Haibike.... "Critical Error"

[Swissete]

Hi guys,

This has happened to me already 4 times in the last month.

When happening, you feel in the pedals the motor is pushing normally, then stopping power for 1/3 of a second, pushing again, skipping power and then shutting off the motor showing the error. There's nothing I can do to troubleshoot it. The point is that it just shuts down and after powering it up again, it works correctly and never happens again on that very ride.

As examples it always happened in Eco which is the only mode I use normally. Between 15 and 25km/h, in plain road just pedaling softly or pushing hard climbing. During the first 5kms of the ride or on the 25th km, with battery full or at 20% only. There's no exact criteria.

The only common denominator I can think of is the creaking noise in the motor zone. The Flyon motor is mounted only with two huge screws that in my case tend to get slightly loose after each 10 rides or so. When they are a bit loose, and I mean lets say 1/30th of a turn (to say something), when pedaling hard you can hear some creacking noises. As a matter of fact, when there's creaking, I can suffer from the critical error. When I tighten like hell both screws and there's no creaking, I have not suffered from the error... not yet. For instance I had creacking noises and had the error, tighten the screws and the next 4 rides were perfect.

Has anyone had the error or the creaking noise?

 

[Sidepod]

I've not had any creaking noises or errors like that. If you say you are having to re-tighten the motor mount screws (2xT40) then i would guess there is an issue with the connector on the top of the motor where it connects to the herness. there will be a specified torque setting for these fixings. I don't know what this figure is.

What I can say is that the clearance around the motor outer casing to the inner face of the bike frame is tight. Take the motor out and make sure there are no cables routed under the motor between the motor case and frame. Make sure the mounting flanges of the motor case are sitting down snug on the bosses of the frame. it's quite easy to see if it's ok. I posted a "motor out" thread on here recently. That may help. What I've said above I found out when I replaced the motor and there was a gap between the motor casing mounting points and the frame. Once the cables were routed correctly it sat down perfectly.

 

[Swissete]

Totally agreeing with you. the mounting of the motor has to be perfect. By the way, mine are Torx-30 and don't know why as I've seen both options. Would like to have a couple of spare screws...

If the mounting is not perfect you can also have the creaking. Look at the below picture. You can see the upper side of the motor was almost touching the frame casing while the below part hast 2mms of space. When pedaling softly I had the creaking cause the motor was pushing up. When pedaling hard I pushed the pedals and the motor down hence cracking stopped . Had to reseat the motor and tighten the two screws again.

Today I've ridden for the fourth time with no noises and no "critical erros". it has been 90Km now with no issues.

 

[Sidepod]

Hmmm, that's just looks like poor tooling/trimming of the component when it comes out of the mould. you could try some thick tape around the motor casing in the area where it touches the carbon of the frame. Bit too tight as it is. I suppose a couple of flat shims under the motor mount would add clearance. The electrical connector should have enough engagement to cope with 0.5mm of shim?

 

[Sidepod]

Could it be that the frame moulding is not letting the motor seat down properly?

 

[Swissete]

To fix that issue I've added a 1mm washer between the frame and the motor and that provides the needed space for them not to touch.

 

[Sidepod]

Wow that seems quite thick. You need to bear in mind the O-ring between the two halves of the main electrical connector. This O ring is very thin, less than 1mm dia so in other words you may well have compromised your IP rating (water ingress) of the motor. It gets squashed between the two halves when you insert the motor. Worth checking.

 

[arawa]

I am probably taking you in completely the wrong direction - but just in case.
I had a similar symptoms (not exactly but close) when my speed sensor was VERY slightly warped. No creaking though. Sometimes power just cut in and out as I pedalled other times there was no power there at all. Switching off and on again usually worked for a while.
Replaced the sensor and all has been well since.

 

[Swissete]

Wow that seems quite thick. You need to bear in mind the O-ring between the two halves of the main electrical connector. This O ring is very thin, less than 1mm dia so in other words you may well have compromised your IP rating (water ingress) of the motor. It gets squashed between the two halves when you insert the motor. Worth checking.

You are totally right and I was not thinking about that. The bike doesn't touch any serious water, not even much mud and when it's raining I just stay home . I live in Spain hence not much raining so not confining me much. Having said that, I have to be cautions with the sealing which for sure is not on par with the design when using washers...

 

[Swissete]

I am probably taking you in completely the wrong direction - but just in case.
I had a similar symptoms (not exactly but close) when my speed sensor was VERY slightly warped. No creaking though. Sometimes power just cut in and out as I pedalled other times there was no power there at all. Switching off and on again usually worked for a while.
Replaced the sensor and all has been well since.

Thanks for the comment Arawa. BTW, did you ever have any of those critical errors forcing the shutdown? or was it just a strange behaviour. Who knows, I may have two different and isolated issues being the creaking and the display error

 

[arawa]

Thanks for the comment Arawa. BTW, did you ever have any of those critical errors forcing the shutdown? or was it just a strange behaviour. Who knows, I may have two different and isolated issues being the creaking and the display error

I did sometimes have error messages displayed with the power cutting out but I don’t think they were the same as yours. Sometimes the power went with no message displayed.
My friend with the same bike had a shut down with a critical error message but our LBS plugged his bike into their computer and instantly identified the fault; he was switching it on with his feet on the pedals

 

[Sidepod]

Perhaps one thing to take from this, always take the battery key when you ride. It may be the only way to do a hard reset, remove the battery.

