How to replace a damaged cable harness in an ebike hub motor 

Love Pete's vocabulary. Richly descriptive, and ,hey, no swearing .

I’m impressed with your patience & verbal skills. Nicely done. Appreciated

I cannot put into words how good this video is. I am an amateur who has been wrestling with a MAC 1000w geared motor these past few months. I've literally learned every single lesson in this video the HARD way. Small geared motors are an absolute nightmare. Not only are there 90 degree angles, no room, the problem of getting the gears to mesh etc etc....but you got sharp edges everywhere too.

My friend is at a mental hospital now. Because he tried the same.

silicon spray is an option on the cable and tunnel to help it slide through. I would say that having 8cm of sheath free cable is okay as the end where you grip with the pliers to pull through will then mean you just cut off that 8 cm and work from there. I haven't tried it as yet but certainly a suggestion at the moment.

Very good info in this vid. I always wondered if it was possible to replace a damaged cable in the Hub motor.

Great idea and top tip, I've never tried sourcing a replacement cable its mainly higo/julet 9 pin in the UK but in the event of another motor fail I would now consider it as an option - shame on the video ending, I would of liked to see some top tips for the internal soldering and perhaps a future video idea for replacing hall sensors and speed sensors, my attempt at a video was with my first motor and with very little skill however it worked for a while. You guys have the knowledge base and the directing skills to produce a high quality video.

Excellent explanation this guy is great

Well done , thank you for your insight to the task at hand

Where did you order the replacement cable harness? Thanks..

Great work ! What a fine company !!!

I learned so much here, basically not to be afraid of all this stuff, all you need is the right tools and a healthy set of balls… and desperation that your motor will not work otherwise…

I use a dremel to smooth any sharp edges at the entry opening, for the cable I slide the insulation down like you do but I make sure I don't trim the nylon cord the same length as the wires so I can incorporated that into my pulling tether with the slitted insulation wrap. Also I use a wee bit of silicone spray to lubricate the cable.

great video, for what most would consider a daunting task.

I frequently encouter the same issue pulling the cable through a too small orifice while pulling electrical cable to install swimming pool lights. I use the same method of decreasing the diameter of the outer sheathing. but leave a longer tail of the inner insulation cord and attach very strong nylon cord to it, then using electrical tape to secure it to the cable. To do this so that the cable will still fit through the races and bends, I make sure to wrap the excess cable as tight as possible to make its diameter as small as possible. The nylon cord used as a fish tape can then be doubled or tripled to add tensile strength. I also use electrician"s luble to ease it through the tight races. I'll be performing this very task this weekend on my boyfriend's bike that I crashed when some clown turned right in front of me. Those front brakes sure worked better than the rear brakes because I went ass over tea kettle over the handle bars, consussion and serious bruising. Asshole didn't even stop to see if I was okay or check to make sure I didn't sue his insurance company into the Stone Age.....I'll let you know how swimming pool technology transfers over to ebike repair. Thanks for the incredibly helpful and informative video.

Excellent video . I have done external splices on rear hub motors with 'cassette issues' but am baffled trying to open up a PEDEGO hub motor to get to the inner connections. There is NO POSSIBLE WAY to open up the motor case! At least not that I can see😡😢😨 I can see zero bolts, screws, nuts, fasteners, or ability to open up the case. I gave up and bought a new motor, rim, throttle, pas, grips, controller kit....this solved the problem much easier than splicing on a new cable that SHEARED OFF because the rim nuts were not properly tightened by a professional after a FLAT TIRE REPAIR! Thanks for showing that this CAN BE DONE by a proper professional. Doing it on a pedego motor seems to be NEAR IMPOSSIBLE. THANKS AGAIN for your video presentation. You deserve an award of the highest magnitude. Searching the interwebs for this content reveals very low results. Thanks for showing us how to to it on a most difficult hub motor, that at least let's you open up the CASE. 👍👌✌💓

I use dialectical grease as a lubricant. Great training... ThanxAlot!

hey, great video. BTW you can also solder all wires together and attach a 14 ga wire, then pull through. Great job.

Thank you so much! Great Video!

If the hole where the wiring goes trough is a bit too small for new wiring use a Dremel tool, with a grinding stone on it, and open up the hole's diameter larger, so the wire slides through much easier, with less resistance. Could also use WD-40 on the wirings outer coat, and inside the hole, to allow easier, and smotther passage of the new wire.

That’s cool and all, but how do you find the right power cable replacements for your particular bike?

