D
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I stuck a replacement motor in a Kakhoff today because the old one was knackered, which, as you know, is a common fault on the Impulse motors. The procedure is very straight-forward. Anybody should be able to do it. the only tools you need are a normal bike crank extractor, a large pair of circlip pliers, an allen key set and a basic socket set.
Most people love their Kalkhoffs, but they have this nasty problem of motors that break. If you bought your bike from a proper Kalkhoff dealer, there is supposed to be some sort of system for dealing with it, but it seems some people are shirking their responsibilities. If you bought your bike from anywhere else, you're stuffed; however, all is not lost. If you have basic spanner-wielding skills, it's not really a significant problem except the cost. You have to send the old motor to Germany and pay for the replacement. The total bill would be about £400. It's guaranteed for two years, so you know that you'll get 2 years biking at £200 per year. That's a lot less than the depreciation on a new replacement bike, so I think it's definitely worth doing. Even if they break every 6 months, you could probably replace them in less than hour after you've done it once. Some people spend more time than that cleaning their bikes. I guess you'd still have the postage cost though.
Procedure:
Remove both cranks (one nut on each);
Remove the chain-guard (one screw);
Remove the battery base (2 screws and a clip at the front);
Wind the chain off the chainwheel;
Remove the chainwheel circlip;
Remove the chainwheel;
Disconnect three connectors;
Remove the three motor bolts;
Thread the battery connector through the hole in the frame and remove the motor;
Send the motor to Germany;
Installation is the exact reverse. It's a bit fiddly to get the gear cable out of the way. It runs over the motor, but tries to jam in the side when you push the motor in place. The new motor comes with the battery connector. You have to remove one wire (spade connector) to get it through, then clip the wire back on. The motor comes configured with the correct software, so it's plug and play. There was one connector on the new motor that's not used. It had a blanking plug in it. I can't remember if that was on the original.
This is where the replacement motor came from. It was brand new:
http://www.pro-cycling-golla.de/Motor_und_Zubehoer/Motor_Tausch_ausserhalb_der_Garantie_und_Gewaehrleistung_artikel580515b352f96.html
Most people love their Kalkhoffs, but they have this nasty problem of motors that break. If you bought your bike from a proper Kalkhoff dealer, there is supposed to be some sort of system for dealing with it, but it seems some people are shirking their responsibilities. If you bought your bike from anywhere else, you're stuffed; however, all is not lost. If you have basic spanner-wielding skills, it's not really a significant problem except the cost. You have to send the old motor to Germany and pay for the replacement. The total bill would be about £400. It's guaranteed for two years, so you know that you'll get 2 years biking at £200 per year. That's a lot less than the depreciation on a new replacement bike, so I think it's definitely worth doing. Even if they break every 6 months, you could probably replace them in less than hour after you've done it once. Some people spend more time than that cleaning their bikes. I guess you'd still have the postage cost though.
Procedure:
Remove both cranks (one nut on each);
Remove the chain-guard (one screw);
Remove the battery base (2 screws and a clip at the front);
Wind the chain off the chainwheel;
Remove the chainwheel circlip;
Remove the chainwheel;
Disconnect three connectors;
Remove the three motor bolts;
Thread the battery connector through the hole in the frame and remove the motor;
Send the motor to Germany;
Installation is the exact reverse. It's a bit fiddly to get the gear cable out of the way. It runs over the motor, but tries to jam in the side when you push the motor in place. The new motor comes with the battery connector. You have to remove one wire (spade connector) to get it through, then clip the wire back on. The motor comes configured with the correct software, so it's plug and play. There was one connector on the new motor that's not used. It had a blanking plug in it. I can't remember if that was on the original.
This is where the replacement motor came from. It was brand new:
http://www.pro-cycling-golla.de/Motor_und_Zubehoer/Motor_Tausch_ausserhalb_der_Garantie_und_Gewaehrleistung_artikel580515b352f96.html
