Newbie - first build - TSDZ2 - Trek Dual Sport 2

[jplanaux]

My Background

About me ... Male 62, retired, living outside New Orleans, other than bicycling as a kid, I gave it up when I got a driver's license. I re acquainted myself with cycling in my thirties because I wanted to explore this thing called triathlon. I was able to train myself to a level where I was able to actually participate in the invitation only Hawaii Ironman. The excessive cycling portion of Ironman triathlon training days are behind me; I have transitioned to recreational/fitness maintenance cycling. My recent cycling consists of 25-30 miles about 5x a week. I cycle with the wife. Our pace is somewhat recreational with enough effort that we are getting some decent exercise. The riding we do is on a flat smooth asphalt surface (no cars) the Mississippi River levee. There is absolutely no reason to use a Ebike in New Orleans. However ... we just bought a place in Colorado (Colorado Springs). There are hills, trails, and gravel in Colorado. As far as mechanical aptitude, I have only needed the services of a bike shop once when I needed to replace a headset. I was tired of buying tools for something that I consider a rare need. I have the tools, and skills to do a Ebike conversion.

My plans

Louisiana - keep a single non Ebike in Louisiana.
Colorado - Build a Ebike, I think I will eventually end up having two bikes - one powered, one Ebike. But for now, I will just have a DIY Ebike.

The build

I have spent time scouring videos, forums, sites and have decided on the following: I know that I may not have the best solution, but this is the beginning of my journey in Bike knowledge. Mistakes will be made along the way. I may end up with too much - or - not enough assist. The goal is to have enough assist for the hills and to also have enough range for two hour rides (+/-). I may use the bike for transportation in Colorado, but probably it's main purpose is for exercise and recreation.

Bike: Trek Dual Sport 2

Bought from Electrify Bike Company
Mid drive Motor TSDZ2 OSF Upgrade Motor Kit 250-750 W, 860C Color Display for TSDZ2 OSF, 52v 40-AMP 17.5 Ah Jumbo Shark E-bike Battery, TRIPLE BOB MOUNT FOR SHARK BATTERIES

Bought from Luna
Luna Charger 52V Advanced 300W Ebike Charger

Biggest concern for me riding Ebike: Will power!!! I'm scared that I will use the assist more and more until I am no longer really getting the amount of exercise that I need. The beauty about going on a out and back ride is that most of the time I am riding back, I am tired. I probably would pedal less if I could - but I can't. I have to get back home. If I had an ebike, I would be lazy. Time will tell.

I will start disassembly today. I will document my build hoping that someone can find something useful.

Upon completion and testing ... Wife will ride and test. She will decide if she wants to convert her bike or buy a new manufactured Ebike.

 

[tomjasz]

Welcome! looking forward to your build. Most able riders don’t get lazy. You’re motivated, that’s the key!

 

[indianajo]

My Background
About me ... Male 62, retired, living outside New Orleans, . There is absolutely no reason to use a Ebike in New Orleans. However ... we just bought a place in Colorado (Colorado Springs). There are hills, trails, and gravel in Colorado.
The goal is to have enough assist for the hills and to also have enough range for two hour rides (+/-).
Mid drive Motor TSDZ2 OSF Upgrade Motor Kit 250-750 W, 860C
Biggest concern for me riding Ebike: Will power!!! I'm scared that I will use the assist more and more until I am no longer really getting the amount of exercise that I need. The beauty about going on a out and back ride is that most of the time I am riding back, I am tired. I probably would pedal less if I could - but I can't. I have to get back home. If I had an ebike, I would be lazy. Time will tell.

Your mid drive TSDZ2 will probably allow you to climb 1000' in an hour in Colorado. My geared hub drive would probably burn a winding. The downside of mid drive, you have to change the chain more often than a geared hub drive, and you probably drag the motor with your feet when the power is off. I'm age 71, and ride about 80% with the power off for cardio exercise. I do use electricity the 60th to 80th hill.
You must be a head down flat back rider to not have problems with the wind these days. I'm sit upright due to my Mother's disk problems. I can go 8 mph in spring, 9-10 in fall. But when the wind is 25 mph in my face, my 3.5 hour ride to or from the summer home can become 6 hours at 4 mph. That is why I bought electricity.
I'm happy you are having no trouble getting the foot over the seat and straight bar. I started having trouble about age 58, and have been riding drop frame bikes since then. As far as distance & duration, I started at 4 miles and worked up to 30 now. My hips cause pain now before my legs wear out. If I find a comfortable seat I may go 80 miles RT some day to festivals or concerts.
Reputed "frame flex" of drop frames was not a problem even when I weighed 213 & carried 50 lb groceries on a $75 girl's MTB. A Quantum Pacific. I'm down to 160 and carry up to 80 lb groceries or ag supplies now, on bike shown left.
Happy wrenching & riding.

 

[tomjasz]

The downside of mid drive, you have to change the chain more often than a geared hub drive

How is that difficult? Chain tool and spare chain. DONE.

 

[jplanaux]

I began the install by spreading the boxes out on the garage floor.

I removed the crankset and BB.

I removed the cable guide below the BB because the screw protruded into the housing. I left the cables to see if the three cables would still fit with the motor installed.

