*** Please Note that this resource is very much under construction and is part of a general re do of the website going on this winter season ***

Enduro BBSHD Build - High Voltage Powered

This is build guide to making an Enduro style ebike with the BBSHD. This is a build that anyone can do themselves and in doing so make a versatile use everywhere light electric vehicle with huge range. Feel free to ask questions on the High Voltage discord channel. If you are interested in building one of these bikes we are able to supply several battery solutions with a range of custom options as well as the High Voltage BAC855 upgrade kit for the BBSHD.

Use the information here to plan your build! The list of components is not exhaustive so if you find some good links please submit them with the form at the end. This is not about building the cheapest possible bike but taking control of your transport and learning how to build and maintain it along the way. By doing so you will have a solid ride that you can use all year round and traverse a wide range of terrain. Estimated range of this bike is well over 100km.

If you are interested in this build please get in touch with the High Voltage team using the form at the bottom of this section. Whether you choose to use components we supply or not we are happy to answer questions and point you in the right direction of an awesome bike!

Enduro Style Frames

There are a huge range of frames of this style from the ELEEK, Vector, Quilbix, Risun, EEB and endless clones and clones of clones. The quality of these frames does vary and in general you get what you pay for. That said you can get a frame of this style for as low as a few hundred dollars. Even a very high spec frame set from Quilbix will only set you back about 600 dollars.

The frame featured here is the ELEEK / Vector Typhoon / EEB style.

BBSHD Motor

The BBSHD is a tried and tested motor that is capable of delivering up to 4kw of power when tuned correctly. For these style frame you will need to use either the 100mm or 120mm Bottom Bracket versions.

This is not going to shift this frame as fast as a giant QS hub. This will not weigh you down in the same way either.

The BBSHD will give you the perfect range of speed and power for getting about town or ride trails and off road.

The purpose of this build is not to smash it at the race track or set speed records but to give the rider an all round utility vehicle versatile enough to ride all day.

The reliable top speed of this bike is 80kph on the flat. It is happy to sit at a cruising speed of 50-60kph for efficient travel.

High Voltage Kit (ASI BAC855)

The bike is powered by the BAC855 which gives the a peak power of 4kw. The motor is protected from damage with temperature monitoring and will throttle back on power once a certain temperature has been reached.

The high voltage kit comes with full support and a range of options and more information can be viewed in the video.

Huge Battery!

One of the great things about the Enduro style frame is a massive space to put a battery. Rio has a few options with the largest one the 20s 15p pack which gives a whopping 3.4kw hours of juice. This gives a huge range. You could literally go and ride in the bush all day with this. Or hook up a trailer and go on a hunting or camping trip.

There is a smaller battery option we will look to make available for around $900 which will give you 20s 8p.

Easy To Repair and Maintain

One of the huge advantages of the BBSHD is that it is really easy to maintain. Many repairs can be done without removing the motor from the bike. It is very reliable motor which is why they are often to go to motor of people doing long range bike tours.

It is easy to carry with a person a selection of tools and spare parts to fix the vast majority of problems that you might encounter!

 Component List and Links

This is not an exhaustive list but will give you a rough idea of the cost and cost range for different components. For a top of the range bike with the biggest battery you are looking at around $5500. You can make considerable savings however by using a smaller battery and sourcing out cheaper or second hand components. You might even get lucky and find an Enduro build with a blown motor that can be converted for not much effort or cost. There is a huge variety of this type of bike in existence.

Enduro Frame - $300 (EEB clone) - $800 (Vector, ELEEK or Qulibix Frame)

Front Fork and Rear Shock - $600

• DNM is an inexpensive but solid option for the suspension on this kind of bike. They will provide a solid performance if not spectacular. They are the best of the budget options.

• Cheaper options such as zoom forks are truly terrible in most cases.

• Other options are to try and score a nice deal for something second hand.

ASI BAC855 Controller kit - $650

BBSHD Motor - 100mm or 120mm BB size - $600

• Options for purchase include Luna Cycle, EM3EV etc.

Battery - $900-$1600 (with High Voltage options)

• - 300 cells 20s 15p 3.4kWh discharges 150A

• - 160 cells 20s 8p 1.8kWh discharges 120A

Front Wheel - $100

• Inexpensive options for a front wheel is an NB Power front wheel or a stock Sur-Ron front wheel and other front wheels for Sur-Ron are available and will be more expensive.

Rear Wheel - Hub, Rim, Spokes and Nipples - $200

• These frames are designed for a 155mm spacing hub motor and can use bicycle wheels with 157mm Super Boost hub in the back and some adjustment of brake spacing. If one wants to use moto rims.

• To use a moto rim on the rear, a custom rim will need to be assembled using a 157mm super boost MTB hub.

Tires and tubes - $200

Shifter/cassette/clutch derailleur/chain - ($200)

BBSHD chain ring - $60-$100

Brakes and Rotors - $200-400

• If you shop around you can get yourself the Magura MT5 estop and a set of rotor for about $450.

Headset - $65 (may come with frame kit in some cases)

How much will the build cost?

The build will likely come to around a similar price to what you would pay for a Chinese enduro hub bike. The difference will be that this will something you build yourself and learned how to maintain along the way. You will also have full control over the spec of the bike and get nice features such as the Eggrider display. If you are novice builder or just starting out you can make full use of the High Voltage community to ask questions and get information.

A high spec build using the ELEEK or Vector Typhoon frameset with the 3.4kw battery will come in at about $5500 USD

A more modest build with an EEB clone frame and lower spec parts and the 1.8kw battery will come in closer to $4050 USD

Future Plans for this Build…

Future plans for this build will look at extending the range of the bike by adding on a trailer system that will enable more battery capacity to be carried as well as cargo to allow the bike to be used for truly long range journeys and adventures.