ITS FIXED !, so I took it for a ride with my wiring in from the display unit and it does work ok, but on high boost it puts the display into protect mode for a split second, I had this problem when charging my phone too, I think the iphone 5 draws too much current as it charges it fine with the bike just sat there doing nothing, but as soon as you give it some power it would put the display into protect mode and kill the power, so I think its only really rated for small phones that dont need a lot of power, I may try charging it with the phone turned off as they dont tend to pull as much power then. Anyway...... I am going on a forest ride tomorrow for some offroading so didnt want it jumping into protect mode all the time, so I went to see what I had in stock as regard to SMT resistors, but although I have loads of them I dont have any large ones, all the ones I have are little ones meant for phones and tablet repairs.
I had a dig around in my scrap parts cupboard and found an old graphics card covered in 2R2 SMT resistors (2.2ohm) , the Russians told me that I could just anything from 2ohm to 8ohm , so all good, the old one is a 3R9 (3.9ohm)
I removed 3 with my hot air rework station, it took literally about 3-4 seconds to get hot enough to take off with tweezers, I thought I would take a few extras as spares in case I need to do anything else at any time.
This is the old resistor after removing it. The board in the controller is covered in varnish, so I had to swab it with some isopropanol first to remove it, it came off easy enough though.
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This is the new resistor on the board, SMT stuff is really easy with a hot air gun and microscope, the hardest part is getting the component inline and not blowing it off the board in the mean time, I just hold it with the tips of the tweezers and give it 5 seconds or so of heat and then check with the tweezers its on properly.
I plugged it in and turned it on and no halls error was on the screen, so allllll good !, I tested the output voltage from the controller to the halls and its now showing as 4.8v and holding, so now im all set for the ride tomorrow, im just going to put the controller back in the bike and take it for a test ride.