Replacement steel gear

TForan

Active Member
#1
Read this today

"Bafang has finally decided to abandon their crappy ass nylon gears on the Ultra Max. They are offering free steel gear replacements for anyone who purchased an Ultra Max with a nylon gear".

Has anyone heard of this ?
 
Last edited:
#3
Yea I think the notion that the nylon gear is inherently flawed, needs to be cleared up: that nylon gear is a sound design choice to protect the motor and reduce noise.

If anything, it should be replaced with a cast and machined Nylon NSM gear (better than the stock material), rather than replacing with a steel component.

for 95% of users the steel is actually a downgrade. only hotrodders using custom tuning need to push this thing to its mechanical limits, necessitating an all-steel geartrain.. which would also require a completely different chain and cassette and various other overhauls to operate at peak power levels. All of which is a terrible idea in my opinion...
 

Thomas Jaszewski

Well-Known Member
#4
Yea I think the notion that the nylon gear is inherently flawed, needs to be cleared up: that nylon gear is a sound design choice to protect the motor and reduce noise.

.
Ask any of the Bafang resellers. This plastic gear issue is MASSIVELY over reported. I've had every Bafang BBS series and back up gears for all. Never used. I do support for a small reseller and we sell LOTS of parts. Fried plastic gears are more often than not rider error! Ride a 250W-750W like a single gear moped and you WILL melt it. Ride it like a bike and shift up and down as you would with any bike, they will run MANY thousands of miles.
 

Thomas Jaszewski

Well-Known Member
#5
Read this today

"Bafang has finally decided to abandon their crappy ass nylon gears on the Ultra Max. They are offering free steel gear replacements for anyone who purchased an Ultra Max with a nylon gear".

Has anyone heard of this ?
Experiments with steel gears have been complete failures, so far...
 
#6
They are shipping bikes from China with the Ultra and the steel gear. Doesn't sound like an experiment to me. People are riding Ultras with steel gears. Not trying to be confrontational. Steel gears are not a complete failure.
 

Thomas Jaszewski

Well-Known Member
#7
Very few are out as yet. Nor are any reviews with significant mileage. You know from Luna FB that the steel gears in BBSHD are experimental. Those last I was forwarded the info from the FB page, failed. Every BBSxx has had issues shortly after the initial release. I don't expect Bafang to have changed. Kinda early to know what the 1000w will bring.
 

roshan

Active Member
#8
Hey guys, let me clarify : there are no issues with Nylon gears on bbsxx motors. Nylon gears on the Ultra motor have been awful. Over 25% failure. Hence bafang has the next version coming with steel gears. We also have replacement steel gears for gen 1 Ultra motors. Hope that helps!
 

TForan

Active Member
#9
It seems that if a manufacturer knows that it shipped a poorly designed or defective gear, it should provide the steel replacement at no cost to the consumer.
 

TForan

Active Member
#11
Which won't be much help if I'm 5 miles away from my house . If it is a weak part, I would think that after paying $3500 for a bike, the part would be sent to all early adopters.
 

roshan

Active Member
#12
We can ship you one if you want. The reason we don't ship to everyone is because 75% of owners won't have any issue and are probably not handy that it'll just scare them to see this gear. Just shoot me an email.
 
#17
There are no bbshd motors made by bafang with steel gears. The nylon gears on bbshd has had no failure issues. We've had exactly 0 failures in over a few thousand motors.
I had 3 HD motors develped loud noise problems after 500 and 600 miles using it for trail riding. nylon gears looked ok but hard to see wear. steel helical gears had visible wear. it could also be worn bearings but its difficult to remove.
Anyone seen this issue?
 

Trail Cruiser

Well-Known Member
#18
These motors are rated at 1,000 watts max. These are actually overbuilt for the rated power, so much so that people "hot rod" it by over volting and massively increasing the amps, producing 3-5 times the original manufacturer's intended output. And then they start complaining that the nylon gear is not up to the job?

The nylon gear has many purpose besides serving as the weak link. It has sound deadening property, vibration damper, sacrificial wear part, among other things.

Consider yourself lucky if your nylon gear broke, if you were using a steel gear, other non-repairable parts could have broken instead.
 
Last edited:
#19
I had 3 HD motors develped loud noise problems after 500 and 600 miles using it for trail riding. nylon gears looked ok but hard to see wear. steel helical gears had visible wear. it could also be worn bearings but its difficult to remove.
Anyone seen this issue?
Grease, Bafang does a marginal job.
 
#20
These motors are rated at 1,000 watts max. These are actually overbuilt for the rated power, so much so that people over volt it and massively increase the amps providing to 3-5 thousand watts. And then they start complaining that the nylon gear is not up to the job?

The nylon gear has many purpose besides serving as the weak link. It has sound deadening quality, vibration damper, sacrificial wear part, among other things.

Consider yourself lucky if your nylon gear broke, if you were using a steel gear, other non-repairable parts could have broken instead.
I think 1500 is an OK level. But some of us tone the amps down a bit for longevity. Want a reliable fast mid drive? Think Lightening Rods. We sell dozens of parts orders daily, and few if any nylon gears. I’ve had spares for every one of my 6 BBSxx motors. 01, 02, and HD’s. They are all still in my parts box. One article by an abusive user has spread a false urban legend.