Alright, more expertise needed. Today I got the battery and motor out of winter storage and everything hooked up. And unfortunately, my hall sensor repair didn't take! Felt pretty disappointed.
To clarify, the QS273 comes with two separate hall sets and two separate runs of wire to two different connectors. Last year I had power loss mid ride, it turned out to be hall error. I switched to the backup halls with no issue, motor ran normally. I used a multimeter on the primary hall sensor wires that were reading as a failure, at the end of the connector where it plugs into the controller, and sure enough, 1 of the 3 halls was not showing up on the meter. During winter break, I took apart the motor, and confirmed directly at the hall sensors themselves that one of them was failed. In my mind, this ruled out a cable issue. I replaced that entire set of halls. I checked continuity after I was done to confirm that the new set of halls was reading correctly, at the end of the connector. It was. In fact, both sets of hall sensor connectors read the same on the multimeter. I set aside the motor for the rest of the winter.
Today I reassembled the motorcycle, plugged in the hall connector for the new set, and tried to throttle. No dice. The wheel jerked a bit, and the controller flashed the error signal for hall sensor error, just like last year. I switched connectors to the backup set, restarted, throttled, and the motor behaved normally. I double checked readings at the connector with the multimeter, and the replaced set of halls gave me the same readings as the backup set. Except only the backup set is working right now. And now I'm scratching my head as to why.
Can anyone give me any suggestions for why this is happening and what I can do to fix it? I won't be taking the motor off or opening it again, yet, because as I mention I have a functioning set of hall sensors that is allowing me to ride my motorcycle as normal. I just hopefully can find the issue so that if the backup fails, I have a plan for how to get the motor running again. Any advice appreciated.