Some wires have overheated

After riding the bike for 15-20 minutes (at full power most of the time), I've noticed some heat under my ass. I've stopped and seen that some wires were very hot, and that the fuse cover was melting. The fuse cover was close to the battery pack, so the tape around the battery pack has been sligthly damaged, too...



Still analyzing the root cause, but it seems that the wires (that actually came with this 20Ah battery) are too small and we should install bigger ones (more section). But the battery should come with proper wires, shouldn't it?

Pedelec sensor not recommended

After some trials with the Pedelec sensor, I do not recommend it (at least the one I tried).

I found two main drawbacks:

- First of all, it's not a progressive system. I thought that the faster you pedaled the more power the motor would supply. But, it's not like this. If you move the pedals (no matter how slow), you have full power from the beginning (there is a 1 second delay). If you stop pedalling, the motor stops completely (with a 2 second delay). This is not a good thing when it comes to comfort and battery life.

- It takes about 2 seconds for the motor to stop once you have stopped pedaling. This is really dangerous with a 1KW motor. It has some delay (about 1 second) when starting pedaling, too, but this is not really a problem (you get use to it easily).

To sum up, I was really disappointed with the Pedelec system. It needs lots of improvements (we may develop our own Pedelec system in the future).

Installing the Pedelec sensor

Thumb throttle works perfectly.



Now, we want to try the Electrical assisted pedaling using the Pedelec sensor.

It consists of a disk with 5 magnets and a sensor to detect the movement.












I was not able to remove the pedal until I used an extractor.















The sensor (with the plastic side looking outwards) is fixed with the shaft nut (which needs to be removed first).









Then the disk with the magnets is inserted in the axle. But, surprisingly, the sensor detects the direction of the movement, so the disk has to be inserted as in the picture below. Be careful with this, otherwise, the motor will start only if you pedal backwards (which is funny, by the way).

Finally a picture of the sensor and disk properly installed.

Some pictures

Motor in rear wheel with only one gear.


Regenerative controller (the one with a label) versus regular controller.


Battery pack (48V 20Ah) with Battery Monitoring System (blue). Size is 31 x 14 x 18 (cm). Around 10 Kg.


Battery pack, regenerative controller and battery charger.


Charging the battery pack for the first time.