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2x10AH batts in parallel in Tonaro mid drive. Wattmeter shows max 5A only pull when going slowly uphill v nr stall speed in highish gear. Can't seem to pull more out under any circs. Power level wires perm joined at max at connector. Other controller with tinned shunt is pulling 9-10A not under...

OK so solved it. Whilst the Tonaro Bighit wiring diag specifies all Grnd wires are black and the sole orange wire is 'weak electric signal' the orange wire was in fact the brake Grnd wire! Checked continuity from brake signal connector hidden in frame. Now works fine with orange connected to...

Yes I gave the other controller a brief mention in the first post. It's an ebay 36V 350W and which isn't road legal due to me tinning the shunt and doesn't have a speed limiter. When I plumb it in the brake cutoff works. So that indicates that there's continuity in the ground wire in the bike...

OK, thanks again, so I'll check continuity but what I don't get is why the other controller works then?

Yes when I bridged the signal to batt neg it stopped the motor

Thanks. OK so connecting to the batt neg gave 2V too! Tried a different batt, still 2V. Ooh er maybe my meter is on the blink?! But it's measuring the 4.5V ok?

Great write up and pics. Did this some years ago joining a LiFePO to a LiPO pack. and has worked for me. But can't recall how on earth I did it so thanks for the heads up!

Wuxing cheapo cable brakes with non-sine KU63 motor controller. Trying to get brake cutoff to work. Motor works but won't cut off when either brake lever pulled. When brake off signal is 4.5V and when pulled drops to 2V, not 0V. Both sides. Presumably the KU63 needs signal to drop to 0V? Can't...

Thanks Dave. Tried changing the 3-SPD switch connections with little effect at slow speeds which is when I want full power. Pas works as I wish with a spare controller so I think that it's the algorithm rather than disc etc.

PAS engages but only supplies weak assist - only a couple of As drawn. No-name controller 36V 350W Brushless E-bike& Scooter Controller With Hall | eBay Throttle fine. Tried reversing rotor, cleaning it and sensor. Can't get it nearer to sensor - about 4mm. Tried re-self studying. Blurb says...

Got it....thanks. Remote Watt Meter Photo by d8veh | Photobucket

Hi d8veh (Dave) Need to do some running repairs to the remote shunt part of the wattmeter you gave me and the pics would be very helpful! Got a fresh link? Ta Grahame

Is that what your Tonaro wiring looks like or just a piccie from EVLabs? The throttle is usually a 3 wire connector pos+signal (1-4V)+neg and just about any 3 wire throttle will do (the price from Powerpedals is OK) BUT it may be that there is a different arrangement with your BigHit. My old...

OK found a man with a van - well, an artic! EPSDirect based in Stevenage with a depot in Arboleas, Almeria. Great for me. Can ship and store until I pick up and then drop off to await their return journey. All for a reasonable fee - much less than hiring an ebike (if could find one!). They...

I can say that my Tonaro BigHit will climb most hills OK with little assistance (and I'm 110KGs) You can gear these crank-drive bikes to suit. By putting a smaller chainwheel (34t) or larger rear cogwheel (32t) on you can enable the bike to increase torque and climbing at the expense of top...

Anyone doing the ZephyrCD - their folder? Was considering but the fold size dimensions seem large (eg 95cms long).

Thanks all. Good ideas. I think the problem is that it is very recently the greater restrictions have come into force for Lithium by air. I think I've found a local company who go near to our destination. Cost is proportional to weight and vol. of course so a folder is a good idea.

Thanks chaps. OK 20" wheels then...! What about GNG kit for good climbing at slow speeds and doesn't matter to me if top speed not great? On a similar 20" bike, say Explorer Folding Bike. Have read about Old-Dave's and d8veh's conversions. What likely problems with fitting (BB width 68mm etc)...

Hi Y'All - some help appreciated. have read around but can't quite find the info I want. Embarking on what I hope will be a simple motorisation of a cheapo 16" alloy folder I already have in mind. Why DIY? So I get more what I want for a decent price. Cheaper bikes tend to be 24V only...

Yep - it's getting draconian. I think temporarily it's even worse than that as that reg above came in in Jan 13 and was superseded in Feb by something more restrictive. That's the trouble with the 'safety' argument - where does it stop eh? We all shouldn't have elec or gas in our homes as it's...