Related Manuals for BAFANG BBS02
Summary of Contents for BAFANG BBS02
- Page 1 CONVERSION KIT User Manual Mid Drive Electric Bike Kit BBS Bafang Mid Drive BBS01, BBS02, BBSHD English Please read through carefully before beginning your conversion...
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Page 2: Thank You
THANK YOU Thank you for purchasing the conversion kit! We know you’ll love it, and with some care, it should last for a very long time. Please read through this manual carefully before operating the kit. This manual uses the BBS HD for installation steps, however, most steps are the same across the board for the BBS 01, 02 and HD. -
Page 3: Table Of Contents
CONTENTS Thank You Safety Item Check List Installation Overview Installation Process Crank Removal Bottom Bracket Removal Front Derailleur Removal Motor Installation Crank Installation Battery/ Battery Cradle Installation Brake lever and Thumb Throttle Installation Display Installation Pedal Assist Sensor installation Wiring Installation Tidy Up Battery Operation Charging... -
Page 4: Item Check List
ITEM CHECK LIST Each conversion kit is tested for quality control before shipping to a customer. Before converting your bike, it’s a good idea to lay each of the components out to visiualize how they will come together on your bicycle. Motor/ Cranks Charger Battery... -
Page 5: Installation Overview
INSTALLATION OVERVIEW Remove Contents Take your components out of the box. Remove the protective packaging. Keep track of all the parts that you remove from the box. Remove the battery and put it on charge. Prepare Your bike Before installing certain components of the kit, your bike may need some initial preparation such as removing some existing components. -
Page 6: Installation Process
INSTALLATION PROCESS Crank Removal Before installing the BBS motor, your pre-existing cranks and bottom bracket must be removed. It is possible, as all bikes are manufactured differently, that your cranks and bottom bracket may remove differently and contain different steps. However we have used a bike that is quite universal to demonstrate the crank removal process to aid you. -
Page 7: Crank Removal
Crank Removal Continued Now the black portion of the crank removal tool should be threaded into the crank as shown in photo 1. Next insert the silver part of the crank removal tool into the black part, as shown in photo 2, and using the multi-sized spanner, continue to thread the silver portion in until it forces the crank to pop off the spindle. -
Page 8: Bottom Bracket Removal
Bottom Bracket Removal The next step is to use the bottom bracket removal tool in conjuction with the ratchet to remove the bottom bracket cups. Photo 2 shows how to insert this tool into the bottom bracket cup, then the bottom bracket cup must be loosen edusing the ratchet until it can be removed. -
Page 9: Front Derailleur Removal
Front Derailleur Removal The front derailleur and front gear cables now need to be removed. If your bike does not have a front derailleur/ front gears you can skip this step. The front derailleur can normally be removed from the frame by simply loosening one Allen key bolt. -
Page 10: Motor Installation
1. The components you have for this motor installation are the main motor, two cranks, two crank bolts, Bafang locking nut, bottom bracket locking nut and the fixing plate that has two bolts. - Page 11 This lock ring should be tightened to 50-60 Nm of torque using the bottom bracket lock ring tool as shown to the right in photo 2. Now the Bafang lock ring can be threaded on to the motor axle. This lock ring should be tightened to 25-30 Nm of torque using the 8FUN lock ring tool as shown in photo 4 of this page.
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Page 12: Crank Installation
Crank Installation BBS kits come with a new set of cranks, these simply slip onto the motor axle. The crank bolts supplied with this kit should be inserted as they are shown in photo 1, and then tightened with an allen key as shown in photo 2. -
Page 13: Battery/ Battery Cradle Installation
Battery/ Battery Cradle Installation This kit comes complete with a custom built battery cradle that interfaces with the drink bottle holder holes in the downtube of your frame and allows you to securely lock the battery into place. To start, make sure you have separated the battery from its cradle as shown in photo 1. -
Page 14: Brake Lever And Thumb Throttle Installation
Brake lever and Thumb Throttle Installation Start by loosening both brake levers and sliding them out of handle bars. Next, slide the thumb throttle onto your handlebar, usually the right side, however it is up to personal preference which side the throttle goes. -
Page 15: Display Installation
Display Installation Mounting the display is easy. The display should be mounted to the clamp first, using two screws. Next, remove the nuts and bolts from the clamp and put the clamp on the handlebars. There are rubber spacers included in the kit that go inside the clamp depending on the thickness of your handlebars. -
Page 16: Pedal Assist Sensor Installation
Pedal Assist Sensor Installation Firstly, install the pedal assist sensor on your frame as shown in photo 1, using the sticky adhesive that is on the base of the sensor. The sensor should then be zip tied in place to make sure it is secure. The magnet should be loosened apart and then placed onto a spoke and tightened so that the magnet will be opposite and parallel... -
Page 17: Wiring Installation 1
Wiring Installation The wiring now has to be connected up so that everything has power and can function correctly. All the wires are color coded so it is simply a matter of connecting the same colored wire ends together. 1. The first wire to connect is the main wire connecting from the controller to the battery. -
Page 18: Tidy Up
TIDY UP In the final stage of the installation, it’s time to tidy up the wires and make everything look nice and neat. In the adjacent images, you can see the provided zip/cable ties being used to bundle and secure the cables coming from the base of the battery/motor, pedal assist sensor, wiring loom and anything else leading up to the handlebars. -
Page 19: Battery Operation
BATTERY OPERATION As previously mentioned in this manual, the key is used to lock the battery into the battery cradle. Turn the key clockwise to lock and counter clockwise to unlock the battery from its cradle. When the battery is unlocked, it can be removed from the cradle for charging. -
Page 20: Charging
CHARGING Charging the battery: 1. Plug the charger into the wall socket/outlet, just like a laptop or mobile phone charger. 2. Check that one of the charger indicator lights glows green 3. Plug the charger, (battery end) into the battery carefully, making sure it is all the way in. -
Page 21: Maintenance And Care
MAINTENANCE AND CARE A little extra maintenance is required over and above a normal bicycle. Spoke tension should be maintained to avoid loose/ broken spokes. This can be done using a spoke tool as shown in the photo to the right. If this is beyond your capabilities, it is recommended that a bike mechanic handles this. -
Page 22: Trouble Shooting
TROUBLE SHOOTING Our troubleshooting advice will take you through a logical way to diagnose any issues that may arise during installation and use. Before commencing troubleshooting, disconnect all components. Do not short cut this process. There are countless times a loose plug has caused grief. By disconnecting all the plugs and then reconnecting just the crucial components, this will solve any loose plug issue. - Page 23 TROUBLE SHOOTING CONTINUED... Fault Solution Any bike with an internal bottom bracket between 68 and 73mm wide will be compatible with this kit. If the bottom bracket has Motor does not fit in any small defects like a bur or foreign particle in the way, you the bottom bracket may need to use a file to smooth these out.
- Page 24 TROUBLE SHOOTING CONTINUED... Fault Solution Get a hold of a multimeter and test the voltage (DC) output from the base of the battery. If this isn’t over 41V on a 36V kit, then the battery may have to be returned to us for testing and potential Kit won’t turn on at all replacement.
- Page 25 TROUBLE SHOOTING CONTINUED... Range extension: If you’re not getting the approximate quoted range out of your e-bike system, take the following steps: 1. Pedal Assist Sensor If you haven’t installed the pedal assist sensor, you might not get the required range out of your kit.
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Page 26: Contact Us
CONTACT US CQ GROUP INTERNATIONAL LIMITED Nanying industrial zone Foshan city China Email: support@elecycles.com www.elecycles.com...
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