Battery Care and Maintenance

Optimal Charging Practices

• Charge regularly - Don't let battery fully discharge frequently
• Store at 40-60% - For long-term storage (over 1 month)
• Avoid extreme temperatures - Don't charge in freezing or very hot conditions
• Use original charger - Third-party chargers may damage battery

Winter Battery Care

• Bring battery indoors - Remove and store inside when below 32°F
• Use neoprene cover - Insulate battery during cold rides
• Warm before charging - Let battery reach room temperature first
• Expect reduced range - Cold weather decreases capacity by 20-40%

Battery Storage Tips

• Check charge level monthly during storage
• Recharge to 50-60% if voltage drops
• Store in cool, dry location (50-70°F ideal)
• Avoid storing fully charged for extended periods

Chain and Drivetrain Maintenance

Chain Lubrication Process

1. Clean the chain - Use degreaser and brush to remove old oil and dirt
2. Dry completely - Wipe with clean rag until no residue remains
3. Apply lubricant - Drop oil on each link while slowly pedaling backward
4. Wipe excess - Remove surface oil to prevent dirt attraction
5. Frequency - Repeat every 200-300 miles or after wet rides

Mid-Drive Specific Care

Mid-drive motors put extra stress on chains and cassettes:

• Check chain stretch - Replace when wear gauge indicates
• Inspect cassette teeth - Watch for wear patterns or sharp edges
• Shift properly - Don't force shifts under heavy motor load
• Use quality components - Higher-grade chains last longer with e-bike power

Brake System Maintenance

Brake Pad Inspection

• Check thickness - Replace when pads are less than 1mm thick
• Look for glazing - Smooth, shiny surface indicates overheating
• Verify alignment - Pads should contact rim or rotor squarely
• Test feel - Brakes should engage progressively, not grab suddenly

Disc Brake Adjustments

1. Rotor alignment - Wheel should spin without rotor rubbing pads
2. Pad position - Adjust caliper so pads contact rotor evenly
3. Cable tension - For mechanical discs, adjust barrel adjusters
4. Hydraulic bleeding - Service hydraulic brakes annually or when spongy

E-Brake Sensor Maintenance

• Test cutoff function - Motor should stop immediately when brakes applied
• Adjust sensitivity - Light pressure should trigger cutoff
• Check connections - Ensure sensor wires aren't damaged or loose
• Clean contacts - Remove dirt or corrosion from sensor switches

Common Error Codes and Solutions

Bafang Motor Codes

Tongsheng Motor Codes

Generic Troubleshooting

• Error 10-19: Usually sensor-related issues
• Error 20-29: Typically throttle or control problems
• Error 30-39: Communication or wiring faults
• Error 40+: Often motor or controller hardware issues

Common Problems and Quick Fixes

Motor Not Engaging

Possible Causes:

• Battery charge too low
• Loose connections
• PAS sensor misaligned
• E-brake sensors engaged

Solutions:

1. Check battery charge level
2. Inspect all cable connections
3. Align PAS sensor magnet
4. Verify brake levers aren't triggering cutoffs

Reduced Power or Range

Possible Causes:

• Battery aging or cold weather
• Incorrect tire pressure
• Drivetrain friction
• Heavy use of throttle

Solutions:

1. Check tire pressure (proper inflation improves efficiency)
2. Clean and lubricate chain
3. Use pedal assist instead of throttle when possible
4. Have battery tested if significantly degraded

Display Issues

Possible Causes:

• Loose display connection
• Water damage
• Settings corruption
• Low voltage

Solutions:

1. Disconnect and reconnect display cable
2. Check for moisture in connectors
3. Reset display to factory defaults
4. Verify battery voltage at display

Unusual Noises

Motor Grinding:

• Check for loose bolts
• Inspect motor mounting
• Verify gear alignment (mid-drive)

Chain Noise:

• Lubricate chain
• Check derailleur adjustment
• Inspect for chain wear

Brake Squealing:

• Clean brake pads and rotor/rim
• Check pad alignment
• Replace worn pads

Routine Maintenance Schedule

After Every Ride

• Quick visual inspection for damage
• Check that battery is secure
• Wipe down if muddy or wet

Weekly (or every 100 miles)

• Clean chain and check lubrication
• Inspect tire wear and pressure
• Test brake function and e-brake cutoffs
• Check for loose bolts

Monthly

• Detailed cleaning of entire bike
• Inspect all cable connections
• Check brake pad wear
• Verify derailleur adjustment

Seasonally

• Complete system inspection
• Professional tune-up if needed
• Battery capacity test
• Update firmware if available

When to Seek Professional Help

Contact a qualified e-bike technician for:

• Persistent error codes after basic troubleshooting
• Motor replacement or complex electrical issues
• Hydraulic brake bleeding
• Firmware updates or programming changes
• Battery pack replacement or cell-level diagnosis

Try This

Schedule a routine inspection every 500 miles or monthly, whichever comes first. Create a simple checklist of bolts to check, connections to inspect, and functions to test. This prevents small issues from becoming expensive repairs.