Rebuilding my first Bafang BBSHD after thousands of kms of use at High Power
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- čas přidán 29. 06. 2024
- Putting my Bafang BBSHD back together. This unit was my first ever ebike motor and has been through thousands of miles of use at 3.5kw and 72 volts. It was in need of a rebuild so I stripped it all down and cleaned everying. This video is it all being regreased and going back together. Looking forward to rebuilding the whole bike! Feel free to ask questions etc.
✅Replacement Gaskets highvoltagekits.com/hv-shop/p...
✅Single gear sprocket adapter highvoltagekits.com/hv-shop/p...
✅PEEK replacement Gear highvoltagekits.com/hv-shop/p...
✅BBSHD upgrade kit highvoltagekits.com/hv-shop/p...
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Timestamps
0:00 - Introduction
0:44 - Main Gear
1:36 - Bearing Trick
2:06 - Nylon Gear
4:52 - Motor Core
6:18 - Bearing Trick Part 2
7:03 - Sprag Clutch
8:01 - Final Assembly
9:15 - To sum up - Jak na to + styl
I've only used mobile one full synthetic. Also you can warm up a coffee cup with grease in it and when it turns to more liquid you can put the nylon gear in the cup and all the grease will have capillary action and get sucked into the cold gear. Works for a lot of bearings too.
Thanks! I wish I had know that trick! I will use that for sure! Like having a solder pot!!!
@@HighVoltageKits I sometimes use that when I get new chains on my road pedal bikes. I really can't remember who taught me that, but I've been doing it since the mid 80's on my skateboard bearings.
Hey... it's the video I saw months ago in my suggested feed again. This is the one that made me decide to swap in a Lekkie Bling ring and 40T HD chain ring. It's the best upgrade for my BBSHD ever. It drives a Shimano Nexus Inter-5e IGH. Chain line is strait as an arrow now and the 40/27 gear ratio is much more kind than the 42/27 I was using. Confession: I installed a PEEK pinion gear since I had it apart for the Lekkie install. Kept the Nylon as a spare... you know just in case. 😁
Sorry I missed this. Keep me posted on how the nexus holds up.
@@HighVoltageKits The Nexus is holding up really well. Around 500 miles on it and it still runs like new. Just don't down shift on power. I don't have the shift sensor). Shimano IGH's don't like it. You can upshift on power all day long and it doesn't care. It's made to 'fall' into the next gear. Without a shifter hooked up it naturally goes to the top gear. 5th in my case.
Great stuff. Thanks for the update
I believe Lekkie says to just tap in the gear to the face plate. Hot and cold method does work really well with press fit bearings, but maybe you didn't get them hot/cold enough.
I will give it another shot. You may well be correct in terms of temps!
Yep , the thermal expansion contractraction does usually work well , if I know I'm doing a rebuild and need to do this the next day , I place the part that needs to be cold in a sealable plastic lunch bag and let it sit in the freezer over night so it's stone motherless cold right through the material, and the items just slid right together , another thing is you have to do it fairly quickly, because ambient air will warm and cool stuff fairly quickly to the point it could spoil the process.
I've done this with car and truck gearbox shafts over the years , it saves a bit of mucking around with the press.
It's a beast of a motor. Love the new bling! Looking forward to a ride out with you soon. I baggsie the fat bike...😂
Sounds good!
The "corn head" grease is also known as Polyurea Grease. It is a high pressure and temp grease. You can get it from Yamaha too. The Yamaha Polyurea Grease is green.
The green sells it! Thanks
@@HighVoltageKits It's called out in the Yamaha manuals for CVT nut that need 150 foot pounds of torque to tighten it. To protects the threads from the pressure and heat and keeps them from galling when tightening. Use it on BB and Head bearings too.
I just used vise to put grant in because it will go in bi hand far enough then I put it in vise.make sure nylon gear is spinning free because when taking the cover off it can pull that bearing out a tiny bit so make sure cover and bearing are in right. I am surprised you have not taking it all apart before I took my bbshd apart completely at around year two unless you have taking apart and didn't tell use I have had my bbshd just over 4 and half years and I put double shunt or mosfet what ever there called and I have had no probablems so for besides parts like cassettes weiring out so I got a i.g.h 8 since then no broken chains
I am so pressed for time I had not got around to the rotor. The rest of the bearings were very smooth so I just wanted it back together at this stage! Hopefully I will be ok. I gave it a quick test and it sounds like its functioning ok. I will use the vice trick in future tho. Cheers
Do you have a new mic? The overall presentation of the video is like we are in the same room, I enjoyed this video very much. I cannot for the life of my extract that first gear from mines, Mr. HV has it now, repairs pretty much complete. I dont think i will need the bling ring right away but gee it does look nice
You can press it put. There are also three threaded holes you can use to put bolts in and push it out
I think you can just cool them all. No need to heat and expand the other part.
It wasn't the most successful attempt. I think you are likely right. I will have to try again at some point.
