GT Harley Davidson NOS Build.

Rat Rod Bikes Bicycle Forum

Help Support Rat Rod Bikes Bicycle Forum:

MazdaFlyer

Like “RadioFlyer”
Pro Member
Joined
Nov 22, 2011
Messages
4,253
Reaction score
10,062
Location
KS
Rating - 0%
0   0   0
I installed the chain today, took a couple of tries to find the sweet spot for chain length and axle location. It went from a 42T chainring to the 44T that came with the motor. Also added another wire cable by putting the headlight on.
in the work stand I was able to verify pedal assist and thumb throttle operation. I still want to clean up the wiring routing. And I need to finish the personalization of the 860C display/controller.
Maybe a test ride on New Years Eve or Day.
 

MazdaFlyer

Like “RadioFlyer”
Pro Member
Joined
Nov 22, 2011
Messages
4,253
Reaction score
10,062
Location
KS
Rating - 0%
0   0   0
I had a moderator move this thread from the “Builds” forum to here. I’d started the buildup sans motor but with the current direction I figured it ought to be here.

Added a couple of 5mm spacers at fixing plate to motor housing bolts required for 73mm bottom bracket. Better now than later. Also added the correct size bolt at rear hub arm to frame connection. And I went through the setup for the display controller. All good so far.
I’m procrastinating on the wiring/cable final locations until I get a test ride in.
I ordered a gear sensor which shuts off power to motor when shifting gears. That is the last piece of the puzzle. My rear hub is a Sturmey Archer internal geared 5speed. Thinking the gear sensor will add some longevity. Hoping I can feed the existing cable through the sensor without having to replace the whole cable. Getting calibration set correctly on the SA rear hub is a little tedious. That should get me to the riding stage of this journey.

DD34DD23-DD7D-4DD6-B22F-39DF10D9AE54.jpeg
D4DDC71E-A72E-4E2D-BEDF-8A9B07B16387.jpeg
92A4A79D-29A0-4774-9333-6A987376A9E6.jpeg
 
Joined
Oct 20, 2021
Messages
66
Reaction score
87
Rating - 0%
0   0   0
I also have a bbshd 1000w Bafang mid drive on my other bike with rear alfine 8 IGH and shift sensor.
I would go ahead and order a new shift cable for 10$ and save your self the headaches. I’ve done two of these shift sensors and it SUCKS with a beat up cable. Trust me.

let me know if you have any questions. Im getting real familiar with these bbshd kits. When the dust settles, let me know if you want to upgrade to 72 volts to really start cooking. I have a extra asi Bac 855 (google it ;)
 

Attachments

  • 277AE4CA-E247-4161-B0B2-B5C51CA5FB5E.jpeg
    277AE4CA-E247-4161-B0B2-B5C51CA5FB5E.jpeg
    445 KB · Views: 29

MazdaFlyer

Like “RadioFlyer”
Pro Member
Joined
Nov 22, 2011
Messages
4,253
Reaction score
10,062
Location
KS
Rating - 0%
0   0   0
I’m probably a little too old to “really start cooking”. I did pull my gear cable today and made a trip to my LBS for a new cable. I even took the shifter apart to to determine if I might have a replacement, but I had to go get a new cable.
 
Joined
Oct 20, 2021
Messages
66
Reaction score
87
Rating - 0%
0   0   0
Good luck on not letting the speed bug bite ya! It’s actually not the speed but the torque that feels so good!
Best of luck!
 

