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CUSTOMER STORIES

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CYC X1 Pro Gen 2 Conversion

​Electrify Bike Co. has converted three mountain bikes to e-bikes for me using Bafang Motors. They have all worked well and we have really enjoyed them.
- Harold Simons
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CYC X1 Pro Gen 2 Ebike Conversion

Electrify Bike Co. has converted 3 mountain bikes to e-bikes using Bafang BBSHD motors for me. They have all worked well and we have really enjoyed them. I have ridden the first bike they converted for 4000 miles mostly on paved trails.
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This summer I decided it was time for me to build a new bike. My goal was to build the ultimate paved trail cruiser; full-suspension mountain bike, high power motor, biggest battery possible, a large front sprocket, and upgraded brakes with motor cutoff sensors. I selected a Scott Spark cross country full-suspension Mountain Bike because it has space in the 
frame triangle for a large battery and the chain stays are tight to the frame allowing me to use a large front chainring. Upon consulting with Mark at Electrify Bike, I decided to use a CYC X1 Pro Gen2 2600 watt mid-drive motor.  It has three modes of operation and is fully programmable. Electrify Bike Company is the only CYC Motors dealer in the Intermountain west and were very helpful with my project. I bought all my parts from them.
Here is a list of my challenges:
  • Mount a 52 volt, 21 amp-hour battery.
  • Build front supporting motor mount.
  • Make chain tensioner work.
  • Modify the front chainring spacers to clear the frame.
  • Route all cables in the frame.
  • Add lights.
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Results:
    I have put 600 miles on this bike now and here is my conclusion. It is now my bike of choice to ride on paved trails. The torque sensor Is smooth and proportional. The throttle is smooth and much more proportional than the BBSHD. This motor is faster and more powerful than the BBSHD, but It also makes more noise. This bike is great on the paved trail but it is awesome on dirt roads and in the mountains. The torque sensor delivers a lot of controlled power making this bike fun and easy to ride in the dirt.
 
Thanks, Mark and crew for all your help!

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There are some good factory e-bikes out there now but going the conversion route allowed me to get a better quality overall build.
- Clint Warner
Read more ...                                                                  

Specialized fuse BBSHD Conversion 
Build write up and review
by: Clint Warner

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Specialized Fuse Comp Donor Bike (2015) model -
Bafang BBSHD 1500W (30A Programming) installed by Electrify Bikes www.electrifybikes.com
BBSHD – 68mm
Lekkie 40T Bling Ring
Eggrider v2 Display
Bafang Half Twist Throttle (Right Hand Side)
Bafang Hydraulic and Disc Brake Sensors E-Brake (Pair)
Mid Drive Gear Sensor
52V Panasonic 14ah GA Shark Pack and charger
FSA BB30 Press fit Adapter
KMC X11 Chain
Custom Triangle Frame Bag – www.rockgeist.com
Light and Motion SECA 1800 12v E-Bike Headlight
Shimano XT 11 speed shifters and derailleur
Sunrace 11-46T CSMS8 EAZ Cassette (Modified to 9 speed 15-46T)
Schwalbe Nobby Nic 27.5+ (650B) x 3.0” tires – Tubeless Setup
When I first contacted Mark at www.electrifybike.com, I was impressed with not only his wealth of knowledge but mostly of his “we can do it” attitude. 
I did a lot of research beforehand on e-bikes and contemplated whether to go with a factory e-bike or a conversion and after much study, decided a conversion was the best choice for me.  There are some good factory e-bikes out there now but going the conversion route allowed me to get a better quality overall build (considering frame geometry and componentry for less money, than a factory e-bike would have cost.) 

