XT90 connectors stuck

Batteries, Chargers, and Battery Management Systems.
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montana2436   100 µW

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XT90 connectors stuck

Post by montana2436 » Apr 20 2019 8:21am

Hello,
I was trying to troubleshoot loose contacts and pressed XT90 connectors too hard apparently. Now I cannot pull them apart. I tried to put hands on the wires directly and pull - still same.

I cannot remove the battery from my bike now. I would hate to damage the connectors as well since the battery is expensive.

What can I try? Could somebody please help?

SirLongAss   100 mW

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Re: XT90 connectors stuck

Post by SirLongAss » Apr 20 2019 9:44am

I'm not sure how you did that lol. So you are probably going to want to cut the wires on both sides of the connectors. Then replace the connectors.

:warn: Make sure after cutting each wire you put tape on it or cover the wire so you don't take the chance to cause a short :warn:

You could also just cut one side off(preferably the batteries connector so you dont short the battery) and take a pair of pliers and try to pull the connector out while supporting the still wired connector so your not applying the force on the wires leading to your bike.

Upnorth   100 µW

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Re: XT90 connectors stuck

Post by Upnorth » Apr 20 2019 1:11pm

There are a ton of cheap counterfeit xt connectors, look for Turnigy (from Hobby King) or Aomy connectors. I think that the real ones are great, cheap ones melt easily and get stuck.

VERY important to do only one wire at a time.

If you can, hack away at the plastic and get to the solder. If you have length to spare then just clip them.

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flippy   10 MW

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Re: XT90 connectors stuck

Post by flippy » Apr 20 2019 3:13pm

my guess you have fake connectors and the barrels have melted due to overloading them.

cut them and fit original ones. if the space is there fit 1 size bigger.
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spinningmagnets   100 GW

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Re: XT90 connectors stuck

Post by spinningmagnets » Apr 20 2019 4:37pm

Between the red and black wires, cut only one, and then put tape over the stub on the battery side.

Then...cut the other wire. Wire cutters have steel blades, and if you cut both at the same time, it will immediately cause a huge short, and it may damage the battery and/or the BMS.

https://www.electricbike.com/matching-c ... ontroller/

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motomech   1.21 GW

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Re: XT90 connectors stuck

Post by motomech » Apr 20 2019 8:15pm

I prefer Turnigy bullet connectors. Easier to install and easier to connect/dis-connect.
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dogman dan   100 GW

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Re: XT90 connectors stuck

Post by dogman dan » Apr 21 2019 7:03am

Said twice, but never can say it too much. cut only one wire at a time. I'd say go to the hobby bullets, the big ones if you are melting plugs.

montana2436   100 µW

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Re: XT90 connectors stuck

Post by montana2436 » Apr 22 2019 6:41am

Thanks. When installing new connectors, would wrapping wires around each other be sufficient or welding them would be better?
dogman dan wrote:
Apr 21 2019 7:03am
I'd say go to the hobby bullets, the big ones if you are melting plugs.
Not sure what you meant by that. Is "hobby bullets" a manufacturer?

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pwd   1 kW

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Re: XT90 connectors stuck

Post by pwd » Apr 23 2019 1:52pm

"hobby bullets" are referring to bullet style connectors from the website hobbyking.com They come in various sizes.
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hemo   100 W

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Re: XT90 connectors stuck

Post by hemo » Apr 23 2019 4:35pm

montana2436 wrote:
Apr 22 2019 6:41am
Thanks. When installing new connectors, would wrapping wires around each other be sufficient or welding them would be better?


Solder the wiring, don't rely on wrapping any wiring.

SwampDonkey   100 W

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Re: XT90 connectors stuck

Post by SwampDonkey » Apr 28 2019 1:15am

Have you tried the Supra X connectors? Its the same ones used on the Sur-Ron, Great looking connectors that you dont even have to solder. And holy cow, these handle 230A continuous! https://www.ebay.com/itm/RPPREB7808STS7 ... 3636437696

Yungyakz   10 mW

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Re: XT90 connectors stuck

Post by Yungyakz » May 07 2019 7:46pm

pwd wrote:
Apr 23 2019 1:52pm
"hobby bullets" are referring to bullet style connectors from the website hobbyking.com They come in various sizes.
xt150 connectors from hobbyking.com ive heard they are good and im going to order some soon. they are basically bullet style connectors with a case over them.

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