Rob,
To break the solid rear pin, you could be bending the pin on the hole in the axle when you tighten the wheel on.
Check that you don't have much play between the pin and the dished washer. I shim mine out with either a 0.1mm or 0.2mm spacer between the axle and the inner bearing..
As for gearing
My 6.5T SP was on 24/87 @ Worksop, I run my 5.5T on 23/87 at Worksop... But now I have 50c batts, I think 6.5 or 7.5T will be enough in there.
LRP/Nosram stuff does get hotter than most, it's the nature of their motors...
__________________
5 Time Oople Invernational SC Champion.
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