Electric Scooter - Motor Controller Failure Part 1

Unfortunately the controller for the rear motor has failed and in the first part of this series of videos I show how to recognise the fault and gain access to replace the faulty unit.
The standard controller unit is always going to be a weak point (probably the only issue for any electric scooter), as the Mosfets are under considerable stress. A replacement unit is being delivered but I am considering an alternative to the standard 37A unit, possibly a 40A Bluetooth programmable controller I already have on my shelf.
The same designer of that module also now has an 80A and incredibly, even an 150A version. However, mounting such a large controller would give me a headache.
The advantage of having twin 2800w motors is you have a lot of headroom to experiment with, as currently the motors are utilised below their full potential.
At some point I hope to draw a wiring diagram, as there is none available, but it's slightly tricky as I have already made many changes to the original electrical system with the addition and change of lights and a tracker etc. I do hope to get this done before the end of summer.
To be continued...

[@johndogg47]

Hi Marcus, I have an x750 scooter 52V and it just quit the other day when accelerating. The speedometer just went black and I can’t get it to turn on. The battery charged up fine so it must be the controller or the screen circuit board itself I’m assuming?

[@marcusoroberts]

John, hard to diagnose remotely. Normally the Mosfets go in the controller, but that shouldn't make your display go black. The display should all be working. I'm guessing the same as you, that it's a total failure of something else in the controller. There is a large electrolytic can capacitor straddled across the voltage rails in the controller that bulges on the lid quite often. Have you checked that? Cheap and easy to replace. Other than that, just change the controller. Sorry I can't be of more assistance. Good luck!

[@Sabrina4life-1234]

Hello I got 3000 watt motors and I was using J&P controllers 2800 watt but once I upgraded motors to type 2 motors my bk B controller keeped blowing every 2 or 3 months I must of brought like 5 of them now I got 3000 watt yunli controllers with a LH-100 display and I keep getting a E10 error code and the same error your showing on your screen but with the solar P1 or janobike T85 for J&P controllers display the flashing box symbol how can I solve this problem cause I need to use 3000 watt controllers

[@FUNNYclippz1010]

Have the same problem could you make a part 2 need it pls and if you have already fixed it pls do a video where you explain how you fixed it and what the problem was

[@marcusoroberts]

@@FUNNYclippz1010 will try to upload. What is the precise problem pls?

[@mcmunoz3372]

Help, please, Marcus!! My greenpower 3 wheeled retro electric mobility scooter is not functioning well. It starts but won't accelerate, moving really slowly. All seem fine and battery is fully charged. I have no clue of where to start or what to look for but with your help I hope to fix it myself if is not to complex. Looking forward to your wise guidance, Marcus. Many thanks.

[@marcusoroberts]

Hiya. First off, is the battery a SLA (Sealed Lead Acid) type? How old is is and roughly how many charge cycles has it received? I ask that because if it is SLA, that is 90% likely to be the culprit. The only way to be 100% certain is to put the scooter on a block (heavy I know), put the throttle on full and measure the each battery cell. I imagine it has more than 1 cell if SLA? Please tell me if it is in fact SLA or lithium powered. Does the power go immediately when you apply throttle or gradually? Cheers!

[@MONICA-SMILES]

@@marcusoroberts Good morning, Marcus! Thanks for your quick response. Let's see.. Lead acid battery it is, bought my scooter in sep. 2018 and charged maybe 6 or 9 times...its starts fine but moves slowly when trying to accelerate the speed, as if something is pulling it from behind... Does it help?... Please note, it is the first time in my life I am tackling mechanical stuff... But with good will to learn new skills, enthusiasm and a Master like you, I have got a good chance to get my 'baby' running again! Many thanks, Marcus!!

[@marcusoroberts]

@@MONICA-SMILES Good morning Monica. I wish you had said lithium battery, because that would not be the problem! How many battery cells make up your battery pack? You need to measure the voltage across each battery whilst under load. Apply full throttle when you put the scooter on a stand or block, and see which one drops below the quoted voltage. Check that out first then we can move onto the controller stage.

[@whiskas242]

Hey my icon is like yours that controller thing but flashes, any ideas of how to fix?

[@magnes7u739]

Hello. Now is have the same problem. Did you fix that ?

