PIREZ BBS01 User manual

Installation Manual
Mid-Drive Motor - Conversion Kit
BAFANG
BBS01/BBS02

© COPYRIGHT: PIREZ ELECTRIC BIKES, 2020.
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Table of Contents
1. INTRODUCTION .......................................................................................................................................1
2. SYSTEM OVERVIEW .................................................................................................................................2
ADVANTAGES OF MID-DRIVE MOTOR SYSTEMS ............................................................................................... 2
STANDARD ARRANGEMENT OF A MID-DRIVE SYSTEM ........................................................................................ 2
MOTOR CONSTRUCTION.............................................................................................................................. 3
SPECIFICATIONS ......................................................................................................................................... 3
PRECAUTIONS............................................................................................................................................ 3
3. PREPARATION .........................................................................................................................................4
CONTENTS ................................................................................................................................................ 4
STANDARD CONVERSION KIT -COMPONENTS LIST ............................................................................................ 4
BATTERY PREPARATION ............................................................................................................................... 5
4. INSTALLATION PROCEDURE .....................................................................................................................6
BOTTOM BRACKET REMOVAL ........................................................................................................................ 6
INSTALL THE MID-DRIVE MOTOR .................................................................................................................. 7
CHAIN RING SIZE ........................................................................................................................................ 9
CHECK THE CHAIN LINE .............................................................................................................................. 10
4.4.1 Narrow-wide tooth pattern ............................................................................................................ 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 -SPACERS &WASHERS ................................................................................................... 19
STABILISER BARS ...................................................................................................................................... 19
6.2.1 Non-full suspension......................................................................................................................... 19
6.2.2 Full suspension ................................................................................................................................ 19
GEAR SENSORS ........................................................................................................................................ 20
KILL SWITCH............................................................................................................................................ 20
7. GENERAL CARE & MAINTENANCE .......................................................................................................... 21
INSTALLATION AND MAINTENANCE SERVICING ............................................................................................... 21
TROUBLESHOOTING ERROR CODES .............................................................................................................. 22
8. WARRANTY ........................................................................................................................................... 23

1
1. Introduction
Congratulations on purchasing your new electric bike product.
We’re certain you'll love it, and with some care and maintenance, it will last you for a long
time.
Please read through this manual carefully before attempting to install your mid-drive
system.
Every bike is different so its difficult to provide an exact step by step procedure for your
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 following any of these will not cause any safety issue or void your
warranty.
If you still require assistance, feel free to contact us and we will assist where possible.

2
2. System Overview
In terms of an electric bike, mid-drive means that the ‘drive’ unit or motor is installed in
the middle of the bike positioned directly in between the pedals at the bike's bottom
bracket as opposed to a hub-drive which is positioned on the front or rear wheel, with
the motor placed in the wheel hub.
Advantages of Mid-Drive Motor Systems
Major benefits:
Can 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 internally, which means no external wiring.
Provides high efficiency, low consumption and longer range compared to similar
output hub motors.
Standard arrangement of a Mid-Drive System

3
Motor Construction
The motor drive unit is made from die-cast aluminium with an electrophoresis black
coating.
The working environment temperature can range between 25°C – 55°C.
The ingress protection grade is rated at IP65.
This means that the unit has:
dust protection rating of 6 (no ingress of dust)
water protection rating of 5 (protected against water jets from all directions).
This is a high, water protection rating, but is not totally waterproof.
The motor should never be submerged in water, exposed to long periods of rain heavy
enough to form puddles, or high pressure washing.
Specifications
The motor provides an identification serial number on the motor casing in the following
format:
BBS01 36V 250W 15A 25km/h 13010001
This defines:
BBS01: Motor model 15A: limited current
36V: rated voltage 25 km/h: max speed
250W: rated power 13010001: Serial Number
Precautions
Our ebike conversion kits are designed to be self-installed, 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 that if you chose to install a kit to your bike yourself or with any other
technician (not affiliated with Pirez) you do this at your own risk and any damage done to
any component or bike during installation is not covered by our warranty.
For full Terms & Conditions please visit our website www.pirez.com.au. Alternately you
may choose to send your bike to us to complete the installation.We offer full installation
of the kit and battery for $250. This installation is performed by our qualified technicians
and ensures you full warranty terms for 12 months.
Whilst we have your bike onsite, our technicians can also recommend or offer additional
servicing, repairs or upgrades of particular components such as brakes and chains.

4
3. Preparation
Contents
1. Open the package and remove the drive unit and accessories
2. Confirm that the specifications of the motor are what you purchased
3. Check that all accessories and cabling have been included in the box as per the
components list below.
Standard Conversion Kit - Components List
BBS01 250W / 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)
Anderson Connectors (Spare)  Crank Arms bolts (2 blue)
Any items purchased separately or upgraded will not appear here.

5
Other required items not included in a conversion kit are freely available at retail stores or
can be purchased through our website.
This includes items such as install tools, spacers, washers, cable ties, spiral wrap, etc
Battery Preparation
Prior to installation the first time, ensure your battery is fully charged. This ensures that
the voltage and state of charge among all the internal cells is equalised or ‘balanced’.
1. Plug the charger into a general power outlet.
2. Check that one of the charger indicator lights turns green.
3. Carefully connect the charger to the battery.
4. Ensure the plug is fully inserted, but do not force it if there is an obstruction.
5. The charger indicator lights should turn red whilst charging
6. Once the battery is fully charged the charger indicator 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 fully discharged.
8. The battery should be charged to 80% at least once every 3-months as a minimum
to maintain healthy cells.
For a premium battery charging regime, Pirez can provide a superior ‘Smart Charger’
which has some unbelievable benefits including universal compatibility, fast charging,
voltage control, watertight, bike mountable and programmable to ensure battery
longevity.
For frequent or long distance riders, we also highly recommend consideration of a spare
or additional battery.
Pirez offer the largest range of 24V, 36V, 48V & 52V batteries in a range of different
models.

6
4. Installation Procedure
The following steps are a guide to install a BBS Mid-Drive motor to most standard bikes.
Some customizations may be necessary due differences in bike models, installed
accessories or even personal preference, but there are numerous resources available both
online and through our website to assist you.
But the most important point is that safety is paramount.
Take care when installing all components, particularly once the battery is connected as
the motor could engage and rotate the drivetrain which can be dangerous if its
unexpected.
Warning: The throttle can engage even if speed level is set to zero. Always
ensure the display is powered off.
Bottom bracket removal
1. Flip the bike upside down or secure on a raised work-stand to remove the original
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. The derailleur can usually be removed
by loosening one bolt with an Allen key then
opening a clamp.
5. You will then find that the chain is looped
through the derailleur.
6. The front derailleur is not used on an e-bike so if you don’t need it you can simply
cut it off and discard, otherwise you will need to remove the chain via a quick link
or with the aid of a chain breaker tool.
7. Remove all the associated cables, then reinstate the chain if you had removed it.
All tools highlighted in bold can be purchased in kits or individually through
the Pirez website: pirez.com.au

7
Install the Mid-Drive Motor
The mid-drive motor should be installed according to the following configuration. Follow
the steps underneath.
1. Affix the chainring to the motor with the
concave surface facing in, using the five (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 bracket more than
10mm.