1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your BAFANG BBS02B or BBS-HD Mid Drive Motor Kit. Please read this manual thoroughly before attempting installation or operation to ensure proper function and safety. This kit is designed to convert standard bicycles into electric bicycles (e-bikes) with enhanced power and control.
2. Safety Information
- Always wear a helmet and appropriate safety gear when riding your e-bike.
- Ensure all connections are secure and waterproof before riding, especially in wet conditions.
- Regularly inspect your e-bike for any loose parts, damaged wires, or unusual noises.
- Do not attempt to modify the motor or battery system beyond the instructions provided. Unauthorized modifications can lead to serious injury or product damage.
- Keep children and pets away from the e-bike during installation and maintenance.
- Familiarize yourself with local e-bike regulations and laws before riding.
3. Package Contents
Your BAFANG Mid Drive Motor Kit includes the following components:
- Mid Drive Motor (BBS02B or BBS-HD)
- Sprocket / Chainring
- Crankshaft
- Throttle
- Brake Sensor (or Brake Levers with motor inhibitor)
- Speed Sensor and Magnet
- Installation Tools (Wrench, Crank Puller, Bottom Bracket Removal Tool)
- All necessary Cables (E-BUS 1T4 Cable, Taillight Cable)
- LCD Display (Optional, various models available)
- Battery and Charger (Optional, if selected)
- Nuts and Bolts for installation
- Instruction Manual
The image above illustrates the typical components found in your kit, including the mid-drive motor, display, various sensors, cables, and tools for assembly.
4. Product Specifications
The BAFANG Mid Drive Motor Kit offers robust performance with various power options. Key specifications are detailed below:
| Specification | Value |
|---|---|
| Brand | BAFANG |
| Motor Type | Mid Drive Motor (BBS02B / BBS-HD) |
| Rated Power Options | 500W, 750W, 1000W |
| Max Torque | 100Nm (500W), 120Nm (750W), 160Nm (1000W) |
| Max Speed | 38-45KM/H (500W), 45-55KM/H (750W), 50-60KM/H (1000W) |
| Voltage Compatibility | 36V, 48V, 52V |
| Bottom Bracket Compatibility | 68-73mm, 100mm, 120mm |
| CAN Bus Technology | Supported for superior control and smooth power delivery |
| Display Options | VD03, VD618, VD61, DPC080, DPC010, VD04, EKD01, P860ML (depending on kit) |
| USB Programmable | Yes (with optional USB programming cable or programmable display) |
This image provides a visual summary of the motor specifications, highlighting the different power outputs and their corresponding torque, weight, and maximum speed capabilities.
5. Compatibility
5.1 Bottom Bracket Compatibility
The BAFANG Mid Drive Motor Kit is designed for universal fit on most standard bicycles. It is compatible with bottom brackets of 68-73mm, 100mm, or 120mm width. To ensure compatibility, measure your bike's bottom bracket length and inner diameter (between 33.5-36mm).
This image illustrates the dimensions for BBS01/BBS02 and BBS-HD motors and how they fit into different bottom bracket sizes. It also shows how to measure your bike's bottom bracket for proper fitment.
5.2 Frame Compatibility
The kit is suitable for most mountain, road, and commuter bikes. Note: It is not compatible with carbon fiber frames or coaster brake (pedal brake) systems. Ensure the sprocket will not hit the chain stay of your bike.
This visual guide provides steps to verify frame compatibility, including measuring the inner diameter and bottom bracket length, and checking for chainring clearance. It also highlights incompatible frame types like carbon fiber and bikes with belt drive chainrings or coaster brakes.
5.3 Battery Compatibility
This motor is compatible with BAFANG batteries and standard, universal 48V or 52V e-bike batteries. The motor is equipped with an XT60 male connector; ensure your battery connector is compatible.
The table in this image provides detailed parameters for different BAFANG battery options, including their capacity, cell type, BMS, and physical dimensions, aiding in selection and compatibility checks.
6. Installation Guide (Setup)
This section outlines the steps for installing your BAFANG Mid Drive Motor Kit. For a visual guide, please refer to the installation video below.
6.1 Pre-Installation
- Prepare Your Bike: Ensure your bike is clean and stable. Remove the existing crankset, bottom bracket, and any other components that may interfere with the motor installation.
- Clean Bottom Bracket Shell: Thoroughly clean the bottom bracket shell of your bike frame. Apply a layer of lubricant to remove any dirt or debris.
6.2 Motor Installation
- Attach Chainring: Secure the chosen chainring (e.g., 44T) to the BAFANG mid-drive motor using the provided bolts.
- Insert Motor: Carefully push the motor into the bottom bracket shell from the right-hand side of the bike.
