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Introduzione

What to inspect and do when looking to resolve an electrical problem or take apart a controller to inspect and enhance it as well as fix other minor issues if they exist- what to look for!

I bought this bike for $80 Canadian and have to figure out issues which I believe I did quickly and now I am reassembling the bike (bought it with plastics taken off and controller removed but the person was wrong to consider replacing his good controller when it was only a wire shorting out even though everything looks new i found the shorted wire within 10 mins. These pics are not in sequence and are only a guide to things I do and why.

This will help you fix your bike and keep you going for years without spending a dime sometimes.

I am also posting these pics on the Endless Sphere website and hope to make YouTube videos soon.

You will need simple tools and very little know-how. You’ll just need a bit of patience, and take your time doing research.

This is an ongoing mission, so check back for updates.

I'm only just beginning the project. These pics are from the last few hours.

  1. Note that you should not be wet or barefeet when handling batteries and powered stuff.  Do Notice Swelling & cracks in lead acid batteries these are stone dead and are not revivable as they have 0 volts. Perhaps the Epsom Salts trick as noted on many YouTube videos will get some life from these but are junk to me.
    • Note that you should not be wet or barefeet when handling batteries and powered stuff. Do Notice Swelling & cracks in lead acid batteries these are stone dead and are not revivable as they have 0 volts. Perhaps the Epsom Salts trick as noted on many YouTube videos will get some life from these but are junk to me.

    • Look for corroded and loose connections - Note the wiring diagram of how these four batteries are wired to make 48 volts. For 36 volts simply remove a battery from the connection.

  2. Remove screws, loosen white plastic screw, slide casing end over wires to expose & remove  controller. Look for any signs of water or overheat damages. In pic 3 notice the red wire and on the board next to it are two pieces what appears to be bare wires. They are shunts & can be soldered a bit on ends to add output power. DON'T solder all the way!! Remove screws, loosen white plastic screw, slide casing end over wires to expose & remove  controller. Look for any signs of water or overheat damages. In pic 3 notice the red wire and on the board next to it are two pieces what appears to be bare wires. They are shunts & can be soldered a bit on ends to add output power. DON'T solder all the way!! Remove screws, loosen white plastic screw, slide casing end over wires to expose & remove  controller. Look for any signs of water or overheat damages. In pic 3 notice the red wire and on the board next to it are two pieces what appears to be bare wires. They are shunts & can be soldered a bit on ends to add output power. DON'T solder all the way!!
    • Remove screws, loosen white plastic screw, slide casing end over wires to expose & remove controller. Look for any signs of water or overheat damages. In pic 3 notice the red wire and on the board next to it are two pieces what appears to be bare wires. They are shunts & can be soldered a bit on ends to add output power. DON'T solder all the way!!

  3. Notice the thick lines of solder on the board especially - this helps the power flow without burning out thin lines- this is an impressive controller on a cheap bike so far! Notice the thick lines of solder on the board especially - this helps the power flow without burning out thin lines- this is an impressive controller on a cheap bike so far!
    • Notice the thick lines of solder on the board especially - this helps the power flow without burning out thin lines- this is an impressive controller on a cheap bike so far!

  4. Inspect connectors for melting corrosion & bad or broken wires or connectors- they should look clean like this one, absolutely No issues so far! This computer isn't burnt like the seller suggests and $100. part from factory- No! Cheap ones available!! Inspect connectors for melting corrosion & bad or broken wires or connectors- they should look clean like this one, absolutely No issues so far! This computer isn't burnt like the seller suggests and $100. part from factory- No! Cheap ones available!!
    • Inspect connectors for melting corrosion & bad or broken wires or connectors- they should look clean like this one, absolutely No issues so far! This computer isn't burnt like the seller suggests and $100. part from factory- No! Cheap ones available!!

  5. Inspect controller insides for broken wires and swelled capacitors and frayed wires loose solder points on the board.  2nd pic looks like the board is wet- normally a bad thing I have a new spray that protects it. Get to that later. I can smell burnt parts at times. Sniff around for the stinky electronic smell for clues and brown/black Hot spots! Inspect controller insides for broken wires and swelled capacitors and frayed wires loose solder points on the board.  2nd pic looks like the board is wet- normally a bad thing I have a new spray that protects it. Get to that later. I can smell burnt parts at times. Sniff around for the stinky electronic smell for clues and brown/black Hot spots!
    • Inspect controller insides for broken wires and swelled capacitors and frayed wires loose solder points on the board. 2nd pic looks like the board is wet- normally a bad thing I have a new spray that protects it. Get to that later. I can smell burnt parts at times. Sniff around for the stinky electronic smell for clues and brown/black Hot spots!

  6. Inspect, lube, or replace bearings in center of wheels being careful not to damage wheel when removing or replacing.  There may be a bearing place by you and bearing can be 3 to 5.00  You have to remove bearing so it can be measured.. some bearings can be taken apart and greased but not good unless in good shape prior.
    • Inspect, lube, or replace bearings in center of wheels being careful not to damage wheel when removing or replacing. There may be a bearing place by you and bearing can be 3 to 5.00 You have to remove bearing so it can be measured.. some bearings can be taken apart and greased but not good unless in good shape prior.

