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Common Diagnostics - Quick Reference

Fast troubleshooting guide for the most common e-bike problems encountered daily

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🔍 Common Diagnostics - Quick Reference

🔋 Battery Won’t Charge

🚨 Quick Check (2 minutes)

  1. Check charger LED - Should show power indicator
  2. Inspect connections - Clean battery and charger contacts
  3. Test outlet - Verify wall outlet has power
  4. Check temperature - Battery should be 32-104°F (0-40°C)

⚡ Common Causes & Fixes

🔌 Charger Issues

  • No LED on charger → Test different outlet, check charger fuse
  • Red/error LED → Check charger voltage matches battery
  • Loose connection → Clean contacts with isopropyl alcohol

🔋 Battery Issues

  • Battery too hot/cold → Let battery reach room temperature
  • Deep discharge → Try 24-hour recovery charge
  • Swollen battery → STOP - Professional service required

🔗 Connection Problems

  • Dirty contacts → Clean with contact cleaner
  • Loose connector → Check for bent pins or damage
  • Corrosion → Light cleaning with baking soda solution

🛑 Motor Cuts Out

🚨 Quick Check (2 minutes)

  1. Check battery level - Must be above minimum voltage
  2. Secure connections - Wiggle all motor/battery connections
  3. Check display - Look for error codes
  4. Test power button - Turn system off/on

⚡ Common Causes & Fixes

🔋 Power Issues

  • Low battery → Charge battery fully
  • Loose battery → Reseat battery in mount
  • Battery cutoff → Check BMS protection settings

🔌 Electrical Problems

  • Loose connections → Check all cable connections
  • Controller overheating → Let system cool, check ventilation
  • Sensor malfunction → Clean PAS/torque sensors

🚲 Mechanical Issues

  • Chain binding → Check drivetrain alignment
  • Brake sensor activated → Adjust brake sensor position
  • Speed limit reached → Check speed settings

📱 Display Issues

🚨 Quick Check (2 minutes)

  1. Check display power - Press and hold power button
  2. Inspect connections - Secure display cable connections
  3. Test different modes - Cycle through assist levels
  4. Check for damage - Look for cracked screen or water damage

⚡ Common Causes & Fixes

💻 Display Problems

  • Blank screen → Check connection, test battery voltage
  • Flickering display → Secure connections, check for interference
  • Wrong readings → Calibrate sensors, update firmware

🔧 Connection Issues

  • Loose cable → Reseat display connector
  • Corroded contacts → Clean with contact cleaner
  • Damaged cable → Replace display cable

🚫 No Power At All

🚨 Quick Check (2 minutes)

  1. Check battery charge - Test with multimeter (should show ~36V, 48V, etc.)
  2. Inspect main fuse - Look for blown fuses in battery or controller
  3. Test key/power switch - Ensure proper key insertion and switch operation
  4. Check main connector - Verify battery to controller connection

⚡ Common Causes & Fixes

🔋 Battery Problems

  • Dead battery → Charge or replace battery
  • BMS lockout → Reset BMS or professional service
  • Bad battery contact → Clean terminals, check torque

🔌 Electrical Faults

  • Blown fuse → Replace with same amperage fuse
  • Loose main connector → Secure battery connector
  • Controller failure → Professional diagnosis required

🔧 Mechanical Issues

🚨 Quick Check (2 minutes)

  1. Inspect chain/belt - Look for damage or improper tension
  2. Check wheel alignment - Ensure wheels are properly seated
  3. Test brakes - Check for binding or excessive drag
  4. Examine derailleur - Look for damage or misalignment

⚡ Common Causes & Fixes

🚲 Drivetrain Problems

  • Chain skip → Adjust derailleur, check chain wear
  • Belt slip → Check belt tension, inspect for damage
  • Grinding noise → Lubricate chain, check for debris

🛑 Brake Issues

  • Brake drag → Adjust caliper alignment
  • Spongy brakes → Bleed hydraulic system
  • Squealing → Check pad wear, clean rotors

📊 Error Code Quick Reference

🚨 Most Common Codes

Error 21 - Speed sensor issue → Check sensor alignment Error 25 - Throttle fault → Calibrate or replace throttle Error 30 - Communication error → Check all connections Error 43 - Battery issue → Test battery voltage and BMS

🔍 Diagnostic Priority

  1. Safety first - Check brakes and structural integrity
  2. Power system - Battery, charger, main connections
  3. Control system - Display, controller, sensors
  4. Mechanical - Drivetrain, wheels, suspension

🛠️ Essential Tools for Quick Diagnostics

  • Digital multimeter - For voltage/continuity testing
  • Contact cleaner - For cleaning electrical connections
  • Basic hand tools - Screwdrivers, Allen keys, adjustable wrench
  • Tire pressure gauge - For checking proper inflation
  • Cleaning supplies - Degreaser, rags, brushes

📞 When to Escalate

⚠️ Safety Issues - Any structural damage, brake failure 🔥 Thermal Problems - Overheating batteries or controllers 💧 Water Damage - Submersion or heavy water exposure ⚡ High Voltage - Never work on systems above 60V without training

🔗 Related Resources

Complete Diagnostic Procedures

Professional Tools & Safety

Quick Reference Resources

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Remember: When in doubt, refer to manufacturer documentation or escalate to experienced technician. Safety always comes first.