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ElectricZX2,
You mentioned that you are having higher motor currents that you are use to. I noticed you said you were running in 4th gear at highway speeds. Do you know what the RPM of your motor is when you are crusing in 4th gear? I have seen very few conversions that should be run in 4th gear under any conditions. Since it sounds like you have a new motor look at the motor graph and see what RPM your peak efficiency occurs at. You should target that RPM especially for long runs.
Just a thought.....
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