1. Introduction
This manual provides essential information for the installation, operation, maintenance, and troubleshooting of your Varstrom TSDZ16 48V 1000W Torque Sensor Mid Drive Kit. Please read this manual thoroughly before attempting installation or operation to ensure safe and correct usage of the product.
2. Safety Information
Always prioritize safety when working with electrical components and bicycles. Failure to follow safety instructions may result in injury or damage to the product.
- Ensure the battery is disconnected before performing any installation, maintenance, or repair work on the motor or wiring.
- Wear appropriate safety gear, including gloves and eye protection, during installation.
- Verify all connections are secure and properly insulated to prevent short circuits.
- Do not modify the motor or any electrical components. Unauthorized modifications can lead to malfunction and void the warranty.
- Keep children and pets away from the work area during installation.
- Regularly inspect all components for wear, damage, or loose connections.
- Adhere to local regulations regarding e-bike usage and speed limits.
3. Product Overview
The Varstrom TSDZ16 is a 48V 1000W torque sensor mid-drive motor kit designed for converting standard bicycles into electric bikes. It features a 160N.m torque output, IPX6 waterproof rating, and compatibility with 68-73mm bottom brackets.
Key Features:
- High Torque and Power: Delivers 160N.m of torque and 1000W power for effective acceleration and hill climbing.
- Advanced Torque Sensor: Provides a natural and responsive pedaling experience by proportionally adjusting motor assistance based on pedaling force.
- IPX6 Waterproof Rating: Equipped with dual oil seals for enhanced protection against water and dust, suitable for various weather conditions.
- Wide Bottom Bracket Compatibility: Supports 68-73mm bottom brackets with an improved mounting design for stability.
- High Efficiency: Operates at over 83% efficiency, optimizing battery usage.
- Integrated Wiring: Includes wiring for a gear shift sensor and connections for front and rear lights.
Components Included (Standard Kit):
- Varstrom TSDZ16 48V 1000W Mid Drive Motor
- Display (DZ40, SW2-M58, or EKD01 - Optional)
- Battery (Optional)
- Brake Lever (Default) or Brake Sensors
- Thumb Throttle
- Cranks
- 46T Chainwheel with Guard
- Speed Sensor & Magnets
- 1T4 Wiring Harness
- Lock Nuts and Fixed Bracket Accessories
- Wrench
- Cable Ties
- Washers
4. Setup and Installation
This section outlines the general steps for installing the TSDZ16 mid-drive motor kit onto your bicycle. Ensure your bicycle's bottom bracket is compatible (68-73mm).
Installation Steps:
- Prepare the Bicycle: Remove the existing crankset, bottom bracket, and chain. Clean the bottom bracket shell.
- Install the Motor: Carefully insert the TSDZ16 motor into the bottom bracket shell. Ensure proper alignment and clearance.
- Secure the Motor: Install the fixing nut and bracket to secure the motor to the frame. Tighten the fixing nut to 40Nm.
- Install Speed Sensor: Mount the speed sensor on the chainstay and attach the magnet to a spoke, ensuring a 10-15mm gap between the sensor and magnet.
- Install Cranks and Chainwheel: Attach the crank arms and the 46T chainwheel to the motor spindle.
- Install Chain: Reinstall or install a new chain, ensuring it is properly routed and tensioned.
- Connect Wiring: Connect the display, throttle, brake levers/sensors, and optional lights to the main wiring harness (1T4 cable) and then to the motor.
- Install Battery: Mount the battery securely to the bicycle frame and connect it to the motor's power cable.
- Final Checks: Double-check all connections, ensure no wires are pinched, and test the motor's functionality before riding.
5. Operating Instructions
Once installed, operating your Varstrom TSDZ16 kit is straightforward. The system offers pedal assist and, if equipped, a throttle mode.
Display Operation:
The specific operation may vary slightly depending on your chosen display (DZ40, SW2-M58, or EKD01). Refer to the individual display manual for detailed instructions.
