Kalkhoff pro connect - new panasonic motor or repair?

[tillson]

What was the solution

If the motor is turning the chain drive sprocket when you apply pressure to the pedals then as flecc suggests, it is very unlikely that you have a mechanical fault with your motor. It sounds very much like the fault which I experienced. This was the motor being stuck in a very low mode of power delivery. This was much lower than the minimum of the three selectable modes which are available. Changing mode on the handlebar selector made no difference to the motor output. Apart from this, all other outward signs were that the motor was functioning properly, just no, or very little assistance.

Unfortunately, due to the sealed nature of these motors, the solution was a replacement unit.

 

[landyguy2]

The motor is turning when I put pressure on the pedal and have the chain of the motor sprocket

 

[landyguy2]

But little or no assistance when pedaling with the chain on but the motor appears to run for a few seconds when the bike is stationary and pedal pressures.
On my view pointing to a slipping clutch under load or the motor in limp mode or something like that caused by electronics

 

[tillson]

It still sounds very similar to my motor fault. If I removed the chain and then put pressure on the pedals, the motor would turn the chain drive sprocket.

When I then put the chain back on and rode the bike, the motor would run but the power delivery was minimal. As you suggest, it's like the motor has entered some sort of limp mode, way below the minimum power setting.

I really don't think that your fault has anything to do with the clutch. The transmission between the motor and the chain drive sprocket sounds as though it is working properly. From what has been discussed, the problem seems to be the motor delivering very low power. I can't advise you how to fix that other than replacing the entire motor unit.

Edit: The only bit I can't explain or understand is why the motor would run when the bike is stationary. Unless it is pulsing and making a running sound but not actually turning due to an electronics fault.

 

[flecc]

They can do that under some phase unbalance circumstances Tillson, sounding like running but stationary.

The clutch will not be slipping partially, allowing some power but not enough. It will either grip or slip completely, and the tests indicate it's gripping. Everything points to electrical failure again, and if so the third 2009 unit to fail in this way. The same thing hasn't happened with 2007 and 2008 units or those since 2009, so maybe there is a batch problem involved.

The old unit suffered a large batch with an electrical problem which left them in Eco mode only when the fault occurred. I got some of those going again using r/h crankcase halves with the sealed-in circuit board, salvaged from units with other faults. Unfortunately there haven't been the new units with other faults to provide such spares, so the repair has to by fitting a new unit.

 

[landyguy2]

I was thinking this would be the outcome but hoping against it.
Just hope somebody has a reasonably priced unit for sale or bite the bullet for a new bike.
Or any offers on a very good bike with faulty motor?

 

[D8ve]

I was thinking this would be the outcome but hoping against it.
Just hope somebody has a reasonably priced unit for sale or bite the bullet for a new bike.
Or any offers on a very good bike with faulty motor?

landy.

I have the complete 36volt setup with 12AH battery but scrap bike.
What bike do you have?
And what price?

 

[landyguy2]

Pro connect with panasonic motor, good all round condition apart from faulty motor.
28 inch wheels and tyres, pannier, lights etc around £250 for the bike as it is or £200 without battery

 

[landyguy2]

Would the 36 volt and battery fit my pro connect with panasonic motor

 

[D8ve]

I'm in Bristol.
I believe the 36 volt stuff is a straight swap.
I am interested in your bike at £200 no need for the battery. You can sell the battery and charger on.

 

[landyguy2]

Ok will think about if I want to sell it or try and find a motor
What would you sell your motor and battery for?

 

[tillson]

I have looked into retro-fitting a 36 volt system to my Pro Connect when the motor failed.

1/ The motor bolt pattern and the casing for the 26 and 36 volt system are both the same. The motor will fit, straight swap.

2/ The 36 volt motor has an external wheel speed sensor, it doesn't detect speed from the motor sprocket as the 26 volt system does.

3/ The 26 and 36 volt battery sockets are different to prevent accidental mix ups.

4/ I don't know if the battery frame locks are the same.

5/ I believe that the handlebar controllers are different. I don't know how you thread the new cable through the frame because the controller wire appears to be sealed into the switch unit and there is a plug on the other end.

It may be a simple job to overcome these points, but I thought I'd let you know the results of my investigation into the 36 volt unit.

 

[D8ve]

I was thinking the 12 amp battery and motor with all bits should be circa £500. But open to offers.

Tillson's research was my guidance in thinking of your gear. An upgrade for you or working bike for me?

 

[landyguy2]

Any pics of all the bits.
I think the battery lick is different as it is on my wife's agattu
Is the battery socket included?
Anyone any info on this type of swamp.
At £500 it would be easier to go for a new motor unit from 50cycles probably.

 

[D8ve]

I have a complete bike with bent headset forks and wheel. All the bits are there including the keys for the lock.
As it's 36volt 12 amps I think it would be a range boost for you.
Price is negotiable. If you came down we could spend some time doing the build and testing the bike before payment?
It's a big bill but seriously good gear. As we both had top bikes. Just different problems.

 

[tillson]

Any pics of all the bits.
I think the battery lick is different as it is on my wife's agattu
Is the battery socket included?
Anyone any info on this type of swamp.
At £500 it would be easier to go for a new motor unit from 50cycles probably.

I've sent you a PM landyguy.