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08-16-2011, 07:04 PM
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#1
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Junior Member
Join Date: Aug 2011
Posts: 2
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Broken spoke problem iZip Trailz
I have had my iZip Trailz for more than a year and have had problems with broken spokes repeatedly. I think I need thicker spokes. I believe that the back wheel has 14 gauge standard spokes, but I'm guessing I need 12. I read somewhere where it was possible to fit that size onto a Trailz with bigger holes in the hub. I am mechanically inclined but I don't have much experience with bicycles least of all DIY modifications to stock parts.
There is a local bike shop that can do the work, but their spoke cutter does not support 12 gauge spokes. Perhaps I could go to a motorcycle repair shop to get the spokes cut and take the bike to the bike shop, but if anyone here has any better ideas, please let me know. If I could just order the spokes and be done with it that would be great, but I don't know where I could go to do that.
I can't imagine the problems I would have with this bike if I had two batteries instead of one. It's got to be too much weight for the size spokes which seems like a design flaw to me.
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08-17-2011, 05:50 AM
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#2
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Junior Member
Join Date: Dec 2009
Posts: 6
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Quote:
Originally Posted by Drummer_boy
I have had my iZip Trailz for more than a year and have had problems with broken spokes repeatedly. I think I need thicker spokes. I believe that the back wheel has 14 gauge standard spokes, but I'm guessing I need 12. I read somewhere where it was possible to fit that size onto a Trailz with bigger holes in the hub. I am mechanically inclined but I don't have much experience with bicycles least of all DIY modifications to stock parts.
There is a local bike shop that can do the work, but their spoke cutter does not support 12 gauge spokes. Perhaps I could go to a motorcycle repair shop to get the spokes cut and take the bike to the bike shop, but if anyone here has any better ideas, please let me know. If I could just order the spokes and be done with it that would be great, but I don't know where I could go to do that.
I can't imagine the problems I would have with this bike if I had two batteries instead of one. It's got to be too much weight for the size spokes which seems like a design flaw to me.
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Hi my bikes are Whizzer motorbikes some 24"s and 26"s with 105 and 120 spokes.Here's a guy that sells stainless steel spokes his name is Bill Warwood 330-947-2744 he's in Ohio. hope this helps
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08-19-2011, 05:56 PM
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#3
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Senior Member
Join Date: May 2010
Posts: 328
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12 ga spokes, for EZip-IZip - $.39 each
The EZip-IZip wheels use 260mm on the motor side & 258mm spokes on the sprocket side.
For the 258mm, I threaded the nipple till 2mm spoke extended through, then ground it off.
Removing the nipple cleans the thread.
Spoke 12 gage 260 mm for 26" wheel: Staton Inc - $.39 each
__________________
Rambo mode! -I- January 15, 2012 - January 19, 2012 RIP
"To survive war, you must become war."
 When I go ... I wanna go to eBike heaven
Last edited by ViBiker; 08-20-2011 at 02:16 PM.
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08-20-2011, 01:28 PM
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#4
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Junior Member
Join Date: Aug 2011
Posts: 2
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Quote:
Originally Posted by ViBiker
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That might do the trick. Thank you.
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11-09-2011, 01:56 PM
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#5
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Junior Member
Join Date: Oct 2011
Posts: 3
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Spokin'
EZip Trailz - rear wheel spoke replacement ...
Practice makes perfect!
Last timed attempt was 11 minutes! 
__________________
A little learning is a dangerous thing;
Drink deep, or taste not the Pierian spring:
There shallow draughts intoxicate the brain,
And drinking largely, sobers us again.
Last edited by Drk_Angel; 11-09-2011 at 11:10 PM.
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12-25-2011, 06:27 PM
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#6
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Senior Member
Join Date: May 2010
Posts: 328
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EZip-IZip Broken Spoke Remedy!
Broken spokes!
I had about 4 instances!
I even resorted to buying 12ga spokes, not installed yet, a Winter project, may require drilling ...
Strangely ... the breaks were on the pedal sprocket side?
I say strangely, because all the 2008 Trailz's always suffered broken spokes on the motor side?
I didn't realize the significance, till I laced a new hub into a wheel.
After careful consideration as to directional torque and how the spokes were supported in the hub flange, I determined that the motor & pedal torque should be sustained by spokes with the elbows turned outward.