- Power On/Off: Typically, press and hold the power button on the display to turn the system on or off.
- Assist Levels: Use the '+' and '-' buttons to cycle through different levels of pedal assistance. Higher levels provide more motor power.
- Information Display: The display shows real-time information such as current speed, battery level, assist level, and trip distance.
- Walk Assist: Most displays offer a walk assist mode, activated by holding a specific button, which provides low-speed assistance for pushing the bike.
- Throttle (if installed): The thumb throttle provides on-demand power, independent of pedaling, up to the set speed limit.
Riding Tips:
- Start in a low assist level and gradually increase as needed.
- Shift gears smoothly to optimize motor efficiency and prolong drivetrain life.
- Be aware of your surroundings and ride defensively, as e-bikes can reach higher speeds than traditional bicycles.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your TSDZ16 mid-drive kit.
- Cleaning: While the motor is IPX6 waterproof, avoid high-pressure washing directly on electrical components. Clean the motor and battery with a damp cloth.
- Connections: Periodically check all electrical connections for tightness and corrosion. Ensure they are clean and dry.
- Drivetrain: Keep your chain, chainwheel, and cassette clean and lubricated. Inspect for wear and replace components as necessary.
- Brakes: Regularly check brake pads and cables/hydraulic fluid for proper function and wear. Adjust or replace as needed.
- Battery Care: Store the battery in a cool, dry place. Avoid fully discharging the battery and charge it regularly, even during periods of non-use.
- Motor Inspection: Listen for unusual noises from the motor. If you detect any, discontinue use and inspect for issues.
7. Troubleshooting
This section addresses common issues you might encounter. For problems not listed here, contact Varstrom customer support.
| Problem | Possible Cause | Solution |
|---|---|---|
| Motor not providing assist | Battery low or disconnected; Display off; Loose connections; Speed sensor issue; Brake sensor engaged. | Check battery charge and connection; Turn on display; Inspect all wiring connections; Verify speed sensor alignment (10-15mm gap); Ensure brake levers are not engaged. |
| Display not turning on | Battery low or disconnected; Loose display cable. | Charge battery; Check battery connection; Ensure display cable is securely plugged in. |
| Unusual motor noise | Loose motor mounting; Internal motor issue; Drivetrain component interference. | Check motor mounting bolts for tightness; Inspect chainring for debris; If noise persists, contact support. |
| Inaccurate speed reading | Speed sensor or magnet misaligned or damaged. | Check speed sensor and magnet alignment (10-15mm gap); Ensure magnet is securely attached to spoke. |
8. Specifications
Detailed technical specifications for the Varstrom TSDZ16 Mid Drive Motor Kit.
| Feature | Specification |
|---|---|
| Brand | Varstrom |
| Motor Model | TSDZ16 |
| Voltage | 48V |
| Rated Power | 1000W |
| Max Torque | 160N.m |
| Max Speed | 55-60KM/H (approx. 34-37 MPH) |
| Motor Type | Brushless Geared Motor |
| Motor Position | Mid Mounted |
| Controller | Integrated, inside the Motor |
| Shaft Standard | JIS |
| Operating Temperature | -10-45℃ |
| Pedal Sensor | Speed and Torque Integrated |
| Chainwheel | 46T |
| Weight | 6KG |
| Efficiency | >83% |
| Noise Grade | ≤60dB |
| Waterproof Rating | IPX6 |
| Bottom Bracket Compatibility | 68-73mm |
9. Warranty and Support
Varstrom provides warranty coverage and customer support for its products.
Warranty Information:
- Return Policy: 30 days return period.
- Repair or Replace: 365 days repair or replacement warranty.
For specific warranty terms, conditions, or to initiate a return or repair, please refer to your purchase documentation or contact Varstrom customer service directly.
Customer Support:
If you have any questions, require technical assistance, or encounter issues not covered in this manual, please contact Varstrom customer support. Provide your product model (TSDZ16) and purchase details for efficient service.
