However after playing with the belts it might not be so bad. I looked at the Neumotors gearbox before and the efficiency quoted was quite poor. Smaller cog drive sprockets can be used without slipping or increased wear issues, by positioning the idler in such a way that you get better wrap around on the cog teeth. Also thinner, somewhat under spec belts which have greater flexibility can be used to achieve large reductions in a single stage. Another is that when the belt does break, it is a matter of seconds to thread a replacement. One principle advantage of an idler is that the tension of the belt can be maintained at specs regardless of changes in temp, humidity, wear, etc.
One of my e-scooters back then employed what I considered a very nifty reduction system using an idler pulley with cog belts.
As I recall, an engineer on the list found essentially no difference in efficiency between cog belt and chain for reasonable sprocket sizes if everything is tensioned properly. Rick, if you can access the archives of the power assist list (HPV) way back to the late '90s?, there is some good info there on belt vs.
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