After looking at my other EZips, I was able to confirm that the spokes were breaking because the torqued spokes had their elbows turned inward!
A picture of my 2008 EZip MT w/16 mod.
As you can see, the inward turned elbows are poorly suited to survive torque.
 
14ga spokes might work satisfactorily with the EZips, if properly directionalized!
Well it's about time for me to pack away the Stepthrough, and put my Winter EZip back on the road.
Configuring my pack heaters ... now.
__________________
Rambo mode! -I- January 15, 2012 - January 19, 2012 RIP
"To survive war, you must become war."
When I go ... I wanna go to eBike heaven
Last edited by ViBiker; 01-21-2012 at 02:23 AM.
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01-21-2012, 02:40 AM
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#7
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Senior Member
Join Date: May 2010
Posts: 328
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I've been rebuilding EZip hubs, (2008 Trailz).
One nice, and bad, feature is that I did not need to drill the hub, to fit the new 12ga spokes. Which means the hub holes were too large, to properly support the oem 14ga spokes!
Wheels did require redrilling to fit the 12ga nipples, 3/16".
__________________
Rambo mode! -I- January 15, 2012 - January 19, 2012 RIP
"To survive war, you must become war."
When I go ... I wanna go to eBike heaven
Last edited by ViBiker; 01-21-2012 at 02:44 AM.
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02-13-2012, 12:45 PM
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#8
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Senior Member
Join Date: May 2010
Posts: 328
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EZip 258-260mm Spokes - Washers!
I'm afraid that the, previously, recommended 260mm spokes, are not capable of being shortened!
Solution!
Due to the added stress added by 12ga spokes, there is the possibility of the oem wheel not being strong enough!
So ... I added a washer, to the nipple, to spread the stress area. Also, most washers are "stamped' from sheet metal, leaving the hole with a nice curved edge, ideal for nipple "angling".
I did consider "seating" the washers with silicone adhesive, or similar. Alloy aluminum, against steel, isn't ideal, but instead, merely wrapped a layer of duct tape around wheel, under washer ... it should "seat" the washers nicely.
... which adds about 2mm, making the 260mm spokes perfect for the 258mm side.
Also worked "properly on the 260mm side ... still plenty of thread grip.
Even the larger, 12ga spokes, did not seem to fit properly into the EZip hub, so I added smaller washers, pulling, the elbow, closer to the hub. Theoretically, strengthening that weak point. ...
__________________
Rambo mode! -I- January 15, 2012 - January 19, 2012 RIP
"To survive war, you must become war."
When I go ... I wanna go to eBike heaven
Last edited by ViBiker; 02-13-2012 at 12:48 PM.
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02-13-2012, 03:55 PM
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#9
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Senior Member
Join Date: Jan 2010
Posts: 1,223
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Well I don't know if anyone else gets this impression, but it strikes me that if there is that much trouble with broken spokes that there could be a big problem with the quality of the design and the engineering behind it (if any) as to make one think twice. Spokes usually just don't break for not reason. Maybe once or twice in a career, but it should be something really rare in a wheel. Yeah I have broken one or two, but it was jumping a bike that really wasn't designed to be jumped and I was much younger then.
What this looks like to me is that the electric motor was just an afterthought to a wheel that was not designed for it. An off the self bike wheel is not designed for the added stresses and types of stresses an electric motor is going to put on a wheel. Yeah it might work for a while and its one thing if its a project you are tinkering with in your own backyard with your own butt on the line. Yet as someone says beef the spokes up and you have a problem with the hub. Fixing one problem often leads to another, unless the wheel was designed for this in the first place.
Breaking a spoke might not be the end of the world, but I sure wouldn't want to break a hub. The question would be where would it break, how would it affect the control of the bike and how lucky are you going to be as to the timing of when it breaks.
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02-14-2012, 12:36 PM
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#10
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Senior Member
Join Date: May 2010
Posts: 328
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As noted, and pictured, previously:
Breakage is, apparently, due to direction of spoke lacing.
Hub spoke flange is capable of 12ga spokes, but marketed with 14ga spokes.
(A, post design, cost cutting, measure?)
__________________
Rambo mode! -I- January 15, 2012 - January 19, 2012 RIP
"To survive war, you must become war."
When I go ... I wanna go to eBike heaven
Last edited by ViBiker; 02-14-2012 at 01:04 PM.
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