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Guides and repair information for electric bicycles.

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Repair EV bike Batteries

IFIXIT has not included this fastest growing sector of repair issues. We have two EV bikes, one a few weeks old, and the other that we have had for 6 years. That is the one that needs attention. As a bicycle it is perfect. However, the motor cannot run because the battery has been exhausted and cannot be charged. There will be millions of these situations, as well as electric motor vehicles that over the next 5 to 7 years will need replacements. For now, I am trying to get some help on how to rebuild the battery pack. Battery packs are not especially complicated. The have basically two or three components: 1. the batteries, 2. a circuit board that supplies energy to instruments and controllers for the bike, and method for assembling the batteries as they are in series as far as I know. If anyone can get me started, educated, advised, or suggested, I will welcome that with open arms. Please reach out to me if you have any questions, but more important to me is to provide advice and help on how I can proceed. Thank you.

Update 9/1/2024

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Update (09/11/24)

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where are the images I uploaded?

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See if this helps. I think I loaded the images correctly but never sure. PLEASE let me know if get them. I will resend if necessary. I added them to the upload icon at the ribbon on the website.

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@mlb_fixit nope! ;-) You can only add imaged to Questions and Answers etc. so follow the guides in the original answer.

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@mlb_fixit you are right, they are not complicated. What they do need is to pay close attention about the connections. Just by the voltage and amperage of most of these batteries, you should already have realized that they are wired in a basic series / parallel connection. I just rebuild one a week ago which was a 48V 20aH battery. All of this from common 18650 13S 4P batteries. Again, not knowing the specs of your battery, I can only speak about the one I just finished. Couple of things you want to do for now. First, we need the specs for the battery. Then we need to see it. Post some well-focused pictures of the battery etc. with your Question Adding images to an existing question - iFixit Repair Guide We'll probably ask you that a couple of times :-)

Next you want to have some basic tools, a couple of good sharp knifes, something like a box cuter or Exacto knife is perfect. Then you want to invest in a handheld battery spot welder. You can get those for about ~$35-$45 USD You will most likely also need some extra nickel strips. Once you have your battery apart, it'll be easier to determine the size of those.

The steps in general are ==>disassemble battery==>remove insulation/shrink wrap==> disconnect battery control board==> evaluate individual cells==>desolder cells==> replace cells==>reconnect wiring/nickel strips==> reconnect battery controller==>rewrap insulation/shrink wrap.

As with anything else, common sense is definitely required. Even those batteries can pack a punch and can cause a fire hazard.

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can you provide me with a few leads such as: where can i buy new batteries, can i short those batteries like a capacitor to provide more safety, can i find instructions on how to remove the plastic "holds" on the front and the back of the battery container? Most of all, can i find a direct route to you or most of all your email/messaging? Please let me know.

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@mlb_fixit I kind of suck with email etc. so the best way is on here. Let's see what battery you have there. Post some good pictures of everything you have so far, so we can follow right along.

No, you do not want to shorten those oit.out. It really is not necessarry. You have plus and minus on opposite ends so you should be okay.

As for buying batteries stay away from Amazon,ebay, aliexpress etc. To many counterfeit batteries and to many used batteries sold as new etc. If you are located in the US check the one on here and if you are going to buy bulk this one

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did you ever get the images i sent of the battery? there has to be a better way to communicate with me but i must need some training on this as i sent the images two times

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@mlb_fixit nope, no images. Sorry, we all try to keep things on iFixit. Thtay we all learn and nobody goes off on a tangent. It just works better than email etc.

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@mlb_fixit is the case seamless? If those then you will have to most likely pull (or push) the complete battery pack out of the case.

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casing is sealed on an edge. front and back have heavy dabs of glue or sealant keeps the batteries and the circuit board in place. I will need a very sharp long knife to cut through it. Will hot air make it easier? I have to be careful of the circuit board that is integrated into the tube

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@mlb_fixit hot air is okay for as long as it is not to hot. A simple hair dryer fill be sufficient. It also will not damage the battery, controller board etc.

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well i have a high and low switch so i will use the cooler leg and move away from the pack and see how it goes. Once i get it out I will lean on you for what I will need to get these batteries stable and balanced. Again, most appreciated.

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Hello, I have now removed the batteries from its container. Can you give me any sense of the next step? Would appreciate it if you could

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@mlb_fixit here comes the fun part. You have to measure the voltages on the cells. They should all be pretty much be in the same area. You are looking for one or two cells that are off. Watch your polarity since some of the cells are placed in an opposite direction.

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OK I have a meter and I will see what the ranges are and let you know. Won't I need some kind of device that will help me balance them? If so, please recommend.

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@mlb_fixit that should have been accomplished by your charge Battery controller board. I have a MiBoxer charger that allows me to charge any individual cells. Remember, right now you are just looking for "the odd man out"

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I will provide you with correct voltages and let's see what happens thereafter. thanks again

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the range of the batteries are between 2.4 through .2.7 V DC. I'm getting the feeling that the batteries are fine, but the BMS has an issue. That will be harder for me to trouble shoot as I don't see any obvious swelling or burn out on the circuit board. I have no experience with circuit boards other than soldering. Any thoughts?

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@mlb_fixit you might just be below the threshold where the charge controller may not allow it to charge. Since you now have it apart, can you post more image of the battery?

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@mlb_fixit have you disconnected the battery pack from the charge controller and measured the voltage of the pack?Take a couple of good pictures of your charge controller so we can try and identify that as well.

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