Levo Gen 2 Specialized Levo Turbo 2020 - wont turn back after 4/5 hours

[asturah]

Hi all, i have seen a few threads on this but wanted to share my experience.

Asfter 4/5 hours of my Levo not in use it wont turn back on unless i open/close the batter compartment door. Then it comes back on all is good. I dont have any issues when riding it, it only does this when its turned off for the above hours..

I took it to the LBS this week for them to diagnose but i expected they would chnage the Main Harness cable from Motor to Battery which they did to the new version cable.

The issue is still there..
What other things could this be, they are beinging me a replacement TCU to try this week so thats something.
The bike is out of warranty now but id like to explore as many options as i can - i have tried cleaning the connecter with electrical contact cleaner - still showing this issue.

Anything else i can try or people with a similar issue who has solved this?

 

[James_C]

I've had it for months. Its currently gone away again though. No idea why.

 

[asturah]

I've had it for months. Its currently gone away again though. No idea why.

What year Levo do you have?

 

[James_C]

2020 gen2

 

[Mikerb]

sticking pogo pin (battery side of the Rosenberger plug connection)

 

[asturah]

What is a sticking pogo pin please?

sticking pogo pin (battery side of the Rosenberger plug connection)

 

[Mikerb]

What is a sticking pogo pin please?

the pin connectors on the battery side of the connection.

 

[asturah]

the pin connectors on the battery side of the connection.

The cable is brand new so the connectors seem fine on that.

On the actual battery connector - those pins seem pretty solid

 

[OzzySmb]

The same thing as you have, after a few hours it won't turn on. I need to plug off the motor to the battery cable, plug it on again, and then all good, the bike switches on.

After long research I discovered my TCU to motor cable has a little kink at the TCU end just before the connector.
The kink was the result of stacking the cable in a small area into the frame, it was just pushed in with many twists, so it got damaged wire(s).
So when I kink it a little, wire(s) must get connected again, and then the bike starts just fine after pushing the button.

Replace TCU to motor cable, it's cheap, it may resolve your problem also.

 

[asturah]

The same thing as you have, after a few hours it won't turn on. I need to plug off the motor to the battery cable, plug it on again, and then all good, the bike switches on.

After long research I discovered my TCU to motor cable has a little kink at the TCU end just before the connector.
The kink was the result of stacking the cable in a small area into the frame, it was just pushed in with many twists, so it got damaged wire(s).
So when I kink it a little, wire(s) must get connected again, and then the bike starts just fine after pushing the button.

Replace TCU to motor cable, it's cheap, it may resolve your problem also.

View attachment 154278

Something to consider but I’m not sure if it’s that.
The wire seems pretty straight and when I remove the TCU and move the cable round it never comes back on.

Only when I open/shut the connector door does it fire up

 

[Tetley]

I've just repaired a problem with my 2020 gen 2.
After not riding for month, I connected the battery cable, and the TCU powered up on its own. It then powered down after a few seconds, and wouldn't switch on from the button, but did on re-plugging in the battery. Lots of erratic behaviour later, and unable to ride it, I removed and tested the battery cable as this was the no.1 suspect. Continuity and insulation resistance was fine, apart from one pin, (which is the brown wire) is not connected, and shouldn't be.
So I then disconnected the motor to TCU cable, and tested - continuity was fine, but insulation resistance was very poor between all combinations of pins. After half hour with hair drier on the plug, the readings were no better, but if I wiggled the wires, the readings changed. So water had been trapped inside, with no escape even with extreme heat.
New cable posted from Berkshire Cycles, and it's fixed!

 

[asturah]

I've just repaired a problem with my 2020 gen 2.
After not riding for month, I connected the battery cable, and the TCU powered up on its own. It then powered down after a few seconds, and wouldn't switch on from the button, but did on re-plugging in the battery. Lots of erratic behaviour later, and unable to ride it, I removed and tested the battery cable as this was the no.1 suspect. Continuity and insulation resistance was fine, apart from one pin, (which is the brown wire) is not connected, and shouldn't be.
So I then disconnected the motor to TCU cable, and tested - continuity was fine, but insulation resistance was very poor between all combinations of pins. After half hour with hair drier on the plug, the readings were no better, but if I wiggled the wires, the readings changed. So water had been trapped inside, with no escape even with extreme heat.
New cable posted from Berkshire Cycles, and it's fixed!

I suppose for 29.99 it’s worth changing - it looks a straight forward change

 

[KTMJack]

I had a problem a year ago . The charging cable is a magnet and it picked up a little piece of metal of the floor and caused it to not start and charge

 

[Tetley]

I had a problem a year ago . The charging cable is a magnet and it picked up a little piece of metal of the floor and caused it to not start and charge

Yes, common fault! Always the first place to look when things don't work properly.

 

[G-Sport]

Useful info on the cable. I think it may well be the green female connector at fault. I cleaned mine and it was good for 24 hours then played up again. Cleaned again and put some special conductive grease on, thinking that a poor contact here might be the culprit but it is still bad.

 

[asturah]

Useful info on the cable. I think it may well be the green female connector at fault. I cleaned mine and it was good for 24 hours then played up again. Cleaned again and put some special conductive grease on, thinking that a poor contact here might be the culprit but it is still bad.

Just fitted a brand new cable - all the ends are clean, but I suppose it’s worth another look.

 

[OzzySmb]

Just fitted a brand new cable - all the ends are clean, but I suppose it’s worth another look.

Did you remove the motor to fit the new cable or you manage to slide it past the motor?

 

[asturah]

Did you remove the motor to fit the new cable or you manage to slide it past the motor?

Motor was fine to stay where it was, enough room to change the cable without disturbing the motor

 

[asturah]

Update:
Bike shop sent a replacement TCU unit but unfortunately this hasn’t fixed the fault.
I decided to take the battery out today just to have a look - but I didn’t really see anything untoward just a fair bit of dirt so cleaned that off.

One thing I did notice on the battery where the battery indicators are - there was a screw just above and when I looked at that it looked like that may of had water on it as it was pretty rusty (the screw).
Can the terminals inside the battery - the other side of the connecter be changed?