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    BBS02 Maintenance

    I've put about 3,000 miles on a BBS02 that I bought from Luna in 2018. Should I replace the gasket, grease, and clutch? Any other maintenance items?

    #2
    At 3000 miles, if you've a total rolling weight <300lbs, ride on the street and don't bog the motor, I wouldn't be concerned about the nylon gear clutch or the pedal clutch. If the motor has been kept relatively dry I'd just refresh the secondary gear grease (the final reduction gear behind the chain ring):

    I'd also check for any abrasions in the wire insulation as it exits the motor, around the steering tube, and up near the controls. If you have an older shark-style battery on a tray, I'd clean the contacts, and check for overheating:

    Last edited by ncmired; 06-06-2022, 06:35 AM.
    BBSHD / BBS02 IGH Builds: Nexus / Alfine 8: 1 2 3 4 5 6, Rohloff: 1

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      #3
      I do ride it pretty hard and it has seen plenty of water/snow/slush/salt. My main concern is when I go to open it and refresh the grease, I'll find that the gasket and clutch need to be replaced and I'll be without a bike until the parts arrive.

      There are two clutches? And there is a nylon one?

      Comment


        #4
        In that case ... Especially salt. With salt, all sorts of problem avenues come to mind (all of the connectors, any exposed bearings, frame, etc.)

        There are three gaskets - 2 paper (secondary and motor core) and one rubber one under the controller. So far as I've seen personally and from reading here, the paper gaskets separate from the castings without much fuss, just a little care. I've not seen or read any issues with the rubber gasket.

        IIRC, in 2018 there were still comments made about the secondary gear grease, as in at least checking that Bafang had done at least some, then usually packing more in anyway - too much (per some BBS02 greasing videos). Mobil 28 synthetic or similar is the got-to, BTW - for both the secondary gear and the nylon gear.

        As far as clutches, yes, there are two - a sprag clutch inside of the nylon gear, and a ratchet-type clutch on the pedal spindle. On the BBS02 it's more complicated to get to the spindle clutch:
        Last edited by ncmired; 06-06-2022, 07:58 AM.
        BBSHD / BBS02 IGH Builds: Nexus / Alfine 8: 1 2 3 4 5 6, Rohloff: 1

        Comment


        • BenganM
          BenganM commented
          Editing a comment
          Is the Mobil grease SHC100 considered to be a good replacement for the Mobil 28? Have problems getting hold of the 28. If so, is good both for the primary (nylon) and secondary gear?

        • AZguy
          AZguy commented
          Editing a comment
          BenganM https://www.aircraftspruce.com/catal...ilGrease28.php

        • ncmired
          ncmired commented
          Editing a comment
          I don't know if the Mobilith SHC 100 grease is compatible (not a grease expert and don't recall seeing it mentioned before). My hunch is that it is, after looking at some of the info, but that's just a uneducated hunch. Back to what we know - yes, the Mobil 28 is used on both the reduction gear and the nylon (or PEEK or metal replacement) gear.

        #5
        Welp, looks like a project. I wonder how far I can go with just a grease refresh.

        Thanks for the info!

        Comment


          #6
          Originally posted by abetoney View Post
          Welp, looks like a project. I wonder how far I can go with just a grease refresh.

          Thanks for the info!
          If the metal gears are kept lubed and moisture free (no rusting), indications are they can last well over 10k. Here's what you don't want to see after pulling the cover off:

          Click image for larger version  Name:	fetch?photoid=96116.jpg Views:	0 Size:	642.2 KB ID:	152364

          Click image for larger version  Name:	fetch?photoid=96119.jpg Views:	0 Size:	945.2 KB ID:	152365

          This is a rather tired and possibly never lubed BBSHD after 7.5k - more pictures here.

          IMO, all new motors should be checked for sufficient greasing - it's very easy to do off-bike and pre crank install. For post install occasional relubs, the Lekkie covers have grease ports. It's also likely that an aftermarket grease nipple could be installed on the back of the gear housing.
          Last edited by ncmired; 06-08-2022, 09:09 AM.
          BBSHD / BBS02 IGH Builds: Nexus / Alfine 8: 1 2 3 4 5 6, Rohloff: 1

          Comment


          • AZguy
            AZguy commented
            Editing a comment
            Yuck!

            I've found pulling the secondary cover is very easy and quick to do on the stand - total time to pop cover, inspect and grease about twenty minutes...

            My approach is after doing a complete relube early in my BBSHD's life, as long as things look good (grease should have little discoloration - expect some darkening from metal particles that two spur cut gears will generate), then I won't dig in further... at least for now (~8000mi)...

          • ncmired
            ncmired commented
            Editing a comment
            Yeah, pret-T-bad. I bookmarked the post when I first read it, because of the pictures. This motor may have been one of the ones that came from Bafang with no lube at all.

            One of my three BBSHD motors came with a little dab of grease in one of the cover cavities, and the gears and ratchet clutch were bone dry - less total grease in volume than the amount of toothpaste I use every day!

            A note to others - resist going apey and packing every nook and cranny in the housing tight with grease like on some BrunoPOWEEER YT videos.
            Last edited by ncmired; 06-08-2022, 10:28 AM.

          • AZguy
            AZguy commented
            Editing a comment
            Looks like water ingress

            Mine was greased "good enough" and the quality of the greases used were better than many of the chinese stuff I've seen but going with the "good stuff" and seeing for myself brought serious peace of mind... I was very interested in looking at the manufacturing and engineering quality and was pleasantly surprised on both given it's chinese... I've seen so much worse... then again like most chinese documentation is either horrible or like in this case non-existent and the manufacturing and engineering quality still a rung or two down from the typical japanese or german stuff for example...
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