How to Install an e-Bike Conversion Kit with Battery: A Step-by-Step Tutorial
Worried that your favourite bike isn't built to handle an electric motor?
Our guide reveals how any quality frame can safely support a high-performance e-Bike conversion kit with battery without compromising its integrity. From motor alignment to clean wiring, we simplify the process so you can stop second-guessing and start riding your custom-built machine today.
You already love your bike. It has the perfect frame, the right seat, and years of memories. But what if you could keep that familiar ride while gaining the power to flatten every hill in your path? It is a common belief that you shouldn't have to choose between your favourite bike and the efficiency of an electric motor.
With the right guidance, a professional-grade conversion is well within your reach. Whether you are looking for a reliable commuter or a high-torque off-road beast, this step-by-step e-bike conversion guide will walk you through the entire process of transforming your ride into a high-performance machine.
Why Choose a DIY Conversion?
Before we dive into the e-Bike conversion kit installation, it is important to understand why more riders are choosing the DIY route. Beyond the thrill of building your own machine, e-Bike conversion kits offer incredible value.
- Massive Cost Savings: Instead of buying a brand-new electric bike, you can save on fuel and parking costs by upgrading the bike you already own.
- Performance Without Limits: You can achieve speeds of 20 to 50 km/h, potentially saving you up to 80% of your travel time.
- Eco-Friendly Commuting: Riding an e-bike is entirely emission-free, helping you protect the environment while staying active.
- Reduced Physical Strain: Pedal assist modes reduce the stress and impact on your knees and thighs, making long distances feel effortless.
Essential Tools & Preparation
To ensure a smooth DIY electric bike installation experience, you need to have the right tools ready. Most of our kits, including the BAFANG e-Bike conversion kit, come with specialized tools like a crank removal tool and a ratchet wrench to get you started.
Your Toolkit Checklist
- 6-sided wrenches (4mm, 5mm, and 6mm)
- Flat wrenches (19mm and 21mm)
- Screwdrivers
- Cable ties (for neat wiring)
- Gloves
Before you begin, ensure your bike is compatible. For a BAFANG mid-drive kit, your bottom bracket should ideally be between 68mm and 73mm. If you are opting for a rear wheel e-Bike conversion kit UK riders love, check that your rear drop-out width is between 135mm and 142mm.
Explore Our Premium e-Bike Kits
BAFANG 500W 48V Rear Hub Cassette Motor Kit
This kit is the perfect middle ground for riders who want significant power and a high top speed without the complexity of a mid-drive install.
- Speed and Power: With a max torque of 65 Nm and 470 RPM, this motor can easily reach speeds of 25 mph (40 km/h).
- Wheel Sizes: Available in 20-inch, 26-inch, 27.5-inch, and 700C options.
- Compatibility: Designed for bikes with less than a 9-speed cassette and a rear dropout width between 135mm and 142mm.
SUTTO/BAFANG 250W Rear Hub Kits
This is our go-to recommendation for UK riders who want a street-legal, reliable commuter.
- Best for: Daily UK riders seeking reliability and a smarter way to move.
- Performance: 36V nominal voltage with 45 Nm of torque for a natural pedal feel.
- Compatibility: Fits 20″, 26″, 27.5″, and 700C wheels, and works with 8–9 speed cassettes.
- Speed: Street-ready assistance up to approximately 20 mph (30 km/h).
BAFANG 750W 48V Mid-Drive Kits
This mid-range powerhouse offers a perfect balance of torque and efficiency.
- Core Data: Features the MM G340.750.C motor with a speed limit of 45 km/h.
- Torque: Delivers a maximum effective torque of 100 Nm.
- Battery Pairing: Often paired with high-capacity 48V 17.5Ah (840Wh) batteries using premium LG cells.
BAFANG 1000W BBSHD Mid-Drive Kits
For those who want "unrunnable" power, our mid-drive motor kits selection includes the high-torque BBSHD.
- Best for: High-performance off-road builds requiring extreme strength and speed.
- Power: A massive 52V system delivering 160 Nm of torque to conquer the steepest hills.
- Fitment: Designed for bottom bracket sizes between 68mm and 73mm.
- Customization: Choose your chainring size from 36T to 52T to match your specific terrain.
The Step-by-Step Installation Guide
Now that you have your BAFANG conversion kit ready, let's get to work.
Step 1: Install the Motor
If you are using a rear wheel e-Bike conversion kit, replace your existing rear wheel with the motorized hub wheel. For mid-drive motor kits, you will need to remove your bike's original bottom bracket and slide the BAFANG motor into the shell. Ensure the motor is snug and secure using the provided nuts.
Step 2: Mount the Battery
The battery is the heart of your build. Most riders mount the HAILONG battery to the down tube using the bottle cage holes. Make sure there is enough clearance for the battery to slide in and out of its cradle.
Step 3: Attach the Controls
Mount the display in the center of your handlebars for easy visibility. Install the speed throttle and the eBrake levers. Our kits provide mechanical eBrake levers or sensors for hydraulic brakes, ensuring your motor cuts power the second you apply the brakes.
Step 4: Wiring and Cable Management
Connect all components using the 1T4 cable. This single harness connects your display, throttle, and brakes to the motor. Use the provided cable ties to secure the wiring along the frame, keeping it away from moving parts and ensuring a clean, professional look.
Final Safety Checks
Before you hit the road, we always recommend a final inspection.
- Check Tightness: Ensure every bolt, especially on the motor and battery mount, is fully tightened.
- Test the Assist: Lift the drive wheel and engage the throttle or pedals to ensure the motor kicks in smoothly.
- Brake Test: Verify that the eBrake sensors successfully cut motor power when squeezed.
Comparison of e-Bike Conversion Kits: Which Is Right For You?
When looking at a comparison of e-Bike conversion kits, remember that hub motors are generally easier to install and great for flat city commuting. However, a BAFANG mid-drive kit setup offers better weight distribution and higher torque for steep inclines.
If you are looking for a front wheel e-Bike conversion kit or a specialized BAFANG 500W front hub motor kit, these can be excellent for simple installations, though we often recommend rear or mid-drive for better traction.
Your Expert Partner in e-Bike Conversions
Installing a BAFANG e-Bike conversion kit is a rewarding project that changes the way you see your city. Here's why thousands of UK riders trust us:
- We're BAFANG Specialists: As the leading BAFANG repair centre in the UK, we don't just sell kits. We understand them inside and out. Every BAFANG e-Bike conversion kit we stock has been tested, tuned, and backed by real-world expertise.
- Professional-Grade Components We stock premium electric bicycle kits built for UK conditions. From waterproof connectors to reinforced cables, every component meets our quality standards. Cheap kits fail. Ours don't.
- Comprehensive Support Got questions during installation? Hit a snag three months later? Our technicians are available via WhatsApp for quick diagnostics and expert advice. Send us photos or videos, and we'll guide you through any issue.
- Complete Kits, No Surprises Every kit includes everything needed for installation, from tools to cable ties. No hidden costs. No missing parts. Just complete, ready-to-install systems.
- UK-Based Fast Shipping We're based in the UK, which means fast delivery and no customs delays.
- Expert Repairs When Needed: If something goes wrong down the road, we offer specialist repairs for every e-bike hub motor system and BAFANG mid-drive kit. From motor rebuilds to controller diagnostics, we restore performance quickly and reliably.
