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  1. #1
    Senior Member knurly's Avatar
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    What could possibly go wrong?

    You are cruising along, enjoying your eBike. A downhill gravel road and you have a thousand yards of rumble bumps. They occur when big tires driven by drug crazed, weekend campers start bouncing on the soft surface.

    No problem, you are at your destination, no need for speed. Regen mode 4 with a hand squeezing the breaks for easy 4mph to enjoy the scenery. Suddenly you feel the regenerative breaking effect let go. Something has definitely gone wrong.


    When you return home, search for "bionx problem" NYCwheels had a good page here-
    http://www.nycewheels.com/bionxtrouble.html

    None of their diagnostics could help. However they said most of the time its a problem with the wiring or cables. I took the entire cable off and started checking it with an ohm meter. The last thing I did was to get confused with what to call the faulty part when I didn't have a name for it. What do I ask for?
    unit.jpg
    There it is. it is the part to the left, the thing the console slides into. I called it a g2 mount when I sent off emails to where I bought the kit from. The emails were return by a bot indicating that the address was bogus. I sent off inquiries to several others with the same results. Today being a holiday in the usa, I wasn't in a mood to wait around. Taking a look at the problem connection-
    break.jpg
    I just didn't think I could repair the broken wire. Evidently, there was no glue on top of the solder connection to provide some strain relief. The broken green wire didn't appear to be properly tinned neither. I wouldn't doubt that the wire had been nicked while stripping in preparation for solder.
    Ok so, I managed to spend a hundred dollars worth of my time to fix it.
    fix.jpg
    To clear the holes on the PC board, heat it with a soldering iron and let a sewing needle fall through the hole. The needle will take a lot of the old solder with it so only need to clean the holes a bit with the tools I had.
    Ready for solder-
    solder.jpg
    Anyways, I'm back in the saddle again didn't have to hire a lawyer to get my warranty honored. Probly voided my warranty by publishing this

  2. #2
    Senior Member
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    Nice.

  3. #3
    Senior Member profstack's Avatar
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    Did the level 4 regen burn out the green wire? Or was it bad from the beginning?

    Here is why I ask. When I test rode the 2011 Bionx regen level 4 on a very steep hill, it worked wonderfully for most of the hill and then let go, whereupon I used the brakes. The salesguy riding near me said that the battery system can only accept so much charging in a short time, so it shuts off the regen for whatever length of time needed to let the battery cool down or do whatever it needs to do.

  4. #4
    Senior Member rscamp's Avatar
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    Wow. That's a poor design...
    Rob

  5. #5
    Senior Member knurly's Avatar
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    Quote Originally Posted by profstack View Post
    Did the level 4 regen burn out the green wire? Or was it bad from the beginning?

    Here is why I ask. When I test rode the 2011 Bionx regen level 4 on a very steep hill, it worked wonderfully for most of the hill and then let go, whereupon I used the brakes. The salesguy riding near me said that the battery system can only accept so much charging in a short time, so it shuts off the regen for whatever length of time needed to let the battery cool down or do whatever it needs to do.
    The salesman was right, from my observations. But it doesn't simply shut off. Rather, it steps down effectively through levels 3-2-1 while the indicator still reads regen 4.

    Taxing the system heavily going uphill the motor will get hot, then the system shuts down again the same way.

    The wire didn't break by current overload. The leads going into the console carry very little current- milli-amps.

    I saw someone the other day taking it easy outside a restaurant. I saw his bionx battery and his touring trailer as well. I asked how long he had it, was he still happy? He must have been from somewhere of Europe, he didn't speak well. His was a 250 model, had it for 2 years. Was less than enthusiastic when asked if the original battery was still performing. Then again, he was only able to give it a partial charge now and again when he stopped at a laundromat.

  6. #6
    Senior Member knurly's Avatar
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    Quote Originally Posted by EBikeFL View Post
    Nice.
    Yep, I'm feeling pretty smug about it>

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