1. Introduction
This manual provides comprehensive instructions for the installation, operation, and maintenance of your Varstrom 48V 500W/750W Electric Bike Hub Motor Conversion Kit. Please read this manual thoroughly before attempting installation or operation to ensure proper function and safety. This kit is designed to convert a standard bicycle into an electric bicycle, offering enhanced performance and versatility.
Image 1.1: Overview of the Varstrom Electric Bike Conversion Kit components, including the hub motor wheel, battery, display, controller, brake levers, throttle, PAS sensor, and wiring.
2. Product Overview
2.1 Kit Components
The Varstrom Electric Bike Hub Motor Conversion Kit typically includes the following components:
- Hub Motor (pre-laced to rim)
- Controller
- Display (optional: VD03, VD04, or EKD01)
- Brake Levers
- Thumb Throttle
- PAS (Pedal Assist Sensor)
- Wiring Cables
- Headlight
- Battery (optional, various types available)
2.2 Motor Versions: Standard vs. Performance
The kit is available in two primary motor versions, 125EVH (Standard) and 125XVH (Performance), each designed for specific riding needs.
Image 2.1: Visual comparison highlighting the differences between the Standard Version (125EVH) and Performance Version (125XVH) hub motors, detailing their applications and characteristics.
- Standard Version (125EVH): A conventional design suitable for daily commuting, casual riding, and low-intensity use. It offers reliable performance for recreational purposes.
- Performance Version (125XVH): An upgraded architecture providing higher speed, greater strength, improved heat dissipation, and reduced noise. This version is ideal for demanding applications such as food delivery, cargo carrying, and long-distance tours.
2.3 Display Options
Three display options are available to customize your riding experience:
Image 2.2: Detailed view of the EKD01, VD03, and VD04 display units, showing their screen sizes, features, and compatibility.
- EKD01 Display: 2.4" TFT screen, IP67 waterproof, supports 9 PAS levels, navigation function, and BIKEGO+ app connectivity. Includes one-key speed limit adjustment.
- VD03 Display: 1.5" LED screen, IP67 waterproof, supports 9 PAS levels, and BIKEGO+ app connectivity. Covers essential functions.
- VD04 Display: 3.5" IPS screen, IP67 waterproof, supports 9 PAS levels, navigation function, and BIKEGO+ app connectivity. Offers enhanced visuals and data clarity.
2.4 Dual-Layer Gears
The motor features durable nylon helical gears with oblique teeth, designed for reduced wear, extended lifespan, and minimal noise (below 60dB). This design contributes to effortless inclines, immediate thrust, unwavering power for heavy loads, and a smoother, quieter ride.
Image 2.3: Illustration of the dual-layer gear system within the hub motor, emphasizing its robust construction and benefits.
3. Specifications
The following table details the specifications for the Varstrom Hub Motor Kit:
Image 3.1: Comprehensive table outlining the technical specifications for various Varstrom hub motor models, including power, speed, torque, and compatibility.
| Parameter | 500W (125EVH) | 500W (125XVH) | 750W (125XVH) |
|---|---|---|---|
| Motor Type | Gear Drive Brushless Motor | ||
| Installation | Front & Rear Hub Motor (Optional) | ||
| Rated Power | 500W | 500W | 750W |
| Peak Power | 800W | 864W | 1056W |
| Rated Voltage | 48V | ||
| Max Speed | 40-45 KM/H | 45-50 KM/H | 55-60 KM/H |
| Max Torque | 65 N·m | 65 N·m | 80 N·m |
| Spoke Hole | 36H*12G | ||
| Brake Type | V Brake & Disc Brake | ||
| Cassette Type | ≤10-Speed (not suitable for screw-on freewheels) | ||
| Efficiency | >80% | ||
| Noise Grade | <60dB | ||
| Waterproof Rating | IPX5 | ||
| Operation Temperature | -20℃~45℃ | ||
3.1 Battery Parameters (Optional)
Various battery options are available, each with different capacities and form factors. Refer to the image below for detailed specifications of common battery types.
