Ezeetorq2 cutting out.

[zebody]

Help please

My much loved exceedingly reliable 2009 ezeetorq2 has let me down.
Power cuts out (battery is fine) battery meter goes from green to red then glows, dims flickers red then no light no power.
On holiday so just gave the usual quick wiggle wires check battery terminals etc.
Kind regards
Zebody AKA Steve

 

[hoppy]

Help please

My much loved exceedingly reliable 2009 ezeetorq2 has let me down.
Power cuts out (battery is fine) battery meter goes from green to red then glows, dims flickers red then no light no power.
On holiday so just gave the usual quick wiggle wires check battery terminals etc.
Kind regards
Zebody AKA Steve

How do you know battery is fine?

 

[flecc]

And are you getting any flashing on the controller's LED when the cutout happens? If so, how many flashes?
.

 

[zebody]

Hoppy
I cannot completely rule out the battery but I can try my second battery once I get home.
But I have just checked the voltage on full charge it was 41.8vrottle

Flecc
5 flashes ( throttle ) then single then to many to count then light stays on but no power.

 

[hoppy]

Hoppy
I cannot completely rule out the battery but I can try my second battery once I get home.
But I have just checked the voltage on full charge it was 41.8vrottle

Flecc
5 flashes ( throttle ) then single then to many to count then light stays on but no power.

Just had similar case on my four year old Tonaro Compy. Was sure it was not the battery, but it was!

 

[Deleted member 4366]

41.8v doesn't mean that the battery is good. I've had those old Ezee batteries at 42v, and then the voltage totally collapses as soon as you try to draw current.

 

[Cyclezee]

Hi Steve,

At six years old your battery will be past it's best, but if you can send it to us we can measure the capacity and run a dynamic load test.

There could of course be another issue as indicated by the controller diagnostic LED.

 

[zebody]

Just got back off hols.
Battery works fine on my other ezee.
I have been parting and cleaning joints with isopropyl .
Clicking noise in controller now.
Any checks I can do on controller?

 

[flecc]

As you already know, the controller LED 5 flash indication is that it's a throttle problem. They are plug-in, so if both are the same 3 or 5 connection ones, you could swap in your other one to see if that solves the problem.

I don't know of any check that can be carried out on eZee's controller, but Cyclezee might know of one.
.

 

[Cyclezee]

That's good news about the battery Steve, if that is the original it has done well.

I have not come across a clicking controller before

I would do as Flecc suggests, connect the throttle from your other if it has the same number of pins and then see what happens.

 

[zebody]

Connected other throttle, same problem.
I have taken off the controller looked at the pub all looks ok no sign of anything wrong.
Will put it all back together re connect and give one last try.
Am I right in thinking :-
Motor ok
Throttle ok
Battery ok
Wire joints ok

Suspect
Controller
Battery meter
On off switch

Which would I buy first?

 

[flecc]

Seems most likely to be the controller, especially since you had a clicking noise from it after the fault occurred, definitely not normal on these. The eZee controller is generally one of the most reliable, but they do fail on rare occasions. I've never known or heard of the battery meter causing this problem, the throttle is just routed through it and the pedelec selector switch.

However, key switches can also fail so it's impossible for me to be confident which it might be. Perhaps you could rig a temporary bypass to take the positive direct from the battery to the controller to rule out the key switch as the cause.
.

 

[hoppy]

Connected other throttle, same problem.
I have taken off the controller looked at the pub all looks ok no sign of anything wrong.
Will put it all back together re connect and give one last try.
Am I right in thinking :-
Motor ok
Throttle ok
Battery ok
Wire joints ok

Suspect
Controller
Battery meter
On off switch

Which would I buy first?

I sympathise having spent ages trying to fix my Tonaro! My battery showed 41 volts plus at the charge socket but about 25 volts at front charge lights. Phil Hughes sent me two controllers to try without success. In the end I took the whole bike down to his house in Tiverton. When he tried a new battery all was well. Perhaps you could take yours to Cyclezee where he could try swapping components in turn?
Best wishes anyway.

 

[Cyclezee]

Hi Steve,

Again as Flecc suggested it is worth checking the key switch.

Also check the soldered joints for the 2 wires that go to the opposite side of the switch from the key. There is a PVC boot that covers it.

Going back to the controller, after swapping the throttle, what is the diagnostic LED on the controller doing?
Does it stay constant red or does it flash and if so how many times?

If the controller is faulty it will need to be replaced.

Back in 2012 eZee completely revised and updated the electrics and the old type controllers are no longer available.

There is however an upgrade kit that replaces all the old parts.

The upgrade kit comes with a new controller, wiring loom with waterproof connectors, new LED console which replaces the old type battery gauge, new half width throttle and handle bar grips, new 12 magnet pedelec sensor and new brake levers.

 

[zebody]

Flecc many thanks I followed your instruction and it appears it is the ignition switch at fault.
Once I bypassed the switch the flickering lights are now steady and the motor works great.

Cyclezee I will email you with details for a new switch for now.
However I may be interested in the 2012 controller setup let me know on your email the cost.

Thanks to all contributors.
Over the 5 years since joining the pedelecs forum I have always acquired good advice to fix my ezee problems myself good job as in the Hull area we have no ebike shops.

 

[zebody]

Back on the road again thanks to all.

Only £25 for part Ezee bikes are the landrover of ebikes.
Both my 2006 ezeetorq mark 1 and 2009 mark 2 going strong .

Kind regards
Steve