Gendronw's blog

Rather that being a step by step "how to", this blog post is more of a resume of how I repaired my XB-600 motor after the wires were cut.

When the axle spun, my tab washers were damaged on the inside....in fact, the tab washer did not moved ....the motor axle as spun in the tab washers too.

After I removed the motor from the bike I needed to remove the caps on both side of the motor. First I removed the allen screws

After the screw were removed, removing the two caps was not an easy task. I used three flat tips screwdriver that I put in a triangle position so that each screwdriver push up a third of the cap. There was a strong force keeping the cap on the motor(I guess this force comes from all the magnets that are around the motor). Each time I was able to push the cap up with a screwdriver I put something under the cap so that it can't come down because of the magnet force. After the cap is about 1 inch from the motor the force don't act anymore so it come loose and the cap is easy to remove.

So here is how it looks like inside both side

On the wires side

here you can see the wires coming in and out of the shaft

All the connections are on the brake side

The 5 small wires goes to the board and the three big ones are connected to coils. Everything is attached with a small rope that I had to cut a bit to access the three big wires. The three big connection were isolated with strange shrink tube glued in epoxy. Strangely, they were easy to remove.

I used a 20W pen style solder iron to unsolder the 5 small wires, and a 200W gun style solder iron to unsolder the three big wires.

Here are the wires I removed from inside the motor

I used the old wires that were cut off the motor to make the repair, this way I don't have to change the end connector to new wires. Reinserting them in the shaft was easier than I expected. I welded them in place and then reassembled the motor.

I reinstalled the motor and I tried to tight the nut the best I can. There was a problem, when the nuts were tight the motor did not turn ! It was locked by the brake !

So I build new washers out of the damaged tab washers I had.

I put one between the brake and the motor and that was enough. With this new washer I was able to really tight the nut with all my strength without locking the motor. I followed the instructions found in this forum thread on how to position the tab washers(you have to put them against the motor. I poured some locktite on the second nut on the brake side just to be sure nothing moves.

When I fixed the motor for the first to the bike, the rear brake was a bit loose, unresponsive...this time I was able to fix the cable so that the rear brake is quick. Using the two brakes, I can lock the rear wheel !

I have done about 30km since that repair and everything is going great. My batteries will need to be replace because right now the autonomy is an issue, but I knew that when I bought the used luyuan bike. Changing the wires in the motor was not very hard, it is a long repair because you have to remove the motor and than put it back on but it is doable !

My next post will probably be on batteries, my total budget for the project and future modification.

I managed to mount the motor on the bike so I was ready to get key in and try it ! So I went outside, put the batteries in and then it worked ! But only for a few feet. After 1 second or two the power would cut off. I was not sure at that time what was the problem, so instead of dismantling the bike again, I just plugged in the charger. After about an hour charging the bike, I went outside for a second test...and it worked ! I was able to ride a bit around the house. So I plugged it in again, for about another hour.

After that hour, I was hungry so I decided to go to my friend's restaurant which is about 3km from where I was repairing the bike. Everything went well for 2.5km, but after that distance, the batteries were too low and I was experimenting cutoff again. Anyway, I was able to get there and my friend found me a plug so I could recharge my bike while eating my "shishtaouk" !

After 1h30 waiting for the charger to do his job, I tried to return home. Just when I got out of the parking lot, I hit a bump and the motor stopped working. I had to push the damn beast back home for 3km !! damn it is heavy !

Back home, I realized that the axle spun in the dropout and cut the wires of the motor. I was so sad !! 5 months of work just to be able to do 3km !

I did not had enough money to buy a new motor, and since winter was at our door, I could not have waited for the parts anyway if I wanted to ride before there would be snow outside.

The next day I was still on vacation so after a lot of thinking I decided to try to do the repair myself. I thought only the wires were cut and the rest was ok...all the 12v(head lamp, flashers, horn) and the keyswitch were working so maybe If i changed only the wires coming out of the motor everything would be fine again.