Image 3.2: Table displaying specifications for various Varstrom battery options, including voltage, capacity, watt-hours, cell type, BMS, charge voltage, size, weight, USB port availability, and cycle life.
4. Setup and Installation
4.1 Compatibility
- Rear Hub Motor: Fits bicycles with a rear dropout width of 135-145mm.
- Front Hub Motor: Compatible with 100mm front fork spacing.
- Brake Systems: Designed for V-brake and disc brake systems.
- Cassette Flywheel: Supports up to 10-speed gear systems. Not suitable for screw-on freewheels.
4.2 Wheel Size Selection
It is crucial to select the correct wheel size for your bicycle. Refer to the markings on your current tire to determine the appropriate rim size.
Image 4.1: Visual guide demonstrating how to identify your bicycle's wheel size from the tire markings and a table showing compatible rim sizes and diameters.
- Step 1: Locate the tire size marking on your bicycle's tire.
- Step 2: Check the label number (e.g., 26x1.95).
- Step 3: Determine your tire size. For example, if the label says 26x1.95, your bicycle tires are 26 inches.
4.3 Wiring Diagram
Follow the wiring diagram carefully for proper connection of all components. Ensure all connections are secure and waterproof where applicable.
Image 4.2: Detailed wiring diagram illustrating how to connect the hub motor, controller, display, battery, brake levers, throttle, PAS sensor, and headlight. Also shows front and rear dropout measurements.
Note: If using a hollow crankset, a right-side PAS sensor may be required.
5. Operation
Once installed, operate your e-bike using the display and throttle/PAS system. Refer to your specific display's manual for detailed operational instructions.
- Power On/Off: Typically involves holding a power button on the display.
- PAS Levels: Adjust pedal assist levels using the display controls (usually '+' and '-' buttons).
- Speed Limit Adjustment: Displays like EKD01 and VD03/VD04 support one-key speed limit adjustment (e.g., holding '+' and '-' buttons together for EKD01, or 'Power' and '-' for VD03) to switch to 25 km/h street-legal mode.
- BIKEGO+ App: Connect compatible displays (EKD01, VD03, VD04) to the BIKEGO+ app for remote locking/unlocking and enhanced data.
- Throttle: Use the thumb throttle for immediate power assistance without pedaling.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your Varstrom e-bike conversion kit.
- Cleaning: The motor and components have an IPX5 waterproof rating, allowing for resistance to water jets. However, avoid submerging components. Clean with a damp cloth and mild detergent.
- Connections: Periodically check all electrical connections for tightness and corrosion.
- Gears: The durable nylon helical gears are designed for minimal maintenance. However, ensure the motor housing remains sealed to prevent ingress of dirt or water.
- Battery Care: Follow the battery manufacturer's guidelines for charging, storage, and temperature. Avoid extreme temperatures.
- General Bike Maintenance: Continue regular bicycle maintenance, including tire pressure, brake checks, and chain lubrication.
7. Troubleshooting
If you encounter issues with your e-bike kit, consider the following general troubleshooting steps:
- No Power: Check battery charge level and ensure all power cables are securely connected. Verify the display is powered on.
- Motor Not Engaging: Ensure the PAS sensor is correctly installed and aligned, and that the magnets are passing correctly. Check brake lever cut-off switches are not engaged.
- Display Errors: Consult the specific display manual for error code interpretations. Often, re-seating connections can resolve communication errors.
- Reduced Performance: Check tire pressure, battery charge, and ensure no mechanical drag on the bicycle.
For persistent issues, contact Varstrom customer support.
8. Warranty and Support
Varstrom offers a warranty for its products:
- Return Policy: 30 days for returns.
- Repair/Replacement: 365 days for repair or replacement.
For technical support, warranty claims, or further assistance, please refer to the contact information provided with your purchase or visit the official Varstrom website.
