Internal Power Cable Failure, Levo 2019

[gmurad]

Just for reference, my bike was purchased 2 weeks ago, built in December and this is how the cable was routed:

There wasn't much strain on the plug, the routing procedure seems similar to the service picture from earlier in the thread. Also most of the cable under the sleeve is "peeled" so it bend easily.

 

[Mikerb]

Having replaced my cable with new version....and yes the original had started to crack....I decided to repair and modify the original to act as a spare. I have repaired the crack with Aquasure and stripped off the flexible section of cable cover plus more of the cable outer sheath. I have also used more Aquasure to seal all cable exit and entry points. The pic shows the modified cable at that stage. The bare wires now only need protection from abrasion so that section will be taped with amalgamating tape which will stil leave it flexible.

 

[gmurad]

Nice, looks good

 

[HKP57]

Having replaced my cable with new version....and yes the original had started to crack....I decided to repair and modify the original to act as a spare. I have repaired the crack with Aquasure and stripped off the flexible section of cable cover plus more of the cable outer sheath. I have also used more Aquasure to seal all cable exit and entry points. The pic shows the modified cable at that stage. The bare wires now only need protection from abrasion so that section will be taped with amalgamating tape which will stil leave it flexible.

I plan to do something similar to my original cable to keep as a spare!

 

[Mikerb]

Taped....amalgamating tape plus a bit of insulating tape on the ends. Amalgamating tape takes about 24 hours to mould to itself so I will pre shape the cable meanwhile such that the bend when installed it mostly pre formed.

 

[Paul Mac]

Taped....amalgamating tape plus a bit of insulating tape on the ends. Amalgamating tape takes about 24 hours to mould to itself so I will pre shape the cable meanwhile such that the bend when installed it mostly pre formed.

View attachment 25789

Wow, you should ask Specialized for a job, with all their expertise and attention to detail, they haven't been able to come up with a fix in 3 years, and you have done better than them in 3 hours!
Makes you wonder how hard they're trying doesn't it. ?

 

[Fatboy2306]

Having had my Levo since August and I’ve been using it in all the foul weather we’ve been having I thought I’d remove the motor cover and check the wiring for signs of water ingress. On removal of the main power cable I noticed a small amount of water had entered the plug at the motor end and there were signs of green corrosion on one of the main power pins already( bike only covered 300 miles) using contact cleaner and a hot air blower I dried out the connector and applied silicone grease to the outside of all the plugs around the “o” rings and refitted the plugs the their respective connections. The bike now fails to turn on!!!! The green leds on the battery flash alternately when the power button is pressed but the bike does not power up. Have rechecked all. Connects and ensured all are clean and dry. Having been in the motor trade for over 30 years and specialising in electronic diagnostics and repairs I have never seen such bad multi plugs! The sealing is shocking at there’s no positive latch mechanism to stop them falling off. All modern vehicles have complex electronic systems and are used in all environments very rarely have I seen water in external connectors and if there was it was because someone had damaged them. Taking it in to the shop on Thursday so I’ll post the findings. Love the bike disappointed it’s failed so soon!!

 

[Fatboy2306]

UPDATE, I’ve just gone out to test it again and now it powers up! My theory is the CAN Bus network is being corrupted by moisture as the modules in the network cannot communicate correctly the battery will not supply power to the motor and as a result does not signal the TCU to illuminate. Have had good results with ACF50 so will plan to spray the wiring and connectors at the weekend and will report effectiveness.

 

[gmurad]

Wow, you should ask Specialized for a job, with all their expertise and attention to detail, they haven't been able to come up with a fix in 3 years, and you have done better than them in 3 hours!
Makes you wonder how hard they're trying doesn't it. ?

They have provided a solution in the form of the the latest version of the cable. That aside solving these issues in production and at massive scale is a completely different scenario compared to a DIY repair.

 

[Mikerb]

UPDATE, I’ve just gone out to test it again and now it powers up! My theory is the CAN Bus network is being corrupted by moisture as the modules in the network cannot communicate correctly the battery will not supply power to the motor and as a result does not signal the TCU to illuminate. Have had good results with ACF50 so will plan to spray the wiring and connectors at the weekend and will report effectiveness.

I would suggest you inspect the power cable closely. Water on the motor end plug pins could either have got in past the 2 green seals or through the cable. In either case water may have got into the plug behind the pins...…..or maybe you even pushed water there by using compressed air. If in fact water had got in via the cable you may have the same problem a lot of others have experienced with the original cable. The most visible sign is a crack in the "d" section of the plug but the same forces that have been causing that breakage also destroy the seal between the flexible section of cable cover and the motor end plug. It sounds to me that once given time for that to dry your fault disappeared. Check your cable! ACF50 is mostly designed to prevent corrosion.

 

[gmurad]

@Mikerb Do you know what kind of grease that white paste applied around the motor end of the cable plug is?

 

[Fatboy2306]

This is what I used for sealing around plugs https://www.dupont.com/content/dam/...iterature/Downloaded-TDS/0901b803809b781e.pdf

 

[Fatboy2306]

I would suggest you inspect the power cable closely. Water on the motor end plug pins could either have got in past the 2 green seals or through the cable. In either case water may have got into the plug behind the pins...…..or maybe you even pushed water there by using compressed air. If in fact water had got in via the cable you may have the same problem a lot of others have experienced with the original cable. The most visible sign is a crack in the "d" section of the plug but the same forces that have been causing that breakage also destroy the seal between the flexible section of cable cover and the motor end plug. It sounds to me that once given time for that to dry your fault disappeared. Check your cable! ACF50 is mostly designed to prevent corrosion.

