Pino Freewheel

The Pino stoker’s freewheel removal

Our Pino is a 2011 model with square taper cranks.

The freewheel is on the left side of the ‘Captains’ crankset. Ignore the motor slung under our Pino, removal of the cranks and freewheel is still the same. Before removing the crank, take off the pedal.

Removal of the cranks is similar to the video below (not mine). You’ll need a crank puller – the video below shows the tools and how to use them to remove the crank.

Once removed the inside of the crank and freewheel looks like this.

It’s best to remove the chainring at this stage by undoing all five chainring bolts. This will leave the spider attached to the freewheel. Although it’s not necessary, you can remove this too, by removing the five retaining bolts. The chainring spider will then come away from the crank assembly and it’ll look like this.

Image Bob Gulliver

To you’ll need Park Tool FR-6 – available through bike shops, Amazon and eBay – and a clamp to hold it in place before placing the crank in a vice. You can make up a clamp using a long bolt, washers and a nut. It just needs to be finger tight to prevent the tool slipping out of the cut-outs on the freewheel.
Rotates anti-clockwise to loosen.

Park tool FR-6
My clamp for holding the tool in place on the crank.

Placing the tool into the crank using the clamp to hold it in place…

In the video I left the spider attached to the freewheel. After placing the Park tool FR-6 into the slots in the freewheel and clamping the tool in place, use a spanner to turn the tool anti-clockwise. The crank can be placed in a vice with some cloth to prevent scratching the crank arm. You may need to use an extension for leverage. Once loose the freewheel should spin off easily…
Once the freewheel is loosened just continue to rotate the spider/freewheel anti-clockwise while holding the crank.

If the spider is still in place, you can now undo the five allen bolts and remove the spider from the freewheel. The image below shows two freewheels. The top one has the threaded sleeve that has come off the crank. If the sleeve stays on the crank, it will look like the bottom one.

The freewheel can be dismantled to grease the bearing by turning the cover plate anti-clockwise.

The stock freewheel has three pawls. Use a light grease to ensure the pawls can move freely and engage properly. Because of this, take-up is often a little slack. This, and that the Hase Freewheels are expensive led me to look at an alternative using a better quality freewheel. Unfortunately, I could not find any good quality flanged freewheels on the internet, so I decided to use a sprocketed freewheel and make an adapter plate to attach it to the spider and crank.

I wanted to use an 18T BMX freewheel sprocket – the Halo Clickster – as it has six pawls and is a better quality freewheel.

I could use bolts evenly spaced in the saddles of the sprocket to hold the freewheel in place and prevent any rotation.
I drew out an adapter and had one made at a local engineering firm. One of the guys turned it around very quickly and it cost me £15.
The finished adapter with the freewheel and chainring in place. The freewheel here is a cheap one I used before committing to buying the more expensive ‘Clickster’. I have this as a spare.
The adapter and freewheel back on the bike. This is a big improvement over the original freewheel. With six pawls and more bearings the take-up is very quick.

Catchup –2021/2

Spring 2021

Like many, covid restrictions really put a bit of a damper on all our plans for the year and we spent the early part of spring riding locally when we could, just taking a flask and some biscuits out so we didn’t need to stop at any cafés etc. In April we managed to get Holland and Cas into the garden to sit and catch up. It was warm enough by then to sit outside. Holland worked in a shop all the way through the worst of the Covid, so was at risk and a risk to us but I’m happy to say that he never managed to catch it. Cas suffered both mentally and physically after being made redundant at the end of the furlough scheme, even though they had worked all the way through. It hit their self-esteem badly and the inactivity it led to meant they put on quite a bit of weight. Too much, considering their health issues. However, a long time friend who we’ve known since she was about 10 years old is now a fitness trainer and specialises in people who not confident, are pregnant or simply don’t want to/can’t go to a public gym for a variety of reasons. Cas gets ‘mates rates’ and Erin has benefitted too, as I think they spend as much time talking as they do exercising!

Karon with the Pino on White Hill – next to Watership Down, on one of our local rides.

