Bafang Hub Motors: Simplified Installation Instructions & Maintenance Tips

Installing, setting up, and maintaining your Bafang rear and front hub motor doesn’t have to be complicated. This guide provides clear, step-by-step instructions to help you get your e-bike up and running smoothly. From the initial installation to ongoing maintenance, you’ll find everything you need to keep your Bafang motors performing at their best.

Effortless Bafang Rear Hub Motor Installation: Your Complete Guide

Transform your bike into an effortless, hill-conquering machine with a Bafang rear hub motor. This guide demystifies the installation process, offering clear steps and practical advice to complement Bafang’s official manual. We’ll cover everything from removing your old wheel to ensuring perfect spoke tension on your new, motorized one. Get ready to experience the joy of a smooth, powerful ride – no matter the terrain.

Tools & Materials Needed

• Torque wrench: Ensures correct torque settings on nuts and bolts.
• 18mm, 19mm wrench or adjustable wrench: For tightening axle nuts.
• 4mm, 5mm, and 6mm Allen keys: For securing various components.
• Phillips screwdriver: For adjusting and securing screws.
• Wire cutters or scissors: For trimming zip ties.
• Chain tool (if necessary): For removing and reinstalling the chain.
• Tire levers: For removing and reinstalling the tire.
• Bicycle grease: Helps in installing components smoothly.
• Zip ties: For securing cables.
• Electrical tape (optional): For additional protection on connections.
• Torque arms (if needed): Adds extra support to the motor installation.

Step 1: Preparation

1. Remove the Rear Wheel
   • Shift the chain to the smallest cog on the rear cassette.
   • Release the brakes if rim brakes are used.
   • Use tire levers to remove the tire and tube from the rear wheel.
   • Remove the existing rear wheel from the bicycle frame.
2. Prepare the Frame
   • Ensure the rear dropouts (where the axle will sit) are clean and free of debris.
   • Apply a small amount of grease to the dropouts if necessary to facilitate the installation of the new hub motor.

Step 2: Install the Bafang Rear Hub Motor

1. Mount the Cassette/Freewheel
   • If your Bafang motor kit does not come with a cassette or freewheel pre-installed, thread the freewheel or cassette onto the motor’s hub using a chain tool or freewheel tool. Ensure it is tightly secured.
2. Install the Disc Brake
   • Place the disc brake rotor onto the motor axle from the correct side and secure it with the provided M5*8 screws. Use a 4mm Allen key to tighten the screws, applying a torque of approximately 4 N.m.
3. Position the Hub Motor
   • Place the Bafang rear hub motor into the dropouts of the bicycle frame. Ensure the motor cable exits the axle on the correct side (typically the non-drive side, or left side) to prevent pinching or damage.
4. Install Anti-Rotation Washers (if included)
   • Install anti-rotation washers at the non-cable outlet side of the motor. These washers help prevent the axle from rotating under torque.
5. Install Stop Pins and Washers
   • Mount the stop pins onto the motor shaft on both sides. Then, add the washers on both sides of the frame to ensure the motor is securely mounted.
6. Torque the Axle Nuts
   • Hand-tighten the axle nuts onto the motor’s axle. Then, use a torque wrench to tighten the axle nuts to the specified torque setting, usually between 30-60 Nm depending on the motor model. Ensure the motor is securely mounted, and the wheel is centered within the frame.

Step 3: Connect the Electrical Components

1. Connect the Motor Cable
   • Plug in the motor cable from the hub to the controller. Ensure the connectors are properly aligned (usually indicated by arrows or keyways) and fully seated. Secure the connection with electrical tape or a waterproof connector if necessary.
2. Install the Display and Controls
   • Mount the display unit and control buttons on the handlebars using the provided brackets. Tighten the brackets with the appropriate Allen key to ensure they are securely fastened.
3. Connect the Battery
   • Mount the battery on the frame (usually on the downtube or rear rack) using the provided mounting bracket. Connect the battery cable to the controller. Ensure the battery is fully charged before testing.
4. Secure the Cables
   • Use zip ties to secure the motor and battery cables along the frame, keeping them out of the way of moving parts like the chain, derailleur, and wheels. Avoid tight bends in the cables to prevent damage.

Step 4: Install the Tire

1. Mount the Tire
   • Reinstall the tire and tube onto the motor’s rim. Use tire levers to help seat the tire bead evenly around the rim. Inflate the tire to the recommended pressure.

