FLUX–Bafang Stator InstallationUpdated an hour ago

Guidelines, Required Tools, and Procedure for Replacing the Stator on the Bafang Rear Hub Motor Used on the Pure Cycles FLUX E-Bike

The following procedure outlines the recommended steps and required tools for removing and replacing the stator assembly on the Bafang rear hub motor used on the Pure Cycles FLUX E-Bike. Care should be taken throughout the process to avoid damage to the motor components, axle threads, wiring, and sealing surfaces. 

Before beginning service:

• Power off the bike completely
• Remove the battery from the bike
• Work in a clean, organized service area
• Protect all motor wiring and connectors during service
  
  

Recommended Tools:

• T-20 tamper-resistant Torx bit or wrench (hollow-center type required)
• T-25 Torx bit or wrench
• Park Tool FR-1.3 freewheel remover tool (optional)
• Park Tool HMR-8 hammer or other non-marring hammer
• Park Tool ATD-1.2 Adjustable Torque Driver or similar capable of low Nm settings
• Clean shop towels
  
  

Removal Procedure

1. Remove the wheel from the bike
   
   
2. Remove the following axle hardware
   • Both axle nuts
   • flat washers
   • Both non-turn washers 
   • Freewheel spacer washer
3. Remove the freewheel (optional) 
   • Remove using a Park Tool FR- 1.3 freewheel remover tool
4. Remove the brake rotor:
   • Remove the six (6) rotor bolts with a T-25 Torx bit or wrench
   • remove the rotor from the hub
5. Remove the hub motor cover bolts
   • Remove the six (6) bolts using a T-20 tamper-resistant Torx bit or wrench
   • Note the T-20 Torx tool must have a hollow center to properly engage the tamper-resistant bolts used on Bafang motors
6. Remove th stator assembly:
   • From the drive side, lightly tap the axle with a non-marring hammer to separate the stator from the hub shell
   • Protect the axle threads during removal to prevent thread damage
   • Carefully separate the stator from the hub shell
7. Remove the cover plate from the original stator assembly
   
   

Installation Procedure

1. Install the original motor cover plate onto the replacement stator assembly.
   
   
2. Insert the new stator into the hub shell 
   • Carefully align the cover plate holes with the hub shell holes
   •     Ensure the cover plate is fully seated into the hub shell with no visible gap
3. Reinstall the six (6) cover plate bolts:
   • Use a T-20 tamper-resistant Torx bit or wrench
   • Tighten bolts evenly in a cross pattern
   • Torque specification: 4 Nm
4. Reinstall the brake rotor:
   • Install the six (6) rotor bolts using a T25 Torx wrench
   • Torque specification: 4 Nm
5. Reinstall the freewheel
   
   
6. Reinstall axle hardware in the following order:
   • Freewheel spacer washer (drive side)
   • Both non-turn washers 
   • Flat washer (non-drive side)
   • Both axle locknuts
7. Re-install the wheel to the bike