1. Introduction and Safety Information
This manual provides essential instructions for the safe installation, operation, and maintenance of your Varstrom 125XVH-ZH Rear Hub Motor Ebike Conversion Kit. Please read this manual thoroughly before attempting installation or operation. Retain this manual for future reference.
1.1 General Safety Warnings
- Always wear a helmet and appropriate safety gear when riding an electric bicycle.
- Ensure all connections are secure and waterproofed where necessary.
- Do not modify the motor, controller, or battery system. Unauthorized modifications can lead to malfunction, injury, or void the warranty.
- Regularly inspect your bicycle and the conversion kit components for wear, damage, or loose connections.
- Be aware of local regulations regarding electric bicycles, including speed and power limits.
- Keep children and pets away from the kit components during installation and operation.
- Avoid exposing the battery to extreme temperatures, direct sunlight, or moisture.
2. Package Contents
Verify that all components listed below are present in your package. If any items are missing or damaged, contact Varstrom customer support immediately.
Image 2.1: Overview of the Varstrom Ebike Conversion Kit components, including the rear hub motor wheel, battery, display, controller, throttle, brake levers, PAS sensor, and wiring.
- Rear Hub Motor Wheel (Pre-laced to selected rim size: 20"/26"/27.5"/700C)
- Motor Controller
- Controller Case
- Brake Levers (or Hydraulic Brake Sensors)
- Thumb Throttle
- PAS (Pedal Assist Sensor)
- Vastrom LCD Display (Optional, specific model may vary)
- Battery (Optional, specific model may vary)
- Extension Cable
- 1T4 Cable (Main wiring harness)
- Headlight
- Plastic Straps for cable management
- Instruction Manual (This document)
3. Product Overview
The Varstrom 125XVH-ZH kit converts a standard bicycle into an electric bicycle, providing pedal assistance or throttle-controlled power. It features a robust rear hub motor and a comprehensive set of components for a complete conversion.
3.1 Key Features
- Powerful Brushless Rear Hub Motor: Available in 48V 500W or 48V 750W configurations, offering efficient and quiet operation.
- Advanced Helical Gearing: Optimized internal structures for wear resistance and extended lifespan, ensuring durability and quiet performance.
- Wide Compatibility: Fits 20" (500W only), 26", 27.5", and 700C bicycle frames with 135mm-145mm rear dropout spacing. Compatible with both disc brakes and V-brakes.
- Integrated Controller: Manages power delivery and system functions.
- Optional Display: Provides real-time riding data, battery status, and control over assist levels.
- Waterproof Connectors: Designed for enhanced splash and weather resistance (IPX5 rated motor).
Image 3.1: The Varstrom 125XVH-ZH rear hub motor, highlighting its power, speed, torque, and waterproof rating.
Image 3.2: Illustration of the advanced helical gearing and internal design for high-intensity use, emphasizing wear-resistance and longevity.
4. Compatibility
Before installation, ensure your bicycle meets the following compatibility requirements:
- Rear Dropout Spacing: Your bicycle frame must have a rear dropout spacing of 135mm to 145mm (5.31" to 5.71").
- Wheel Size: The kit is available for 20" (500W version only), 26", 27.5", and 700C wheel sizes. Select the kit that matches your bicycle's wheel size.
- Brake Type: Compatible with both disc brakes and V-brakes.
- Cassette Flywheel: Supports cassette flywheels with up to 10 speeds.
Image 4.1: Detailed motor dimensions and rear dropout compatibility (135-145mm).
Image 4.2: Examples of various bicycle types compatible with the Varstrom motor, including mountain bikes, road bikes, cargo bikes, city bikes, recumbent trikes, and folding bikes.
5. Setup and Installation
Installation of the Varstrom Ebike Conversion Kit requires basic mechanical skills. If you are unsure about any step, consult a professional bicycle mechanic.
5.1 Installation Diagram
Image 5.1: Comprehensive wiring diagram showing the connection points for the hub motor, controller, battery, display, throttle, brake levers, PAS sensor, and headlight.
