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Bbshd failures and troubleshooting

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    Gasket maker is fine. There are also gasket kits you can find on eBay that you simply cut out whatever shape you want the gasket to be. If done properly either should work.


      Hello guys.
      My brother came from the bike trip and when I want to start my bike again, I can't.
      i ja s realised, that the circuit breaker installed between batteries and engine is keeping disconnected.
      1. Batteries are ok, tested with voltmeter.
      2. 2.Testing the controllerthrough power connector showed, that the + and - are shorted. I have dismantled the controller, tested it again, definitely, shorted. For me it means controller is dead.

      Now the question:
      Is it possible that the rotor/stator parts are broken too?
      How can I test the rotor + stator? 3 strong power wires on stator/rotor are shortened too. Is it ok?

      I am afraid when the rotor is fried and I will replace only controller, I will fry the new controller again.



        You might inspect the wiring harness for pinches or chafing. I had a kickstand pinch the harness and take mine down. Easy fix.


          To test the windings, you can compare resistance across all the motor phase wires. All should match.
          Fabrication is fun! Build something today. Show someone. Let them help. Inspire and share. Spread the desire.


            So my BBSHD rotor snapped on me this past week. No warning, no sounds, etc. Just sitting stopped at a light, throttled 30-50% as there was a car right in front of me, then once I got to aprox 25mph it just lost all power and made horrible grinding sounds. I shut down all power and pedaled it home. After opening it up to diagnose the problem, I find the rotor spiral shaft snapped off directly where it meets the rotor cylinder.(see pic). I was directed to california ebikes for the replacment rotor by a fellow forum user here as I could not find the part from LUNA. Also wanted to include the nylon gear is like new and no issues. My questions are these:
            1) Is the rotor from caliebikes the correct part for the BBSHD with hotrod programming?
            2)Does Luna sell the proper part just not listed on site? I rather stay using all LUNA parts
            3)If LUNA does NOT sell the part for self repair, do they offer in house repair of this part? If so cost?
            4)any recommendations on replacing this part(regreasing etc)
            Thanks guys


              Defjr333 I sent you a PM two days ago, I don't know if you got it, but I was asking how old the motor was? This is basically a defect and if the motor was purchased relatively recently we would just send you a replacement core, ideally asking that you send the original over to us for parting it out once we got you all sorted out. If you can get back to me or email support, we can help you out with this..

              Anyway in answer to your question, yes that is likely the same rotor at cali ebike.
              Yes we sell the rotor as part of the core
              The rotor is not repairable if it snaps like that, and either the rotor or entire core needs replaced. Replacement involves just bolting the new core onto the original casing.
              Mobil28 is a good grease for adding when changing this out. I hear you should not mix it with the grease already on there but I have never had a problem over years, YMMV.


                It looks like they broached the keyway all the way out to the gear and cracked the part.


                  Thanks Paxtana. I just replied with a PM containing info u requested. Thank you for the help.



                    Good Day - the name is Brian. I have a BBSO2 750 B - its fitted to a regular hybrid type road.mtb. . It works really well and has transformed life for to some extent as I am partly paralysed from the waist down - but I can ride in a somewhat dodgy fashion which I really enjoy as I can only walk with the help of 2 crutches and even then very slowly and painfully . Our area is very hilly , even so I find that it has a max range of about 52km

                    However I have a problem --

                    2 weeks back I was riding in pouring rain and after some time the motor cut out . That is the PAS did not work , also the throttle was dead - everything else seemed normal. I had a local e bike shop look at it and they decided the controller was the problem . I have ordered one from Lunacycle and it will arrive hopefully if the SA post office does not lose it .

                    After a few days sitting in the sun the bike came back to life ! I used it this morning - everything seemed normal - after about 8km or so it cut out again. After 5 minutes it worked again - this happened a few times .

                    I think the thumb throttle and the lcd screen are ok . Could it be the controller . Has anyone else had something like this happen ?

                    Any advice and opinions would be most welcome.

                    See less | Go to post


                    Click image for larger version

Name:	inner ring gear.jpg
Views:	1170
Size:	214.4 KB
ID:	86100 Just wanted to share a problem that I encountered, its symptoms and solution. I have a BBSHD installed on my Gazelle cargo bike. The bike weighs about 80 lbs total, I'm 165, I often have groceries at about 20 lbs, a 9 year old passenger at 80 lbs, and we live in a very hilly area.

                    I never installed the throttle, preferring the purity of a pedelec. In my situation, with the heavy loads and hills that I consistently encounter, the choice NOT to install the throttle was a mistake. Starting off on a hill requires a tremendous amount of force on the pedals to get the beast moving. After a complete crank rotation or so the pedal assist kicks in and we are off to the races. One day I was torquing the pedals hard to start on a hill and felt the pedals and crank snap! hard and then immediately catch once more. This alarming jarring scared the beans out of me but nothing seemed amiss afterwards. The end result was I often now experience under significant torque a SNAP! and the pedals sharply advance and catch once more.

                    Thinking that I hurt the clutch I ordered a new one for $24ish, only to discover that it was actually the inner ring gear that the clutch engages! This inner gear has several teeth chipped in exactly the shape of the clutch "arms." I wasn't expecting that one. Unfortunately, the $38ish ring gear is on backorder so I will have to patiently wait. While investigating this problem inside the motor, I decided to make a jackass of myself by breaking the PAS magnet which has now disabled my pedal assist.

