Magic Pie 5 popped out and crushed wires

[Dangwillo]

So I have a Magic Pie 5 with 48vbat.  I had it attached to a Specialized FSR.  It was fine on the road for days, but then in the backyard on dirt, it popped out, and gouged the wire which comes out of the axle, and now it runs on its own at a low wattage, but the throttle does not work(lights up).  I suspect under the heat shrink their is some kind of open wires connecting, or even cut.  What should I expect to find under the heat shrinkage and is it easily to fix.  This was my fault for not using torque bars I suspect, but I figured the dual suspension would compensate. any suggestions would be great.

Thanks,
Chirs 

[Dangwillo]

Could the crushed wires damage the controller? And how would I know? 

[Dangwillo]

I cut open the protective covering which covers the wires.  It appears that the black/negative? and green/throttle control took the major impact.  The green cable is crushed and wire is exposed, and the negative wire is just sort of smashed, but no wire is exposed.  Since the throttle appeared to be the only thing not working, I assume the wire is damaged to the point of limited contact, as the tire would spin when I wiggled the wire.  Now to repair that crushed wire, and see if it does the trick.  I will try and post a pic.

[Bikemad]

If you can't do a simple external repair you might want to check out Gary's Videos showing how to remove the controller and how to shorten and reuse the damaged cable once the controller has been removed.

If you solder onto the existing wires as Gary suggests, you must safely insulate each joint to prevent the joints from shorting against each other or the metal sides of the controller housing.

As your motor is still running it sounds like your controller will hopefully still be OK.



Alan
 

[Dangwillo]

Thanks Alan.  I will check out the video.  I cut and spliced the wire and I still am getting the same reaction.  The wheel spins on its own off and on, and now the display does not read?  I will pull off the cover and see if any thing came loose on the controller.  Thanks again!

[Dangwillo]

Which wire go where on Magic Pie 4.  Thought I had MP5, but controller saws mp4.  Anyway there are three wires blue, yellow and green, and there are thre terminals marker ABC, Where do the wires go?

[Bikemad]

Here are the connection details on the original Magic Pie 4 controller:



Later MP4 and MP5 use the older style Hall sensor connector and blade type push on connectors for the phase wires like this Smart Pie:





Perhaps the position of the phase wires on the later MP4/MP5 controllers is the same as on the Smart Pie controller? 

Alan