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!