Can This Worn Connector be Causing My Power Loss?

[Transit Artist]

Another idea? Mount battery somewhere else and use tube as rocket launcher.

View attachment 388015

Already plotting my second battery so no space left outside. But rocket launching is my most common comment. Says something about our society.. not sure what. Maybe I'll plant potatoes and carrots in it or stuff it with flowers.

 

[99t4]

Now I just need to tend to the male side. If I can't find the exact size (plastic base) can I replace these chewed up blades or are they fused together in the making?

Unscrew the connector and take it out to inspect how it is made. My guess is that the metal conductors are molded into the plastic.

Depending on your motivation level, you may find a suitable replacement by searching around. In fact, someone with the almost exact situation as you is currently working through their slide-in battery connector problem and found an exact replacement, so follow their progress, you might get "lucky" as well:

The first problem with the battery and motor hub

Hi. It seems that I have my first real problem with the battery. But I hope that is just connectors... The battery is stuck and won't go out, even if unlocked! How it started: One day I charged the battery to about 90% and went to work. After I was returning, the battery on throttle started...

endless-sphere.com

Be aware, your planned mode of repair is not really addressing the real problems of poor design, cheap materials, and incorrect component choice for its planned use. You are just prolonging its misery by replacing the prematurely worn items for like.

 

[Jeff23spl]

You mention taking it out twice a day....I expect you cannot charge it where the bike is parked ? because this would save a lot of wear and spark on non-spark protected connector if you could let it in.
Many talk about the battery moving since it change when you take a bump but even if it would be secured properly while riding, if there is no turn off without draining the caps, you are also melting the terminals twice a day by putting back the battery. So having a switch could wear the switch during those 2 time a day instead of the connectors if you don't want to mess with pre-charging with a resistor.

The option of using an anti-spark XT90 (or similar) connector with flexible leads remain your best option. Have you measured if you take both plastic caps off and extend the wires to be able to connect/disconnect it once the battery is pulled out, if you could be able to pack that extra wire lenght inside, between the battery and the frame end ?

If not, taking both connection out thru a sealed hole is the second best option. Unless you sink the ride into the water , it will remain splash proof and the connector itself won't suffer from rain either.

The other option is to get copper plate the thickness required and made the shape with scisors and a file and epoxy them back where it should seat or a little bit more extended

 

[Transit Artist]

Be aware, your planned mode of repair is not really addressing the real problems of poor design, cheap materials, and incorrect component choice for its planned use. You are just prolonging its misery by replacing the prematurely worn items for like.

I totally agree. This is my path of last resistance for the moment. Thanks for that link. Seems exactly what I'm experiencing

 

[Transit Artist]

You mention taking it out twice a day....I expect you cannot charge it where the bike is parked ? because this would save a lot of wear and spark on non-spark protected connector if you could let it in.

The other option is to get copper plate the thickness required and made the shape with scisors and a file and epoxy them back where it should seat or a little bit more extended

I charge separately from the bike because I'd read of, possibly in the context of adding a second battery (and not fully understood), that fires can emanate from hot batteries being charged while still connected to hot components.. as I would expect to be the case every time I'm done riding. Is doing this a fireproof solution?

I am indeed leaning towards carving the plastic base and/or mounting it on a separate plate.

 

[99t4]

In General, best charging practice dictates always charge supervised, meaning observed, where you can keep an eye on the battery while charging. Charging/discharging is when a battery is most likely to catch fire or explode.

fires can emanate from hot batteries being charged while still connected to hot components

Optimum charging between approx. 50-80degF. Damage occurs below 32 and above 110degF. How hot is your battery getting?

 

[Transit Artist]

In General, best charging practice dictates always charge supervised, meaning observed, where you can keep an eye on the battery while charging. Charging/discharging is when a battery is most likely to catch fire or explode.
Optimum charging between approx. 50-80degF. Damage occurs below 32 and above 110degF. How hot is your battery getting?

Good question, not sure how I'd measure that without buying a device. Recommendations?

Supervision is why I charge it separately. The recharger has once or twice refused charge to my hot battery but at that point it's near so I can remember to try again. I can't hang around the garage waiting for a charge. No safe outdoor space otherwise.

 

[yooper2001]

I cleaned and sandblasted the inside of an old gas grill, and have a discrete secure latch on the lid. I have it farthest away from my house on a cement patio. Works great (except in winter). I have no worries if the batteries go.

 

[Transit Artist]

I cleaned and sandblasted the inside of an old gas grill, and have a discrete secure latch on the lid. I have it farthest away from my house on a cement patio. Works great (except in winter). I have no worries if the batteries go.

Snazzy, and sounds like it makes for good pictures. Though currently trying to figure out how to charge on-bike to avoid wearing the connectors as suggested by @99t4

 

[99t4]

Good question, not sure how I'd measure that without buying a device. Recommendations?

IR no contact thermometer

You mentioned you battery gets (dangerously?) hot? How are you measuring the temperature?