Proper way of using the battery cover?

[Ted3]

Hello,

are there instructions on how to properly attach the battery cover so that it won't fall ?
I've got eONE-SIXTY carbon (CFA II frame) 630Wh 2021 with this cover:

On this video the cover is removed (and not attached) by pulling up, but by doing so the upper part gets locked (as shown in the exploded view diagram)?
On the lower side right under the black pin (#32 in the following diagram) where the rubber hole is attached (in the frame) there's a silver part (also visible in the #32 in the diagram) that turns around 360 degrees, I guess this one must be positioned upwards so that the cover attachs into it? But when you pull the cover upwards locking it in the upside part, the cover no longer reaches the silver part at the bottom.

So must the cover be pulled down, up or put in the middle ? And do the small latches on the left & right sides of the cover attach somehow ?

 

[conman]

I've got 2 velcro straps around mine, got tired of going back to look for it.

 

[Ted3]

OK I found 2 instruction videos, the second one finally clears things up:



Unfortunately on the second video there are only 9 views as I posted this, the link was found on the merida bike model page under "VIDEOS". So many covers have been lost by users worldwide because there are no proper instructions shipped with the bike.

 

[steve_sordy]

Despite attaching the cover in what was as far as I could tell the "correct" way, it kept coming off. My bike was bought ex-demo from JEJames and I discovered that at some point, either me or one of the JEJ team had not fitted the cover properly and sprained the guide fins.

If you look carefully at the edges of the cover, down the long sides, there are small fins. There is a narrow channel between the fins and the edges of the cover. That channel should be filled by the edge of the carbon fibre frame. The fins on my cover were all over the place meaning that the cover could never be fitted correctly.

What I did to fix it was to heat the fins with a hairdryer and move them into place with a screwdriver, flat blade, flat scraper, steel ruler (whatever works). Then I fitted the cover into place but this time ensuring it was fitted properly. Then I secured it with three loops of zip ties to ensure that it stayed in place. It was a hot summer at the time so I left it like that for a few rides before removing the zip ties. When I removed the cover, the fins were all perfectly placed. I refitted the cover, no zip ties this time, and it has stayed in place ever since.
I don't remove the battery very often, preferring to charge in situ, but each time I remove the cover it is always spot on and I take care to replace it properly.

If you are in your winter, I would suggest that once the cover is in place and secured with the zip ties that you give the edges of the cover another good blasting with a hairdryer. That should soften the fins and the edges of the cover and allow it to settle into the correct position. Good luck!

 

[Ted3]

After 3 years of charging the battery to full every day, even when the temperature where the bike is as low as 5C (and the battery colder than that after riding e.g. in -10C), the battery lasts for only around 1,5h while a new battery lasts for 3 hours.

With the old battery I never removed the cover so it stayed on perfectly as it was installed from factory, now I'm learning how to fit the cover properly.

I checked the fins, they seem OK. Even when the cover seems properly secured in the top and the bottom part after installing the cover as instructed in the video, the fins dont easily attach on the both sides, leaving a small cap on either side (or both sides) of the cover.

What's the best way of securing the fins? Simply pushing hard, or must the cover be slided downwards or upwards while doing so ?