What’s Inside a Mid-Drive Motor EBike Conversion Kit (Box Opening and Testing)

If you have decided to convert your current bicycle to an eBike, you may choose to incorporate a mid-drive motor kit. These motors are a great addition to your bicycle and a great way to break into the world of electric bikes. The box will come with multiple components, listed below.

I will create a list of items found in the box when purchasing a Bafang BBSHD 1000-watt, 52-volt mid-drive motor kit, and I will also summarize the testing procedure for the new motor.

Continue reading to find out more!

What’s In the Box?

When unboxing the Bafang BBSHD 1000-watt, 52-volt system, you will see multiple items. Below is a list of each component found in the box.

• Bafang 1000 W motor
• Brake handles with brake shutoffs
• Left and right cranks
• Standard 46-tooth chain ring
• Extension for battery power hookup
• Assorted nuts and bolts for assembly
• Tool to tighten the motor to the frame
• DCP 18 display unit with USB charging port
• 6-volt light
• Throttle
• Crank Puller and bottom bracket tool
• Speed sensor
• Main wiring harness
• Washers
• Gloves
• Zip ties
• Stickers (to show legality if biking in Europe)

Connecting the Components in the Box

While unboxing the mid-drive motor, many make the misconception that the display module is the heart of the motor kit. In actuality, the controller, found inside the motor housing, is the heart and main component of the mid-drive motor kit. The display simply shows speed and allows you to change modes and pedal assist settings.

The first step to testing the Bafang mid-drive motor kit is to set the motor on a piece of cardboard, countertop, or floor, with the wires that are built in spread out neatly. Each wire attached to the motor serves a separate purpose. The wires leading out of the motor will be the main wiring harness, the speed sensor, the shift sensor, extra accessories like lights, and the battery cable.

Lay out all of the items that came in the box, and begin attaching them to the correct cables coming out of the motor. First, hook up the main wiring harness. Each item will have arrows on it showing how to plug them in. There are four leads coming off the main wiring harness: two yellow female ends that connect to the brakes, one green-tipped wire that connects to the display, and one yellow wire that leads to the throttle.

Hook up a single brake to the brake wire for testing purposes. Next, hook up the speed sensor. This item has a magnet inside that feeds signals to the controller. The shift sensor is an optional item and does not affect the testing. You can hook the speed sensor up, but it is not necessary for this portion. The next wire is for accessories, so you can hook the 6-volt light that comes in the Bafang kit up to ensure it works properly pre-installation.

Lastly, hook up the battery wire. Ensure the battery is turned off prior to connecting the wires. Keep in mind this kit does not come with a battery. You will need to purchase a battery separately. Make sure you have a battery with the proper voltage. Each motor is rated for a certain battery voltage. This model, the Bafang BBSHD mid-drive motor, is rated for a 52-volt battery.

These wires may feel stiff. This is because they are water resistant. Water resistant cables are thicker due to the higher level of waterproofing. Because this system is plug-and-play, it is simple to put together and will not require any difficult programming.

RIDE e MTB Tip: Are you thinking about building an eBike? It isn’t very hard – Heck I’ve got step by step instructions with videos along with all the tools. Check it out 👉 How to Build a Mid-Drive Electric Bike

Testing the Components in the Box

Now that everything is hooked together, you can begin the testing process. First, use the switch sensor to turn the display unit on. This unit will give all pertinent information regarding speed, eBike mode, and pedal assist level.

Turn up the pedal assist level. This is a good test of the motor and will ensure it functions properly. Once you have upped the pedal assist level, use the throttle. You will hear the motor engage. Change the assist level a few separate times and listen to the speed of the motor change.

Grip the brake and ensure the motor shuts off when the brake is engaged. Turn on the included light and make sure it functions properly.

Using the switch sensor, you can switch the eBike motor into sport mode. Sport mode gives maximum speed. Hold down the plus key, which will switch the motor to sport mode. Listen to the motor speed and note the increase.

Next Steps

Now that you have ensured your motor functions are properly and all wires and components are in tip-top shape, you can install the motor kit and all its parts and pieces on your bicycle. Always ensure you have test fit the motor and battery to ensure your bicycle has the proper dimensions to support the conversion kit.

You will first need to disassemble your current bicycle (I recommend a bike stand to make this process easier). You will need to remove the pedals, crank arms, front derailleur, bottom bracket assembly, chain, front and rear brake cable, and handlebar grips. If your bike has shifters and brakes integrated together, leave the right-side assembly if you will be using the shifter.

Assembling the motor and battery on the bicycle is more complex than disassembling the old components. You will want to refer to the user manual included with your mid-drive motor kit for complete instructions. You can also read another of my articles that details attaching the mid-drive motor kit and battery to a bicycle. This article will give good information on attaching this kit to your bike and will help get you on the road or trails quickly!

RIDE e MTB Pro Tip: With eBikes growing in popularity learning all the terms and definitions can be a bit overwhelming. Let me help with this comprehensive glossary. 👉 eBike Glossary

Wrapping Up

The main considerations when converting a bicycle to electric are to ensure that your current bike frame has the proper dimensions to support the motor and battery setup, you have room to run the necessary cables, and that your battery and motor are the proper voltage to combine seamlessly.

The next step after checking out the items in the box is gathering the tools. Read about the tools you need 👉 Tools Needed to Build a Mid-Drive eBike

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