See how I did my repair on the next post !

So I finally received the parts I needed to fix the motor on my bike frame. Dealing with Extreme Support on that issue was a pain.

First, when they sent the motor, there were no spacers, nuts and tab washers. I asked Extreme for parts : "needed to fix the motor on the bike frame". They sent me part number "XB600-160R" Rear Break Assembly.

This part was only a drum brake kit. Again they sent the part without any nuts or bolts to fix the brake on the bike frame(the brake also need to be fixed on the frame). Those nuts and bolts were easy to replace with something I had in the garage, but it's sad that Extreme always ship incomplete parts.

So I wrote them a email, telling them I needed theses number on the exploded view available on their website.

69. Nuts
70. Lock Washer
71.Axle Spacer
72.Free wheel
76.Rear Tire spacer
77.Lock Washer
78.Nuts

http://www.x-tremescooters.com/electric_bicycles/xb600/XB-600_explode_diagram.pdf

They sent me parts number:

XUNIV-425 Chain Sprocket Free Wheel

XB600-115 Rear Wheel Lock Axle

Still no Nuts !! I could not go out with my scoot because of four nuts ! I was amazed at how bad there service is ! And I still don't know how it is possible to put a chain on that freewheel. I already had a freewheel from the origial Luyuan Bike (which was of better quality) but I had lost a few bearings in the transfer from the old motor. Using the bearings in the extreme freehweel and a bit of vaseline, I was able to put my old one on the Extreme motor without loosing any bearings in the process.

So I wrote them again that I needed those nuts. The service this time was great. They sent the 4 nuts for free with part number "XMISC Non Inventory Item " !! They also sent 2 tab washers with it, so at that time I had two sets of tab washers.

I fixed the motor on the bike, but since I had no washer, I was not able fix it correctly. I should have read this thread completely before going for my first ride.

http://visforvoltage.org/forum/3651-replacing-xb500-controller

I put the tab washer on the wrong side, and I did not tight the nuts enough.
More on my first ride in the next post !

This post will probably be the biggest one. Plugging everything was the biggest challenge. I managed to reconfigure all the Wiring to get everything to work, using the wiring diagram provided by Milleym (http://visforvoltage.org/forum/3712-xb600-wiring-diagram-groovy). Since my old luyuan bike had two 48v battery pack, I wanted to plug them in parallel to be able to get more amps to the motor. Here is how I did that.

First, after removing all the wires on the bike, I was left with a big mess of wires about 6 feet long.

I was able to keep about 60% of those wires. The only things I needed to change were the connectors going to the controller and the one going to the speedometer. I bought a 9 pins connector, that I welded on the new XB-600 controller and on the mess of wire. This way I can unplug the controller more easily.

I aslo changed the battery connector.

Every connection has been welded and then isolated with shrink tube(and sometime a bit of tape too), just like here on the throttle connector wires.

-----

To be able to use the two battery packs in parallel I used an adapter that came with my old charger. This adapter was needed to charge the two batteries outside the bike

Based on that plug, I thought of something to be able to use a switch to get the two batteries in parallel. Since my charger has two +48v output(one for each battery) I wanted to charge the two battery independently without getting them off the bike. Here is how I made it.

Here is what it looks like under the seat

Here is the new switch under the charger socket on the bike. I will need so secure this charger socket cause there is now a lot of power on that connector ! While trying to take a measure with a voltmeter I made a fireball by shorting two pins with the probe (i'm not sure which one!). Fortunately nothing was destroy... this has reminded me to be careful with batteries.

On my old bike, the two battery were independent. The key switch had three position so that you can select either battery A or B. Now, one of the position leads to nothing so that is why you can see on this picture that the red wire is not connected to anything. The purple one as been added to get battery metering on the speedometer. You can also see the back of the old "exigence switch" that I glued there, cause it did not fit under the throttle anymore.

Glue was also used on the Horn and blinker module which I found was too loud.