                    Faced with no other choice I have installed my throttle while I wait for parts. This allows me to pedal and permits operation of the motor in an albeit hot rod manner. The important lesson I have since learned is that the throttle works wonderfully to start a heavy loaded bike moving from a stop up a hill. If I would have used that to start my bike moving, instead of relying upon heavily over-torquing my pedals, I would still be riding on my original parts today. Lesson learned.

                    Now one could argue that the ring gear or the clutch should be strengthened to accommodate these forces. Sadly, I don't work for Bafang and these solutions are for future iterations of our beloved kits.

                    Last edited by Mergner; 04-30-2019, 09:50 AM.


                    • joebreeze
                      joebreeze commented
                      Editing a comment
                      I completely know what you are talking about mate , except I didn't have all that weight and my motor teeth broke also ?

                      I weigh 190 lbs , and the bike is a normal FS MTB 10 SPEED. I had the thing out 1 day and as im a 'stand up off the seat' kind of rider I broke teeth off the clutch engaging gear.

                      At first the forward slip feeling reminded me of a chain slip , so I adjusted the chain tension / derailleur alignment and went off , torquing the pedals hard to check the chain and WHAM CRACK SLIP . Later I realized what had happened , that I had broken the motor in 1 day.


                      to quote Eric 2016 "The BBSHD is built like a tank" , a WW2 tank maybe.
                      Last edited by joebreeze; 06-17-2019, 08:38 PM.

                    • Yubarider530
                      Yubarider530 commented
                      Editing a comment
                      You just described my problem and riding style exactly. Heavy rider, heavy, loaded bike and trying to start from dead stops with PAS. Looks like I'm ordering a new gear ring. I wish I had read this a few months ago.

                    I wouldn't hold my breath waiting for Bafang to solve a problem that only applies to 1% of riders. Cost and weight could go up, and Bafang is pushing the envelope in both areas for most users. You didn't say what driveline you have but a lower 1st gear would seem to be the answer. Sturmey Archer makes a 3 speed IGH that's strong and accepts casettes. This can make up for the lack of a front derailer.
                    For more than 100 years, Sturmey-Archer has been a pioneer in the design of internal gear hubs, hub brakes and dynamo lighting. Sturmey-Archer makes cycling easier and safer.


                    • joebreeze
                      joebreeze commented
                      Editing a comment
                      Call me old fashioned , but I like to use the pedals . Way more than 1% of riders want to ride normally by not using the lazy throttle (i'm not delivering food) and not granny gearing it at every traffic light or incline.
                      Last edited by joebreeze; 06-30-2019, 08:46 PM. Reason: I thought of something else to add , duh.

                    I use assist level 0 for much of my riding, and level 1 mostly. Level 2 for hills and headwinds. The throttle is for keeping up with cars at traffic lights, or when my 65 year old self needs to maintain 30MPH to keep from getting run over. My granny gears are only used when sharing a sidewalk with pedestrians and assist level 0. I wonder what percentage of riders find standing on the cranks in high gear useful? The aerodynamics are lousy and spinning makes more power. On a 40 mile ride I might use the throttle 4 times.
                    The motor allows me to ride at speeds and distances that I couldn't do otherwise in any sort of comfort. I don't see how that makes me lazy.
                    But if standing on the cranks and breaking parts makes you feel like Superman that's up to you.
                    Last edited by Retrorockit; 07-01-2019, 08:22 AM.


                    • joebreeze
                      joebreeze commented
                      Editing a comment
                      You are allowed throttle , you are 65.Throttles are illegal in NY , NJ

                    I was very rough on my bbshd with my 1st bike, and my new build weighs around 90lbs plus my 190-200lbs. The only issue I have had was a snapped rotor gear that was determined to be defective and replaced under warranty. I do use throttle most the time to get going and will switch over to pedals once I'm around 5-10mph. Seems to work wonderfully with S/A 3 spd IGH.


                      Hi, the DPC-18 display on my BBS03 motor is showing a red exclamation mark in a circle at the top right corner of the display and the motor is not delivering any assistance. Any idea what could be wrong. The motor performed perfectly with a 965 display on another bike and even worked on this bike with the DPC-18 display once, but now isn´t responding. I´d be grateful for any suggestions.

                      Thank you for your help.


                      • paxtana
                        paxtana commented
                        Editing a comment
                        (!) means either the ebrakes are engaged or the ebrake wires are shorting against themselves, or the gearsensor wire is engaged and/or shorting against itself.

                        " (!) This is comes up when the ebrakes are engaged. It may also come up when using the gearsensor, or if the ebrake/gearsensor plug is being short-circuited. Unplug the brakes, unplug the gearsensor, check the pins on the plugs to make sure there's nothing being shorted. Often this can happen just from the brakes being improperly installed."

                      • Millesime2000
                        Millesime2000 commented
                        Editing a comment
                        Thanks paxtana! Yeah, all it was was that the connected brake lever was not fully engaged, thus triggering the brake light. Now i know what the light is and what to do if it comes on :)

                      Installing a kickstand or center stand can pinch the wires also.