My Stand broke whilst it was charging and I had the same problem. Managed to remove broken off male plug from battery socket by drilling a small hole at an angle across the centre (avoiding the pins) and pulling it out with the drill bit. Found powatechnic on EBay, paid £50, sent them the charger on Monday, received it back with a new plug before 9am Thursday. That’s excellent service at the best of times, incredible for a company in a Covid lockdown Area.
Yamaha Battery/Charger Problem
- Thread starter georgehenry
- Start date
Hi all with Yamaha battery/charger connector problems. Update on how mine are doing now almost three years post repair.
I started this thread to document a potential disaster when a small metal pin connector at the battery where the charger plugs in broke, and meant I could not charge the battery. I found that this was a problem that could not be fixed by the shop I bought the bike from, or any other. I was told I would need to buy a new battery and charger.
Luckily with help from a technical able friend we managed to fix the problem and replaced the connectors.
It is now almost three years since my connectors broke and my original charger and 400Wh battery are still working really well and have powered my bike for another year and a further 1,326 miles and a total of 4,202 miles since that battery pin connector broke.
As it continues to perform so well It demonstrates the quality of the Yamaha, battery, battery management system and charger, and how wasteful it would have been to be forced to throw them away for the cost of in my case a pair of connectors bought of ebay for under a tenner.
As I have said previously and at the time, I still find it quite disturbing that if you are unlucky and damage the connectors on your Yamaha battery and/or charger there is no support available to get them fixed. You either have to fix them yourself, like I did, which involved overcoming the defeat bolts and opening up the battery case or find a third party business that could do it for you. The normal recommended battery guru, Jimmy at insat surprisingly said he could not when approached by someone else with the same problem.
Other people who had this problem and found this thread have posted how they fixed it providing useful contacts which might still be useful if you have a similar problem with your own Yamaha battery/charger.
Someone else might know whether Yamaha are still using these connectors on their batteries/chargers or have updated them?
I started this thread to document a potential disaster when a small metal pin connector at the battery where the charger plugs in broke, and meant I could not charge the battery. I found that this was a problem that could not be fixed by the shop I bought the bike from, or any other. I was told I would need to buy a new battery and charger.
Luckily with help from a technical able friend we managed to fix the problem and replaced the connectors.
It is now almost three years since my connectors broke and my original charger and 400Wh battery are still working really well and have powered my bike for another year and a further 1,326 miles and a total of 4,202 miles since that battery pin connector broke.
As it continues to perform so well It demonstrates the quality of the Yamaha, battery, battery management system and charger, and how wasteful it would have been to be forced to throw them away for the cost of in my case a pair of connectors bought of ebay for under a tenner.
As I have said previously and at the time, I still find it quite disturbing that if you are unlucky and damage the connectors on your Yamaha battery and/or charger there is no support available to get them fixed. You either have to fix them yourself, like I did, which involved overcoming the defeat bolts and opening up the battery case or find a third party business that could do it for you. The normal recommended battery guru, Jimmy at insat surprisingly said he could not when approached by someone else with the same problem.
Other people who had this problem and found this thread have posted how they fixed it providing useful contacts which might still be useful if you have a similar problem with your own Yamaha battery/charger.
Someone else might know whether Yamaha are still using these connectors on their batteries/chargers or have updated them?
They have indeed updated he design!
Looks more like the Bosch plug type now.
Just had the same problem, roughly 1000 miles on my bike. I think it got knocked over while charging. I tried gluing it, using a bondo type material, all attempts only got me a few more charge cycle before it broke again. After reading this and several other forums I found a nice connector and plug on Amazon to repair mine. Hopefully this lasts. $14 (usd) fix.
This is roughly the same diameter as the original hirose connector, I had to just clear out a flat spot to mount it and bore the mounting hole a hair. Search Cnlinko M12 4Pin Waterproof Connector if you are interested. If I did it again I might get the next larger size, M16, as the wires on the charger were just a few strand too many to fit in the pins, the battery has smaller wire and worked perfect. Also I went in blind and the M12 mounts with 4 bolts and the M16 looks to mount more like the original. The M16 is obviously larger an I cannot verify it will fit as nicely as the M12. M12 seems to have same pin size as original. Also both have a nice dust cap and simple locking clip.
Went together surprisingly simple.
I forgot yo mention you need a torx tamper/security bit T10H and T8H to crack this egg....
In case its helpful my (US) charger wire color codes / pinout:
Charger | Battery
Yellow | Blue
Black | Black
Red | Red
Blue | White
This is roughly the same diameter as the original hirose connector, I had to just clear out a flat spot to mount it and bore the mounting hole a hair. Search Cnlinko M12 4Pin Waterproof Connector if you are interested. If I did it again I might get the next larger size, M16, as the wires on the charger were just a few strand too many to fit in the pins, the battery has smaller wire and worked perfect. Also I went in blind and the M12 mounts with 4 bolts and the M16 looks to mount more like the original. The M16 is obviously larger an I cannot verify it will fit as nicely as the M12. M12 seems to have same pin size as original. Also both have a nice dust cap and simple locking clip.
Went together surprisingly simple.
I forgot yo mention you need a torx tamper/security bit T10H and T8H to crack this egg....
In case its helpful my (US) charger wire color codes / pinout:
Charger | Battery
Yellow | Blue
Black | Black
Red | Red
Blue | White
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Looks like a neat repair/upgrade from the poor Yamaha item. I bet this has happened to quite a few owners and makes me wonder how many people have been riped off for new batteries and chargers when they are told by the dealer there is nothing they can do to repair.
For UK owners there are options possibly with a similar looking connectors.
IP68 Waterproof Connector Aviation Plug 2 3 4 Pin 20mm Panel Cable Screw Fit UK | eBay
WP20 4Pin Waterproof Chassis Panel Mount Aviation Plug Cable Connector Com | eBay
IP68 Waterproof Connector Aviation Plug 2 3 4 Pin 20mm Panel Cable Screw Fit UK | eBay
WP20 4Pin Waterproof Chassis Panel Mount Aviation Plug Cable Connector Com | eBay
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I started this thread as I was so taken aback that there was no support to rectify an essentially very simple and cheap problem to fix. The Yamaha plug when I had my problem was impossible to obtain.
The good news is that my original 400Wh battery is still going strong, now 4,456 miles and over 3 years after I fixed it.
The more I read pedelec the more I am put of electric bikes that have bespoke control systems/batteries etc that make them difficult/impossible to fix x years down the road.
The good news is that my original 400Wh battery is still going strong, now 4,456 miles and over 3 years after I fixed it.
The more I read pedelec the more I am put of electric bikes that have bespoke control systems/batteries etc that make them difficult/impossible to fix x years down the road.
That screw fit option is a great idea for those of you less inclined to solder/de-solder. Nice find.
I might just use some form of locktite / threadlock on the battery due to vibration.
I forgot yo mention you need a torx tamper/security bit T10H and T8H to crack this egg....
This color code info is what I have been searching the web for. A previous owner repaired the connector wrong and the color code was wrong. I re-terminated the charger and am now charging the battery.
Thank you for sharing this color map!
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not cheap tho!
Hi,
Thanks a lot for this trick, I ordered the M12 at https://fr.aliexpress.com/item/32859998459.html. The M16 looks to fit, it's 28mm large but it looked really tight with no clearance for mounting so I took the M12.
Very disappointed about charger price, impossibility to find the original one. Sometimes I don't understand engineers, the connector is so weak for a bike wich may fall, I just walked on the connector and broked it.