Turbo Trek Marlin 5 (CYC X1 Pro Gen II)

Joined
Mar 26, 2022
Messages
7
Location
Stuttgart
In an effort to possibly help others...please find the following as a short story of 5 months of research and building an E-bike to gain freedom for a young assistant looking for transportation in a foreign land that doesn't allow automobile licensing until age 18 (Germany).

The sacrificial lamb 6-year old Trek Marlin 5:



The near finished product on the first ride - big smiles!:



The hope is to ride it to school in the warmer weather - 25 mile round trip. Better than the big yellow bus! (charter coaches actually in Germany)

Parts used:

CYC X1 Pro Gen II mid-motor kit with ASI 2000:



High Voltage Controller Mount:



EM3 Triangle Bag:



100 cells of Samsung 40T (21700):



and a Daly 20S 100 Amp BMS.

 
Apologies for the delay in additional info...update the original post with all the parts.

Comment on the BAC mount - can't say enough good for High Voltage folks - went back and forth over 4 times to confirm the fitment of the 3D printed mount. To ensure the fit snuggly against the Trek Marlin frame. Spot on upon delivery and added the 'Turbo' to the side a la new Porsche electric sportscar (no combustion engine!). A bit of a farce really...



We had to purchase a more powerful soldering gun as well to address the very large wire gauge. YouTube made it look easy, but proved otherwise for the inexperienced...younger fellow did one connection, the older did the other. Can you guess who did what? :lol:



Applying power from the self-built 72V pack had our eyes closed a bit...no turned out to be a non-event!

The panel blinked to life and all was well!



First ride resulted in only throttle available. Hmmm. The student then did a test ride for full 25 miles with a couple of hiccups, if you will. System crashed with no propulsion/panel. Some shaking wires brought it back to life to complete the trip. I took it for a spin and it died again! A note to CYC Customer Service ID'd a simple issued...we reversed the wires! The motor hall cable and the plug to the torque sensor are similar in build and color...switched them and bingo! Now everything works!

We took it for another all throttle ride and 42 mph was achieved on flat ground! Crazy fast! It will go faster if we exchange the front chain ring to something larger...
 
Additional miles resulted in the identifying a worn drivetrain from the several year old Trek - ridden on technical, sandy trails of Florida...chain either skipping over the rear sprocket and/or in the lower gears (smaller) cross-chaining to point of jamming in the front chain ring...some due to the limp tensioned rear derailer.

So new OEM parts were ordered along with a 30% larger front chain sprocket! Of course, assistant didn't realize all Shimano rear cassettes and derailers were not the same. So back to Amazon for another order of proper bits. Lesson learned, I hope!

42 tooth front chain ring (CYS provided a 32 tooth):





And:



And:



Part numbers are the key!

Unfortunately, we are baffled at how to adjust the derailer...eventually buggering up the wire. We locked it in 6th until we can source another wire...allowed us to give it a whirl...

Bike is much more manageable - easy pedaling get 15 mph cruise - perfect for the school trip.

Drivetrain now takes full throttle and ~3000 watts. Not quite topped out, but 45 mph is the new max! On a bike!
 
Well, a large pot hole resulted in a 'cracked' battery pack and no juice. 4 mile ride home under pedal power took a bit longer than desired.



Close Up:



A new copper / nickel pattern had to be cut and spot welded in.



Also, had some assistance with derailer adjusting and with the addition of a new cable/sheath, back in business with full 7 speeds available.

Quick lap around the town had a new topspeed of 48 mph...crazy fast on a 2.25 tire! Caution is the word!
 
Looking like a sweet build from here :)
 
neptronix: Thanks! He made another 40 km commute to school and topped 52 mph. Starting to get friends interested and wanting to do the same...seems automatic since Germany limits driving age to 17.5 year old for automobiles.
 
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