Bafang BBS02 Review – How Reliable is it?

This post contains affiliate links, to find out more information, please read my affiliate disclosure

Introduction

Hello and welcome to my review of the popular Bafang BBS02 mid-drive electric bike conversion kit. This review is based on my own personal experiences installing over seventy of these units over a three year period. I really like the Bafang and it is an excellent motor, but like all things electric there are a multitude of gremlins that rear their head from time to time – this is definitely not a motor to fit and forget!

 

bafang bbs02 750w mid drive electric bike conversion kit with choice of 48v or 52v battery

 

The are more useful links at the bottom of this article on where to buy the Bafang BBS02.  from various locales

Overview

The Bafang BBS02 is available in three different configurations: 36v 500w / 48v 500w and 48v 750w.  The 750w version is the most popular as it offers the most bang for your buck!  The motor itself is physically the same as the lower powered BBS01 250w / 350w, the only difference being the internals and controller. The installation criteria is the same as the other Bafang units for the classic 68mm-73mm bottom bracket fitment, this motor is also available with a bottom bracket shaft extension to allow fitment to Fat bike bottom bracket sizes of 100mm and 120mm.

Pressed fit bottom bracket compatibility

As with all the Bafang e-bike kits, there is the potential to install it on a full suspension or hardtail mountain bike that uses a pressfit bottom bracket, although you will need to purchase the correct shim adaptor kit and motor stabiliser bar, or if you know a good engineer, you could get one fabricated. This is not a job to be taken lightly, but it is possible if done correctly. If your bike has an FSA PF30 pressfit bottom bracket then a PF30 to BSA reducer can be easily purchased and fitted.

Legal Information

If you are not familiar with e-bike law, in your country, it is worth checking beforehand. The Bafang BBS02 750w is legal in the US, but not road legal in the UK, EU or Australia, as the power output is rated at between 500w-750w. Peak power is substantially higher – up to 1470w on the 48v 750w model with a 52v battery fitted. If you are in the UK and planning on using this on private land, that is absolutely fine, but if you are going to use it on public roads then you should be aware of the potential legal implications first. Please read this post on UK/EU electric bike law.

This Electric bike kit comes with the following components:

  • The motor unit with integrated controller
  • LCD Display
  • Wiring loom
  • Inner and outer lock-nuts
  • Chainring
  • Plastic Chain-guard
  • Thumb throttle
  • Brake levers with cut-off sensors (only compatible with cable brakes)
  • Speed sensor and wheel magnet
  • A bag of various Allen bolts and screws

Bafang bbs02b 48v 750w mid drive electric bike conversion kit with battery

 

Installation

Installation of this motor is the same as other mid drive motors. If you are looking for a nice and easy conversion to do yourself, but you have little or no experience with bicycle mechanics, you should be warned that the installation can be quite challenging! See my guide on how to install a Bafang BBS02.  The installation will need to be carried out by someone who is fairly competent. Removing the bottom bracket on your bike can be a right pain, and you will require a lot of patience!

Technical Data

This electric motor produces considerably more torque than its smaller siblings (up to 120N.m), I have listed the peak power output for all the motor and battery configurations below:

BafangBatteryPeak Power
BBS02 500w 36v36v (42.2v x 25A)
1055w
BBS02 500w 48v48v (54.4v x 18A)864w
BBS02 500w 48v52v (58.8v x 18A)
1058w
BBS02 750w 48v48v (54.4v x 25A)1200w
BBS02 750w 48v52v (58.8v x 25A)1470w
The voltage figures in brackets are for a fully-charged battery. Note: As the voltage drops, so will the power.

I have listed the power output to include the 52v battery option, as this is quite popular, although I no longer advocate the use of a 52v battery with the BBS02, due to reliability issues (please see below).


Like all the other BBS motors, the BBS02 uses an internal cadence sensor, and gives electric assist based on pedalling rpm. The pedal assist is very responsive, and can be fine-tuned using the 9 power levels available – update: It seems that most of the DP-C18 displays being shipped from China only allow for 5 levels of assist. If you require the full 9 levels go for the P850c display.

bafang dp c18 colour display

The motor kit is supplied with a thumb throttle, but I would  exercise caution when using this. Heat dissipation is not as good on the BBS02 as it is with the BBSHD and even the latest ‘B’ version of the controller (with the upgraded INRFB3077 MOSFETs) can be prone to premature failure when using a throttle inappropriately.

If you need to use the throttle regularly, it would be worth changing the throttle ‘start current’ settings in the controller firmware (you will need a compatible USB lead and software).

It is crucial to be in a low gear on steep hill climbs or starts, as subjecting the motor to unnecessary load can cause the controller to blow.

Personally, I am not a big fan of these throttles. They are not particularly good for modulating the power, and function more like an on/off switch, although reprogramming the controller can make the throttle more user-friendly.


As with all the other Bafang models, the controller firmware settings can be changed with a USB programming lead and software (which you can download for free here).  If you are doing this for the first time you should exercise caution and do your homework first. A good source of information on Bafang programming can be found on this excellent thread on Endless Sphere.

This kit is available with either a 44t, 46t or 48t steel chainring. If you are climbing lots of steep hills, I would definitely recommend an aftermarket chainring of around 36t .

One thing you will have to be aware of, if you do fit a smaller front chainring, the substantially lower gearing can make the bike prone to power wheelies, especially when hitting full throttle in a low gear on a steep hill start.

If you want to fit the brake levers with cut-off sensors, then bear in mind that these are only suitable for cable operated brakes. I would only recommend installing this kit on a bike with decent hydraulic brakes. Because this motor is so powerful, I would recommend the hydraulic brake cut off sensors or completely new hydraulic brakes with the sensors already built in.

bafang bbs02 750w mid drive motor installed on a full suspension mountain bike

Reliability

I have installed more BBS02 750w motors than any other (in excess of seventy units) and I have had a high rate of controller failure (17%). Whether this is down to the way the bikes are being ridden or the MOSFETs in the controller simply can’t handle the voltage and current, it is hard to say for sure. But there does appear to be a correlation between using 52v batteries and controller failure.

