 750W |
| Maximum Torque | 80N.m |
| Max Speed | 45 KM/H |
| Noise Level | < 55dB |
| Waterproof Rating | IPX5 |
| Compatible Wheel Sizes | 26", 27.5", 700C (29") |
| Compatible Dropout Spacing | 135mm - 142mm |
| Brake Compatibility | V-Brake & Disc Brake |
| Cassette Compatibility | 10-speed cassettes |
| Operating Temperature | -20°C ~ 45°C |
| Battery Compatibility | 48V/52V (10Ah-20Ah) |
| Connector Type | XT60 (for battery) |
Image 9.1: Comprehensive motor specifications.
Image 9.2: Comparison of various compatible LCD displays.
Image 9.3: Compatible battery types and their parameters.
10. Warranty and Support
Your BAFANG 48V 750W Rear Hub Motor Electric Bike Conversion Kit comes with the following warranty:
- Returns: 30 days from the date of purchase.
- Repair or Replace: 365 days from the date of purchase.
For warranty claims, technical support, or any inquiries, please contact BAFANG customer service through your purchase platform or the official BAFANG website.
