If you are unlucky enough to have this happen then most likely the nylon gear has failed. My advice when you buy a BBS02 drive unit is to buy two instead. thanks for you encouragement, hi karl, You can clearly see the differences in version A (left) and version B (right). This Bafang motor can be installed on any bike with a standard crankset: mountain bike, city bike and even tandem. document.getElementById( "ak_js_1" ).setAttribute( "value", ( new Date() ).getTime() ); Click to share on Facebook (Opens in new window), Click to share on Twitter (Opens in new window), Click to share on Reddit (Opens in new window), Click to email a link to a friend (Opens in new window), Bafang Completely Redesigns The BBS02 And Tells No One, Intrusive Chainstays & Non-Standard BB Size Issues, Improper mounting and alloy frame failure, Nylon Gear Failure From Axle Grease Seepage, Replacing The Nylon Primary Reduction Gear, California e-Bikes 100mm BBS02 Drive Unit & Kit, AC Inverter + Batteries = Portable Generator, Buying Batteries from the US at China prices, Road Bike BBSHD 1000W 8-speed 36lbs ~$1200, Bullseye Bluto Pro 10-Speed BBS02 46lb ~$2049, Deadeye Monster Single Speed BBS02 42lbs <$900, Bullseye Monster 8-Speed BBS02 46lbs ~$1750, Ace Single Track Full Susp BBS02 9speed 40lbs ~$1500, Cheapo Commuter BBS02 8 Speed 45lbs ~$780, Walmart Dolomite 7-speed 59lbs BBS02 ~$700, Deadeye Monster 6000W Ascent Nexus-3 IGH 45lb $2868, Sniper Full Susp Ascent 3000W 10sp 46lbs $3520, Deadeye Monster Cyclone N171 57 lbs ~$889, Soul Stomper 3 Speed IGH Cyclone 63lbs ~$1268, Luna Apex 2500W 28Ah 2500W Ultra Max $5499, Luna Rhino 5000W Cyclone 3Sp IGH Cargo Fatbike $3350 80lbs, Luna Giant Anthem 2 BBSHD $3779 Ludicrous 50Amp opt, Luna KHS 3000 10 speed BBSHD Ludacris $2849 50lbs, Luna Ruckus $1899 65lbs BBSHD 8 Speed 50Amp opt, Luna 96v Custom Apocolypse Racing Scooter, Luna Apocalypse 3000W 2WD 35mph Kick eScooter, Biktrix 2016 Juggernaut BBS02 7 speed $2499 USD, Sondors ebike Single Speed 59lbs 350W $499 + $194 Shipping, Sondors DIY 12T Mac AWD 2600W 74lbs ~$1871, Felt LEBOWSKe 11 speed 48lbs Bosch 400W $5799, e-Fatbikes Reviewed by Electric Bike Review, 30 Tall Puppet and 4 Person Mutant Ebike, Hallelujah! Can this be programming setup? I never am. However, the first one had three cables coming out of the controller (conncetions to battery, display, and speed sensor), while the second one now has four cables (one additional one with a yellow connector) which I presume is for connecting a gear shift sensor (thats how I set it up and it works fine). I myself installed it on 2 of my bikes: on my Trek hybrid bike and on my wifes Decathlon hybrid bike. The BMS does not communicate with the controller/motor whatsoever. No worries for this kit: the Bafangs BBS02 meets the IP 65 standard well and is water resistant. Put the female plug on the battery side to minimize shorting risks. Very light weight (around 9 lbs). Controller Before trying anything in this guide, please start by unplugging anything that is optional such as ebrakes, gear sensor, removing aftermarket switches etc. You can see clearly that the offset is different between Version A on the left and Version B on the right. it is a washer, originally with 1 or 2mm or rubber coating which i have scraped off trying to get further. The BBSXX does have an on/off switch operated from the handlebar switch via the display but like a TV on standby, the controller's circuits must remain live. I dont know if the A and B controllers are swappable. The chainring looks warped when the drive unit spins around & chain falls off. The Speeed program is not only simple to use but has a detailed help section which thoroughly explains what each setting does. Is the assembly complicated? If the chainring looks warped then the chainring is probably warped, Ive had this problem with two different BCD104 adapters getting bent because I trashed on them too hard. Bafang now equips a large majority of electric bicycles in Europe and even claims to equip 40% of the market. This article will explain the differences that Ive found with the BBS02 version A and BBS02 version B and explain how to program the BBS02v2 so that the PAS will work properly with the newer controller. it is made of 99.5 aluminium 6mm thickness. Any other mid-drive ebike kit is going to take a lot more time and energy toinstall and get working properly. the parts/connectors were mostly selected for the reason of size and fitting together as much as possible contacts with compatible ampere ratings. It appears be be secured with a sleeve inside the shaft. I can put one of my 36V packs, about 41 volts at full charge on my BBS02 and it powers up, but with a low battery icon, If I had one at 38V, I'd try it, but that will have to wait til I run it down them down with a ride. insert a needle between the frame and the washer (external edge of the