Carrera Crossfire suddenly stopped working - battery flashing

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lumisoft
Posts: 2
Joined: 18 May 2022, 9:45am

Carrera Crossfire suddenly stopped working - battery flashing

Post by lumisoft »

My Carrera Crossfire mk2 stopped working. As soon as I put in the battery and turn it on - it starts flashing - but not rapidly - like once a second. It's 100% not the battery - since I tried it on my missus ebike and it's fine. Also tried her battery on my crossfire - and does the same - as soon as you turn it on - it starts flashing(I mean all 5 battery bars starts flashing). Opened it up to look at the controller - but crossfire one is all glued up and filled with rubber - can't even check the components. I was driving in the rain 2 days ago - so thought it might had gone into the controller box - but it's completelly filled with rubber(or whatever is that black subbery stuff that they have filled the controller box with). Wondering if Crossfire has a fuse somewhere that might be blown? Just don't get it. Tried to disconnect all wires - check if they are clean and plug them back - still no difference. And i don't even have a chance to turn the bike on - it happens straight as soon as I turn the battery on. Any ideas? Thanks

P.S. - It is still under warranty - but halfords state that I have to wait 6 weeks just for their specialist to have a look at it and then I would have to wait month or two for parts due to shortage. I use it to travel to work daily - can't wait 3 - 4 months just for them to fix it.
Bonzo Banana
Posts: 413
Joined: 5 Feb 2017, 11:58am

Re: Carrera Crossfire suddenly stopped working - battery flashing

Post by Bonzo Banana »

I don't think the Suntour HESC system is particularly reliable sadly. In fairness Halfords have sold absolutely huge amounts of ebikes with this motor system but there seems to be common torque sensor issues and intermittant connections. I also seem to remember that someone had an issue that when ridden in the rain it was like 2 days later before it would operate normally again presumably when the water had dissipated somehow from some component.

The other annoying common issue is getting parts replaced as supply issues are a big issue with Suntour HESC so Halfords struggle to get replacement parts in a timely fashion and don't hold them in stock that much.

All I can suggest is check all connections, make sure they are water tight, maybe some switch cleaner to disperse water and improve conductivity. Also check the torque sensor.

Best of luck, they are great bikes when they work. There is a gig economy rider in Bristol who uses one for his food deliveries and clocks up huge miles on one as he uses its as his commuter bike to main work as well as deliveries. He is on youtube. I think he is a fair weather cyclist though.
foxychick
Posts: 384
Joined: 5 Jul 2012, 12:05am

Re: Carrera Crossfire suddenly stopped working - battery flashing

Post by foxychick »

That is no way to treat a customer, ask them for a replacement bike while you are waiting as they do have a crossfire e-bike demo fleet, tell them you need it for work. Hope this helps and do not take no for an answer as they have known about these issues for years.
Bonzo Banana
Posts: 413
Joined: 5 Feb 2017, 11:58am

Re: Carrera Crossfire suddenly stopped working - battery flashing

Post by Bonzo Banana »

foxychick wrote: 18 May 2022, 11:48am That is no way to treat a customer, ask them for a replacement bike while you are waiting as they do have a crossfire e-bike demo fleet, tell them you need it for work. Hope this helps and do not take no for an answer as they have known about these issues for years.
Yes I'm sure he can apply some pressure to Halfords to get a solution. Maybe a refund and purchase of another bike or at least some sort of loaner ebike. If a shop gives an unreasonable timeline for repair I'm pretty sure you can go to trading standards. For some goods its a maximum of 30 days I think, that might be cars but it may be similar for other goods. If they can't repair within 30 days then demand a refund or similar would be my approach.

To be honest while its a great system while it works because of the torque based power delivery considering the issues and lack of spares I would try to get a refund as a priority. I often look at s/hand ebike parts on ebay and you see a lot of failed mid-drive motors but also Suntour HESC parts often turn up a bit. So just like many high end mid-drive ebikes many of these bikes have become uneconomic to repair and people are just breaking them down for parts. Scrapping ebikes only a few years old is not where we want to be with regard the environment.

Looking currently 4 out of the 44 items are Suntour HESC items which is not too bad I suppose considering how many HESC bikes are sold by Halfords. 8 are Bosch but mainly batteries which self-brick if not charged for a while so no surprises there.

https://www.ebay.co.uk/b/E-Bike-Compone ... ition=7000
lumisoft
Posts: 2
Joined: 18 May 2022, 9:45am

Re: Carrera Crossfire suddenly stopped working - battery flashing

Post by lumisoft »

Ok just a quick update. Even though they have sealed the controller with black rubber gueue - I suspect it's water damaged since there is a massive hole right at the bottom were wires are being threaded through. I disconnected all wires and all it takes is to connect the controller alone to the battery wires without anything else connected - for the battery LED's to start flashing. Clearly shorting somewhere. Shame - but I was planning to get a custom controller anyways - this might be the push that I needed. And yes - I have tried to pursue Halfords to issue a replacement bike - but with no luck. Already had issue with it at the start where it kept shutting down - as I read - it's a very common issue with these bikes - where it just shuts off - with fast flashing battery LED's and then all you can do is put the battery to deep sleep - connect it to the charge for 10 secs and off you go. Annoying - but halfords just replaced the battery for me - which of course didn't resolve anything since it was fault with battery.

UPDATE: - tried to connect to my misus bike - deffinatelly the controller is faulty.
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