[@ELTOROGI_36]

i have also a little box on my lcd i know it is the controller, but if the controller have error does it has an effect on battery performance?

[@MissHitAllTheTime]

I have that box appear only once for a quick few secs after I turn display on and off a few times that disappeared and never came back but recently I got the symbol showing M appear so does that mean my motor is no good or a controller problem can trigger that M to show up???

[@marcusoroberts]

Sounds like a controller issue, or possibly a dodgy connection. I've had similar before. In the 9 years I've been riding hub, dual hub and chain scooters, never has a motor let me down

[@MissHitAllTheTime]

i was talking to a friend and a few also told me its hard to burn out the motor but the motor also have cables too... do you have email where i can send you the pics of the inside of my scooter wires and cable once I took it off??? i took it to e scooter repair shop and the but guy told me that it's my controller that is bad but he didnt tell me if it was both he just said rear controller since i told him my rear wheel stopped working...but when i press dual mode button the front wheel is also unable to move. when i rode home i went up some hill with the front motor working cause i put dual mode on but after 4 miles it started making weird sound coming from the front wheel which i thought my front motor had gone bad too....or did i maybe also messed up my front controller??? so is there a way to let me send you the pics so you can take a look and let me know if its controller, throttle or my motor that has gone bad??? the scooter repair shop is charging me $150 to replace controller if i bring him the exact ones for my scooter but if i want them to use their spare parts which may not even be the same parts for my scooter they charging $300. @@marcusoroberts

[@ricksuarez9653]

My scooter stop running and it wont turn off but when i charged it works again..can you help me pls..

[@Matt_matt1]

Hello I seek your advice on my kugoo m4, 36v lithium, it was involved in crash and since the back motor seems to get power but not rotate, it then gives error 001 but it just refers to motor failure. I have rewired the motor and the same thing happened. Cheers

[@ruestjacques]

My problem is that my scooter shuts off when I go flying downhill, especially on large bridges. If I’m in third gear just tap my brakes for control going downhill. What is the correct way to use gears going downhill on an electric scooter. My Joyor y9 goes 28mph for 50.9 mile range. Thanks 🙏

[@marcusoroberts]

@@ruestjacques that is normal and not a fault of the Scooter. What model?

[@hyrulemasterchef9573]

So I just ordered a Fieabor 80p off Amazon. The controller failure light came on. Same problem. How do I get a new part? Fieabor themselves won’t respond to me. Amazon sends to ship it back. Can I trust that? “Once the seller signs saying they’ve received it, you’ll get your money back”

[@smoxesk]

HOW DID THINGS GO ????

[@richsmith8938]

I have a failed rear motor controller. I'm not technical. Is it possible through the display to disable the controller and ride the scooter with the front motor only? Help if you can,

[@marcusoroberts]

Hi Rick, no it is not possible to disable the rear motor from the LCD control throttle. You can however still ride it with only the front motor, when you select dual motor option. I really don't recommend this as with front motor only the scooter very 'twitchy' and handling becomes aggressive.

[@MissHitAllTheTime]

i rode it like this when my rear motor stopped running and now my front motor doesnt work....it was twitchy and making weird sounds while it was starting to move until it hit a certain speed then the weird sounds goes away.... now when i turn on dual mode it doesnt even work for the front motor...@@marcusoroberts

[@dinomartinovic1204]

I have problem with Wizzard 2.0 E-Scooter, it does work only on charger, when I put it out he shuts down. Can you help??

[@marcusoroberts]

Do you have a SLA (Sealed Lead Acid) battery? It sounds like a battery failure, or one of the cells has gone. This is going to 95% of the problem. If you have a lithium battery, then this is unlikely and is therfore more likely connection problem. Which battery do you have?

[@trickyyy1457]

Hi bro I have a 1000w chaos scooter and it stuck at 2 bars and gose 2mph and it don’t charger the lights stays green any tips I though it was battery but now thinking it the controller

[@marcusoroberts]

Doesn't sound like the controller. Maybe the charger unit is faulty. If you measure the output of the charger unit and make sure you get a good healthy voltage coming out. I can't remember what the polarity of the pins is, but it's 0v or less than 12v then the charger is duff. Otherwise the battery or a loose connection

[@trickyyy1457]

@@marcusoroberts I check the battery’s there all 11v each so there all good but it wouldn t know what els could be

[@PURGE-3000]

I have that lil box also. I changed and put 2 different controllers with display 5 wiring ? Am I forgetting something or need to connect something else for it to start ?