@@HighVoltageKits I would like to make a LMX 64H inspired bike. I have a steel frame that is easy to weld motor attachment. Where do I start?
Join our discord and start posting. Maybe create a build thread. It’s a good place to learn
Been following since the BBSHD "BAC800 controller testing video's"a while back. Great stuff. 👍👌
Have you needed to replace any bearings (due to excess play) during this rebuild ?
Thanks. Been enjoying seeing your progress as well. Bearings all felt silky smooth and solid. I replaced one seal on the axle and the gaskets. That's all.
@@HighVoltageKits
BBSHD - WHAT A BEAST ! I would love to see a review video of that "Lekki bling cover" & how much it improves chain offset/chainline
I look foward to seeing it all put back together & up & running 🏃♂️ Stay safe mate 👍
I need help. I’m getting a kit fitted next week. Here’s what it is: “I can do BBSHD with 48v19.2ah 922wh LG battery 500c or 850c display £1200 fitted”.
I saw you said this battery is too weak. I also don’t know what the kit you sell is all about. Bit of an information overload.
I basically need the baby without the labour pains.
Check out this link to our Discord server highvoltagekits.com/discord I am sure we can help. We have a great community.
@@HighVoltageKits can you get similar products in Britain?
Another great video. A question please about the 'sprag clutch bearing' located in the center of the nylon gear. I am not sure what the protocol is for whether this one way simple clutch/bearing in the center of the nylon gear should be greased? Is greasing this inside diameter..what looks to be a bearing but only allows for one way rotation....is greasing this considered a wrong practice? It didn't look like you applied any grease on the ID of this bearing surface...maybe because grease wouldn't allow the sprag clutch to bite adequately in the single direction of rotation? Curious your thoughts on whether grease should be applied to the nylon gear inner bearing...or grease should deliberately not be applied?
I did put some grease in there by hand but not much. I small amount should suffice. Good catch as I did not touch on it when I did the video. Cheers
I would also change connectors for motor on more solid
What did you go with? The ones I have do have jackets and are not the usual spade ends.
@@HighVoltageKits I was using halves of XT90 in order to have secure connection without sags over 50 amps. Since it's 3.5KW and 72V, over 50 amps is pushed through wires, which are ok, but the connectors I suppose are max 20-25A stable
Awesome video! I was wondering why you didn't grease the main bearing.
I mean main gear 😮
I think I did but forgot to put in that clip. It's not on the bike tho so I will check! Memory plays tricks and it 100% needs doing!
I would of thought you would install a Peak Gear, since you do Sell them.
It did cross my mind. They also sold out of the most recent batch and I want to get moving on this bike.
Can you change the mainshaft length easily or does it need a complete casting, Im thinking dropping down to 68mm
I know you can buy stuff to make it longer and the process does not look to be that involved. I have not heard of going the other way before but I don't see why it would not be possible. You are welcome on our discord where you can post videos and pictures and get more help / advice. Cheers
WE WANT AXIAL FLUX MOTORS, NOW!
That would be cool to see them start to reach LEVs
What torque value is recommended for the main cover bolts? Lekkie recommends 6Nm and according to obscure Chinese video it should be 3Nm. 6Nm sets the thurst bearing preload too high which makes the axle impossible to turn. Had no other choice but to use Loctite at 2Nm only.
I am not sure. I went with what felt right. There is locktight on those bolts as well. The axle seems to be turning well so I must have done it ok. Wish I could clarify that more.
@@HighVoltageKits As far as I know there is no official service manual for BBSHD compared to TSDZ2 for example despite the status of the most documented motor. Finding out a proper gasket thickness would be the next step to torque down those bolts properly. On endless-sphere they said that it's due to possible machining tolerance errors.
That pedal shaft. Does it have the freewheeling clutch and TWO bearings, left and right? Or just one bearing?
There are four bearings. One needle bearing, two cartridge style and one thrust bearing as well as the sprag clutch.
@@HighVoltageKits Fantastic. So while the clutch can fail, those pedal-shaft bearings are pretty well done, would you say?
great video.... i know you've done some videos on the bac855 but could you do one more in depth, why the bac855 over the phaserunner pros an cons tunability, limits, battery (can you easily swap back an forth 52v-72v easily etc, i've looked and all i can find is bac is locked from manufacturer? an phaserunner is diy friendly but limited on display choice, then there's people arguing back an forth(annoying!)... thank you
You can do similar things. The Phaserunner takes a bit more tuning etc but you do have the Grin app. The display options are awful though. The main difference with us it that is fully plug and play. We have our own app so you can access the BAC controller and change anything of relevance. We also have full customer service on everything from bike build to installation which sets us apart. I am not sure I am best placed to do a comparision as I have not used the phase runner myself. Essentially if you like tinkering then its a good option. If you want plug and play with full support then there is our kit. Cheers
@@HighVoltageKits thanks bud, i'll have a think about what i wanna do
Nice video,i have the bbshd use it to get to work daily,you ever have hall sensor error? I rode to work with no issues then as soon as i turned it on to go home i had the error msg hall sensor, had to ride home like i was towing a car 😂. 2 days later it seems ok now but speed sensor is playing up.
