Bafang Completely Redesigns The BBS02 … And Tells No One

With the introduction of the BBSHD, I had expected that the BBS02 had reached the end of its product lifecycle and would be quietly retired away. To my surprise, Bafang did a complete redesign of the BBS02 without telling any of its US based dealers what they were doing and released it without any fanfare. The new BBS02 version B has a totally different case, controller, nylon gear, pinion gear and bearing sets that are completely incompatible with the BBS02 version A. Not only that, the new controller has different firmware that does not work with ‘Karl’s special sauce’ the programming settings that all of you have gotten to know and love by now. This article will explain the differences that I’ve found with the BBS02 version A and BBS02 version B and explain how to program the BBS02v2 so that the PAS will work properly with the newer controller. We will also discuss how to go about getting the correct parts for your BBS02 version B in the event that anything should break.

Don't know what version BBS02 you have? Look at the shape of the controller and it's obvious.

Don’t know what version BBS02 you have? Closely look at the shape of the controller and it will be obvious. Version B sports the evil PacMan look. Wagga-wagga-wagga.

The BBS02 750W version B was introduced without notifying US-based dealers that the changes were coming. The pictures on their website at some point switched over to the newer version B, but that was it. This became quite a problem, as Bafang will only allow dealers to order spare parts for their drive units while they are in the middle of a production run. Bafang finished their production run for the BBS02 version B with an entirely new part set and released it out into the wild without selling spare parts for the unit to US (or Chinese) dealers. Since Bafang won’t even talk to anyone who doesn’t want to buy $500,000 worth of drive units at a time, this has left everyone out in a lurch.

The v2 of the BBS02 has a rubber washer at the end of the axle that I have yet to figure out how to get past

The v2 of the BBS02 has a new rubber washer at the end of the axle that I have yet to figure out how to get past without completely destroying it.

To further complicate matters the new controller for version B had different programming that would cause the PAS to not function properly if the “Time Of Stop” variable on the PAS programming page was set to less than 10. Since I have been touting ‘Karl’s Special Sauce’ as being the best thing since sliced bread, and those programming settings had a ‘Time of stop’ setting of 5, pretty much anyone who set their version B controller to my programming settings was sure to have a flakey PAS that would pretty much not function properly. This was less than ideal.

Rotor width on v2, the motor seems like the same unit

Rotor width on v2, the motor appears to be the same unit

I’ve updated my programming page to reflect a ‘Time Of Stop’ of 10 on all my .el files and images, but I have to admit I’m still a little miffed at Bafang. I haven’t had much of a chance to test the programming on the BBS02vB but it seems pretty similar to version A. I’m guessing the Time Of Stop changes happened when people kept complaining that when they stopped pedaling the bike would keep going for quite a ways. If you don’t have ebrakes that immediately cut the power this can obviously be a safety issue. You basically end up having to brake against the power of the motor until it shuts off even though you’re not even pedaling. Instead of fixing the firmware variable settings they somehow changed the programming on the controller to react differently to the same settings (factory default for TOS is still 25 on both versions).

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You can clearly see the differences in version A (left) and version B (right). The circular plate is different as are the pinion gear, bearing & nylon gear.

The procedure for taking the drive unit apart is nearly identical for the two units. The version B also has a rubber gasket that mates the controller to the housing to keep out water. The only other difference I found was that the Version B does not have the rubber plug above the circular plate that houses the nylon gear. The nylon gear seems to be an identical shaft diameter but the offset of the gear is different. I mounted a Version A nylon gear into a Version B unit and it was very clear that it was not going to work properly. The pinion gear is also very different and not interchangeable between the units. When you are ordering parts to repair your BBS02vB make sure that your Bafang parts dealer has some idea of whether the parts they are selling you are for Version A or Version B. If you start talking about the different versions of the BBS02 and the dealer seems to not know what you are talking about then you should probably find another dealer to work with. Right now Lunacycle has most of the different parts for the Version B drive unit, but they had to threaten to cancel a million dollar order to get them. A million dollars, that’s just crazy talk. At this point, Chinese companies are actually buying replacement parts from Lunacycle because it’s the only place they can get them from. What a funny twist of fate. I am still totally amazed that in less than a year Lunacycle has grown to be the biggest Bafang Mid drive reseller in the US to the degree that some Chinese Bafang resellers are buying parts from his US-based business. Go Eric.