[@marcusoroberts]

Hi, so you're saying you changed both controllers? You only need to change (or repair) one controller. The left one (Controller B) is for the rear motor and the right one (Controller A) for the front motor. Sorry, I want to help but not sure of the question. Could you explain more please? Thanks!

[@PURGE-3000]

Marcus Roberts I mean I bought 2 controllers and installed both. Both had the box symbol blinking. I bought another one and that one worked. I guess those 2 previous controllers I bought from China did not work.

[@marcusoroberts]

@@PURGE-3000 cool. Is it up and running again?

[@PURGE-3000]

Marcus Roberts yes. Thanks for the info though. Really helpful.

[@mohammadrezai1784]

I have some problem help my plz

[@ToHaru-Chan]

Hey dude! I have a T113 with 3200W and sometimes one motor just cuts off! I don‘t know if it‘s the front or rear motor, but when I pull the throttle it starts normally and after 2-3 seconds it loses power af! I release the throttle and repull it again and everything works fine again for a couple minutes! Then it starts again! I believe it‘s the same problem as yours, but on my scooter it doesn‘t show this rectangular prism on the right of the LCD!

[@marcusoroberts]

What happens if you only use rear motor? Does it cut out then? If you use both motors, do they both cut out our does the front motor continue working! All the wiring goes to left controller for the rear motor, and the front motor is wired in parralel. Does the battery charge ok? I suspect the controller is to blame even if there is no fault code showing.

[@ToHaru-Chan]

I think I solved the problem! I switched the motor pairing to 16 and everything worked fine after that and until now!

[@ToHaru-Chan]

Still kinda strange though!

[@ToHaru-Chan]

Maybe it was just the overheating motors! Because I drove when it was really hot outside! Like 38 degrees or so!

[@marcusoroberts]

@@ToHaru-Chan yes they set to default 15 usually but should be 16. Well done dude.

[@CFlenox]

what's that thing in your mudguard x)?

[@marcusoroberts]

It's a number plate :)

[@Steelbee]

Great video!!

[@marcusoroberts]

Way kind!

[@chrislemont558]

Mate, I'm having trouble finding a replacement controller. Not sure what type it is cos nothing is written on the box. Help!

[@ToHaru-Chan]

For what scooter? The T112 has 37A contollers! You can buy them from FLJ directly.

[@chrislemont558]

@@ToHaru-Chan No it's a 2000w Dual. This controller looks too big.

[@ToHaru-Chan]

@Chris LeMont When it‘s a noname brand scooter I can‘t help you!

[@chrislemont558]

@@ToHaru-Chan It has no name. It was just called 2000w Dual Scooter, I bought from Aliexpress last year, but I think I've found an equivalent model.

[@ToHaru-Chan]

Chris LeMont Ok! I wish you the best of luck!😊

[@randygl2904]

What's your scooter's brand and model?

[@marcusoroberts]

Hi Randy, it's a T112 from FLJ scooters. You can get through Alibaba very cheaply. Thanks.

[@waynedavies3185]

On my scooter, I have the small letter "M" show up on my small dash display, and I have had issues with the power cutting in and out. I have brand new batteries in my scooter (less than 3 mos. old since old ones replaced. I also noticed that while this "M" is showing and while the motor is running, I loose the speedo readings (in other words the speedo doesn't work). If I turn the motor wheel, before the "M" is showing on the display, the speedo works properly, but once the "M" lights up, it stops working again. At times, the motor completely stops running, and the letter "M" disappears, but if I turn the motor wheel by about 2 inches by hand from where it last stopped, like a miracle, the motor fires up again, and the letter "M" returns back on the display. Would you say that my issue with my scooter is the same problem you had in this video, regarding the controller. The fellow that has always worked on my scooter, keeps saying it's a battery issue, yet the same thing has occurred, with good used batteries that meet his standards of both voltage, and current ratings. I'd like to also know, if that small letter "M", tells me there's a controller issue causing this problem? Can you help me by answering my questions on this matter?

