Super hiryuu - A BBS02 / Leafmotor / MXUS 3kW Dual sus. bike

One note about the BBS02 kit..

The pedal thread on the drive-side stock crank arm went loose on me after 50 miles and the pedal kept threatening to fall off onto the ground while riding as a result, despite me constantly tightening it.

I replaced both crank arms and noticed something.. the chainring side would stick out about 10mm, causing me knee pain. I thought this was just my crankset, so i swapped out 4 different cranksets and saw that the problem was in the BBS02 drive's bottom bracket's design.

If your stock crankarm threads go crap on you, you can stick a regular bike crank arm on the non-chainring side, but you are going to need a chainring-side crank from a crankset that was designed for a wider bottom bracket, but 1 or 2 chainrings instead of 3 in order to correct the offset.

In my case, i have hooked up one of those cheapo walmart single speed bike cranks on the chainring side, and this corrects the offset enough to continue riding.

Will update with a pic later.
 
[youtube]7iGlK1M9dJ0[/youtube]

I have to file/grind this crank down tomorrow. I have corrected only half of the offset this way. The pain in my right knee while riding has discontinued, however.
 
The filing of the crank was mostly successful, i've got some more to go still, but eventually it will be nice and equidistant.

After 3 years, i finally got a flat on the Schwalbe Marathon Plus tires. It was after riding offroad very fast and at the limit of my bike and body through a gulley that was absolutely chock full of goathead stickers!

I suppose i shouldn't be surprised that after that drifting sideways through sand and foliage at 30mph, i got a side-puncture. Completely avoidable if i can manage to just behave :)

[youtube]0dpz0Sh-V-c[/youtube]
 
You look good Nepi!

I'm down 22lbs. I'm 51 and I'm just below my weight when I was 30 :)
No sugar, dairy, wheat.

I cheat a bit, but most of my food intake is RAW :)
Juice some RAW beats. It will make your lower intestinal track happy ;)

Peace Electrical Brother!


Tommy L sends....
 
Thanks, Tommy!

I've been going through physical therapy this winter and can almost walk fairly well.. can pedal well on a recumbent bike at the gym, but not on this bike, due to the seat positioning and pedal offset.. eventually it hurts quite badly :/

So i'm looking for something more powerful that i can ride with the pedal input being more optional than required. ( which is how all my other bikes were built anyway. )

I've decided to get rid of the BBS02 kit. It just doesn't have enough power for me. It gets amazingly hot just on stock power... there's no potential in giving it more juice, unless you want to increase the voltage and thus increase the cadence past the point where it's pedal-able.. in the future, i may consider a higher powered mid drive for this bike though.

I've decided to order up one of the newer leafmotor hubs based on it's efficiency claims, which are impressive. It will either go on this bike or my 700C aluminum hardtail. I'm basically going to be the guinea pig for this motor. Going off the efficiency graph, it is more like a 1750-2000w continuous motor than a 1500w motor.

leafmotor.jpg


http://www.leafbike.com/products/di...w-rear-hub-motor-bike-conversion-kit-987.html
 
Project update.. i've decided to ditch the bbs02 due to it's wide pedaling characteristics and offset on the right side cranks. I tested it on a 68mm BB bike ( this bike is 73mm ) and the problem with offset and wideness persists. Since my knees are damaged from a fall 2 years ago and also congenital deformity, it is not comfortable or painless for me to ride.. so i hereby swear off mid drives until one comes about that has normal bottom bracket spindle length.

The BBS02 is a good piece of kit, otherwise. I really enjoyed riding with it offroad. It felt like it did not interfere with the bike's characteristics at all ( handling, center of gravity, suspension, etc ) unlike a hub motor.

I thought about going back to a tried and true MAC motor for this bike, but i've got this motor on the bike now and it is now officially my favorite hub motor due to it's efficiency and high output per weight.. my tests and data on that motor are here. I will update this thread with pics later.