Conclusione

To fix electrical issue look at pics and see how things come apart and what to look for.and simple fixes.

Altre 18 persone hanno completato questa guida.

EastCoastCanMan

Membro da: 10/10/2014

629 Reputazione

1 Guida realizzata

Can You help me my problem dos not seem to be covered bike has fully charged battery lights all come up bike take off great 10 minutes into journey it's stops lights go out turn key off then back on it gos again 30 secs later stops again turn key it gos again and so on and so forth the batteru as i said is fully charged but in case the leds were trying to fool me i put it on charge less tjlhan 10 mins fully charged again any ideas( please help) …..keith.starbuck37@gmail .com

keith starbuck - Replica

I ve a 750w rear wheel hub ebike class 2 . sounds to me like your codes are off on yours find out how to default the control screen might have to call the company that sold it .they can give you all the codes my email is steinjason650@yahoo.com i can send you the list ive got.

JASON STEIN -

hi Keith, that behavoiur can be caused by faulty battery cells, if the bikemjerks while powering, think controller , battery cells are breaking down under load.

GewizRepairs - Replica

Can battery's be bought to replace the bad ones and do you sell them with a repair Manuel?

Mark Richardson -

Please pardon if this post is inappropriate, but I’m desperate. MY bike with a Bionx G2 system, that just worked perfectly for me, was stolen. I still have the Bionx G2 Battery (wasn’t on bike when it was stolen), which is strong, and the charger so I'm trying to piece together another system from parts available online. I was able to get a Bionx G2 motor, controller & dock. Couldn't find a G2 (downtube) battery mount but was told that a G1 battery mount would work. I plugged the system together and the controller shows me 4 screens, none of which will let me control the motor normally. I have provided links to pictures of the 4 different screens. Do you have any idea what’s wrong and how I could fix it?

https://electricbikereview.com/forum/att...

https://electricbikereview.com/forum/att...

https://electricbikereview.com/forum/att...

https://electricbikereview.com/forum/att...

baaadmoon - Replica

The engine in my ebike has stopped while I was riding and will not go again. The electrics come on but I don’t get a boost. If anyone can help me, Mathew.hindmarsh@gmail.com

Mathew Hindmarsh - Replica

Did anyone reply to this. I have fhe exact same problem

dmbfannh -

I have same problem but no solution yet

lynneandmacey -

This is an old post but applicable to hel others with same issue. Fault is generally wiring issue and likely things got wet and wires corroded. They could look good but without a tester for voltage and or continuity you can’t do much except wiggle wires and hope to get power. Your issue is a wire, bad throttle connection or connection to the motor. It’s always good to have a cheap spare controller $15.00 eBay. Get the controller for sensors and sensorless and then you have test unit for many bikes. Find controller with 36 & 48 volt.(assuming yours is 36 or 48 volt battery.

you guys with SLA(sealed lead acid) batteries are beating a dead

EastCoastCanMan -

I got a motrac in a lot with some pit bike and dirt bike stuff and it had been wrecked the front rim is bent and some of rye plastics are broken, no big deal, my issue is I had no keys for it so I changed the ignition switch and I can not get it to do anything, it came with a charger so I plugged it in, still nothing, there is a circuit breaker on the side of the bike sticking out from under the seat and when I flip the breaker it makes a quick alarm noise and that’s it, can anybody point me in the direction to fixing it or a place to order parts because I got nothin there either

tom.hillriegel - Replica

Sounds like dead batteries especially SLA have to be constantly charged or they sulfate.

Poor connections that look good especially going to motor or corroded… will power in and then off or not power on. If you short things, out a capacitor in the controller be easy to change for $3.00 DIY in 30 mins but Wiring/connector issues be first priority! A bad or corroded connection will leave you bewildered but an easy, cheap fix!

EastCoastCanMan -

If any of you guys have only 2 wires going into the motor then you should be able to hook the battery directly to those wires. Make sure bike powered wheel is lifted so it doesn’t take off on you. Some motors will run as is and others you still need to turn the throttle.

Most important is where the wires go into the motor, that is an area that if it gets damaged will short out against the shaft where it goes into the motor, you will see a coil or spring wrapped around the wires, sometimes that spring coil shorts out those wires. I usually pull the spring out and add some protection to those wires.

Fully charged doesn’t mean it is above the threshold where the controller shuts it down. You must put a multi meter on it and see what the voltage goes down to eg., for a 36 volt bike it’s low cut off will be around 26-28 volts to protect the battery from getting too low.

EastCoastCanMan - Replica

Many of my repairs were corroded terminals and poor connection, and where the wires go into the shaft on the side of the motor/wheel gets damaged, suspect anything exposed to the elements. IGO bike fuse was good but the connectors in each end of the fuse casing barely touched the metal and when power was drawn it would last a minute then quit!