[@marcusoroberts]

Hi Wayne, The 'M' means there's a motor problem. Almost certainly. Does it happen when you select the rear motor, or what happens when you select dual? It's a very small chance that it's a bad connection, but I'd bet it's a bad motor.

[@waynedavies3185]

​@@marcusoroberts .. First off, Thank You for your kind reply. Wasn't sure if I would hear from you, seeing video was made in 2019. Next, I own a scooter bike, not a two wheel scooter like you have. Inspected the new batteries, and only after a couple of months use, they have all swelled up. They are rated at 20 amps. each by the company that makes them, but now I find they were a very poor buy, due to quality, and will not buy another set of them for my bike in the future. With the battery casings so badly warped, I rather doubt they will give 10 amps of power now. They had welded togther from the heat of charging and usage, and screw driver had to be used to pry them apart. So that's one issue solved, that I was not aware of till today. I also found out today, that the armature inside the motor might have been replaced, from a different model of same make of scooter, which might be another bit of this mystery solved. The armature came from another used "Motorino" scooter bike, that had good controller wiring on it, and to save time in rep[airing my bike, armature, and wiring was installed into my old wheel hub. The guy that did the repair, is doing a check on whether that armature is good enough to run in that hub, or whether there's an issue with it, as well as with the new batteries that were in it. He's going to reopen it up, and check the whole unit, at his expense (even if it requires getting another better armature for my bike). I'll know in a day or so, about his findings. He has a new shipment of batteries coming in tomorrow, so they will be both checked, and then be installed It's possible, that there maybe, bad winding in that armature he installed, that he didn't know about. Normally when my scooter is running right, that scooter can easily travel at 55kms. per hour at top speed with two people on it. Just sitting on the rear wheel stand, it max's out at 62 kms. with no effort at all without cutting, in and out. I'm hoping this guy will finally get it back in the same order again. Thanks for letting me know what that "M" means. It's not listed in the owners manual, that I finally found on the internet, and didn't get when the bike was new. Kind regards, and again thanks for the come back.

[@waynedavies3185]

@@marcusoroberts ... Thank you for your kind reply, and confirming that the letter "M" is definitely a motor issue problem in my scooter bike. I have only one drive motor, located on the back wheel. My scooter looks more like a Vespa (but is an electric motor version), than a foot/standup scooter version you have, with two motors (both front and rear. Mine runs on 60 volts Dc, (5 batteries in series). I installed a brand new set of 20 amp batteries, on My 30 2020, and already they have over heated, and wrapped from excessive heat. I'm again replacing them with what I hope are better batteries, of the same value. The fellow that worked on my scooter, after the pedal chain cog, spun off, and cut through my rear wheel wiring, told me he had replaced the whole armature (Wiring included), from another bike like mine (new wiring was also included). It appears, that what replacement part he installed had defects somewhere within it, which is causing the cutting in and out of the motor's operation, even with fully charged batteries. My scooter is back at his shop, and it's now his job to correct the problem at his expense, as I have already paid for the repair back in May of 2020, and it wasn't corrected fully by him, so he now has to finish the job I paid him to do, at his expense. Thanks again for your kind reply. I'll update you once the repair is finally completed. Take care and safe. Wayne.

[@marcusoroberts]

@@waynedavies3185 Hi Wayne, thanks for sharing. So, it sounds like the batteries are Sealed Lead Acid rather than Lithium..? Please keep us updated. Stay safe!

[@MissHitAllTheTime]

i think i have this same somewhat similar problem with mines...wondering if the M which i keep thinking something is wront with my motor is the speed controller that controls the rear motor making the rear wheel not work which just shows M and is not the motor problem but the controller that controls the rear motor is the problem. even though display shows up with M???

[@lakey526]

Hi Marcus. Not sure if you are able to help. I have just bought the t112 scooter and want to set it up like yours with mirrors, seat and what looks like a number plate. I want to make mine street legal as i am using mine as a mobility scooter. I'm 58 but still like to have that power there. Can we chat some how. My name is phil by the way?