Lubricating the outer surface of the wire and metal hole helps. Another way to do this is to "waste" some wire. (If there's length to spare) By cutting off a longer piece of the outer jacket and sending the 3 exposed colored wires in 1 by 1. When all 3 of them are through, the whole cable can be pulled through easily.

vaseline is a good way of getting big things into small holes.

Thank you. Thats nuts.

Great video!

So many people asking where to buy the replacement cable and not a single answer. It looks like grin used to sell this cable by the meter but that product has bee discontinued. It's strange that it's so hard to find when there's such a need for replacement cable. Waah. I need some.

You should pet the motor head gently and whisper "everything will be fine, don't worry, relax" to make it go easly

Fantastic video. So where can you buy the cable? Would any motor hub cable wire would work? Thanks for the great video. Please help.

I am going to attempt this job next week.... But I have pulled Big wires through conduit and I use a Lube on the big stuff.... so I will lube the cable before I pull it through, after I do my Tape job...... and I will not cut all the wires at the same point.... I will cut each inner wire at a different length, so I will have a longer taper .... Thanks for the video and info here.... I wonder if KY jelly will work?

Can you use a slightly larger reamer to open the hole to make it easier to pull cable through the hole???

Great video I got 3000w motor witch doesn't have temperature sensor what steps has to be taken to install temperature sensor pls advice Isit possible to just fishing the temperature sensor wire in or all the hub wires have to comes out then push the new wires in including temperature sensor wire

J did that with break wire. Works fine 😊

This video is great. What would make it awesome is a source for the cable. Because otherwise, I get my hopes up, figure I can repair it, and then learn I can't get the cable. So the video just mocks me.

Thanks for this great video. Can you let me know where I might buy the cable and 9 pin connector from?

Jim Carey look alike! Very well explained

A job l have to do of which I'm not looking forward too. Good vid

Just pull inside the old cable until you get damaged area inside the motor. Than you can fix it inside the motor. Only downside is you end up with a shorter cable :))

I've used two stroke petrol, squirt a bit in the axle and over the cable, it slides in, you only have one go at it so mark where it needs to stop at, then blow the petrol dry and all done.

I be never ever seen anything like it I snapped my hub cable right at the wheel this guy made it look so hard Ive never ever done any electrical or cable soldering but it was so easy don't watch this.unbelievable

would it be useful to coat the cable with a bit of petroleum jelly so it pulls through easier?

I'm just wondering, how did the group insulation break, if it cut going thru the turns, one of the wires may have rubbed against a burr and short

Where I can I get a replacement cable for a bafang 750 hub motor?

Where can I find a hub cable for a Swagtron EB7 ?

cable lube is your best friend here!

Thank you for this video. Would you consider doing one that shows how to replace the plastic cogs on this GMAC one day?

May I suggest a little die electric grease to help the cable slide? Not the mention it will provide some moisture prevention as well. I love your tips on how to pull the cable through.

Would it be easier if while you were wrapping the tape you wrapped it around like a brake cable or a gear shifting cable? There skinny and strong but flexible. that way if the tape breaks you still have the cable underneath and it's stronger to push through to the other end and then you can just snip it when finished?

I have a qsmotor that is stuck. I've cut all the wires but the stator still will not spin. Any ideas why ? Thanks

Where can I source a cable for my e scooter motor. It has hall effect sensors/wiring but my scooter doesn't them. The motor is 1200 watts peaking at 2700. How do I determine what wire gauge I need?

Thanks really helpful , just wondered if you could've used a small amount of lube or vasoline.

Question,can you guys find new spindles if the spindles are broken,i cant🌊

Striping the outer jacket to allow enough wire to enter the motor then using thin-walled teflon tubing and slide the wire though the protective teflon ? Lubrication? Protection of coil windings when working on motor, cutting off damaged cable and pulling out wires individually...

The connector end on mine is different to any that is available to be bought can I just cut the old end off and attach it to the new cable?

lube for pulling electrical wire work?

what about cutting the outher sheath at a tapering angle?

You should put some lightbnon conductive grease on the part going trought the hole to facilitate the job.

Note to you. Use a little electric contact grease on the side the wire that is going through.

My cable harness is cut at the axle inlet but the wires aren't damaged yet it seems like I wouldn't have to take stuff apart to repair it or would I? Think I might be screwed but at least it's light enough I can still ride it as a regular bike

I have this problem but with a bigger 1000w rear hub motor. How much would this cost (roughly) to fix?

I would file the metal around the hole smoother , mine had a really sharp tiny burr that soon severed the cable even after being very careful by my third tyre swap . Also i now dob the hole with a glue gun after fixing to minimize any movement near the hole after refitting . Still I'm on 4000 miles now which means its paid for itself easily on fossil fuel vehicle costs. I have had all sorts weird symptoms with wire chaffing also and now am very careful on cable routing and extra wire protection over the bicycle in vulnerable places . .

