Electric Bike Conversion Kit

Update: Newer versions of the 750W BBS02 are shipping with better mosfets that probably won’t blow. Before you take apart your blown controller and switch them out be advised that it is MUCH easier to just buy a new controller with the newer IRFB3077 mosfets, more info about it is here. The BBS02 controller is the weakest part of the BBS02 unit. When Bafang switched to the 9 Mosfet unit and bumped the power up to 750 watts for the US market they did not replace the poor quality mosfets in the controller with ones that could take more power. Poor programming from...

Karl Gesslein / May 6, 2015 BBS02 axle I have hundreds of hours trailriding on the BBS02, here is the BBS02 motor problems I have had so far One bent axle Two broken plastic gear covers One blown controller Two bent chainring adapters One motor has an awfully squeaky clutch Three broken speedos and one lost magnet Two stripped out Bafang crankarms One stripped out nylon gear Granted I am a 205 lb guy who carries a 16lb battery on his back and trailrides like a total hooligan. What steps can you take to minimize the damage to your drive units? Get a smaller...

Karl Gesslein / August 18, 2015 Your BBS02 will give you years of service and love if it is treated properly.  The BBS02 loves to eat Watts, but not too many and not too fast. The Pedal Assist system even at its highest setting will only put out around 750 Watts which the BBS02 can eat all day long without overheating or causing problems. The real problems happen when using the throttle at higher power levels. Always hungry for more watts, your brand new baby BBS02. Be careful, this beast has bite.   The throttle on the BBS02 when set to the...

Karl Gesslein / August 24, 2015 Makes me hungry just looking at it. It took several years for BMC to realize that Nylon planetary gears in their larger geared hubs like the Mac motors could not take the kind of loads that people were dumping into them. Eventually they learned their lesson and switched to using composite gears, but with the BBS02 Bafang still haven’t wised up and made the primary reduction gear out of composite materials or metal. The primary reduction gear feeds against the metal helical gear on the motor and takes a tremendous load when the motor is started under load from a standstill....

Karl Gesslein / November 22, 2015 In the past, I’ve told people when they replace the nylon gear (instructions are here) to use heavy axle grease on it as the Lithium grease that it ships with is incredibly light and tends to just spin-off the primary reduction gears when they are spinning at around thousands of RPM. After 5 minutes of Internet research, I’ve found that doing this is a terrible idea and can actually CAUSE your nylon gear to soften and fail prematurely (it was really a ploy to help sell more nylon gears for Bafang). This takes me back to my original...