Kalkhoff pro connect - new panasonic motor or repair?

[landyguy2]

Went on a run a few weeks ago and at the end of run freewheeling down a hill onto a farm track - on the track it appeared to have list assistance

Meant to look at it but didn't before I needed it the week after when I have had the symptoms of motor noise/whirring when pressure on pedals but no drive assistance
I have also tried another known good battery to see if any difference

 

[Deleted member 4366]

It must be the clutch.

 

[landyguy2]

Did not appear to slip before.
Sometimes had to turn it off and on again to get assistance but sometimes that at bottom of a hill and not turned on early enough
When turning the drive pinion it turns clockwise and turns the motor

Turning anticlickwse it just turns the drive pinion

 

[landyguy2]

Can anything be done with the clutch if it is faulty

 

[flecc]

The clutch is ok then as I thought, this particular type only ever jams and has never slipped to my knowledge.

Check that Hall sensor board behind the motor is in place, it is possible for them to come adrift from the mounting and be slightly out of register.

 

[landyguy2]

Hall sensor seems to be in place on the locating spigots
Any more ideas from anyone

 

[flecc]

If you have a meter, can you check the continuity all round the three motor phase connections. Below is a photo of the old unit motor but yours is similar. Check black to white, white to red and red to black in turn. Your colours may be different, but you are checking for continuity all round the three. There should be virtually no resistance.

 

[landyguy2]

Get between 0.1 to 0.2 ohms

 

[flecc]

That's fine then, as long as there's continuity between all the connnections.

Since you had to turn on and off before to get power, it looks very much like an electrical fault, but the motor noise and the fact the torque sensor is signalling ok seems to indicate the main circuit board is ok.

It could be a dud Hall sensor board. I can send you another one to try if you send me an address to send it too, either by PM or using the email address below. No charge:

ebike@flecc.co.uk

 

[landyguy2]

Have sent a message to you thanks

 

[Deleted member 4366]

If the motor whirrs when you operate the the pedals, it must be a drive-train fault. If it buzzes or stutters, it's an electrical fault. You can normally tell the difference between the sounds of the motor when it's turning and when it's not.

 

[landyguy2]

Definitely whirrs

 

[Deleted member 4366]

I guess you checked all the gears all over for a couple of broken/stripped teeth?

 

[flecc]

There's only the nylon main gear driven from the motor shaft helical teeth. The nylon teeth would have to stripped off across their width, so that should show easily:

 

[landyguy2]

Have inspected the nylon gear an no obvious damage
Turning the nylon wheel turns the motor pinion

 

[Deleted member 4366]

In my simple reckoning, if the motor is rotating but the chain doesn't pull, it has to be one of these:

• The motor pinion is slipping on its shaft
• The nylon teeth must be stripped somewhere
• The clutch is slipping
• The outside sprocket is slipping on its spline
• The chain isn't engaged with the sprocket.

 

[flecc]

The motor gear is the shaft itself cut with helical teeth, so the first isn't possible. The outside sprocket is multi-splined, slippage could occur is the circlip came off but the sprocket would then be driven off the end of the shaft taper and leave the chain hanging. I think landyguy2 would have seen the chain off the motor sprocket if that was it.

But if the motor is turning I agree it would have to be something like the clutch slipping or the nylon teeth stripped. Landyguy2 hand tested for the clutch slip which indicated it was ok so should show at least some signs of drive.

 

[landyguy2]

Yes I would think it was one of those also or was hoping it would be something visual like that
Flex is sending me a hall sensor board to try out

 

[landyguy2]

Flecc even

 

[landyguy2]

How to check if clutch is slipping under load?