If your pinion gear bearing fails you will need to get the right circular plate to replace it

If your pinion gear bearing fails you will need to get the right circular plate to replace it

Even with all the shortcomings of the BBS02 it is clear that Bafang is committed to the 750W platform. It doesn’t make sense that they would spend all the money they spent on retooling the BBS02 if they didn’t think they were going to make a whole lot more of them. I didn’t see anything in the Version B that would lead me to believe that the BBS02vB is going to be any more robust that the Version A. That being said I still have 10 ebikes with the BBS02vA that I beat on pretty regularly. The BBSHD still needs a dramatic increase in power for it to remain competitive in the marketplace. I suspect that Bafang will release a 35Amp version of the BBSHD at some point at the end of this year or early 2017 which I believe whole-heartedly that the BBSHD platform can easily support in its existing state. Keep in mind this is entirely speculation, but I believe it is coming.

IMG_20160615_122118407_HDR

You can see clearly that the offset is different between Version A on the left and Version B on the right

Does it still make sense to buy a BBS02 750W drive unit? If you are trail riding on singletrack I would say that the BBS02 still holds its own against everything else out there on the market. If you are building an electric cargo bike or a tandem or if you want to run the drive unit at full throttle all the time then the 1000W BBSHD is a safer bet. The mid drive market is heating up with the release of the 3000W Tangent Ascent which is one of the most fun mid drives I’ve ever tested. Dave from Tangent is putting together a 6000W Astro 3220 based Ascent drive unit that I’ll be installing and testing in the coming weeks which I have high hopes for. Normally 4000W would be the most power that any sane person would want to put through a bicycle drive train, but I’m not a sane person. I live only to destroy, rebuild and destroy again.

Ride On.

The pinion gear is also different between the different versions

The pinion gear is also different between the different versions

On the B version the motor case is printed with BBS02B, with the original A version it just says BBS02

On the B version the motor case is printed with BBS02B, with the original A version it just says BBS02

38 thoughts on “Bafang Completely Redesigns The BBS02 … And Tells No One

  1. Does it have better sealing for grease, because I’ve ordered 750w bbs02b and Already orderd mobilgrease 28 😀 to regrease everything before installing the kit. Just wondering.

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    • The new bearing does not look like it will be any better at keeping the grease from migrating to the primary any better than the BBS02vA. I have not tested it though.

      You can always regrease just to be safe. It’s much easier to just do the secondary side which only takes 5 minutes. Just wipe off all the grease you can and pack the primary side with the mobilgrease 28. That is probably all you have to do.

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      • I’m thinking only regrease the secondary side with mobilgreas 28 and check after a while for any leaking drama to the primary side, if its any better than the old model.

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  2. Since it is red colored so it shows if it leaks into the primary side, just for fun u know. Then I’ll grease both sides with mobilgrease 28.

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  3. The “rubber washer” is a standard lip seal quite common on industrial electrical motors and pumps its made out of a steal with rubber on the outside. On the other side it should be marked with the outer and inertia size of the seal. Just putt a small flat screwdriver between the motor housing and the outer part of the seal and pry it out, they are sheep to replace try to get one with viton rubber they are much more resilient against petrolium based products.

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  4. I ordered a bbs02 from Paul that I received two weeks ago. I must admit that I was a bit dumbfounded when I used your instructions to take it apart for a regrease and a lot of things differed between the instructions and the actual motor. Now I know why 🙂
    Guess it’s a good thing I hadn’t gotten around to do the programming stuff yet!

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  5. Does the new BBS02 have a gasket on the metal gear side like the BBSHD? If so take care not to damage it. At least one kit builder with a BBSHD tore the gasket and water migrated into the motor.

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  6. Version B is shit! Ive installed 3 version A’s with no problems! Installed my first B version on a customer and controller crapped out at 2.9km!!!! What a fucking joke! Theres nothing new or better with the version B so why the hell did they change it??? Please enlighten me and unboggle my mind!

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  7. Could you show us the way you are taken off the cover plate on a BBS02B. I have try and was not able to lift the plate.
    Thank’s

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  8. Bafang seem to say the upgrade to version B has improved “waterproof, stability, power, energy” the waterproofing upgrade catches my eye, has anyone had problems with this on the A version? I’m in China and looking to buy my first mid-drive, I am trying to decide between BBS02A, BBS02B and BBSHD.

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  9. Hi according to a BaFun distributor in China the new B model has improved waterproofing. Any ideas if this is true? I am looking to get my first Mid-Drive and wonder whether to choose the BBS02A, BBS02B or push the boat out and go for the BBSHD. Thanks.

