Wet Torq! Help Wanted!

[Cyclezee]

Went out for a ride late this morning, conditions very wet, lots of spray coming off the tyres, but not raining.
After just under 10 miles the red led came on at the handlebar box and I had no power. Switching the controller of and on again after a couple of minutes, I got 6 flashes indicating the battery was flat.
When I got home I put the battery on to charge, it was fully charged, 41.5v after only 2 hours indicating that the battery hadn't been flat.
Switched on again, but the handlebar led remained red.
Then I thought it must be water in the wiring connectors. I removed the cover from the cable connections to the motor on the front forks, so I pulled the connectors apart, dryed them thoroughly, reconected and tried again, no joy.
Next I turned the bike over to check the connections under the bottom bracket. The one plug connector which is, surprising not heat shrinked was very wet, I disconnected it and blew away as much of the water as I could, then tried again. This time no lights at all, on the handle bars or the controller.
My thinking is that I need to take apart all possible connections, allow them to air dry and test again. Then if all is well, thoroughly waterproof all connections with self amalgamating tape.
One major concern is that as the controller led is not lighting up,water has got into it and I will have to replace it.
Expert opinion required please!

J hn

 

[flecc]

Probably only water in the controller John, and a thorough drying out usually returns everything to working. I've experienced this myself, and turning the bike over makes things a bit worse since the keyswitch cable acts as a conduit to channel more water in.

Dry upright in a warm room if possible, and best of all if you can run a small fan heater directed at that area and a dehumidifier running as well as this speeds up the process to within one hour usually.
.

 

[Cyclezee]

Thanks Flecc for you speedy response,
Bit of an update, I didn't notice this at first, but ther are 2 plug connectors under the bottom bracket coming out of the controller, neither heat shrinked. I take your point about leaving the bike sitting the right way up to allow water to drain should it have got into the controller.
With all plugs disconnected, I have 5 lights flashing on the controller, which could be expected.
For some inexplicable reason my wife won't let me bring the bike into the house!
In the meantime, as you suggest, I have a fan heater blowing warm air at it from about a metre away.
Tomorrow I will get some contact cleaner from Maplins and use it on all connections before putting them back, then test. If all is OK, I will seal everything with self amalgamating tape, apart from the the ones in the connection box on the front forks. For those I will use heatshrink so it is not too difficult to take apart should I need to take the front wheel out.

Your Torq Talk torq is a really useful source of information.

J hn

 

[JamesC]

Went out for a ride late this morning, conditions very wet, lots of spray coming off the tyres, but not raining.
After just under 10 miles the red led came on at the handlebar box and I had no power. Switching the controller of and on again after a couple of minutes, I got 6 flashes indicating the battery was flat.
When I got home I put the battery on to charge, it was fully charged, 41.5v after only 2 hours indicating that the battery hadn't been flat.
Switched on again, but the handlebar led remained red.
Then I thought it must be water in the wiring connectors. I removed the cover from the cable connections to the motor on the front forks, so I pulled the connectors apart, dryed them thoroughly, reconected and tried again, no joy.
Next I turned the bike over to check the connections under the bottom bracket. The one plug connector which is, surprising not heat shrinked was very wet, I disconnected it and blew away as much of the water as I could, then tried again. This time no lights at all, on the handle bars or the controller.
My thinking is that I need to take apart all possible connections, allow them to air dry and test again. Then if all is well, thoroughly waterproof all connections with self amalgamating tape.
One major concern is that as the controller led is not lighting up,water has got into it and I will have to replace it.
Expert opinion required please!

J hn

Does your new Torq have on the handlebars the battery meter with green/yellow/red and the switch on the side for pedelec mode ?

The only trouble that I have had on the Torq 1 with rain has been the damp getting into this battery meter. The rubber grommet does not properly seal the wire entry point, and well worth further sealing with the amalgamating tape after drying out the box.

Needs a very fine Phillips screwdriver to open the unit for a "blowdry".

James

 

[poppy]

Went out for a ride late this morning, conditions very wet, lots of spray coming off the tyres, but not raining.
After just under 10 miles the red led came on at the handlebar box and I had no power. Switching the controller of and on again after a couple of minutes, I got 6 flashes indicating the battery was flat.
When I got home I put the battery on to charge, it was fully charged, 41.5v after only 2 hours indicating that the battery hadn't been flat.
Switched on again, but the handlebar led remained red.
Then I thought it must be water in the wiring connectors. I removed the cover from the cable connections to the motor on the front forks, so I pulled the connectors apart, dryed them thoroughly, reconected and tried again, no joy.
Next I turned the bike over to check the connections under the bottom bracket. The one plug connector which is, surprising not heat shrinked was very wet, I disconnected it and blew away as much of the water as I could, then tried again. This time no lights at all, on the handle bars or the controller.
My thinking is that I need to take apart all possible connections, allow them to air dry and test again. Then if all is well, thoroughly waterproof all connections with self amalgamating tape.
One major concern is that as the controller led is not lighting up,water has got into it and I will have to replace it.
Expert opinion required please!

J hn

What byke were you riding and what distamce did you make?

 

[flecc]

there are 2 plug connectors under the bottom bracket coming out of the controller, neither heat shrinked.

I'm surprised at that, they normally have heatshrink sleeves on them with ends tiewrapped.

For some inexplicable reason my wife won't let me bring the bike into the house!

If the wife can't stand the presence of the bike, perhaps you could pop her outside while you have the bike indoors.
.

 

[Cyclezee]

Does your new Torq have on the handlebars the battery meter with green/yellow/red and the switch on the side for pedelec mode ?

