I upgraded the motor to a AstroFlight 3215. It's just a bit higher power and faster. I also changed from using the BEC & Servo tester to the new beta version ebikes.ca RC Cycle Analyst, which has the BEC and servo controller built in. Pictured here is my entire new RC e-bike system.
It took a little while and I thought it broke my ESC, but eventually I figured out how to make the beta version of the ebikes RC CA work with my Castle Creations Phoenix HV ESC. It didn't break it but apparently the RC CA sent signals to the ESC that caused it to flash error codes, so I had to do a full reset of the ESC using the CC management software to clear the errors.
Here are the RC CA settings that worked for me: http://recumbents.com/wisil/e-bent/rc_d ... nalyst.htm
Here are the CC HV160 ESC settings that worked for me: http://recumbents.com/wisil/e-bent/rc_d ... ttings.htm
Here's the new motor mounted, I had to cut a notch in the frame to make it fit.
I sent the ESC (controller) back to Castle Creations to be upgraded to a Phoenix ICE2 as part of a service advisory. It took a long time for them to upgrade it.
The real world is finally getting warmer and I was able to take it for a ride around the block (actually several laps around the block). The controller works well, though it seems like minimum throttle cuts in a little harder than with the old servo tester / BEC system. Performance at very low speeds seems to be comparable to the old servo tester / BEC system, so I still have to pedal up to 5 MPH or so before throttling up. The new motor has a bit more grunt and longer legs. I had the CA set to cut off at 99A and 35 MPH, and the power definitely shut off at 35MPH and did not all more throttle until I got below 35. With the 3210 it maxed out at 30 MPH. When I looked a the IMax (amps) later it showed a max of 99 amps. 80 amps was max with the old motor..
Next I need to remove the speed limitation to see how fast it goes, and see if the watts / mile is significantly worse than the 26 wh/mi average with 30 MPH cruising that I was seeing last year. I really don't need to go faster than 30 MPH on a bicycle so I will probably be changing the final gear to a bigger chainring to reduce the max speed.