Gear Shift Sensor Installation video for a Bafang Mid Drive system BBS02 / BBSHD E-bike
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- เผยแพร่เมื่อ 16 ก.ค. 2021
- Hopefully, this video will show you exactly how to install a gear shift sensor onto your e-bike. I think it's one of the best additions for your e-bike to keep it running long and prosperous.
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To prevent splaying on bike cables I use electrical solder on the cable end before I cut it. Just need an inch of solder coverage and it will cut clean and not fray. It will stay neat and clean over the life of the installation.
I use a drop of thin superglue. Let it dry. Separate your fingers. maybe give a light sanding, as an alternative, if solder not handy.
@@whazzat8015 "separate your fingers" :D , "maybe give it a light sanding" - not the fingers :P
@@kilrain_dev The cable, and maybe then my nails.
fantastic idea
Dipping the end of the cable in flux, heating it lightly and thereafter putting a tiny drop of solder on helps to avoid the trouble you had with single steel strands. The solder holds the strands together and you can even sand them down to somewhat of a point.
I just use super glue
@@scotth5503 Yep - twist the strands tight and put a drop of the thin stuff on.
Haha I just made a point to come here and comment about using a dot of super glue. Looks like it's already covered...solder would be good too. Anything to keep it together. I had to order a new cable and wait on it because it splayed when I took it back apart....should have just left it well enough alone lol
080090❤❤
Yay !! I was wondering where the Gear Shift Sensor went and how to fit it as I'm getting a Bafang mid drive Motor with battery, so I'm schooling up on as much valuable info and resources as I can find and as you are more direct and to the point I find a lot out watching your TH-cam Videos, Thanks for sharing your experience and knowledge as it is most appreciated and useful .👍👍😎💨🏴☠️
love how you are just being yourself and share all the good info
I'm glad you're FINALLY recommending theses!...hee hee
I know right 😂
Tx Johhny, just installed the shift sensor today on my BBS02 project bike - Perfect advice!
Nice job Johnny love the videos keep up the good work.
I had the same problem with the cable, ended up fitting a new gear cable, they're cheap enough, as for the sensor in action, brilliant! ..need this with that much torque!
Can’t recall how I did this the last time, so I’m glad for this…. (Yes, did this for the first build, and doing one for the current build also.)
I put mine at the front, super easy to do and works as it should
At the front??
Thank you so much for all your videos. I learned a lot on eBike from you and the least I can do is to subscribe say thanks.
This is good cheap insurance for the drivetrain.
Most kits I found didnt include this sensor, and for only another 30$ including the splitter cable gets it done.
Thanks for showing how Johnny.
Hello Johnny,
Really enjoy your videos. If you cut the shift cable clean and put a bit of solder on the tip it won't fray. I actually stopped putting the caps on them and solder the end now. They slide through the shift sensor better as well.
Good tip. I used to do that myself. Not sure why or when I stopped🤔
I like your attitude.
It can be mounted on the upper end of the bike also, the cable stops will dictate best location, and and gear sensor cable extension (``24) are cheap on Amazon ...if you get in a bind.
Another trick that I used was applying super glue to the end of the wire, it wicks in-between the stands and holds it together nicely
Trick, use construction grade superglue to just hold the steel cable end together before threading through the sheath. You will need to moisten the metal but breathing on it should be enough
Thanks dude!
Do you have a video on how to shift with a mid drive like the BF units you commonly install?
Does it make a difference if installed in different direccion.
I install it, if possible, closer to the front of the bike for a good reason. If there's a suspension fork (usually the case) there are less shocks on the front end than on the rear end. Hard hits on the rear wheel can sometimes trigger the shift cutoff, if the sensor is placed close to the rear axle. That plastic insert is too small, I just use the shift wire housing with a plastic ferrule, that fits perfectly into the sensor. Some chain oil in the cable housing and shift sensor helps reduce friction and improve shifting performance. by the way, that chain on this bike is waaaaaaaay too short :D
Yes I know. This isn’t a video on sizing chains!!!!!!! 😂😂😂
I put mine on the handlebars at the shifter to avoid running yet another wire along the frame. I created a small bridge piece of cable housing to go between the sensor and shifter. With a BBS02(b) or BBSHD these should be a standard part of a kit.
Shift sensors are not nearly as much of a necesity on torque sensing mid-drives.
Don't forget this guys a professional 😂
Do I need a gear shift sensor if I have a torque sensor?
3:25 What I have found helpful is to dip the end of the cut cable in superglue then baking soda...let cure / trim. Rock solid!
what does the baking soda do?
