I have a Crystalyte 405 kit with a 35A Crystalyte controller and a 48 Volt SLA battery pack mounted on my Sun EZ Sport Recumbent. I have had this kit for about 5 months and it has worked well, with only a few bugs. Today while cruising at 11 MPH the motor went dead and the LEDs on my thumb throttle went out. I used a VOM meter to detemine that the battery was charged to 48 volts and that I was getting juice up to the controller. The LED on the controller does not light when the battery switch and controller off/on button are both in the on position. My analysis is that the controller is dead. The good news is that I spoke to Earl at PowerRiderStore and it is covered under warranty.

All of the plug connectors are properly connected and snapped together. Did I miss anything in trouble shooting? Could the problem be anything other than the controller? Your thoughts please....

You've likely blown a mosfet in your controller. The lower wound motors like the 405 already have a pretty high peak amp draw, and its not terribly hard to overload equipment that may not be up to snuff. Unfortunately, Renaissance's motor simulator is down at the moment so I can't check that, but i'd think its a mosfet problem personally.

As it turns out the problem was the motor all along. It was intermittently quitting on me. While trouble shooting one day I noticed that the Controller LED went out when I connected the COAX cable connector from the motor. When I disconnected the cable the LED came on again. I immediately ordered a new motor, installed it a couple of months ago and have been going strong ever since.

Now what can I do to fix the old motor. I have been informed that the problem is most likely one of the thin wire leads going to the cable connector. Has anyone had any experience trouble shooting and repairing the wiring on a Crystalyte 405 motor?