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BionX battery won't come off

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BionX battery won't come off


Old 02-15-10, 02:42 AM
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Location: Pasadena, CA
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Bikes: Dahon Mu SL, KHS Mocha w/BionX PL350

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BionX battery won't come off

Just got a new bike and transferred over my BionX 350 to it today. I had a bit of a hard time getting the battery onto the track but was eventually able to lock it in. But now I can't get it off! Because of the design of the battery case and how it overlays the frame, I can't get a good look at what it's stuck on.

Has anyone else had problems with the battery getting stuck? I'm not sure what to do. :/
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Old 03-03-10, 08:23 PM
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Sounds like the battery bracket rail might have warped when you installed it. It's easy to do, especially if your frame tubes are relatively large in diameter. (You might have been better off inserting a spacer or two under that bracket before tightening down on those screws.)

Perhap a modest upward pull on the battery as you try to slide it off to try and staighten it out a bit? Or invert the bike for a bit so the weight of the battery does the same thing? Or try to straighten the profile of the bracket by depressing the front part of the track (which you can probably reach) a bit?

Good luck!

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Old 02-03-15, 06:54 PM
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I just wasted a lot of money because of the Bionx stuck battery issue. In my opinion the problem is caused by a poor design with bad manufacturing tolerances. If you use the supplied counter sunk screws to mount the battery rail you must be sure to grind them flat with the rail or drill the counter sunk hole a little larger. These screws must be 100% flat or recessed or you will never get your battery off again without destroying it. As my unit was manufactured, the screws were not 100% flush so my battery went on and ever came off. Bionx blames the problem on the screws coming loose and then getting caught but if that was truly the case the battery could be removed by applying upwards pressure – which was not the case. The best solution is to NEVER use the counter sunk screws in the counter sunk holes of the mounting rail. Only use the pan head screws in the designated pan head holes - even if it means mounting the battery in a less than optimal location. Bionx did replace the battery that had to be destroyed in order to remove it, but it seems that their policy is that even though the parts have a warranty they will only honor their warranty if you take the unit to participating dealer (which in my case was 200 miles away - for a total of 800 miles of driving to take the bike in and then go back and get it 3 weeks later) and you have to pay all labor charges to resolve their mistake.
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