washer. I have a beach cruiser with standard brakes that was converted to an e-bike by a local guy that has since moved. The battery is housed in a custom built aluminium case and not so easily removed or unplugged day to day. Try to replace the seal with one that have viton rubber its more resilient against oils. The thermistor is placed more on the right side of the controller, so it might still be dissipating enough heat in this more connected part and stay cooler than the middle placed FETs, which will not be able to dissipate their heat quick enough to the case cover, as there is the isolating putty-like mass. Throw them away and buy another one. It seams totally random. I suspect that Bafang will release a 35Amp version of the BBSHD at some point at the end of this year or early 2017 which I believe whole-heartedly that the BBSHD platform can easily support in its existing state. If you buy a drive unit with a battery pack most reputable vendors will set the LVC on the BBS02 to match the pack it is mated to. Want to figure out all your problems? Use only genuine BAFANG parts and wear eye protection during maintenance. i killed the motorcoil of my bbs02 750w produced 2014, but the controller is ok. im very sad that this happened, although i created a great cooler on the motor. You must ensure that there is always grease in this area, especially on the teeth around the large ring and the small ring. When you start troubleshooting the BBS02 the first thing you need to figure out is the problem with the battery or with the drive unit. Dont now it this small thing can make a different. The problem starts here.. I am the proud owner of no less than 8 drive units mounted on different bikes and at least one of them is always broken at any given time. If you have a 68mm BB BBS02 then most likely the main locking nut on the drive unit has loosened up. I apologize. This grease can break down the nylon and cause the gear to fail prematurely (as shown above). If we compare it to a Bosch motor with the same performance, we notice that Bafang simply divided the price by 4! check out the. If your motor stops working and it has been under load the first thing you should do is put your nose right next to the unit and take a good long sniff. This motor is rated at 750 watts but puts out 1470 watts peak when asked and does it more quietly than any ebike on the market. Is it the controller or the battery? The BBS02B lasted 30km. Does it still make sense to buy a BBS02 750W drive unit? Here is a list of everything you need to successfully configure/program your BBSHD/BBS02. Ive used both BBS02A and B. If I write a topic about the modifications in one of the forums used, I will post the link here (if Karl does agree / allow this). Is dielectric grease somehow screwing everything up inside the controller or is just heavy rainfall enough to destroy the controller? Thank you. If so take care not to damage it. Bafang finished their production run for the BBS02 version B with an entirely new part set and released it out into the wild withoutselling spare parts for the unit to US (or Chinese) dealers. At least one kit builder with a BBSHD tore the gasket and water migrated into the motor. Aliexpress.com. I love this bike, Im addicted, its been four days and I need a ride !!! is it possible for the 36v 500w system with the irfb3077 mosfet?. There are 2 areas to grease and the operation takes about 20 minutes. I live in Lyon and even if the weather is fairly mild most of the year, it sometimes rains. 2016 is when they changed. Hi! Proceed with taking our Step-By-Step Bike Compatibility Quiz by clicking the button below!. but too much is too much. Older BBS02's have 2qty so called "drain holes" where the bolts secure the controller to motor. This reducer is easily accessible: it is located under the plastic cover of the motor: there are 5 screws to remove. When you are ordering parts to repair your BBS02vB make sure that your Bafang parts dealer has some idea of whether the parts they are selling you are for Version A or Version B. Testing The Giant Green Button Does It Really Deserve The Space It Takes Up On The Handlebars? yes, its the same. If it is too tight or too loose you will have problems. Thanks. Hi I ordered another DCP14 display and switch and installed them and the bike will still not turn on. does it switch off if it gets too hot? I did try to clean the pins and also where its connectecd in the battery. For more information on shark contact maintenance and practices for keeping it in good working order please see this page. So you remove the old crankset and mount the BBS02 kit instead, then plug in the cables andthats it! This will oftenly cause a burnout of one or more FETs in the 9 FET array of the BBS02B. You are always going to have some percentage of failiur in a production series, overall i cant se major reason why the b