Cable / Wire Harness installation

For VoltBike models:

Bikes with hub motors using internal/external controllers and cable harness

Introduction:

Typically cable harness problems will allow you to turn your bike’s screen on, but the motor or other components may not function correctly or consistently. Wiggling or moving the cable harness may also indicate a bad connection.

Trouble shooting electrical cable problems may involve multiple variables at play. In order to determine if your wire harness or some other component needs replacing or repairing, it may require examining electrical components, connectors, and assessing what your E-bike is “doing” and “not doing”.

Isolating variables and swapping in test components one at a time can sometimes be the best method to get your bike rolling again. Having a second VoltBike for testing the motor, LCD screen or throttle can help eliminate particular components as a source of a problem. When problems arise affecting two or more electrical components this may be an indication the controller or wire harness could be the source of the failure.

Error codes will vary on the type of failure and model of bike or model of LCD screen on your E-bike. Typical causes of failure may include:

-controllers plug to motor plug has disconnected

-communication error from a bad cable / wire connection

-melted controller / motor plug

-over heating from improper Amp setting

-over heating from constant “throttle only” usage

-water and corrosion damage

Tools Required:

 - flush cutter

- spare zip ties

To replace the cable / wire harness follow the below instructions:

steps 1-5 removal

steps 6-9 install

1. Remove the battery and hold the bike’s power button ‘on’ to discharge the controller. The screen may flash for one second and go out. The bike is now fully discharged.

2. Carefully remove the rubber grommet that fits in the downtube and unwrap the plastic cable coil or cut upper zip ties to provide more cable harness slack at the handlebars. This will allow you to easily connect or disconnect the lower plugs.

3. Disconnect the four upper plugs of the cable harness from the handlebar.

4. Carefully cut the zip ties under the crankset. To access the cable harness plug, the PAS cable and power wire cables may first need to be wiggled and pulled out of the downtube to make space. Once the cable harness is located and pulled out it can be unplugged from the controller.

5. Carefully pull the cable harness from the top downtube hole until the entire cable has been removed from the frame. This is a good time to confirm you have the correct style and length of the new cable harness to install.

6. To install the new cable harness, first feed it through the rubber grommet and then into the top hole of the downtube and down through the frame.

Tip: Feeding the cable harness through the downtube can be challenging. Use a thinner derailleur cable as a guide. This will allow you to pull on the guide cable while feeding the wire harness in at the top. Take your time to ensure it doesn’t snag or disconnect other connectors inside.

7. Once the cable harness has been routed through the frame, carefully reconnect it to the controller plug. Note the alignment arrows on plugs to ensure the pins are not bent or damaged.

8. Carefully Re-connect the four upper plugs at the handlebar. Note the alignment arrows to ensure pins are not bend or damaged. Install any plastic coil wrap or zip ties to secure the front cables. Ensure they do not interfere or snag when turning the handlebars side to side.

9. Test the new cable harness: Reinstall the battery and test the bike to ensure any related electrical problems have been resolved and no error codes are shown. Power the LCD screen on, twist throttle, PAS sensor, lights, and brake sensor motor inhibitors. (Warning! Lift the rear wheel off the ground prior to testing the motor)

Once the bike has been tested successfully, remove the battery again, and turn the bike on to discharge the controller and continue with the installation/repair.

10. Carefully insert cables and plugs back up inside the downtube. Use zip ties to ensure the cables are secure and will not be snagged or fully exposed to dirt and water.

Note for internal controllers: The removal and installation of a new cable harness is basically the same process. Prior to removing the old cable harness, sealant at the frame’s box may need to be carefully removed and then reapplied after the new cable harness has been installed to prevent water or dirt contamination. The controller and cable plugs are located in the frame box that can be opened by removing the four Phillips screws and side plate. The cable harness needs to be routed through the frame and into the frames controller box.

Error codes for 860C colour deluxe screen                     

Error codes for 850C colour screen                             

01 Communication Error Check the cable connection

02 Controller protection Check three-phase power line.

03 Three-phase power line connection /Check motor cable plug to controller plug

04 Battery low Charge the battery

05 Brake error Check the brake connection/ motor inhibitor sensor error

06 Throttle error / malfunction

07 Hall error/ internal motor Hall sensor connection.