 

[Tyrrell]

Yes feet on pedals is the problem, I have the same with mine, turn it on without putting feet on pedals it’s good as gold and no critical errors showing

 

[Jackware]

The PW-X motors have the same guidance as the Flyon;

 

[Swissete]

The error shown when pushing the pedals while booting up is different. It's identified. In my case, the critical error says "unknown".

BTW, last seven rides with issue at all.

 

[brian isaacson]

i have had the issue with sporadic critical error message and motor shutdown since i bought my flyon nduro 10 6000km ago. happnes only in eco mode and never on the other power settings. some rides over 60 km without a problem and then next ride it comes back. can it be temperature related-the weather in alberta can go from 2-3 c to 16-20 c over course of a day and the problem seems to occur when its colder but again the pattern of failure is intermittent. otherwise no issues with the bike apart from it being a little too heavy for extreme technical trails. when the error does occur, i power off and then on again and it will other cycle again to the critical error message or work fine for a while. starting up with feet off the pedals is not an issue -luckily the manual points this out. any help to address this very annoying issue will be appreciated

 

[brian isaacson]

Hi guys,

This has happened to me already 4 times in the last month.

View attachment 46775

When happening, you feel in the pedals the motor is pushing normally, then stopping power for 1/3 of a second, pushing again, skipping power and then shutting off the motor showing the error. There's nothing I can do to troubleshoot it. The point is that it just shuts down and after powering it up again, it works correctly and never happens again on that very ride.

As examples it always happened in Eco which is the only mode I use normally. Between 15 and 25km/h, in plain road just pedaling softly or pushing hard climbing. During the first 5kms of the ride or on the 25th km, with battery full or at 20% only. There's no exact criteria.

The only common denominator I can think of is the creaking noise in the motor zone. The Flyon motor is mounted only with two huge screws that in my case tend to get slightly loose after each 10 rides or so. When they are a bit loose, and I mean lets say 1/30th of a turn (to say something), when pedaling hard you can hear some creacking noises. As a matter of fact, when there's creaking, I can suffer from the critical error. When I tighten like hell both screws and there's no creaking, I have not suffered from the error... not yet. For instance I had creacking noises and had the error, tighten the screws and the next 4 rides were perfect.

Has anyone had the error or the creaking noise?

i just posted my first entry on the forum about this exact same issue. i have 6000 km on my flyon nduro 10 and this has been a continuing problem. i've been trying to figure out the patttern of the failure -very frustrating as the bike will work beautifully for a couple 100 km and then the error message appears for no apparent reason. its only in the eco mode and never in any other power setting.last night after a 20 km ride during which it kept happening every few meters, i finally just left it on low without an issue. when i got home i left the bike on my stand and put it back to eco. after a minute just leaving it on the stand, the critical error appeared without even being on the bike. the only thing that seems to point to a pattern or etiology is the ambient temperature. it was very cold during my ride yesterday- 2-3 C with a cold wind. today i rode the bike 60 km with the temperature around 12 c and no issues whatsoever. the temperature here in alberta can fluctuate markedly thruout the day as we are near the rocky mountains. i never ride this bike in the rain so I dont think moisture is the issue. i also have never heard a creaking noise from the motor.
when the bike works without this electronic glitch, its pretty terrific but the critical error message is a real downer when it happens.
anyone have any other ideas? if it is indeed an ambient temperature problem, I have no idea how to insulate the motor or electronics.

 

[arawa]

Sorry to hear of your problems. Apart from the information i have posted previously, both my friend’s and my Flyons have been faultless with no more error messages. However, we are never out in temperatures as low as you are experiencing and like you rarely are out in rain.

 

[Pistolpete]

Hi guys,

This has happened to me already 4 times in the last month.

View attachment 46775

When happening, you feel in the pedals the motor is pushing normally, then stopping power for 1/3 of a second, pushing again, skipping power and then shutting off the motor showing the error. There's nothing I can do to troubleshoot it. The point is that it just shuts down and after powering it up again, it works correctly and never happens again on that very ride.

As examples it always happened in Eco which is the only mode I use normally. Between 15 and 25km/h, in plain road just pedaling softly or pushing hard climbing. During the first 5kms of the ride or on the 25th km, with battery full or at 20% only. There's no exact criteria.

The only common denominator I can think of is the creaking noise in the motor zone. The Flyon motor is mounted only with two huge screws that in my case tend to get slightly loose after each 10 rides or so. When they are a bit loose, and I mean lets say 1/30th of a turn (to say something), when pedaling hard you can hear some creacking noises. As a matter of fact, when there's creaking, I can suffer from the critical error. When I tighten like hell both screws and there's no creaking, I have not suffered from the error... not yet. For instance I had creacking noises and had the error, tighten the screws and the next 4 rides were perfect.

Has anyone had the error or the creaking noise?

I'm just a newbie at this game but have you tried putting some locktight on the screws,you can get the type thats medium strength so you can undo them again if you need to, that should solve the issue for that part at least!