How to replace a damaged cable harness in an ebike hub motor
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- Опубліковано 14 гру 2019
- In this video Pete shows us one of his favorite technique for replacing cable harnesses which go THROUGH the axle of an ebike hub motor. Without this trick it can be a real bitch of a job with lots of cussing involved, as the replacement cable often follows a path with several blind bends before it is exposed again inside the hub.
The most common reason for needing a cable replacement is that the hub motor has experience an axle spinout event or improper installation which has damaged the wires right where the exit the axle slot, and that doesn't leave enough room for a standard repair with solder splicing and heat shrink. It's also necessary when motors have melted wires due to excessive phase current from being run too hard.
If you are doing a cable replacement on a motor that has had an axle spinout where the phase wires severed and shorted against the hall wires, it would be smart to check the functionality of all the hall sensors while you have the motor apart and replace any halls that don't toggle. The exposure to battery voltage on the hall signals can fry them too.
Good luck with your repair!
www.ebikes.ca/learn/troublesh... - Навчання та стиль
My friend is at a mental hospital now. Because he tried the same.
Love Pete's vocabulary. Richly descriptive, and ,hey, no swearing .
I cannot put into words how good this video is. I am an amateur who has been wrestling with a MAC 1000w geared motor these past few months. I've literally learned every single lesson in this video the HARD way. Small geared motors are an absolute nightmare. Not only are there 90 degree angles, no room, the problem of getting the gears to mesh etc etc....but you got sharp edges everywhere too.
I had to use a chisel to clean off the nylon gear edges to reassemble after 10K Km,
I’m impressed with your patience & verbal skills.
Nicely done. Appreciated
silicon spray is an option on the cable and tunnel to help it slide through. I would say that having 8cm of sheath free cable is okay as the end where you grip with the pliers to pull through will then mean you just cut off that 8 cm and work from there. I haven't tried it as yet but certainly a suggestion at the moment.
Where did you order the replacement cable harness? Thanks..
Damnit.. this was my exact question... I'm trying to talk to the manufacturer or at least a distributor in China about getting the entire front hub motor and fat tire assembly replaced but I doubt that is gonna happen.. getting ahold of these people is impossible it's almost like it's done on purpose so they don't ever have to honor any warranties
grin technology wow guys seriously
Great idea and top tip, I've never tried sourcing a replacement cable its mainly higo/julet 9 pin in the UK but in the event of another motor fail I would now consider it as an option - shame on the video ending, I would of liked to see some top tips for the internal soldering and perhaps a future video idea for replacing hall sensors and speed sensors, my attempt at a video was with my first motor and with very little skill however it worked for a while. You guys have the knowledge base and the directing skills to produce a high quality video.
Very good info in this vid. I always wondered if it was possible to replace a damaged cable in the Hub motor.
I learned so much here, basically not to be afraid of all this stuff, all you need is the right tools and a healthy set of balls… and desperation that your motor will not work otherwise…
True, True, and True.
and a can of silicone lubricating spray
That’s cool and all, but how do you find the right power cable replacements for your particular bike?
great video, for what most would consider a daunting task.
Hi mate,can you give me help please,i did change my cable but a white wire was inside the motor unwelded , do you think that wire should be weld, .. in the screen show me a error 3
I use a dremel to smooth any sharp edges at the entry opening, for the cable I slide the insulation down like you do but I make sure I don't trim the nylon cord the same length as the wires so I can incorporated that into my pulling tether with the slitted insulation wrap. Also I use a wee bit of silicone spray to lubricate the cable.
Interesting, never done this but was thinking the same thing, silicone oil on the cable and leave the nylon cord for strength. A bit of lubrication goes a long way. That's what she said.
My thoughts exactly while watching this…
vaseline is a good way of getting big things into small holes.
Hahhaha. Spit.
