Ebike power loss after cable broke at axle. (FIXED)

[Nazan]

I was riding my ebike when the wheel nut got loose and the wheel fell off.(i didnt have axle lock nut on) I was riding about a speed of 35mph when this happened. Nothing happened to me but the hub motor stopped working. It only made some noise but did not move. So i checked the wire and 2 hall sensor wires got damaged and the yellow phase wires insulation tore at the end of axle. So i replaced the cable on my own. And now when i test it the wires all work but the controller still did not give power. It was the same issue only noise but no movement. So i connected a different motor to the controller and that worked. So it was not the controller. I checked the hub motor and the 2 hall sensor wire were giving different readings. So i assume it is a hall sensor issue. I then connected the motor to a different controller 35amps. (Old one wad 40AMPS) and it worked but sometimes makes noise. Sometimes runs smoothly and the display shows motor symbol. but now the torque is very weak. Is it the problem of hall sensor?. If so should i replace the whole hall sensor board or just the sensors. I guess it might have shorted with the phase wires.

 

[Tony01]

Yeah, definitely damage on the inside of the motor for sure- shorted phase wires, or damaged sensors or a whole sensor board. Trust me going down the road of fixing a motor where the wires ripped off is a huge pain in the butt. I would just get a new motor if they’re not too expensive.

 

[E-HP]

I was riding my ebike when the wheel nut got loose and the wheel fell off.(i didnt have axle lock nut on) I was riding about a speed of 35mph when this happened. Nothing happened to me but the hub motor stopped working. It only made some noise but did not move. So i checked the wire and 2 hall sensor wires got damaged and the yellow phase wires insulation tore at the end of axle. So i replaced the cable on my own. And now when i test it the wires all work but the controller still did not give power. It was the same issue only noise but no movement. So i connected a different motor to the controller and that worked. So it was not the controller. I checked the hub motor and the 2 hall sensor wire were giving different readings. So i assume it is a hall sensor issue. I then connected the motor to a different controller 35amps. (Old one wad 40AMPS) and it worked but sometimes makes noise. Sometimes runs smoothly and the display shows motor symbol. but now the torque is very weak. Is it the problem of hall sensor?. If so should i replace the whole hall sensor board or just the sensors. I guess it might have shorted with the phase wires.

It’s easy to check the hall sensors with a small battery and voltmeter

Testing BLDC motor's Phase Wiring - Hall Sensors and Wiring. - Electricbike.com Ebike Forum

Testing electrical components of a typical hub motor with a digital multi meter. First take a few minuets and look over the wiring going into the motor for cuts, scrapes, missing insulation and other wiring issues or poor connections that should be resolved first. Smell for...

electricbike.com

You may just need the right phase and hall wire combination. Usually the controller would be most susceptible to damage when the cables get shorted, but since it seems to be working, and the motor seems to be spinning with a false positive with the other controller, I’d check the wiring order after verifying that the halls are good.

PS. Invest in good torque arms. This is a rookie move and a hard lesson.

 

[Nazan]

Yeah, so i had opened the motor and fixed it. But i had to open it twice cause the hall sensor failed. Now its all good. It waa a simple diy fix ig. Thanks