Bluebeard06

HI. Have to dig the bike out again and have a look. I can't offhand remember whether the potting compound is a hard substance (like epoxy) or a soft one (like silicon). The controller itself is an aluminum casting with the contents covered with a clear soft potting compound. I have just looked up the Zip company. See: http://www.currietech.com/dealers/wiki/images/0/04/Owner%27s_Manual_-_Bicycles.pdf

The connectors are filled on the back side with a potting substance so difficult to measure when connected. I have measured the battery voltage on the connector going into the controller (and checked fuse anyway..). There are two thick wires to battery and another 2 thick wires to motor. There are 5 thin wires to handlebar display/control. 2 lots of 2 wires to brakes. 2 thin wires to pedal crank and about another 3 thin wires to the motor. I can measure about 9v to the handlebar controller. I don't know whether brakes and pedal crank sensors are, say, as simple as a reed switch & magnet or some electronic device.

Hi Mark. 1st the handlebar display/control does not light up at all. The battery measures 25v (or better) at the terminals and the battery display works ok and shows full battery. All connectors appear sound and no wires are damaged. Although 5 years old it has only been used about 6 times for 1/2hr. 2nd am looking at controllers on Ebay. Is a hall effect sensor the one to sense the pedals are being used?? Cheers, Roger

Hi Mark. I don't think the motor should be at fault as surely the control panel should light up regardless?? (And doesn't). This particular Zip model doesn't have a throttle it is purely pedal assist. The control panel allows 3 levels of assist to be chosen and shows 5 levels of battery power (when it's working that is!!!). Do you think the controller you used would be compatible with that or does it expect a different setup? Cheers, Roger

Thanks 4 yr thoughts. It wouldn't surprise me if connecting the motor directly to the battery did work but I can hardly use the bike where a single on/off switch gives me all or nothing..!! As an electronic engineer I can identify all the connectors ok (and they all look tight). Have tried plugging and unplugging each one... Don't see how the problem can be other than the electronic block or the handlebar control panel. Understand that Zip is no longer in UK. Can any other control block be used??

HI. Since reading the replies I have tried plugging in the charger and (after a little while) trying things again. 1st to say is a 24v battery so I didn't think 25v seemed to bad but then I don't know the characteristics of lithium batteries (like a fully charge 12v lead acid battery is 13.8v). Anyway with the charger on (and showing green as fully charged) the indicator panel on the battery itself shows 1 x red and 2 x green leds which agrees with the fully charged condition. I have measured the same 25v on the plug going into the electronics block but the handlebar control panel still shows zilch and consequently I don't think that playing with the motor itself is going to help. Any other ideas? Cheers

This e-bike was bought in July 2010. It has been stored inside and charged up but has only been used about 6 times for 1/2hr. So really like new. It additionally has a speedo & lights. This version will either assist you when you pedal but also has a twist throttle so can be just a ride on & go. The reason it has had so little use is that at 72 I find it very painful to sit on for more than short periods and since I am retired I don't have to use it for work. The asking price is £350 which means you get a virtually new bike for half price. Come & collect it or could maybe deliver in 50m radius.

I have one of these e-bikes which is barely used. Between trying it last year and now this year it has stopped working, As an electronics engineer I tried measuring the voltage with the battery unplugged which shows as 25v (The battery display shows as 1 x green & 1 x red lights). I have tried removing the cover over the controller and everything looks intact ie everything is plugged in and no wires are damaged but the handlebar display still shows nothing. Any ideas??? Bluebeard06