408/4012 Crystalyte Hub Motor Kit
$500aud and $110aud for freight = $610aud

The kit includes everything you need excepting the batteries, if its your first ebike I suggest you start with 12ahr size sealed lead acid batteries as found in jump starter battery packs (see this link  ).

Components     1 x Dual speed 408/4012 hub motor laced into a 20" or 26" rim. (tyre and tube not inc)     6 speed cluster   1 x Dual speed 20 Amp PWM controller     1 x Twist grip throttle   1 x set of auto motor cut-off brake handles   High amp on/off key switch     20amp fuse holder

Specifications   System Voltage: Std : 36-72 Volts Torque:   Refer Torque graph Speed: 27 km/h@36v - 36km/hr@48v in a 26" rim  on level ground.   Range: Depends on the size and type of batteries, terrain, and the amount of pedal assist To suit rim sizes:   16", 20", 24", & 26"  (Laced only available in 20" & 26" ) Features: Dual windings for good Speed and Torque on hills. Warranty:   12 month warranty Enquiries Click here

The Crystalyte 408/4012 36-72volt 20A controller

The controller can run on 36 to 72volts and draws up to 20amps.
The controller doesn't need any adjustments to run on either voltage.

Has 408/4012 mode switch that mounts on the handlebars.

 The Crystalyte 408/4012 Motor

The Crystalyte 408/4012is a brushless, gearless hub motor and as standard comes laced into a 20" or  26" wide dual wall aluminium rim with thick spokes (2.6mm diameter) for extra strength with an efficiency of over 80%.

As Crystalyte motors do not have any gears inside them the speed the motor turns is exactly the same speed (rpm) that the outside of the wheel turns. So the top speed you can achieve depends on what size rim you put on the motor, conversely the amount of torque you have also depends on the size of the rim you use (the smaller the rim the lower the top speed and higher the torque).

A novel way to get around this problem partly is to have one motor which has two separate sets of windings in the one motor. One set of windings can be used for high top speed and the other when more torque is required. Although it does prove helpful on medium steepness hills to have a higher torque winding to improve torque up the hill, really  a geared motor is best for steeper hilly areas.

Anyway the Crystalyte dual speed (or dual function) motor has two sets of windings. One is the same as the 408 motor windings the other the same as the 4012 Crystalyte motor, both sets of windings are inside the one motor. A switch on the controller allows you to change which set of windings your using. In reality most people will only use the 408 windings and quite rarely use the 4012 set, but of course it depends a lot on the terrain your going over.

Top Speed in 408 mode is almost the same as a  408 motor alone (you do loose a slight amount of top speed about 10%)

If in a 26" rim running on 36volts the top speed (from my own measurements) is about 27km/hr. If running at 48volts the top speed (from my own measurements) is about 36km/hr. 

If in a 20" rim at 48v it will reach 30km/hr top speed 

In 4012 mode top speeds will be somewhat less but torque will be higher (sorry I dont have the exact speeds as yet).
 

Below are independent torque graphs made of this motor.
Windings used are 408/4012 combination.
Test was done at 48volts and results are calibrated for a 24" rim.





The figures above are for a 24" rim

So for a 20" rim :
high speed windings (408) give 24/20*52 = 62Nm
low speed windings (4012)  give 24/20*70 = 84Nm   
therefore % increase in torque when switching windings = 84/62*100-100= 35%  
 

And for a 26" rim:
408 windings give 24/26*52= 48 Nm
4012 windings give 24/26*70= 65Nm
therefore % increase in torque when switching windings = 65/48*100-100= 35%  

So if my calcs are ok, then there about 1/3 difference in torque between windings on the 408/4012 motor.

What's in the kit:

1. dual speed motor spoked into a strong/wide aluminium rim (I've got thicker spokes on these also, 2.6mm diameter)
2. controller : can run on 36volts up to 72volts, maximum amps is 20amps.
3. throttle: thumb type or twist type
4. high amp key switch for on/off and a 20amp fuse with fuse holder
5. torque bar (this goes on the axle to stop the axle spinning in the bike frame)
6. 6 speed cluster on the motor
7. left and right brake handles with cut off switches

No batteries are included with the kit
. I would suggest using 4 lots of 12ahr size jump starter batteries to begin with. see here for more info.

* Top speed is taken to be the max average speed reached riding on a flat road without pedalling.

Essentially, the bigger the rim, the higher the top speed and the lower the torque.
Conversely, the smaller the rim, the lower the top speed and the higher the torque.

The motors have no internal gearing so they are very quiet but not really the best motor for steep hills (if using a 26" rim ).

If your planning on going up steep hills at slow speed the motor will lack power (unless you can get a good run up and keep the speed up). Its very good for riding on terrain that is flat or with only moderate hills.

INSTALLATION:

Installation:  

Installation is quite straight forward, there are a few things to note:
1. the spokes will be quite loose when you get the kit. Please adjust them to your desired tension before riding. 
2. because the Crystalyte kits are designed to use with a large cluster and still fit into a standard bike frame you will find the wheel will be about 1cm or so off the centreline of the bike. You can 'dish' the wheel to get the wheel in the centre of the bike. (will put up a section on dishing a rim shortly) Your brake pads will need to be adjusted to suit the rim.
3. ensure that you use the torque arms supplied with the kit, these stop the axle turning in the frame. (see link) 

Note: when you receive the motor kit, the spokes will be quite loose, please adjust to the tension you require and if necessary you can dish the spokes to centre the rim (dishing means pulling the rim slightly to one side using the tension in the spokes). Spokes MUST be tightened before riding your bike.

I will put up some more detailed installation instructions on here as time permits. 

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