Sounds like its make loose or on the way out. You can replace them. Never had a hall sensor error myself though. Before you go too far though I would remove the controller which you can do while the motor is on the bike and check that its not the connection itself that has come loose. They are usually glued in with silicone but anything is possible. Make sure that it is firmly pushed into the motor side. Hopefully it will just be that.
@@HighVoltageKits there is a guy selling 60a bafang controller upgrades on ebay,was thinking of getting one.
Hey mate how did you press the large gear into the bearing after the hot and cold method didnt work?
I used my father in laws bearing press. I forgot to record it tho sorry. It was pretty slick.
I'm surprised you're putting back the nylon gear not the peek gear.
They were sold 😆 I also still want to see how far I can push the Nylon. Maybe I will regret it!
@@HighVoltageKits lol nice. HV customers first. Lol.
When you put them motor core back in was there a gasket? can't say I saw one installed?
It's there. I did go and double-check, though!
@@HighVoltageKits Sorry bout that.
What silicone is used to seal around the phase wires ?
I use anything automotive grade
Does this have a functional thermister for rollback?
We have one with the upgrade kit we do. Stock motors have them they just don't use them.
NO to Mobil 28 grease, it's a bentonite thickened grease for very high temperature, specifically for aeroplane wheel bearings. other than that it's useless. I tested aeroshell 22 (the shell equivalent) and it was the worst grease for gears. poor adhesion, low fluidity (maybe at high temperature...) and bad ep capability. corn head grease is much better, but definitely mineral oil based and possibly damaging to the nylon gear. basically, the best is a high tack synthetic grease mixed with some transmission oil or better yet, industrial PAO gear reducer oil (220W and thicker)
Thanks for the info. It does get pretty hot at times which was why I assumed it was the go to. Maybe it's one of those things that persists even though it's not the best thing. Maybe I'll find an alternative if it does not last. Cheers
@@HighVoltageKits hot is relative. neodym magnets start to demagnetize at around 100°C, that is hot to the touch, but any grease can handle 120 celsius before dropping. the gearbox really shouldn't get that hot at any time. I've noticed some heat buildup on a large industrial worm gear reducer, unable to touch it for more than a second, but that was "only" 80 celsius
Motah
Powahhhh
Do you know of a reputable supplier for 52v and 60v batteries? I bought the BBSHD from Luna Cycles, and have put about 4,000 miles on it, but they never have batteries in stock, and I don't know how much longer my current battery will last.
Golden motor, eco cycles, You can also chat to Rio@highvoltagekits.com for something more custom.
Thanks, I'll check them out.@@HighVoltageKits
Also em3ev are top battery builders..
in the description you have stated 35kw instead of 3,5 lol
Corrected. Thanks 👌 😊
Which pedal sensor?
Its a magnetic cadence sensor on the bbshd
According to your knowledge are all BBSHD motors so reliable or have you been just lucky with yours?
BTW Tongsheng released a new motor, available from PSWpower.
There is plenty of evidence as to the reliability and longevity of the BBSHD and its ability to handle thousands of kms so I am definitely far from unique. Its not indestructible though and you will find horror stories, usually its owner error though. I looked after mine with the gear ratio I used mainly. Maybe I got lucky in some respects! I saw the TongShen update. I will see if I can get one to compare with the 02 from TOSEVEN.
@@HighVoltageKits Cheers for the info. Most people praise Tongsheng for torque sensor and customisation with OSF software but the reliability is not so great. I'm hoping they finally solved that and that Bafang will have worthy budget competitor.
Also wanted to comment on the robustness of the BBSHD.
I use this setup on my Enduro eBike and have over 20 000 kms on this build.
My bike is heavy at around 130lbs, the only thing I changed was the nylon gear for a PEEK gear. The ASI BAC855 controller I use is set at 4500W and FW set between 45 to 50, so it spin very fast. For this reason, I choose Lucas Red "N" Tacky, a high quality lithium complex grease and this on both the primary and secondary gears. Contrary to other greases, this one will stick to the gears and will not get expelled inside the casing at high RPM. It also make the motor very very quiet.
Cheers
@@enduroebikeaddict I'm just getting into ebikes so opinions like that matter to me, thanks.
Your bike looks cool as well. Is the frame custom or an off the shelf one?
Summing up the cost of the BBSHD, extra controller and bits is it not cheaper to go for the CYC X1?
@@enduroebikeaddict I think Lucas Red n Tacky is petroleum based so may react with the nylon gear making it soft.. Mobil 28, Mobil SHC 100 and AeroShell 22 are all synthetic greases so zero reaction with Nylon. Having read your comment again, you have replaced the nylon gear with a peek gear which may be fine with the Red n Tacky.
That pedal shaft. Does it have the freewheeling clutch and TWO bearings, left and right? Or just one bearing?
Clutch, two cartridge bearing as well as a thrust bearing and a needle bearing on the non drive side