5.2 Step-by-Step Installation Guide
- Prepare Your Bicycle:
- Remove the existing rear wheel from your bicycle.
- If applicable, transfer your cassette flywheel to the new motor wheel.
- Install the Motor Wheel:
- Carefully insert the Varstrom rear hub motor wheel into the bicycle's rear dropouts. Ensure the motor cable exits towards the non-drive side.
- Secure the wheel with the provided axle nuts, ensuring it is centered and tight.
- Mount the Controller:
- Find a suitable location on your bike frame for the controller and its case, typically near the seat tube or down tube.
- Secure the controller case using screws or straps. Place the controller inside.
- Install the PAS Sensor:
- Mount the PAS sensor on the bottom bracket spindle, typically on the non-drive side. Ensure the magnet disc is properly aligned with the sensor.
- Install Handlebar Components:
- Mount the thumb throttle, brake levers (or brake sensors), and the display (if included) onto the handlebars. Adjust their positions for comfortable access.
- Connect Wiring:
- Connect the motor cable to the controller.
- Connect the 1T4 cable to the controller, then connect the throttle, brake levers, display, and headlight to the 1T4 cable.
- Connect the PAS sensor to the controller.
- If using an optional battery, connect it to the controller.
- Ensure all connections are firm and secure. Use plastic straps to manage and secure cables, preventing them from interfering with moving parts.
- Final Checks:
- Double-check all connections.
- Ensure the wheel spins freely and the brakes function correctly.
- Verify that no cables are pinched or obstructing steering or pedaling.
6. Operation
Once installed, operating your Varstrom ebike conversion kit is straightforward. Familiarize yourself with the display and controls before your first ride.
6.1 Display Functions (Optional)
If your kit includes a display, it provides crucial information and control over the ebike system. Common display models include VD03, EKD01, and VD04, each offering varying features.
Image 6.1: Comparison of available display units (VD03, EKD01, VD04) showing their screen sizes, mounting options, PAS levels, waterproof ratings, and additional features like Bluetooth and navigation.
- Power On/Off: Press and hold the power button on the display to turn the system on or off.
- Assist Level Selection: Use the '+' and '-' buttons to cycle through pedal assist levels (typically 0-9). Level 0 provides no assistance.
- Throttle Operation: The thumb throttle provides power on demand, independent of pedaling. Use it cautiously, especially at higher assist levels.
- Information Display: The display shows current speed, battery level, trip distance, total distance, and assist level.
- Headlight Control: The headlight can typically be turned on/off via a button on the display or a separate switch.
- Street-Legal Mode (25 km/h): Some displays (EKD01, VD04) offer a quick-switch to a 25 km/h street-legal mode by holding the '+' and '-' buttons together.
- Bluetooth & App Connectivity: Certain displays (EKD01, VD04) support Bluetooth for remote locking/unlocking and advanced ride data tracking via the 'BIKEGO+' app.
6.2 Riding Tips
- Start in a low assist level to get accustomed to the motor's power.
- Use the throttle sparingly until you are comfortable with the ebike's acceleration.
- Always be aware of your surroundings and traffic.
- Plan your routes considering battery range, especially for longer rides.
7. Maintenance
Regular maintenance ensures the longevity and safe operation of your Varstrom ebike conversion kit.
7.1 General Care
- Cleaning: Wipe down the motor, controller, and battery with a damp cloth. Avoid using high-pressure water jets directly on electrical components.
- Connections: Periodically check all electrical connections for tightness and corrosion.
- Cables: Inspect cables for fraying, cuts, or damage. Replace damaged cables immediately.
- Fasteners: Ensure all bolts and nuts, especially those securing the motor wheel, are tightened to the manufacturer's specifications.
7.2 Battery Care (If applicable)
- Charging: Use only the charger provided with your battery. Do not overcharge or completely discharge the battery.
