My bike is barely engaging the motor then it flashes error 24

[shockslayer]

The motor cable has damage that was under yellow tape near the controller. You have to zoom in, it's the small yellow cable

 

[shockslayer]

People always say they checked the motor connector, but they never confirm that it's in ALL THE WAY TO THE LINE.

The motor cable often gets nicked where it comes out of the axle, so check there first, then anywhere where cable ties are holding it to the frame. If you zip the tie too tight, you can squish the wires inside the cable. Check all along its length to the controller that nothing has rubbed against it. Lastly, check all the connectors at the controller end: Bullets can be loose, hall connector pins can be not clipped in properly or that connector can be dirty.

Assuming that you have the rack battery, the controller will be in the compartment at the front of it. You need to look in there to see the motor connectors at that end. They all dismantle in differnt ways, but normally 2 or 4 screws to get the cover off.

I checked the motor cable near the controller and it has yellow tape that was hiding damage. Do I need to replace the motor cable or is it possible to splice or solder

 

[saneagle]

I checked the motor cable near the controller and it has yellow tape that was hiding damage. Do I need to replace the motor cable or is it possible to splice or solder

A new one is only about £10.

 

[shockslayer]

How do I go about finding out which is the right replacement?

 

[saneagle]

How do I go about finding out which is the right replacement?

You get one the same as what you already have. We don't know what you have, so impossible to recommend one.

ebay ebike motor cable - Google Search

 

[shockslayer]

If I can't find one is it possible for me to just solder that one yellow wire?

 

[thelarkbox]

If I can't find one is it possible for me to just solder that one yellow wire?

Assuming you have the very common 'waterproof' 9 pin motor plug/socket arrangement, its just a case of matching length and controller connectors.
Is there something unique about your connection?

Yes you can solder the damaged wire, or wires, marine grade heat shrink can be got via ebay etc and has 'hot glue' inside to seal a fix 'permanently'.

 

[shockslayer]

If I were to solder the wire how would I go about doing that? It's just the one wire but I'm not sure how to get enough play in that wire so I can work with it. The damaged wire is the big yellow one inside the motor cable.

 

[thelarkbox]

well i would cut the whole lot in 2 strip back more sleeve and remove all damaged wire before continuity testing each side, If passing the test resolder 1 by 1 with heats shrink to seal.
But I would probably buy a new cable.

A 'bodge job could be done with some sort of heatshield like a strip of old pcb to isolate the wire you want to solder. but if problems still exist post fix your back where you started. and resealing could be problematic

 

[saneagle]

If I were to solder the wire how would I go about doing that? It's just the one wire but I'm not sure how to get enough play in that wire so I can work with it. The damaged wire is the big yellow one inside the motor cable.

There must be more than the one wire damaged to get the problem you've described, so there might be another exposed wire underneath or somewhere else. Is that the same damage as where the chain rubbed on it?

 

[shockslayer]

There must be more than the one wire damaged to get the problem you've described, so there might be another exposed wire underneath or somewhere else. Is that the same damage as where the chain rubbed on it?

No this is a different part of the motor cable, this part of it was near the controller.

 

[matthewslack]

You've probably realised this already, but just in case not...

The cable damage has probably lead to hall sensor failure, so fixing the cable will not fix the problem.

The cable is too knackered to sensibly repair and reuse, so you can be quite brutal with it to diagnose the problems: cut out all the damage and use terminal blocks and extra lengths of similar sized wires to reconnect everything properly.

That eliminates the doubt about the cable. If you still have the code 24, then do the hall sensor checks. If that is the problem you need to open up the motor and replace the hall sensor(s).

At the same time, remove the damaged cable, look online for same, order and fit.

 

[shockslayer]

You've probably realised this already, but just in case not...

The cable damage has probably lead to hall sensor failure, so fixing the cable will not fix the problem.

The cable is too knackered to sensibly repair and reuse, so you can be quite brutal with it to diagnose the problems: cut out all the damage and use terminal blocks and extra lengths of similar sized wires to reconnect everything properly.

That eliminates the doubt about the cable. If you still have the code 24, then do the hall sensor checks. If that is the problem you need to open up the motor and replace the hall sensor(s).

At the same time, remove the damaged cable, look online for same, order and fit.

You've probably realised this already, but just in case not...

The cable damage has probably lead to hall sensor failure, so fixing the cable will not fix the problem.

The cable is too knackered to sensibly repair and reuse, so you can be quite brutal with it to diagnose the problems: cut out all the damage and use terminal blocks and extra lengths of similar sized wires to reconnect everything properly.

That eliminates the doubt about the cable. If you still have the code 24, then do the hall sensor checks. If that is the problem you need to open up the motor and replace the hall sensor(s).

At the same time, remove the damaged cable, look online for same, order and fit.

How do I go about finding the right cable? The website for the bike doesn't sell the cables

 

[saneagle]

How do I go about finding the right cable? The website for the bike doesn't sell the cables

Take the cable off. Look at it, measure it, then compare it with those in the link I provided above.

 

[shockslayer]

How do I go about finding the right cable? The website for the bike doesn't sell the cables

So I'm to the point I doubt theres anything I can do to make this bike work. I soldered the wires that seemed to be the issue and still the same original problem

 

[shockslayer]

Take the cable off. Look at it, measure it, then compare it with those in the link I provided above.

I really don't know how to find the right cable and I already tried soldering the wires that were damaged. Im kind of running out of ideas other then paying a shop to fix it

 

[thelarkbox]

As pointed out above the damaged cable probably resulted in a short and damage to one or more of the hall sensors in the motor. so even a perfect repair of the damaged cable will still leave you with the problem.

the hall sensors are easy to diagnose and repair, ( https://ebikes.ca/documents/HallSensorTestingFinal.pdf ) you may even find a plug in replacement pcb on ebay for a fiver.

Look at the motor cable ads linked to above match one to yours, in both length and connecting ends. If really stuck pull your cable take photos and post here for direction. the motor end will be either 3x or 9x round connector in most cases and the controller/sensor end will either be julet waterproof connectors or more generic automotive style smt connectors. And since you can solder if one or two connections dont match (unlikely) .. the point of a new cable is removing uncertainty with a possibly damaged cable.

 

[matthewslack]

It is a big job to open up the motor and replace hall sensors, but take it in small steps and ask for help here when you need it, and it can be done.

It will almost certainly be cheaper to replace the motor than pay a bike shop to fix the hall sensors.

 

[saneagle]

I really don't know how to find the right cable and I already tried soldering the wires that were damaged. Im kind of running out of ideas other then paying a shop to fix it

Take the cable off, lay it on the ground and photograph it. We can't help if we don't know what you have.

 

[chris_n]

You do of course realise that the bike you have bought apart from having butchered wiring ( how it could get into that state is beyond me) actually appears to be illegal to use as a bicycle in UK other than on private land.