Joined in 2023 
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63 About this deal
I started on this slippery slope with a high end Turner mountain bike i bought used off Craigslist and installed a 40amp BMC geared hub motor from Hi Power Cycles. If you want to know everything about programming your motor, you should read the blog post linked above. That post is the definitive tutorial on the interwebs, despite its age. All I am doing here is calling out some of the things I have done that deviate from the norm, work for me and why it seems that is. So I will not be explaining things as if you have never seen any of the BBSHD settings screens before. This article assumes you have at least read the above blog post and familiarized yourself with the screens and settings. Amps create heat, heat weakens the nylon gear and too many watts snap the pinion. So how do we get around this? Simple, know the limits but don’t get too close. Sure these are now nearer the limit, but ridden correctly (let the motor spin and don’t labour in the wrong gear), a reliable ride can still be had. At the lower volts where big amps are needed, we have capped the limit to 2800w @52v and 3250w @72v but as you increase your volts A ludicrous controller at 50A has 2500Watts – so does ours, but now add 10 -15% improvement through field weakening!
A 52v battery will give a higher peak power output (in full power mode). If the motor isn’t used on its performance limit then it should run slightly cooler, as less current will be required to achieve the same power level (when compared with a 48v). This is very small though – example: 48v x 20A = 960w / 52v x 18.5A = 962w. The Eggrider OLED Smart Display is a great choice as it offers Smartphone integration as well as precise info on how your motor is performing with graphed data. It has a whole lot of other features, such as adjusting performance on the fly, that makes this the choice display for the BBS kits. This is all you need if you are upgrading your old BBS01 or BBS02, or swapping out a different sized BBSHD bare motor Any alteration modification to this controller or its subsequent wiring, even cutting the power leads to make shorter will immediately invalidate any warranty. Even battery disconnected, the controller can still maintain current and can still be shorted/damaged. The controllers are waterproof, but can still suffer from water damage through the connector and hence are not covered for water damage. This kit comes as standard with a 46t steel chainring. This, in my opinion, is too higher gearing, especially if you are climbing lots of steep hills. There are however aftermarket chainringsavailable or a 104BCD chainring adapter.
Enter The BBSHD
Mid drive motors provide powerful eBike performance while keeping the bike original enough that pedaling without the motor powered on has no effect on the ability to pedal the bike as normal The BBSHD also has IP65 enclosure rating which translates to completely dust proof, and waterproof from low pressure water jets from any direction. So it’s water resistant for outdoor use. But don’t use your BBSHD for submarine applications. You know dashcams create a record of evidence. Surprisingly, they are also visible to nearby drivers, and become a deterrent just by being in plain sight. Discussion So once we had ridden the bike it was obvious we were going to have to make some changes if we were gonna claim the most awesome bbshd ever.
Add a safety layer to ebike charging practices, with residential/commercial grade components rather than the cheap stuff. Ebike Battery Charge Safety: Use A Cutoff Timer This firmware is compatible with all displays that works with the original Bafang firmware. A custom configuration tool is provided since BafangConfigTool is not compatible due to a different set of supported parameters. Do not use the small rear cogs (10T-14T) in high power modes. High PAS in small rear cogs will kill your range! (your legs are not assisting).BBSHD Mid Drive kit is light but strong and unprecedented levels of engineering (Rated 1000W – 1600W dependent on setting and have a proven to work reliably at 2800Watts) and Max Torque 160 NM) More efficient than HUB motors giving greater distance and response. This mid drive provides powerful ebike performance meanwhile keeps the original pedaling in comfort. With an integrated speed sensor, this mid-drive motor is compatible with standard bikes. 9 power levels available with “on the fly” switching. One thing is for sure…this beauty will not waken the neighbors. This bike is so silent I am really aware that nobody can hear me coming…and I am afraid for someone to walk out in front of me. Going this fast and being this quiet is a scary sensation. Remove the old 9 -10=11 speed cassette and use the gear range from 15T to lowest gear. We love the Shimano XT CS-M771-10 speed cassette as shown in the photo. Use spacers to give you a perfect chain line for the gear of your choice. For 27.5 and 29er set ups we recommend a 28T rear gear. For 26″ wheels a 26″ T gear. For fat bikes as big as you can get! (32T +) Please note that as authorized ASI dealers all product support is provided by High Voltage. ASI will not support High Voltage customers directly. In the unlikely event of an issue which requires ASI technical expertise, High Voltage will undertake that communication with ASI on the customers behalf. Availability / Waiting List! / No Deposits Both controllers have a maximum operating voltage of around 60v. This leaves little margin for error when using a 52v battery. 52v batteries fully charged will produce 58.8v, but I have tested some with a multi-meter and seen over 59v on occasion. A 48v battery will produce 54.4v fresh off the charger – this leaves a reasonable buffer zone.
If you want to reprogram your controller, then consider buying a USB programming kit – available HERE. Key information:
The subject of what settings to use when programming a BBSHD comes up now and again. Its a question with a fairly complicated answer that does not lend itself to your typical Facebook 2-sentence post. So here is the long version. I have my own suite of settings that suit my personal riding style. I am primarily a pedal-pusher: I want to get exercise when I ride, so I seldom use the throttle. But if you try to take that throttle away, you’ll have to pry it from my cold, dead thumb.
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