Levo Gen 2 Motor and harnesses waterproofing

[1Nixxxo]

Hi!
Stated research on waterproofing materials for harnesses and motor. Bought 3M Scotch 1601 liquid tape for harnesses isolation where wires enter the plugs.

didn’t have an opportunity to try it on Levo cause I’m still waiting for delivery.

Sprayed it in on plastic plate, took a small brush and covered USB C cable just to see how it goes. I do like the result (maybe 2 layers will work better), I like the fact that this film can be removed with the knife. Removed the film from from plastic and it looks like a plastic bag the can be stretched 3-4 mm before it starts to tear apart. Thinking about applying a wide layer on motor gasket and around connector ports too to seal everything.

Had anyone tried liquid tape already? Any bad experience?

 

[boBE]

I would start with replacing the connectors with ones that are designed for the worst conditions: construction equipment. Those connectors live in water/dirt/mud/worse for years without a problem. Look for Deutsch DT connectors, they work.

 

[1Nixxxo]

I would start with replacing the connectors with ones that are designed for the worst conditions: construction equipment. Those connectors live in water/dirt/mud/worse for years without a problem. Look for Deutsch DT connectors, they work.

You mean to replace brose connectors entirely? Do they stock compatible plugs?

 

[boBE]

Replace whatever connectors we can. With molded-in ones we are stuck but they can be semi-sealed with silicone grease.

 

[1Nixxxo]

Replace whatever connectors we can. With molded-in ones we are stuck but they can be semi-sealed with silicone grease.

Sure. I bought Molykote 111 Compound specifically for that purpose.
Basically I'm more worried about water ingress in a places where wires enter plastic connector. TCU harnesses look so unprotected, especially in case if small wires got bended by power cable for instance. That’s exactly where I intend to put liquid seal.

 

[Mikerb]

the 1601 3m spray looks to be a good solution for the TCU and the in line connectors in the top tube. There is little or no need for anything other than grease for the connections into the motor PCB, and the V3 motor to battery cable seems to have been totally reliable.
My bike has been through 2 very wet UK winters with no problems. It has the V3 cable, the TCU and top tube in line connector is taped ( insulating tape and amalgamating tape) and I made a gasket to go between the frame and the TCU.
One other area where the 1601 could possibly be useful is where the TCU cable passes in and out of the frame behind the rear shock. Water ingress there can run along the cable down towards the motor PCB connectors.
I make sure the connectors on the motor PCB are fully protected with lithium grease and refresh that once a year.
Trying to seal the motor casing is probably only possible with the motor removed from the bike.
The only other protection I would recommend is a cover over the battery/charge port connection. I made a neoprene cover held onto the bike with HD self adhesive velcro.

 

[1Nixxxo]

the 1601 3m spray looks to be a good solution for the TCU and the in line connectors in the top tube. There is little or no need for anything other than grease for the connections into the motor PCB, and the V3 motor to battery cable seems to have been totally reliable.
My bike has been through 2 very wet UK winters with no problems. It has the V3 cable, the TCU and top tube in line connector is taped ( insulating tape and amalgamating tape) and I made a gasket to go between the frame and the TCU.
One other area where the 1601 could possibly be useful is where the TCU cable passes in and out of the frame behind the rear shock. Water ingress there can run along the cable down towards the motor PCB connectors.
I make sure the connectors on the motor PCB are fully protected with lithium grease and refresh that once a year.
Trying to seal the motor casing is probably only possible with the motor removed from the bike.
The only other protection I would recommend is a cover over the battery/charge port connection. I made a neoprene cover held onto the bike with HD self adhesive velcro.

Thanks, that the answer I was waiting for! Do you have Kenovo or aluminum Levo? I ordered basic model with cables running open sidearm, so yeah, I was looking at the plastic cover holding cables together and thinking about how water will run directly through this cover right into motor casing ? Good idea to completely seal this sidearm opening with Liquid tape, great idea!
I was also considering to apply silicon and to spray along the gasket on the motor just to be totally sure it’s safe ?

Can you attach photos of your DIY neoprene cover, plz? Was thinking about the same solution ??
And what’s your opinion on spraying liquid tape on the hole under the chainstays where Specialized used foam and plastic lip to to stop the ingress mayhem or this hole involved in the motor cooling?

 

[1Nixxxo]

Also, it seems to be a nice solution Power cable guide. Quite easy to do with TinkerCAD.