EastCoastCanMan - Replica

How to fix ,when I start motorbike battery operated the fuse blow up right away?

sogodrcbitor - Replica

This sounds like a issue with where the wires go into the motor, especially if it’s older Hub motor. The wires got chafed and are shorting out at that area or the steel spring is doing thing into the motor wires, or there is a burnt wire somewhere and it’s shorting out the fuse. Some disassembly to get to the controller may be necessary. Unplug things one at a time. Use tape to colour code wires so no confusion. Tell me what led up to this situation. Did you drive in rain or took a big hill, etc.,??? Inspect wires and for burnt connectors as this happens when the connections are weak from the elements of corrosion.

Please give feedback to whatnresolves your issue and more info on bike and battery type.

rjpoirier_nb -

Check the connectors especially going to motor, follow it back from there.

Look at where the wires go directly into motor look for frayed wire as in some motors there is a steel spring wire that goes around the wires to protect them. Sometimes this spring wire cuts into the wires, look for that or a damaged wire at this location.

We need to know more info like the type of motor, type of plug to the motor or how many wires go into the motor.

Do you get any signs of life, eg does the display come on but you get no power to motor, the brake lever could be pushing against the switch inside it and telling the controller that the brake is activated. You may have to find the controller and decipher which wires go to brake levers and disconnect for testing purpose. If you drive eBike in rain all plugs connectors especially lower on the bike would be suspect of corrosion and separation.

please give feedback for what works for you to fix it.

rjpoirier_nb - Replica

I have a golden motor electric kit which recently just shutoff the battery meter reads that it is charged however when I move the throttle the bike doesn’t run could it be a short in the motor and how do I fix this issue?

Pablo - Replica

Pablo, that sounds like a bad connection from the controller to motor, throttle wire or controller itself. Likely controller to motor wires got wet and corroded. Be good to have a VoM to test for voltage and/or continuity on your wires.

EastCoastCanMan -

I have an intermittent problem with acceleration when turning the throttle with a full charge.. The bike works fine while up on the kickstand, but not while riding it. The bike is less than two years old but not used often. What could be the problem?

Donna Christensen - Replica

Hello, i Have a Lectric XP bike and i took a spill on some black ice the other day and now the motor doesnt work or front and rear lights. The little display screen gets power but nothing from the trottle or lights. Any thoughts or help?

Dre NYC - Replica

Dre NYC Check the wires where they go into the motor, its typically on the side of the motorized wheel (assuming your wheel is with motor built in. check that connector and check the wire as it may have been damaged in the spill. Its a common problem but generally an easy fix.

EastCoastCanMan - Replica

Donna Christensen, it sounds like weak batteries or a bad connection. Likely the batteries if it’s lead acid. Consider upgrading to lithium or lifepo4 and can go 12 volts above what you have but not too much wattage or things heat up, like the controller and or motor.

EastCoastCanMan - Replica

Just installed pas on my tandem trike.

A less than complete very slow rotation of the pedals causes the bike to want to run at full speed. Any ideas?

Bob & Kim Stackpoole - Replica

Hello sir i have a problemon my bafang 8fun mid drive motor the battery is new and lcd controler functional but the motor doesnt run..but sometimes it runs but after 300meters it will stop and never run again can you jelp me on my problem..wirings are good motor os not over heated please reply to me at my email ratz000001@gmail.com thankyou soo much

Alfred Lugue - Replica

Hi it's Andrew i have a please mountain bike it power's on the control switch but soon as i twist the throttle or pedal it makes a thump in the moter and won't turn and i turn the wheel it feels like something is rubbing inside thanks so much

a.d.thomas248 - Replica

Sorry for that mistake it's Andrew again the bike is a pedalease just wondering if you have any ideas what to do i have started putting money in to it would be great if you have any experience with those bike s thanks so much

a.d.thomas248 - Replica

same thing just happened to me i noticed a drag = lower power then no power

jhndavid904 - Replica

Hello -

I have a Galvani A2b bicycle that starts with the E16 Error Code - “Torque Offset Under Limit.” I’ve looked online for information I can use to address the problem, but have come up empty. I think it may have to do with the braking, but that seems to work fine. Further, it appears that no local repair shops offer service on this brand and model, as Galvani bicycles are no longer sold. I’d welcome any suggestions from readers as to how I should proceed.

Thanks!

Charlie Morgan

cnlmorg@tds.net

Charlie Morgan - Replica

i had the same problem. go a block then die. bought a brand new battery rode to work and back, charged it, same thing. i have the codes but didnt seem to help. Can I replace the controller?

Steven Nowack - Replica

Good day, Sir.

Hoping you can help with this problem.

The bike is a Stealth, 60 volts.

The machine had no issues other than needing new batteries.

It is stored inside and very well maintained.

The new batteries were installed and attempted to charge.

Here is the problem.

When plugged into the charger, no lights on the charger would illuminate with the key in the off position.

Turn the key on, and the charger lit up, with power to the drive.

Unplugged the charger and the drive stopped.

No power to the drive or accessories. with brand new batteries.

Thanks in advance.

Stephen - Replica

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