It looks as though the sensor detects movement of the shift cable running through it. Pretty simple really. I'm hoping my local bike store has cable cutters for sale. I figure i will be doing some e conversions for family and friends after they try mine out so buying some nice tools is not a worry.
Can a 21 speed hybrid bike converted to ebike/bafang mid-drive?
Is the red light on the sensor supposed to blink all the time or just when you are shifting?
Is the orientation of the shift sensor critical. In your video you show it going both ways. Thanks
Can anyone tell me if it's possible to fit this sensor on a Shimano Nexus 3 speed hub gear.....Not your usual derailleur, it looks like a good bit of kit that I'd like to fit but I'm unsure if it can be fitted to a hub gear ?
Hello! Can u pls help me? I have a KTM ultra fun, 1x12 speed bike, with a 34T chain wheel at the front. Can I install Bafang mid drive set? It comes with a 36T chain wheel. Will it suitable without replacing the full drive? Thank you!
My gear shift sensor kit only came with one little addon piece of plastic, the piece you added at 1:39, not the piece seen at the top end of the cable housing in your left hand seen at 1:51. No kits on amazon seem to have that piece. Am I going to run into issues not having that piece/pieces?
Hi please what is the benefits of that sensor
My motor didn't has it
Is it necessary?
The way he came to the frame of the video is cute 😂
hi i have a Focus Thorn 2016 with mid motor "impulse evo rs". the circuit board/controller is broken. it is difficult to find original spare parts. Is there a universal controller that I can buy? I don't need PAS, I want to buy a controller, a throttle and an LCD display
Does the direction it’s installed matter ?
Hi Johnny my name is RC. I am having a problem with a sondors lx. I have code 21 and 36 . I found the negative terminal broken. How do I erase the codes because the bike is still shutting off when you try to operate it.
Thanks
What Schwinn model bike is that? I like the way it looks with the motor kit installed.
Axum
cool, could you do a video on post conversion, tuning the motor, adjusting brakes, shifters, sensonrs, checking display and everything working? appreciate the detail thanks
All in the works 👍
I really like the Axum for a good budget e-bike.
I guess I've been lucky installing gear sensors. I will be prepared in future if it doesn't go as smoothly next time. Thanks.
I'm curious how important it is that you're in the highest gear when installing the sensor? I ask because you were in the 2nd lowest. Can I assume it's mostly adjustable once the install is done, and it's just best practice to be in high gear?
Kudos on your cable management aesthetic.
Best to be in high gear. The chain location and the shifter position are independent 👍
Hi Johnny 👋 This is the dude who just bought two DM01s from you. Shipment was speedy - thanks for that. Is it important to mount the speed sensor as close to the center of the wheel as you can? In regard to my shift sensor, I'm going to have to come up with a plan because my shift cable has a sheath throughout. I guess I'm just going to have to make a gap in it somewhere.
Johnny, have you ever tried just loosening the two screws on the plastic gear sensor and then slipping the cable in that way, much easier. I found it extremely frustrating to try to push the cable through the gear sensor, because it's a tight fit and it has to go around that little pulley and each time like what happened to you it frays the cable.
Johnny do you ever have issues with the shift sensor and “rapid fire” shifters that can down shift 3 gears at a time? I’ve had some serious derailment issues when down shifting a bunch of gears. For example shifting down 3 gears then another 3 gears really fast. Is there any way to get these things working fool proof? Or do you just need the user to shift carefully & deliberately ?
Yes. Ride deliberately and thoughtfully. It’s not a high powered sports car!😀
Anyone have any luck installing break cut offs on a hydraulic drop bar system with STI shifters?
Newbie here, in Vancouver Canada.. how does the gear shift sensor sense the cable movement???.... It looks like the metal cable is in all the way through the sensor when at rest, and when shifter is pulled, it is still sensing the same metal even though it moved... so what changes at the sensor when it moves? Did I miss something? Great videos.. where can I buy the mid drive Bafang motor( 1000 W or 750 W ) and assembly parts ? Where can I get the specialized tools needed in Vancouver? Thanks I am an industrial electrician and I know I can do this easily with your videos and tools...
There is a little roller inside the mechanism that senses when the cable rolls over it and it cuts power to the motor momentarily.
Your helping me so much I’m saving up for a bafang motor is it okey if I just install the thumb throttle and the brake sensors and the display?
