October 15, 20241 yr The bike has been little used (under 200kms) and has been in a dry lockup garage for many years. When I tried to get it going (we want to give it away to a needy lady in our retirement village), I was able to connect the charger which showed an orange light for an hour or so and then a green light - so disconnected. This model has the key integrated into the battery casing (extract from Manual with pictures of lock attached) - but I can't turn the key past the Off position, so no Indicator lights on top of the battery, nor response from the handlebar control unit On/Off button. If you think this might be a problem with the lock - can I use Silicone spray into the keyhole or lock casing? What about WD40? Or must I use graphite powder? NB The lock also functions as the On/Off switch for the battery – might spray be a risk of damaging the On/Off switch. Other troubleshooting suggestions greatly appreciated.
October 15, 20241 yr Did you charge the battery on or off the bike? if off the bike the chances are the battery is not quite all the way home and the locking lug is not aligned with its hole correctly. A firm shove with the heel of your palm should sort it.. Its a snug fit by design .. a squirt of lube or wd40 would be ok but i would avoid conductive graphite.
October 15, 20241 yr Author I charged the battery while it was ON the bike. Thanks for the comment on spray lube YES, and graphite NO. Charlie
October 15, 20241 yr If I am reading correctly and its a 13-14 yr old bike and battery with only 200 km on the clock that took about an hour to fully charge. Fixing the lock might not be the end of your issues ;( ist things 1st tho.. if a lube fails to get results? Pull the battery and work the lock gently with the key to ensure it operates fully before putting back on the bike, A sheet of paper slid between the battery and its base/home can record the lock lug position and confirm if its sat correctly where it can engage or allow you to jiggle it home if necessary. rub a pencil over the lug end if needed.. Whisper contribute in here and appear to offer good support for older machines even in 2nd or 3rd hand ownership, so if still struggling during the working day its worth a call or email imho When the battery is off the bike and the lock is working as expected Take the opportunity to take a proper meter reading of the battery voltage for a health indication, With the battery turned ON. Ideally you will get a 42v reading, on battery level indicators and even bike voltage readings are not as reliable as a meter reading
October 15, 20241 yr The bike has been little used (under 200kms) and has been in a dry lockup garage for many years. When I tried to get it going (we want to give it away to a needy lady in our retirement village), I was able to connect the charger which showed an orange light for an hour or so and then a green light - so disconnected. This model has the key integrated into the battery casing (extract from Manual with pictures of lock attached) - but I can't turn the key past the Off position, so no Indicator lights on top of the battery, nor response from the handlebar control unit On/Off button. If you think this might be a problem with the lock - can I use Silicone spray into the keyhole or lock casing? What about WD40? Or must I use graphite powder? NB The lock also functions as the On/Off switch for the battery – might spray be a risk of damaging the On/Off switch. Other troubleshooting suggestions greatly appreciated. IIRC, you push the key in to turn it. The whole lock has to move back a bit before it will rotate.
October 26, 20241 yr Author Hi all Thanks for your contributions - 'we have lift-off!' The WD40 helped. Also found that take the battery casing apart allowed the locking lug to move freely and with a bit of wiggling I got the key to turn to the (power) On position. Battery then tested at bottom terminals with a digital meter at 40v. Some of the screw lugs of the battery casing had broken so these were reattached with superglue and then reinforced with Loctite Kintsuglue - a moldable/flexible glue/putty https://www.henkel.com/press-and-media/press-releases-and-kits/2018-02-05-much-more-than-glue-loctite-kintsuglue-824138 Battery indicator ontop of the battery shows green lights ie Full. Handlebar display shows all indicators. Power assist Up and Down buttons work. And the bike runs well in pedal assist and throtttle modes. So thanks again for your assistance. Charlie
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