Leaf / leafmotor / leafbike 1500w motor
http://endless-sphere.com/forums/viewtopic.php?f=30&t=66489
 
superhiryuu_2015.jpg


The bike is now finalized. I am super stoked on the result. It is capable of going 40mph for long periods of time and has no problem kicking butt up 7% grade at 30mph.. no heat problems whatsoever at the motor and super efficient.. effing love it.. this bike is like the grand concerto of my ebike building: it does everything i want to do, and does it extremely well. Not sure if i will build anymore ebikes after this... will probably start working on an emotorcycle next.

Battery: 20AH 15C 12S ( 47v nominal ) Zippy lipo ( eventually will upgrade to multistars or maybe even high density 18650 )
Top speed: 38mph ( 100% mode ), 45mph ( 120% mode )
Controller settings: 65A batt, 180A phase
Controller: em3ev infineon-type 12FET
Tires: 2.0 Schwalbe Marathon Plus ( upgrade to Schwalbe almotion in the future )
Frame: Turner O2 circa early 2000's.
Frame bag: em3ev with the logo taken off ( i plan on sewing on my own custom one. )
Brakes: 203mm shimano icetech up front, regen on setting '1' on back.. no rear mechanical brake.
Torque arms: ebikes.ca + custom setup.
Shocks: fox shock float R in rear, rockshox tora 'superlight' up front.
Max power: 3000W.
 
Didn't see this video in the leafbike motor thread? :) anyway..

[youtube]HvaqMXdixaM[/youtube]
 
[youtube]GGYlNlor_Vc[/youtube]

Bumped up the amps today and saw a max of 87A. Looking at the video, i seem to be accelerating about as fast as videos i've seen of crystalyte H4080 motors.

Going on a 10 mile ride tomorrow at 40-45 and will update with results to see if heat accumulates in the motor, etc..

I really want to get this motor hot. I'm not there yet. It probably needs 100A, but we'll see.
 
leafmotor_time2vent.jpg


Did a 22 mile ride with the leafmotor at 35-43mph with lots of stop and go and hilly action.. it was 67f outside with minimal wind.. by justin's math i would have hit around 110C at the stator on the way back ( steady 1% grade going home, and was averaging 40mph all the way home. ).

I think it's time to vent this motor. 90% of the road into Salt Lake City is 40-45mph.. i need just a bit more thermal headroom, because if i hit a headwind on the way back or whatever, i'm screwed.

Did not smell varnish coming out of the motor when it was at 127F thankfully. 127f was the peak temp after letting the motor sit.
 
Thanks nep for the leafmotor specs, putting my order in for same motor next week,im very excited.
 
Glad i could be of help!
Not much going on with the build. I have been busy hunting down a used hybrid car. With gas prices being low, it's really a buyer's market at the moment. Picked up a Honda Insight for $2,500 yesterday.. that's another project for another thread though... :)

I found out that a weak link in my system was yet again the 12fet controller. After that long ride, the 12ga. battery wires were very hot.. i figure that i am getting less performance and efficiency due to voltage drop, which gets as bad as 3v of drop... This is not acceptable.

So what i did was unsheath some 16ga. copper wire and solder it to the power traces on the controller. Then i doubled up the phase wires so that they were 12ga x 2.

I suspect that there will be a notable difference in performance and watt hours per mile from this, which is something that i could use, considering that i only have 1.1kw-hr on board.

This is NOT my best soldering work, but my tip is basically beginning to fail me after soldering a crapton of 10 gauge joints whilst making battery harnesses etc. It'll do tho..
 
Apparently, yes.

I momentarily shorted a FET to the power rail while soldering, then removed the solder and checked for continuity and it looked like i was in the clear. I looked for continuity extensively.
I suspect that some leftover charge in a capacitor hit a FET leg.

The controller did operate at full amperage for a few minutes when i installed it on the bike, which was odd.

I've got an 18FET on the way, so no more worries about pushing the 12FET to the maximum it can tolerate, i suppose.

