Bafang BBS02/BBSHD mid-drive motor troubleshooting

So something's not working quite right with your Bafang Motor Kit. Don't panic! Below you will find information about what to do if you encounter a common issue. These are DIY conversion kits, so you have to be prepared to get your hands dirty and do some tinkering every once and a while!


                                 HERE IS A COMPLETE ERROR CODE LIST FOR BAFANG BBS02/BBSHD MOTORS:


ERROR 04/ERROR 05: Throttle error and throttle does not work

1. Unplug and replug your throttle making sure to line up the arrows and pins to ensure proper connection when reconnecting the throttle. Make sure the throttle pins aren't bent.

2. If Step 1 does not solve the error, unplug and replug all of the connections on your kit Main Wiring Harness (display, throttle, brake levers) including the Main Wiring Harness connection with the motor lead and Battery connections with the motor leads. Make sure no pins are damaged on the Main Wiring Harness and line up the arrows and pins when reconnecting everything to ensure proper connection.

3. If Step 2 does not solve the error, unplug just the throttle from your kit. Does the error go away? You need a new throttle.


ERROR 06: Low voltage cut-off protection

Your battery pack is providing insufficient voltage. Charge your battery pack! Make sure you are using a 48V or 52V battery with your kit.


ERROR 07: High voltage cut-off protection

Your battery pack is providing too high of a voltage. You can only use a 48V or 52V batteries with the BBS02/BBSHD.


ERROR 08: Hall Sensor error

1. First unplug and replug all of the connections on your kit including all of the Main Wiring Harness connections (display, throttle, brake levers) and all of the Motor lead connections with the Battery and Speed Sensor. Make sure no pins are bent/damaged on any of the connection plugs and line up the arrows and pins when reconnecting everything to ensure proper connection.

2. If Step 1 doesn't solve the error, the Hall Sensor plug connection (white plug) from your controller to your motor core may have come loose or has silicone interference impeding the connection. In order to fix this, you need to loosen the controller from the motor to unplug and replug the white Hall Sensor plug. You will need to check all the pins on the white plug to make sure they are straight and remove any silicone interference from the connection area and then properly replug the white plug back into the motor core.

3. If Step 2 doesn't solve the error, you either need a new Hall Sensor or may need a whole new motor core if the motor windings were burnt and blown, which caused the Hall sensor to malfunction.


ERROR 10/11: Max Temperature protection cut-off

Turn off your motor kit and let it rest and cool down could take a few hours.


ERROR 12: Controller error

You most likely need a new controller.

But just in case...first, try unplugging and replugging all of your connections and making sure there are no bent pins and everything is properly connected.

There is a slim possibility that it could be one of the plugs from the controller is not properly connected to the motor core. You can open up the controller and check the plugs into the motor core.

If you are not able to resolve the error, please create a Support Ticket here.


ERROR 21: Speed Sensor error

1. Please check to make sure your Speed Sensor and magnet are installed correctly. The magnet must be installed within in 1-2mm of the Speed Sensor with the smooth side of the magnet facing the Speed Sensor. Make sure that the Speed Sensor is fully screwed into the Motor lead plug.

2. If Step 1 does not fix the error, you most likely broke your Speed Sensor and need a new one.


ERROR 30: Communication error

It is most likely a simple connection issue.

1. First unplug and replug all of the connections on your kit including all of the Main Wiring Harness connections (display, throttle, brake levers) and all of the Motor lead connections with the Battery and Speed Sensor. Make sure no pins are bent/damaged on any of the connection plugs and line up the arrows and pins when reconnecting everything to ensure proper connection.

2. If Step 1 does not fix the error, check that none of the wiring on your setup is being pinched, especially the cables coming from the controller. Check to make sure that none of the wiring on your installation is too taught and is pulling the cables from the controller.

3. Open up the controller from the motor core and unplug all of the controller plugs and replug them again ensuring there is no silicone interference and everything is properly connected.


INTERMITTENT POWER CUT-OFF: 

This typically occurs when there is a connection issue between the battery and mount, which causes there to be intermittent instead of constant power between the battery and motor. In order for the battery to be able to properly power the motor it needs to have a solid connection with the mount that connects the battery leads to the motor. This issue can arise with wear and tear on the old 4-prong connections of the 48V 11.6Ah battery to the mount. Follow the steps below to fix this issue:

1. Turn your whole system off and remove the battery.

2. Once the battery is removed try and turn on your Bafang motor on with the power button (though the motor won't power on because there is no battery it should use any residual power in the system so it doesn't spark when you fix the connection).

3. After step 2 is completed, use a pair of pliers to tweak/ squeeze the two outside male prong connectors on your battery mount inwards to make sure that your battery has a good solid connection with the mount.

If following these steps does not fix your issue, you may have connections that are too damaged with wear and tear that need to be replaced. Please create a Support Ticket here and we can help get you some replacement connections.