Elation eBike Technical Support - V2

[zx6rj1]

Hey guys, seeing that Elation is no longer supporting the product due to going out of business, lets share information here !

I will copy critical information here, just in case things are missing in the future:
http://polygon-quatro.blogspot.com/2011/10/elation-ebike-technical-support-v2.html

Index:
Motor : http://endless-sphere.com/forums/viewtopic.php?f=2&t=32773#p475901
Throttle: http://endless-sphere.com/forums/viewtopic.php?f=2&t=32773#p475906
Shunt Resistor: http://endless-sphere.com/forums/viewtopic.php?f=2&t=32773#p476262
Modifying to external controller: http://endless-sphere.com/forums/viewtopic.php?f=2&t=22514
Charging Port: http://endless-sphere.com/forums/viewtopic.php?f=2&t=32773#p476337
Freewheel Crankset clutch: http://endless-sphere.com/forums/viewtopic.php?f=2&t=32773&start=15


I'll start with the original specification, had to get this from the wayback machine.

===
Description Order # Price
200 Watt with LiFePO4 Battery Pack ebk200-1 $1,430

# Common Equipment for kit

* eLation designed crank system
o 28/38/48 T Gear ring set based on BCD 64/104 four hole standard.
o 48 T steel gear ring for motor drive based on BCD 104 four hole standard.
o eLation Alloy Cranks
o eLation Spider and sprag clutch drive
* eLation designed motor mount system
o Bike mount plate
o Bike Flexi Chain
o Motor mount plate
o 24VDC 200W Brushless motor with planetary gears
* Built in motor controller with protection circuit to prevent
o over current
o over temperature
o under voltage
* Half Grip Twist throttle control
* 3 LED battery status indicator, built into throttle grip housing
* On/Off switch, built into throttle grip housing
* ALL mounting hardware and detailed instructions
* Weight added to bike (excluding battery) 4kg


# LiFePO4 Battery Pack

* 24VDC 10Ah 3C (5C max) LiFePO4 Battery Pack, including key lock security
* Battery Management System (BMS)
* eLation Battery mounting kit
* 110-240VAC 24V 5A battery charger (approx 2-3 hours for full charge)
* Battery Weight 3kg (including case)
* Battery Dimensions 350mm*85mm*85mm

 

[zx6rj1]

MOTOR

Elation v2 uses Cyclone motor (170w version??)

There are great dissassembly pictures here:

http://mrbill.homeip.net/albums/cyclone_motor/index.html

 

[zx6rj1]

Problem: Intermittent connection after long use.

In my case it started after >2 yrs, so I suppose this is normal wear/tear or dirt.

Solution: Spray WD40 from the front of the switch. Avoid spraying the electronics. A more elegant solution would be to replace the switch, as it looks generic enough and may be available from Jaycar, etc.

Note, someone suggested that "Inox" is better than WD40.

Don't forget to cut the power from the key when assembling/dissasembling! I nearly fried it.

The "ORO" Throttle also looks similar to Cyclone.

 

[kfong]

I believe most of it is just a repackage cyclone. Just an improved motor mounting system. The original mounts from cyclone were garbage. I ended up making my own.

 

[AJK]

I have a v.3, have had some troubles, but only with the plastic bits that are part of the add-ons to the system (ie. battery face, charger, thumb throttle). Disappointed that there is now now assistance/service as I now have an issue with the crankset and sprag. Allan sent me up a replacement, but I think that's the last of the support. Shame as the motor is great (fastest bike on the bikeways!), but now not certain about keeping it.

Allan wrote the following when posting up the replacement crankset and sprag. Does this mean much to anyone?

"You will need to hacksaw through crank in such a way to allow the sprag to be knocked out. Then replace sprag, and attach new crank."

Cheers

 

[heathyoung]

You can replace the (crappy) oro throttle with a standard throttle.

Upgrading the power of the controller to 350W is also easy, just swap the shunt resistors with those half their value. I had a 180W that I converted to a 350 one weekend (since 180W is lame, and it has a 200W sticker on it anyway - that means its 200W - right )

 

[zx6rj1]

That's not good. My V2 crank developed intermittent "jam".

If it's the same design as V3 then it may not be replaceable.

 

[zx6rj1]

You can replace the (crappy) oro throttle with a standard throttle.

Upgrading the power of the controller to 350W is also easy, just swap the shunt resistors with those half their value. I had a 180W that I converted to a 350 one weekend (since 180W is lame, and it has a 200W sticker on it anyway - that means its 200W - right )

Please expand in details ? What is this "shunt resistor" ???