I frequently encouter the same issue pulling the cable through a too small orifice while pulling electrical cable to install swimming pool lights. I use the same method of decreasing the diameter of the outer sheathing. but leave a longer tail of the inner insulation cord and attach very strong nylon cord to it, then using electrical tape to secure it to the cable. To do this so that the cable will still fit through the races and bends, I make sure to wrap the excess cable as tight as possible to make its diameter as small as possible. The nylon cord used as a fish tape can then be doubled or tripled to add tensile strength. I also use electrician"s luble to ease it through the tight races. I'll be performing this very task this weekend on my boyfriend's bike that I crashed when some clown turned right in front of me. Those front brakes sure worked better than the rear brakes because I went ass over tea kettle over the handle bars, consussion and serious bruising. Asshole didn't even stop to see if I was okay or check to make sure I didn't sue his insurance company into the Stone Age.....I'll let you know how swimming pool technology transfers over to ebike repair. Thanks for the incredibly helpful and informative video.
hey, great video. BTW you can also solder all wires together and attach a 14 ga wire, then pull through. Great job.
Fantastic video. So where can you buy the cable? Would any motor hub cable wire would work? Thanks for the great video. Please help.
Excellent video . I have done external splices on rear hub motors with 'cassette issues' but am baffled trying to open up a PEDEGO hub motor to get to the inner connections. There is NO POSSIBLE WAY to open up the motor case! At least not that I can see😡😢😨
I can see zero bolts, screws, nuts, fasteners, or ability to open up the case. I gave up and bought a new motor, rim, throttle, pas, grips, controller kit....this solved the problem much easier than splicing on a new cable that SHEARED OFF because the rim nuts were not properly tightened by a professional after a FLAT TIRE REPAIR!
Thanks for showing that this CAN BE DONE by a proper professional. Doing it on a pedego motor seems to be NEAR IMPOSSIBLE.
THANKS AGAIN for your video presentation. You deserve an award of the highest magnitude. Searching the interwebs for this content reveals very low results. Thanks for showing us how to to it on a most difficult hub motor, that at least let's you open up the CASE. 👍👌✌💓
Thanks for the feedback and encouragement, we hope to keep making and sharing more content on servicing/repairing ebike parts. Most likely the hub motor on your Pedago is one that has a threaded side cover plate, so you need to make a special tool that allows you to grip a set of 3 or 4 notches that you'll see on one side of the hub and unscrew the plate. If they've used a glue on the threads then you'll also need a heat gun to warm the shell and soften the bonding agent.
..havnt got any real bikey tools...no vice..no experience..no muscles ...BUT.. Confidence! You gave ..with very clear, carefully filmed close ups of all that's wrong and all that might be done to make it come right! Thank you! My ebike is rock-bottom of the range..4-5 years old..(a Wayscral 315).. .its motor looks bigger and less likely to be so squashed inside. The cable, same thickness as yours, so!!! Could be eazy peazy!!
@@jeanetteleuers7329 the wires CAN be repaired, dont listen to the beginning of the video, i am a certified electrician. Simply splice as much wire as you can, apply Rosin Flux compound, apply some solder, slide over a shrink wrap, slide over a soldering butt connecter, heat up, connect, slide the shrink wrap over, heat up, connect. jobs done. Opening the motor is stupidity when there was clearly a half inch of exposed wire. I could fix that wire with 1/8 inch LOL.
@@willjay9808 thank you!!! I realised, though, that right now I can't be SURE of the problem. I looked at all the outer wiring I could see, and noticed one part of the cable to the main connection/battery was pinched and_screwed down when it obviously should not have been. If there is any kind of crack or break in the cable at that point...it could be the cause of the motor failure. It had stopped suddenly before and then fixed again...when I dismantled the battery and then banged it back with a bit of force...it was as if a jolt to the battery in its fixing, could make the wire disconnect/reconnect.
I'm going to examine that wire first. Cut off the sheathing where..it feels a bit peculiar to touch, through the cover..as if a sharp bend is there somewhere...a disconnect point...everybody HOPE for me! 😁
Well done , thank you for your insight to the task at hand
Great work ! What a fine company !!!
