This guide applies to Assist and Assist PLUS (Gen1) batteries.

If you find water or moisture inside your electronics box, the first step is to determine whether you are seeing normal moisture/condensation or whether the battery has been exposed to a significant amount of water.

Important: If your battery has been submerged, exposed to significant water ingress, or you are unsure whether water may have entered the battery itself, do not use or charge the battery.

Moisture or Small Droplets Inside the Electronics Box

Small amounts of moisture inside the electronics box can occur due to humidity and condensation.

When the electronics box is closed, the air trapped inside can contain moisture. As the system warms during use and later cools, this can result in small droplets forming inside the box.

If you notice light moisture or condensation:

1. Remove the battery and thoroughly dry the inside of the electronics box.
2. Wipe the battery dry.
3. Inspect the battery, connectors and terminals for signs of corrosion or damage.
4. Make sure the electronics box and sealing surfaces are completely clean and dry before reinstalling the battery.

Check Your Battery Terminals

Salt and moisture inside the electronics box can cause corrosion over time.

Inspect the battery connections regularly. If the gold terminals are beginning to turn green or show signs of corrosion, clean them using a suitable electrical contact/terminal cleaner before use.

Riding in High-Humidity Conditions

If you regularly ride in a high-humidity environment, you can place a fresh, dry piece of tissue or paper towel underneath the battery inside the electronics box to help identify and absorb small amounts of condensation.

Always replace it with a fresh, dry piece before your next session.

Battery Becomes Wet or Submerged

If you:

• drop the battery into the water;
• find a considerable amount of water inside the electronics box;
• believe salt water may have reached or entered the battery; or
• notice damage to the battery's protective wrapping,

STOP USING THE BATTERY IMMEDIATELY.

WARNING: Do not use or charge a battery that may have been compromised by water until you have contacted Foil Drive Support and received further instructions.

What to Do

1. Remove and Isolate the Battery

When safe to do so:

• Disconnect the battery from the electronics box.
• Remove it from the system.
• Move it to a well-ventilated outdoor area away from people, buildings, vehicles and combustible materials.
• Place it on a non-combustible surface where it can be safely monitored.

2. Inspect the Battery

Without opening or dismantling the battery, check for:

• splits, cuts or damage to the outer heat shrink;
• swelling or deformation;
• bubbling or hissing;
• unusual heat;
• unusual smells;
• leaking;
• smoke; or
• any other abnormal condition.

Bubbling or hissing following saltwater exposure may indicate that water has entered the battery. Treat this as a potentially compromised battery.

3. Contact Foil Drive Support

Take clear photos of:

• the complete battery;
• the outer heat shrink from all sides;
• the battery terminals/connectors;
• any visible damage;
• the inside of the electronics box; and
• the approximate amount of water found inside the box, where possible.

Email the photos and details of what happened to [email protected].

Do not charge or use the battery while waiting for assessment.

If the Battery Was Submerged

If the battery itself has been submerged in salt water, you should assume that the battery may have been compromised.

Do not attempt to recharge or continue using it.

Move away from the battery and monitor it from a safe distance for any signs of:

• increasing temperature;
• swelling;
• bubbling or hissing;
• smoke;
• unusual smells; or
• fire.

Contact Foil Drive Support for further instructions regarding handling and disposal.

If Only a Small Amount of Water Entered the Electronics Box

Finding water inside the electronics box does not automatically mean that water has entered the battery itself.

If the battery has not been submerged and only a small amount of water entered the electronics box:

1. Remove and dry the battery.
2. Thoroughly dry the electronics box.
3. Inspect the battery's outer heat shrink and terminals.
4. Check carefully for corrosion, splits, swelling, bubbling, hissing or other abnormalities.

If there is any uncertainty about whether salt water entered the battery, do not charge or use it. Contact Foil Drive Support with photos for assessment.

Transporting a Water-Damaged Battery

WARNING: Transporting a potentially damaged lithium-ion battery can be dangerous.

Avoid transporting a battery that is hot, swollen, hissing, bubbling, smoking, leaking or otherwise showing signs of failure.

If the battery appears stable but needs to be moved, place the battery on the passenger seat within view and arms reach and return home immediately. Do not prolong the journey with the battery in the car unnecessarily. Once home, contact Foil Drive Support for further guidance. 

Battery Is Smoking, Hissing, Bubbling or Becoming Hot

Treat these symptoms as a battery emergency.

If you notice unexpected heat, swelling, smoke, unusual smells, leaking, bubbling, hissing or any other abnormal condition:

STOP — ISOLATE — MONITOR

1. ISOLATE

If it is safe to do so, disconnect the charger and move away from the battery.

If the battery can be safely moved without exposing yourself to heat, smoke, flames or other hazards, relocate it outside and away from people, buildings, vehicles and combustible materials.

Place it on a non-combustible surface such as concrete where possible.

If the battery is already smoking heavily, venting, extremely hot or on fire, do not put yourself at risk attempting to move it. Evacuate the area and contact emergency services.

2. CONTAIN

If the battery can be safely handled and there is no active fire or dangerous venting, place the battery into a suitable container filled with fresh water.

Ensure the entire battery is completely submerged.

Full submersion helps cool the battery and surrounding cells. A lithium-ion battery can retain significant stored energy even after the initial incident appears to have stopped.

Do not retrieve, open, dismantle, puncture or otherwise interfere with the battery once it has been contained.

If there is an active fire, significant smoke or rapidly escalating condition, prioritise evacuation and follow the instructions of your local fire and emergency services rather than attempting to contain the battery yourself.

3. MONITOR

Contact your local fire department or emergency services for immediate assistance and advice.

A battery that appears to have cooled or stopped smoking can still present a risk of re-ignition or further thermal events. Keep people away from the area and continue monitoring from a safe distance until emergency personnel advise otherwise.

Once the immediate situation is under control, contact Foil Drive Support and provide as much information as possible about the incident.

Where safe and available, retain:

• The affected battery
• The charger used
• Other Foil Drive components involved
• Photos or video of the battery, charger and surrounding area
• Details of what occurred before, during and after the incident
• Any fire department or incident reports

Do not use your Foil Drive until further notice. This includes charging other batteries.

Following any suspected battery incident:

Do not charge, connect, test or use the affected battery or any Foil Drive components involved in the incident until you have spoken with Foil Drive Support and received further instructions.

Remember

ISOLATE — Stop charging/use and, only if safe, move the battery away from people and structures.

CONTAIN — If safe and there is no active fire or dangerous venting, fully submerge the battery in fresh water.

MONITOR — Contact emergency services, keep the area clear and continue monitoring from a safe distance.

Disposing of a Water-Damaged Battery

A damaged lithium-ion battery must not be placed in general household waste or standard recycling bins.

Contact your local battery disposal or hazardous-waste facility and advise them that the battery is a potentially damaged lithium-ion battery that has been exposed to water or salt water.

Follow their instructions for safe disposal.

Preventing Water Ingress

Before every session:

• Check that the electronics box sealing surfaces are clean.
• Remove sand, salt and debris from the seal.
• Check the condition of the latches.
• Make sure the battery and electronics box are clean and dry.
• Confirm the electronics box is correctly closed and securely latched before entering the water.

To help reduce the likelihood of the Gen1 latches opening while riding, Foil Drive developed V2 Latch Protectors.

These can be fitted to Assist and Assist PLUS systems for additional latch security and can be purchased directly from the Foil Drive website here, or at your local dealer.