Indeed it´s a difficult task to get the bike approved.
So many details have to be taken into consideration.
This is just a small list of the points that had to be taken care of:
1. Chain guard around the radius where the cranks rotate.
2. Detailed information about the battery. ( Cell type, manufacturer, Kw/h and voltage )
3. Controller manufacturer ( Technical data )
4. Industrial type connectors ( Waterproof automotive types )
5. Tail and Headlight with E-approval. ( I used LED types to prolong battery live )
6. Electric Horn
7. License plate holder
8. Rear view mirrors.
9. Disc brakes with visible oil reservoir on the brake levers
10. ECE R100 approval ( This is damn tough and costs a small fortune if you plan to manufacture in series )
11. Details about the suspension
12. The bicycle tires had to be discarded. I´m using 18 * 3.00 inches Heidenau tires. The bikes handling improved dramatically.
Feels so secure and flats are now a thing of the past.
13. A light ( Green LED ) that shows the rider when the throttle is armed and ready.
14. Speed limit of 45 Km/h. Has to be tamper proof!
15. A self retracting kickstand is a must have!
16. This is not necessary but i did it anyways for security reasons. An hydraulic pressure switch in the brake hose turns on the rear brake light when the lever is pulled.
17. A rear reflector must be installed.
18. The license plate has to be illuminated.
19. The disc brake system is tested with a decelerator that is bolted to the bike and measures the meters per second the brakes have in stopping power. This test has to be repeated 10 times without any fading!
They told me that i´m the first here in Saxony to go through the entire process and finish with a street legal e-motorbike.
But there will be others in the rest of Germany. Not everyone here forms part of the frightened about everything dudes on the Pedelecforum!
In the end it´s plain and simple.
Everyone said that this is impossible.
Then some guy came around that didn´t know this and just did it.