 

[Mikerb]

Thanks, that the answer I was waiting for! Do you have Kenovo or aluminum Levo? I ordered basic model with cables running open sidearm, so yeah, I was looking at the plastic cover holding cables together and thinking about how water will run directly through this cover right into motor casing ? Good idea to completely seal this sidearm opening with Liquid tape, great idea!
I was also considering to apply silicon and to spray along the gasket on the motor just to be totally sure it’s safe ?

Can you attach photos of your DIY neoprene cover, plz? Was thinking about the same solution ??
And what’s your opinion on spraying liquid tape on the hole under the chainstays where Specialized used foam and plastic lip to to stop the ingress mayhem or this hole involved in the motor cooling?

My bike is MY2019 Levo Comp ( ally).
For details of the neoprene cover search for "Its a cover up" thread on the forum by me ( mikerb).
Re the motor casing, we may have some confusion here. The motor itself has magnesium casings. You cannot get to the complete joint where one half of the casing is joined to the other when the motor is in the bike. What you see on both sides of the bike are the black motor covers. These have no gaskets and no seals. Any water or dust/dirt that gets between the motor and the covers can run out through a drainage hole on the underneath of the motor so the main thing is to ensure that hole does not get blocked. In terms of limiting ingress of dust/mud/water into the motor covers all that is required is a good mudguard arrangement on the back wheel. Specialised now fit a rubber protector on the chainstay cross member and a chunk of motofoam on the other side of that inside the motor cover. All I would recommend to supplement that is a rear mudguard that comes down flush with that cross member, a small piece of motofoam to block the hole when the rear calliper cable and speed sensor cable run into the motor cover, some additional motofoam inside the non drive side motor cover and plenty of lithium grease around the connections into the motor PCB. Quite apart from riding through 2 very wet winters my bike has been semi submerged in one riding fail through flood water..............no problem at the time or since.

 

[Mikerb]

Also, it seems to be a nice solution Power cable guide. Quite easy to do with TinkerCAD.

not needed. It was not the fact that the cable was "kinked" that caused the problems with the previous version of the cable. It was that the "kink" in turn applied pressure to the d shaped cap at the motor end causing it to split and allow water ingress or in more severe cases break one or more of the cable connections inside the cap. The V3 version of the cable resolved that problem by removing the stiff outer cable casing for about 3/4 of the cable length, replacing it with a much less stiff covering; then using small zip ties to make effective seals at each end of the cable. Version 3 was introduced in January 2020 and I have seen no reports of that version of the cable causing any issues since then.

 

[Mikerb]

ps...........I like the fact that you are prepared to look out for potential design weaknesses as far as waterprofing is concerned and being prepared to deal with them. The Levo is by no means alone in having those design weaknesses. I have yet to see an EMTB that deals with the electrical side of its design that does not need some additional work! Many Bosch equipped bikes have batteries in the down tube with a flimsy cover right in the path of everything thrown by the front tyre, some held in with flimsy catches or locks that will sonn get clogged with dust etc, charging points with totally ineffective covers, usually positioned in the most vulnerable place on the bike you could think of, 3kg of battery sat on its connection pins whilst the bike is thrown around rough terrain, power buttons and/or bar mounted controllers that are no more waterproof than a mobile phone. Most issues easily resolved with a bit of forethought.

 

[1Nixxxo]

My bike is MY2019 Levo Comp ( ally).
For details of the neoprene cover search for "Its a cover up" thread on the forum by me ( mikerb).
Re the motor casing, we may have some confusion here. The motor itself has magnesium casings. You cannot get to the complete joint where one half of the casing is joined to the other when the motor is in the bike. What you see on both sides of the bike are the black motor covers. These have no gaskets and no seals. Any water or dust/dirt that gets between the motor and the covers can run out through a drainage hole on the underneath of the motor so the main thing is to ensure that hole does not get blocked. In terms of limiting ingress of dust/mud/water into the motor covers all that is required is a good mudguard arrangement on the back wheel. Specialised now fit a rubber protector on the chainstay cross member and a chunk of motofoam on the other side of that inside the motor cover. All I would recommend to supplement that is a rear mudguard that comes down flush with that cross member, a small piece of motofoam to block the hole when the rear calliper cable and speed sensor cable run into the motor cover, some additional motofoam inside the non drive side motor cover and plenty of lithium grease around the connections into the motor PCB. Quite apart from riding through 2 very wet winters my bike has been semi submerged in one riding fail through flood water..............no problem at the time or since.