version whod be of less quality. Lithium is today the top level of lifespan and this battery allows me to do 25 miles without problem. No, just buy a new BBS02, its much easier and probably cheaper. You must take care when removing rear tires for service on fatbikes as the speedocomes quite far out into the tire area and can easily break when you try to force the tire past the speedo. thanks for your reply. Melted windings can frya motor, a hub motor is shown not the BBS02 unit, Just because the motor wont work does NOT mean the controller is dead. damnit henrik. If so, clean the entire compartment and re-grease, especially the 2 sides of the big wheel. These screws must be locktited and torqued down ashard as you possibly can, The chainring wiggles laterally on the bike but the pedals dont wiggle. Not easy to remove, but definitely pryable. Concretely, I use it to commute (mainly from the city with some climbs) but also to go hiking in the fields and the forest. Any ideas if this is true? Are there any indications that the new nylon gear is any more temperature resistant? There are lots of other ways to try to fix this problem, but none work as well as either of these two solutions. Without acheap watt meterthis is very difficultto do. Almost every drive unit I have ever taken apart the rubber washer is ripped or shredded. Rotor width on v2, the motor appears to be the same unit. It happens when you are taking your BBS02 off drops, you can try to replace it or you can do what I do and just keep your opposite foot forward on that bike when you ride without pedaling. All times are GMT-8. This could be a battery (no longer think this is a battery issue; see my battery voltage test vid. You can always regrease just to be safe. The M600 can't be programmed by the user and is loud unless you opt for aftermarket nylon reduction gear. However, if you try to pedal the bike with the motor turned off, or if the battery cuts out because the charge gets too low, you can't . All of our 750W BBS02 motors have come with "Upgraded controllers" for the past 5 years! See images, if interested. So yes, it takes a bit of energy to install the Bafang BBS02 B, but you will be surprised yourself by the simplicity of the assembly. I strongly advise you to use a 48V battery with your Bafang BBS02 because it will allow you to get the best performance from your motor. I bought a second hand Bafang BBS02, 750w kit. Go Eric. The BBSHD still needs a dramatic increase in power for it to remain competitive in the marketplace. Thanks for any help you can provide! You can purchase this cable with this order link: Buy this Bafang programming cable @Aliexpress - Global shipping Buy this Bafang programming cable @Amazon - US shipping . It may seem like a detail to you, but I assure you that when you drive in a field or in the city at dawn, its really very pleasant! 10-04-2017, 04:39 AM I have a relatively new BBS02 36v 500w installation that now won't start. You are using an out of date browser. Thanks much! Unfortunately, first version BBS02 controllers are now as rare as hens' teeth. Original model A, model A with updated FET's, and then the BBS02B. just bang away on the outside of the washer till she buckles. check out the. you might be able to get into the inside , but youd destroy the rubber around the spindle (the inner black ring is rubber on the spindle). Version B is shit! so i have no other way to repair the old one. It just out of the blue decided it wanted to be unpredictable. If you are using the throttle on power level 9 regularly then you must readthis articleon care and feeding of your BBS02 if you want it to not die a quick and untimely death. As I told you above, I use my bike equipped with the Bafang BBS02 kit on a daily basis. Instructions for programming your controller arehereand the programming guide ishere. What is the difference between the 750w BBS02 and the 1000w BBSHD motors? Adults and teenagers Use : Road and off-road In this video, Felipe will show what are the most common issues with Bafang BBS 01 02 HD motors, what are the effects on the motor parts and how to prevent them from happening again. Most parts are still acceptable readable: Great work, the cooling fins are something I was planing on doing myself. Just not main battery to controller connectors. 3rd version controllers are not compatible. I've already ordered another controller for it for $90 clams from Dillinger this time. When there is no load on the battery the voltage will quickly recover. "in situ". I removed the grey potting from the controller and eventually found what I think is a burnt out circuit board. Sometimes customers that have ridden ebikes with each of these motors on flat terrain say they cant notice much of a difference between the BBS02 and the BBSHD, so it is really dependent on the specific rider, installation, application, and riding factors.