Zugo Battery | Battery Rebuild
🔋 Zugo E-Bike Battery Rebuild Service
Get your Zugo battery back to full power—or upgrade it for more range and better performance.
At EMP, we specialize in rebuilding Zugo e-bike batteries using premium lithium-ion cells and professional-grade assembly. Whether your battery is no longer holding a charge or you’re looking to extend your ride time, we’ve got a reliable solution.
⚙️ What We Do
We rebuild your existing Zugo battery, replacing all internal cells while keeping the original case, fitment, and compatibility with your bike.
- Complete internal cell replacement
- Optional capacity upgrades
- Retains original mounting system and connectors
- Fully tested before shipment
🔋 Upgrade Options
Don’t just fix it—upgrade it.
Zugo batteries can often be upgraded using high-performance cells from Samsung, LG, or Molicel.
Upgrade benefits:
- Increased range per charge
- Improved power delivery
- Reduced voltage sag under load
- Longer lifespan (typically 3–5 years with proper care)
🧪 Diagnostics & Testing
Every battery goes through a thorough process:
- Initial inspection and diagnostics
- Precision rebuild with matched cells
- BMS functionality check
- Full charge and discharge testing before return
⚠️ Important Notes on Zugo Batteries
Zugo batteries are generally serviceable, but like many modern systems, they may include smart BMS electronics.
- If the issue is related to the BMS or communication system, repair options may be limited
- If so, we’ll provide clear feedback and next-step recommendations
📦 How the Process Works
1. Fill Out Intake Form
Complete the Battery Service Intake Form
2. Ship Your Battery
Send your battery (and charger if available) to our facility
3. Evaluation & Invoice
We inspect and confirm final cost if not prepaid
4. Rebuild & Test
Your battery is rebuilt, balanced, and tested
5. Return Shipment
We ship your battery back with tracking
⏱ Turnaround Time
- Current estimate: 6–8 weeks
- Expedited service available upon request
💰 Pricing
- Typical rebuild cost: $550 – $650
- Final price depends on battery size and upgrade level
- Return hazmat shipping: typically $50–$60
✅ Why Choose EMP?
- U.S.-based battery specialists
- Premium-grade lithium-ion cells only
- Honest diagnostics and clear communication
- Trusted experience across a wide range of e-bike brands
🚫 Please Note
- This is a battery rebuild service, not a new battery purchase
- You must send in your existing Zugo battery
- We do not typically stock ready-to-ship Zugo replacement batteries - However, we do have existing casings for this model and can provide complete replacements or spares if required.
🔧 Battery Rebuild Service
We rebuild your existing battery using fresh, high-quality cells to restore or increase capacity and performance.
- Full disassembly, rebuild, and testing
- Upgraded capacity options available
- Uses brand new name-brand cells
- Turnaround time: Approximately 14 business days
- Timeline includes the time it takes for us to receive your battery and complete the rebuild
⚡ Custom Battery Builds
Fully custom battery solutions designed to meet your exact specifications. This is ideal for unique applications or when a standard battery will not fit your needs.
- Custom shapes and sizes
- Custom BMS (Battery Management System) configurations
- Choice of cells and performance levels
- Option for enclosed case or raw (naked) pack
- Built specifically for your application
- Turnaround time: Approximately 21 business days
🔋 Battery Packs (Encased)
Battery packs built using one of our in-stock cases. These are a great option if you want a reliable, ready-to-fit solution.
- Uses pre-designed cases from our inventory
- Proven, reliable configurations
- Faster than fully custom builds
- Turnaround time: Approximately 14 business days
🔬 Battery Cells (Individual Cells)
We supply high-quality lithium-ion cells for repairs, upgrades, and custom builds.
- In-stock cells: Ship within 3–6 business days
- Out-of-stock (air shipping): Approximately 10 business days
- Out-of-stock (sea shipping): Approximately 40 days
📦 Shipping & Intake Process
- Place your order or request a quote
- Fill out our Battery Intake Form
- Send in your battery (include charger and key if required)
- We inspect and test your battery
- We contact you with results and recommended options
Important Information
Turnaround times begin once your battery is received and checked into our system.
During high demand periods or for complex builds, timelines may be slightly extended.
Shipping Method
- All batteries are shipped via ground service only (FedEx or UPS) in compliance with DOT and IATA regulations for lithium batteries.
- Expedited air shipping is not available for lithium battery products.
Delivery Time
- Ground shipping typically takes 3–7 business days within the U.S.
- Tracking information will be provided as soon as your order ships.
Local Pickup
- Pickup is available at our Las Vegas facility:
4856 Judson Ave Suite 155 Las Vegas, NV 89115
Monday– Thursday, 9:00 AM – 4:00 PM ( Friday by appointment).
Returns
- Returns are accepted within 14 days of delivery on unused, unopened batteries.
- For rebuilds and custom packs, all sales are final unless defective.
Important Notes
- Shipping is limited to the continental United States.
- Customers are responsible for providing a valid shipping address — carriers cannot deliver to P.O. Boxes.
- Signature may be required at delivery for higher-value battery orders.