Also in April, I undertook a few charity rides, raising money for Postrate Cancer Research. It was prompted by a few of my old Army mates being diagnosed. As we were all ex-56 Battery colleagues, it was decided to ride/walk/run/swim distances of 56 units. I completed 3 x 56 mile rides, others swam 56 lengths of the pool or walked or ran 56 miles during the month. It got me out and I rode alone, so had some ‘me’ time to contemplate life, the universe and all else.

About this time I decided to sell my recumbent trike. I found it difficult to ride as I wished, as my pacemaker needs some upper body movement to know when I’m active and increase my heart rate accordingly. Sat in the recumbent chair, my legs were busy, but my upper body not so. I was constantly struggling as my heart rate just wasn’t fast enough. Yes the electric motor I had fitted helped, but it seemed pointless to rely on it, as riding a ‘normal’ bike I have far fewer episodes like that. Anyway, I sold it to a lady (ex-services) that now has long covid and has mobility problems, so I think the trike will be useful to her.

Prosecco picnic with the Nutty Tandemers. A great long weekend in Scotland.

In June ‘21 we had our first trip away with the Tandem, driving to Callender in Scotland, staying on a holiday campsite (in a mobile home) and meeting up with another two couples to go out riding together. By this time restrictions had eased somewhat, so it was easier to stop for lunch and socialise in the evenings.

It was a lovely long weekend and the weather stayed kind. The scenery in the Trossachs was lovely and it was great to ride in new places with toatlly differnet landscape to our local lanes, which we now know every single inch of! Our friends are great Prosecco advocates, so there were plenty of stops for Prosecco picnics. In the evenings we took turns in entertaining the other couples and on our last night we all went out to dinner together to a local hotel.

On the way back home Karon and I stopped off to ride and bag some BCQs – a national cycle treasure hunt and we called in to see friends in Dumfries and Galloway. Later in June we took part in a 10-mile time trial in the New Forest – another fund raiser, this time for ME research. We started riding out with the Tandem Club and managed a get-together with long standing friends to celebrate birthdays and anniversaries.

New Forest time-trial in aid of ME research.

In August the Tandem Club laid on an impromptue rally on the outskirts of Nottingham. We stayed the week with some friends in the town. They had helped organise the event, so we just tagged along with them and never missed any of the activities etc. We were featured on the local BBC News website and they used one of my photos. Also in August we headed over to East Sussex and Kent to collect some more BCQs and complete the SE area of the UK. Once again it was good to be out in new pastures.

The Pino in Nottingham during the National Tandem Rally

Normally in October I would have made my annual pilgrimage to Germany, back to Lippstadt where I was stationed all those years ago, but this year, I met up with just a few friends and their spouses to go on a walking tour in London. Our friends had organised the ‘Jack the Ripper’ tour, which was interesting and not too gory. Fascinating to see some of the old streets and architecture that has changed little since those times.

Some of my paintings and digital work over 2021 with a few earlier pieces to complete the matrix.
My DeviantArt site

Just before New Year ‘22 we drove to Blewbury and met up with three cousins and their husbands/wives. We sat in the Red Lion and had lunch together and did some catching up. Family get-togethers are a rarety these days as most of the older generation that used to regularly get-together are no longer with us. 

Christmas at home 2021.
Cousins get together in the Red Lion, Blewbury.

Covid prevented us from going to Spain early in 2022 for some winter sun, though it would have been nice to escape for a while, the hassle of travel at that time of restrictions was just not appealing.

We stayed local and it really was a repeat of the year before with us just riding locally on the better of the early spring days. However, in April we did manage to get away, up to Hull for a weekend, for an Army reunion. It was good to meet up with some of my (now) old colleagues from those days back in the 1970s but also sad to find out several had succumbed to covid or other ailments since we last met.  Karon and I stayed in the area afterwards for a few days and went out riding… yes, to collect a few more BCQs.

56 Battery Royal Artillery reunion in Hull in April 2022

In May we decided to take the plunge in continental travel again, and drove to the Saarlaand in Germany to attend a long-weekend tandem meeting we had been invited to. The place we stayed was very near the French and Luxembourg borders, so one of our rides passed through both countries. Some of the scenery was spectacular with steep hills overlooking the River Saar – very picturesque. 

One of my holiday sketches from Siena ended up on a book cover.

In June we went through the trauma of having a new kitchen fitted. It didn’t go particularly smoothly, but we got there in the end, and the new kitchen does look lovely.

