1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your BAFANG G020 500W E-Bike Conversion Kit. This kit is designed to convert a standard bicycle into an electrically assisted bicycle, offering enhanced performance and versatility for various riding conditions. Please read this manual thoroughly before installation and use to ensure safe and optimal performance.
2. Consignes de sécurité
⚠️️ Please mind potential fire risk and strictly follow the instruction manual for charging and storage.
- Portez toujours un casque et un équipement de sécurité approprié lorsque vous utilisez votre vélo électrique.
- Ensure all connections are secure and properly insulated before riding.
- Do not modify the motor or controller system. Unauthorized modifications can lead to malfunctions and void the warranty.
- Be aware of local regulations regarding e-bike usage, speed limits, and power output.
- Inspectez régulièrement votre vélo électrique pour détecter tout signe d'usure, de dommage ou de pièces desserrées.
- Tenez la batterie éloignée des sources de chaleur et des matériaux inflammables.
3. Contenu du colis
Your BAFANG G020 500W E-Bike Conversion Kit includes all necessary components for conversion. Please verify that all items listed below are present in your package:
- 48V 500W Rear Wheel Hub Motor (Cassette type) with pre-built rim (suitable for 135-142mm rear wheel dropout)
- Control Unit and Control Unit Box
- Accélérateur au pouce
- Left Pedal Assist System (PAS) Sensor
- Waterproof 1T4 Main Wiring Harness
- Phares
- Outils d'installation
- Optional: LCD Display (various models available, e.g., EKD01, DZ40 Mini, SW2-M58, 500C, DPC18)
4. Spécifications
The following table details the specifications for the BAFANG G020 500W Hub Motor and related components:
| Attribut | Valeur |
|---|---|
| Modèle Bafang | H400 |
| Quoitage | > 400w (500W Rated, 750W-800W Peak) |
| Conception | Sans balais |
| Voltage | 48V (également compatible avec 36V) |
| Nom de marque | Bafang |
| Type de moteur | Moteur à engrenages sans balais |
| Certification | CE |
| Origine | Chine continentale |
| Modèle N° | H400B |
| Compatibilité des tailles de roues | 20/26/27.5/700C/28/29 inches |
| Vol évaluétage (DCV) | 36 V / 48 V |
| Puissance nominale (W) | 500 W |
| Noise Grade (dB) | <55 dB |
| Spécifications des rayons | 36H * 12G |
| Usage | eTour, eCity, eRoad |
| Efficacité (%) | 80% |
| Construction | Entraînement par engrenage |
| Compatibilité des freins | Frein à disque |
| Température de fonctionnement | -20℃-45℃ |
| Niveau d'étanchéité | IP X5 |
| Salt Spray Test Standard (h) | 96h |
| Suitable Rear Dropout Size | 135-142MM |
| Suitable Front Dropout Size | 100MM |
5. Guide d'installation
Careful installation is crucial for the performance and safety of your e-bike. Follow these steps:
5.1. Vérifications préalables à l'installation
- Wheel Size Verification: Ensure the conversion kit's wheel size matches your bicycle. Refer to the tire sidewall for your bike's wheel size (e.g., 26x1.95).
How to choose the suitable wheel size. - Dropout Measurement: Measure your bike's rear and front dropout sizes to ensure compatibility with the hub motor. The rear hub motor requires a 135-142mm dropout, and the front hub motor requires a 100mm dropout.
Measuring bicycle dropout widths. - Type de frein : This kit is designed for disc brakes and a cassette-type flywheel for the rear hub motor. It is not compatible with rotary or freewheel domes.
5.2. Component Placement Overview
The following diagram illustrates the typical placement of the e-bike conversion kit components on a bicycle:
5.3. Schéma de câblage
Follow this wiring diagram carefully to connect all components. Ensure all connectors are firmly seated and waterproofed where applicable.
Liens clés :
- Moteur de moyeu: Connects to the controller.
- Capteur PAS : Mounts near the pedal crank and connects to the controller.
- Câble 1T4 : This main wiring harness connects the controller to the display, throttle, and brake levers/sensors.
- Contrôleur: The central unit, connecting to the motor, battery, and all control components.
- Batterie (en option) : Connects to the controller.
- Phare: Connects to the main wiring harness or controller.
- Brake Lever/Sensor: Connects to the main wiring harness.
- Accélérateur au pouce: Connects to the main wiring harness.
- Affichage (facultatif) : Connects to the main wiring harness.