Step 5: Final Adjustments and Testing

1. Check the Alignment
   • Ensure that the rear wheel is properly aligned and that the tire spins freely without rubbing against the frame or brake pads.
2. Adjust the Derailleur
   • If necessary, adjust the rear derailleur to ensure smooth shifting across the cassette. This might involve fine-tuning the derailleur’s cable tension or limit screws.
3. Test the Brakes
   • Reconnect the brakes if they were disengaged during the installation. Test the brakes to ensure they are functioning correctly and that the pads are properly aligned with the rim or rotor.
4. Power On and Test Ride
   • Power on the display and test the motor by slowly accelerating while the bike is lifted off the ground. Ensure that the motor engages smoothly and that there are no unusual noises or vibrations.
5. Go for a Test Ride
   • Take the bike for a short test ride, starting at a low speed to verify that everything is working correctly. Test the motor’s various assist levels, throttle (if applicable), and ensure that the bike handles well.

Step 6: Post-Installation Check

1. Retighten Bolts
   • After your test ride, check all bolts, especially the axle nuts, to ensure they remain tight and secure.
2. Inspect Cable Routing
   • Double-check the cable routing to ensure there is no rubbing against moving parts and that the cables are secured.
3. Battery Management
   • Follow the manufacturer’s guidelines for charging and maintaining the battery for optimal performance and longevity.

Keep Your Bafang Rear Hub Motor Running Smoothly: Essential Maintenance Tips

1. Regular Cleaning: Keep the rear hub motor clean by wiping it down with a soft, damp cloth. Avoid using high-pressure water jets, which can force water into the motor housing.
2. Check the Spokes: Regularly inspect the spokes around the rear hub motor to ensure they are tight and evenly tensioned. Loose or broken spokes can affect the performance and longevity of the motor.
3. Lubricate Moving Parts: Periodically lubricate the moving parts of your bike, especially the chain and gears, but avoid getting lubricant on the motor itself.
4. Inspect Electrical Connections: Check the motor’s electrical connections regularly for any signs of wear or corrosion. Ensure that all connectors are securely attached and free of dirt or moisture.
5. Monitor the Motor’s Temperature: After long rides, especially on steep inclines or with heavy loads, check the motor’s temperature. While the motor is designed to handle heat, consistently high temperatures can indicate an underlying issue that may require attention.
6. Battery Care: Properly maintain your battery by keeping it charged between 20% and 80% and storing it in a cool, dry place when not in use. This ensures consistent power output to the motor and prolongs battery life.

Smooth Bafang Front Hub Motor Installation: A Step-by-Step Walkthrough

Installing a Bafang front hub motor on your bicycle can significantly enhance its performance and functionality. While the Bafang installation manuals provide essential guidance, they can sometimes be too generic or technical for those unfamiliar with e-bike components.

This step-by-step guide bridges that gap, combining the insights from the manuals with practical tips and tricks to ensure a successful installation. Whether you’re working with a standard or non-standard frame, this guide will walk you through each step of the process – from removing your bike’s existing wheel to carefully lacing and tensioning the new motor-equipped wheel, and making all the necessary electrical connections for peak performance.

Tools & Materials Needed

• Open-End Wrench – To fasten BC3/8 cap lock nuts on the motor axle.
• Internal Hexagonal (Allen) Wrench – For securing screws and tightening components like the brake lever.
• Crank Puller – To remove crank arms during PAS sensor installation.
• Bottom Bracket Tool – For removing and reinstalling the bottom bracket shell.
• Adjustable Wrench – To tighten various lock nuts and bolts.
• Screwdriver – For adjusting and securing smaller components.
• Zip Ties – To neatly secure wiring and components along the bike frame.
• Torque Wrench (optional) – Ensures nuts and bolts are tightened to the correct torque.
• Cutting Pliers – To trim excess zip ties after securing cables.

Step 1: Unpacking the Conversion Kit

• Check Components: Ensure that your kit includes all necessary parts such as the front hub motor, controller, wiring harness, brake levers, throttle, display, pedal assist sensors (PAS), and all hardware (washers, nuts, zip ties, etc.).

Step 2: Prepare the Bike

1. Remove the Front Wheel
   • Use the quick-release mechanism or wrenches, depending on your bike model, to remove the front wheel.
2. Remove the Existing Disc Brake
   • Detach the disc brake from your old wheel to reattach it to the new hub motor.

