I have a Tucano Deluxe 36v folding bike on which the standard caged bearings /axle/cup bottom bracket arrangement is giving me trouble.
My wife Pat’s bike (same model) seems to be fine. At least, so far. Here is a recent snapshot of our bikes, taken during a quick rest break whilst on a 30 km wander.
Mainly, my problem is that the whole arrangement tends to work loose and/or the bearings get chewed-up, leading to an unpleasant, noisy, pedalling experience (yes, we do pedal our electric bikes quite a bit).
It doesn’t seem to matter how many times I take the bottom bracket apart and put it back together again, or whether I vary the adjuster/lock nut tensions.
Here is what the bottom bracket axle, cups and bearings look like. The bearings were originally in a cage, but the cage got really badly chewed-up, so I switched to fitting loose ball bearings, which I positioned with suitable gobs of grease whilst carefully reassembling the parts.
Here are the components without the left hand (non drive-side) lock nut.
I purchased a bag of 100 grade 10, 6 mm ball bearings from http://www.simplybearings.com to replace the original chewed-up bearings. The original bearings were in a cage, with 9 on each side/cup. Without the cage, each cup takes 12 ball bearings.
This is what the cage looked like after I took the bottom bracket apart. This was less than a fortnight from receiving the bike as new and under 50 km of use. Suffice it to say that the cage was not caging anything much.
The inside of the bottom bracket frame was littered with metal filings that had broken away from this. The ball bearings were still in place, but badly pitted.
Like I said, there is one cage on each side of the bottom bracket assembly, each with 9 x 6 mm ball bearings.
I have several options to service this.
Firstly, I could just let the supplier sort out the problem. However, my confidence in the whole arrangement is already at a low and I would like to improve on the situation. Also, I enjoy a little mechanical tinkering – treating it as a learning experience for future maintenance. The argument for is of course that the supplier should ultimately be responsible for this fault and should bear some cost for fixing the problem. I will soon let the supplier know of this and a couple of other problems I have found and call them to account. I swear my bike was assembled on Friday afternoon and my wife’s on Monday morning!
Secondly, I could just simply replace the chewed-up caged bearings (9 ball bearings in a flimsy cage) myself. I don’t like this option since the failure of the cage seems to lead to a lot of shrapnel that could end up damaging other parts and it doesn’t seem to take much for it to fail.
Thirdly, I could lose the bearing cages and just fit loose bearings. In this case I would fit 12 x 6 mm ball bearings in each side/cup, since without the bearing cage there is more room. As mentioned earlier, I have some grade 10 ball bearings that I have procured for this purpose. This is quite a tempting option and is probably my fallback.
Finally, I could replace the axle/cup/ball bearing system with a cartridge bottom bracket. Because the bike has a controller box mounted behind the BB and a non-standard (normal bike), wider, BB shell, I am obviously limited in choice and need extra long BB cartridges. However, this is my preferred option.
So far, I have found this: http://www.eclipsebikes.com/153mm-cartridge-bottom-bracket-p-996.html – a 153 mm cartridge unit which I have managed to fit, but there are two problems.
Firstly, the shell is not quite long enough. It could do with being another 5 to 10 mm so that the end retainer does not have to be screwed right inside the BB shell. The Tucano Deluxe bottom bracket width is 83 mm, measured from the left outside of the frame to the right outside of the frame.
You can see this screwed-in too far effect in the picture. Fortunately the frame has a sufficiently deep thread to be able to do it, after a little cleaning up.
Secondly, the axle is not quite right on two counts. It is shorter than the original axle, thus altering the chain line – although to be honest the chain line looks passable to my inexperienced eyes. I rode 10 km with it and it seemed not to give any trouble.
With the alternative cartridge system, the chain sits straight on the 2nd gear cog (out of 6), instead of the 3rd gear cog with the original scheme. The original axle is a whopping 165 mm long excluding the threads on which the crank nuts bolt into, which makes the cartridge solution 12 mm shorter overall.
The second count is that the left/non-drive side of the axle is the longer side (by about 5 mm), rather than the chain/drive side. I am guessing that this BB cartridge was intended for a chain drive on the left side of the bike; and, of course, I cannot reverse the cartridge due to the thread directions – although I have thought about switching the whole drive train from the right side to the left. I haven’t quite wrapped my head around whether this will cause problems with motor direction as well as with other drive components.
However, the 153 mm cartridge arrangement does seem to work and has a smoother, solid feel to it, with very little lateral movement in the cranks. I will probably write-up a follow-up of this issue as time passes, or if I find a better cartridge to fit.
Filed under: eBiking | Tagged: ebike, bottom bracket, tucano, bearings, cartridge, mechanics, maintenance | Leave a Comment »