- Secure Motor: On the left-hand side, install the Y-shaped motor mount bracket. Secure it with the M6 bolts using a 5mm Allen wrench.
- Install Lock Nuts: First, install the grey lock nut with the flat side facing the bike. The indicator arrow should go clockwise. Tighten it with the provided wrench. Then, install and tighten the outer black lock nut with the same wrench.
6.3 Display and Controls Installation
- Mount Display: Attach the LCD display to your handlebar. Ensure it is securely fastened and positioned for easy viewing.
- Install Throttle and Controller: Mount the thumb throttle and the control pad (if separate) on the handlebar, next to the grips.
- Brake Levers/Sensors: Replace your existing brake levers with the provided brake levers that include motor inhibitors, or install the brake sensors on your existing hydraulic brakes. The brake sensors attach to your brake levers and cut motor power when activated.
The image on the left shows a complete brake lever with an integrated motor inhibitor, while the image on the right displays separate brake sensors designed for hydraulic brake systems.
6.4 Speed Sensor Installation
Attach the speed sensor to the chain stay of your bike. Secure the magnet to a spoke on your rear wheel. Ensure a distance of 5-8mm between the speed sensor and the magnet. Use the small red LED indicator on the sensor to find the correct position; it will blink when the magnet passes by.
This image shows the speed sensor and its corresponding magnet, which are crucial for the display to accurately measure and show your e-bike's speed.
6.5 Wiring
Connect all components to the main E-BUS 1T4 cable and then to the motor. Use the provided zip ties to organize and secure all cables along the bike frame for a clean and safe setup. Ensure all connections are firm and waterproof.
This diagram illustrates how to connect the throttle, brake levers, display, speed sensor, headlight, battery, and rear lamp to the mid-drive motor via the E-BUS 1T4 cable.
7. Operation
Your BAFANG e-bike conversion kit offers multiple modes of operation for a versatile riding experience.
7.1 Riding Modes
- Pedal-Assist Mode: The motor provides assistance as you pedal. The level of assistance can be adjusted via the display. Features a slow start function for smooth acceleration.
- Throttle Mode: Engage the throttle for motor power without pedaling. This mode provides instant acceleration.
- Walk Assist Mode: Provides low-speed motor assistance (e.g., 6KM/H) to help you push the bike uphill or through crowded areas. Useful for climbing slopes up to 15%.
7.2 LCD Display Functions
The LCD display provides essential riding information and allows for customization of motor settings. Common display features include speed, battery level, assist level, trip distance, and time.
This image showcases several BAFANG display models (EKD01, DPC010, DPC080, VD03, VD618, VD61, P860ML), detailing their screen size, battery indicator, handlebar holder size, speed limit, compatible voltage, light sensation, PAS levels, and USB port availability.
7.3 Programming Flexibility
The CAN bus motor offers extensive programming flexibility. If your display (e.g., VD03, VD618, VD61) is not programmable, you can use an optional USB programming cable to customize parameters via a computer. With programmable displays (e.g., DPC080, DPC010, VD04, EKD01), settings can be adjusted wirelessly from the screen or a dedicated app.
8. Maintenance
Regular maintenance ensures the longevity and optimal performance of your BAFANG Mid Drive Motor Kit.
- Cleaning: Keep the motor, battery, and display clean. Use a damp cloth to wipe down surfaces. Avoid high-pressure washing directly on electrical components.
- Lubrication: Periodically lubricate the chain and other moving parts of your bicycle.
- Connections: Regularly check all electrical connections for tightness and signs of corrosion.
- Battery Care: Follow the battery manufacturer's guidelines for charging, storage, and temperature. Avoid fully discharging the battery.
- Brake Inspection: Ensure brake levers and sensors are functioning correctly. Adjust as needed.
9. Troubleshooting
If you encounter issues with your BAFANG Mid Drive Motor Kit, refer to the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor not providing assist | Battery low/off, loose connections, brake sensor engaged, display error. | Check battery charge and power, inspect all cable connections, ensure brake levers are not engaged, check display for error codes. |
| Display not turning on | Loose power cable, battery off/dead. | Verify display power cable connection, check battery power and charge. |
| Inaccurate speed reading | Speed sensor/magnet misaligned or damaged. | Adjust speed sensor and magnet distance (5-8mm), check for damage. |
| Unusual noises from motor | Loose motor bolts, internal damage. | Check motor mounting bolts for tightness. If noise persists, contact support. |
If the problem persists after attempting these solutions, please contact BAFANG customer support for further assistance.
10. Warranty and Support
BAFANG products are designed for reliability and performance. For any warranty-related inquiries or technical support, please refer to the warranty information provided with your purchase or contact BAFANG customer service directly. Keep your purchase receipt as proof of purchase.