MazdaFlyer

Like “RadioFlyer”
Pro Member
Joined
Nov 22, 2011
Messages
4,253
Reaction score
10,062
Location
KS
Rating - 0%
0   0   0
Finished up installation of gear sensor.
Checked operation in work stand, A-OK.
Took some outdoor photos - Check.
Went for pedal only test ride - Check.
Took pedal assist test ride, all systems go - Check.
Took thumb throttle test ride, all systems go - Check.
MazdaFlyer grinning ear to ear - Check.
The torque or G-force can set you back on the seat…cool stuff.
Now for a distance test…

5E1DD8FA-41E5-4489-9020-E62AA7759911.jpeg
55D70820-AB24-4061-9E73-59C79469DE4F.jpeg
9744C974-49A1-4D62-AF84-9864739C8A73.jpeg
E0ABFE26-79C0-456F-B574-833CA58E94FE.jpeg
A4B0445D-9E8A-4F08-9767-8608F7A589EE.jpeg
139E88A0-F6C2-45BF-B25A-3232BA4D8A98.jpeg
 
Last edited:

MazdaFlyer

Like “RadioFlyer”
Pro Member
Joined
Nov 22, 2011
Messages
4,253
Reaction score
10,062
Location
KS
Rating - 0%
0   0   0
I had sourced a pair of Ergon GA3-L grips for this bike to match wheels. With twist grip shifter the right side was too long. I finally decided to cut the right side down.
I was able to cut the blue part of grip with a razor knife and was able to peel it off the plastic insert. The peel took a while, then I used a hacksaw to shorten the insert. Also cut a notch in the insert to fit the clamp. I could probably do a cleaner job on the next one.
I think it will do the job though, fits nicely.

B0818F86-D4EE-47D7-AD1E-3A6518161B7E.jpeg
536EB5D0-7066-49A8-BDC1-9713CF7CA056.jpeg
F604165C-3566-4C3B-9BC5-FEFBC2364B06.jpeg
 

MazdaFlyer

Like “RadioFlyer”
Pro Member
Joined
Nov 22, 2011
Messages
4,253
Reaction score
10,062
Location
KS
Rating - 0%
0   0   0
Went for a mixed surface shakedown cruise this morning. First ride since the test ride.
Between cold, ice and snow and some landscape work I’ve not been on a bike. I drug home a chiminea, then built a platform for it which led to hardscsping our fire pit sitting area. Seems I have to be creating something to stay sane in the pandemic.
anyway the bike works pretty smooth although I’ve never ridden a factory eBike so I don’t really have a benchmark for comparison. The main thing I’ve noticed is to take it easy on u-turns when braking or coasting, when starting to pedal again in the turn there is definitely some torque at play. It was a surprise the first couple of times. I need to do my usual bike path, street, sidewalk route.

256CE805-847C-4230-B980-B7B80F1B21C9.jpeg
000F93A8-B1E1-495D-81E2-DB6FA7971A4A.jpeg
0A7B897D-20F2-4991-A468-E3D5EDD5C538.jpeg
 

MazdaFlyer

Like “RadioFlyer”
Pro Member
Joined
Nov 22, 2011
Messages
4,253
Reaction score
10,062
Location
KS
Rating - 0%
0   0   0
Out for 9.89/10.00 mile ride. Cyclemeter app said 9.89, eBike display said 10.00 miles. Guess I’ll have to do a tire circumference check…think the eBike display settings are for diameter in the imperial mode though.
Experimented with pedal assist settings. 1 to 3 still a cardio workout ride, helps with cadence or changes in grade. 4 to 6 some exhilaration, fun stuff. 7 to 8 a bit scary at first, could get use to it. I didn’t try 9…next time.
It’s amazing at how responsive this eBike conversion kit is.
EDE13229-432A-4FE0-991B-16304CC99D42.jpeg
 
Last edited:

MazdaFlyer

Like “RadioFlyer”
Pro Member
Joined
Nov 22, 2011
Messages
4,253
Reaction score
10,062
Location
KS
Rating - 0%
0   0   0
I haven’t had this Bafang powered bike out for around 4 months. I did pull it out today and the battery has held its charge, it was reading 100% and ran fine. It is a kick to ride, I’m thinking close to an electric motorcycle. I need to get it out more often. Old photo…
7EA81DF8-6D47-4C4D-9A69-74589E8C9B7D.jpeg
 
Last edited:
Top