RANS Fusion E-Bike Build

Starts with a used 2007 RANS Fusion

RANS FUSION Standard Bicycle Specs

Wheels JetSet 26 559 36h w/disk hubs (but rim brakes)
 

The Custom build will need the following parts:

Sram X5 Trigger shifter 9sp 1-1 activation ratio to replace the grip shifter.
The grip shifters will be removed from the standard build and the rear shifter will be replaced with a trigger shifter. This will make for a more uniform look to the handlebar and will require new grips.
Amazon

Rock Brothers
The Pedals and bar grips will be replaced with the Rock Bros product that has been used on previous conversions. 

Front Wire & Tool Bag
The Front mount Tool bag is great for tools and to place excess wiring. 

Bafang Motor 

BBS02 mid drive motor 750w
Male xt60 to Anderson connector
crank arms
throttle

Brake Cutoffs: mechanical brakes

Display Upgrade: P850c

Chainring: 46t

Lekkie one nut
This is the best way to secure the motor to the bottom Bracket shell. 

Cloud Nine Saddle
After a few miles on the Standard Bike with the Standard 'saddle', I know I needed to do something different.  I did not like the standard 'saddle' and it did NOT look good on the bicycle. It looked weird.

The Saddle configuration is different on the Crank Forward Bicycles. RANS has a specific Seat Tube & Seat Tube mount that is adjustable of angles.  Crank Forward Bicycles sitting position is much more upright. Having a wider more cushioned saddle is desired.  The Cloud nine is a recommended seat for this bicycle.  I'm having a little issue with not using a Brooks Saddle, but it would take some modification on a Brooks Saddle & the Rans Mounting bracket if I wanted to go that route. 

So for now, It will be the Cloud Nine Saddle.  

Cloud 9 Saddle

Mounting Bracket of Saddle

All of the new parts have arrived and the process of the E-Bike conversion has begun.

All of the parts that will be replaced have been removed with no surprises.

Grips

Brake Levers

Front Gear shifter

Rear Gear Shifter

Front Derailer (with the mid drive motor, there is no need for a triple front chain rings)

Pedals 

Crank Arms

Bottom Bracket 

The bicycle then was cleaned of any dirt and grease.  The Frame was in perfect condition.

A mock up install of the new part was done to check for motor/chain line alignment, cable routing options for speed sensor, gear shift sensor, wire harness route, display mounting, Electronic controller, Sram 9 speed shifter, new brake levels & throttle, male xt60 to Anderson connection extension to match motor to the batteries that I use on all of my E-Bike builds. 

It is super important to NOT have wiring or cable wires be pitched. The main wire from the motor to the wiring harness will run between the motor and the bottom bracket frame for a clean installation and to keep cable from snagging.  The rear shifter cable runs under the bottom bracket frame as well. So it is important to NOT let the motor press against the cable or wiring.  The Shift Cable stops keep the motor from twisting too high on the frame.  A quick pre install of the motor into the bottom bracket confirms that the shifting cable worked smoothly and the motor wire moved freely between the motor and the bottom bracket. 

Next Step 

Test the motor and display to see if it would turn on. I connected all of the components, then connected the 48 10aph battery to the system.  I turned on the display and NOTHING.  

FAILURE.

Trouble Shooting

unplugged and re-plugged all connection.  - nothing
used a different battery - nothing
used the batteries on a other e-bike - yes the batteries work
plug the new display into another E-Bike - Yes, the display works fine. 
I was not able to test the "male xt60 to Anderson connection extension" maybe it is faulty, although it is new. I called the seller and they suggested sending everything back for them to troubleshoot and resolve the issue. It could be a faulty motor controller, or a component.  
I did not test the Speed sensor extension. It might be possible that could be a faulty unit, although new. 
BUT it could be a 'user error' .
We will soon find out!  


RESOLVED !

All of the E-Bike parts were shipped back to the Seller (JohnnyNerdOut).  That was a very good experience in dealing with this company.  
They found the issue, and it was a faulty pin on the wiring harness. They packed up everything and included a new wiring harness and in a few days, everything arrived!   

This time my bench test was a success! 
I was able to install everything in couple of hours.  

Let the Ride testing begin !