Matt made a good video explaining the use of the Stabilizer bar.
A new tool to help extract those hard to get to 8mm bearings which support the ends of the motor rotor on the BBS01/02 and BBSHD. This tool will be on the website shortly. For anyone who has tried to replace these bearings will know they are next to impossible without the proper tool since they are both in a blind hole recess. Watch for this tool in the “Tools” section of the website.
From time to time we have customers telling us that they are getting an 08H error code on their display and motor won’t run. We have tested many motors and never found a faulty hall sensor. If this happens to you, try unplugging the Pedal Sensor (PAS). The black connector inside the controller housing. We are finding that when you do this the 08H problems goes away. If that is the case for you, just replace the PAS circuit. We suspect that some of these circuits are pulling down the 5v power circuit in the controller triggering the hall sensor error 08H.
Tech Talk with Tom-Error Codes
For more ideas and solutions take a moment and Google your issue. Proper nomenclature helps! There are many great posts and best of all YouTube videos covering most issues with how to repair and diagnose. I don’t list them here since they are the property of others, but are easy to find. Google is your best friend. Chances are better than not you aren’t the first to have a problem and the solution has already been discussed. All in a days work for the DIY hobbies, and probably the best way forward to learn and consider all the options. You may fins many ideas of interest.
Error 04 Throttle no homing; Unplug the throttle, if the error goes away, replace! Done!
Error 05 Throttle abnormality; Maybe the throttle is damaged/not working, Could be or working intermittently, Check throttle case for damage, check wiring for a loose/bad connection to the battery. A pinched or damaged wire could be the culprit too.
Error 06 Low voltage protection,;If your pack is at 41V (48V pack) or at 44V (52V pack),Check programming to be certain Low Voltage Cutout is properly set.
Error 07 Over voltage protection; Make sure you are using a 48V or 52V battery. This motor does not function on a 36V pack.
Error 08 Hall sensor; Sometimes error 8 shows with a grinding noise. Look over the motor plug to make see it is connected properly, unplug and replug. It could happen if the motor has been unplugged. Make sure that the plug pins are not bent.
Open the controller and unplug the white connector going to the motor, check if all the pins are there and straight, then plug it back fully and seal it back with silicone. Look for videos on YouTube there are many helpful from various resellers.
Error 09 Phase line abnormality; Broken wire or circuit, Check wiring loom for breakages.
Error 10 Controller overheat; The temperature sensor in the controller is likely triggered, let is cool a bit. Occasionally it shows up and I have no explanation.
Error 11 Temperature sensor in controller abnormality; Same as Error 10, Mystery usually self corrects.
Error 12 Current sensor abnormality; Possible bad controller.
Error 21 – Speed sensor error. Your speed sensor may be broke A good part to keep in you spares kit, likely replace. You could have a loose connection, not threaded in all the way. OR often the magnet isn’t close enough. Red light comes on when the magnet is closest and passing the sensor only.
Error 15H – Speed sensor error for the 750c display; See Error 21.
Error 30 – communications/controller error: Usually a harness or more often a display problem. Check for bent pins and crushed wiring harness.
Unplug all devices check all pins and plug them all back in, being certain they are fully
Inserted. Google YouTube “BBSHD bypassing the LCD”
All The best,
Sales, support and BBSxx user. email@example.com
Many customers assume that California Ebike may be like many other dealers in the Ebike world. Once you buy your kit and battery that the helpful smile on the dealers face fades away and you own it. Here is a quote from one of our many happy customers that found out we mean what we say when it comes to our warranty.
Hi Doug, thanks so much for sending the bbshd speed sensor to me. That was just what I needed. I suppose I should stay off the internet. As usual I filled my mind with the worst of possibilities when there are orderly steps to follow before freaking out. I guess a person can jump to conclusions when a loved one is ill. My trusty steed is back to prime functionality due to your timely kindness. Thanks again. Jim Oxford.
Most ebike conversions do not require any additional components to make a successfully installation. However, a number of customers need to convert recumbent bikes, recumbent trikes, tandems and hand cycle trikes as well as the special built bikes. For most of these people one or a variety of extension cables make even the most difficult conversions easy. See the diagram below to see what extension cables you may need.
Here are the links to make it easy to find the extension(s) you may need.
(Y) Cable Splitter
More and more customers have been asking about the feasibility of using a Bafang mid drive on their belt drive bike lately. So I have been doing a lot of research on this topic and will present my findings in the post. First let me point out that I am not a bike expert and since there are so many brands and models of bikes out there, you will need to do some research on your own to insure the best possible outcome to converting your bike. With that said let’s get into it.