[@marcusoroberts]

Hi Phil, sorry for tardy response. How might I help? I think the T112 is a really terrific scooter. I was one of first to get one and is a good choice. The number plate on the T112 is rigged and took it off my Evo Uberscoot which is fully road legal; one of the very few in the UK to have that status. The number plate is just for the photos.

[@lakey526]

@@marcusoroberts Hi Marcus. Thanks for getting back to me it's much appreciated. I feel like scooter riders are all being painted with the same brush, and i think it's because of the young'ns who tare around with no regard to safety or highway code etc. I have walking difficulties and want to use my scooter for mobility. I am 58, have full UK driving license, ( clean) and don't want to have my scooter compounded or points on my license. I'd like to get my t112 road legal with all relevant lights, registration etc. I don't know if it's going to be possible but I have to try. When you think, most vehicles are able to break speed limits so i don't see why you can't have a powerful scooter ( which can be restricted to say 30. I realize it might be impossible to achieve what I'm after but i have to try. Do you have any suggestions mate. By the way, are you still scooting? Regards Phil

[@tamarjohnson8615]

I have an error code that looks like a screw symbol does anyone know what kind of error that is?

[@marcusoroberts]

Hi, it means a throttle/LCD related problem.

[@pauloa.7609]

@@marcusoroberts hello! I changed the lcd for another exactly same model (new) and that "screw symbol" aka throttle problem persists. Maybe it can be the controller's fault? The scooter accelerates by itself all the time. I've bought two new controllers (1 for the rear motor and one for the front motor) meanwhile, just curious about the problem.

[@MissHitAllTheTime]

what does the symbol that looks like a rectangular box on the display mean???? and if i see this one [M] ?@@marcusoroberts

[@tambaytripmoto9697]

Boss panu ba dagdagan ang speed

[@marcusoroberts]

I don't understand you. English.

[@ashirhussain6554]

The motor dont work

[@ashirhussain6554]

What happend

[@MONICA-SMILES]

Marcus! Hi! Hope you are well safe and happy.. Apologies for the late response.. The situation... Well it is lead acid.. Took some pics could that help?? Many many thanks

[@marcusoroberts]

Hi Monica, I'm good thank you and trust you are too. Well, thanks for clarifying but it's almost certainly the battery. Not sure if it is one large pack or several connected? If it's several connected (might be series but more likely parallel) it will be a damaged cell and there's no way to fix other than replacement of battery - hopefully they're is a lithium replacement. If several batteries then you need to lift the scooter off the ground, run full throttle and measure for lower voltage on each battery. But look, it MIGHT be a controller fault too...

[@MONICA-SMILES]

@@marcusoroberts Marcus!!! I can't believe it!! We fixed it, we fixed it!! My 'baby' is in good health and running!! Thank you, thank you, thank you!!! 💋💋💋💋💋💋💋

[@marcusoroberts]

@@MONICA-SMILES hey Monica today's wonderful news. Well done!

[@MONICA-SMILES]

@@marcusoroberts indeed!! And you are the best, Marcus!! 👏👏👏👏👏👏

[@marcusoroberts]

@@MONICA-SMILES you did it all yourself 👏👏

[@SamusWorth]

Wait is Ur scooter registered for road use of so how lol

[@marcusoroberts]

Type Approval Process. Cost more than a car. Will never do again. EVER!

[@SamusWorth]

@@marcusoroberts ouch yh when I went to register my dualtron for the road I saw how much it would of all costed n thought hell no haha

[@marcusoroberts]

@@SamusWorth my previous scooter had a certificate of conformity. I only had to fulfill the V55 and Certificate of Newness. This however had to go through full DoT testing in addition. Took forever.

[@SamusWorth]

@@marcusoroberts ouch yh when. I saw all that will my scooter I just thought screw that haha

[@TheLondonCyclist]

@@marcusoroberts Silly man lol why on earth would you register a little electric scooter? Zzzz lol

[@ashirhussain6554]

And i have battery

[@MissHitAllTheTime]

i had this problem with scooter for the front motor when the display was doing this before the motor stopped running. kzbin.info_BshnDVhECE the mph its showing is jumping from different numbers and motor or wheel making weird sounds similar to this guy's scooter.

[@ashirhussain6554]

I have Momas s2