Our E-Bike Process

Step-by-Step E-Bike Diagnosis and Repair Process

1. Initial Assessment

Our process begins by gathering as much information as possible from you, the rider. We ask specific questions to understand the symptoms you’re experiencing, such as:

• Sudden loss of power or diminished range
• Unusual noises coming from the motor or drivetrain
• Problems with the display, throttle, or controller
• Reduced braking efficiency
• Odd handling or vibrations

This helps us narrow down potential problem areas so we can dive into the right diagnostics.

2. Visual Inspection

Before we dive into deeper diagnostics, we start with a detailed visual inspection of your e-bike. This helps us spot any obvious damage that may have caused the issue. We check:

• Battery & Wiring: We look for loose connections, exposed wires, or signs of corrosion, which can interfere with the electrical system.
• Motor & Cabling: We inspect the motor casing and all connections for wear and tear or external damage.
• Brakes & Tires: A thorough examination of the brakes and tires ensures nothing is visually out of place or overly worn, which can compromise safety.
• Frame & Suspension: We look for any cracks, bends, or other structural issues that might affect the integrity of the bike.

This step alone is often enough to find the culprit, but it’s just the beginning.

3. Battery Testing

The battery is one of the most common sources of problems, but diagnosing battery issues is no simple task without the right tools and expertise. Here’s what we do:

• Battery Health Assessment: Using specialized tools and diagnostic software, we assess the battery’s performance under various loads to see if it's charging, discharging, and holding power correctly. This is much more complex than simply checking voltage levels and requires precise measurements that most riders can’t do at home.
• Charge Cycle Analysis: We simulate real-world use to see how the battery performs over a range of conditions. If the battery drains too fast or doesn’t reach full capacity, we can tell immediately.
• Battery Management System (BMS) Diagnostics: If your e-bike uses a BMS, we use advanced testing methods to check whether the BMS is working correctly, ensuring the battery charges safely and efficiently.

When batteries fail these tests, it’s often hard to pinpoint the exact issue without the tools we use, which is why this can be a frustrating problem for riders to solve on their own.

4. Motor and Controller Testing

The motor and controller are the heart of your e-bike’s performance. Diagnosing issues with these parts requires more than just looking at them; it involves deep system checks that are beyond what most riders can do without specialized equipment.

• Controller Diagnostics: We use a series of load tests to see how well your controller is delivering power to the motor. If power delivery is inconsistent or weak, it points to a faulty controller. These tests simulate real-world conditions that can’t be replicated by simply checking wiring.
• Motor Performance Testing: We spin the motor under controlled conditions to test its efficiency, looking for internal faults like overheating, resistance, or mechanical issues that might be causing performance drops. Our tools allow us to pick up on minor problems that may not be noticeable to the untrained eye.
• Wiring System Check: We run extensive tests to ensure that every wire between the motor, controller, and battery is intact and free from damage. Tracking down breaks or shorts in the wiring system is something that requires both experience and precise equipment.

If we find issues in the motor or controller, repairs or replacements are often necessary to restore peak performance.

5. Throttle and Display Diagnosis

Throttle and display malfunctions can be tricky to diagnose since they involve both electrical and mechanical systems working together. Here’s how we approach it:

• Throttle Responsiveness Check: We test how your throttle responds under load, identifying any dead spots or irregularities that might signal a failing throttle. Diagnosing throttle issues isn’t straightforward, as it can involve complex interactions between your e-bike’s motor, controller, and wiring.
• Display System Inspection: If your display isn’t showing accurate information or isn’t functioning at all, we go beyond the surface to check for deeper connection issues. This involves verifying the communication between the display, the controller, and the battery, which requires advanced diagnostics and often involves replacing faulty components.

Trying to fix these issues without the proper expertise usually leads to more confusion, but we make sure every component is functioning in harmony.

6. Brake System Check

A functioning brake system is critical for rider safety, and we inspect it thoroughly for any problems that could compromise performance:

• Hydraulic Brake Testing: For e-bikes with hydraulic brakes, we ensure there are no leaks, and the fluid levels are correct. Diagnosing hydraulic systems is a specialized task, requiring a precise understanding of fluid dynamics and brake pressure that most riders can’t assess on their own.
• Mechanical Brake Assessment: If your e-bike has mechanical brakes, we check the tension of the brake cables and adjust them as necessary to ensure smooth, reliable braking. Adjusting these properly requires a delicate balance that can be difficult to get right without experience.
• Brake Pad & Rotor Condition: We closely examine the brake pads and rotors to identify signs of wear, such as thinning pads or warped rotors. These components wear down over time and can dramatically affect braking performance if not maintained.

We make any necessary repairs or replacements to ensure your brakes are working at their absolute best.

7. Tires and Drivetrain Inspection

For a smooth and efficient ride, we also inspect your e-bike’s tires and drivetrain. Here's how:

• Tire Wear and Pressure Check: We check for uneven wear, punctures, or cracks that can affect handling and safety. We also ensure your tires are inflated to the correct pressure, which is crucial for both performance and comfort.
• Drivetrain Inspection (Chain, Cassette, Derailleur): We examine the drivetrain components for wear, stretching, or misalignment. This includes lubricating the chain and making any necessary adjustments to the derailleur to ensure smooth shifting. Riders often struggle with drivetrain maintenance due to the precision required to set everything just right.
• Pedal Assist System (PAS) Testing: We test the PAS to ensure it engages correctly and works seamlessly with the motor. The PAS system relies on sensors and software, which we check to make sure everything is calibrated and functioning as intended.

Without regular care, these parts can wear down quickly, but we make sure everything is in top shape for peak efficiency.

8. Test Ride and Final Adjustment

After completing all the diagnostic and repair work, we take your e-bike out for a test ride to ensure everything functions properly:

• Real-World Testing: We simulate the kinds of rides you’d take to check that the motor, battery, and all components are working harmoniously. Any odd noises, performance lags, or braking issues are addressed immediately.
• Final Adjustments: If necessary, we make small adjustments to fine-tune performance, ensuring everything is as smooth and responsive as it should be.

Only after we’re confident in the e-bike’s performance do we consider the job complete.

9. Customer Feedback and Handover

We provide you with a detailed explanation of the diagnostics and repairs we performed, offering tips on how to maintain your e-bike for the long term. We’ll also discuss any potential upgrades or additional services that could improve your ride.

At CJ Bikes, we use advanced tools and years of expertise to diagnose and repair even the most complex e-bike issues. While many of the tests and checks are difficult or impossible to perform at home, our expert team has the skills and equipment to ensure your e-bike gets back to peak performance quickly and safely.