Karon and Holland on Glastonbury Tor.

Over the year we had several trips in to Newbury as Karon had a series of private dental appointments to try and save her teeth from the effects of her auto-immune disorder. It was an expensive course of treatment and not one we had really planned for in retirement, so our savings took a bit of a hit.

Riding with Dutch and German friends alongside the river Saar in Germany, May 2022.

In July, we had another trip to Germany, but this time we cycled all the way – to the International Tandem Rally which was being held near Osnabrück. We used the trailer and cycled from home, first north towards Milton Keynes, then east for Harwich. It took us five days to get to Harwich and then we had an overnight sailing to the Hook of Holland. Four days to get across the Netherlands and just the one to reach the campsite where the rally was taking place. We stayed in a small holiday home on site and went out with friends each day to explore the surrounding countryside and visit nearby towns. At the end of the week, we packed up the bike and trailer and cycled home again, reaching home on the 16th of August after leaving on the 20th July, so nearly a month away. Once again (like when we cycled through France in 2019) it was very hot with a couple of heatwaves in that time.

On our way to Harwich for the ferry to the Hook of Holland, July 2022
Scenery during one of our International Tandem Rally rides in Germany, August 2022.

In October we drove up to Scotland to visit friends and relatives, staying for just a week up there but managed to see some of Karon’s Aunties and Uncles, my sister and brother-in-law and some very good friends who live in Dumfries and Galloway. Unfortunately, I managed to pick up a bout of covid on the way back from Scotland. Luckily I was only bad for a couple of days and laid up for a week.

Karon on Arthur’s Seat, Edinburgh, October 2022.

In November we attended an old Army friend’s wedding in Kent and had another good get-together.

Karon and friend Ida at the Kent wedding.

Christmas was fairly quiet for us, with Cas and Holland coming for the day. Cas stayed over and Holland walked home as he’s less than a mile away. 27th December Holland was not well – with severe neck cramps and spasms – and he asked me to drive him to A&E. It was dark and wet and innexplicably, I missed a red light, which resulted in a car crash. Though both Holland and myself were ok from the accident, the car is a write-off and the occupants of the other car had some injuries, but nothing life-threatening. Not a great way to end the year.

Christmas Dinner night out locally, with friends.

So, I am without a big car at the moment, which means no travel with the tandem. At least we had decided not to go to Spain again, so there are no up and coming trips in jeapordy. Hopefully everything will be sorted by mid-May when we are due to go back to Germany for the annual tandem meet their. We will stay on the continent after, as the International Tandem Rally is in Brittany this year, a week later. Then in August we have the National meeting in Stratord on Avon. We’ll cycle there from home and camp for the week.

Not a good end to the year.

That brings me up-to-date. Not a brilliant year but we have managed to get away and have added some good memories to our cache.

Our 2022 Summer tour to Germany

Video clips from our ride from home to the International Tandem Rally at Tecklenburg, near Osnabrück, Germany, a week there cycling with The Tandem Club, then our return trip.

In all we covered just over 1,000 miles and were away from home for 28 days. To avoid cycling through London, the most direct route to Harwich from home, we headed north first, almost to Milton Keynes, then turned right and headed east, across the country. Along the way we collected BCQs (British Cycle Quest). We did the same on our return journey, but a little further south.

In The Netherlands we followed routes suggested by a Tandem Club member who lives there, and as we all know, local knowledge counts for a lot. Some days were too hot to be honest, but we only had two days rain, and on one of those we chose to take a rest – it was the day before we started heading home.

ITR2022

Photos, maps and words here.

Our ride through France 2019

Watch an automatic Powerpoint presentation about our 2019 ride from home to Portsmouth then through France to the Mediterranean then on to Toulouse. This was created for a presentation in Germany, so the brief captions are in English and German.

Hase Pino freewheel removal

It’s a few years since I last serviced the freewheel on the Pino, and it felt like it could do with some fresh grease in the bearings: Tools needed are the Park Tool FR-6 and 1″ socket or spanner to fit, a bolt and washers to clamp the tool in place, a vice, hammer and punch or drifter.