Excellent explanation this guy is great
You should pet the motor head gently and whisper "everything will be fine, don't worry, relax" to make it go easly
This video is great. What would make it awesome is a source for the cable. Because otherwise, I get my hopes up, figure I can repair it, and then learn I can't get the cable. So the video just mocks me.
A lot of motors have sufficient extra cable length outside the axle that you can just repurpose what you have and shuttle it further down. You can also DIY a 3 phase motor cable using thin walled FEP shrink tubing and putting that over the flexible stranded noodle wire after removing the thick silicone insulation.
Lubricating the outer surface of the wire and metal hole helps.
Another way to do this is to "waste" some wire. (If there's length to spare)
By cutting off a longer piece of the outer jacket and sending the 3 exposed colored wires in 1 by 1.
When all 3 of them are through, the whole cable can be pulled through easily.
Thank you so much for this comment
If the hole where the wiring goes trough is a bit too small for new wiring use a Dremel tool, with a grinding stone on it, and open up the hole's diameter larger, so the wire slides through much easier, with less resistance. Could also use WD-40 on the wirings outer coat, and inside the hole, to allow easier, and smotther passage of the new wire.
Thank you so much! Great Video!
Thanks for this great video. Can you let me know where I might buy the cable and 9 pin connector from?
So many people asking where to buy the replacement cable and not a single answer. It looks like grin used to sell this cable by the meter but that product has bee discontinued. It's strange that it's so hard to find when there's such a need for replacement cable. Waah. I need some.
The problem is that the cable we sold by the meter was larger in diameter than most of the axle bores on these Chinese motors, we had it made for our controller production not for rework of hubs. The easiest solution is just to buy a 1 meter extension cable of the same style connector as is used by the controller, like this:
ebikes.ca/shop/electric-bicycle-parts/wiring/motor-wiring/z910-ext.html
Otherwise we would also often scavange the cable from motors that had other kinds of damage on them. For the motors that we make here, we sell replacement cable directly, ex:
ebikes.ca/shop/electric-bicycle-parts/wiring/motor-cables/l1019-hg6-motor-cable.html
(Ideally all motor manufacturers would be so considerate ;-) )
I use dialectical grease as a lubricant. Great training... ThanxAlot!
Just pull inside the old cable until you get damaged area inside the motor. Than you can fix it inside the motor. Only downside is you end up with a shorter cable :))
lol great idea
I am going to attempt this job next week.... But I have pulled Big wires through conduit and I use a Lube on the big stuff.... so I will lube the cable before I pull it through, after I do my Tape job...... and I will not cut all the wires at the same point.... I will cut each inner wire at a different length, so I will have a longer taper .... Thanks for the video and info here.... I wonder if KY jelly will work?
Great video I got 3000w motor witch doesn't have temperature sensor what steps has to be taken to install temperature sensor pls advice
Isit possible to just fishing the temperature sensor wire in or all the hub wires have to comes out then push the new wires in including temperature sensor wire
I've used two stroke petrol, squirt a bit in the axle and over the cable, it slides in, you only have one go at it so mark where it needs to stop at, then blow the petrol dry and all done.
Great video!
Can you use a slightly larger reamer to open the hole to make it easier to pull cable through the hole???
Thank you. Thats nuts.
Would it be easier if while you were wrapping the tape you wrapped it around like a brake cable or a gear shifting cable? There skinny and strong but flexible. that way if the tape breaks you still have the cable underneath and it's stronger to push through to the other end and then you can just snip it when finished?
Hi
Great video and great video quality camera.
What camera model you used for this video? I can suggest you use a smooth ointment like grease or oil or even soap for spreading on the cable
cable lube is your best friend here!
A job l have to do of which I'm not looking forward too. Good vid
would it be useful to coat the cable with a bit of petroleum jelly so it pulls through easier?
