Genesis Assault & Battery conversion – Kinaye's 1st high-performance Ebike

We consider the Assault to be the project that spawned the Kinaye brand. The Assault is the origin of our passion (addiction?) with high-performance direct drive hub motor ebikes. It began modestly, with inspiration from Endless-sphere folks such as Farfle, 100Volts+ and evolutiongts. ES member Farfle designed a custom swing-arm which replaced the stock swing arm on the Genesis, adding about 3" to the wheel base and providing for up to 150mm Drop-out width for larger Hub motors. Farfle manufactured about 50 of the swing arms and sold them to ES members, but eventually quit making them.

Some folks chose to install Crystalyte or Cromotor Direct Drive Hub Motors. However, after fledgling Kinaye founders spearheaded the USA group buy for the then – a newly introduced MXUS 3000W DD Hub motor, We naturally chose to use this light-weight and efficient hub motor for our own build. The 3000W MXUS motor paired quite nicely with the Genesis V2100 frame. It is lighter than either the Crystalyte 40XX series or the Cromotor, and can sustain 3000W of power continuously and up to 10KW of power for brief periods. It is also what we consider to be the maximum power for the relatively lightweight and low-cost frame of the Genesis V2100.

The Farfle Swing arm we used for testing was a second-hand unit built by Farfle himself, and later purchased from ES member Icewrench. We originally had intentions of mass-producing the Farfle swing arm (with Farfle's permission of course), but unfortunately were not able to reach the price-point that was affordable when compared to other alternatives in the ebike market. It just turned out to be a non-profitable venture, and one that we feared would not be well-received. The Genesis V2100 is still in production by Kent Manufacturing, sold primarily through Walmart at a very reasonable price, and even without the Farfle Swing arm – it makes a very suitable donor frame for conversion into an Electric Bike.

Of course for ~$150, the Genesis V2100 is by no means a high-end bike. Most of the components are VERY Low-end. Ultimately we replaced nearly every part on the bike, except for the main frame and swing arm assembly. This Included:

  • 2007 Fox Talas RC2 36 Suspension Forks (1 1/8" Straight Tube)
  • FSA "The Pig" Headset
  • Fox Float RP3 Rear Shock
  • Avid BB7 Mechanical Disc Brakes & Rotors
  • 128mm Wide Bottom Bracket & Large "Q-Factor" Cranks to clear the wider swing-arm
  • Custom-Built 17" Motocross Front Wheel with a 20mm Through-Axle DMR convertible Front hub, made by Holmes Hobbies (Who we still purchase our Motocross Rims from)

For the battery housing, we designed and had produced the "Kilowatt Bag" – which is a top-tube saddle bag, designed to mount in front of the rider and draped over the bike's top tube. The Kilowatt-Bag can fit a total of 6 bricks of Hobbyking 6S 16Ah Multistar batteries for a total of 18S-32Ah (2.13 Kilowatt-hours of energy).

As mentioned earlier we used the 3000W MXUS direct drive hub motor, specifically the high-speed (3T) winding, mated it with a 17" Motocross Rim (same size as the front wheel), and installed racing moped tires on both wheels. Great deals can be found on light motorcycle tires at the Treatland website which specializes in moped parts, has an excellent selection, and great pricing on light motorcycle/moped tires and tubes.

The motor is powered by a Xie Chang Programmable controller, often times referred to as an "Infineon"-brand controller. We chose an 18FET version with IRFB4110 MOSFETS, capable of running up to 100V maximum at about 70A tops. These controllers are easy to program; we're able to dial in exact settings and parameters using a special TTL cable and member-supported open-source software available on Endless-sphere.

On Race Day, this build with the 18FET x 4110 controller – we have ran as high as 99V, 100A (battery) and 180A phase current for brief moments. Click here to see the fastest drag run we made on this set-up. For commuting and street riding, the bike is configured as 18S LiPo (75V nom.) with battery current adjusted down to 50A. This provides a very smooth and comfortable ride while still allowing top speeds of nearly 50 MPH. Even then it is very unlikely to overheat the motor after long rides.

The Cycle Analyst V2.3 was chosen for the handlebar display because it provides good electrical information, can be readily adjusted to further limit the battery amps, and alter the low-volt cut-off point if you want to conserve power for longer rides. It does this by overriding the throttle signal to the controller, limiting the bike's power consumption when certain speed or current limits are reached. It also provides a very detailed battery gauge (Voltmeter) so you know the charge state of my battery at every moment, and is vastly superior to the bar meters and 3 color LED battery gauges usually found on cheap motor kits.

To conclude, the Assault represents the roots from which Kinaye has grown: It is a modest project with impressive performance. With the exception of the Farfle Swing Arm, this project is still a straight forward and relatively inexpensive project for the DIY ebike builder, although with the currently available Vector Frames we now sell, we don't anticipate the Genesis V2100 Frame will be as popular as it once was for high-performance Ebike conversions.