Park Tool FR-6 with bolt and washers/spacer for clamping it in place.
The crank with freewheel removed from the bike and chainring removed. (Not my photo)

Locate the tool into the slots on the freewheel then clamp in place with a bolt. Place the crank into a covered vice then use a 1″ socket or spanner to loosen the freewheel anti-clockwise. An extension to the socket or spanner may be necessary for leverage.

Once loosened the freewheel can be removed. This sits inside a threaded sleeve within the crank, and in this case that too came off. The sleeve can remain in the freewheel or be removed and replaced within the crank.
Once the freewheel is removed, replace the tool and clamp to the freewheel, then clamp the tool in a vice. This makes drifting the faceplate on the freewheel much easier.

The tool clamped in place over the freewheel to allow the freewheel face plate to be drifted loose.
Drifting the faceplate loose on the freewheel. Again, it is anti-clockwise to remove.
The opened and freshly greased freewheel. There is a ball-race on each side and in between two opposing pawls held in place by a wire spring.
The complete freewheel. These are made in Taiwan and the only source I have found is JD Tandems.

Pino update

Adding a second battery

The International Tandem Rally in 2022 in the first week in August, was near Tecklenburg, South West of Osnabrück in Germany. We thought it would be good to ride from home, using the Stena Line Ferry from Harwich to the Hook of Holland. Once in the Netherlands the going would be mostly flat but between us and Harwich and in Germany there would be a fair amount of climbing.

The route from home to Harwich (North leg) and the return route (Southern leg), planned to collect BCQs along the way.
Hook of Holland near Rotterdam and the International Tandem Rally site near Osnabrück.

At the time, the 17.5Ah battery fitted to the Pino was good for around 30 miles with reasonable use on the unloaded tandem, but I was a bit anxious that hauling the loaded bike and trailer would reduce the range as the motor would be needed more, especially in hilly terrain. With this in mind I looked at either obtaining a second ‘reserve’ battery or another to add to the bike.

The type of connector in the mounting bracket on the current 36 volt 17.5Ah (630Wh) battery, then 3 years old, which I bought from China has been changed and I thought it unlikely to be able to buy a second identical ‘spare’ to match the existing bracket, so I looked at connecting a second battery.

The logical choice was a rack mounted battery. I wanted a system that would allow me to use just one or both. Two batteries for a shortish local ride would be overkill and unnecessary weight. However, on a longer ride, in much hillier terrain or on a fully loaded tour, the ability to have both batteries providing power would drastically increase our range. An advantage to using both batteries at the same time rather than one then the other, is that at maximum draw by the motor, each battery is only providing 50% of the power, so the batteries are not stressed nearly as much as a single battery providing all the power.

Looking for more information on the web, I came across ‘Area 13 e-bikes‘ and some useful videos on battery care and how to add a second battery to an e-bike. With the advice from this video I ordered the Dual Battery Parallel Connector. This would allow me to safely use the two 36 volt batteries of different capacity on the same system, or either battery individually. Something similar is available in the UK, but costs a lot more. Delivery from the ‘States took a little over a week. I ordered some XT90 connectors to match the ones on the Dual Battery Parallel Connector. Because the original battery did not have an isolating switch, I also bought an inline on/off switch so I could isolate the exposed connector on the down-tube battery bracket when we were using the bike without that battery fitted. Without the switch I am pretty sure the connector would be live and very prone to shorting out if it got wet.

The Dual Battery Parallel Connector with XT90 connectors, bought from Area 13 e-bikes in the USA. Something similar is available from UK suppliers, but at double the cost. Even with shipping, the US type I bought was way cheaper.
My soldering left a lot to be desired and after losing power on a ride, due to a loose connection I swapped out the XT connectors for a more basic type above. The connections are protected with self amalgamating tape.
The original down-tube mounted battery and bracket, showing the exposed connector which would be live without an isolating switch if we were just using the rack-mounted battery.
The finished set-up, as it is in September 2023.
The end result… The Pino with the original down-tube mounted was 17.5Ah battery but after 4 years its performance was no longer acceptable, so I recently replaced it with a 13Ah in the same size casing. The new tube-mounted battery has an on/off switch and recessed connections. Both batteries now provide a total of 35.5Ah or 1278Wh which is enough for a day ride with a touring load.
Just visible at the top, behind the seat tube is the waterproof rocker switch which allows me to isolate the down-tube battery bracket. The rack battery has a switch and USB outlet, plus a rear light.
A rather distorted view. The Dual Battery Parallel Connector is tucked between the rack struts and rear mudguard, covered with some old inner tube which I cut along and opened out. It works a bit like extra wide bar-tape and is held fast with some velcro.

