BbsHD MAIN HARNESS DAMAGED

Oscdav · Feb 22, 2021

Hi, I have had a complete power failure and discovered that the main harness at the motor end got squashed and badly damaged by being tightly trapped between the lower part of my bottom bracket and the motor itself after it hit a log at speed.
I need to source this harness section from here in Norway and renew it from the motor.
Do you think that the controller is fried and how do l test for this?
Also,where would be the best place to buy the harness section and controller from here? Your help would be much appreciated.
Thanks, Oscdav

Sparfuchs · Feb 27, 2021

Oscdav said:
Hi, I have had a complete power failure and discovered that the main harness at the motor end got squashed and badly damaged by being tightly trapped between the lower part of my bottom bracket and the motor itself after it hit a log at speed.
I need to source this harness section from here in Norway and renew it from the motor.
Do you think that the controller is fried and how do l test for this?
Also,where would be the best place to buy the harness section and controller from here? Your help would be much appreciated.
Thanks, Oscdav

its quite hard to tell what happened because the pics are bad quality. But in the first pic it looks lite the wire got squashed but left enough space to cut the broken piece out and solder the wires back together again. If there isn't enough space you could open up the motor and pull the wire out of the case, then solder it and put it back in. I guess that's quite easy and cheap

fechter · Feb 27, 2021

Finding that piece of wire would be hard. Maybe try posting in the Items Wanted section of the forum and try to find someone that has a fried BBSHD with a good cable.

I would just cut out the damaged section and solder the wires back together with heat shrink tubing around them and try it.

Depending on which wires made contact with each other, the controller may or may not be fried. One wire is carrying battery voltage and if it makes contact with the serial data line, it's toast.

Oscdav · Mar 16, 2021

Hi, And thank you both for your help. Just got round to taking and downloading what I hope are are better pics.
They show the white wire to be worn threadbare and the brown sheaving showing obvious sign of distress.
At the very least, all the rest have been pinched, some badly.
Now I need to reply get to work on cutting and soldering together!
Hope that this will give me an clear answer as to wether I have fried the controller or not.

AHicks · Mar 16, 2021

If this is the 1 into 4 harness that leads forward to the display, brakes and throttle, I'd be tempted to just replace it, and re-route it to get it out of harms way.

Oscdav · Mar 16, 2021

Hi! It has 8 different coloured wires running from motor and is damaged approx 20cm further along to those you mentioned.
1 in 4 right?

Thanks.

fechter · Mar 16, 2021

Yes, that's the cable.

I thought those would be hard to find, but I see several on Amazon that are reasonably priced:

https://www.amazon.com/Electric-Bic...ocphy=9031942&hvtargid=pla-911684067571&psc=1

The 8 Pin male is used to connect with the Bafang BBS01B BBS02B BBSHD EB-Bus 8 Pin female connector;
The other 4 connectors are used to connect with Ebike throttle, display and brakes;
All Connectors are Waterproof ;
Length: 137cm;
Compatibility: Bafang BBS BBSHD Mid Motor Conversion Kit.

$12.99 & FREE Shipping

Personally, I would still cut out the damaged spot and solder the wires back together.

tomjasz · Mar 17, 2021

If you saw some of the solder jobs I have seen with DIY customers...

$14 and no pain.

Oscdav · Mar 18, 2021

That sounds like my horizon and eventual destiny

BbsHD MAIN HARNESS DAMAGED

Oscdav

100 µW

Attachments

Sparfuchs

1 kW

fechter

Administrator

Oscdav

100 µW

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AHicks

10 kW

Oscdav

100 µW

fechter

Administrator

tomjasz

1 GW

Oscdav

100 µW

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