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Installation Manual

Mid-Drive Motor - Conversion Kit

BAFANG

BBS01/BBS02

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Summary of Contents for BBS01

Page 1: ...Installation Manual Mid Drive Motor Conversion Kit BAFANG BBS01 BBS02 ...

Page 2: ...ritten consent and with express attribution to the copyright owner Pirez Electric Bikes The only exception is that one temporary copy may be downloaded into a single computer s memory and one unaltered permanent copy may be used by the viewer for personal and non commercial use only No part of the downloaded copy may be subsequently reproduced disseminated or transferred Note Copyright infringemen...

Page 3: ...tern 10 4 4 2 Chainring upgrades 11 4 4 3 Lekkie Benefits 11 4 4 4 Chainring Adapters 12 INSTALL THE BATTERY 12 INSTALL THE DISPLAY UNIT 13 INSTALL THE BRAKE CONTROLS 13 4 7 1 E Brakes 14 4 7 2 Brake Sensors 14 INSTALL THE THROTTLE 15 INSTALL THE SPEED SENSOR 16 INSTALL THE CABLING 16 CABLE IDENTIFICATION CHART 17 FINALISE NEATEN 18 5 SYSTEM VERIFICATION 18 6 OPTIONAL EXTRAS 19 BOTTOM BRACKET SPAC...

Page 4: ...ur precise configuration however this manual is a guide which describes the basic installation steps If you encounter any installation difficulties please refer to the resources provided on our website A general search on the internet may also find tutorial videos or instructions specific to your problem however we don t necessarily endorse any of these methods and care should be taken that follow...

Page 5: ...an be easily installed on a standard bike frame Positioned at the centre of gravity provides better control Has high starting torque Max torque 80Nm which provides good performance on climbing Utilises a double clutch adding to a safer operation Comprised of a speed sensor and torque sensor to provide the Pedal Assist feature which helps you whilst pedalling Motor controller is integrated internal...

Page 6: ...led however it can still be a difficult process as all bikes can vary considerably After many years of perfecting these installations and fixing customer mistakes we always recommend using an experienced e bike technician to do your installation We have seen instances where a customer has damaged two motor controllers through poor installation resulting in repair costs exceeding 300 Please note th...

Page 7: ...350W Motor or BBS02 500W 750W Motor Display Unit DP C18 Chainring DP C18 Grommets Chainring Cover DP C18 Bolts 3 silver Lock Ring Nut M33 Main Cable Harness Lock Ring Cover M33 Thumb throttle ST 3 9 Screws 5 silver Speed Sensor Bolts M5 x 10mm 5 pink Speed Sensor Holder with screw Triangular Fixing Plate Speed Sensor Magnet with screw Bolts M6 x 12mm 2 black Brake Levers 2 units Crank Arms 1 pair ...

Page 8: ...tor light will change to green There is no way to over charge the battery Warning Never leave a battery unattended whilst charging or left to charge overnight Extended charging could result in overheating and cause a fire This also reduces the longevity of your battery 7 When it is fully charged the charger will stop charging the battery automatically Charging time can vary up to several hours if ...

Page 9: ...riginal crankset and crank arms front derailleur and bottom bracket from the bottom bracket shell of the bike frame 2 Remove the crank arms using Allen keys or a crank arm removal tool depending on what sort of crank arms your bike has 3 You can then use a bottom bracket remover and ratchet handle to remove the bottom bracket cups as shown here 4 Remove any front derailleur or front gear cables Th...

Page 10: ...e 5 black bolts M5 10 Do NOT use Loctite with these bolts 2 Attach the chainring cover optional to the chainring with the five 5 silver screws ST3 9 3 Carefully feed the motor drive motor axle through the bottom bracket If you encounter resistance your bottom bracket shell may need to have burrs or weld overflow smoothed with a rounded file 4 Ensure the thread of the axle extends beyond the bottom...

Page 11: ...e fixing plate perfectly aligned 7 These spacers and washers are available through our website 8 The motor should be pressed up against the down tube of your bike frame before tightening the bolts on the motor Make sure any cables that run along the down tube of your frame are clear from being clamped down by the motor as this could cause these brake or gear cables to fail 9 Rotate and hold the dr...

Page 12: ... the M8 inner hex bolt using an 8mm Allen key Again use Loctite if you wish as this bolt is prone to loosening 15 A pair of pedals can now be installed on the crank arms Ensure the pedal spindles are lubricated prior to installation to prevent rust oxidation Pedals not included in kit 16 This completes the motor installation so the bike can now be returned upright to finish the bike conversion Cha...