The beauty of this system is that either both batteries or just one can be used, without the other being on the bike. The large capacity rack mount battery weighs 5.8kg (12.7lb) and the down-tube battery weighs 3.5kg (7.7lb).

A long weekend with the Nutty Tandemers

Late June 2021 we put the Pino in the car and headed for Callander on the edge of the Trossachs National Park. We arrived on Wednesday 23rd and so did Jane and John. Colin and Diane would be joining us Friday evening.

Day 1

Thursday was our first ride and Jane and John had bought their Pino along too. Like us they had e-assist but their’s is the official version from Hase, with a Shimano Steps system. For this first ride the weather was good and we decided to head West, out along the south side of Loch Venacher, much of it along tracks beside the Loch. At the far end we continued around Loch Achray then headed for the ferry terminal and café at the end of Loch Katrine.

After lunch in the café we took the road back along the Northern shores of the Loch to arrive back at Callander. In the evening John and Jane came over to our chalet for nibbles and drinks.

Day 2

On our second day we again headed West, retracing the return leg of the previous day, but once past Loch Achray we turned South and climbed Duke’s Pass. The long, flowing and winding descent was definitely the highlight of the day! (3:35 in the video)

In Aberfoyle we stopped at the first café we spotted for lunch then carried on, past the only ‘Lake’ in Scotland, the Lake of Menteith. Back in Callander, after some food, we enjoyed drinks and nibbles in our chalet again, but this time we were joined by Colin and Diane who had arrived late that afternoon.

Day 3

Day 3’s ride was led by Colin and Diane. This time we headed north alongside Loch Lubnaig, following the course of an old rail track for the most part. We stopped off at the Broch Café near Strathyre for coffee and cake then continued towards Lochearnhead. Here we picked up the trail that runs up Glen Ogle, crossing the Glen Ogle Viaduct. A stint on the A827 delivered us to Killin where we parked up behind the Falls of Dochart Inn to sit outside the Falls of Dochart Smokehouse and enjoy a lunch of smoked salmon washed down with some very nice bubbly.

Karon and I took our leave briefly, to head through the town to collect a BCQ, leaving the others to explore the falls of Dochart. I can’t say I enjoyed the climb out of Killin, as we retraced our outward leg back up to Glen Ogle. Once there, the remaining route was mostly downhill which was a relief!

In the evening we all headed into Callander town for a meal together in the Bistro Restaurant at the Roman Camp Hotel.

Day 4

Day 4 saw us retrace the first part of the previous day’s ride as far as Loch Earn, where we turned off to follow the Southern shore of the Loch. At St Fillans, at the far end of the Loch we stopped for a picnic ‘Prosecco’ lunch. Back on the bikes we continued along the north shore as far as Briar Cottage where we stopped for more Prosecco in a Lochside garden, hosted by friends of Colin and Di.

On the way back Karon and I took a detour to bag another BCQ while the others waited for us at Kinghouse…in the pub there. Our last day ended with us all sat on the decking of Colin and Di’s chalet enjoying nibbles and copious amounts of more prosecco!

A great end to a great weekend – Thanks Nutty Tandemers!

Catch-up Christmas 2021

February 2020 we were in Spain when Covid reared its ugly head and started its advance from China. Initially we had looked at finding some winter sun in Cuba and doing some cycling and painting there, but decided against flying anywhere. So we packed the Pino into the car and spent a few days driving down through France and Spain to arrive in Dénia. We had an apartment about 5km north of the town, right on the beach, but we were there to ride. In January there had been a terrific storm and much of the beach was washed inland so there was still a big clean-up going on during our stay.

Among the orange groves near Dénia.

Some of our cycling friends were staying in a hotel in the town and, as luck would have it, as we drove towards our apartment, we spotted them on the road, so pulled over for a quick chat and to arrange to meet in a couple of days to join them for a ride. So, over the next two weeks we had a mix of joining up some days, riding alone others, and on one day we drove north into the mountains to a small town to explore an abbey and do some painting.