UPDATE: So far this year (2019) I haven’t had any reported issues with the BBS02B 750w

The 36v and 48v 500w version seems to be the most reliable, to date I have only had one controller failure on this model.

Can a 52v battery compromise reliability?

 

48v 17.5ah e-bike battery

A 52v battery when fully charged is at 58.8v, this is very close to the motor controller’s maximum operating voltage of 60v. I would personally stick with a 48v battery which is 54.4v fully charged. I have never had any issues with the motors that used 48v batteries. If you would still prefer to fit a 52v battery, then it would be worth buying a spare motor controller.

Having said that, I used a 52v Bafang BBS02 for a year and covered nearly 2000 miles, and I never had any issues – I later sold the bike, and it is still running well to this day!

The motor also uses a nylon primary gear, that can degrade over time. Replacements are easy enough to find, and there are plenty of good tutorials on YouTube for stripping this motor down.

Things to consider

  • For the 500w and 750w 48v models, I would personally stick with a 48v battery, as the power gained by using a 52v battery is minimal, and in my opinion is not worth the risk.
  • You will need a Bafang lock-ring spanner – the BBS02 will sometimes come loose due to the torque of the motor and may need periodic tightening.
  • The speed sensor can be easily knocked out of alignment with the wheel magnet – this will throw up an error code and pedal assist will stop working.
  • Some of the colour displays can be problematic – I find the black and white C965 display to be the most reliable, although the latest DP-C18 colour display seems to be pretty good (although most of these displays only allow for 5 levels of pedal assist).
  • I would definitely recommend fitting a Bafang gearshift sensor, with between 500w – 1470w going to the rear wheel, you will drastically shorten the service life of your rear derailleur, cassette and chain.
  • A heavy-duty chain is definitely recommended – there is a lot of torque going to the back wheel.
  • If you are planning on keeping the bike long term, it may be worth stocking up on some spare parts. It is always useful to have a spare controller and a nylon primary gear.

A demonstration of the gearshift sensor working, on a BBSHD powered bike

Riding a Bafang powered Electric Bike

The BBS02 is guaranteed to put a smile on your face – the days of being intimidated by steep hills are a thing of the past!

All of these motors are quiet and smooth running, I have ridden all three versions, and in my opinion, there isn’t a massive amount of difference between them in the lower power levels, it is only in the higher levels you really notice the extra power of the 750w version.

There is no doubt that in full power mode the 750w version is very quick, and a lot of fun to ride. Power-wise, there really isn’t a lot between the BBS02 and the BBSHD, although the latter has a lot more grunt, and the motor and controller can handle the extra power for a prolonged amount of time, whereas the smaller motor can become unreliable when subjected to constant hard off-road use.

Bafang BBS02 750w with 52 volt battery Installed on a Cube Aim Pro

Conclusion

As long as you are aware of this motor’s limitations, it is a fantastic piece of kit. If you constantly use it in full power mode, and use the throttle a lot, then it will inevitably let you down. I would advise you to purchase a spare controller or otherwise it may be worth spending the extra money and going for a BBSHD.

Install this kit on a decent bike, with good brakes and suspension and you will have a great high performance e-bike that is guaranteed to put a smile on your face!

I hope I haven’t put you off with this review, as I really believe this is a great electric bike conversion kit. As long as you can accept the potential long-term maintenance that will inevitably need to be carried out, it is well worth the money.

Below are some links to trusted Bafang BBS02 vendors that ship globally and also links to the motor kit from various Amazon locales. I have also compiled a list of parts.

Buy the Bafang BBS02 750w

bafang bbs02 mid drive electric bike conversion kit
Buy on eBay
Buy on Aliexpress
Buy on Amazon

Please feel free to leave your comments below and subscribe for regular updates on new content and partner offers.

Please follow and like us:

Bafang BBS02 mid-drive Electric bike conversion kit

8

Value for Money

9.0/10

Ease of Installation

6.0/10

Efficiency

9.0/10

Pros

  • Performance - The best bang for your buck!
  • Excellent Value for Money
  • Very efficient

Cons

  • Does not handle abuse well
  • Can be difficult to install for the inexperienced
  • Expect to do periodic maintenance

72 thoughts on “Bafang BBS02 Review – How Reliable is it?

  • May 7, 2019 at 3:49 pm
    Permalink

    Hello. Is a BBS02 48v a good match with a Shimano Nexus 8. Thanks, Don

    Reply
    • May 7, 2019 at 4:54 pm
      Permalink

      Hi Don,

      You will be fine with a Nexus 8 as long as you fit a gearshift sensor and dial back the start current on the pedal assist (and throttle if you’re fitting one). I converted a bike for a customer over two years ago using a BBS02 750w on a bike with a Nexus 8, and it is still going strong at over 2k miles.

      You can find the Bafang software here and a good programming guide is available here.

      The programming leads are available from most Bafang suppliers on Aliexpress and Amazon.

      If you need any more info, please let me know.

      All the best,
      Tony

      Reply
      • October 13, 2019 at 12:55 am
        Permalink

        Interested thanks for the review ride is a trek 3500 hardtail with shimano hydraulic brakes its Canada ?? so the ride may be between scorching an minus 25 some time any winterization tips

        Reply
        • October 14, 2019 at 12:15 pm
          Permalink

          Hi Aaron,

          The main thing to remember in sub zero temperatures is you won’t get the same battery range. Lithium batteries tend to lose around 20% when the temperature dips below -10. Also it is important to charge the battery at a comfortable room temperature, and store the battery inside if it isn’t being used for a while. The motor itself shouldn’t be effected by the cold.

          Your Trek will be a nice and straightforward bike to convert.