Yes
And speed sensor
@@JohnnyNerdOut ok thank you
i think if you don’t need PAS, you can configure the throttle to work differently for each PAS setting. Otherwise the throttle is just on or off with no way to modulate the power
I’ve got the bbshd with the 42t chain wheel that comes with kit. The chain alignment is out, will the lekki bling ring help? Does it cover the motor a little where it gets attached?
Yeah, the 42T lekkie cups the BBSHD cover, so the alignment will be much better using the 42T lekkie bling ring, which has an 18mm offset , although I'd also buy a few lekkie spacers too, they're inexpensive, just in case you need them too, a 1mm and a 2mm spacer should be ok for most installs, as some installs can bring the (lekkie) front sprocket too close to the bike chain stays frame, ideally you want a 1.5mm or 2mm gap between the front sprocket and the bike frame, using a spacer behind the front sprocket will allow for fine adjustment as needed, although they're not always required.
How do you do that Bafang software parameters? I would love to see your recipes.
Tip: after you cut the cable us a little super glue to keep the wires from fraying.
How does the sensor work? Is it optical like a computer mouse that senses movement of the cable or what? Maybe a friction wheel? Same question for the non magnetic inline brake sensor... thanks.
Senses movement of the cable. Some kind of laser probably. Dirt tends to accumulate on the shift cable inside the sensor and you have to clean it off once in a while.
same principle on my Nexus 4? P.s. you're the best Johnny
i'll take that as a yes then.
Do they have a similar sensor for brakes? I was wanting to do a drop bar installation with road bike brake levers.
yes, you will need in-line brake cutoffs. Available here: www.johnnynerdout.com/product-page/in-line-brake-cut-off-sensor
I use a cheap old pair of wire cutters.
I've had for about 15 years now.
No problem cutting gear cables.
On the gear shift sensor.
I never spin the cable I just push them in never had a problem.
You didn't mention you can wire them on any mid drive ebike controller.
Just need the 2 cut off wires
Ground & signal wires
And get the 5 volts wire shared from the throttle or pedal assist.
Then you have the 3 wires to work the shift sensor
It work no problem
Hey Johnny I got a brand new bafang mid drive and I only have 55 miles on it and it just stopped working and I got error 30h, I was riding when it stopped, checked all connections and changed the display and still another error 30h?what is your guess?
I checked for a bad connection somewhere or a severed wire somewhere. If not you could always try switching out your display and then start switching out small components like that until you find the culprit.
electricbike.com/forum/forum/kits/bafang-mid-drives/troubleshooting-bbshd-and-bbs02/976-error-30-in-the-bbshd-and-bbs02
4:30..."Make sure it's in the highest gear". Look away folks...him not paying attention. LOL
It happens. Point to something and say something the opposite 🤦♂️
We still love ya....LOL@@JohnnyNerdOut
Hi Johnny. Can you tell me if an Eggrider V2 display is compatible with a 52V battery. Also do you sell them, and would you send to Mexico.
Yes they are compatible. I can but would need to create a custom invoice. Best to call or text the shop 👍
Mine failed because of the rain so I don't bother with it and just use my brake sensors like a clutch
Is it harder to install a mid drive kit onto a bike with drop bars instead of flat?
Yes. Mainly with brake cutoff installation and running wires
Johnny didn’t explain, if you stick a straight pick in each end you will notice the 2 holes bend down towards the existing wire about 15 degrees, it’s not a straight through hole, if you put a slight bend on the wire aim towards existing wire it will go through. And you won’t need to worry about end Frey, I usually dip end in candle wax, just since we have a bunch
Does it matter which way you run the cable through the sensor?
Only if you ever only change up gear and never down during a ride 😉
So the small rubber thing it comes with is supposed to sit in that hole in the frame ? I'm confused as to how it actually detects the cable moving is then as I thought that rubber thing was going to slide on the cable and then be fed inside the middle of the sensor to press against some switch, but then there would be nothing holding the sensor housing in place to the frame 'hole'. I thought maybe you used a random piece of something to make it stick on there, Its hard to see exactly from the video.
Im guess there is a little tension pulley in the house to where the cable is going to run on top of it so when ever there is tension put on that pulley it trips it and cuts power to the motor and then kicks the motor back on
Bafang kits com with a speed sensor. Can that act as a substitute for a gear shift sensor or do you need to install both ?
They are totally different sensors. Install both 👍
Any tips on gear slip? Middle cogs on an newish Acera want to shift under load. ,no discernible wear. Replaced chain, aligned hanger, adjusted range and indexing. Checked idler wheels for play, chainline, cables and shifter seem OK.
