Varstrom Tong-Sheng TSDZ Mid-Drive Ebike Conversion Kit User Manual

1. Introduction

This manual provides essential information for the installation, operation, and maintenance of your Varstrom Tong-Sheng TSDZ series mid-drive ebike conversion kit. This kit is designed to transform a standard bicycle into an electric bicycle, offering enhanced performance and a torque-sensing pedal assist system. Please read this manual thoroughly before installation and use to ensure proper function and safety.

2. Safety Information

• Always wear a helmet and appropriate safety gear when riding an ebike.
• Ensure all components are securely fastened before each ride. Regularly check bolts, nuts, and electrical connections.
• Do not attempt to modify the motor or battery system. Unauthorized modifications can lead to serious injury or damage and will void the warranty.
• Keep the battery away from water, heat sources, and direct sunlight. Use only the charger provided or recommended by Varstrom.
• Be aware of local regulations regarding ebike usage, speed limits, and power output.
• If you are unsure about any installation step, consult a professional bicycle mechanic or contact Varstrom support.

3. Kit Components

Your Varstrom mid-drive conversion kit includes the following essential components:

• Mid-drive motor (TSD-Z2B, TSDZ8, or TSDZ16, depending on your selection)
• LCD display (DZ40, SW-M58, or EKD01, depending on your selection)
• Chainring (42T for 500W, 44T for 750W, 46T for 1000W)
• Thumb throttle
• Speed sensor
• 1T4 main cable harness
• Installation screws and washers
• Wrench
• Motor extension cables
• Brake levers (with motor cut-off function)
• Optional: Battery and charger (if purchased as a bundle)

Image: Overview of the Varstrom mid-drive ebike conversion kit components, including the motor, chainring, and various cables.

4. Setup & Installation

4.1 Compatibility

The 48V 500W TSD-Z2B, 48V 750W TSDZ8, and 48V 1000W TSDZ16 mid-motors are designed to fit bicycles with 68-73mm bottom brackets. Please verify your bicycle's bottom bracket size before attempting installation.

4.2 TSDZ16 Motor Upgrades

The TSDZ16 motor features several enhancements for improved performance and durability:

• Reinforcement Device: A reinforcement device is integrated to prevent the motor from shaking downward, enhancing riding stability.
• Additional Screw Holes: Two extra screw holes allow for further motor reinforcement or custom mounting, particularly useful for electric tricycles or recumbent bikes.
• New Motor Cover: A redesigned motor cover helps keep the motor clean and facilitates neater wiring management for an aesthetically pleasing setup.
• Bidirectional Free-Wheeling Clutch: This new clutch design eliminates drag from traditional one-way clutches, allowing for motor-out power cycling.
• Enhanced Nylon Design: The nylon components are designed to support higher torque with an external clutch for superior performance.

Image: Detailed view of the TSDZ16 mid-motor upgrades, showing the reinforcement device, additional screw holes, and new motor cover.

4.3 Wiring Schematic

The kit utilizes a 1T4 main wiring harness for connecting the display, throttle, and brake levers to the motor. The speed sensor and optional battery connect directly to the motor unit.

Image: Diagram illustrating the wiring connections for the TSDZ2B mid-drive kit, showing the motor, 1T4 cable, display, throttle, brake levers, battery, and speed sensor.

For detailed installation instructions, it is recommended to consult the specific installation guide provided with your kit or refer to reputable online video tutorials. Professional installation is highly recommended to ensure correct and safe assembly.

5. Operation

5.1 Display Functions

Your kit includes one of three display options: DZ40, SW-M58, or EKD01. Each display provides essential riding information and control over the assist levels.

Image: Comparison table detailing specifications for DZ40, SW-M58, and EKD01 LCD displays, including screen type, dimensions, speed metrics, voltage compatibility, and assist levels.

5.2 Pedal Assist System (PAS)

The TSDZ mid-drive motor features a torque-sensing pedal assist system. This means the motor provides assistance proportional to the effort you put into pedaling, offering a natural and intuitive riding experience. Use the display to select your desired assist level.

5.3 Throttle Operation

The included thumb throttle provides on-demand power, allowing you to accelerate without pedaling. This is useful for starting from a stop or navigating steep inclines. Use the throttle judiciously to conserve battery life.

6. Maintenance

• Regular Cleaning: Keep the motor, battery, and electrical connections clean and free from dirt and debris. Use a damp cloth; avoid high-pressure washing directly on electrical components.
• Battery Care:
  • Charge the battery regularly, even when not in use, to maintain its health.
  • Store the battery in a cool, dry place, away from extreme temperatures.
  • Avoid fully discharging the battery.
• Component Checks: Periodically inspect all bolts, nuts, and mounting hardware for tightness. Check wiring for any signs of wear or damage.
• Chainring and Chain: Keep the chainring and bicycle chain clean and lubricated for optimal performance and longevity.
• Professional Service: For complex issues or annual checks, it is recommended to have your ebike serviced by a qualified technician.

7. Troubleshooting

For issues not listed here or if solutions do not resolve the problem, please contact Varstrom customer support.

8. Specifications

8.1 Motor Performance

• TSD-Z2B 500W Kit: 80 N·m torque, up to 45 km/h speed.
• TSDZ8 750W Kit: 140 N·m torque, up to 50 km/h speed.
• TSDZ16 1000W Kit: 160 N·m torque, up to 55 km/h speed.

All motors are 48V compatible and designed for 68-73mm bottom brackets.

8.2 Battery Parameters (Optional, if purchased with kit)

Various battery options are available, each with specific capacities and dimensions. Below is a general overview; refer to your specific battery's label for exact details.

Image: Table showing various ebike battery parameters, including voltage, capacity, cell type, BMS protection, charger specifications, and dimensions for different models like Shark, G80 Max, VoltzX, Yingwu, and Hailong batteries.

9. Warranty & Support

Varstrom products are covered by a manufacturer's warranty against defects in materials and workmanship. The specific terms and duration of the warranty may vary by component. Please retain your proof of purchase for warranty claims.

For technical assistance, warranty inquiries, or to purchase replacement parts, please contact Varstrom customer support through the retailer where you purchased the kit or visit the official Varstrom website.

Contact Information: Refer to your purchase documentation or the Varstrom brand store on Amazon for the most current support contact details.