On the older bike the controller was placed behind a little door under the seat. The Xb-600 controller is now too big so I had to find him a new place. I just exchange it's place with the 48-to-12 volt converter.
Before

After

One of my big concern with the wiring were the two Diodes in parallel just before the brake light. They were not present on my old bike, and the plan did not specified the value of those diodes. I went to an electronic store, and bought a big fat one. It was too hard to weld in place, so finally I bought smaller one which are just fine. I think their value are 1amp at 400v. the big one is something like 3 amp at 600v.

That is basically what I did to plug everything. I should be able to ride the bike by now, but I still don't have the nuts to fit the motor on bike frame...but that's another story, probably the subject of my next post

Fitting the new parts on the bike was a big job. The shaft on the new motor was too big for the frame and the new speedometer required some plastic cutting to be able to fit it in place.

To be able to install the motor I needed to grind some metal of the frame. I used a high speed rotation tool similar to "Dremel" and it worked well ! Now the motor fits in !

I can't fix the motor right now cause I don't have the drum brakes and the nuts. A guy at Extreme told me that everything needed to fix the motor on the bike is in the Rear Break Assembly kit(Extreme part number : XB600-160R)so I must order this soon. I was able to transfer the freewheel from my old motor to the new, but I lost a few bearings in the process(wich was a pain in the a**) so I will also order one of these because it is making strange sound. That's about it for the motor.

I asked my friend Pierre to help me with the speedo. Using the same high speed rotation tool, he was able to cut the plastic to make place for the new speedo. Now it fits right in, it's tight there, but I think it's going to be O.K., Thanks a lot Pierre !

***Next Post will be on the Electric rewiring***
Thanks a lot to milleym for giving us the wiring wiring Diagram of the XB-600 !

Dismantling the bike was an easy task. After getting the batteries off I Unscrewed everything. Now the bike looks like this !

There was a series of wires that were running from the back(where the controller is) to the front of the bike. I put an identification on every connector before disconnecting them.

After the almost everything was removed, the bike seemed so small ! I tried to put the new Extreme motor on the bike...haaaa deceptions, the new shaft is too big ! I will need to grind the frame a bit so that the shaft can fit. This also mean that my old nuts and washers used to fix the motor on the frame won't work ! The new instrumentation is also going to be a problem. The old speedometer was installed behind a plastic cover. I will try to cut that plastic cover to fit the new speedo.

Since the new parts I bought are not from the bike I just dismantled, the plugs on the new speedometer and controller are not the sames as the old one ! I will have to modify the plugs on the bike wiring so that everything connect easily and that every connection is secure.

The project is on his way, but it looks like I won't drive my Ebike Soon !

Getting the new parts was not easy. I sent emails to Website like freeenergystore.com, e-ride.ca, daymak.com and ebikes.ca without success. They all said their parts where not made for this kind of ebike. Then I found the Xtreme website, the xb-600, and Visforvoltage ! After a few emails with Xtremes I ordered a xb-600 motor, controller, speedometer and throttle directly on their onlinestore. Total price for the parts : 260$ but their Shipping to Canada is extremely costly !
It cost me 130$ for shipping to Quebec city plus 60$ for customs fees ! So about 450$ Total !

Anyway I was happy to have new parts, and shipping was fast.

Here is a picture

Hi to all members of the Visfovoltage community !

I'm on a big project right now, and I want to share it with you. It's not over yet, but I'm working Hard to get it done.

I bought a Used 48V Luyuan Bike that look very similar to the XB-600. The Bikes worked for about half a kilometer before it dies completely. I knew the bike was broken, and I wanted to make a better bike by buying parts over the web.

The bike as two batterie pack, one 14amps/h and one 7 amps/h. The 14amps goes under the feets and the 7amps goes under the seat. The charger Is construct to charge the two battery packs independently, and I plan to use it that way on my modified bike but I want to be able to use the two battery packs in parallel when I'm riding...to get more amps to the controller.

That's it for my first post !

Here are a few pictures of the original bike