The only trouble that I have had on the Torq 1 with rain has been the damp getting into this battery meter. The rubber grommet does not properly seal the wire entry point, and well worth further sealing with the amalgamating tape after drying out the box.

Needs a very fine Phillips screwdriver to open the unit for a "blowdry".

James

James,

I had this problem with a previous Torq, so I had already waterproofed the switch with silicone around the joints, apart from the little drain hole on the underside, I also gave it light squirt of WD40 for luck.

J hn

 

[Cyclezee]

I'm surprised at that, they normally have heatshrink sleeves on them with ends tiewrapped.
If the wife can't stand the presence of the bike, perhaps you could pop her outside while you have the bike indoors.
.

I was also rather surprised not to find heatshrink. I think I will use self amalgamating tape on those rather than heatshrink as I hopefully won't need to take them apart again.

As for her indoors, how unreasonable can women be Even mentioning your name didn't cut any ice, can you belive it, dissing the Guru

J hn

P.S. Riding the 4 miles home without power wasn't half as bad as I had expected, no noticeable motor drag.

 

[Cyclezee]

What byke were you riding and what distamce did you make?

Poppy,

I was riding an Ezee Torq Trekking and travelled just under 10 miles in wet conditions.

J hn

 

[MR E]

John

Had similar problem recently on my Torq--- see my post on "Dead Torq" dated about a month ago.

Mine turned out to be a high resistance connection between battery and controller , in the wiring under the bottom bracket , but did not materialise during any wet conditions.

The controller led changing from either flashing 6 times to indicate flat battery or not lighting up at all.

Hopefully it may just be this and not the controller.

All I did was to reconnect the connectors , wrap in self amal tape and using new cable ties , --sorted

 

[HarryB]

I think the problems with water getting into the battery meter box is a red herring. I was always having problems with the meter - for example all three leds lighting simultaneously and the controller showing brake switch failure (I didn't have any brake switches fitted). I waterproofed the box but still the problem persisted. Eventually it turned out to be the connection from the meter box to the controller under the bike - this really is very exposed and a trap for mud. The mud holds the moisture in and even the heat-shrink won't keep out the damp.

My advice is to check under the bike and keep it all clean - if you have any problems with the meter or the controller flashing errors - undo the heat-shrink, clean the connectors with contact cleaner and re-seal with self amalgamating tape.

 

[Cyclezee]

Harry,
If you read back in the thread, you will see that there was no heatshrink to prevent moisture or dampness. Flecc also suggested it could be water in the controller, so I am drying and cleaning before reconnecting and waterproofing.

J hn

 

[Cyclezee]

David,

Thanks for your advice, that is what I am trying. I will report back later in the week when I have had time to reconnect and waterproof.

J hn

 

[wotwozere]

Hi

I think electric bikes should be waterproof to be a normal form of transport. It is very wet in the winter.

thx

Bob

 

[HarryB]

Harry,
If you read back in the thread, you will see that there was no heatshrink to prevent moisture or dampness. Flecc also suggested it could water in the controller, so I am drying and cleaning before reconnecting and waterproofing.

J hn

I think this is a problem unique to your bike - most will have heatshrink to protect this connector. Perhaps 50 cycles swapped out the controller and didn't put back the heatshrink? However I do think that even the heatshrink fails to give adequate protection for the connectors under the bike - I also think this connector isn't up to the job (but that is just personal opinion based on it failing on my Torq).

 

[Cyclezee]

Dry Torq

When I got back from work this evening, I cleaned all connections with contact cleaner then reconnected them. The bike is now working again perfectly. Once I new it was OK I wrapped all connectons with self amalgamating tape. Hopefully that will keep the weather out.

J hn

 

[flecc]

When I got back from work this evening, I cleaned all connections with contact cleaner then reconnected them. The bike is now working again perfectly. Once I new it was OK I wrapped all connectons with self amalgamating tape. Hopefully that will keep the weather out.

J hn

That's done the trick on both mine John, so I doubt you'll get any more trouble. Of course the controller box is still a bit vulnerable, but that usually only gets wet when things are extreme.
.

 

[Cyclezee]

That's done the trick on both mine John, so I doubt you'll get any more trouble. Of course the controller box is still a bit vulnerable, but that usually only gets wet when things are extreme.
.

Thanks again for your help and advice Tony

J h

 

[HarryB]

Hi

I think electric bikes should be waterproof to be a normal form of transport. It is very wet in the winter.

thx

Bob

I agree - it has been a major gripe with me over the years. I had to cycle the Torq home unpowered on a few occasions. Once you know the failings you can keeps things moving - and on the Torq they are:

The battery terminals - symptoms are no power even with a green light on the meter - keep the terminals clean and dry.

Connections under the bike - all sorts of symptoms relating to the controller, the meter box - keep it clear of caked mud and replace the heatshrink with self amalgamating tape - you can always replace the the heatshrink on top for originality.

Connections to the motor - symptoms show hall sensor failure - water proof the five pin multiplug as above. Rough running could be one of the three large connectors though this has never happened to me.

In terms of waterproofing the connectors on the Cytronex look like they are in a different league. The ones to the motor and battery are very clever twist to close multipins types. No loss of power so far but only time will tell.

 

[MR E]

Torq electrics protection

As soon as I can get some time and ....daylight , I am going to make up a small plastic cover to go under the bottom bracket to provide a form of mudguard -- probably made out of an old Ice cream tub , with small holes at each side to insert and fix with cable ties.
This should prevent most of the water and dirt getting to these vunerable connectors , without being obtrusive.

Nothing worse than a dead torq.