dwkayaks wrote: the reason I want to un-plug the Hall connector is that when I plug it into the motor Hall connector , the motor just shutters and barely turns the wheel when I advance the throttle .
This probably means that the hall and phase wire combination is not correct for that motor/controller combination. If the controller and motor did not come together pre-installed on the bike (working from the factory), then even if they came as a "kit" it is possible they are not yet wired to work together.
Alternately it could just be a loose or bad connection on one of the hall wires, so the signals are not quite right and the controller isn't able to sense the motor's position correctly. I'd check that first, but if there's no connection problem, then:
There's 36 possible combinations between the 3 blue/green/yellow wires between both connectors, and only one of them is likely to work on a geared hubmotor (the other would spin it backwards which wont' move the wheel on-ground, and off-ground might just barely spin it backwards from friction in the clutch).
The other combinations would have various other effects but aren't usable. There is a thread How To Determine The Wiring For A Brushless Motor that can help you fix that.
When un-plugged the motor works fine , except on start-up when a loud clunk is heard when applying the throttle to start off .
That's probably the controller first spinning the mtoor backwards then finding no load on it it spins it the other way, and as the clutch and gears engage it thunks. My bigger Fusin kit (sensorless) always does that.
If it does what you want without the halls connected, I'd just leave them disconnected and save the troulbe of figuring out what combination of hall and phase wires you'd need for it.
I was thinking that the motor studdering was caused by out of phase controller signals to the motor , and that brings my thoughts to, is this fixed by entering the correct number of poles in the CA ?
The CA has nothing to directly do with what the controller does to operate the motor, only what speed it operates the motor at (assuming the CA's throttle output is connected to the controller's throttle input).
The problem is between the cotnroller and motor.