May I suggest a little die electric grease to help the cable slide? Not the mention it will provide some moisture prevention as well. I love your tips on how to pull the cable through.
Thank you for this video. Would you consider doing one that shows how to replace the plastic cogs on this GMAC one day?
Just pull the motor cover off. Once it's off, all you need for the gears is a good external snap ring plier to take off the small snap rings that hold the gears on their axle stubbettes. The mid priced external snap ring plier sets with multiple replaceable end bits work well.you need a small diameter end tip. Don't bother with a set that doesn't list the end tip diameters you need the smallest or next smallest end tips to fit in those snap ring holes.
Note to you. Use a little electric contact grease on the side the wire that is going through.
Jim Carey look alike! Very well explained
Striping the outer jacket to allow enough wire to enter the motor then using thin-walled teflon tubing and slide the wire though the protective teflon ? Lubrication? Protection of coil windings when working on motor, cutting off damaged cable and pulling out wires individually...
Thanks really helpful , just wondered if you could've used a small amount of lube or vasoline.
Yup!
Hi Green tech, thank you for this video. Very interesting.
I have just a question : why we cannot solder the cable directly on the Spule ? thank you
We're not sure what a Spule is. You can solder cables together, but not right where they exit the axle if that is where they are torn (which is usually the case in the event of an axle spinout)
what about any water based lubes? my damn rear brake rotor bolts came loose several times now and cut my cable, while riding tonight my motor kept applying the electric motor brake, which i never even setup, and it attempted to go into reverse while i was finishing this short but troublesome and very short ride, as i was riding it into my front yard and it ripped the wheel right out from the slots holding it in place. good times
I would file the metal around the hole smoother , mine had a really sharp tiny burr that soon severed the cable even after being very careful by my third tyre swap . Also i now dob the hole with a glue gun after fixing to minimize any movement near the hole after refitting . Still I'm on 4000 miles now which means its paid for itself easily on fossil fuel vehicle costs. I have had all sorts weird symptoms with wire chaffing also and now am very careful on cable routing and extra wire protection over the bicycle in vulnerable places . .
I'm just wondering, how did the group insulation break, if it cut going thru the turns, one of the wires may have rubbed against a burr and short
I be never ever seen anything like it I snapped my hub cable right at the wheel this guy made it look so hard Ive never ever done any electrical or cable soldering but it was so easy don't watch this.unbelievable
My hub wire is torn / chewed at the end also..how did you do it? Video looks like I need to be a pro or an idiot to work that hard.
The difficulty really depends on how exactly the cable run fishes through the axle. We did the video on the GMAC motors which are among the most challenging jut to show how it can be done in the worst case scenario. If the cable is just going through a straight bore to the other side without any sharp bends then of course it is much easier.
Trying to replace a juiced hyperscrambler 1100w mac motor cable. No support from JUICED :( thank you for a general idea of what I've got to do
You should put some lightbnon conductive grease on the part going trought the hole to facilitate the job.
a small squirt of dry lube on the outer casing when pulling through works just fine, plus some applied on the inside
Lastly, why not thread on the nuts on the axel then vise it up? so much easier.
Where can I source a cable for my e scooter motor. It has hall effect sensors/wiring but my scooter doesn't them.
The motor is 1200 watts peaking at 2700. How do I determine what wire gauge I need?
Hi. Are you based in the U.S.?
Do you have a bike shop?
I have the same problem. My hub motor cables are ruined primarily because I have been riding without a torque arm.
The rear hub motor twisted sometimes while I was riding and ruined the hub motor wires
I had a very hard time finding a torque arm in bike stores
what about cutting the outher sheath at a tapering angle?
I have a qsmotor that is stuck. I've cut all the wires but the stator still will not spin. Any ideas why ?
Thanks
J did that with break wire. Works fine 😊
Also wouldnt a better way be to removel the spindle completely then re installing it with the wire already placed in the bore holes?
External splice for me, Id repair, shrink wrap individual then one big shrink wrap over the lot ..butted to the motor.
