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A DIY Battery Replacement

(C) 2024-2025 ekspla

During a bicycle ride on a chilly winter in Dec. 2023, my XOSS G+ suddenly stopped working. That was caused by the degraded battery (about 4 years & 28000 km of use) and the cold atmosphere at around 0 deg C. I replaced the battery by myself after the ride.

My DIY fix needed tools as followings,

a sharp knife, a pair of tweezers, a fine screw driver and a soldering iron.

The fix was not very difficult, but I had to be very careful in opening the backpanel. This was because the six phillips screws on the backpanel were sealed by glue to make them water resistant. I used the sharp knife and the tweezers to remove the glue on the screws very carefully.

Once the glue removed, to unscrew and open the backpanel were quite easy. Fig_XOSS_unscrewed

The damaged battery was sticked on inside the backpanel by an adhesive tape. Because the connection points on the PCB were kindly marked as B+/-, there was little risk to connect the new battery wires in the opposite direction.

A replacement battery (503035 with a protection circuit, 3.7 V 500 mAh) could be easily obtained on any ec stores (Amazon, ebay, Aliexpress, Taobao, etc.) for less than 5 US$.

After the replacement by soldering, I switched off the power and closed the backpanel without the glue.

The capacity of the degraded battery at full charge was measured by a constant current sink of 0.5C to be 260 mAh at room temperature of 20 deg C. It was degraded in capacity to about a half.

Fig_old_LiPo_capacity.png