- Storage: Store the battery in a cool, dry place, away from direct sunlight and extreme temperatures. If storing for extended periods, charge it to 50-70% every few months.
- Disposal: Dispose of old or damaged batteries according to local regulations for lithium-ion batteries.
8. Troubleshooting
This section addresses common issues you might encounter with your ebike conversion kit.
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor not providing power | Low battery charge Loose electrical connection PAS sensor not engaged Brake lever sensor activated | Charge battery Check all cable connections, especially motor and battery Ensure PAS sensor is correctly installed and magnet disc is spinning Check brake levers are fully released |
| Display not turning on | Battery not connected or dead Loose display cable Damaged display | Check battery connection and charge Ensure display cable is securely plugged into the 1T4 cable Contact support for replacement |
| Inconsistent pedal assist | PAS sensor misalignment Damaged PAS sensor | Adjust PAS sensor and magnet disc alignment Inspect PAS sensor for damage, replace if necessary |
| Unusual noises from motor | Loose spokes Internal motor issue | Check spoke tension and tighten if loose Discontinue use and contact support |
If you encounter an issue not listed here or if the suggested solutions do not resolve the problem, please contact Varstrom customer support.
9. Specifications
Detailed technical specifications for the Varstrom 125XVH-ZH Rear Hub Motor Ebike Conversion Kit.
Image 9.1: Table detailing motor specifications including brand, model, type, rated power, peak power, rated voltage, max speed, max torque, spoke hole count, brake type, cassette type, efficiency, noise grade, waterproof rating, and operation temperature.
| Specification | 48V 500W Version | 48V 750W Version |
|---|---|---|
| Brand | Varstrom | |
| Model | 125XVH | |
| Type | Gear Drive Brushless Rear Hub Motor | |
| Rated Power | 500W | 750W |
| Peak Power | 864W | 1056W |
| Rated Voltage | 48V | |
| Max Speed | 45-50 KM/H (approx. 31 MPH) | 55-60 KM/H (approx. 37 MPH) |
| Max Torque | 65 N.m | 80 N.m |
| Spoke Hole | 36H * 12G | |
| Brake Type | Disc Brake / V Brake | |
| Cassette Type | ≤10-Speed | |
| Efficiency | >80% | |
| Noise Grade | <60db | |
| Waterproof | IPX5 | |
| Operation Temperature | -20°C ~ 45°C | |
9.1 Controller Specifications
| Controller Model | DC Rated Voltage | Rated Power | Limit Current | Rated Current | Under-Voltage Protection | Over-Voltage Protection |
|---|---|---|---|---|---|---|
| 48V500W | 48V | 500W | 22±1A | 11±1A | 39±1V | 62.4V |
| 48V750W | 48V | 750W | 22±1A | 11±1A | 39±1V | 62.4V |
9.2 Battery Specifications (Optional)
If you purchased a battery with your kit, refer to the specific battery model for detailed specifications. Below is a general overview of common Varstrom battery options.
Image 9.2: Table comparing various Varstrom battery models, including voltage, capacity, cell type, BMS max protection current, USB port availability, weight, cycle life, and charger compatibility.
10. Warranty and Support
Varstrom products are designed for quality and reliability. For warranty information and customer support, please refer to the following:
10.1 Warranty Information
Please retain your proof of purchase for warranty claims. The warranty period and terms may vary by component. Typically, motors and controllers come with a 1-year warranty against manufacturing defects. Batteries (if purchased from Varstrom) usually have a separate warranty period. For detailed warranty terms, please visit the official Varstrom website or contact customer support.
10.2 Customer Support
If you have any questions, require technical assistance, or need to make a warranty claim, please contact Varstrom customer support through the following channels:
- Official Website: Visit the Varstrom Store on Amazon for product information and support links.
- Email: Refer to your purchase documentation for the customer support email address.
- Online Contact Form: Check the Varstrom official website for a contact form.
When contacting support, please provide your product model (125XVH-ZH), purchase date, and a detailed description of the issue.
