Electric Motorcycle Blows Up!!!!

[bennelson]

OK, well, no giant fireball, as there was no gasoline involved.

I was stopped at a three-way stop sign. When I went to pull away from the stop sign, it didn't go and a giant plume of smoke puffed up from under the seat.

I hit all the power and disconnects and pushed it out of traffic.
I walked 2.5 miles home, stopping at the former Curtis controller guy's place.

He seemed to confirm that the problem was most likely the controller. I saw NO damage to the DC/DC converter or the main power contactor. I didn't see anything wrong with the motor, but it's hard to see anything without the cover off anyways.


Yep. I just walked in the door and the first thing I do is post a message about it! Haven't even had a glass of water left.

[MetroMPG]

Bummer!! Maybe related or not - but did you have a pre-charge resistor in the circuit?

Got warranty?

[ttoyoda]

You let out the magic smoke. Everyone knows electronics don't work if you let the smoke out.

On the serious side, maybe you just blew out an electrolitic capacitor. The plates can short, the electrolyte boils out, lots of smoke.
If that is all, it should be an easy fix.

[bennelson]

Originally Posted by MetroMPG

Bummer!! Maybe related or not - but did you have a pre-charge resistor in the circuit?

Got warranty?

Yes, I did. I believe the pre-charge resistor only effects the controller when turning the contactor on and off, which is only done manually at the start and end of a ride.


It sure was a lot of smoke.

Just got back with the cycle in the back of the S10. I lowered the back, but haven't had time to lower the front yet. Sure rides low with the blocks AND a cycle loaded in it!

[Daox]

Sorry to hear that Ben. Hopefully you'll have it sorted out soon.

[bennelson]

Yep, it's the controller.

See the pix.

Notice the hole?



This is what it looks like from the other side.


The inside of the controller has epoxy filled in there so it's totally waterproof. When this thing went, it must have blasted a hole right through the end there!

That also means that you can't just get in and replace a single electronic part.
I am calling Alltrax customer service tommorow. Why do I have the feeling my one year warranty just expired.

See all the photos here:
http://gallery.mac.com/benhdvideoguy#100075

[ttoyoda]

The inside of the controller has epoxy filled in there so it's totally waterproof.

Also it makes it that much harder to reverse-engineer/check-for-patent-violations.
There are epoxy removers that claim to be "safe" but I think the PC board has epoxy in it..
http://www.fiber-tensioners.com/BIO-SAFE1025specs.htm

[SVOboy]

Total bummer!

[bennelson]

Actually, I did just dig up the original purchase date info.

Yep, if it was a one year warranty, it was up last week!

[ttoyoda]

Actually, I did just dig up the original purchase date info.
Yep, if it was a one year warranty, it was up last week!

But was that date the order date, or the date it arrived and you had possesion? Because I would think the warranty would start when you got your hands on the part.