I saw your build for battery holder is very impressived.Myself have tested on 4x 12v x 12hr battery it couldn't last me acceptable range. So what happens i add another battery 5x 12v x 12hr battery SLA. It works fine and it gives me a range isn't too impressive say about 20km+. that is 5 SLA batteries!! so after i had a considering i upgrade my batteries a lifepo4. (I personally against anyone to buy from vpower batteries, got issue, battery cells too many= too many connection is too many problems) luckily my battery pack last me very well until now. You can vist my flickr.com/photos/kentlim26 i used my cyclone to run 43km (1000watts kit) range with a wonderful speed, nice wind sound at high speed!! Go fast is safe for the controller, Don't go too slow. The motor is build to run fast at least 2000rpm. now i am using the other kit 900watts cyclone motor.. the range is better (at least above 55km), further, troque is higher, and it can cadence your pedal speed, can say very silent to run the motor as it used plantary gears. You can buy the motor 900watts ~1200watts if you like to change them. The 48v controller can work with 900watts kit. (can consider please!!) you will see your range is further much much more. I am using a lousy end lifepo4 battery. Kelly controller can also match with cyclone 1000watts motor too, incase if you like to do a upgrade, as for the wiring i am not too sure.
As for the spokes (how old is your bike??) is your chain is very old - how many kilometers you have run ? This one you got to watch out, never used a super old chain, must changed them when is too old. as for me, i think i will change them every 6months for using or you feel it was wore off. the spokes thing, my broke off few times, make me shocked !!. There are thicker spokes for 26inch wheel, use the thicker stainless steel ones (was my recent discovery). it sure can accept 60km/h speed without breaking them. Nevermind, the shop owner recommend me spokeless rim i used it. I think they are a good match for cyclone motors. i bought it at SG$145.00 only. name teny rim. used a thicker spokes, it will solve all the problems. If you are using a very old spokes, please checked them every few trips of hi- speed. * some information about bicycle chain - KMC chain can accept 1200kg of tension*, so i think other nice branded bicycle can do that too. some are rustless type
I know the range you are getting for 4 SLA batteries... - the voltage seem to finished very fast right ? I had even thought cyclone motor are power eater flat my batteries within mins. the answer wasn't exactly correct. It is the SLA batteries inside got nothing much give out, except some peanuts current for the cyclone motor. It cannot match with the cyclone motor for a acceptable range. Now i am using my lifepo4 - i have felt myself like bird free from a cage. I can go to my dream stalls and eat my favourite food ( singapore got plenty of food stalls thousands of food varieties) i never worry about my range.
please visit my thread. you also need to build a soft connection. Using a 300k 5watt or 10watts to connection the power + to + the controller .. Switch on 1st, then 2seconds later... Switch on the main one + to +. use a double switches.
Conhis hub motor run on April 2010, 48v 1000watts hub motor distance run 5800km, and Re~alive cyclone kit bought in year 2009, Bought a greentime controller 18fets- 4110 , 48v~ 90v , 3-speed mode. Latest top speed I got for my greentime controller 76.8km/h ! , yet to reach 80km/h, or I will never reached 80km/h ?