          All the best,
          Tony

          Reply
  • May 15, 2019 at 6:00 pm
    Permalink

    Hi Tony,

    Thanks so much for all of your ebike reviews. I can’t afford the $3500 (I live in Canada) for a new Cube ebike so am considering a kit for my current bike which I love. Can you please give me your opinion on the best ebike kit for my Cube Attention SL (2017)? Is the BBS02 48v a good match?
    Spec:
    Chain set Shimano Deore FC-M612, 40x30x22T, 175mm
    Cassette Shimano CS-HG50, 11-36T
    Chain Shimano CN-HG54
    Brakeset Shimano BR-M315, Hydr. Disc Brake (180/160)
    Rims CUBE ZX20, 32H, Disc
    Hubs Shimano Deore HB-M615, Centerlock

    Thanks so much!
    Jo

    Reply
    • May 15, 2019 at 7:23 pm
      Permalink

      Hi Jo,

      Yes, the BBS02B 48v should be a fine fit. I’ve checked the specs, and your bike uses a Hollowtech II threaded bottom bracket. I have installed the BBS02 on several Cube mountain bikes including an Aim Pro and an Acid.

      The only thing I had to do on both these bikes is file away a small piece of the internal cable housing (where it meets the bottom bracket) in order to make the motor fit more horizontally. You haven’t necessarily got to do this, if you don’t mind the motor facing down at a 45 degree angle.

      It would also be a good idea to get a gearshift sensor. Thankfully, the latest Bafang motors have an extra lead coming off the controller, so should be able to install the sensor on the chainstay.

      Apart from the filing, the installations were straightforward. Here is the link to the supplier I use (including battery options). You would want to get the smallest chainring possible, they offer an alloy 42t alternative to the standard Bafang chainring which is 44t / 46t. You may need to adjuster the rear derailleur slightly to compensate for the offset, but I haven’t found this to be too much of an issue on the Cube.

      If you need any more advice, please let me know.

      All the best,
      Tony

      Reply
    • May 16, 2019 at 6:11 am
      Permalink

      Hi Tony, great review and very well laid out with pros and cons. I know this might be a bit strange but I was wanting to get one of these and attach to an old school bmx just for some fun riding around the park and into the city. Maybe 15 k’s Max. Could you see any problems or have suggestions. Thanks Paul.

      Reply
      • May 16, 2019 at 8:21 am
        Permalink

        Hi Paul,

        Thanks for you comments, I’m glad you found the review useful.

        The main issue with fitting a mid-drive motor to an old school BMX would be bottom bracket compatibility.If yours has a standard 68mm threaded BB, then it wouldn’t be a problem, but if it has a one-piece crank or US type BB then you would need to find a good engineer who could machine a shim to take up the slack.

        The other option would be to get a hub motor laced into the appropriate wheel size – the main issue here is that BMX rear dropout spacing is usually 110mm and most hub motors are standard 135mm.

        You would also need a compact battery pack – my supplier does a 36v compact bottle battery that would do the job.

        If you need any more advice, let me know.

        Thanks,
        Tony

        Reply
  • May 17, 2019 at 12:46 pm
    Permalink

    Hi Tony, thanks for an awesome article. I am looking to install a motor in my felt f2 bike, do you know if it would fit?

    Reply
    • May 17, 2019 at 1:48 pm
      Permalink

      Hi Rob,

      Thank you for your positive comments.

      The Bafang or Tongheng mid-drive motor would not be a straightforward fit, as your bike has a FSA BB30 pressfit bottom bracket and the inner dimensions of the BB shell are 42mm. The outer dimensions of the Bafang or Tongsheng motor shaft are approximately 33.5mm.

      You can get a BB30 to BSA adaptor here, but you would still need to fabricate a motor mounting plate.

      If you can get the motor to fit, you may find the gear indexing not as good, as the Bafang motor has a slight off-set.

      If you need any more advice, please let me know.

      Regards,
      Tony

      Reply
  • June 27, 2019 at 2:30 am
    Permalink

    Hi Tony, thank you so much for this great and useful review! I just bought the BBS02 48V 500W to fit my 2015 Cannondale Trail SL 29 1, and i must say it looks great. Today i made my first ride to work (excuse my english, i am a french canadian) with it and it was perfect, but when i came back tonight, the chain dropped 5 times (during a 17 km ride)… I am not sure but i think it’s when i hit a hole in the street. I guess it is because my chain is too long and needs to but shortened? Anyway, thank you again. Christian

    Reply
    • June 27, 2019 at 8:22 am
      Permalink

      Hi Christian,

      Thank you for your positive comments, glad you found the article useful.

      Regarding your chain issue, it may be worth removing a couple of links to see if that helps.

      If you still have problems after this, it might be worth buying a Lekkie Bling from Luna Cycles or PreciAlps. These chainrings can improve the chainline and reduce the chance of the chain coming off.

      All the best,
      Tony

      Reply
  • July 21, 2019 at 7:00 pm
    Permalink

    Hello Tony, your articles have really helped me and raised some questions.
    I have a Cube Stereo 2010.
    My bottom bracket appears to be 76mm wide with a hollow tech II threaded bb.
    I was looking at a bbs02b kit but worry I’m going to have problems. I know I’ll have to fit a 36t chainring which is the same as my large crank currently, but I’m struggling to work out if things will fit in the motor/crank arm area. Does the bbs02b kit come with a wider bb option like the bbshd?
    Thanks
    Kev

    Reply
    • July 21, 2019 at 10:03 pm
      Permalink

      Hi Kevin,

      I have just checked the spec on the 2010 Cube Stereo and it does appear to have a standard threaded Hollowtech II BB, with Shimano XT groupset. The bottom bracket shell should be 73mm wide, so the standard BBS02 should fit.

      I have converted quite a few full suspension mountain bikes with either Hollowtech II or SRAM GPX BB’s and never had any major issues apart from the chainline offset caused by the motor can impair shifting to the lowest gear on the cassette.

      With a 73mm BB there should be ample thread left on the motor shaft to fully tighten the inner lockring, but sometimes there is not enough thread left to fully tighten the outer lockring.

      The only other issues I have come across on occasion is the motor lockring may need to be periodically tightened, and you may find fitting the battery to be a tight squeeze or the holes on the battery mounting plate will not align with the bottle cage bosses.

      I hope this information helps.

      All the best,
      Tony

      Reply
      • July 22, 2019 at 5:13 pm
        Permalink

        Thanks for the advice Tony.

