{"id":405,"date":"2015-10-25T16:19:08","date_gmt":"2015-10-25T16:19:08","guid":{"rendered":"http:\/\/www.chrisscycles.co.uk\/?p=405"},"modified":"2016-09-18T14:42:29","modified_gmt":"2016-09-18T13:42:29","slug":"electric-bike-repair","status":"publish","type":"post","link":"https:\/\/www.chrisscycles.co.uk\/index.php\/2015\/10\/25\/electric-bike-repair\/","title":{"rendered":"Electric Bike Repair – Another Satisfied Customer"},"content":{"rendered":"

Electric Bike Repair:<\/strong><\/p>\n

A\u00a0customer brought in his Kalkhoff Sahel Compact for an electric bike repair.\u00a0 He said ‘the chain was slipping’.\u00a0 We quickly ascertained that this was not the case, and it was in fact something not connecting in the drive mechanism.<\/p>\n

\"Kalkhoff<\/a>
Kalkhoff Sahel Compact Electric Bike<\/figcaption><\/figure>\n

This bike is a pedal assist type, so the motor will only cut in to boost your pedal power.\u00a0\u00a0With an impressive battery this gives the bike a very respectable range – up to 100 miles or so on a good day.\u00a0\u00a0Although this obviously depends how much power assistance you select.<\/p>\n

He had been quoted \u00a3600\u00a0for his electric bike repair.\u00a0 To\u00a0replace the drive assembly (yes, you have to buy the whole thing and presumably pay a fitting fee too!).\u00a0 As the bike was out of warranty, we had nothing to lose by removing it from the bike and opening it up (after consulting Joe, the very helpful service manager at 50 Cycles<\/a>, the importers over in Leicestershire).<\/p>\n

 <\/p>\n

 <\/p>\n

\"Electric<\/a>
Separating the two halves of the drive unit.<\/figcaption><\/figure>\n

Dismantling was fairly straightforward but time consuming.\u00a0 We\u00a0took photos at every step to show the position of everything,\u00a0including the electrical connections.\u00a0 We can’t be too careful when working on an electric bike repair\u00a0for the first time!\u00a0\u00a0Once the drive unit was removed and on the bench, it was a simple matter of removing 8 bolts around the casing edge and separating the two halves (as shown in photo). \u00a0My assumption before opening the casing was that there was a freewheel mechanism of some kind inside that engaged when you pedalled, but freewheeled when you stopped (this would normally be on the back wheel on a standard bicycle).<\/p>\n

My assumption proved to be correct. \u00a0I could see as soon as I opened the casing that there were two pawls on the pedal spindle.\u00a0 These were supposed to flick out with spring assistance and engage the drive when you pedalled. \u00a0These two pawls (see photo) were gummed up with old dry grease and were not moving, so the pedals were spinning free and you were going nowhere.<\/p>\n

\"Drive<\/a>
2 pawls on the pedal spindle<\/figcaption><\/figure>\n

 <\/p>\n

After carefully removing the two pawls and the wire spring (see photo), they were thoroughly cleaned in solvent and reassemble on the shaft with fresh oil, then re-assembled.\u00a0 The casing does have a rubber gasket between the two halves but I also put a thin smear of silicone gasket around it to make sure it sealed.\u00a0 You don’t want water and road gunk getting inside there!<\/p>\n

\"Drive<\/a>
The spring and the two pawls were cleaned in solvent<\/figcaption><\/figure>\n

 <\/p>\n

After that it was a simple matter of putting it all back on the bike.\u00a0 The drive unit is a very snug fit in the frame and required some leverage to get it in place and\u00a0connecting everything up.\u00a0 A quick test drive confirmed that everything was in working order.\u00a0 The customer was relieved to have a bill that was a small percentage of what it could have been. \u00a0I reckon I spent the best part of 5 hours on the bike, but gave it all a check over while it was in the workshop. \u00a0I advised him to replace the front tyre in the near future as it was starting to show small cracks, but apart from that it was good to go. \u00a0NEXT!<\/p>\n

 <\/p>\n

Contact Chris’s Cycles to carry out your electric bike repair!<\/h2>\n","protected":false},"excerpt":{"rendered":"

Electric Bike Repair: A\u00a0customer brought in his Kalkhoff Sahel Compact for an electric bike repair.\u00a0 He said ‘the chain was slipping’.\u00a0 We quickly ascertained that this was not the case, and it was in fact something not connecting in the … Read More<\/a><\/p>\n","protected":false},"author":1,"featured_media":576,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_exactmetrics_skip_tracking":false,"_exactmetrics_sitenote_active":false,"_exactmetrics_sitenote_note":"","_exactmetrics_sitenote_category":0,"footnotes":""},"categories":[239,409],"tags":[245,242,240,241,243,244,246],"class_list":["post-405","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-bike-repairs","category-electric-bikes","tag-bike-repair","tag-bike-repairs","tag-electric-bike","tag-electric-bike-repair","tag-kalkhoff","tag-sahel","tag-satisfied-customer"],"yoast_head":"\nElectric Bike Repair - Another Satisfied Customer - Chris's Cycles<\/title>\n<meta name=\"description\" content=\"Contact Chris's Cycles to carry out your electric bike repair. 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