Motor cutting out, thoughts?

[saneagle]

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[sjpt]

The terminology is confusing. Many people (including me when I first started looking at ebikes) quite reasonably thing the display is the controller, as it's what you use to control the electrics.

However, it's not. What is called the controller does the work of feeding battery electricity to motor in the appropriate way. This can be quite a complex task. Many motors work in three phases; three fat wires to provide power to the appropriate motor windings, and three thin sensor wires used for the motor to inform the controller of the exact position of the motor. If the controller is not correctly programmed, or any of those wires has a bad connection you may well see the motor burst into life and then stop. The controller is also connected to the display to allow the user to control the behaviour of the controller.

Controllers are often placed at the end of the battery or battery holder, sometimes within the motor, and sometimes in a box of its own.

Answer Saneagle's questions and he will be able to narrow down the possible issues.

 

[Nealh]

Could well be the usual suspect of the motor connector not fully pushed home .
Hence not full contact is being made.
If the motor works even intnittently then there is nothing wrong with it and th fault lies else where.

Controller is the metal box which the battey, motor and all else is connected to.
Handle bar ldisplay is just that, it can be led or lcd model.

 

[Nealh]

Reading above one also has had a faulty pedal sensor as well , one should replace the damaged magnet disc .
The disc it self needs to be 100% secure on the axle and one should not be able to rotate it around it's axis , it should only rotate when the pedals cranks are rotated .
If the disc isn't secure then it needs to be looked at.
Whilst at it make sure the sensor unit is also 100% firm and secure , the gap should be 1mm between sensor head and disc magnets.

 

[volt x]

Reading above one also has had a faulty pedal sensor as well , one should replace the damaged magnet disc .
The disc it self needs to be 100% secure on the axle and one should not be able to rotate it around it's axis , it should only rotate when the pedals cranks are rotated .
If the disc isn't secure then it needs to be looked at.
Whilst at it make sure the sensor unit is also 100% firm and secure , the gap should be 1mm between sensor head and disc magnets.

I hear what you're saying but watching a technician on You tube saying the disc can move away from the sensor and like you say it needs to be very close to the sensor. I have moved it closer to the sensor and in doing so. I can't find anyway to secure it to the axle. It turns with the axle without problem.

As I have mentioned the throttle that operates the motor when walking the bike is intermittent. The peddles are not turning when this is operating so that eliminates the disc , I imagine. The mysterious controller is probably the issue here. I will take it out and post a photo. I couldn't find any loose wires yesterday but who knows now that I know what the actual controller is. I might find something.

 

[volt x]

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I had the controller out yesterday but I didn't know that's what it was. It was the first time I ever looked at it and couldn't see anything amiss. Now I'll say it again if you actually want to help. Why not as others have on here suggest where I might find the controller. That would be the easier route.

 

[volt x]

Here's some photos. The red and brown connection doesn't fit into anything I can find, so I'm assuming they are for a different device.

 

[saneagle]

I had the controller out yesterday but I didn't know that's what it was. It was the first time I ever looked at it and couldn't see anything amiss. Now I'll say it again if you actually want to help. Why not as others have on here suggest where I might find the controller. That would be the easier route.

I would have been able to tell you where the controller was and what to do with it if you had answered my question about which version of the bike you have and provided the photo I asked for. Instead, you decided to open the motor after I told you that you wouldn't find any answers there.Now you're trying to blame me for you not getting a solution to your problem.

Actually, I meant the version of the bike and a photo of it, not the controller. I accept that I didnmake that clear enough.

 

[volt x]

I would have been able to tell you where the controller was and what to do with it if you had answered my question about which version of the bike you have and provided the photo I asked for. Instead, you decided to open the motor after I told you that you wouldn't find any answers there.Now you're trying to blame me for you not getting a solution to your problem.

Actually, I meant the version of the bike and a photo of it, not the controller. I accept that I didnmake that clear enough.

Yesterday I was going to visit my brother in hospital as 3 weeks ago the police knocked on my door to tell me he was involved in a very serious RTC. They said they could bring me to the hospital. I said I have a problem walking and I would prefer to cycle out. Telling them I have not used public transport since 2019. They persuaded to go with them.

I left the hospital and got on a bus from Hackney to Islington. It took me longer to walk home from the bus stop than the bus ride. My condition is mad, lastweek when visiting the hospital, I struggled onto the ward and smiled at my brother and his mate. Eventually my brother wanted to go outside using his wheel chair, his mate pushed it and struggled to keep up. When I did catch up I decided to push the chair and I'm walking like a parent using the child's buggy. If you know what I mean it's somewhat faster than you'd expect. Hence why I say my condition is mad. FND. Now the last thing I need is a hard time. I joined this thread saying I have a similar issue to the original poster. I probably didn't mention we have the same bike, my bad .

All I know is I've got a lot of do da going on. My brother lost the best part of his right leg, he was two minutes from dying but for the police being close when the call went out. They saved his life. My pathetic issue is my bike is my mobility scooter, but that's not working and I know little about parts.

Now I don't know why you think I'm blaming you for anything. I'm saying all you had to say was if you don't know what the controller is. You'll usually find it near the battery. In my case it's underneath it. The thing is none of us know what going on with people online looking for help on forums such as this. For me my head is all over the place and all I needed was someone to do the thinking for me. I'm going to try my bike and get out to see my brother. I would have opened up the hub no matter what. I googled it and there's loads of people doing it.