Motor body (sure, not casing, pardon) consist of two parts joined together with long bolts and there’s a gasket between two halves. Motor should be removed, yes, that’s the point. Haven’t decided on removing it yet, but might ask my mechanic to remove it just for sealing purpose alone.
I have a huge snd ugly rear MudHugger and also ordered another flexible mudguard.
Silicon water resistant compound is already ordered.
Motofoam in the holes where cables enter is mandatory, sure ??

 

[1Nixxxo]

ps...........I like the fact that you are prepared to look out for potential design weaknesses as far as waterprofing is concerned and being prepared to deal with them. The Levo is by no means alone in having those design weaknesses. I have yet to see an EMTB that deals with the electrical side of its design that does not need some additional work! Many Bosch equipped bikes have batteries in the down tube with a flimsy cover right in the path of everything thrown by the front tyre, some held in with flimsy catches or locks that will sonn get clogged with dust etc, charging points with totally ineffective covers, usually positioned in the most vulnerable place on the bike you could think of, 3kg of battery sat on its connection pins whilst the bike is thrown around rough terrain, power buttons and/or bar mounted controllers that are no more waterproof than a mobile phone. Most issues easily resolved with a bit of forethought.

Thank you!
I also ordered all harnesses and planning to order a spare TCU as well ??
Why? Because Merida e160 2019 was ridden in super terrible and harsh conditions without a single flow, was even submerged once without any circumstances. Actually, now I understand that Shimano produces superb motors in terms of protection from the elements, really! My mates have at least 9 Merida e160 with e8000 and none of the died from water ingress (but some of them did after unsuccessful firmware update ?).
So I got used to Shimano motor sealing and want to prevent water ingress on my new Levo from the start.

 

[1Nixxxo]

not needed. It was not the fact that the cable was "kinked" that caused the problems with the previous version of the cable. It was that the "kink" in turn applied pressure to the d shaped cap at the motor end causing it to split and allow water ingress or in more severe cases break one or more of the cable connections inside the cap. The V3 version of the cable resolved that problem by removing the stiff outer cable casing for about 3/4 of the cable length, replacing it with a much less stiff covering; then using small zip ties to make effective seals at each end of the cable. Version 3 was introduced in January 2020 and I have seen no reports of that version of the cable causing any issues since then.

Thanks for info! I hope they succeeded with MK3 cable. But to be totally sure I’ll apply Liquid tape to seal small wires on both sides of power cable and will seal it back with zip-ties. 5 minute job, 200% peace of mind.

 

[1Nixxxo]

My bike is MY2019 Levo Comp ( ally).
For details of the neoprene cover search for "Its a cover up" thread on the forum by me ( mikerb).
Re the motor casing, we may have some confusion here. The motor itself has magnesium casings. You cannot get to the complete joint where one half of the casing is joined to the other when the motor is in the bike. What you see on both sides of the bike are the black motor covers. These have no gaskets and no seals. Any water or dust/dirt that gets between the motor and the covers can run out through a drainage hole on the underneath of the motor so the main thing is to ensure that hole does not get blocked. In terms of limiting ingress of dust/mud/water into the motor covers all that is required is a good mudguard arrangement on the back wheel. Specialised now fit a rubber protector on the chainstay cross member and a chunk of motofoam on the other side of that inside the motor cover. All I would recommend to supplement that is a rear mudguard that comes down flush with that cross member, a small piece of motofoam to block the hole when the rear calliper cable and speed sensor cable run into the motor cover, some additional motofoam inside the non drive side motor cover and plenty of lithium grease around the connections into the motor PCB. Quite apart from riding through 2 very wet winters my bike has been semi submerged in one riding fail through flood water..............no problem at the time or since.

Nice design! Thank you!
Neoprene cover

 

[1Nixxxo]

Today my spare harnesses arrived! Levo should show up in a few weeks, so it was time to try Liquid Tape on new ones just to see what happens.
Result is greate IMO, should keep any moisture out definitely!
Applied three layers, each after 15 minutes, took an hour to dry, but seems that they need more time before the smell is gone.
As I couldn't find Plastic Dip Liquid tape, I had to somehow apply it from spray can. What I did is that I sprayed liquid into the plate and than used ear cleaning sticks to apply the liquid. Small brush will be more up for the job, but at least my method worked. Harness stayed flexible, without any kinks, looks safe to bent even more, all holes are sealed 100%.