Any reason you didnt put a drop of machine oil or a small burst of wd40 down the bore hole? Maybe help the jacket slide through more easily?
How about a little cable lube? Yellow 77 perhaps etc etc
Tip if you need to clamp the threaded end use blocks of timber so the thread won't be damaged. Great video I be doing within the next couple of weeks..
If I didn’t have damaged wires but just wanted to turn the motor cable into a quick connect plug(for convenience), do you have any videos on that?
Underrated comment!
I know it’s been said many times but what is wrong with applying some spray lubricant just before or during pulling the cable sheath ?
Funny that Pete forgot to try that/demonstrate it that day, or he just likes a good tussle.
Could you put a smear of silicone lub on the outer cable
Is your store in the tri-state area?
I need help with this desperately
Question,can you guys find new spindles if the spindles are broken,i cant🌊
Where did you get your ebike cable from?
GrinTech supplies some types. My trouble always with wiring is finding the right gauge wire.
Where I can I get a replacement cable for a bafang 750 hub motor?
This is exactly what they make wire pulling lubricant for.
Grease?
The connector end on mine is different to any that is available to be bought can I just cut the old end off and attach it to the new cable?
Yup, as long as you know how to solder wires.
This is great but my motor is big. That means I need a heavier replacement cable to take the 50 amps+ my motor draws. Does anyone know where I could get one? The motor is a 3 Kw QS 12"
Silicone spray helps the jacket slide through easer.
This is great. I just feel sorry for this dude who sounds exactly like Jordan Pederson
Great video. Question.
Some motor stems use a white "foam" or puddy to keep the cable from moving around in the stem. Do you know what this foam/puddy is called? Or can I use any type foam sealant? Can't find anything online.
/bklyn 👑
Usually it's a white silicone based sealant, we've never seen any using a foam product.
My cable harness is cut at the axle inlet but the wires aren't damaged yet it seems like I wouldn't have to take stuff apart to repair it or would I? Think I might be screwed but at least it's light enough I can still ride it as a regular bike
Just keep it from getting worse or shorting against the axle metal with some kind of strain relief and you should be fine. I wouldn't attempt to rewire it unless it's actually broke.
Always use spray or wire pulling compound.
Is wire pulling compound better than any off the shelf lubricant you can get?
need a new axle for my das-kit 500w shaft spun :( going nuts trying to find replacement and some torq arms
My motor has all the colored cables that go to the PCB that's fine no problem but then there's also a black and white skinnier wires coming from the same large cable but they go into the coils underneath the magnets so I'm changing my main power cable but I don't know where they connect to I don't want to rip them out so should I just cut all the color ones out and resolder to those skinny wires that are in the coils leaving the original ones in place wherever they are installed to and just connecting to them with the 2 from the new cable
Most likely it is for a motor temperature sensor. Resoldering to those leads would be the best bet.
@@GrinTechnologies thank you for the reply I appreciate it , I did just that and everything is working good as new now, just wasn't sure about that one wire that's all. Thanks again and take care!!!!
The construction of these hub motors, is very similar, to wind turbine generators, just add the magnetic polarity. Has anybody done experiments, or reverse the polarity on these, similar to people's alternator experiments, in order to generate electricity? I love my 3000 watt motor. Debating whether I should replace the one black wire, for the hall sensor, (If possible) or locate the make of this used electric bike I bought, In order to get the proper cable, going to the hub motor.
Thoughts, suggestions?
Thank you so much community.
Great video as well! Thank you.
There is nothing required at all to run these or any other hub motors as a generator. Just spin the hub and it will create a voltage on the phase leads, and you can either rectify that with a 3 phase diode bridge to run off the back-emf voltage directly with no regulation, or you a motor controller in regen mode to have fully programmable output voltage. Tons of people have done this in all kinds of neat power generation applications.
lube for pulling electrical wire work?
Electrician wire lube works along with another light gauge wire with tape.