Is your store in the tri-state area? I need help with this desperately

Could you put a smear of silicone lub on the outer cable

If I didn’t have damaged wires but just wanted to turn the motor cable into a quick connect plug(for convenience), do you have any videos on that?

what do you do when the outer casing of the cable gets stuck in the axle

This is great but my motor is big. That means I need a heavier replacement cable to take the 50 amps+ my motor draws. Does anyone know where I could get one? The motor is a 3 Kw QS 12"

Where did you get your ebike cable from?

what about any water based lubes? my damn rear brake rotor bolts came loose several times now and cut my cable, while riding tonight my motor kept applying the electric motor brake, which i never even setup, and it attempted to go into reverse while i was finishing this short but troublesome and very short ride, as i was riding it into my front yard and it ripped the wheel right out from the slots holding it in place. good times

I’ve made cable repair but display continues to display 30h communication error. Could it be my controller is fried from when the cable was damaged?

Hi Green tech, thank you for this video. Very interesting. I have just a question : why we cannot solder the cable directly on the Spule ? thank you

Trying to replace a juiced hyperscrambler 1100w mac motor cable. No support from JUICED :( thank you for a general idea of what I've got to do

Can this soldering process work with high voltage cables? Like a 48v 1500w cable to be precise

I need to do this to a 1000 watt motor. Where do I get the wire?

The motor cable to my e-bike has been sliced by someone, cut clean roughly 8-10 inches away from the hub motor. It looks like there are 7 wires to reconnect inside there. There was never a connector. Is this repairable by adding some kind of cable connector? This is a 3 month old bike in otherwise like-new condition.

My motor has all the colored cables that go to the PCB that's fine no problem but then there's also a black and white skinnier wires coming from the same large cable but they go into the coils underneath the magnets so I'm changing my main power cable but I don't know where they connect to I don't want to rip them out so should I just cut all the color ones out and resolder to those skinny wires that are in the coils leaving the original ones in place wherever they are installed to and just connecting to them with the 2 from the new cable

Can I use a rear hub motor for front ????

Hi Great video and great video quality camera. What camera model you used for this video? I can suggest you use a smooth ointment like grease or oil or even soap for spreading on the cable

Bro I need help I didn't leave a little little amount of the colored cable on there and I don't know which wire's to wire back the blue yellow and green

Silicone grease on the outer cable?

What is a blue slate?

Are You and NYC ??

Also wouldnt a better way be to removel the spindle completely then re installing it with the wire already placed in the bore holes?

External splice for me, Id repair, shrink wrap individual then one big shrink wrap over the lot ..butted to the motor.

HOW DO YOU CHAGE A STRIP HUB MOTOR BOLT?

Why didnt you just put some oul or greese on the cable? Would that cause a problem?

Have you ever tried a little bit of dishwashing liquid on the cable?

Tip if you need to clamp the threaded end use blocks of timber so the thread won't be damaged. Great video I be doing within the next couple of weeks..

I know it’s been said many times but what is wrong with applying some spray lubricant just before or during pulling the cable sheath ?

Is it a 1000W motor?

How much does that usually cost?

a small squirt of dry lube on the outer casing when pulling through works just fine, plus some applied on the inside Lastly, why not thread on the nuts on the axel then vise it up? so much easier.

How about a little cable lube? Yellow 77 perhaps etc etc

Any reason you didnt put a drop of machine oil or a small burst of wd40 down the bore hole? Maybe help the jacket slide through more easily?

Hey man i have the same problem. Can somebody please tell me what kind of wires those are..I've been looking for these phase wires and all that I can find is the 9 pin connector but not the actual wires that go through the axle..

can someone tell me how to get your control cable through the little axle hole in your torque arm?? the connector block on the end of the cable is too big to fit thru the hole. ive watched alll the vids on youtube on torque arm installation but nobody talks about this problem!! I am thinking about cutting off the end of the torque arm that slips over the axle so that it looks like an open ended wrench.. that is the only solution i can think of? other than cutting the connector off and feeding it thru the torque arm hole and splicing the connector back onto the end of the cable which i dont want to do.

need a new axle for my das-kit 500w shaft spun :( going nuts trying to find replacement and some torq arms

Electrician wire lube works along with another light gauge wire with tape.

What if you used a lubricant to help slide the cable through? Is that advisable?

sand paper the cable?

can I "oil" it a bit?

sir, can I use any other series hall sensor instead of series labelled on that?