Overvolted Carrera e spec is a monster!

anon4

Esteemed Pedelecer
May 9, 2017
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A while ago I modded my Carrera Vulcan by ditching the suntour controller for a derestricted generic one, this improved the bike quite a bit as I had a throttle and got full assistance when I wanted it. Since my controller is dual voltage and I was struggling with range in these colder months I ordered a 48v 13ah hailong battery and installed it. Hory shet! Can't vouch for the speedometer accuracy but I think it's within +/- 2mph. I'm getting around 24mph on flat ground and it will push to around 30mph on a gentle downhill. Hill climbing is off the charts. This motor was made for 48v in my opinion, it handles it well and only gets a little warm. The controller is rated 13 amps but the motor will pull up to 17 amps according to the display and so far the range seems promising. I'd estimate 25 miles using max assistance
 

wheeliepete

Esteemed Pedelecer
Feb 28, 2016
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Welcome to the dark, sinister and dangerous world of over-volting:DYour motor should be fine at that amperage and there's always the shunt mod if you get bored. Have fun and enjoy!!:p
 

anon4

Esteemed Pedelecer
May 9, 2017
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Welcome to the dark, sinister and dangerous world of over-volting:DYour motor should be fine at that amperage and there's always the shunt mod if you get bored. Have fun and enjoy!!:p
No thanks, the last time I tried that I shorted the controller and melted a hole through it lol
 

marcuspassey

Pedelecer
Jan 27, 2019
44
1
wow if I get my bike fixed wouldn't mind doing this. can you just buy the same size deristricted controller and plug right in?
 

wheeliepete

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Feb 28, 2016
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any chance of a link to the controller ....
I think this is the controller and display anon4 used on his Vulcan. You will also need a new BB, PAS sensor and throttle,if required, to go with it and a small frame bag to put it in as it wont fit where the old one did. New connectors on the battery to match the new controller.
https://www.ebay.co.uk/itm/36-48V-350W-Motor-Speed-Controller-LCD-Display-For-Electric-Bike-Scooter-ZH/232781266082
Have a look at this thread, post #53 onwards.
https://www.pedelecs.co.uk/forum/threads/carrera-crossfire-vulcan-tuning.31768/page-3
 

Nealh

Esteemed Pedelecer
Aug 7, 2014
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The controller is 13a rated so if you want a bit more torque/amps better off just buying a KT 20a one with option of reducing the current if required.
Shunt mod is an option if you already have a controller in use but if buying new just get the correct one. Some have modded the shunt and messed up blowing the controller by adding too much solder or shorting other components.

If modding or upgrading controller amps, you need to take in account your battery specs and whether they are able to deliver the extra power asked. No use upgrading if the cells or BMS can't deliver.
 
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wheeliepete

Esteemed Pedelecer
Feb 28, 2016
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I agree Nealh, but I seem to remember anon4 having trouble pulling 15 amps from his battery, assume it was limited by the BMS and he didn't fancy the job of replacing it, but your right, I would go with a 20amp KT and turn it down to a level the battery was happy to supply, but the Brainpower offers a cheaper alterative to those wanting to save a bit.
 

anon4

Esteemed Pedelecer
May 9, 2017
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Just seen the posts here. The controller is rated 13a, but actually pulls up to 18a. There is an amp limiting feature in the LCD but it seems to have no effect. I believe the issue with the other controller was actually a fault that was triggering the BMS, official rating from phlyion is 19 amps. That is probably a similar controller wheeliepete but different LCD, I use this one currently
£23.86 40%OFF | 24V/36V/48V Electric Bicycle Controller with LCD Display Panel Electric Bike Scooter Brushless Controller E-bike Accessories
https://s.click.aliexpress.com/e/bjwZ0i4p

I had the bigger vertical type with the separate buttons previously but the buttons failed eventually, this one is solid and cheap, also takes 48v if a battery upgrade is planned. I upgraded to a 13ah hailong and the range and torque is much superior. I finally got round to configuring the speedo properly, no load speed is 28mph, real speed on flat around 24mph if no wind
 

anon4

Esteemed Pedelecer
May 9, 2017
515
77
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wow if I get my bike fixed wouldn't mind doing this. can you just buy the same size deristricted controller and plug right in?
You need to cut the wires and crimp some connectors, quite easy with decent tools

For battery and motor phase wires, ignore thin wires on battery plate they are not required

https://www.ebay.co.uk/itm/50-Sets-4mm-Male-Female-Wire-Bullet-Crimp-Connectors-Terminal-Kit-With-Sheath/292622340782?epid=2120054915&hash=item4421a692ae:g:BMUAAOSwb3hb67jd

For the 6 hall sensor wires (buy 6 way)

https://www.ebay.co.uk/itm/Quality-2-8mm-Black-Mini-Connector-Kits-2-3-4-6-9-Way-Motorbike-Motorcycle-Car/131876356727?hash=item1eb4718277:m:mZFYNtXYpTSwxCqVrfpQMQA

For throttle and pas sensor if the connections on those don't match the new controller as they like to send a different connection to what is pictured

https://www.ebay.co.uk/itm/SM-2-5mm-Connector-Sets-2-12-Pin-Male-Female-Housing-Crimps-JST-SM-Style-/232466321521?pageci=b8fc9c61-8cd8-45f5-89dd-792b9fd8b8d7

Crimp tool

https://www.ebay.co.uk/itm/Pro-Wire-Crimpers-Engineering-Ratchet-Terminal-Crimping-Pliers-Tool-0-14-1-5mm/253639757314?hash=item3b0e1b8e02:g:kCEAAOSwwAFa6YXo

I recommend manual wire strippers, and it's actually easier to just use side cutters on the thin hall wires, takes a bit of practice. Get some spare wire handy and practice your soldering in case anything goes wrong, good luck!
 

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