Evo 29er: the hunt for a second wheelset and/or new rims

[Joergen8]

Got the package today. Unfortunately both of the winter covers were pierced clean through by the motor axle. Luckily the motor cable doesn't seem to have too much damage, I was afraid it would get sheared by the weight of the motor. One of the connector pins was bent, and the motor flange has received a kink (from dropping?) that I have to clean up so it doesn't mess with spoke alignment.

My friend has agreed to build the wheel, so I'll get to testing in a couple weeks.

 

[Ravi Kempaiah]

Got the package today. Unfortunately both of the winter covers were pierced clean through by the motor axle. Luckily the motor cable doesn't seem to have too much damage, I was afraid it would get sheared by the weight of the motor. One of the connector pins was bent, and the motor flange has received a kink (from dropping?) that I have to clean up so it doesn't mess with spoke alignment.

My friend has agreed to build the wheel, so I'll get to testing in a couple weeks.

Joergen,
Sorry to hear that.
I worked on your motor during the weekend and left Madison on Sunday evening. I was told that the motor was shipped out.
I specifically left a note saying the winter covers should not be covered on the motor axles. I feel so disappointed.
I will send you a winter cover free of charge.

 

[Joergen8]

No worries! I appreciate your offer. It's just cosmetic, and I'll try to glue one of them to see if it looks better or worse. The motor had come loose from the packing material, and was rolling around inside the package.

I just tried the motor on the bike, and it works. The walking assist gives around 10 km/h with a little friction applied by hand, where the euro motor gives 7km/h.

Edit: I was able to manipulate the TMM4 sensor to simulate pedal torque, and while floating on a repair stand, my Euro wheel goes 30,4 km/h and the US motor goes 44,3 km/h. So this confirms what others have already discovered, that it's the motor (windings and or gearing reduction) and voltage that determine the max speed on BH bikes.

Factoring in wind resistance, IRL the bike goes 28km/h on the Euro wheel, and I expect around 37 km/h with the US wheel with a full battery.

This concludes my 1.5 year long quest for more speed. Yay!

 

[Joergen8]

Here's how to manipulate the sensor into spinning the wheel, prop the bike on a mechanic repair stand first! Remove the little cover that has two hex screws, on the outside of the dropout / sensor block. Get a pointy tool, possibly made out of a small screw driver, bent slightly near the tip, aim for the triangular notch on the lower part of the sensor frame (on which a magnet is seated), and apply a small bit of sideways pressure towards the right (in this picture) to stimulate the sensor. WATCH OUT, you'll cut your fingers off if you put them into the wheel. Preferably have somebody holding the brake lever ready to stop the wheel.

This triangular notch is what you're manipulating to slightly move it towards the front of the bike at a sub-millimeter level.

 

[Joergen8]

Here she is, all laced up nice like. A local bike expert did the wheel building. We chose Sapim Strong spokes, which aren't 13G (2,3mm) all the way like the original spokes, but just the bend and a couple inches above it is 13G, the rest is 14G. I would have wanted 13G spokes of course, since weight is no issue, but I have a feeling Belgian quality spokes hold up the same as Chinese 13G ones.

I put on the rim tape, tube, tyre, cassette, brake disc, mounted the wheel and... the bike goes 35,4 km/h (22mph). About a 30% increase, so I'm happy with the results.

The motor does feel a bit less torquing(?) and aggressive from a standstill, as I suspected, but also smoother. I assume this is due to the smaller reduction in the planetary gear. I suspect the difference would be a bit less noticeable with the US controller, that supposedly runs the motor at 350W, while the Euro controller runs 250W. And even less noticeable with the newer 48V 500W versions the US market got for 2016.

 

[J.R.]

Great news! Been waiting with bated breath to hear the news. I have no idea why, but I feel like I had a vested interest in this project...crazy.... Please don't ask me for my share of the money I know it wasn't cheap to do! What's next?

 

[Jack Tyler]

Congrats to you, @Joergen8 . Glad the ride was pleasing.