MP3 Internal Controller - Corosion - Again

[Bedmountain]

Hi Guys

Struggling to keep the faith at the moment. My last set-up has got me a further 400 miles before total failure again. Last time it was due to water getting into the controller. I replaced the controller with the newer universal one which looks a lot more waterproof...

I started getting a problem a few weeks ago when the motor started cutting out intermittently then just cut out. I started the long walk home and a few miles in the the throttle worked again and I was able to get to work. Happened a few times after that then stopped working at all.
I took the controller out and there is a build up of rust and white stuff in the wheel where it houses the internal controller. The controller itself had a component that was rusty on the top. I tried to scrape it a bit on top and it just snapped off.

I have an old style spare controller lying around that I am going to put in and try one last time. I wish I knew what I was doing wrong. I have a drip loop on the wire going into the controller. I can't see any other way to install the controller than the way I'm installing it and it's not like I'm riding through wet weather regularly. If I can't stop water getting into the controller then I'm never going to get more than a few hundred miles out of one and at that rate it's more expensive than petrol!...

If anyone has any tips or suggestions I would be really grateful to hear them.

Thanks very much
Ben

[Eriknoort]

Do like me "stop with the internal controller"
Extend the wiring and use an external controller.
I use a 100A Kellycontroller on my Magic Pie III for a year now. (5000 km)
Never had any problem with water of moisture anymore.
I draw 70A while accelarating and that is a lot of fun.

[Andrew]

The GM controllers have always been a weak link in the chain. Do as said above. If you want to you could run the Magic Pie without the small thin hall wires and get a 'sensorless' controller which will make the bike even more reliable and sturdy, the only down fall is you loose some of the torque. But saying that a good quality controller will let you pull more amps anyway.

Here's a good tutorial on easy wire lengthening.
http://youtu.be/7t9nT3Hn9b0

I use a 12fet Lyens 'sensorless' controller for my Magic Pie without the hall wires.
http://www.lyen.com
Edward Lyen beefs up and will program the controller to your need. You can email him and tell him your spec and battery and he will help you out.

You could just get a 6fet 'mini monster' from him programmed for 25a and what voltage battery you use. It will take over 1000w peak.  I see peaks of 1200 with this controller on one of my bikes. It is a very efficient controller made for long commutes.

Andrew

[Bedmountain]

Thanks guys - really appreciate the replies - I will check out both of your suggestions and hopefully come up with a more reliable build.

[GM Canada]

Hello again, Sorry to hear you are still having issues. Follow the link below and create a support ticket.

Gary