6. Mode d'emploi
6.1. Cycling Modes
Your BAFANG e-bike conversion kit offers four flexible cycling modes:
- Mode 100% électrique : Ride without pedaling, using only the motor's power via the thumb throttle.
- Mode d'assistance au pédalage (PAS) : The motor provides assistance as you pedal, making long distances and uphill climbs easier.
- Mode Boost : Facilitates pushing your bike when loading or walking uphill.
- Mode vélo normal : Ride your bicycle as a traditional bike, with no motor assistance.
Combine these modes as needed to tailor your cycling experience to your preferences and terrain.
6.2. Fonctionnement de l'affichage
The intelligent LCD display allows you to monitor your cycling statistics and control various settings. Different display models offer varying features:
Each display typically allows you to:
- View current speed, distance, and battery level.
- Adjust Pedal Assist System (PAS) levels (e.g., 0-9 levels).
- Allumer/éteindre le système.
- Control headlights (if connected and supported by the display).
- Access settings and diagnostics.
For specific instructions on your display model, please refer to its individual manual.
6.3. Vidéo produit
Watch this video for a visual guide on the BAFANG e-bike system in action:
7. Entretien
Proper maintenance ensures the longevity and safe operation of your e-bike conversion kit:
- Nettoyage régulier : Gardez le moteur, le contrôleur et la batterie propres et exempts de saletés et de débris. Utilisez unamp tissu ; éviter le lavage à haute pression directement sur les composants électriques.
- Vérifications de connexion : Vérifiez régulièrement le serrage et l'absence de corrosion de toutes les connexions électriques. Assurez-vous que les connecteurs étanches sont correctement scellés.
- Entretien de la batterie: Store the battery in a cool, dry place. Avoid extreme temperatures. Follow the manufacturer's guidelines for charging and discharging to maximize battery life and prevent fire risks.
- Inspection des freins : Regularly inspect your disc brakes for wear and proper function. Ensure brake levers are responsive.
- Pression des pneus: Maintenez une pression de pneus correcte pour des performances et une sécurité optimales.
- Entretien général du vélo : Continue to perform regular maintenance on your bicycle's mechanical components (chain, gears, frame, etc.) as you would with a non-electric bike.
Dimensions du contrôleur : The controller unit measures approximately 9cm (length) x 5cm (width) x 3cm (height). The controller box is designed to house this unit securely.
8. Dépannage
If you encounter issues with your BAFANG G020 E-Bike Conversion Kit, consider the following common problems and solutions:
- Moteur non enclenché :
- Check all electrical connections, especially the motor, battery, and controller.
- Assurez-vous que la batterie est chargée et correctement connectée.
- Verify the PAS sensor is correctly installed and aligned.
- Check the display for any error codes.
- Écran hors tension :
- Assurez-vous que la batterie est chargée et connectée.
- Check the main power cable from the battery to the controller.
- Vérifiez que le câble d'affichage n'est pas endommagé ou que les connexions ne sont pas desserrées.
- Incompatible Brakes (Hydraulic): The kit is designed for mechanical disc brakes. While it may be possible to adapt it for hydraulic brakes, ensure compatibility with your specific hydraulic brake system or consult a professional e-bike technician for assistance.
- Controller Type (Sine Wave vs. Square Wave): The controller type (sine wave for smoother operation, square wave for more abrupt power) is typically specified in the product details. If you experience unexpected power delivery, verify the controller type and ensure it matches your expectations.
Si le problème persiste, contactez le support client pour obtenir de l'aide.
9. Conseils d'utilisation
- Mesures précises : Always double-check your bicycle's wheel size and dropout measurements before purchasing and installing the kit to ensure a perfect fit.
- Connexions sécurisées : After initial installation and periodically thereafter, inspect all wiring connections to ensure they are tight and properly seated. Loose connections can lead to intermittent power or component failure.
- Optimiser les modes de conduite : Experiment with the different cycling modes (Pure Electric, Pedal Assist, Boost, Regular Bike) to find the most efficient and comfortable setting for various terrains and personal preferences.
- Gestion de la batterie : For optimal battery life and safety, avoid fully draining the battery frequently and store it at a partial charge (around 50-70%) if not used for extended periods.
10. Garantie et assistance
Your BAFANG G020 E-Bike Conversion Kit comes with a one-year warranty. For any technical support or issues, please contact our customer service. We have professional technicians in Europe (France, Poland, Germany, Spain, Italy) who can provide assistance and help resolve problems.