        Reply
  • August 2, 2019 at 7:49 am
    Permalink

    Hi Tony

    I’ve just fitted a 750w 48v bafang to each of our two bikes. It was a bit of mission but went ok and the bikes go great.

    You said above:

    ‘You will be fine … as long as you fit a gearshift sensor and dial back the start current on the pedal assist (and throttle if you’re fitting one).’

    I’ve fitted the throttle but don’t anticipate using it. What I am particularly interested in is re dialing ‘back the start current’, as in my testing last night, even on assist 1, the power came on pretty strongly when starting from stationary. I wouldn’t find it a problem, but my wife may, so I was wondering if that start power could be reduced, so it doesn’t kick quite so hard. Also… I’m using the DPS18 and it only shows 5 levels of assist, yet you also talk of there being 9 levels, something I’ve seen elsewhere. Are these things which can be adjusted by programming the controller?

    All the best

    Renton Maclachlan
    New Zealand

    Reply
    • August 2, 2019 at 8:50 am
      Permalink

      Hi Renton,

      You can reduce the start current using the Bafang configuration software and a USB programming lead. The best guide on how to program the Bafang is available at the electricbike-blog.com.

      I usually set the start current to 10%, I think it comes out of the factory at 20%, which as you have said can be a bit much. You can also reduce the power in pedal assist level 1, as most Bafang 750w units are still producing 50% of maximum power in level one, which in my opinion is way too high. I usually set assist one to around 15-20% maximum.

      Regarding the DP-C18 display, it is unfortunate that a lot of these displays are shipped from suppliers limited (at the firmware) to 5 levels of assist, and there is no way of increasing this to 9, unless you can actually hack the firmware in the display – reprogramming the controller won’t make any difference. Luna Cycles in the US sell these displays with the full 9 levels available. Because of this I usually use the P850c colour display, as these allow for 9 levels to be used.

      If you need any more information, please let me know.

      All the best,
      Tony

      Reply
  • August 2, 2019 at 7:59 pm
    Permalink

    Thanks Tony, Much appreciated. We don’t really need the 9 levels of assist… we’re not likely to need that number, but winding down the assist power will be helpful. I will probably wind them all back when I see what they are set at. I have just ordered a programming cable from China so it will be a few weeks till I can modify the settings.
    I got the smallest front cog offered by Bafang with the kit (42 tooth?) and I suppose for general easy medium cruising/cycle trail use that will be fine. Is that right?
    Thanks again.
    Renton

    Reply
    • August 2, 2019 at 8:43 pm
      Permalink

      Hi Renton,

      The smallest chainring usually offered is a 44t, but some of the suppliers now offer smaller chainrings with the kits. A 42t / 44t will be fine for regular riding, but if you were going to be tackling lots of steep climbs then it would be worth getting a 36t Lekkie Bling Ring. They are high quality CNC machined chainrings made specifically for Bafang motors, and better still they are based in New Zealand!

      Cheers,
      Tony

      Reply
  • August 4, 2019 at 5:25 am
    Permalink

    Hey Tony, Great info on your website. Quick question, would any of the Bafang kits work on the following bikes:
    Trek 7.2 FX circa 2008
    Trek 2.3 circa 2009
    I wanted to start it out on 7.2 FX bike and eventually move it to the road bike.
    Thanks in advance and keep up the great work.
    John

    Reply
    • August 4, 2019 at 5:42 am
      Permalink

      Hi John,

      Thanks for you comment, glad you like the site.

      The Bafang mid-drive should fit either of your bikes without too much hassle. I converted a Trek FX hybrid not that long ago, and if my memory serves me correct it was a nice and straightforward conversion.

      If you need any more info, let me know.

      Cheers,
      Tony

      Reply
  • August 7, 2019 at 10:18 am
    Permalink

    Value for Money

    7.5

    Ease of Installation

    8

    Efficiency

    0

    Hi Tony,
    thanks for sharing your knowledge, it is really useful.
    One question from my side, the spec of the drive sais it is IP65. What is your experiecne using it in really MTB condistions, I mean in rain, crossing creeks, muds etc., or even on very fine dusted roads?

    regards,
    Arpad

    Reply
    • August 7, 2019 at 12:16 pm
      Permalink

      Hi Arpad,

      I’ve used a BBSHD in very wet and muddy off-road conditions without any issues, heavy rain and riding through puddles and shallow water. I believe that there is a fair degree of water resistance, although I have been told not to fully submerge the motor or use a pressure washer.

      I don’t think the BBS01 / BBS02 is quite as water resistant, I have had at least two reports of water ingress into the motor by customers using their bikes in wet weather off-road riding. One had an electrical failure and the other caused a bearing to prematurely fail.

      I hope this information helps.

      All the best,
      Tony

      Reply
  • August 13, 2019 at 10:54 am
    Permalink

    Hi Tony

    Thanks for the great article, you certainly know your stuff.

    I am investigating installing a motor on a 2014 Merida Big Ninety-Nine XT Edition (Carbon frame). Do you know if it would fit? Would the Carbon frame be a problem?

    Thanks for your help

    Tim

    New Zealand

    Reply
    • August 13, 2019 at 12:07 pm
      Permalink

      Hi Tim,

      You may have problems with a carbon frame, depending on the thickness around the bottom bracket area. I have installed both the Bafang BBS02 and BBSHD onto Carbon bikes before without too much problem. The other thing I couldn’t find on the spec sheet for your bike was the bottom bracket type. Being a 2014 model it is probably a Shimano Hollowtech II or pressfit bottom bracket. If it is the latter then you would need to measure the width of the bottom bracket shell.

      If you can send a couple photos of the bottom bracket area (left, right and underside) to my email address: cycletek@outlook.com I will be able to have a better look.

      Cheers,
      Tony

      Reply
  • August 13, 2019 at 3:41 pm
    Permalink

    Great review of this brand thanks !
    how are these motors in the snow and cold , is there a operating temp range . I live in ontario Canada and i ride in temps as low as -15-20 and am considering outfitting my foes mutz fatbike with one.
    thanks
    Mike

    Reply
    • August 13, 2019 at 7:18 pm
      Permalink

      Hi Mike,

      Thanks for your complement, glad you like the review!

