The New Hotness

The Bafang BBS02 came with (because I added it to the order) what looks like a genuine shift (“gear”) sensor made by the original company in the Czech Republic:

Terry Bafang - shift sensor - installed — Terry Bafang – shift sensor – installed

On a typical bike, it mounts against a cable stop with the cable housing holding it in place against its other end:

Tour Easy Bafang BBS02 - shift sensor - installed — Tour Easy Bafang BBS02 – shift sensor – installed

The Terry Symmetry has only two lengths of housing: in front of the adjuster on the downtube and behind the stop brazed to the chainstay. In either position, the sensor would move as the shift cable flexed and (IMO) put unreasonable stress on the electrical cable running to the motor.

Yes, the Tour Easy has those same two lengths of housing, but the forward one joins a sheaf of wires & cables that barely moves.

Fortunately, the sensor fits neatly between stations 1 and 2 along the downtube, with a snippet of PTFE lIned housing holding it firmly in place, with the 3D printed battery mounting blocks including paths for both cables:

Terry - Bafang battery - all stations - solid model — Terry – Bafang battery – all stations – solid model

The shift cable originally ran from the adjuster in the front to the guide under the bottom bracket along a slightly diagonal path I could not possibly match. Instead, the path is now parallel to the downtube from the front adjuster:

Terry Bafang - OEM shift stop — Terry Bafang – OEM shift stop

.. to the rear block, where it angles downward over the motor to the bottom bracket:

Terry Bafang - shift cable clearance — Terry Bafang – shift cable clearance

The front block at station 1 has a Delrin / acetal bushing to align the cable with the rest of the blocks:

Terry shift guide - acetal installed — Terry shift guide – acetal installed

Yes, it’s a round peg jammed in a hexagonal hole:

Terry shift guide - acetal hole — Terry shift guide – acetal hole

Turning it from stock is well within the capabilities of Tiny Lathe™:

Terry shift guide - acetal cutoff — Terry shift guide – acetal cutoff

For great slippery, a similar UHMW PE bushing supports the cable bend at the rear of the station 4 block:

Terry shift guide - UHMWPE installed — Terry shift guide – UHMWPE installed

The Basement Laboratory Warehouse Wing disgorged an overly large rod taxing Tiny Lathe™ to its limit:

Terry shift guide - UHMWPE turning — Terry shift guide – UHMWPE turning

Memo to Self: next time, just saw off a stub and move on.

The New Hotness

Bafang BBS02: Terry Symmetry Shift Sensor & Cable Guides