Common faults and solutions of electric bicycles

1、 Battery system malfunction

1. The battery cannot be charged or is not fully charged

• Phenomenon: The charger has no response and the battery level does not increase for a long time.
• reason:
  • Battery aging (end of life).
  • The internal fuse of the battery is blown or has poor contact.
  • Charger malfunction (no output voltage or abnormal indicator light).
• solve:
  • Replace the aging battery, check and replace the fuse.
  • Adjust the contact between the battery and the safety seat to ensure stability.
  • Replace or repair the charger and avoid using non original equipment.

2. Significant decrease in battery life

• Phenomenon: The driving range is significantly reduced when fully charged.
• reason:
  • Single battery damage (such as inconsistent voltage).
  • Low temperature environment leads to a decrease in the efficiency of active substances.
• solve:
  • Use professional equipment to test the battery pack and replace faulty units.
  • Avoid charging below 0 ℃ and store at 50% battery capacity.

3. Abnormal heating of the battery

• Phenomenon: The battery case is hot to the touch while charging or riding.
• reason:
  • Overcharging leads to an increase in internal pressure.
  • Poor heat dissipation or internal short circuit of the battery pack.
• solve:
  • Stop using immediately and check the charger voltage (should be ≤ 59V).
  • Send for repair and testing, and replace the battery pack if necessary.

2、 Motor system malfunction

1. The motor rotates and does not rotate/does not rotate

• Phenomenon: The motor suddenly stops or has difficulty starting during cycling.
• reason:
  • Insufficient battery power or poor contact of contacts.
  • Dirt on the photosensitive film inside the speed control handle and controller malfunction.
• solve:
  • After fully charging, check if the contacts are oxidized and polish them with sandpaper.
  • Clean the photosensitive film, and if it is ineffective, replace the speed control handle or controller.

2. Motor abnormal noise/vibration

• Phenomenon: The motor makes abnormal noises or the body vibrates while riding.
• reason:
  • Bearing wear, magnetic steel detachment, or foreign objects getting stuck.
• solve:
  • Disassemble the motor to inspect the bearings, apply lubricating grease or replace them.
  • Clean up foreign objects and tighten the magnetic steel.

3. Insufficient power

• Phenomenon: The motor is powerless when climbing or carrying heavy loads.
• reason:
  • Motor overheating protection (temperature exceeding 80 ℃).
  • Hall sensor malfunction or poor circuit contact.
• solve:
  • Suspend use until cooled down and check if the Hall element is damaged.
  • Reconnect the circuit to ensure good contact.

3、 Controller malfunction

1. The vehicle cannot be started

• Phenomenon: There is no response when turning on the power lock.
• reason:
  • Controller burned out and switch signal line disconnected.
• solve:
  • Check if the 5V power supply of the controller is normal. If not, replace the controller.
  • Use a multimeter to test the voltage of the switch signal line (1-4.2V).

2. Unstable/jerky vehicle speed

• Phenomenon: Sudden changes in speed while driving.
• reason:
  • Controller parameter drift and Hall signal abnormality.
• solve:
  • Reset controller parameters (requires professional equipment).
  • Check if the motor Hall element is damaged.

4、 Brake system malfunction

1. Brake failure

• Phenomenon: The brake handle has no resistance and poor braking effect.
• reason:
  • Brake pad wear and brake wire breakage.
• solve:
  • Replace the brake pads (adjust the clearance for drum brakes).
  • Check if the brake wire is broken and reconnect it.

2. Brake noise

• Phenomenon: A sharp friction sound is emitted when braking.
• reason:
  • The brake disc is contaminated with impurities and the brake pads are deformed.
• solve:
  • Clean the contact surface between the brake disc and brake pad.
  • Replace the deformed brake pads and adjust the tension of the brake spring.

5、 Other common questions

1. The car lights are not on

• Phenomenon: The headlights or turn signals cannot be illuminated.
• reason:
  • The light bulb is burnt out, the circuit is short circuited, and the switch is damaged.
• solve:
  • Replace the bulb with the same specification and check if the circuit is damaged.
  • Use a multimeter to test the continuity of the switch.

2. Tire leakage/blowout

• Phenomenon: Insufficient tire pressure or sudden deflation during driving.
• reason:
  • Nailing, high tire pressure (over 45psi), aging and cracking.
• solve:
  • Use tire repair fluid or replace inner tube.
  • Regularly check tire pressure and avoid exposure to high temperatures.

3. Short circuit/poor contact of the circuit

• Phenomenon: Intermittent power outage of the vehicle or garbled dashboard.
• reason:
  • Rainwater erosion, loose plugs, and aging wiring harnesses.
• solve:
  • Wrap the damaged wire harness with insulating tape.
  • Reconnect all plugs to ensure good contact.

6、 Maintenance suggestions

1. Regular maintenance: Check the battery, brake, and bearing status every six months.
2. Correct charging: Avoid recharging when the battery is depleted, use the original charger.
3. Waterproof and moisture-proof: Avoid contact with deep water and dry key components promptly after rain.
4. Professional maintenance: Malfunctions involving high-voltage batteries or controllers require professional personnel to operate.

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