I'm not happy with hanger pivot bolt play, and was wondering if you had any tips before replacing the RD? They are hard to get these days.
ALSO Safety tip. I always pull battery before working on chain/gears. Bumping the throttle could suck a finger through a place you would rather not. This is also a concern when dealing with a dropped chain in front. I carry a little hook I made from coat hanger, for that.
Sounds like you literally checked everything. If it’s still persisting, maybe take it in and see if they can catch something you didn’t? Tons of good videos on YT about the matter from people who specialize in it though, I’m sure you tried that🤔
@@JohnnyNerdOut THX. Yes, its either just that hanger bolt play or something where someone gets his experience with seeing a lot , to pay off. The BBSHD puts so much more power though the drive train, it brings things out. I understand Justin L-E's bias towards hub motors as power goes up.
@@whazzat8015 hmmm the BBSHD shouldn’t be ruining your drivetrain though unless something is out of adjustment or it’s being driven incorrectly. Once you get to 2-3k watts a mid drive starts putting a lot of strain on parts 👍 once you get that dialed in I think you’ll be 😃
Hello Johny, thank you for all the videos! I would like to buy a second hand ebike, mostly for commuting with a child seat on roads. I was trying some bike (with good components alivio, hydraulic brakes, ..) from 2018 with bafang M300 and I was surprised how loud and unpleasant the shifting was even when I tried to stop pedaling (probably due to cadence sensor). On my grandfather 2013 rear hub motor the shifting is so smooth and pleasant (I know - because the force is not going trough chain). My question is: If I want to smooth shifting, should i just install this gearshift sensor, or buy newer motor with torqsensing (because you can control the motor better during shifts) or just buy something with rear hub motor? Is there some downside to installing gearshift sensor? Like shorter motor lifespan? Thank you very much! Josef
A gear shift sensor is a must on cadence mid drives IMO. I would even install one on a torque sensor if possible. The GSS will prolong the life of almost components on your bike 👍
@@JohnnyNerdOut Yes, I thought so just from the test ride. The person who was selling the bike (which had 10 000 km) didn't find it strange even though he was changing the chain twice a year. Thank you for a response! :)
"Hey Guys" Lmao
Johnny, don't new cables come with the ends soldered and neat? You could have fed the cable through with the soldered end and then cut it after to avoid fray fuss.
Love the videos! Just installed a gear sensor on a Schwinn Axum DP myself and it is working super well. Couldn't have done all of this without your help!
Yes new cables do, but the old wires that come on old bikes oftentimes are splintered and barely held together.
What battery did you use?
@@BikesNotDrugs FTH Power. It's an American company that rebuilds batteries. Their quality is excellent, but selection on sizes limited compared to Chinese manufacturers.
Your derailer gears are pulled all the way foward in your top caset gear. Is that the way it should be? I put a 30 tooth on my midrive and a new chain for climbing but chain is to loose and comes off over bumps in bottom gear.
Chain was not sized yet in this build
@@JohnnyNerdOut can you do a video on setting chain length
@@fulllfreezer in the works 👍
@@fulllfreezer most derailleur size the chain by taking it around the largest cogs, Outside of the derailleur , add a couple links to it. In any case it should say in the manual for your derailleur
Hey Jonny my gears are all messed up. Now that put on the sensor. I cant seem to find the other video about adjustment of the gears pleaee advice thanks
Book a troubleshooting consultation with me and we can get you sorted. johnnynerdout.com
@@JohnnyNerdOut i got it figured out thank you for the reply
I know I will sound dumb, but what is the function of this sensor? What does it do exactly?
It cuts power to the motor during shift events. Helps keep your drive train from wearing out faster.
You definitely want a longer chain
Whats the difference with the 2 types of gearshifter sensorers from Bafang?
They are marked as a
1 : Plastic gear shifter sensor
2 : Metal gear shifter sensor
Is it just the housing 🧐
Yes. Plastic is smaller, but plastic. I like th plastic personally
@@JohnnyNerdOut easier to make plastic snuck/waterproof and it wont rust 😁
Can you put it up by the gear shifter
The shift sensor wire isn’t long so probably not, unless you get an extension for it. Also the Shift sensor is a hard rigid thing, so you want it somewhere the shift cable isn’t bending or curving. Right at the gear shifter probably isn’t ideal, as the cable usually bends there. But you could put it anywhere you want really given the considerations i mentioned
What does a gear shift sensor do and what is the point of having it?
cuts off the motor during shifting making it smoother.
Looks like my Schwin Axium
metal or plastic shift sensor?