I will also do this mod in a cleaner way in the future.. IE, use a tip that isn't half dead.
 
Well, my ol 12fet 4011 came to the rescue. Gets hotter on the 70 amps i set it to. It is the weak link now while i wait for an 18 FET.

I ran this motor on 20S Lipo today. Unloaded speed is something like 70mph and 85mph on 115% mode... accelerates like a monster.. doing 45 up 3% grades.. gahahaha! yea, the motor and controller didn't like that much tho... :)
 
[youtube]TmoRNMSzHjY[/youtube]

Hit 60mph today. I'm amp limited to 75A on a 12FET 4011, so i'm sure i could have gone faster.. but i just wanted to see what 72v could bring.

Anyway, i took a particularly hilly ride at 48v right after, and got the motor a bit hot. I think as the temperatures climb, i can no longer abuse this motor at 43mph for long periods of time.

It is time to vent it.
 
Okay, big update.

Drilled cooling holes in the hub motor.

I've got a manitou air shock up front now. I also replaced the mechanical disc brake with a tektro auriga e-comp hydraulic.. holy crap, that was a huge braking upgrade! the shimano icetech 203mm soaks up the heat happily from that force too!

hiryuu_spring.jpg


Upgraded from my trusty marathon pluses to the spendy marathon almotion. Dropped about 1.5lbs off the bike as a result.. less rolling friction, less momentum, and wider... can't hate!

hiryuu_almotion.jpg


I built an upgraded torque arm for the bike for the side that was unfortunately held together by water hose clamps. That side DID hold up, but i wanted an extra margin of safety for the 60mph/6kw run. It uses the original vbrake post as a leverage point. This bike is unique in that you can move the vbrake post downwards from the default 26" positon, so i took advantage of that. I used an ebikes.ca torque arm as the base, then two aluminum stock bars as the lever.

The other torque arm is still the original hacked up vbrake arm rig.

hiryuu_torquearm.jpg


Came up with a cool solution for mounting a kickstand to a dual suspension bike. I used a walmart genesis 29er hardtail kickstand which bolts to the dropouts, and cut it slightly to fit my bike. It's smashed in between the torque arm, the nut, and the frame, so it ain't going anywhere.

hiryuu_kickstand.jpg


This bike will now do 60mph on the flats if i want it to on 72v. I posted a video of that on my channel but will not repost here. Go find it if you want proof... and after the 60mph run, i proceeded to climb a 3% grade at 40-52mph constant. Then did more riding at 40... and she held up just fine! the hottest temp i measured at the coils was 143f. Air cooling does indeed have an effect! even better on a very efficient motor! :)

I'm back to 48v and 40mph though, i've had my fun :lol: :twisted:
Definitely not too safe to ride that fast anyway. The problem is keeping the front end on the ground and also reacting quickly enough with such a light vehicle.
 
Very cool and nice upgrades. Thanks for all the good info you share!

Ps, what do you think of the air fork?

I bought a cheapy, and the damn thing seems so sticky, jerky when pushing on it. It doesn't have any negative air adjustment, so I think that's just the way it is. It's nothing like the entry air shock for the rear.
 
The air fork is real nice. It's stiffer for sure, which helps a lot. No more front end bouncing and bottoming out.

[youtube]TWQi-d3s7PY[/youtube]

Took a 13 mile ride today. Average speed was about 40. 7 of those miles were consistently at 40-45mph. I got the motor up to 83C. It was 22C / 72F outside and the sun was beatin' down on me and the motor.

This thing is a baby cromotor. I love it.
 
Great run,was nice to see the city landscapes.those cheap axle kickstands,if you are always kicking them up and down[they will loosen your axle bolt] keep an eye.
 
Glad you liked it, beast. Yea, the kickstand is a little flimsy. I don't expect it to last forever... but finding a decent kickstand for a dual suspension bike is a huge challenge.
 
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