Come the end of February we headed back home, spending another few days on the drive home… just in time for the first lock-down. With Karon being classed as vulnerable, neither of us wanted to mix and after one shopping trip to the local supermarket, where I queued for 3/4 hour to get in, I decided not to risk it again. We struggled for a few weeks to get onto any home delivery system and Holland did some shopping for us, dropping it off at the doorstep. Eventually Karon got onto Sainsbury’s home delivery and we were fine from then on.

I used the time to do a few things in the garden and clear out both sheds, I was also riding most days, on my own until things eased and Karon joined me. In the summer we put the Pino in the car and went a little further afield to break the monotony of repeated rides around local lanes.

A socially distanced garden get-together with Holland.
Riding further afield in Wiltshire.
On the South Downs on a roundabout ride to Eastbourne.

In the autumn, when things got a little worse again we stayed local and as it got colder we cycled less and stayed home more, doing the odd painting and reading etc. Christmas 2020 was a quiet affair but Cas and Holland spent the day with us and Cas stayed over that night.

In April 2021 I undertook a fundraising challenge to ride 56 miles. In fact I managed three 56 mile rides – West along the Kennet and Avon Canal and back, South to Winchester and back and a loop Eastwards towards Hartley Wintney, making use of the labyrinth of little lanes around us.

It was on one of these rides I had pretty serious problems with my pacemaker and had some bouts of atrial fibrillation. It wasn’t me but the pacemaker that wasn’t behaving. A few adjustments at pacing clinic sorted it and I’ve been fine ever since. With slightly warmer weather Karon and I started getting out more together, on the Pino which helped us get a bit more cycling fit for in June we headed North into Scotland to spend a long weekend in a chalet on a campsite in Callander, along with another two tandeming couples – one pair in their caravan and the other in another chalet. We went out for day rides and socialised in the evenings. Though it was only a short break, it was so good to get away – things almost felt normal!

Out and about in Scotland – Glen Ogle with the ‘Nutty Tandemers’

On the way back home we met up with friends in Galloway and Dumfries and called in to see my sister in Cumbria. In July we took part in another ten-mile time trial, even though I had said we would never again! We stayed in a B&B in Lyndhurst so it was another mini-break for us. It was wet on the TT but it really didn’t matter. At least this time, we weren’t last.

On the TT10 in the New Forest.

July we had an outdoor get-together at a friend’s house on the fringe of Odiham. AS the weather was good we cycled there on the Pino and carried our picnic and booze on the trailer.

Friends joint birthday/wedding anniversary celebration.

In August we were off again, to Nottingham for the National Tandem Rally. We stayed with a couple we knew, but had got to know better back in Spain. They had helped organise the rally and planned all the routes, so most days we rode with them – bigger distances than we were used to, but we survived the week. To top it off, we weren’t the only Pino pair…

A pride of Pinos? A pootle of Pinos?

We also hosted a Tandem Group ride from home and enjoyed tea and cake in the garden after. On a roll and with the weather on our side, we then spent a week in East Sussex and Kent collecting some BCQs (British Cycle Quest) and in doing so completed all the clues in the South East.

In a normal year, come October I, and maybe Cas and/or Holland would pop over to Lippstadt for Herbstwocke and meet up with some of my old Army buddies. Of course, with Covid this was not really feasible, so we decided to meet up in East London for a few drinks, a meal out and a walk around the East End… the ‘Ripper Tour’ to be precise. At the end of our walk we ended up in one of the oldest pubs in the city of London, which had survived the Great Fire of 1666.

Over the year I had been painting, though maybe not as much as I could have. Here’s a snapshot. The bird in the lower left and the lion and girl, lower right, are older, included just to complete the matrix.

2021 work.

Since October it’s been back to local lanes on nice days and staying in on bad. Christmas was a repeat of last year with Cas and Holland here for the day and now we are half-way through January already. I’m hoping we can get abroad at least a couple of times this year, more with luck!

Solo e-bike conversion

Fitting a Bafang to a solo ‘should’ be straightforward, but my Qubic steel framed MTB threw up a couple of issues.
I bought the motor and battery separately through AliExpress. There are dozens of suppliers, many based in China but a lot of sellers now have the option of buying from a distributor in the UK or EU, which makes delivery times a bit faster, though you will probably pay more for these options. I opted for a German source and it took about 10 days for delivery, but there was a German bank holiday at the time of order which delayed dispatch.

