Improved, re-wired: Toughened Typhoon 6000 Watt eMoto

This bike is used primarily off-road and reliability improvements are needed. This video gives a close-up view of my Typhoon after re-routing and re-wiring it. With great disappointment my electric motor controller died from water intrusion. Fortunately, Hi-Power Cycles replaced it under warranty.

Watch the video of the bike before I replaced the controller:

   • Naked Typhoon eMoto Servicing Closeup  

The controller housing is an aluminum extrusion with exterior cooling fins. I sealed all possible water entry points with silicone sealant to prevent a recurring electrical short because the replacement controller wire entry grommets and the cover end plates were NOT sealed.

I also improved the wire routing and sealed wire connectors. I used heat shrinkable tubing around many connectors and placed zip ties on each end of the tubing thereafter to prevent water intrusion.

I used strategic locations to tie-down the wiring and separated some of the wires into more logical positions to facilitate potential maintenance or repair. The wires are protected from brush or crash contact. I added plastic wire conduit to protect bundled wires and/or excess wire lengths to provide additional protection. The wires under the seat and plastic covers are now restrained to prevent chafing/rubbing.

Other modification: inner rear fender plate (to protect the wire routing area under the seat). Mud and debris impacts the wiring area and makes it difficult to clean. A flat sheet of plastic was used and zip tied across the 2 seat support bars. Watch video:    • Typhoon eBike DIY Rear Fender Fabrication  

Future plan: add skid plate (for motor)
Watch all my Typhoon rides:    • 6kW eMoto rides  .

#eMotoIsFun
#LovingLevo