This is extremely valuable information. I've been considering to put a regen on my travel bike as well and really need to see something like this. Previously I have lost four rear wheels to cracks, mostly from braking too hard with regular brakes in mountain descents. Braking forces can be very high.
No wonder why a clutch has a specific torque rating. Also, let's share the Bosch baudrate for can com Steel gears only when you find your safe peak power, do you think steel gears would have caused a more catastrophic failure ?
From what I've read the failure chain with high power is: the nylon-gear fails then replaced with PEEK-gear which fails then replaced with metal-gear then the axel key fails which is replaced with a stainless steel key. It is a process :) There are those of us that like to experiment, and push the system to see what it can do.
if you were to upgrade to steel gears, and a stainless steel keystock, i think if anything broke- the wheel would completely lock up. The nylon is like a fuse for catastrophe
ou ch those planetaries are roached ,ive seen afew do that clutch lock mod on the endless sphere forum ,and the upgrade to metal planetaries seems the go,but there is very noticable increase in motor noise
Sure seems it would have been easier to just remove the brake rotor and not get it contaminated. I get you barely need it with regen but why fight it. Couple of things, I like to take a black marker and sort of paint over old scratches to see if the next time I remove motor there are any new issues that shouldn’t be there. Also a little more grease on inner casing is not a bad idea either. Easy fix for front wheel swinging around is a velcro strap around tire and downtube . lol, sometimes I wonder if you spend more time fixing things than just out riding. Makes for good content though! My biggest issue this year was I switched phones and lost the old ANT battery bms app and can’t monitor my battery anymore..otherwise all my e-bikes run just fine with no issues accept a little winter maintenance to clean everything up for the next year.
yeah im always lazy with that brake rotor you can usually get away with not removing it. But since my welded clutch requires a gear puller to get it back on the motor, yeah it would be easier to just take the rotor off. It got a little bent up but I just went flying down the street and it sorted itself out
Sorry if you already answered this but 12:55 do you know the dimensions for that key that runs parallel with the shaft??thanks also great video thank you so much been very helpful
yeah, But then other parts of teh motor will break that are harder to repair. With a welded clutch and steel gears, I think the wheel could potentially lock up. Whereas nylon gets chewed up and breaks out of the way
@EBikeBuilder_ if you have it on the table .. two of the legs lay on the bench and third lays on the clutch /gear plate... if you have it pressed on that gear holder and the axle.. the arms will not swing anywhere and the turn force is down on the bench .. try it it will work (I worked on other gears in industry and if possible we lay them on the side)
Isn't the "noisy boy" maybe noisy because the nylon gears are rubbing on the plate on 2 of the 3 gears? I like the plugs found to fill the drilled holes for summer time cooling 🪭.
the gears were spinning OK. I think when the nylon gears were grinding and breaking , the bearings inside the nylon gears got all F-d up. and the gears were getting smushed around sideways during the nylon woodchipper event
i have 2 motors, so I used a jam nut from my spare motor. its M12 x 1.25 jam nut. I am not sure of thickness, probably 3 or 4mm thick. In the future I might try something like www.menards.com/main/hardware/fasteners-connectors/nuts/hex-jam-nuts/midwest-fastener-reg-12mm-x-1-25mm-zinc-class-8-extra-fine-thread-jam-nut-1-count/87592/p-1541140120262-c-8915.htm
I could not find the jam nuts anywhere. So I took a nut and cut it in half to make 2 jam nut. I just had to use a file metal tool to rounded up the outside. I think the problem occurred because we should leave a tiny space between the jam nuts and the bearing washer. That's the purpose of the jam nuts other wise you would not need them. What do you think?
thanks for taking us on the Bafang gear repair journey...
it was a journey to say the least 😅🤣😂🙏
This is extremely valuable information. I've been considering to put a regen on my travel bike as well and really need to see something like this. Previously I have lost four rear wheels to cracks, mostly from braking too hard with regular brakes in mountain descents. Braking forces can be very high.
Awesome stuff. Keep on doing what you are doing
No wonder why a clutch has a specific torque rating. Also, let's share the Bosch baudrate for can com
Steel gears only when you find your safe peak power, do you think steel gears would have caused a more catastrophic failure ?