For the donor bike I chose a used 2015 Specialized Fuse Comp Hardtail (Large Frame).  I particularly like the Fuse for several reasons:
  1. ​The Fuse comp has a large OD frame tubing and a unique split chain stay design that adds structural rigidity to help compensate for the extra torque that the motor will put on the drive train.  I also wanted to minimize any frame flex caused by the motor, which I have felt in other donor bikes.  It turns out that the Fuse frame was a perfect choice with no noticeable flex after conversion.  Also, the triangle and bottom bracket of the fuse are big enough to handle most any type of battery and accommodates the Bafang 68mm motor with a common PF30 adapter, making it a very e-bike conversion friendly donor frame.
  2. The Fuse comp comes from the factory with better than average hydraulic brakes and is compatible with 203/180 rotors which I added as part of the build.  This is particularly important for the increased stopping power needed with an e-bike.
  3. The Fuse has a fairly “slack” head tube angle of 67 degrees.  This is important for maintaining stability when riding in the mountains of the west where steep downhills are common.  The slack head tube angle causes the bike to steer more slowly, allowing the rider to feel more secure when navigating steep ugly terrain.  I can’t emphasize enough how important this one aspect is to make the perfect big mountain e-bike.  Most of the commonly used bikes for donor e-bike builds and even most factory e-bikes use more traditional frame geometry with head tube angles approaching 70 degrees or more.  This is fine for flatter terrain or trails where a quick turning bike is desired but really suffers in the steeps.
  4. The Fuse uses is a 27.5 Plus (650B) size tire.  This tire gives you the footprint and rolling ability of a 29er but gives you much of the stability of a 4” fat bike tire.  This gives you a bike that handles well and fairly quick but can still do well in less-than-ideal off-road and in good singletrack conditions.​
The fit and finish of Electrify Bike Co.’s work was impeccable and their service and professionalism was exceptional.  I would highly recommend them to anyone not wanting to tackle doing the conversion themselves.
Now to the build.  When I first contacted Mark at www.electrifybike.com, I was impressed with not only his wealth of knowledge but mostly of his “we can do it” attitude.  He had never converted a bike like mine but was willing to do it at a very fair price.  I instructed him that I wanted to build the best big mountain bike possible and not spare any expense.  I also wanted an e-bike build that could produce as much torque as possible for towing a trailer for bike packing use with the added benefit of allowing me to keep as much of the human power capability of the drivetrain in the event that the battery failed me on a long mountain ride.  The fit and finish of Electrify Bike Co.’s work was impeccable and their service and professionalism was exceptional.  I would highly recommend them to anyone not wanting to tackle doing the conversion themselves.

Motor/Battery/and Display: Bafang BBSHD 1000w motor, 52V 14AH Shark Battery, and Eggrider v2 display (see photo below).  This motor can be programmed to handle up to 30A of power (1500 watts) without any trouble and even though it comes at a several pound weight penalty over the BBS02, it is the most durable choice for a bike for pulling or any sustained hill climbing.  With now over 400 miles of hard use on the motor, I have had zero trouble and have no regrets on this decision.  I am currently using the the Eggrider v2 display.  This display is much smaller than the other displays on the market and one of the biggest benefits is that it’s Bluetooth enabled, allowing the user to easily change any of the motor programming wirelessly with a simple and free phone app.  This has been a great tool as I have made many small fine-tuning programming changes while on the middle of rides.  With my current ​programming settings (see screenshots below), I can attain 32 MPH on road, and still climb any possible hill I can find off road using the throttle only 80% of the time. 
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​Chainring: Most e-bike builds use the 42 tooth or larger Lekkie-type chain rings in order to provide enough back spacing to proper chain line for the full range of the rear cassette.  The problem with that is a 42 tooth chainring is too large to use under human power for hill climbing in the event of a power failure.  I first went with a Precialps 32 tooth chainring to provide maximum torque, which works great for pulling and for maximum torque, and while the chain line was acceptable, I felt it was a bit too much torque and left a bit to be desired.  I am currently using the new Lekki 40 tooth chainring.  That is the smallest chainring available that can fit over the Bafang secondary reduction gear, providing for an even better chain line and in my opinion the most versatile gear ratio range with the my modified 11-46T cassette.
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Cassette: Strength is more important than weight for an e-bike build, so I swapped out the factory aluminum cassette for the stronger and more versatile “All steel” Sunrace CSMS8 EAZ 11 speed 11-46T cassette.  It is important that for an e-bike build for climbing or pulling that you choose a cassette with steel, and not aluminum, sprockets.  Beware of the aftermarket cassettes that use steel for the main sprockets but use aluminum for the granny gear, there is enough power in the BBSHD and a small 32T chainring to destroy aluminum sprockets.  This is the gear that takes the most load, makes sure it is robust enough for e-bike use.  This Sunrace cassette has handled anything I have thrown at it with ease and 400 miles in, showing no sign of any concerning premature wear.  I took the extra step of modifying the cassette by removing the two smallest 11 and 13 tooth sprockets and replacing them with spacers.  I put these spacers on the inboard side of the cassette, thereby shifting the entire sprocket set outboard, further improving the chain line.  This is an easy modification that requires no drilling or cutting and one I highly recommend to improve your ebike’s chain line.  With this cassette modification and the new Lekkie 40T chainring, I have changed my 11 speed to a 9 speed, but with a perfect chain line and can go from my new high of 15T to the 46T granny gear with no issues whatsoever.
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Chain: Similar to the cassette, e-bike chains get a lot of wear and tear put on them by the increased forces put through the drivetrain.  Not wanting any trouble in the field, I switched to an all-steel KMC e-bike rated chain from day 1 and it is still going strong.
 
