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How to Repair Electric Bikes

What you need

  1. How to Repair Electric Bikes, How to Repair Electric Bikes: step 1, image 1 of 1
    • Note that you should not be wet or barefeet when handling batteries and powered stuff. Do Notice Swelling & cracks in lead acid batteries these are stone dead and are not revivable as they have 0 volts. Perhaps the Epsom Salts trick as noted on many YouTube videos will get some life from these but are junk to me.

    • Look for corroded and loose connections - Note the wiring diagram of how these four batteries are wired to make 48 volts. For 36 volts simply remove a battery from the connection.

  2. How to Repair Electric Bikes, Inspect controller connections and controller itself.: step 2, image 1 of 3 How to Repair Electric Bikes, Inspect controller connections and controller itself.: step 2, image 2 of 3 How to Repair Electric Bikes, Inspect controller connections and controller itself.: step 2, image 3 of 3
    • Remove screws, loosen white plastic screw, slide casing end over wires to expose & remove controller. Look for any signs of water or overheat damages. In pic 3 notice the red wire and on the board next to it are two pieces what appears to be bare wires. They are shunts & can be soldered a bit on ends to add output power. DON'T solder all the way!!

  3. How to Repair Electric Bikes: step 3, image 1 of 2 How to Repair Electric Bikes: step 3, image 2 of 2
    • Notice the thick lines of solder on the board especially - this helps the power flow without burning out thin lines- this is an impressive controller on a cheap bike so far!

  4. How to Repair Electric Bikes: step 4, image 1 of 2 How to Repair Electric Bikes: step 4, image 2 of 2
    • Inspect connectors for melting corrosion & bad or broken wires or connectors- they should look clean like this one, absolutely No issues so far! This computer isn't burnt like the seller suggests and $100. part from factory- No! Cheap ones available!!

  5. How to Repair Electric Bikes: step 5, image 1 of 2 How to Repair Electric Bikes: step 5, image 2 of 2
    • Inspect controller insides for broken wires and swelled capacitors and frayed wires loose solder points on the board. 2nd pic looks like the board is wet- normally a bad thing I have a new spray that protects it. Get to that later. I can smell burnt parts at times. Sniff around for the stinky electronic smell for clues and brown/black Hot spots!

  6. How to Repair Electric Bikes: step 6, image 1 of 1
    • Inspect, lube, or replace bearings in center of wheels being careful not to damage wheel when removing or replacing. There may be a bearing place by you and bearing can be 3 to 5.00 You have to remove bearing so it can be measured.. some bearings can be taken apart and greased but not good unless in good shape prior.

Conclusion

To fix electrical issue look at pics and see how things come apart and what to look for.and simple fixes.

21 other people completed this guide.

EastCoastCanMan

Member since: 10/10/14

713 Reputation

1 Guide authored

38 Comments

Can You help me my problem dos not seem to be covered bike has fully charged battery lights all come up bike take off great 10 minutes into journey it's stops lights go out turn key off then back on it gos again 30 secs later stops again turn key it gos again and so on and so forth the batteru as i said is fully charged but in case the leds were trying to fool me i put it on charge less tjlhan 10 mins fully charged again any ideas( please help) …..keith.starbuck37@gmail .com

keith starbuck - Reply

I ve a 750w rear wheel hub ebike class 2 . sounds to me like your codes are off on yours find out how to default the control screen might have to call the company that sold it .they can give you all the codes my email is steinjason650@yahoo.com i can send you the list ive got.

JASON STEIN -

hi Keith, that behavoiur can be caused by faulty battery cells, if the bikemjerks while powering, think controller , battery cells are breaking down under load.

GewizRepairs - Reply

Can battery's be bought to replace the bad ones and do you sell them with a repair Manuel?

Mark Richardson -

Please pardon if this post is inappropriate, but I’m desperate. MY bike with a Bionx G2 system, that just worked perfectly for me, was stolen. I still have the Bionx G2 Battery (wasn’t on bike when it was stolen), which is strong, and the charger so I'm trying to piece together another system from parts available online. I was able to get a Bionx G2 motor, controller & dock. Couldn't find a G2 (downtube) battery mount but was told that a G1 battery mount would work. I plugged the system together and the controller shows me 4 screens, none of which will let me control the motor normally. I have provided links to pictures of the 4 different screens. Do you have any idea what’s wrong and how I could fix it?

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