XM-3500li Controller Problem: Hi Torque is gone - do these controllers break?

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stalcottsmith
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XM-3500li Controller Problem: Hi Torque is gone - do these controllers break?

I have been enjoying my XM-3500li for almost a year now and I have learned a lot. I ride it almost every day for my 2 mile commute and for pleasure. I have replaced a couple cells, made my own battery cable replacement at a marine store, upgraded head lamps, replaced the dc-dc converter, etc.

A month or two ago I noticed the controller was taking time to make the switch from low torque to high-torque mode. I used it like a low gear and high gear for a while on the belief that this would extend the range. Occasionally it would switch after I already expected it to have switched and while I was applying throttle, so it would kick in with a "thonk." I thought that couldn't be good for it and tried to avoid it as much as possible. It seemed to get better after warming up a little.

Then one day, the low torque didn't engage at all. That's fine, I prefer high-torque mostly and left the switch in that position, taking care when possible not to apply too much throttle too quickly off the start. Unfortunately now I am in the opposite situation. Low torque is working but high torque is out.

I have no idea what to do about it and my closest advisor on things electrical is busy fighting whale wars in the southern ocean.

Can anyone suggest what I might try to do to either fix the controller or determine if it must be replaced?

Also, I have a sticky kill switch on the left brake. It seems to fall to a position where it can cut power to the motor so after breaking I usually have to push it back out a little. This may contribute also to the "thonking" as if I do this after applying throttle, it will thonk. Can I replace this with a standard break thingy? If I didn't by from x-treme can I still get a replacement part?

Have I killed my controller? What about these fancy Kelly controllers? Would I be better off with one of those? Is it within my ability to install?

Much Appreciated,

Steven

Iccarus
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Joined: Saturday, December 20, 2008 - 08:05
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Re: XM-3500li Controller Problem: Hi Torque is gone - do ...

Hi Steven, Your problem with the hi/low is probably the switch. You could just bypass it and leave it on high speed only. I think the manual says not to change the switch while in operation. If you look underneath the brake switch you'll see it's held in place by a screw. The same thing happened to mine and I thought if I lubed it it would fix it but it turned out it I just had to loosen the screw slightly ant move the switch position a little and tighten it down again. I put a kelly on mine and upped it to 24 and then 28 cells it does 54mph and I rigged up variable regen brakes too. I love mine even with it's flaws. Your controller is probably fine. There's two wire coming out of that switch, IO forget the colors, one is green and yellow I think, anyway one is 60v and one is like about 36v that's how it works. try spraying some contact cleaner and praying the crap out of it and work it back and fourth. It will either fix it or make it worse. If that doesn't work I would bypass it. Hope this helps.

2008 XM3500li Mods/Kelly KBL12251/84v 28cell 40AH pack/ Variable regen brake trigger on left brake handle/Givi/Cycle Analyst/Homemade BMS

KMX Typhoon Home build (recumbent pedelec) with two Astro Brushless 3220motors/twin castle Phoenix ICEHV 160/ Cycl

Iccarus
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Last seen: 5 years 1 month ago
Joined: Saturday, December 20, 2008 - 08:05
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Re: XM-3500li Controller Problem: Hi Torque is gone - do ...

Steven, I thought about it a little and it's likely that operating that switch under power likely burned up the contacts so the contact cleaner probably won't help. Either bypass it or order a new one from XM.

2008 XM3500li Mods/Kelly KBL12251/84v 28cell 40AH pack/ Variable regen brake trigger on left brake handle/Givi/Cycle Analyst/Homemade BMS

KMX Typhoon Home build (recumbent pedelec) with two Astro Brushless 3220motors/twin castle Phoenix ICEHV 160/ Cycl

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