How to replace a damaged cable harness in an ebike hub motor

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!
https://www.ebikes.ca/learn/troubleshooting.html

Видео How to replace a damaged cable harness in an ebike hub motor канала Grin Technologies