      Regarding motor performance in extreme cold temperatures, the Bafang BBS02 / BBSHD seem to perform okay, I have sold kits in the past to customers in Norway and Finland and the feedback has been positive. The main issue will be that lithium battery packs do not perform so well at these temperatures and will work at a reduced percentage of their total energy capacity. As long as the battery is stored and charged at a comfortable temperature (around 18 degrees centigrade), you shouldn’t have too many problems (apart from a reduced range).

      The motor itself has a fairly good degree of resistance to moisture ingress, although you may want to strip the motor down and check it over at the end of each winter season.

      If you need any more info, let me know.

      Cheers,
      Tony

      Reply
  • August 14, 2019 at 11:42 am
    Permalink

    Thanks Tony for the quick response , with this info this brand sounds like the one to go with
    Regards
    Mike

    Reply
    • August 14, 2019 at 1:45 pm
      Permalink

      Hi Mike,

      Glad to help, if you need any more info, let me know.

      Cheers,
      Tony

      Reply
  • September 7, 2019 at 7:56 pm
    Permalink

    Hello
    I currently own a volt pulse x but would like to upgrade the fun level, and am considering fitting this unit to my giant roam, with 28 inch wheels. Will this fit? Your review has certainly got my interest as i was considering a rear hub conversion but no longer. I have hydraulic brakes so would install the recommended cut out switches if I can source them.

    Reply
    • September 8, 2019 at 9:01 am
      Permalink

      Hi Roy,

      I have installed the Bafang BBS02 and BBSHD on the Giant Roam. Here is a link to a YouTube video of one of the conversions. Both the conversions I did were straightforward and the motor was a good fit.

      If you need to fit the hydraulic brake cut-offs, they can be purchased from eBay or Amazon UK, here is a link to them on Amazon from a UK supplier.

      If you need any further advice, please let me know.

      Regards,
      Tony

      Reply
  • September 11, 2019 at 6:01 pm
    Permalink

    Hello Tony
    Thanks for coming back to me, having viewed the video helped convince me it’s the way to go. Can I seek your advice a little more. I have viewed Aliexpress and am in the process of purchasing;
    BBS02B 48V/750W with a 48T drive sprocket as that is what my giant roam has fitted at present, (saves shortening chain)
    Hydrolic break sensors
    Bestbikes gear sensor
    DP-C18 Display
    48v 17.5ah (samsung 35c celled battery, from what I have read I should avoid 29E celled batteries) complete with battery charger.

    Is their anything else I need?

    I weigh 74kg and really want the kit for odd comuting and fun on dirt tracks. My home town is relatively flat but would like to travel with the bike so need to be prepared for more hilly terrain.

    Thanks in advance

    Reply
    • September 11, 2019 at 6:28 pm
      Permalink

      Hi Roy,

      It looks like you have ordered everything you need. Regarding chainring size, the 48t should be fine, as you live in a relatively flat area.

      The 35E Samsung cells are a big improvement on the older 29E cells. The DP-C18 sometimes comes configured with only 5 PAS levels which cannot be changed to 9. If this is a problem, I would go for the 850c display. Apart from that the DP-C18 is a really nice display unit.

      The only other thing I recommend is a good set of puncture resistant tyres – Schwalbe Marathon Plus tyres are not only puncture resistant, but they are also rated for e-bike use. I have covered over 8k miles on Schwalbe Marathon Plus tyres and never had a puncture! Well worth the extra £50 – £60 for a pair.

      Let me know how you get on, if you need any help or advice with the installation, please let me know.

      All the best,
      Tony

      Reply
  • September 12, 2019 at 1:20 pm
    Permalink

    Hello Tony
    Thanks for the tyre recommendations, I am hoping to sell the volt pulse x, before finally purchasing all that I have listed. I will add those tyre mind.
    Thanks again for your help and information.

    Reply
    • September 12, 2019 at 1:37 pm
      Permalink

      No worries Roy, if you need any further advice, let me know.

      Cheers,
      Tony

      Reply
  • September 18, 2019 at 5:25 pm
    Permalink

    Hello Tony
    My pulse x is now sold, so currently reviewing my intended purchases. May I ask, having read a number of forums re purchasing kits, there is strong theme regarding buying from a British company for potential warrenty issues, you mention using Aliexpress, have you ever had any issues with them or warrenty claims? Spending close to £1000 and with a Chinese company does raise some concerns. I have seen Eclipse bikes offer the same items albeit at a greater cost.
    Interested in your views
    Kind regards
    Roy

    Reply
    • September 19, 2019 at 11:20 am
      Permalink

      Hi Roy,

      Most of the reputable sellers on Aliexpress will honour warranties, but the main problem is time and cost. Most suppliers will require the buyer to pay for and arrange postage of the faulty part or motor back to China (which can be costly). They will usually post the replacement part back at their expense.

      I have experienced a couple of issues, where the part has never been returned or has somehow got ‘mysteriously been lost’ in the post. I have ended up having to foot the cost myself.

      Most of the decent suppliers on Aliexpress, who have a good reputation, will do their best to help. But the process can be painfully slow.

      I have purchased kits and batteries from Eclipse in the past without any issues, my only complaint is they can take a while to answer emails.

      The other option would be to purchase from eBay or Amazon UK, they both have a certain degree of buyer protection, and it is easier to get a refund if a problem can’t be resolved.

      Regards,
      Tony

      Reply
  • September 19, 2019 at 1:51 pm
    Permalink

    Hello Tony
    Thanks for coming back to me again. I think based on what you say I will find a UK supplier, it will cist a little more no doubt but it could prove significantly less in the long run should I experience a warrenty issue.
    I suspect other individuals reading your blog are also facing this same dilemma.
    Kind regards
    Roy

    Reply
    • September 20, 2019 at 8:27 am
      Permalink

      Hi Roy,
      It’s definitely a good idea, especially if you’re going to rely on your bike for regular transport. It might also be worth trying Francis at Electron cycles in Epsom. I know he specialises in high performance ebike kits like the Bafang BBSHD and CYC X1, but he may be able to help you with a BBS02. They also do a wide range of very high quality batteries, and they are incredibly knowledgeable regarding the Bafang motor.

