Xtreme x500 clone with weird power issues - Any ideas?

[WattNot]

Hi ES. I've been reading the forums here with much interest over the last few months, and it's time to join as I've just taken on my 2nd project. It's causing some headaches I must admit. I bought a broken down XTreme X500 clone on eBay. And it was really broken down, I've had to replace and renew at least 50% of the components. I've got a power problem that's really making me scratch my head. When the motor and batteries are all connected as they should be (through the controller), it produces so little power at full throttle that I can hold the back wheel still with my hand. It sounds like its going for it, but there is no torque whatsoever, barely enough to propell it's own weight. So I tried connecting the batteries directly to the motor and missing out the controller all together. Totall different story.....loads of power. It nearly came off the stand I had it on . So is it just a faulty controller and as simple as getting a replacement? Or is the controller ok and is kicking in some sort of protection mode. Anyone of you experts got any ideas or solutions that might help? Cheers

[Kin]

In addition to the controller problem, you may also be having a problem with the controller. I'm trying to think of an easy way to test out whether that is the problem.

I was going to suggest you short the 5v pins on the throttle connection, but I don't know how that will react. Perhaps there is a safty mechanism that prevents that. It's also possible that full voltage is 0% throttle, and low voltage is 100% throttle. Alternatively, if you have a spare throttle (e.g, from your first throttle), I would try connecting that.

The only other problem I see could be the controller. However, it's cheaper to try out the throttle. I'd be careful about connecting batteries directly to the motor- if you're using Lipo you could really pump some high current through it and burn things out in short order :p


I would wait on seeing if anyone else knows if shorting the pins corresponding with the throttle signal will give 100% power.

[WattNot]

Thanks for the advice Kin, I've actually ordered a new controller yesterday, so that'll sort the question out once and for all! can't wait to try it out properly. the 500w motor really put out some power when connected directly to the batteries. Don't worry, the batts are just 4 x 12v/7Ah SLA's, nothing exotic But I would love to swap in some A123's or something similar in the future. The LiPo route would be great, but they're a bit daunting for the beginner.

[Dave-s]

You might have a problem with the motor.
The motor might be semi fried. i.e it still turns when power is applied, but not fully functioning.
Some of the windings in the motor might be shorted together (the insulation on the winding might have melted due to strenuous work, thus shorting the windings) so you are not getting full power when applying power via the controller.
The controller has a current limiting function, not allowing the motor to pull as many amps as it wants to operate.
When you connect the batteries directly, the motor has no current limitation, and is pulling more amps than usual.
The problem also might be with the controller itself, or the throttle.

[WattNot]

So, the controller solved the issue straight away. I bought a controller rated up to 800 watts and it all seems to work fine. Now I've just got to take the whole scooter apart and service it all, replace the brakes and a lot of the wiring. Then I'll see how it goes. Thanks everyone for the help

[Kin]

Glad to hear of success! Oi, wish the winning answer wasn't the one i posited as a minor sidenote. Glad you didn't have to buy an extra throttle.