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    • Ive used both BBS02A and B. The BBS02B lasted 30km. Needed a new controller and just recently gave me an error code 21! Easy fix but annoying! My BBS02A is still running. Waterproof wise ive never tested either. Next trial is BBSHD nx year. I hope this one last the longest.

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      • as ebike retailer im totally worried about your comment, Im about to give two kits bbs02 B to customers, and you saying that they will probablly fail at 30km… shit, this is real bad news man.

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      • I have done just over 200 km in August on my BBS02B with no problems what so ever. You are always going to have some percentage of failiur in a production series, overall i can’t se major reason why the b version who’d be of less quality. The materials chosen in the constructions seems to be the same with minor redesigns of the components. Overall i think Bafang have made a good product they just want to make more money and that’s why they have rediaignd it with a minimal of compatible parts.

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      • Gilvoni almost all chinese products has lemons. Maybe you will be lucky that you get two good ones. All im saying is if your using a bafang kit, you MUST have spare parts. I built 3 bikes this summer and that one was a lemon. I still build them because i give my customers warranty on parts.Which i have in stock. If you research endless sphere theres always a solution to these fails. With the right grease the motor itself almost never fails. Its the cheap components that comes with it that will always fail first. So have spare parts!

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  10. I have had no issues with my BBS02vB. If you install them on a bike and ride full throttle all the time then whether you are running A or B it will fail. I would take user comments with a grain of salt.

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  11. i just installed my first new BBS02B with a 965 display and i had issues with the motor pulsating (on and off that shakes the whole bike ) at low speed start on PAS but problem goes away as i pedal to increase to faster speed.
    I have made a dozen of BBS02 bike conversions without any issues.
    Have anyone experienced this? Can this be programming setup?
    Hope someone can help me since Bafang and my supplier in china does not respond to my email.

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  12. Karl,

    Have a question. I’m considering get a mid drive for my FS Commencal mini DH 2009. But I’m between BBS01B and BBS02B. I prefer the BBS01B because it is lighter. I do some DH with jumps and stuff and weight is an issue.
    Is the extra weight worth it?

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  13. i have a bunch of ego tool batteries… figured i would use them for my first foray into ebike
    is bbs02 the best ‘bang for the buck’? occasional city travel is the extent of what i plan to do. the cheaper the better, so long as it is confirmed to be compatible with these ego’s i already have. i plan to initially slap it on an aluminum walmart-bought schwinn that is basically new but just collects dust

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  14. I have on of these BBS02B that I bought from Paul in august. It was manufactured in april 2016.

    I have ordered a circular plate from Doug that I have now to return. I’m in Canada and postage is $33 for a
    $15 part!

    Also I received a large gear from Paul and it just doesn’t fit in. Way too large or different geometry.

    What a bummer.

    I’ve documented it at endless sphere for those interested. Several photos available there too.

    https://endless-sphere.com/forums/viewtopic.php?f=28&t=58898&sid=3c5856ba8084da7ad3d7ae39f4ac1569&start=900#p1260795

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  15. I purchased a bbso2 version B and within 24 days my internal nylon gear peanut butterI’m wondering if it was due to me packing the secondary Gear with the moly grease now I just got another bbso2 virgin B and I am going to pack it with the mobile grease 28 and hope for the best does anyone know if the internal gear went out on the first one due to the black moly grease used

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  16. I’m brand new at this e-bike thing, and I’d just like to say “holy crap”, there are so many things to consider ! I Hate to sound stupid but here my predicament, Just recently bought an E-bike it has a Bafang bbso2 mid mount motor, not sure what version, and its gone hey-wire. It just out of the blue decided it wanted to be unpredictable. I was in PAS 1 just starting to pedal and it took off 0 to 24 in 3-4 sec, stop pedaling and the speedometer goes rapidly back down to 0 then the battery symbol on the display starts flashing and then NO POWER. I charged the battery and now the darn thing will not even turn on. I love this bike, I’m addicted, its been four days and I need a ride !!! Can anyone help, suggest something to try ? How do a know if I’ve fried my controller ??? Thanks for reading !

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  17. I just received a new BBS02 and it had two small short wires out of the motor black and black with white stripe. Anyone know what these wires are used for? They have small female spade connector. The wire is about 24 Awg.

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    • I think that cable is for lights 6v maximum 300mA gets turnd on if you hold the + button for a couple of seconds along withe the back lighting on the display. On my motor it is a red and black wire the white cable was cut off.
      I connected it up to a relay and a fuse and used a buck converter to get a voltage from the battery that I could use for a headlight.

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