Electric Vehicle are essential household transportation. While they lack the comfortable seats of cars, they offer greater convenience for daily commutes. So how should you repair them when they break down?

Common Electric Vehicle Faults and Repairs

1. Battery won't charge or charges incompletely

① First check for poor connections, including whether the battery fuse contacts the fuse holder properly and whether the charger connects securely to the power source.

② If all connections are sound, inspect the fuse inside the battery fuse box for breakage. Replace the fuse if broken.

③ Another possibility is a false full charge indication caused by the charger's indicator light. Replace the charger if this occurs.

2. Battery runs out quickly after a full charge

This may indicate battery aging, requiring battery replacement or repair. If the battery is intact, the issue could stem from a short circuit in the motor section causing excessive current. Replace the motor if necessary.

3. Motor fails to start after rainfall

Check if the controller has been waterlogged. If water ingress is detected, the anti-runaway protection mechanism is likely activated. Clear any mud or moisture from the throttle plug to resolve the issue.

4. Noticeable shaking of the bike frame when starting or turning

① Check if the handlebar-to-stem connecting bolts and nuts are loose

② Check if the positioning nuts (thin, dual-piece, commonly known as the front fork nine-piece set) connecting the stem to the frame sleeve are loose; tighten appropriately if found loose

③ Based on usage duration, determine if wear on the upper and lower ball bearings of the nine-piece set is the cause

④ Check if the nuts at both ends of the front wheel alignment shaft are loose.

5. Unexplained whole-vehicle vibration during riding (increases with speed)

① Check if front/rear tire pressure is too high.

② Check if front/rear suspension has good rebound.

③ Spin front/rear wheels freely and carefully check for noticeable axial play (side-to-side wobble). If present, replace bearings.

④ Check if front/rear tires show noticeable misalignment (asymmetric tread wear relative to rim). If present, deflate tires, realign, and reinstall.

Replace tires deformed from prolonged abnormal pressure.

6. Dashboard power indicator does not illuminate, but motor operates normally

Reconnect dashboard positive/negative leads. If issue persists, replace positive/negative wires or replace indicator bulb.

7. Motor does not rotate

① Turn the ignition switch forward. If the wheel rotates smoothly, the controller's power transistors are intact, indicating the controller is likely undamaged. Resistance when turning backward indicates a brake circuit fault.

② If the above methods fail to resolve the issue, inspect the motor's Hall sensor wires, organize connectors, and check for poor contact.

③ If the Hall sensor wire is intact, measure the voltage between the ignition switch wire and the ground wire. If no voltage is present, determine whether the fuse has blown and replace it, the wire has come loose, the connection is soldered, or the wire needs to be replaced.

8. After turning on the power switch to activate the power supply, the motor immediately rotates.

Determine whether the throttle handle is damaged; if so, replace it with a new one.

9. Motor intermittently starts and stops

① This is typically caused by poor battery terminal contact or faulty contact between fuse holders inside the battery box, resulting in unstable power supply. Remove the power connector and connect the power cable directly to the controller.

② If the issue isn't power-related, it may indicate a malfunctioning electric vehicle controller, requiring replacement.

10. Excessive motor noise

Multiple causes may exist; specific analysis is required.

- If caused by excessive bearing clearance: Replace the bearings.

- If caused by loose or detached magnets: Reattach the magnets.

- If caused by axial movement within the motor: Add appropriate shims axially.

- If caused by a loose or misaligned brush holder: Adjust the carbon brush holder.

Daily Inspection and Maintenance for Electric Vehicles

1. Check if front and rear wheel nuts are securely tightened;

2. Verify front and rear tire pressure meets specifications;

3. Inspect outer tire tread for wear or cracks;

4. Listen for abnormal sounds like impacts or rattling during wheel rotation;

5. Examine all components (especially front fork and frame) and fasteners for secure attachment to prevent loosening, detachment, or breakage that could cause accidents;

6. Verify front and rear brakes function smoothly and reliably; ensure brake cables operate in lubricated condition.

Warning: During use, regularly inspect fasteners on front axle, center axle, rear axle supports, etc., for loosening or detachment. Tighten immediately to prevent hazards.

Electric Vehicle Cleaning and Maintenance Precautions

1. Do not use high-pressure water jets for cleaning, as internal electronic components and wiring may become wet and create accident hazards.

2. Gently wipe painted or plastic surfaces with a cloth dampened in neutral detergent, then dry thoroughly with a clean cloth.

3. Apply lubricating oil to metal parts of the vehicle body for maintenance.

4. Strictly avoid applying oil to front/rear brakes, hubs, or tires.