Thanks Mikerb, I only used a hot air blower so as to dry out any moisture and not drive it further up the cable, agree ACF50 more corrosion orientated but won’t do any harm to reduce possible corrosion issues through cable fractures or the like. Could not see any signs of cracking or damage to the connectors but planning to have a closer inspection this week. Have used Molykote 111 on the connector seals which has been used and recommended by automotive manufacturers for exactly the same problems.

 

[Mikerb]

@Mikerb Do you know what kind of grease that white paste applied around the motor end of the cable plug is?

Its a lithium grease....lots of different brands. Some contain zinc. Used for anti corrosion and as a water repellant.

 

[Paceman]

Its a lithium grease....lots of different brands. Some contain zinc. Used for anti corrosion and as a water repellant.

If this stuff helps why aren't Specialized dealers using it as part of their maintenance routine when servicing our bikes?

 

[Deleted member 4988]

Having replaced my cable with new version....and yes the original had started to crack....I decided to repair and modify the original to act as a spare. I have repaired the crack with Aquasure and stripped off the flexible section of cable cover plus more of the cable outer sheath. I have also used more Aquasure to seal all cable exit and entry points. The pic shows the modified cable at that stage. The bare wires now only need protection from abrasion so that section will be taped with amalgamating tape which will stil leave it flexible.

View attachment 25782

What is the thin brown wire? mines actually become detached when I checked when mine buggered

 

[Deleted member 4988]

Having replaced my cable with new version....and yes the original had started to crack....I decided to repair and modify the original to act as a spare. I have repaired the crack with Aquasure and stripped off the flexible section of cable cover plus more of the cable outer sheath. I have also used more Aquasure to seal all cable exit and entry points. The pic shows the modified cable at that stage. The bare wires now only need protection from abrasion so that section will be taped with amalgamating tape which will stil leave it flexible.

View attachment 25782

Is this stuff the same as Seamgrip ?

 

[Mikerb]

What is the thin brown wire? mines actually become detached when I checked when mine buggered

I have never seen a wiring diagram but my guess is that 2 thicker guage wires are the main high voltage circuit for the motor and the smaller guage wires are the low voltage feed to the pcb.

 

[Mikerb]

Is this stuff the same as Seamgrip ?

I have never used Seam Grip but I think it is a thinner type of glue. Aquasure is mostly targetted at neoprene repairs but has many other uses. It is very flexible and cab be used to fill holes as well as sticking stuff together. I have used it to repair wetsuits and wetsuit boots but also wellies and shoes. I used aquasure becausethe "d" part of the motor end plug is a hard rubber whereas the rest of the plug is some form of plastic. It is therefore designed to have some flex. Also aquasure will both fill and bond.

 

[Deleted member 4988]

I have never used Seam Grip but I think it is a thinner type of glue. Aquasure is mostly targetted at neoprene repairs but has many other uses. It is very flexible and cab be used to fill holes as well as sticking stuff together. I have used it to repair wetsuits and wetsuit boots but also wellies and shoes. I used aquasure becausethe "d" part of the motor end plug is a hard rubber whereas the rest of the plug is some form of plastic. It is therefore designed to have some flex. Also aquasure will both fill and bond.

Thanks for the heads up Mike, I've got some Seam Grip so I might just give it a go and it'll be better than nowt !
Just going to apply it in the same areas as you did but also apply it around the connection on the TCU also

 

[Fatboy2306]

What is the thin brown wire? mines actually become detached when I checked when mine buggered

The brown is not shown on the diagram but you could do a continuity check and find out easy enough. This diagram is for the early level plug but it’s more than likely the pin designations are the same

 

[Mikerb]

I doubt you can do a continuity check. Those connections will terminate on the mtor pcb and could be switched on transistors before connecting on to the plug from the Tcu. Just solder it up and wrap until you can get a replacement cable.

 

[Deleted member 4988]

I doubt you can do a continuity check. Those connections will terminate on the mtor pcb and could be switched on transistors before connecting on to the plug from the Tcu. Just solder it up and wrap until you can get a replacement cable.

Thats the problem tho Mike, it has become detached but there will no way it can be re-attached without cutting right back at the base then it'll be to weak.

This lead it now a spare as I was sent a warranty replacement but I'd still like to get it serviceable

 

[Mikerb]

I see...not a lot you can do with that Im afraid.

 

[deefa]

mines gone and rutland (nottingham) are refusing to send me a replacement. Saying i have to bring the whole bike to them to fit. crazy !

 

[Paceman]

mines gone and rutland (nottingham) are refusing to send me a replacement. Saying i have to bring the whole bike to them to fit. crazy !

If you have a more local Spesh dealer you should be able to order one through them.

 

[deefa]

Thank's paceman, just been in touch with mike vaughan cycles and they were very helpfull and understanding.

 

[Mikerb]

My mate got the local lbs to order one. They just asked for a photo of the cable and the serial number on the bike.

 

[rs4kev]

anyone had experience of how long Specialized take to issue these. mines gone again (3rd time) but am now being told the new cable is ordered and will solve the problem. fingers crossed.

 

[Bomble]

My dealer had one in stock, bike had died in the middle of nowhere, they fitted the super duper new cable and got it working again.
Charged it up to go out the following day, tried to turn it on and it was dead again.