I like the plastics ones because they are smaller but the metal will likely have better longevity
I've never seen that before why is the drive chain that sort.
Chain looks too short. Might just be the original chain and he is not yet done with the installation.
Why not just remove all the gears and even from the handlebar and only use bafang motor and peddle assist.
What is ur thought on that?
Like a unicycle?
@@JohnnyNerdOut hahaha of course u still use both tires but just remove the gears and use the motors peddle assist modes levels while biking and not shifting at all.
Would that work or is it more effective to still be able to shift gears during bike ride
@@theartteacherdaniel5096 oh I see what you mean. That would be like using your gas pedal instead of your gears on a manual transmission car. It would work but it would put a lot of strain on the drivetrain and cause parts to need to be replaced much faster 👍
@@JohnnyNerdOut oh OK i see so it may be better to not remove the gears. Thanks for your reply
Would like to speak with you about upgrading motor on a radcity. Is best call you direct.
you can book a consultation directly from my website:)
Hey Johnny. I’m not sure you want the rear mech forward like that. The chains too short. Why do you stretch them forward like that. Thanks for the videos they are enjoyable.
Properly sized chains should only have about 1 extra link when in the lowest gear. It should pull the mech forward almost to its max.
Yes this chain was lengthened before being completed. 👍
Next to bottom gear, too.
Park Tools, and some manufacturers, give instructions.
The cable cutters look *just* like mine! (Pedro’s, I think.)
You have to re-set up shifting after installation?
What?
You will need to re-tension it.
You will need to index the derailleur.
Buonasera ... ho elettrificato la mia bici grazie anche ai tuoi video e su consiglio ho cambiato la catena che era ormai vecchia con una per E-Bike... come mai in prima , seconda e soprattutto terza tende a slittare ??? Sai darmi un consiglio??? ps ho lasciato di un cm buono la nuova catena più lunghetta perchè altrimenti la dovevo fare più corta dell'originale anche se di poco, può dipendere da questo? oppure è ora che cambio anche le corone del pignone della ruota posteriore visto che sono vecchiotte pure loro??? Grazie mille :-)
What is the purpose of the gear shift sensor?
Think of it as an automatic clutch
@@JohnnyNerdOut That is brilliant. Thanks for the clarification.
What does this sensor do?
You put the shifting cable through it. it can detect when the cable is shifting, and cuts motor power momentarily to prevent shifting under load and crunching your gears
@@soandsononame8750 Thanks, I guess that's more important with American style ebikes, here we only have 250W.
I've bought a kit but I can't seem to get help with questions, I gave up trying. Why can't someone give a phone number to call and ask? Is that such a huge request??? I'm giving up.
Who did you buy it from?
How about a u tube of the tools you use. We tool junkies need the the brand name and where to buy.
I have a video on that topic!
Chain way too short…about to rip rear derailleur off the frame.
Chain adjustment is usually the last thing I do after I finalize which chainring I am going with
Did you mean lowest gear.
Put mine on the “down tube”, not knowing any better.
You can do that just fine 👍
you can get a sensor for like 15 $ on amazon prime shipped
The exactly same one is £5 to £6 on AliExpress & £9 on eBay.
Maybe a drop of super glue can prevent the cut end from splaying
Probably wouldn’t fit through the cable housing then. I think light solder is the best
Stay-brite solder seems to be a bit better than 63-37 electronics solder...
@@JohnnyNerdOut Sand like solder, usually works fine after you unstick your fingers
Is it possible to run a 40 and 30 tooth sprocket together up front?
Probably but really not needed for 99.9% of riders
@@JohnnyNerdOut I am the 1% that wants cruising speed and tourque for pulling a trailer up a hill.
@@fulllfreezer consider using a higher powered motor?
I had a 42 tooth Eclipse chainring. There weren't many hills I had trouble with, even with a loaded B.O.B. trailer. Note that I was not able to grab the very lowest gear.
The new build promises to rectify that issue, as well as have a 42 tooth bottom gear.
Addendum: was running a BBS-HD, *turned up,* with a 21 amp-hour 52 volt battery.
Not trying to be hater, but FYI the chain is a few links too short.
With all due respect it's been mentioned at least 20 times in comments 😉
just bought $20 worth of zip ties..
new to ebikes. stage level: learning...What is an eBike Shift Sensor and How Does It Work
I'd probably lengthen that chain a bit.
Here’s a great reference on chain sizing 👍
www.parktool.com/en-us/blog/repair-help/chain-length-sizing