I discovered the Johnny Nerdout channel on YouTube and got the itch to build an ebike. I love his philosophy of starting with a bike that you like and one that fits you well. I found a solid Trek 7200 hybrid (22.5" frame. I am tall!) on FB marketplace and went for it. Added a Bafang BBS02 with the C500 display, and paired it with a 48-volt, 17.5AH battery pack. In addition to what came with the kit, I also added the shift sensor (less than $25). It came out GREAT.
Here are some things I learned:
- Sometimes things (crank arms, the crank cartridge) can be on REALLY tight. If it won't break free, first make sure you are turning the correct direction (there ARE some left handed threads) and then find a way to extend your wrench handle with a piece of pipe or something. It WILL come loose with enough force.
- Things don't always fit exactly perfect as on the videos. A 68-73mm motor is REALLY made for a 68mm bottom bracket. On a 73mm bracket you will need spacers and the locknut won't be used.
- The C500 display (and maybe others) came with TWO layers of plastic on the screen. After pulling the first one off, I thought my screen was scratching VERY easily and was a POS, only to FINALLY figure out there was ANOTHER layer of plastic on the screen. Now it looks much better.
- Many, many bikes have the brake handles integrated into the shifters, so in my case I had to buy a new front shifter (only about $20) so I could use the brake levers that came with the kit (with sensors).
- The Bafang kit is really well thought out and everything is easy to plug and play. Did not have to strip a single wire on the whole project (but did use a ton of zip ties!).
Here is a pic of my finished build. In retrospect, I wish I'd have gone with a 52-tooth chainring, as it climbs INCREDIBLY well in 3rd gear even. I think I'd still have more than enough torque in my lowest gear with a bigger chainring, and my top end would be even stronger. Thanks, Johnny for your guidance!