      Let me know how you get on.

      Regards,
      Tony

      Reply
  • September 20, 2019 at 2:58 pm
    Permalink

    I have a GT Grade carbon drop handle gravel bike
    Do you think the bike is suitable for a conversion and if so what would you recommend
    I mainly ride country lanes in Herts & Bucks

    I could not find any comments on range

    Reply
    • September 20, 2019 at 4:03 pm
      Permalink

      Hi Mike,

      I have checked the spec on your bike, and it looks like it has a Shimano Hollowtech ll bottom bracket, so it should be compatible with the Bafang mid-drive motor. The main issue I have come across with carbon framed bikes in the past, is the area frame area around the bottom bracket. Some carbon road bikes have a beefed-up area surrounding the bottom bracket, which can make installation difficult or even impossible.

      The only way to be sure, would be to remove the crankset and bottom bracket and measure the thickness from the inside of the BB shell to the outside of the surrounding frame.

      Regarding battery range, this would depend on the kind of battery you fitted. A 48v 13ah battery would give you a potential range of anywhere between 25-50 miles depending on how much power you were using, weight, terrain etc.

      If you can take a photo of the bottom bracket area and send it to me at: cycletek@outlook.com, I should be able to let you know for sure.

      Cheers,
      Tony

      Reply
  • October 3, 2019 at 2:04 am
    Permalink

    Hi Tony,
    I have recently purchased a Polygon Entiat TR6 on which I would like to install a Bafang BBS02B 750W Mid Drive using a 48v 13s4p battery with Sansung 35E cells.
    BB is 73mm. Crank Set is Samox 32T. I am concerned about how little room I have in the area where it comes close to the chainstay. Think that is the correct term. Moving it out might mess up the chain line too much.
    Need help to confirm it will be OK before purchase.
    Thanks a lot
    Jeff.
    Australia.

    Reply
    • October 3, 2019 at 9:42 pm
      Permalink

      Hi Jeff,

      I’ve just had a look at the specs on the Entiat TR6, and personally I think it could be a bit of a tight fit. Looking at the bike from the rear, the chainstay comes out at quite an angle from the BB area. Even if you could fit a spacer between the motor and BB shell, you’re not going to have a lot of thread left on the motor shaft to fit the outer lockring.

      It’s a bit difficult to be certain without the bike being here in front of me, but taking into account the wider clearance needed for the 3″ tyres and the angle of the chainstay, I would have to say no. I’ve had issues with chainstay clearance on MTB’s with standard 2.2″ tyres.

      It might be worth having a look at the CYC X1 Pro, it’s still quite a new system (and expensive), and hasn’t been mass-produced yet. But Luna Cycles seem to like it. The other option would be a Cyclone system.

      If you need any more advice, let me know.

      All the best,
      Tony

      Reply
  • October 3, 2019 at 10:11 pm
    Permalink

    Hi Tony,
    That stops my head from aching. Will look into your suggestions.

    Thanks heaps,
    Jeff

    Reply
  • October 5, 2019 at 9:56 am
    Permalink

    Hi Tony,
    Great article which gives me lots to think about. I have a Cube Hyde Team 2011 with a Shimano Alfine 8 speed hub, would it be suitable for the Bafang 48V 500 W. How difficult is it to change the power assist levels to make the power assist similar to the Bosch eco, tour and emtb and can you st it up for power assist only with no throttle function;
    Thanks,
    David

    Reply
    • October 5, 2019 at 5:50 pm
      Permalink

      Hi David,

      You shouldn’t have any issues with an Alifine 8 as long as you fit a gearshift sensor. You do not need to fit the throttle and it will not make any difference to the running of the motor.

      The best way to set the power to be more like the Bosch would be to get a USB Programming lead and download the free software and use the Hackers guide to programming the BBS02 found on the electricbike-blog.com.

      You can actually get the BBS02 running really smoothly, and delivering nice progressive power, by fine-tuning the settings using the software.

      It is always important to set the ‘start current’ on the pedal assist to less than 10% when using an IGH. I have installed a lot of BBS02 750w and BBSHD on to bikes with the ALfine 8, and Nexus 8 without any long-term issues.

      I hope this helps, and glad you like the article.

      All the best,
      Tony

      Reply
  • October 12, 2019 at 3:12 pm
    Permalink

    Value for Money

    8

    Ease of Installation

    0

    Efficiency

    2.5

    have a MTB with a BBS02 kit and having a blast with it. It has let me get back on bikes. (Retired and past the shape of riding without motor) Considering a Fat Tire build. Not sure what bike (maybe cheap from Walmart) and build from there. What is your take on rear hub vs mid drive for Fat Tire bike build? Would appreciate your input.

    Reply
    • October 12, 2019 at 7:18 pm
      Permalink

      Hi Lee,

      In my experience, I prefer a fat tire bike with a mid-drive. You can purchase a BBS02 motor shaft extension kit from PreciAlps in France. It’s possible Luna Cycles or California ebikes sell the modification kit.

      A hub motor would be a good enough option for a fat bike, but if you’re used to a BBS02, I would stick with that.

      All the best,
      Tony

      Reply
  • October 13, 2019 at 7:40 am
    Permalink

    Value for Money

    10

    Ease of Installation

    5

    Efficiency

    10

    Riding a Kona Jake the Snake CX bike with a BBS02B and 48v battery.

    I’m racking up 18 miles a day on a Monday-Friday commute, in rainy Manchester, UK. That includes a primary school drop off and pickup near home, so a variety of riding conditions.

    It’s saving me about £100/month on train tickets, so after 3 months the battery is paying for itself. Work bought my motor! Plus, it’s way faster. Train in Manchester are the worst, so many delays and cancellations. Don’t miss it, even when it’s pouring with rain.

    The only issues I’ve experienced are 2 instances of creaking, both fixed by tightening the lock ring. I also had the battery fly off and skid down the road once… Forgot to lock it! Everything well built though, it’s totally fine.

