GT Harley Davidson NOS Build.

[MazdaFlyer]

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]

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.

 

[bruised]

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

 

[MazdaFlyer]

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.

 

[bruised]

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]

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…

 

[toro1978]

I love the look of a drum brake front wheel installed in a triple tree suspension fork.

 

[MazdaFlyer]

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.

 

[MazdaFlyer]

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.

 

[MazdaFlyer]

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.

 

[Mr Miyagi]

That reminds me..."I need to machine a fork brace! Your build turned out very nice man!!

 

[MazdaFlyer]

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…

 

[MazdaFlyer]

Getting pretty good battery service

 

[MazdaFlyer]

This bike is a Holly Roller now! Santa provided a set of Maxxis 26”x2.40” wire bead Holly Rollers. Both wheels are tedious to get off and I wouldn’t want to fix a flat away from my tools. It could probably be done with lots of profanity.
Anyway I got the tires changed out.
The former Sandy Beach 26x2.50’s measured out mounted at 2.30” wide. The Holly Roller 26x2.40” measured out mounted at around 2.30” also, so no clearance issues, except the inflated diameter is a bit larger. The tread is thicker.
We have fog and drizzle here so I just did a short test to corner and back.

 

[MazdaFlyer]

 

[MazdaFlyer]

Had this out for a little over 10 miles today and around 14 miles or so on last battery recharge. Still have 66% left I used a variety of pedal assist levels, a little throttle. Seems to be holding pretty well.

The eBike clock needs setting.

 

[MazdaFlyer]

Had this out today, started with full charge on battery. I used a variety of pedal assists1 to 5 and mostly 3rd and 4th gears settings. I didn’t use the throttle. I had 89% of battery power left when arriving home.