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Old 10-13-2012, 11:41 AM   #9 (permalink)
Ryland
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Location: Western Wisconsin
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honda cb125 - '74 Honda CB 125 S1
90 day: 79.71 mpg (US)

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On my E-bike I mounted the batteries on either side of the rear wheel and it worked out great! it also meant that I had a rear rack that I could use to haul cargo, as for your rear spoke breaking... the extra 20 pounds on the rear was most likely not the cause, a flawed, cheap, rusted or loose spoke was most likely the cause, loose spokes are the most common reason for breakage.

I have a rear hub motor with a 7 speed free wheel on it and I've never had an issue with shifting gears, I've also never had an issue with it cutting out going up hills, but that would be because the speed controller is undersized and has a thermal shut down that is kicking in, so a higher power speed controller might be something to think about, even if you don't upgrade the motor a higher voltage speed controller will help you cut the losses in the wires as long as you don't over speed the motor, your speed controller limits the voltage to the motor at part throttle, so you could have a 96V battery pack and speed controller and as long as you didn't give it full throttle the motor would never see that full voltage, but the number of amps in the wires between the battery pack and speed controller would be much lower and at 22mph your motor would still only be seeing 24v or whatever voltage it requires to go 22mph, of course that would be a bit of over kill, but going with a speed controller that can handle higher amps and maybe a step up in voltage could be your best investment.
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