Yes I'm still having the same intermittent stuttering issue. It happens mostly when I'm accelerating hard or if I'm pulling a heavy load (trailer) the motor will start having this sensation of ticking or misfiring. It's hard to describe. If I ease off the throttle a bit and then try to increase power smoothly it minimizes the problem. I've just been ignoring it since I don't care to replace the halls or wiring just yet.
It's interesting that the hall wiring fixed your issue rather than the hall itself. Was there a nick in the wire or something? They are really thin wires so I guess they could be damaged inside without necessarily showing damage on the insulation.
I'm now leaning towards throwing my HS into a 20" wheel. I don't think I'll have any issues with overheating if I do that. I should be able to run 88.8v and 65 amps no problem with that setup. Top speed is enough for practical purposes street riding with traffic. Battery capacity is the limiting factor riding at high speed anyway. The acceleration should be awesome in the 20" wheel, 130lbs of thrust, almost double what I have now!
My area is fairly flat but there are big hills around that I'd like to be able to go up without fear of my motor going up in smoke. The 20" wheel should take care of that. Most of my riding is on roads, sidewalks and paved paths. Commute distance is nil for now, but it was about 9km each way up until recently. My transportation is my bike, so it's more than just a hobby for me.
I've got an 18fet 4110 controller on the way plus 1 kilowatt hour worth of batteries. Now I'm just debating between 24" and 20" wheel to migrate my HS3540 to. Leaning towards the 20". Probably going to run 24" front 20" rear. Will throw up some pictures when everything arrives.