 

[saneagle]

Now the last thing I need is a hard time. I joined this thread saying I have a similar issue to the original poster. I probably didn't mention we have the same bike, my bad .

I don't want to give you a hard time, so I'll let the others sort you out. Sorry for interfering.

 

[Nealh]

Volt X one needs to listen and give answers to those who are trying to help you find the fault, we are trying to fault find by experience but it is far easier if we had the bike in fron tof us to (but we don't). So one needs to carry out the the suggestions the site users are trying to help you with.
The fault finding is a process of illimination so the fault could be anywhere , each time we suggest something one needs to carry it out and confirm it has been done otherwise we are wasting our time .

Saneagle is revered as being most likely as one of the foremost fault finders of ebikes in the UK and worldwide , his experience is wide and far and covers more bikes then any of us have knowledge of. He is like Yoda or O.B One on the ebike scene.

Going back to one of my queries in #23, there should be a moulded motor connector approx. 8" - 10" from the hub motor axle . As the hub has been removed and opened make sure this connection has been fully pushed home (best to take a pic of this so we can see it , it only needs to be 1 or 2 mm short of the line and can cauase the issue of a hub not working correctly.

 

[Nealh]

The magnet disc will move if it has lost it's grip, the disc has small plastic splines that grip the axle. Over time these can stop gripping the axle and cause the disc to move, one has to either replace the disc for a new one where the splines should be able to grip the axle better or alternatively one can try a little bodge trick.
To do this one will need to remove the chain ring/crank arm, once done apply a turn or two of electrical tape or amalgam tape to the axle then carefully push the disc on to said tape (this should give the splines something extyra to grip on and keep it in place ). The disc spacing is quite critical for the sensor to see a regular signal form the magnets so it needs to be quite close at about 1mm.

 

[thelarkbox]

+1

You beat me to it @Nealh ..

In the 2 yrs ive been lurking in here saneagle has helped 100's of ebikes get back on the rd. if he appears terse or short its simply the result of typing the same thing 100's if not 1000's of time..

 

[lenny]

The thing is none of us know what going on with people online looking for help on forums such as this. For me my head is all over the place and all I needed was someone to do the thinking for me.

 

[Nealh]

I can understand it when we give some posters short thrift as often they don't listen or carry out some simple test that are asked of them.
Once we know a few simple facts and get answers then things can move forward as the answers often are a big help to us in irradicating a fault.

 

[volt x]

I don't want to give you a hard time, so I'll let the others sort you out. Sorry for interfering.

No No wires have been crossed assumptions made and oops all hell brakes out. I appreciate your offer of help and would gladly accept any you have to offer. The way things are going in my private life are not helping me to take note of what's been said or offered. I did use my bike today ( Volt Pulse X ) same as the original posters, just a different name.

On the way to visit my brother the closer I got the better the bike moved. When going home it was almost trouble free. The baring in the hub might be an issue. That has been replaced some time ago. The axle is solid but if I shake the bike holding the handle bars. It doesn't feel right and there's terrible crunching sounds coming from the hub.

Anyway sorry things went awry and I wish you the best.

 

[volt x]

The magnet disc will move if it has lost it's grip, the disc has small plastic splines that grip the axle. Over time these can stop gripping the axle and cause the disc to move, one has to either replace the disc for a new one where the splines should be able to grip the axle better or alternatively one can try a little bodge trick.
To do this one will need to remove the chain ring/crank arm, once done apply a turn or two of electrical tape or amalgam tape to the axle then carefully push the disc on to said tape (this should give the splines something extyra to grip on and keep it in place ). The disc spacing is quite critical for the sensor to see a regular signal form the magnets so it needs to be quite close at about 1mm.

I've just had the crank off and removed the disc. The splines are in good condition and the disc, though I can hold to stop it rotating. It is as rigid as I think it could ever be. Watching some You Tube videos some sit on the square part of the axle. Mine doesn't and it sits on the round part. BTW recommendations on some of these videos suggest a 3mm to 6 mm cap between the sensor and disc. I've set mine at 3 mm. As it is I don't think this is my issue. Yesterday the bike rode almost without motor cut out. It might be the controller needs replacing .

The mileage is showing 0751 , I'm assuming once it reaches 9999, it reverts to 0000. Which would mean 10751 is my actual mileage. Could it be the motor is nearing it's end of life, there are some awful sounds coming from it. Thinking about the disc wouldn't it have to stop rotating with the axle to cause a problem. That could happen if dirt or something got caught between the sensor and disc. Either way I'm looking to buy a new disc but it would seem the size I need is 75mm and is not as easy to find in the UK. I know I could get a 65mm with a new sensor but the wiring will be different.

 

[jamesporritt]

I did use my bike today ( Volt Pulse X ) same as the original posters, just a different name.

How do you know it's the same bike with a different name?

 

[Nealh]

3 - 6mm doesn't give a strong signal strength , it any at all.

 

[thelarkbox]

Visit www.ebikes.ca ->Learning->Troubleshooting for a mosfet test walkthrough to test your controller, meanwhile minimise the magnet ring-sensor gap.