My long time friend the pransing horse

[Tioli]

It's time to fit a new battery plug as the battery and motor have two different plugs.
It seems the rubber coating is not working that well as the paint is getting scratched up just taking the battery in and out.

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The salesman did say if I don't like it it just peels off. I'm sure it has applications but I think my original ideas of a clear protective contact film is better.

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I ordered a XT90S gold plated anti spark plug but they sent me a XT90 'which is the older model. Not that it's going to make much difference.
I'm really nervous about this.

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First off strip the wire back a bit.

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Then twist

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[Tioli]

I want to do this well so bought some flux to make sure it going to be clean and connect well.

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Pre solder the wire

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Pre solder the plug

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Set the wires up with the plug end cap and shrink tube

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Connect and how easy is that.

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[Tioli]

The next step should have been put the shrink tube on one wire before connecting the other. Well I skipped that and went straight to solder the next one up.

You can take it from me that these batteries make a decent spark when you short them out.

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Think I took a chunk out of the soldering ion.

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My never used battery may now be toast. I will clean it up and put it togeather first.

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I think I was lucky

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I want to make the plug waterproof so add a length of glued tube and while still hot press between the wires to make it all snug. Not so nice on the fingers but effective.

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[Tioli]

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The other plug is for charging. Can't say I like the idea of a open plug flapping around so will make it water proof.

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First a nother leangth with one end heated and pinched togeather while hot.

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Then just the right amount of heat to,bring it in snug and slightly dipped in the middle section to act as a locator.
It makes a vacume pop sound when you take it off so alls good.

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Do the same for the main plug

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[Tioli]

I'm going to bring the wires up this side. I could use the gap I the middle but feel the wires are more protected next to the sprocket.

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The sprocket hangs lower so should offer more protection tucked in next to the drive.

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Now add some of that cable tidy wrap for neatness and protection

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[Tioli]

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Two wires leave half way along. One goes straight up for the gear change sensor and the other for the speedo.

The two that come round the front is the main power plug and main wiring harness plug for all the sensors and gauges at the handle bars.

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I only chose this route as its the best way I could find where the wires lay naturally enough, I dident have to do some type of loop to use up exes length and the plugs are facing down to stop water ingress

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[Tioli]

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Teleportation makes this look like the Stone Age

[Tioli]

I have a problem.
From what I understand electric motors like to spin. If you slow them down your heading to a dead short. The system on the bike is a total loss system as there is no regeneration. So the best way to save power is let the motor spin, keep the revs up.

To do this in the lower gears I have looked and looked for a 9 speed rear cassette with a 40 or 42 tooth big gear and can't find one.

So I have a plan to make my own.

Rear cassettes come with some of the bigger gears on a carrier and the end smaller ones signal with spacers.
So if I remove two small signal gears and replace it with one in between gear and put a big one on the wind I will get my range.

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The big gear I'm going to use is off a BMX front sprocket. I think the reason the chain is not fitting is the sprocket is to wide to fit in the chain. As the chain goes round it rides on the tips and goes slowly out of sink.

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The front sprocket is a narrow wide sprocket where the teeth are different alternate sizes to make a bigger pushing area as possible.

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My cassette top and a used one I can use the casting off to hold the new big sprocket.

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[Tioli]

So it's healed togeather with pins. Big end

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Little end

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Meet the grinder.

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Punch them out.

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Now we have a carrier.

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[Tioli]

All ready to take to Bob's

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And then I find this. Pause for 2 seconds and order one.

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My you beaut new big disc.

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Should do the business.

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