Step 3: Install the Front Hub Motor

1. Install the Disc Brake on the Motor
   • Attach the disc brake to the non-cable side of the motor using the appropriate screws (M5*8 screws for H600).
   • Insert the stop pin onto the shaft on the non-cable side.
2. Insert the Motor into the Fork
   • Carefully insert the motor into the front fork, ensuring that the motor cable is on the correct side (non-disc brake side).
3. Install Washers and Lock Nuts
   • Place a 2mm washer on both sides of the frame.
   • Secure the motor using BC3/8 cap lock nuts. Torque the nuts to 30-36 N.m using an open-end wrench.

Step 4: Install the Pedal Assist Sensor (PAS)

1. For Non-Standard Bottom Brackets
   • Attach the Sticky PAS Sensor: Remove the red tape to expose the adhesive side and stick it to your frame.
   • Install the PAS Disc: Slide the PAS disc onto the crank arm, ensuring that it is flush against the bottom bracket.
   • Align and Secure the Sensor: Adjust the sensor’s height and angle for proper alignment with the magnets on the PAS disc. Secure with zip ties.
2. For Standard Sealed Cartridge Bottom Brackets
   • Remove the Cranks: Use an Allen wrench to remove crank bolts and a crank puller to detach the crank arms.
   • Remove the Bottom Bracket: Unscrew the drive side (reverse-threaded) and remove the bottom bracket shell.
   • Install the Metal PAS Sensor: Slip the PAS sensor onto the bottom bracket cartridge on the drive side, then reinstall the bottom bracket with the sensor in place.
   • Reinstall the Cranks: Reinstall the drive side crank, aligning the crank arms 180 degrees apart, and tighten with an Allen wrench.

Step 5: Install the Controller

1. Mount the Controller
   • Use the provided hose clamps to attach the controller to your bike’s frame. Adjust the location depending on your frame’s geometry.
2. Secure Cables
   • Use zip ties to neatly secure the cables running from the hub motor along the fork to the frame.

Step 6: Install the Handlebar Components

1. Remove Existing Components
   • Remove the grip shift and brake lever assembly from your handlebars.
2. Install the LCD Display
   • Attach the Bafang display to the handlebars and secure it with the supplied grommets.
3. Install the Control Pad
   • Slide the control pad onto the handlebars and secure it with the provided bolts.
4. Install the Brake Lever
   • Attach the new brake lever next to the control pad and tighten it using a 5mm Allen wrench.
5. Install the Throttle
   • Slide the throttle onto the handlebars and secure it with an Allen wrench.

Step 7: Connect the Wiring

1. Connect Wiring Harnesses
   • Plug the throttle, LCD display, and brake cables into the wiring harness. Align the arrows and pins on the connectors for proper connection.
2. Secure Connections
   • Use zip ties to secure the wiring and prevent movement during rides.

Step 8: Connect the Battery

1. Connect Anderson Plugs
   • Pull back the rubber housing on the battery’s Anderson connections and connect red to red, black to black. The connections only fit one way.
2. Secure the Battery Connection
   • Use the provided clip to secure the Anderson connections.

Step 9: Final Checks and Power On

1. Double-Check All Connections
   • Ensure all components are securely installed and connections are properly made.
2. Turn on the Battery and Display
   • If your battery has a power switch, turn it on. Then power on the display to activate your e-bike system.

Step 10: Test the System

1. Perform a Test Ride
   • Test the bike in a safe area to ensure the throttle, pedal assist, and brakes are functioning correctly.

Extend the Life of Your Bafang Front Hub Motor: Key Maintenance Practices

1. Regular Cleaning: Like the rear motor, keep the front hub motor clean using a soft, damp cloth. Avoid direct water exposure to the motor to prevent damage.
2. Inspect the Fork and Mounting Hardware: Regularly check the front fork and the mounting hardware to ensure that the motor is securely attached. Tighten any loose bolts or nuts as needed to prevent wobbling or shifting.
3. Check the Brake System: Since the front hub motor often includes a disc brake, ensure that the brake pads are not worn out and that the brake disc is free of dirt and debris. Proper brake maintenance is crucial for safe operation.
4. Cable Management: Inspect the cables leading to and from the front hub motor for signs of wear or damage. Ensure that cables are securely fastened and not rubbing against any moving parts.
5. Tire Pressure: Maintain the recommended tire pressure for your front wheel. Proper tire inflation reduces rolling resistance and ensures that the motor operates efficiently.
6. Periodic Inspection: Every few months, inspect the motor’s housing for any cracks or signs of wear. Although rare, physical damage to the motor casing can lead to more severe issues if not addressed promptly.