XB600 help.... Bike dying after only 10 miles!!!!!
OK, straight to the point..... I have an XB600 that I have upgraded to 60V with the controller "shunt" mod performed.
All seemed to be going fine, then one day after about 10 miles it died on me. I opened up under the seat to check things out.... Well I first noticed the 20A fuse holder had not only blown the fuse, but had also melted the one whole side of the fuse holder. So I bought and replaced it with a new one, upping it to a 30A fuse and holder. Once again all seemed fine but I dont think i ever rode it much over 10 miles.
Well yesterday after riding about 7 miles it "ran" out of juice again, so I opened everything up again to check..... The 3 phase wires to the motor had melted and were almost fused together, mostly the yellow one. I checked the pack voltage... 63V yet the "fuel" gauge was down to 3/4 (ps. I never modified it to register for 60V). My question is this..... What would make the bike show a low pack voltage and cut out like that when the pack is perfectly charged? I have checked each of the 2 month old batteries in the pack and charged individually, all checked out fine. Is this most likely something wrong in the controller or the motor? I would like to have a plan of attack before I take everything completely apart. The weird thing is, from a full charge, about 68V, it runs fine and acts perfectly normal until it hits about 63V (around 7-10 miles), then it acts like it is starving for voltage.
Any ideas anyone??
If it ends up being the controller I might just end up getting a new 72V one and adding a 6th battery in the mean time. I guess if I do that I might end up replacing all the wires from the controller to the motor with higher gauge ones, hell I might as well replace ALL the wiring at that point too!
Merry Xmas. It sounds as if you are hitting the low voltage cutoff of the controller. The controller starts to shut down to save the batteries from discharging to low, but that controller is a 48v so the LVC should be like 40v or so. I can't see how it would be the motor if it runs fine at 68v. Have you tried hooking it back up to just 48v?
My guess would be the controller. It could be that you are pulling alot more amps from the controller now than before. You might open it and take a look inside. If you shorted the phase wires and the fuse I would think it it delivering more current than before which could be draining the batteries faster. Is the bike quicker from the starting position than before? Not really sure what else it could be besides the controller.
How did you wire your 5th battery in? It should register across the voltage gauge if it is in series with the rest.
Well, I hope it works out for you. I looked at the schematic on the xb600 and it appears to me that the voltage gauge is wired to the blue wire from the controller. The orange wire from the controller outputs the same voltage to the keyswitch as the battery pack voltage. Then the keyswitch connects it to the blue wire. So wouldn't the voltage gauge be reading the true battery pack voltage? I am not quite sure how your 5th battery is wired. It sounds as if you wired it in between the controller and the main battery pack I wired mine by cutting the last negative lead wire of the original 48v pack and wired it to positive on the 5th battery then attached the 5th battery negative wire back to the original negative ground wire.
As you probably know I have since wired in a 6th battery and have been running at 72v for well over 300 miles now. If you do change the controller You might think of getting the e-crazeyman controller that is good up to 84v. It has worked well for me. If the controller is working properly at 68v how can it have a bad cap or mosfets? Don't the mosfets basically turn power on and off. If one is bad would it work properly at any voltage? If you want to measure the controller to see if it working properly couldn't you measure the no load current on center kickstand. It should be below 2amps. Just some thoughts. Good Luck.