I chose a 15Ah battery with USB outlet and the 250W motor kit (UK street legal limit). As I have hydraulic brakes on the Qubic I also sourced brake sensors from Amazon. I used a UK supplier so they cost more but I wanted a faster delivery.

The hydraulic brake sensor consists of a small magnet that can be superglued or bonded to the lever and the sensor unit that attaches to the brake housing. They come with self adhesive pads, but I used Sugru ‘putty’ glue to ensure they stayed put.
The battery with on/off switch, recharging port, lock to prevent removal from bracket and the USB port. For a 15Ah battery, the housing is quite large – bigger than the 17.5Ah on the Pino.
A Bafang kit and battery – this one went onto my trike but the contents of the kit are the same.

First job is to remove the bottom bracket on the bike. I had a Shimano Hollowtech with external bearings, so this was very straightforward. The motor slides into the BB shell and is locked in place by a castellated lock-ring.

The motor in-situ. I had to add spacers to move the motor out further on the drive-side as fully pushed home it was contacting the chain stay. I used some spacers from the old BB on the drive side and a couple of spacers in the clamps on the non-drive side.
The spacers on the clamp to move the motor more to the drive side. There was still plenty of thread for the locking ring on the BB.

My other issue was that the bottle-cage fixings did not align with the battery bracket, so I bought three brackets from eBay. These elevated the bracket from the downtube and reduce the space for the battery. It’s a tight fit.

The kit and battery fitted onto the bike. The battery is large for a 15AH and only just fits in the available space. There’s a millimetre between the seat tube and the battery and just enough space below the cross bar to allow removal of the battery.
The battery mounting bracket in place. At some stage I will re-route the gear cables as the brackets are too close to the cable guides on the frame.
One of the three clamps used to fit the battery bracket. I had to drill a hole in the bracket to fit this in place. You can see the bottle cage mounts on the frame, which did not align with the mounting points on the bracket. I looped the excess control wire under the battery bracket to keep the job a bit tidier.
The thumb throttle and control pad. Strictly the throttle is illegal, as it can power the bike independently of pedalling but I find it very useful for pulling away at junctions or to get the bike moving on hill-starts.
The control display. Connections are pretty fool-proof as they are colour coded male-female type connectors. The display can be metric or imperial and shows typical trip computer information like odometer, trip distance, average and maximum speeds.

USB outlet for Pino battery

The Hailong battery on the Pino e-bike kit didn’t have a USB outlet and as I use my iPhone for navigating and tracking our rides, an outlet would be useful for keeping the phone charged, as GPS use tends to drain the phone battery pretty quickly.

The battery is a 36V 17.5 Ah Hailong.

There is a compartment towards the back of the battery mount that houses the connectors and wiring, accessible by removing the four cross-head screws, so that seemed to be the logical place to start.

My battery didn’t have a fuse or large connector, so there was more free space available.

The battery produces 36-39V and a USB phone charge lead needs only 5V at about 2-3 amps. A search on Amazon provided me with a suitable ‘step-down converter’. Input from 8V-50V and output at 5V 3A. It had a USB lead too so seemed perfect for the job.

I removed the battery mounting bracket cover and tapped into the positive and negative outlets on the power supply, then ran a USB lead from the socket up to the handlebars.

The box of tricks was too big to fit inside the mounting bracket, so I zip-tied it to the seat tube. It’s sealed with epoxy resin, so is waterproof. With everything in place, it worked…. for about a minute, then the charge died. Disconnecting it and reconnecting, the same thing happened. Faulty unit, so I got a refund and went looking for an alternative.

This one was cheaper but not sealed. However, it was small enough to fit into the compartment in the battery mounting bracket. I slipped a length of MTB inner tube over it to protect it and prevent any solder on the underside coming into contact with the metal base of the compartment. There’s a USB socket and wiring connectors, so it’s more flexible than the first type I tried and being housed within the mounting bracket makes the whole thing a lot tidier. Better still, it works….

…but not for long. Within a couple of rides it failed, so I have given up on the idea of adding a USB socket to the battery for now.