Melted Connections - Beware...!

[dylan]

Hi Folks
Just thought I would share with you my lucky save the other day
I just popped open the battery bag on my BPM 500W Rear conversion bike when I noticed melted connectors
The three bullet connecters for the motor power wires had all melted together
Goodness knows how they didn't actually short out
These connecters must have a resistance & not be up to the current flow
I have now soldered each bullet connector together & covered in heat shrink tubing
I have included a picture of the melted remains of the insulated boots covering the connectors
I strongly suggest you check yours asap
Could have been a lot, lot worse...!

 

[izeman]

i always wondered why they install this crap for controller - motor connections. i even melted 4mm banana plug quite easily so their insulation melted into each other. i now only use 5.5mm goldies for anything between 1 and 4kw peak. some guys even use 2 of them in parallel for more power.

 

[Ypedal]

yep, i've seen dozens of those melted down to goo..

they " can " work for a while, but if you disconnect and reconnect them a few times, they get progressively worse......

 

[Skedgy Sky]

Had this happen to me once - I even think one time it went as far as destroying my motor somehow. Don't remember much on it anymore.

I've even started to cut those off when I see them, even though I don't have much to replace them with... but I think using anything else is better than keeping them on.
For under 1000W, I think they may be OK.