From what I've read the failure chain with high power is: the nylon-gear fails then replaced with PEEK-gear which fails then replaced with metal-gear then the axel key fails which is replaced with a stainless steel key. It is a process :) There are those of us that like to experiment, and push the system to see what it can do.
@@NoInfoFound- Like the BMX process of failed wheels improved led to fail stems improved etc?
if you were to upgrade to steel gears, and a stainless steel keystock, i think if anything broke- the wheel would completely lock up. The nylon is like a fuse for catastrophe
ou ch those planetaries are roached ,ive seen afew do that clutch lock mod on the endless sphere forum ,and the upgrade to metal planetaries seems the go,but there is very noticable increase in motor noise
Sure seems it would have been easier to just remove the brake rotor and not get it contaminated. I get you barely need it with regen but why fight it. Couple of things, I like to take a black marker and sort of paint over old scratches to see if the next time I remove motor there are any new issues that shouldn’t be there. Also a little more grease on inner casing is not a bad idea either. Easy fix for front wheel swinging around is a velcro strap around tire and downtube . lol, sometimes I wonder if you spend more time fixing things than just out riding. Makes for good content though! My biggest issue this year was I switched phones and lost the old ANT battery bms app and can’t monitor my battery anymore..otherwise all my e-bikes run just fine with no issues accept a little winter maintenance to clean everything up for the next year.
yeah im always lazy with that brake rotor you can usually get away with not removing it. But since my welded clutch requires a gear puller to get it back on the motor, yeah it would be easier to just take the rotor off. It got a little bent up but I just went flying down the street and it sorted itself out
if its hard to pull off the axle its a tight fit ... if it would come off easy there is some play... a tight fit is better for sure
even with the planetary gear carrier so tight on the axle, It can still shift back and forth when doing regen and acceleration, its crazy !!
Sorry if you already answered this but 12:55 do you know the dimensions for that key that runs parallel with the shaft??thanks also great video thank you so much been very helpful
5mm x 5mm x 10mm stainless steel keystock is what you want on Ali Express www.aliexpress.us/item/3256805856788568.html
Do they have better gears like steel or anything that would make em a bit stronger?
yeah, But then other parts of teh motor will break that are harder to repair. With a welded clutch and steel gears, I think the wheel could potentially lock up. Whereas nylon gets chewed up and breaks out of the way
why not lay the puller on the side? should be easier
easier to hold gear puller from the top , or the legs will be swinging all over
@EBikeBuilder_ if you have it on the table .. two of the legs lay on the bench and third lays on the clutch /gear plate... if you have it pressed on that gear holder and the axle.. the arms will not swing anywhere and the turn force is down on the bench .. try it it will work (I worked on other gears in industry and if possible we lay them on the side)
Isn't the "noisy boy" maybe noisy because the nylon gears are rubbing on the plate on 2 of the 3 gears? I like the plugs found to fill the drilled holes for summer time cooling 🪭.
the gears were spinning OK. I think when the nylon gears were grinding and breaking , the bearings inside the nylon gears got all F-d up. and the gears were getting smushed around sideways during the nylon woodchipper event
the key MUST be softer as the axle!! otherwise the hole in the axle will wear out
the hole in the axle already kind of started wearing out , even with the softer key, regen is rough on that
Where did you get the jamnuts dude? The exact same thing happened to me. Those nuts are weak and bad quality.
i have 2 motors, so I used a jam nut from my spare motor. its M12 x 1.25 jam nut. I am not sure of thickness, probably 3 or 4mm thick. In the future I might try something like www.menards.com/main/hardware/fasteners-connectors/nuts/hex-jam-nuts/midwest-fastener-reg-12mm-x-1-25mm-zinc-class-8-extra-fine-thread-jam-nut-1-count/87592/p-1541140120262-c-8915.htm
I could not find the jam nuts anywhere. So I took a nut and cut it in half to make 2 jam nut. I just had to use a file metal tool to rounded up the outside. I think the problem occurred because we should leave a tiny space between the jam nuts and the bearing washer. That's the purpose of the jam nuts other wise you would not need them. What do you think?
Time to go direct drive.