Enduro DIY Ebike Build Update: Battery, Motor and More!
August 30, 2025
This Enduro DIY ebike build has officially entered the fun part: the point where the key components show up and the bike starts feeling like a real machine instead of a pile of parts.
I’m aiming for an enduro-style ride that’s tough, quiet, and easy to live with—something I can rip off-road without constantly worrying about vibration, heat, or fragile connectors. This update covers the last big pieces I needed to lock in the direction of the build: battery fitment, controller mounting and wiring, brakes, rolling stock, and the rear hub motor.
Battery Fitment: Making a 72V Pack Live Happily in the Frame
The battery is a Powerful Lithium custom pack originally made for the EBOX 2, and the big win is that it fits inside the Enduro eBike frameset.
What mattered most to me wasn’t the label on the battery—it was how it fits and how it’s protected. A metal frame plus off-road vibration is exactly how you end up with wear points over time, so I lined the inside of the frame with EVA foam (cosplay-style foam from Amazon) as a buffer. I cut it to fit, overlapped it slightly, and left myself a clean path to run cables out through the top.
To keep the pack from shifting, I used three Velcro battery straps. With the foam taking care of the “no metal-on-battery” problem, the straps handle the “no movement” problem. Once it’s snugged down, I still have a bit of extra room in the cavity for add-ons later (lighting, a step-down, etc.).
Controller Setup: FarDriver 72300 + Clean Wiring (No Drama)
I went with the Econic Cycles FarDriver 72300. It’s a popular controller for a reason, but the real story for this build was mounting it.
The frameset has controller mounting holes that appear set up for a different controller pattern, so I had to make my own solution. I drilled new mounting holes into the steel portion of the moto seat mount area. It wasn’t the easiest job (that steel is no joke), but once it was bolted down with nylon nuts, the controller fit looked right and felt secure.
On the wiring side, I wanted a setup that didn’t turn into a splicing project. I used the Econic wiring kit for the FarDriver and added:
A Bluetooth module so I can tune settings from my phone
An ignition switch
A Sur-Ron style throttle
Domino grips
For the display, I’m running the Chaojie touchscreen display. The plug-and-play connectors and splitter make everything cleaner—more like assembly than improvisation.
Cockpit: High-Rise Bar + Direct Stem Mount
I’m using a 31.8mm handlebar with a 90mm rise paired with a direct stem mount with 30mm rise.
This is one of those choices that’s less about looking cool and more about controlling the bike when the terrain gets rough. A taller front end tends to feel more natural standing up off-road, and it gives me a better “attack position” without feeling like I’m folding over the bars.
Braking: Magura MT5 + Sintered Pads for Heat and Bite
Stopping power matters even more once you start building around a 72V system.
I’m going with Magura MT5 hydraulic brakes (four-piston) and pairing them with sintered metal pads. My goal here is consistent braking when things heat up—especially for a heavier, faster build where long descents and repeated hard stops are normal.
I also grabbed carbon fiber spacers for the fork install to take up any extra room at the headset.
Wheels and Tires: 17s, Trials Rubber, and Real Tubes
For the wheel setup, I chose 17-inch KKE Sur-Ron wheels:
Front: 17x2.15
Rear: 17x2.5
Up front, I mounted a 203mm rotor and a Shinko SR241 17 x 2.75 trials tire. I’ve run this tire on my Sur-Ron, and it’s a solid choice when you want something that can handle dirt confidently but doesn’t feel completely useless when you hit mixed terrain. I also used a motorcycle tube plus rim tape/rim strip for protection.
The reason I committed to the Sur-Ron wheel platform was simple: finding the right rim in 17” with the right spoke count for the hub motor plan was way more limiting than I expected. This path gets me the size and strength I want without turning it into a custom rim scavenger hunt.
Drivetrain Choices: Single Speed Simplicity
I’m keeping it straightforward:
44T single chainring
152mm cranks
Single speed chain (116 links, with expectation I’ll end up closer to 112)
Shimano master link
The 152mm crank length is an intentional move. With a lowered enduro stance, long cranks can become a clearance problem fast. I’d rather give up a little leverage than start clipping pedals when the trail gets choppy.
Motor Direction: QS 205 3.5T Direct Drive (Quiet and Confident)
For the rear hub motor, I’m using a QS 205 3.5T.
The appeal here is the direct-drive character: I’m expecting a quiet ride and a smooth, reliable feel. I’m also building with top-end performance in mind, and this winding choice should support that goal.
The plan is to lace the QS 205 into the KKE rear wheel. Both are 36 spoke count, which keeps it within the realm of “doable without weird hacks.” The motor’s hall sensor connector also matches up to the FarDriver harness, so it stays plug-and-play instead of turning into a wiring mod project.
I also added a 26T freewheel for the single-speed chainline.
