6000km motor shaft noise on Bafang BBS02 / BBS01 (Loctite) • DIY Electric Bike Motor Mid Drive

Links showing how to:

This motor was reliably used on a heavy food delivery cargo bike for over 6000km. Same procedure applies for both BBS02 and BBS01 motors.

BrunoPOWEEER is everywhere:

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My Fast Electric Bicycle setup:

Motor:
•Bafang BBSHD 1000w 48v (1455watts peak)
•Custom controller settings with 100% throttle enabled at PAS-0 and no speed limit (unloaded wheel spinning at 102kmh with 46T)
•46 tooth chainring (74.1km/h top speed on flat)
•189 RPM at 58.8v (factory settings 160 RPM maximum)
•4.8kg motor

Battery:
•Homemade 14s 5p 58.8v 14.5Ah battery pack capacity
•1,5 hours safe fast charge (6A 350w charger set at 59v)
•3.65kg battery pack transported inside my backpack connected to the bike with XT90-S high discharge anti-spark connector.
•70x NCR18650PF Panasonic High Current cells
•Waterproof "bare cells" pack style for better cooling
•No BMS for 100% charge (4.2v per cell) = 100% performance!!
•Range (with BBS02 motor): +/-26km in the city / 36km continuous full throttle with only few stops

Dashboard:
•V3 Cycle Analyst with with 1.00m ohms shunt
•Bafang C961 display
•2x 15 watts LED headlights (two modes: normal or high bean)
•Waterproof red LED voltmeter to monitor battery sag and performance during the ride.

Throttle / Brake Sensor:
•Left thumb throttle (connected to the BBSHD controller) adapted to road bike handlebar, set up between the brake lever and the bar (almost invisible) mounted on a copper T-joint (used for plumbing, same thickness as the handlebar) the long bit cut in half riveted to the bar with the other bit sticking out enough to mount the throttle.
•Magnetic cut-off sensor in line connected to my mechanical rear brakes

Bicycle:
•9kg Trek Road Bike
•Easton (rear) Shimano (front) performance 700c racing wheels with aerodynamic flat spokes
•Mechanical brakes

[haqitman]

My BBS02 just started making this exact noise at about 4500 miles. I will try the loctite, hoping it works. Thanks for putting this out there.

[suwidah]

Hi Bruno!
Yesterday I tried to do the loctite part as a preventive procedure after 3000km. It was hard to pull the shaft of the base but with extra force it was pulled out and damaged the shaft teeth :'D. The shaft was pulled with the whole bearing part with it just like the BBSHD. I think Bafang was watching your videos and applying loctite themselvesg!!! P0WEEEER!!!

[harryguy]

Was the bearing toast causing the shaft to spin in the inner bearing race???Must have been for the shaft to be spinning inside the bearing....or those bearing have a shit load of friction due to the rubber seals.That bearing looks to be enclosed by the case so a rubber sealed bearing is not needed.

[dado]

Hello Bruno, so Bafangs has more bugs and also comming out of the motor. ;))) How is new display? Does it now show real SOC of battery?

[MrEugeneleo]

what's the most likely problem for pinion gear? Is there a video??

[FreeSolarPanel]

Hello, I have such a question. May the motor work as well as I can fix it. Thanks in advance.

[uberflutak]

I'd have loved to have seen Bruno squash the bug at 01:43 with the end of the shaft

[elainahancock]

The bearing came out with the motor shaft when we pulled it out, I'm not sure what to do! Should I pull the bearing off and then loctite the shaft into the bearing?

[robyros]

HI BRUNO,
I KNOW OF A PERSON THAT FRIED THE CONTROLLER OF THE BBS-HD 1000
HOW IT CAN BE APPENED ? EVEN IF A BATTERY HAS A BMS OF 60 AMPERE
CONTINUOUS, THEN IS THE CONTROLLER THAT TAKE ONLY THE MAX CONTINUOUS AMPERE THAT IS PROGRAMMED. AND IN THE CASE OF THE BBSHD ARE 30 AMPERE.
SO, IT'S STRANGE THAT 12 MOSFET 3077 HAVE HAD OVERHEATING PROBLEMS,
MAYBE IT'S SOMETHING ELSE !?!? WHAT DO YOU THINK ? IS IT EASY TO CHANGE THE INTERNAL CONTROLLER OF THE BBS-HD ? HOW IS IT GOING YOUR BBSHD ?
EVERY DAY I WAIT FOR NEW YOUR BBSHD RIDE VIDEOS !!!
I HEARD OF A PERSON HAD INCOMPATIBILITY OF THE C965 UNIT AND BBSHD.1000
IT WAS NOT ABLE TO READ THE WATTAGE, MAYBE BEACAUSE THE UNIT WAS FOR 36V AND NOT FOR 48V AND THIS PERSON SOLVED THE PROBLEM USING THE C961 UNIT (THAT IS THE SAME YOU USE WITH YOUR BBSHD) - INFACT THERE ARE EVEN 5 KIND OF C965 UNIT . THE FIRST IS WITH 3 BOTTONS FOR 36 VOLT, THE SECOND IS 3 BOTTONS FOR 48 VOLT, THE THIRD IS 5 BOTTONS FOR 36 VOLT AND THE FOURTH IS WITH 5 BOTTONS AND 48 VOLT AND THE FIFTH IS THE DP C10 UART UNIT WITH 5 BOTTONS AND FOR 24-36-48 VOLT..
SO LET MEKNOW AND UPLOAD OTHER VIDEOS OF YOUR BBS HD !!!

[MySatora]

Ive got my motor apart at the moment and would like to do this but how could you ever take it apart again? It took me long enough to get it out the first time without it being glued in. Any ideas? Thanks for the videos, they have been a great help.

[jphildo]

hi can you give me the dimensions of that bearing if you have one out to measure.

[annespacedroid]

I'm all for Why not just replace the rubber ting though?

[uilleamgilvoni]

Hi man
do you recommend to use Loctite 641 from the beginning?

Cheers!

[salahoukrid]

18500 km in 7 months 😁😁😁 with Elops 940e

[phishiphishi]

Sorry .... i just cannot listen to your voice any longer