5. Troubleshooting
Problem: Why won’t my bike turn on?
This is the most common problem we encounter and the solution is typically very simple.
Solution:
1.
Check that the battery is fully charged. Use a voltmeter and test the output on the charging terminals
if you do not have an ebike computer. The voltage should be within 10% of your nominal voltage.
For instance, if you have a 5000W system, you should get ~around 86V /- 5v.
a.
If you are having trouble charging the battery, please look below about charging your battery.
2.
Make sure the main connector from the battery output lead is plugged in and secure.
3.
There is a problem with the controller
Check to see if controller light is red on actual controller
a.
If no light is on, you most likely have a bad controller. Most typical problem is the on/off
switch going bad. Send in controller for testing.
b.
If there is a light but the wheel doesn’t spin when the throttle is connected- Then unplug every
wire you see plugged in. This includes 4 pin throttle wire, 6 pin cycle analyst, main XT-90
yellow battery to controller wire, 3 XT150 phase wires in the swingarm and hall sensors in the
swingarm. Check all connections. Ensure all are making contact and plug them all securely
back in. Retry the throttle and see if it works.
Problem: I drove my bike until it went completely dead and now it will not charge.
This is a problem that occurs when you fully deplete the battery. The BMS on the battery protects the
battery from discharging any further and force shuts itself off. First step would be to unplug the battery
from the controller and try to charge. If that does not work, to “wake up” the battery, you must “jump” the
BMS.
Solution:
1.
Unplug the yellow XT-90 connector and pre-charge resistor assembly (if applicable). The pre-
charge resistor is a small 2 pin red and black wire that serves as a bridge to take in the current
from the capacitors inside the controller to absorb any inrush currents and prevent sparks when
plugging in the main XT-90 connector. Once both are unplugged, plug the XT-90 connector from
the battery back into the controller directly. You might get a pop when you do so. After this,
your BMS should awaken and be able to be charged again.
Problem: I cannot get my battery to charge or my charger is not working
Many users do not realize the importance of properly charging your battery. Please look at the
section in the manual about charging your battery. Most common solution is blown fuse in the charger
Solution:
1.
You have a fuse(s) blown in the charger. Remember all chargers have 2 fuses, one located in the
front screw cap and the other located in the rear where the power plug wire goes into.
a.
How to Properly Charge Your Battery
Problem: I am not getting the advertised range
In the electric bike world, many manufactures quote a standard maximum range of 20 watt hours per mile for
an electric system. This is in the BEST CASE SCENARIO in the real world, with little to no pedaling. When
giving our range estimates, we are talking about a 170lb rider, totally flat ground, smooth surface, no wind
and cruising in the most efficient range of the system. For instance, on our 2000w system with 12.5ah
battery, using this calculation we would get 32.3 miles maximum range (51.8v x 12.5ah = 647.5. 647.5 watt-
hours divided by 20 watt hours/mile = 32.3 miles range). Our range estimates are slightly more conservative
