Clyte Cristalyte HS3540 european delivery

Hi,
I just opened my HS3540 after almost 8 weeks waiting time.

Not bad looking from outside. Very different from inside

There is only one known problem which is fixed.

Take a look at the pictures:

The rubber sealing is rubbing the cable


windings are done in a very poor way, touching the metal frame all the way. Soon or later it will short




the cover has a very small opening for unknown reason, milling it to 25mm diameter will open place for a slave bushing (pipe ID 17, OD 24, length 22mm) which will keep the wires in the channel.


alto some more knowledgeable members than me succeed to install big wires, my 12AWG silicone will not fit without modifications.


Also some insulation damage:


all the pictures:
https://picasaweb.google.com/103032106192258014983/CristalyteHS3540#

The casting of the motor is very good, but the assembly quality is very poor.

as HS3540 cost the same as 3 GM48V1000W can you guess what will be my next purchase

some disappointment: seems 6004 bearing will hardly fit, it is 42x20x12.and these 20 compared to 17mm can provide some more space for the wires, but the casing wall will get very thin

I always thought that Crystalyte is a higher end product, at least compared to 9 Continent. I have not opened my 9C hub yet but when I do, I will know what to look for. Thanks for the report.

looking forward to allow some 10AWG wires to fit without much torture I can propose using different bearing with 25x37x10mm, two metal rings, where the additional mouse hole in the inner ring will provide enough space for the wires
The new bearing is not as strong as the original, but this is the trade.

here is the rev.1 idea



the black area is the new bearing itself

The motor is now "sensor ed" with ss411a, using ptfe insulated silver wire.

The housing diameter is bored to 25mm

New plastic bushing installed, in order to keep the wires away from the side cover.

Nice work there. I wish I could get you to upgrade my HS for me. I have been running mine totally stock on my 20S@50amp greyborg, just playing russian roullete with it, i know my phase wires are damaged from rubbing and from me twice spinning the motor in my dropouts. But I am like one of those old school guys who suspects he has cancer and refuses to go to the doctor in case he gets bad news....

pavlik ,
thank you for openning your motor and pointing it to us.
I totaly agree - machining quality of metal parts is acceptable as good as it gets for Chinese brand, quality of alloy/metal is a different thing.
Horror stories of metal collar shearing from 5series motors and other dissasters of series 5 motors are well documented on ebikes.ca website in Maintenance section.
I totally agree, windings on this new HT/HS China motors are shoddy and touching metal frame - that's really bad and somebody must had been blind not to see it before relieasing it into production.
Yes
But writing about it are we not malcontents like some called you in other thread?
I must say riding on this is a Russain rullete.
I prefer to spend more and spend my time riding my ebike than fixing problems.

Motor still running after thousands of kilometers

running on 48V, max battery current 40A