What is a "standard throttle"


Edit: Found it:
http://endless-sphere.com/forums/viewtopic.php?f=28&t=14846&start=0

Is it really that easy ??

 

[Ricky_nz]

Even better than modifying the internal controller, convert to external one and dump even more power into the poor little motor :lol:

I started with the 300W NZ version of the Early V2
http://endless-sphere.com/forums/viewtopic.php?f=2&t=22514

 

[zx6rj1]

That's just crazy

 

[heathyoung]

On the internal controller ones you have to remove the PCB to do so, but yes, replacing the shunt resistors for double the power is trivial.

External controller is more fun, I would think too - the internal controller's mosfets are strained because they take the heat load of the windings, and their own 'on' resistance (which climbs with temperature - so its a nasty cycle).

 

[zx6rj1]

PROBLEM: Charging port intermittently disconnect

After prolonged use, the connection is lose. Sometimes need to wiggle to get a charge. I had ignored this until last week when the battery died on the way to work.

Replacement: Jaycar XLR port, Part #PS1018
http://jaycar.com.au/productResults.asp?keywords=ps1018&keyform=KEYWORD&SUBMIT.x=24&SUBMIT.y=4

It fits almost perfectly, just need to sand the edges a bit

Replacement is quite easy, just remember the polarity. Note that turning off the key does not cut power, so solder the live wires extra carefully and avoid contacts.

 

[Rusty the Peddlehead]

Found a place
Electro Bikes - 10/58 Deshon St Woolloongabba
Ph: 07 3392 0588 - 1300 781 866

These guys have 2 or more v2 bike kits complete.
Ring em to find out more.
No good to me as Im looking for a drive sprocket for my 48volt v 3 motor.

 

[FionaB]

Anyone know where to get a new battery (or substitute battery) for an elation v2 bike now that the elation founder has ceased trading? Some helpful person in my household turned off the power point to the charger for the battery, and now the battery is permanently dead.

 

[lesspedal]

I would go here. http://www.pingbattery.com/servlet/the-24V-LiFePO4-Battery-Packs/Categories

For more range than the elation 10 ah battery, get the 15 or 20 ah batt.
You will have to arrange your own connections etc.

 

[Rusty the Peddlehead]

Fionab,
These people may have a battery.

Electro Bikes - 10/58 Deshon St Woolloongabba
Ph: 07 3392 0588 - 1300 781 866

I found this place at Deshion Street Woolloongabba with several used and brand new what appears to be elation
V2 kits. Im still chasing a bloody drive sprocket for my v3 and found these helpful guys showing me kits they inherited from the somewhere !
Alas these kits are no use to me by I'm sure someone on this forum can use them to get their old V2 going again.
hope this helps.Ask them for some photos if your not is Brisbane.

 

[bigtoneloc]

Hi all,

I had elation one kit, then when the chain kept falling off bought the v2 kit which has been great.

Lesspedal, is it safe to use a 20A battery mentioned in http://www.pingbattery.com/servlet/the-24V-LiFePO4-Battery-Packs/Categories when the original v2 kit ships with a 10A battery?
I'm in the same boat as the battery is fading after a few years use. I'm thinking of getting the 15A or 20A and installing it on my rack for extra range.
It's the voltage that cant be exceeded but higher amps are OK?

The wiring doesn't look too complex I reckon I can run up a lead for it back to the engine and pull out the old battery holder and wiring.

Tbone.

 

[lesspedal]

Yeah mate, as long as it is 24v.
I have thought about the ping 24v, 20 ah, reckon I could get 50klms of hard riding.

Amp hours is simply how much fuel is in the tank.

 

[bigtoneloc]

Lesspedal,

Thanks for the advice. Yeah the extra range is appealing, I was riding from Maroubra to Nth Sydney and had to take the charger with me for the return leg. I want to avoid that if possible.
it's nice to slide up the bike track with the engine barely humming, it will be a bummer when the world catches on.
It's a shame about elation, my dealings with Allan were pretty good. Ahead of it's time maybe?
I've just sent $447 Australia dollars (inludes $80US delivery etc) for the 20A battery to Mr Ping.
I figure that equals 7 tanks of gas in my commodore!
I will let you know how I go.

Tbone.

On another note, I passed a place on Botany Rd Alexandria with these Wolf Gaucho ebikes parked out the front, they looked pretty nice!

