How to Replace a Damaged Hall Sensor in an Ebike Hub Motor

In this video Justin demonstrates the repair an eZee hub motor that had a damaged hall sensor as a result of an axle spinout. While it is shown on an eZee hub motor that has a hall sensor PCB, the process is more or less universal. It is even easier in cases where the hall sensors are glued just into the stator and connected with wires rather than a printed circuit board.

Hall sensor replacement is a fairly common repair process with ebike hub motors. The main reasons for hall chips becoming damaged include:
1) Exposure of the hall signal to high voltage (from axle spinout for instance)
2) Excessive motor stator temperature (usually evidenced by very dark copper wire too)
3) Water ingress damage (usually hall IC is OK, but the leads can be corroded)
4) Mechanical damage from a broken leg on the hall chip as a result of vibration
5) Physical scraping of the hall chip from poor mechanical tolerances or stator getting loose

In general, a motor with a damaged hall sensor can still be run without replacing the halls by using a motor controller that can operate in sensorless mode. This is our recommended option for most people as no opening or service of the motor is required. The only downside is that starting off from a dead standstill can be a bit jerky.

Видео How to Replace a Damaged Hall Sensor in an Ebike Hub Motor канала Grin Technologies