Oh God- What have I done?

[jdone]

Wonder if anyone can help with this- not feeling too confident at the moment...

Bike is a Burisch Synergy GT (2012 model).
Decided I'd like to increase upgrade various facets including cadence (see Burish thread) so I bought a 11T freewheel cassette from China.

One of the problems (now rectified in post 2012 models) with this bike is that there is no service connection to quick release the power cable that runs from the controller to the motor.

With local bike guy on hand to assist with free-wheel replacement I went ahead and cut the wire, roughly in the place I would place a weatherproof power connector after the casette was fitted.

I expected to see 2 maybe 3 wires but I now find myself looking at 8 (shown below)





When I come to reconnecting ; do I need to connect all of them (what could possibly require 8 wires)?
If so; has anyone ever done this and what connectors did they use ( if this is actually just connect 2 or 4 wires I can source these connectors OK at Farnell)

Many thanks in advance.

 

[trex]

you need to connect all the wires.
The three thick wires (yellow, green and blue) are for the motor phases, the other 5 wires are for the 3 hall sensors (5V, ground and 3 Hall signals). If you use connectors, separate the 3 phase wires (30A) from the 5 Hall wires (100mA).

 

[jdone]

you need to connect all the wires.
The three thick wires (yellow, green and blue) are for the motor phases, the other 5 wires are for the 3 hall sensors (5V, ground and 3 Hall signals). If you use connectors, separate the 3 phase wires (30A) from the 5 Hall wires (100mA).

Thanks for that..makes an easy job more difficult but great answer.

 

[Deleted member 4366]

Just strip them back a bit, thread some heat-shrink sleeve on them, and then solder them together, then position and shrink the sleeve to insulate them. It would be quite difficult to use connectors to get a waterproof connection.

What you should have done is disconnect the wires at the controller, remove the pins from the connect block (5 hall wires), and thread them through the free-wheel. There should never be a need to cut the wires. Normally the bloch should pass through. What stopped it?

 

[jdone]

Cheers D8veh I 'll look into that..seems much easier than using 2 different connectors (based on the amp rating).

Looking at the new Burisch's; they have a single connector so I've mailed them to see what goes...

I must have had the back wheel off 5 or 6 times now so it wasnt so much a case of what stopped me - it was more a case of wanting to fit some sort of quick release system (for use whilst out and about) as it's an obvious design oversight/cost saving

Cheers