Bafang BBS01 harness issues

[bluesoleli]

Hi Everyone,

Just currently helping a friend with a Yuba Mundo (not me, who wanted a BPM on the Yuba) trying to install a BBS01 motor and has hit the wall with the wiring harness being too short if threaded along the top tube along the Yuba mounts for wiring (along with brake cables etc.). The harness and connectors get to about 3/4 of the way up and around the frame and then it's not long enough for a clean install!

I noticed the harness has like a 9 pin plug or whatever that comes out of the motor and into the harness which houses the display, throttle and ebrakes. Is there such thing as a longer harness or extension cable from motor to harness? I see extension cables for display, but that's only half the problem right now... we still need it for e-brakes and throttle. Hmm...

Strangely, I was watching a review from EBR where Court Rye reviews the Bafang BBS02 Surly big dummy and they managed to get the cable around the frame really clean - how did they do this?

http://electricbikereview.com/8fun/bbs01/

Thanks.

 

[samsavvas]

Hi Everyone,

Just currently helping a friend with a Yuba Mundo (not me, who wanted a BPM on the Yuba) trying to install a BBS01 motor and has hit the wall with the wiring harness being too short if threaded along the top tube along the Yuba mounts for wiring (along with brake cables etc.). The harness and connectors get to about 3/4 of the way up and around the frame and then it's not long enough for a clean install!

Hi,

I have a Surly BD in Adelaide. My BBSxx harness is plenty long enough to travel up the seat tube and along the top tube to join up with the various control leads. I can't imagine why the Yuba should be any different. You may want to check that you are not losing cable length somewhere in how you are routing it - maybe as it comes out of the motor housing. I find it's best to bring the cable out to the rear and between the chain stays and straight up the seat tube. However if you are running out of length, why not take it straight up the down tube? If there are no braze-ons just use cable ties or maybe those little plastic clip-on cable clamps (ebay or any of the Eu bike stores).

Of course, depending on where your friend obtained the BBSxx kit, you may indeed have one that has a shorter harness. I know that in Germany (where the kist is fitted to many different types of bikes), it's possible to buy the kit with a harness length to suit the style of frame (particularly with regard to recumbent use). You may also want to check the GreenBikeKit web site where there are some extra cabling options that may be of use, Paul at EM3ev has also been very helpful with problems such as yours.

I think that the BBSxx installation at the E-bike Review website you mention looks pretty dodgy. The battery is very poorly mounted from a mechanical and safety p.o.v! I wouldn't be trying to copy it!

Sam.

Edit: Maybe check these Mundo builds out for some ideas:

http://www.cargocycles.com.au/kranky-mundo-yuba-mundo-centre-drive-electric-assist-cargo-bike.html

http://endless-sphere.com/forums/viewtopic.php?f=6&t=64647

It looks like both have taken the main BBSxx cable straight up the down tube from the motor to handlebars. In your post you mention that the Mundo provides some sort of mounts specifically for electric assist cabling. Despite having been around a few Mundos I wasn't aware of this, but it looks like they won't be of much use to you anyway - they may have been designed with hub motor assist in mind. Interesting that Cargocycles build makes good use of one of the commonly available controller enclosures - presumably to keep the rat's nest under control. GBK have these. I suspect that they have also had to use an extension cable for the rear wheel speedo sensor. Also from GBK (and elsewhere).