I tried to get the motor installed with the brake cable still below the BB - but it wouldn't fit easily. I probably could of forced it, but I decided the cable should be re-routed. I then had to wash my hands and look at You-tube. I never have dealt with hydraulic brake cables. I disconnected at lever and figured that I couldn't pull the cable through the frame. I disconnected the cable at the disk end, and clipped as small a piece from the cable. Hopefully it will be long enough when I re-route it.

The motor slipped right in. I installed it per instructions.

I mounted the battery to check the weight and appearance.

I decided to quit for today since I needed to buy a new shifter cable and brake parts.

Tomorrow, I'll try and just wire things up loosely to check if the motor works.

 

[jplanaux]

After fitting the kit into the frame (mechanically - not electrically), I started looking at the wiring and cables. I had to shut the job down because I don't have the parts needed to complete the project.

Motor wiring:
I noticed that the vendor included the wrong cable from the motor to the display - so I am waiting on that cable so I can test. I want to cut and solder the final wiring, but I want to wire up loosely to verify that it works prior to cutting the wiring up.

Re-route and fix rear hydraulic brake line:
I guestamated that my brake line can be re-used - but I still need to terminate the end, bleed the brakes, etc. So I ordered this kit and waiting for delivery: Kit to fix brake line. I trimmed about 3/4" and I'll run the line above the bottom bracket which will be a shorter route than the old routing.

Charger Wiring:
I ordered the Super Shark Battery and the Luna charger, so I am going to make a short connector to connect to the battery plug using these connectors: Connectors

Bike Parts
I ordered a new chain and rear derailleur cable.

I don't think I'll have the brake parts, but I am hoping to have everything else. If I have everything else, I can test, complete electrical wiring, and do a test ride - just using the front brake (a safe test ride).

I'll post more when I make further progress.

 

[jplanaux]

Update:
I finally got the correct wire from the motor to the display. I was able to loosely connect the electrical wiring to test. I didn't want to cut the battery to motor cables until I proved that I didn't need to send the parts back. Anyway, I proved that it worked and was able to start the final wiring. I used the XT60 connectors and soldered them in. After I had a good connection, I zip tied the wires in place and tested the bike. It worked! ... until it didn't. I ended up with the E8 error. I didn't install the speed sensor - I'm still not convinced that I require it. So I hooked up the speed sensor and that error went away.

I am still waiting on parts to re-run my brake line. I wanted to do cable management, but I am waiting on that cable. So maybe by the end of the week, I can have a functioning eBike.

One problem that I am not sure of though is that my throttle is not working. I am going to start testing the cables and throttle and see if I can troubleshoot to find out if it is a configuration problem or something else.

 

[jplanaux]

So I'm finished ... kinda. I still haven't ridden the bike more than a few miles - but from what I've ridden, E-BIKES are AWESOME.

It took two weeks to do a conversion which should have taken a couple of hours.

What went wrong? Lack of experience (didn't order the parts I needed) and shipping times. The parts I didn't have on hand: An electrical adapter cable from Luna charger to battery, bleed kit, brake fluid, parts to shorten brake hose, new shifter cable kit.

Other than that, I fully recommend converting an e-bike.

 

[BravoRomeo]

This was a timely thread for me, as I just did my first conversion yesterday, also a TZDS2. Thanks for sharing your experience! Will write up a post on my project soon.

 

[Jimmy666]

So how have you liked the Tzds2 so far?

 

[electricsquirrel]

Biggest concern for me riding Ebike: Will power!!! I'm scared that I will use the assist more and more until I am no longer really getting the amount of exercise that I need. The beauty about going on a out and back ride is that most of the time I am riding back, I am tired. I probably would pedal less if I could - but I can't. I have to get back home. If I had an ebike, I would be lazy. Time will tell.

Hi, I've had a BBS02-equipped MTB for about five years, now. When I began using it, I was very unfit, and I used maximum assist *everywhere*. Over time, quite naturally, and almost without thinking about it, I've used the assist less and less. I'm now down to a typical '4' (maximum was '9'). I still use maximum for the steeper hills, as I do most of my shopping by bike and rucksack, but I find that my strength and stamina have improved a lot over the five years. I'm sixty years old, for what it's worth.

Obviously, it's just a slice of my own experience, but I felt it was worth stating.

 

[jplanaux]

So how have you liked the Tzds2 so far?

I just bought two more. I have a total of four TSDZ2 (two for me and two for wife). I have two homes. Two bikes at one house and two at the other. I was only going to use an Ebike in Colorado, but I loved it so much, I decided I am Never going to ride an unassisted bike again.

 

[Jbangs]

I just bought two more. I have a total of four TSDZ2 (two for me and two for wife). I have two homes. Two bikes at one house and two at the other. I was only going to use an Ebike in Colorado, but I loved it so much, I decided I am Never going to ride an unassisted bike again.

Good afternoon! I really never thought I would utter those same words "never going to ride an unassisted bike again" but here I am like you!! I've commuted for years on my regular bikes. One day back in April of 2021 I'm slogging home (all uphill, usually against the prevailing wind) at 4mph and I'm thinking about how little fun I am having. I did some research and put down the big bucks (for me!) and bought a TREK Allant 7s. Revolutionized my world. I have since converted my Surly Ogre with the TSDZ2 kit and I love riding this bike. It was my best fitting bike out of my bikes and I have it set up to go out there for some tours again except I now have some electric help for the mountain passes. I think I lucked out on my first choice being a torque assist motor. Really did not know the difference between cadence and torque until I tried a cadence motor and did not like the ride of that after experiencing the torque motor ride.