Shifter/Derailleur: Removing the factory 10 speed cassette in lieu of the new 11 speed drivetrain required me to upgrade my shifter and derailleur as well.  I chose the higher quality and more durable 11 speed Shimano XT Dynasys shifter and derailieur.  Adjusting the high and low limits to accommodate my modified cassette, I feel that this drivetrain provides a more solid shifting platform for quicker solid shifts all the time and an overall more reliable drivetrain.
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​Tires: Like with everything else, normal MTB tires were not designed to handle the torque that an e-bike motor delivers.  I decided to replace my factory tires with the new Schwalbe Nobby Nic tires that are one of the few aggressive MTB tires rated for e-bike use.  I highly recommend these tires…I have never had a flat in the field (I do run a tubeless setup), but these tires handle the torque well, even at lower pressures.
 
Other Mods:
 
Suspension Seatpost: While hardtails provide better structural rigidity for e-bike conversions, they can be hard on “the tail”.  To take a bit of the edge off, I added the Sunrace NCX suspension seat post.  This is a great seat post that functions, in my opinion, as good as a “high-end” thud buster type post at a better price.    
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​Custom Rockgeist Frame bag www.rockgeist.com: I don’t like to draw any unwanted attention to myself and I wanted to be able to conceal the battery within the triangle.  I chose to use a custom-made frame bag from Rockgeist to do this.  They have a very easy to use online design tool whereby I could choose the fabrics and colors I wanted as well as specify any special instructions.  The entire bag can be designed using a simple online utility whereby the customer uploads a simple photo of the bike following their instructions.  I added some custom dividers so that the final bag keeps my battery separate from the main compartment and also provided channels for running the wires out of sight.  The end result is a very clean, tailored look.  The frame pack fit perfectly and exceeds my expectations.
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​Light and Motion 1800 SECA 12-volt off-road headlight:  The 6v factory wiring for headlights on the Bafang motors is far from adequate for off-road-use.  I needed something much brighter.  The Light and Motion 1800 SECA off-road light was designed for e-bike use, but must be hard wired into the battery in order to work.  Since my battery is a 52v, you must also use a DC to DC converter to make the headlight function properly.  I first used an inexpensive eBay type Chinese converter, but it didn’t last one month.  I now use a Grin-Tec adjustable converter, which is much better designed, properly epoxy potted and the only one I would recommend for this modification.   
I feel that the end result is practically as perfect of a build as one could design.  Frankly, there is nothing that the current build leaves to desire and I plan to ride this bike for years to come.  I hope this writeup is useful for anyone considering a similar setup.  