Page 13: ...ff the chainring On many bike conversions the standard chainring will work fine But depending on your bike frame and accessories some chain line adjustment may be recommended or even necessary Our conversion kits include a standard 46 tooth chaining This standard Bafang chainring although extraordinarily strong only has an offset of about 2mm to bring back the chain line into alignment This may be...

Page 14: ...rk but will prematurely wear out the cassette chain and the chainring Remember e bikes are powered and the impact of motor power on your drivetrain is much greater than human power from pedalling alone 4 4 3 Lekkie Benefits Besides the superior functionality the Lekkie chainring is made of high grade light weight Aluminium alloy and is an attractive upgrade from the standard stamped steel Bafang c...

Page 15: ... chainrings from 38T to 55T with a 130mm BCD Note BCD bolt circle diameter Warning Never install or refit a fallen chain whilst the battery is on For safety reasons we recommend disconnecting the battery to prevent the motor from engaging accidently Install the Battery Prior to installation we recommend fully charging your battery before its first use Ensure your battery is compatible with your mo...

Page 16: ...upplied 2 Adjust its location to your preference so that it will be easy to glance at whilst riding 3 Attached to the Display Unit is the Pedal Assist Controller PAC which includes the ON OFF and control buttons 4 The PAC should be slid onto the handlebars on the side preferred by the rider This will be affected by where you placed the Display Unit the type of throttle you have and your brake leve...

Page 17: ...itch the circuit is open and the controller lets power pass through to the motor When you pull the magnet further away from the sensor the switch closes the circuit that sends voltage to the controller which then instantly cuts the power to the motor 1 To install simply plug the brake sensor yellow plug into the main cable wiring harness 2 Attach the rectangle reed switch and the magnet on the bra...

Page 18: ...e sensor can be installed anywhere along an exposed section of the brake cable wherever there is a join between the wire cable and the protective plastic sheath Install the Throttle The standard conversion kit includes a universal thumb throttle as shown here The most common setup for the throttle is to place it on the left hand side of the handlebar however this depends on rider preference and th...

Page 19: ... 5 Once you are satisfied that the sensor is aligned with the magnet cable tie the holder to the chainstays to secure it in place 6 Connect the speed sensor cable to the sensor and to the main cable harness 7 Test the sensor with the Display Unit turned on If the sensor and magnet are not aligned or close enough to be detected the Display will indicate an Error Code 21 Speed Sensor Fault In this i...

Page 20: ... Brake Levers or Sensor yellow female Right Brake Lever or Sensor yellow female Throttle yellow male Main cable to motor black female Motor controller cables 6 Volt Light Motor to main cable black male Speed Sensor black screw clamp Gear Sensor yellow female Battery red black Take care to not damage the pins when connecting plugs ...

Page 21: ...c reasons Your kit includes several cable ties that you may use to secure any of your cables against your frame We can t specify exactly where to locate these ties as it depends on the style and model of your bike your type of battery and any accessories that you may have However it is important to ensure cables are secured to ensure rider safety as well as preventing damage to the cables Do not o...

Page 22: ...er Bars Stabilizer bars are designed for those who have problems with loose Bafang motor movements There are two custom models of stabilizer bars laser cut from high strength 304 stainless steel and have a mounting angle of 40 degrees They may also be painted or left with original stainless steel finish 6 2 1 Non full suspension This fixing plate will fit most non full suspension bikes and will at...

Page 23: ... throttle can then be easily engaged accidentally This can be particularly problematic if you have twist throttles as it is a natural response to grab the throttle tighter which could initiate more power Not having an on and off switch can be a safety issue which is not only unsafe to the user but potentially dangerous to someone unknowingly moving the bike or to an innocent bystander Implementing...

Page 24: ...allation and Maintenance Servicing Pirez offer a range of workshop services to suit your needs We offer Standard Bike Conversions Dual Suspension Bike Conversions or we can offer you a quote for any bespoke or customised conversion for unusual vehicles In addition we recommend servicing your mid drive motor system every 3000 5000km We have a range of servicing options to meet your needs including ...

Page 25: ...y be a poor connection to the motor Unplug check pins reconnect 09 Phase line of motor error Check the motor module 10 Controller over temperature The controller has reached a high temperature If riding let the motor cool down or it will disable 11 Motor over temperature error The motor has reached a high temperature If riding let the motor cool down or it will disable 12 Current sensor failure Ch...

Page 26: ...and safely operate any product item Inexperience or knowledge failure will not be accepted as a valid reason to afford a warranty claim Choosing to install conversion kits by yourself or by an unauthorised technician is done so at your own risk and any damage occurring during or as a result of the installation is not covered by warranty This warranty excludes products used for commercial use such ...

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