Wheel lacing is one of those jobs where details matter, so I’m having my buddy Paul handle the motor-to-wheel build. Depending on measurements and clearance, the lacing could be a cross pattern (better for torque loads) or radial if there isn’t enough room to cross spokes cleanly.
What We Like
Battery fitment is surprisingly clean inside the frame, with room to spare
EVA foam + multiple straps feels like the right move for long-term vibration protection
FarDriver 72300 mounting is solid once bolted down, and BT tuning is a huge quality-of-life upgrade
Plug-and-play wiring and display integration keeps the build tidy
Magura MT5 + sintered pads is a confidence choice for a heavier, faster ebike
17” wheel setup with trials tires is a proven off-road direction
Direct-drive QS 205 should deliver the quiet, smooth feel I’m chasing
Things To Consider
Expect to drill (or fabricate) for controller mounting if your frameset holes don’t match your controller
Battery protection isn’t optional off-road; plan foam, straps, and cable routing before final install
Hub motor wheel builds may require new spokes and a lacing plan based on actual measurements
Single-speed simplicity is great, but chainline and clearance need attention during final assembly
Final Thoughts
At this stage, the build finally feels coherent: the battery fits correctly, the controller is mounted securely, the cockpit and braking choices match the way I want to ride, and the wheel/motor plan checks the boxes for strength and reliability.
The next big leap is getting the QS205 laced into the rear wheel and moving from “parts on the bench” to a complete rolling chassis. Once that happens, the real test begins—how it behaves under load, how quiet it is at speed, and whether the setup feels planted the way an enduro-style ebike should.
Links
Enduroebike Garmata Frameset + MX2 Moto Seat: https://www.enduroebike.com/index.php?route=product/product&path=137_125_126&product_id=410
RFLOXA Hawk31 Pro (use promo code RUNPLAYBACK for 5% off): https://www.rflo-xa.com?aff=11
Econic FarDriver BT Dongle (use promo code RUNPLAYBACK5 for a 5% discount): https://econiccycles.com/products/fardriver-sinewave-controller-bluetooth-module
Econic FarDriver Harness (use promo code RUNPLAYBACK5 for a 5% discount): https://econiccycles.com/products/fardriver-sinewave-controller-replacement-wire-harness-small
Econic FarDriver Pre Wire Kit (use promo code RUNPLAYBACK5 for a 5% discount): https://econiccycles.com/products/controller-essentials-key-ignition-w-voltmeter
Econic FarDriver 72300 (use promo code RUNPLAYBACK5 for a 5% discount): https://econiccycles.com/products/fardriver-sinewave-controller-nd72300-w-bluetooth
Eonic Chaojie Display (use promo code RUNPLAYBACK5 for a 5% discount): https://econiccycles.com/products/fardriver-sinewave-controller-chaojie-touchscreen-display-w-optional-3d-mount
Powerful Lithium 72v 30ah Uranus Battery: https://powerfullithium.com/products/72v-uranus-battery-for-ebox-2
Magura MT5 Hydraulic Brakes: https://amzn.to/4oYKQeb
Sintered Metal Brake Pads: https://amzn.to/3JYT9X6
KKE Surron Wheels - 2.15" Front and 2.5" Rear: https://amzn.to/3JHIlMZ
70/100-17 Motorcycle Tube: https://amzn.to/3JFcGvG
Shinko SR241 17" x 2.75" Trials Tire: https://amzn.to/3JHIlMZ
31.8 Handlebar with 90mm Rise: https://amzn.to/4p0F1N4
44T Chainring: https://amzn.to/3UVJMdc
152mm Crankset: https://amzn.to/3JCrR94
Battery Straps: https://amzn.to/4eAbeoa
Direct Stem Mount with 30mm Rise: https://amzn.to/45QMmHT
EVA Foam: https://amzn.to/4n6G7VN
Motorcycle Rim Strip: https://amzn.to/4lNSNjl
Single Speed Bike Chain: https://amzn.to/4fWKH6M
Shimano Master Link: https://amzn.to/4gap6rF
203mm Rotor: https://amzn.to/45TbEnd
26T Freewheel: https://amzn.to/3Voioof
Bell Super 3R MIPS Bike Helmet: https://amzn.to/3TJ1vTR
Fox Racing Bike Gloves: https://amzn.to/40P5SyQ
Fox Racing Hip Bag: https://amzn.to/3xmW4mT
Hafny Handlebar Bike Mirror: https://amzn.to/3FVubmN
Veeape Electric Air Pump: https://amzn.to/3LPLTf9
Denlix Military Sling Bag: https://amzn.to/3LTKN2c
Lamicall Bike Phone Mount: https://amzn.to/3LXmD6O
Onvian Wireless Bike Alarm: https://amzn.to/42KUgyE
RunPlayBack Merch: http://shop.runplayback.com/