The chart below is based on the Gates Carbon Drive belt system
Since Gates seems to be the only viable game in town, they are naturally the system we will be talking about. Also, in order to use the Gates drive pulleys, you will need chain ring adapters to be the interface from the Bafang to the Gates bolt on pulleys. I have chosen the California Ebike BA104, BA130 (used on BBS01/02/03) and the HD130 (used on the BBSHD 68mm and 100mm bottom brackets) adapters to calculate offset compatibility. There are other factors that you will need to consider and I will go into that further down in this post.
Why not just build “Special” offset pulleys?
We wanted to build special offset pulleys to help accommodate more brands but Gates Rubber has patented their pulley geometry and will not allow 3rd parties to produce pulleys. They also will not make specials according to their engineering department. So, in our opinion, Rohloff is probably the only consideration for a successful belt drive system. We had hoped to find a solution for the Nuvinci but at 12.2mm and 14.2mm offset misalignment, we felt there is no way at this time to make them work.
What else is there to consider?
I will list here some of the more obvious things to look at.
Many customers wanted to use the beautifully engineered Tout Terrain belt drive bike. The Bafang can’t be fitted to this type of bottom bracket.
See the above. Gates ask you to check if your sprocket will clear the chainstay once mounted? Before you make that determination see how your Bafang mid drive will fit up.
The above is a ruff sketch of the BBS01/02/03 mid drive assembly areas for consideration. Will the final gear housing (113mm diameter) stay clear of the chainstay when mounted up against the 68mm bottom bracket?
Or on the BBSHD. Answer the same question but now the housing is 132mm diameter.
We will add more content to this subject as it becomes available but we felt that our customers should know what to look for when considering a belt drive system. Belt drives are fantastic when mounted with proper alignment but marrying a Bafang mid drive to the belt drive bike is a challenge unless you do your homework.
I would love to hear from those of you who are able to make successful installations. Tell us the make and model bike that you use and send some photos.
Lithium batteries are energy dense storage units that are very suitable and cost effective for use with electric assist bicycles. However one should have at least a rudimentary knowledge of how they operate and how they should be cared for.
As you can see from the chart below, Lithium batteries, unlike many other batteries, have a specific safe and efficient realm they operate in. In this realm, the voltage stays very consistent and the battery stays chemically stable.
The nice thing is that you have very little to be concerned about because the type of lithium batteries sold by California Ebike have a built in battery protection circuit.
Battery Protection Characteristics of Lithium batteries
PCM or PCB (protection circuit module or board), sometimes called a BMS (Battery Management System) is the “heart” of a Li-Ion battery pack. It will protect a Li-Ion battery pack from overcharging, over-discharging and over-drain, therefore it is a must have to avoid Li-Ion battery pack from exploding, firing and damage.
Li-ion should never be discharged too low, and there are several safeguards to prevent this from happening. The equipment cuts off when the battery discharges to about 3.0V/cell, stopping the current flow. If the discharge continues to about 2.70V/cell or lower, the battery’s protection circuit puts the battery into a sleep mode. This rend
ers the pack unserviceable and a recharge with most chargers is not possible. To prevent a battery from falling asleep, apply a partial charge before a long storage period. Therefore remember to charge your battery every 1 or 2 months. Never charge your lithium battery when the temperature is below 0°F.
Lithium-ion operates safely within the designated operating voltages; however, the battery becomes unstable if inadvertently charged to a higher than specified voltage. This causes the battery to become unstable and dangerous not to mention ruining the battery.
Lithium Battery Charger
The Lithium battery charger is a voltage-limiting device that is similar to the lead acid system. The difference lies in a higher voltage per cell, tighter voltage tolerance and the absence of trickle or float charge at full charge. While lead acid offers some flexibility in terms of voltage cut‑off, manufacturers of Li‑ion cells are very strict on the correct setting because Li-ion cannot accept overcharge.
Therefore, always use a charger that is specific to your battery and do not interchange them.
Typical battery chemistry types:
Li-ion 3.7v/cell max
LiFePO4 3.2v/cell max
Credits: Battery University
How hard is it to install a Bafang Mid-Drive Ebike Conversion Kit?
The Bafang 8FUN mid-drive electric bike conversion kit has been wildly popular in the last few months. And for good reason! The self-contained unit has great power, low-maintenance, and a straight-forward installation. But you’re probably wondering what it takes to install the kit.
Let us show you how…
Many things in life are “straight forward”, but it seems like there’s always some little hang-up that creates enormous problems. We completely understand and that’s why we created this installation video to show you the exact installation steps.
So what do you think?
With a few of the right tools the installation goes smoothly, but we understand there may be something unique about your particular bike that you’re concerned about. We would definitely like to hear your concerns, so please put your question in the comments below. Or feel free to contact us directly and we’ll work with you to make sure you have the best electric bicycle conversion kit for you.