 

[bigtoneloc]

Oh and I just checked my original battery and after 2 years it's only showing 5A after a charge (not the original 10A), no wonder I'm pedalling!

 

[CommuterK]

Found a place
Electro Bikes - 10/58 Deshon St Woolloongabba
Ph: 07 3392 0588 - 1300 781 866

These guys have 2 or more v2 bike kits complete.
Ring em to find out more.
No good to me as Im looking for a drive sprocket for my 48volt v 3 motor.

Hey Rusty the Peddlehead,
I am also looking a drive sprocket for the V3 motor. It's proving difficult - have you had any luck?
Kind regards

 

[Rusty the Peddlehead]

Hmmm !

I curse my stupidity for buying a bloody Elation shite box.(seemed like a good idea at the time)
I still cant source parts. I had a friend knock up a couple of sprockets but he lacks the drill bits to drill the hardened
drive shaft. So I have to source a machinist to tap new holes.
But wait thats not all ,the el cheapo, poor design peddle clutch is slipping. This is a pressed unit and not serviceable, good one Allan. I cant source a clutch.
I still charge the battery regular with the hope I will one day get a clutch.
Thinking of selling the lot for parts and buying a ZOCO e bike. Looks good, no dumb arse design problems like the elation. The NuVinci N360 hub looks sweet and requires no maintenance or adjustment. No more wearing out cassettes or constantly cleaning out grass ,twigs and dirt from the cassette.
The Zoco seems like a sensible replacement without the worry I had with Elation. The real plus is spare parts will be available from other dealers if my local one should suddenly close up shop.

Sooooo if anyone knows where to get the peddle clutch biso for an Elation E bike kit please let me know.
Thanks heaps.
Rusty.

 

[zx6rj1]

My V2 Freewheel Crankset had given up for a long time now. So I am researching how to get the Sprag clutch fixed.

The Clutch seems to be CSK-PP34 (or CSK35PP)

Previous communication with Allan from elsewhere:
http://endless-sphere.com/forums/viewtopic.php?f=28&t=21248&start=15

Quotes from Allan:

In V2 I was using an off the shelf CSK-PP35 with keyway on both rings

Detail:
OD 62mm
ID 1.37", 24TPI. This lines up with standard bike threads
Width 15mm. This is 1mm norrower than standard to allow to give 'perfect' fit to cranks able to accept freewheels.
Outer ring Keyway 8mm wide, 1mm deep
Combined bearing and sprag with seals on each side

NOTE:
Once the bearing is on, it is not the easiest to remove as there are no tags, etc to allow easy undoing. I considered this at time of design, but felt for eLation needs it was not needed as we sell the crank 'spider' as a complete unit. It does not mean it can't be removed (awkwardly during assembly), but is pretty much there to stay once operational. For the time being, based on eLation's needs this is not needed to change. However, if there is enough interest I can review this choice and have a batch done to accomodate removal.

At present for my prototyping needs I uses a grinding wheel to cut a couple of goove on inner ring edge to allow for tools to remove

It seems the Sprag Clutch is not designed to be replacable


Possible source to buy the Sprag Cluth:

http://www.vxb.com/page/bearings/PROD/Kit10973
http://www.amazon.com/CSK35PP-Bearing-Freewheel-Backstop-VXB/dp/B0045DYEKU
http://simplybearings.co.uk/shop/product_info.php?products_id=152526


What it possibly looks like:

Alternatives:

If I can't get the clutch out, it seems an alternative is to replace the whole crankset with Cyclone Chainwheel parts. Not ideal, but...
http://www.cyclone-tw.com/order-chainwheel.htm

 

[jk1]

You can get freewheel cranks from here it seems:

http://www.ebay.com.au/itm/AFT-Motorised-200w-Electric-Motor-Bike-Bicycle-Kit-/190661139307?pt=LH_DefaultDomain_15&hash=item2c644a1b6b

This is the only place i have found that use the ACS crossfire freewheel in the cranks, they are even better then the ENO freewheel and a lot better then the cylone brand DICTA or elation type CSK 35.

http://endless-sphere.com/forums/viewtopic.php?f=28&t=25153&hilit=freewheel+acs+crossfire&start=45

 

[diesirae]

Can anyone direct me on to where I can purchase a battery for my elation bike. Not sure where the model no is on the battery. The battery is slightly slimmer then the original one. It's a long rectangle shape. Mind is a 200w motor.