CUSTOMER GALLERY

BBS02 with 42v mini-cube
REI Coop MTB with BBS02 and 52v mini-cube battery. Very cute!
KHS SixFifty 3500 with BBSHD and 52v Super Shark. Also KHS SixFifty 600+ with BBSHD and 52v SuperShark battery
Madsen Cargo "Bucket" ebike, BBSHD 1000W, Jumbo Shark 920WH. All set for long beach rides!
Specialized Fuse - BBSHD - 52v Shark - Eggrider
KHS Sixfty 6500+, BBSHD, 52v Super Shark
Radiant Fat Mini Step-Thru - 750W
Building a KHS 1000 Fat Bike - BBSHD - Jumbo Shark
KHS 600+ w/BBS02 Mid-drive Motor, 52v 14ah Super Shark
Cattrike, TSDZ2 OSF, 52v 14AH Super Shark
KHS Sport Tandem - BBS02 - Jumbo Shark
Xtracycle Edgerunner, BBS02 Mid-drive, Jumbo Shark
Fleet of Radiant Fat Mini-Step-Through 750w bikes.
Fleet of Radiant Fat-Mini Step-Thru bikes headed for Daybreak, Utah
Marin East Peak FS XC MTB w/Bafang BBS02 mid-drive, 30Q mini-cube in saddle bag.
KHS 1000 Fat Bike, BBSHD, 52v 17.5ah Jumbo Shark
Surly Krampus 29er 3.0 Bafang BBS02 Mid-drive & 52v Jumbo Shark Battery
Surly Krampus 29er 3.0 Bafang BBS02 Mid-drive & 52v Jumbo Shark Battery
Giant Stance - BBSHD 52V 14AH Super Shark
Edgerunner BBSHD SuperShark
The whole family on an Xtracycle Edgerunner with BBSHD, SuperShark battery, infant seat.
TSDZ2 Coaster Brake motor with Mini-Cube Battery
She rides this Electrified Chopper at the Burning Man Festival. TSDZ2 Coaster Brake motor with Mini-Cube Battery
Trek Farley EX with BBSHD and Jumbo Shark Battery
Trek Farley EX with 1000 Watt Bafang BBSHD and 17.5AH Jumbo Shark Battery
Giant Liv Women's road bike, BBS02, 52v 14ah SuperShark
KHS Smoothie, BBS02 with mini-cube battery in saddlebag.
KHS Smoothie Comfort Cruiser with BBS02 and 3lb saddle bag battery.
Cannondale Tandem with BBSHD and Jumbo Shark battery
Cannondale Tandem with BBSHD, Zurich brakes, Box 2 E-bike drive-train, Jumbo Shark battery.
Handcycle with TSDZ2 OSF
Reactive Adaptations Bomber RS Handcycle with TSDZ2 OSF, 30T chainring, 52v mini-cube battery.
Fat Tad recumbent tadpole style fat tire trike. With a BBSHD this thing screams.
Invacare Top End XLT Handcycle with TSDZ2 mid-drive motor.
Invacare Top End XLT Handcycle with TSDZ2 mid-drive motor, Jumbo Shark Battery, X-shifter.
Giant Trance full Suspension with BBSHD and 52v Shark battery.
Specialized MTB with BBS02 and Super Shark battery.
Rans Stratus XP recumbent with Rolhoff 14spd IGH, BBSHD & 3400wh dual batteries in the side bags. :)
KHS SixFifty 6500+ with BBSHD Mid-drive & 52v Shark Battery
Giant Trance full Suspension with BBSHD and 52v Shark battery.
Sunseeker Eco-Tad SX with BBS02 and 52v Super-Shark Battery.
MainStreet Pedicab with BBSHD
Folding Electric Bike with Bafang Mid-drive Motor & Saddle Bag 3lb Battery
KHS Smoothie Comfort Cruiser with Torque Sensing Tongsheng TSDZ2 mid-drive motor with 3-speed & coaster brake.
KHS Smoothie Comfort Cruiser with BBS02 and 3lb saddle bag battery.
I count five huge wins on this awesome Priority Continuum Onyx bike: 1. TSDZ2 mid-drive motor, 2. Flexible Open Source Firmware. 3. Gates carbon drive. 4. N380 continuous transmission, 5. Super Shark battery.
Motobecane Gravity Fat Tire Bike with BBSHD & 52v Shark Battery
Specialized Camber Comp BBSHD
Specialized Camber Comp, FSR, 1000 Watt BBSHD Mid-drive motor, 52v SuperShark Battery
Electra Townie with ultra-light 750 watt hub motor. Easy on the throttle - you will burn rubber.
KHS SixFifty 6500+ with BBSHD Mid-drive & 52v Shark Battery
Motobecane Gravity Fat Tire Bike with BBSHD & 52v Shark Battery
Specialized Hard Rock with Cycle Analyst and 1000w Mac Motor.
Electra Townie with ultra-light 750 watt hub motor. Easy on the throttle - you will burn rubber.
Customized Giant XTC. 750/1200 watt rear hub motor with lots of torque for the hills and can still hit 25mph. Range in excess of 50 miles. Add Cycle Analyst and a torque sensor to achieve lift off. All for less than 39 lbs. Sweet!
KHS 500 Fat Tire Bike with BBS02 & 52v Shark battery.
Customized Giant XTC. 750/1200 watt rear hub motor with lots of torque for the hills and can still hit 25mph. Range in excess of 50 miles. Add Cycle Analyst and a torque sensor to achieve lift off. All for less than 39 lbs. Sweet!
Folding Electric Bike with Bafang Mid-drive Motor & Saddle Bag 3lb Battery
Invacare XLT handcycle with TSDZ2 mid-drive motor
KHS SixFifty 6500+ with BBSHD Mid-drive & 52v Shark Battery
Soma Pickup Artist Cargo Bike with BBSHD & 52v 17.5ah Shark+ battery
KHS Smoothie Comfort Bike with TSDZ2 and mini-cube battery in basket.
Soma Pickup Artist Cargo Bike with BBSHD & 52v 17.5ah Shark+ battery
Cannondale Prophet Lefty with BBSHD & upside down Shark battery.

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  • Shop
    • Mid-Drive Motor Kits >
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