Haibike frame Bosch Gen 2 motor to Bafang M560

[charlton]

I did it! I converted my Bosch Gen 2 motoro to bafang m560
Big thanks to:
Bafang motor Adapter Kit:
Tom Tomblarom

Motor, Battery and misc stuff:
Kent @ North Bay Bikes/California Ebike North Bay Bikes

Before:

After:

 

[charlton]

As for the adapter kit. It is truly superb. Everything fits like a glove. Tom has done a fantastic job. Kent from North Bay Bikes was extremely helpful during the whole process answering all my myriad of questions since I purchased everything through him. Great guy and very supportive throughout the process!

I'm not a bicycle repair guy by any measure. This was my first bicycle as an adult. I made some mistakes.

The first issue I tackled was the battery mounting. Kent said I might have to use some self tapping screws but I got really lucky. Which I wasn't looking forward too. However I got super lucky and the battery I got, it's mounting plate fit perfectly where the old mounting was for the bosch battery.

Pro tip: I always take a picture of the screw head, near its location, so I can remember where it goes. As I didn't do everything in one day and I have a terrible memory


Battery mounting plate on old welded on bracket:
Top view: Because of the recessed design of the new battery mounting plate I was able to reuse the old screws



The bottom portion of the bracket was just a bit too far. I put two old nuts on the old screw to let the battery "rest" on it. When mounted.


Next up removing the crank arms! Big mistakes were made here. I bought the right tool and it still didn't work. When you remove the plug for the crank arm. Be sure to remove the freaking washer that's in there. In this picture you can see the washer. But during the process it looked like just part of it.

I stripped the inside using the right tool!


I went to a local bicycle shop to remove the crank arms after I stripped one side. I asked for a quote to take off the crank arms. I said they can cut them and they can damage the casing the casing of the motor, as I am replacing it. They said it would be more than $200 but they couldn't give me an exact number. I was like a dremel can do this and it costs less! so that's the route I went.

The washer came out during dremeling and people I felt terrible! But we must carry on!


The crank arms on the haibike go deep into the bosch motor cover and I couldn't get to it. I decided to just cut off the cover. Really wanted to resell the motor! oh well.




All the critical bolts and nuts to remove the motor are NOT on the chain side.






If you were curious! You can remove the whole motor without removing the crank arms. If you cut off the cover. =X
After that it was pretty much smooth sailing. Everything fits as it should with the conversion kit.

 

[charlton]

reserved

 

[rod9301]

Why did you replace the Bosch?

 

[charlton]

I wanted a throttle and a little more power.