    Reply
  • October 23, 2019 at 9:26 pm
    Permalink

    Mine has not been reliable. I have the mid drive with 48v battery. Power kept cutting out, so bafang sent a new motor (didn’t have to purchase the entire kit. Now it is better but there are still mini surges and cut outs of power. This makes for a frustrating and unhappy riding experience. And on my husband’s bike, the controller sometimes just quits operating for no apparent reason, then comes on again. I do not consider this to be a reliable brand and would appreciate recommendations for alternatives.

    Reply
    • October 24, 2019 at 12:18 am
      Permalink

      This is one of the biggest downsides to Bafang mid-drive motors. There seems to be a definite lack of consistency regarding quality control across the range. I have experienced lots of issues with the BBS02B 48v, and very few with the 36v versions. Having installed well over a hundred of these motors over the last few years, the 36v models are much more reliable in my opinion.

      The only real viable alternative is the Tongsheng TSDZ2. I have installed a lot of these motors this year, and so far I haven’t had any issues. Unfortunately like the Bafang motor they can suffer from reliability issues.

      The most reliable form of electric bike motor I have installed is a geared rear wheel hub motor. They don’t produce the same kind of power as the mid-drive, but I have had zero motor failures out of maybe 80 or so installations.

      If you need any more advice, please let me know.

      Regards,
      Tony

      Reply
  • October 24, 2019 at 11:46 am
    Permalink

    Hi Tony,
    First of all. Thank you for posting so many good tips, tricks and sharing your knowledge. Very much appreciated 🙂

    I just ordered an aluminium frame to replace my carbon frame as I have lost a little faith in carbon as a material after my fork broke…
    I ordered the Octane One Prone 29″ Frame 2019 size L.
    I`m starting on a project to build a commuter bike and light trail bike, so think the Octane should be perfect…. If BBs02 fits…

    Do you think the BBS02 will fit… ?

    https://www.chainreactioncycles.com//no/en/octane-one-prone-29-frame-2019/rp-prod155477?utm_source=CRM&utm_medium=email&utm_campaign=OrderConfirmation&utm_content=SCAN

    Reply
    • October 24, 2019 at 8:12 pm
      Permalink

      Hi Kristian,

      Glad you like my website, positive feedback is always appreciated?

      In answer to your question. The frame in question has a standard BSA 73mm threaded bottom bracket shell, so the BBS02 will indeed fit. The only issue you may have is 73mm is at the limit of the BBS02 motor shaft length. You will have enough thread to tighten the inner lockring, but you may not be able to fully tighten the outer lockring. This really depends on the angle of the chainstay. Apart from that you should be fine.

      If you need any more advice, please let me know.

      All the best,
      Tony

      Reply
  • October 26, 2019 at 8:44 pm
    Permalink

    Hi Tony,

    Have you ever fitted a BB02 to a Trek Roscoe 7? It comes with 28t sprocket as standard and the chain stays flare out barley any room at all.

    Thanks

    Reply
    • October 27, 2019 at 11:03 pm
      Permalink

      Hi Gary,

      I haven’t fitted a BBS02 to a Roscoe 7 before, but looking at the specs it might fit. The bottom bracket is the right spec, but the angle of the rear chainstay might be a problem.

      The main issue is a 73mm wide BB is at the limit of a standard BBS02 motor shaft, and if you need to use spacers (due to the chainstay angle) it won’t leave enough thread to fit the outer motor lockring. The other problem will be the front chainring offset. I have fitted BBS motors to bikes with a SRAM 1 x 11, 11-42 rear cassette before and whilst you could shift to the 42t at the rear, the offset would cause cogging, poor shifting and cause the chain to keep coming off.

      You can purchase a 104BCD chainring adapter for the Bafang, but not a 94BCD (which is the BCD size of your current chainring). I would maybe go for a 104BCD and up the gearing on the front to a 32t or 34t, which will be fine if you are doing mostly XC riding. You might need to set the limit screw on the rear mech to prevent shifting to the lowest gear.

      If you need any more info, let me know.

      Regards,
      Tony

      Reply
  • November 5, 2019 at 5:46 pm
    Permalink

    Hello Gary,

    I need some advice from you. I bought Cube Tm Pro and bafang bbs 02. Seller told me that this cube have PF 30 but in reality it is PF 41 bb92. So i bought Axle Extension 100 mm Press in modification kit for bafang + lekkie 42 t bling ring for better chain line. Now i need some Adapter to reduce pf 41 to BSA. You think that adapter like this will do the job ?
    https://ozo-electric.com/en/accessories-for-mid-drive-motors/1010-shimano-pressfit-bottom-bracket-adapter-for-bafang-middle-drive-motor-bbs.html

    or there is much more what i have to do.

    Best regards
    Slawek

    Reply
    • November 5, 2019 at 6:56 pm
      Permalink

      Hi Slawek,

      I have not used one of those adapters personally. The main problem when fitting the BBS motor in PF BB shells is the limited clearance between the motor shaft and housing, but looking at the way that adapter has been machined it should work.

      Let me know how things go.

      Regards,
      Tony

      Reply
  • November 7, 2019 at 5:49 pm
    Permalink

    Hi Tony,
    Love this article. Very informative. I’m looking at installing a bafang BBS02B 36v500w on my wife’s Specialized Stumpjumper(26in) I think its a 73mm BB. She has a Ebikeling geared rear hub motor now and likes it except for continuous issues with the Cheap PAS and have tried aftermarket PAS with limited success. Also planning to install BBSHD on my old Gary Fisher Sugar 2(I think its 2001 or 2002) and I think its a 73 BB also. Do you see any issues with either of these builds? Secondly I will be getting the 500c displays. I think you can make changes to speed limit, start level, etc right from the display…do I need the USB programming cord? Thank you in advance!
    Tom

    Reply
    • November 7, 2019 at 8:11 pm
      Permalink

      Hi Tom,

      Glad you like the article, thanks for the feedback.

      You shouldn’t have any problems fitting the Bafang to the Stuntjumper, I’ve fitted them before to older Specialized MTB’s without any hassles.