Use heat gun to stretch casing out to thin its diameter, or, my preferred method for such situations is to remove outer casing and replace with heat shrink tubing to reduce it diameter. Professional, just as protective as original casing, and with a little soldering flux as lube, the extra hour of work is reduced down to 5 min while still withholding equal amount of integrity, both morally and structurally. “Work smart, not hard, use your brain and save your back”! Your welcome 👊🏻
Also, using heat ( not so much to burn coils, ) to soften the wire casing apon removal is also way easier than tug of war. If not possible, cut casing flush with motor and pull wires out individually. Your welcome again!
- Just a man on a mission for speed.
Pete!? Someone needs to bring you breakfast in bed for the next year,.. and maybe run some bubble baths as a reward for sharing that knowledge! Thank you! Liked & Subbed! PS: Was pleasantly surprised it was from GRIN Technologies! I own two of your TorqArmV4 Torque Arms!! 👌
Hahaha Pete definitely deserves a bubble bath! He's the hardest working man in showbusiness.
can someone tell me how to get your control cable through the little axle hole in your torque arm?? the connector block on the end of the cable is too big to fit thru the hole. ive watched alll the vids on youtube on torque arm installation but nobody talks about this problem!! I am thinking about cutting off the end of the torque arm that slips over the axle so that it looks like an open ended wrench.. that is the only solution i can think of? other than cutting the connector off and feeding it thru the torque arm hole and splicing the connector back onto the end of the cable which i dont want to do.
Usually you would mount the torque arm to the other side of the motor where the cable is not coming out of the axle. If you cut the torque arm open into a 'C' shape it will loose most of its strength. This is one of the reasons why we really dislike end axle cable exits, and why almost all the motors that we stock and sell (like the RH212, FH212, GMAC, All Axle, Crystalyte, DD45 etc.) have side cable exits instead.
HET thats is a reverse circumcision technique used in oil industry to feed cables bravo
Have you ever tried a little bit of dishwashing liquid on the cable?
The motor cable to my e-bike has been sliced by someone, cut clean roughly 8-10 inches away from the hub motor. It looks like there are 7 wires to reconnect inside there. There was never a connector. Is this repairable by adding some kind of cable connector? This is a 3 month old bike in otherwise like-new condition.
Yup. You can solder the wires all back together as they were with no connector, or use this opportunity to add one as you wish
HOW DO YOU CHAGE A STRIP HUB MOTOR BOLT?
Hey man i have the same problem. Can somebody please tell me what kind of wires those are..I've been looking for these phase wires and all that I can find is the 9 pin connector but not the actual wires that go through the axle..
Every motor is different so you might want to email our tech support with more info on what you're running!
Is there a repair for damaged motor axle threads or is this a case of replacing the entire inner armature assembly? Thank you.
You can often just chase the threads with a die to get them in good enough form, and use washers under the nut so that the nut is further out where the threads are more in tact.
@@GrinTechnologies I think these might be too far gone. Wonder if JB weld applied & then threaded would work? Used to be able to buy liquid metal that I think was good for making threads.
Where can I find a hub cable for a Swagtron EB7 ?
I would get some electrical lube and cover the cable with it. The lube is a special type for electrical use. I’ve even used dish soap in a pinch.
What if you used a lubricant to help slide the cable through? Is that advisable?
talcum powder
Why didnt you just put some oul or greese on the cable? Would that cause a problem?
I’ve made cable repair but display continues to display 30h communication error. Could it be my controller is fried from when the cable was damaged?
Communication errors are between the controller and the display, and don't have anything really to do with the connection between the controller to the motor which is covered in this repair video. So yes it is quite possible that your controller is damaged too, or you have another wiring issue with the signals, unrelated to the motor cable.
I have this problem but with a bigger 1000w rear hub motor. How much would this cost (roughly) to fix?
It all depends how much you charge yourself for your own labour, because it's unlikely you'll be able find someone competent you can pay to do it for you ;-)
Silicone grease on the outer cable?