Varstrom 48V 500W/750W Ebike Hub Motor Conversion Kit Instruction Manual

1. Introduction

This manual provides detailed instructions for the installation, operation, and maintenance of your Varstrom 48V 500W/750W Ebike Hub Motor Conversion Kit. This kit is designed to transform a standard bicycle into an electric bicycle, offering enhanced power and speed for various riding conditions. Please read this manual thoroughly before installation and use to ensure safe and optimal performance.

2. Safety Information

Always prioritize safety during installation and operation. Wear appropriate safety gear, including a helmet. Ensure all connections are secure and waterproofed where necessary. Do not attempt to modify components beyond their intended design. Consult a professional bicycle mechanic if you are unsure about any installation steps.

3. Package Contents

Your Varstrom Ebike Hub Motor Conversion Kit includes the following components:

• Pre-laced Motor Wheel (Front or Rear Hub, depending on order)
• Intelligent Controller
• Brake Levers (with motor cut-off sensors)
• Thumb Throttle
• PAS (Pedal Assist Sensor)
• Wiring Cables (including 1T4 cable)
• Headlight
• LCD Display (Optional, VD03, VD04, or EKD01)
• User Manual

Note: The ebike battery is sold separately and is not included in this kit.

Figure 1: Overview of included components and wiring connections.

4. Product Overview & Specifications

The Varstrom Ebike Hub Motor Kit is available in two main versions: Standard (125EVH) and Performance (125XVH), offering different power outputs and features to suit various riding needs.

Figure 2: Detailed specifications for various Varstrom hub motor models.

Figure 3: Comparison between Standard (125EVH) and Performance (125XVH) motor versions.

Key Features:

• High Efficiency: Motors achieve >80% efficiency for optimal power usage.
• Quiet Operation: Noise levels are kept below 60dB for a smoother ride.
• Waterproof Rating: IPX5 rating ensures reliability in various weather conditions.
• Durable Gears: Features durable nylon helical gears for extended lifespan (Performance version).

Figure 4: Illustration of the dual-layer gear system for improved torque and durability.

5. Compatibility

The Varstrom Ebike Hub Motor Kit offers broad compatibility with various bicycle types and sizes:

• Wheel Sizes: Compatible with 20", 26", 27.5", and 700C (28"/29") wheels.
• Dropout Widths: Rear hub motor fits bicycles with a rear dropout width of 135-145mm. Front-drive version is compatible with a 100mm dropout.
• Brake Systems: Supports both Disc and V-Brakes.
• Gears: Compatible with cassette flywheels (not for screw-on freewheels) and works with up to 10-speed gear systems.

Figure 5: Guide for selecting the correct wheel size for your conversion kit.

6. Setup & Installation

Follow these general steps for installing your ebike conversion kit. Refer to the detailed wiring diagram (Figure 1) for specific connections.

1. Prepare Your Bicycle: Ensure your bicycle is clean and stable. Remove the existing front or rear wheel, depending on your kit type.
2. Install Motor Wheel: Mount the pre-laced motor wheel into the appropriate dropout (front or rear). Ensure it is securely fastened.
3. Mount Controller: Secure the intelligent controller to your bicycle frame in a protected location, typically near the battery or motor.
4. Install Brake Levers: Replace your existing brake levers with the provided ones, which include motor cut-off sensors.
5. Attach Throttle: Install the thumb throttle on your handlebar.
6. Install PAS Sensor: Mount the Pedal Assist Sensor near your crankset. Note: A right-side PAS sensor is needed for hollow cranksets.
7. Connect Wiring: Carefully connect all components to the controller using the provided wiring cables. Match colors and connectors as per the wiring diagram. Ensure all connections are tight and protected from moisture.
8. Install Display: Mount your chosen display (VD03, VD04, or EKD01) on the handlebar and connect it to the main wiring harness.
9. Connect Battery: Connect your 48V/52V ebike battery (sold separately) to the controller.
10. Final Checks: Before riding, double-check all connections, ensure brakes are functioning correctly, and verify that the motor engages and disengages properly.

Installation Video Guides:

7. Display Options

Customize your riding experience with three advanced display choices, all connecting to the BIKEGO+ app and featuring one-key speed limit adjustment:

• VD03 Display: A compact 1.5" LED screen, ideal for limited handlebar space or budget-conscious users. Covers essential functions.
• VD04 Display: A larger 3.5" IPS screen offering enhanced visuals and data clarity.
• EKD01 Display: A wide 2.4" horizontal display, also providing enhanced visuals and data.

Figure 6: Visual representation of the VD03, VD04, and EKD01 display units.

8. Battery Parameters (Optional)

While the battery is sold separately, here are typical parameters for compatible 48V/52V battery systems to help you choose based on your range and power needs:

Figure 7: Table detailing various battery specifications for different capacities and types.

9. Operation

Once installed and the battery is connected, operate your ebike as follows:

1. Power On: Press and hold the power button on your display unit to turn on the system.
2. Select Assist Level: Use the '+' and '-' buttons on the display to select your desired pedal assist level. Higher levels provide more motor assistance.
3. Throttle Use: The thumb throttle provides instant power without pedaling. Use it for quick acceleration or maintaining speed.
4. Braking: The brake levers are equipped with motor cut-off sensors, which will instantly cut power to the motor when applied, ensuring safe stopping.
5. Speed Limit: Adjust the speed limit via the display (refer to display-specific instructions for details).
6. Power Off: Press and hold the power button to turn off the system when you are finished riding.

10. Maintenance

Regular maintenance will prolong the life and performance of your ebike conversion kit:

• Cleanliness: Keep the motor, controller, and battery clean and free from dirt and debris. Use a damp cloth, avoid high-pressure washing.
• Connections: Periodically check all electrical connections for tightness and signs of corrosion. Ensure waterproof connections remain sealed.
• Cables: Inspect cables for any damage, fraying, or kinks. Replace damaged cables immediately.
• Battery Care: Follow the manufacturer's instructions for your specific battery regarding charging, storage, and temperature. Avoid fully discharging the battery.
• Mechanical Components: Regularly check your bicycle's brakes, tires, and other mechanical parts as you would with a standard bike.

11. Troubleshooting

If you encounter issues, try these basic troubleshooting steps:

• No Power: Check battery charge, ensure battery is properly connected, and verify all main power cables are secure.
• Motor Not Engaging: Check PAS sensor alignment and connection. Ensure brake levers are not engaged (motor cut-off). Verify throttle connection.
• Display Not Working: Check display cable connection to the controller. Ensure the battery has power.
• Intermittent Power: Inspect all wiring for loose connections or damage.

For persistent issues, consult the detailed troubleshooting section in your kit's specific manual or contact Varstrom customer support.

12. Specifications

13. Warranty & Support

Your Varstrom Ebike Hub Motor Conversion Kit comes with a warranty:

• Return Policy: 30 days return.
• Repair or Replace: 365 days repair or replace.

For further assistance or technical support, please refer to the contact information provided with your purchase documentation.