      The Gary Fisher will be okay as well, I think it has a Hollowtech II type BB (threaded 73mm). I’ve done a Gary Fisher hardtail from the same era and that was a nice and straightforward conversion.

      The only issue you might have is getting a battery pack to fit in the limited frame space, but there are lots of different options available. My supplier does a 48v14ah battery in a frame bag, that might do the job.

      The 500c is a good little display, you can change the speed limit and PAS levels from the settings menu. For more advanced programming the USB lead is handy to have, you can change things like PAS settings to make the motor smoother. Here is a link to the best Bafang programming guide on the internet.

      All the best,
      Tony

      Reply
      • November 11, 2019 at 8:50 am
        Permalink

        Hi Tony

        This has been invaluable info. Could you please give me a live tutorial? My Bafang display has stopped working and I can’t power on but I need a bit of guidance as all the tech terms go way over my head

        Reply
        • November 11, 2019 at 10:39 am
          Permalink

          Hi Tony,

          If you can email me your phone number to: cycletek@outlook.com, I can give you a call this afternoon.

          Regards,
          Tony

          Reply
  • November 11, 2019 at 6:27 am
    Permalink

    Value for Money

    10

    Ease of Installation

    0

    Efficiency

    0

    Hi Tony, I have a 2011 Intense Uzzi with 73mm bottom bracket. Will the BBS02 clear the chainstay? Also, is the 500 watt version more reliable than the 750 watt? I don’t plan to go off-road often.
    I must say you are doing a great service helping old riders get back into serious cycling again.
    Many thanks.
    Mak
    Malaysia

    Reply
    • November 11, 2019 at 10:36 am
      Permalink

      Hi Mak,

      I have looked at the specs and frame Geometry of the 2011 Intense Uzzi, and it looks like the BBS02 should clear the chainstay. I have fitted a lot of BBS02’s to full-suspension MTB’s and this isn’t usually a problem. Worse case scenario you may need to purchase a couple of spacers. These are listed for the BBSHD, but they should also for the BBS02.

      Regarding reliability, in my experience the 36v 500w version is much more reliable than the 48v 750w version. I have only ever had one controller failure on a 500w, but I have had about 12 failures on 48v 750w controllers. What I do now with the 750w is only use a 48v battery and limit the maximum current to 18A, and reduce the start current to 10%. I haven’t had any issues with the 48v 750w BBS02 this year so far.

      Thanks you for your positive feedback, glad you are finding my site helpful. If you have any more questions, please let me know.

      Kind Regards,
      Tony

      Reply
  • November 12, 2019 at 3:33 am
    Permalink

    Hi Tony, thanks for the prompt reply. Please keep up the good work. Not many will do it gratis!
    Cheers,
    Mak

    Reply
    • November 12, 2019 at 9:33 am
      Permalink

      Thanks Mak, glad to have been of assistance.
      All the best,
      Tony

      Reply
  • November 15, 2019 at 7:38 am
    Permalink

    Hi Tony, couple more questions please. What is a good, reliable display for the 500 watt Bafang? Ditto for the 750 watt Bafang (in case the 500 watt is out of stock).
    Also, what reliable options are there for aftermarket controllers?
    Thanks for your time again.
    Mak

    Reply
    • November 15, 2019 at 10:15 am
      Permalink

      Hi Mak,

      For reliability, I always go for the old style C965 display. It’s quite basic, but it is reliable and cheap to replace if it goes wrong. The P850c colour display is also fairly good. The newer DP-C18 display can be problematic, and only allows 5 levels of pedal assist (depending on the firmware), whereas the others allow up to 9 levels.

      I have purchase a few replacement controllers from okfeet on Aliexpress, and they have always been reliable. They have good customer service as well. They are not the cheapest on Aliexpress, but they seem reliable.

      Regards,
      Tony

      Reply
  • November 16, 2019 at 1:50 am
    Permalink

    Hi Tony, we can rely on you to be not only prompt, but succinct and precise in your replies. Much appreciated.
    Cheers,
    Mak

    Reply
  • December 2, 2019 at 5:23 am
    Permalink

    Hi Tony, I just bought the BBS02 750W and after hooking it up the error code 30 appears and m stuck. try reconnecting the connectors several time and still the same. BTW i am using the DP C18 display
    hope you can help

    Reply
    • December 2, 2019 at 10:44 am
      Permalink

      Hi Derek,

      There are several things that could be causing the error code. Make sure none of the connector pins between the wiring loom and motor are bent. If they are alright, then the fault could be with the wiring loom itself (I have come across this a couple of time before). It is also possible there is a fault with the display.

      The worse can scenario is a fault with the controller itself (in the motor). If this is the case, then you would need to contact the supplier for a replacement under warranty.

      If the connector pins are looking good, I would contact the supplier to see if they can send you a new wiring harness out. If it is still showing the error code after that, then it’s going to be either the display or motor controller.

      Please let me know how you get on.

      Regards,
      Tony

      Reply
  • December 4, 2019 at 7:42 pm
    Permalink

    Hi Tony,
    Great site! Super helpful!
    I’m going to convert my wife’s size small Cannondale Bad Boy commuter bike to an ebike with the Bafang kit. We live in Portland, OR where it rains a fair amount and her commute will take her up a 1,000ft hill. With the rain and the elevation gain, would the 750w motor be enough or should I opt for the HD?

    Thanks,
    Chris

    Reply
    • December 4, 2019 at 10:37 pm
      Permalink

      Hi Chris,

      Thanks for your complements, glad you like my site.

      Regarding the motor selection, the BBS02 750w should be more than adequate as far as power is concerned. But for long-term reliability, the HD seems to be more robust (in my experience).

      Having said that, I used a BBS02 powered hybrid bike for 12 months and 2000 miles and never had any problems. I was 280lbs (at the time) and used to regularly climb 2000-3000ft on an average ride of 30 miles.

      I’ve converted a couple of Cannondale Bad Boys in the past, it should be a fairly straightforward conversion. If you need any more advice, let me know.

      Cheers,
      Tony

      Reply

Leave a Reply

Your email address will not be published. Required fields are marked *