8 pin connector broken

[ElectricStreet]

I have a Magic Pie 2 hub and I accidently broke the # 6 pin when I plugged it in to the controller.  It bent and then broke.  I couldn't find a replacement at Golden Motor and I bought one from a local electronics store.  The pin arrangement is the same but I notice the wire gauge looks much smaller. I soldered the wires to the original wires and when I tried it, the bike accelerated about one second and shut down.  Does the difference in the conductivity change affect the signal?  What's happening here?

[Bikemad]

Did you check that each pin was connected to the correct colour wire, or did you simply join the matching coloured wires?
If the replacement plug was not wired exactly the same as the GM plug this could cause problems.

Thinner wires should be OK for the majority of the functions with the exception of the lighting circuit.
If you have high powered lights fed from the thin lighting feed wire it can cause a problem with excessive voltage drop across the ground wire which can sometimes cause the throttle to operate automatically when the lights are turned on.

Double check that the wiring is correct and that no two wires are touching each other.

Alan
 

[ElectricStreet]

All the pin locations correspond to the diagram for the MP2. 

[ElectricStreet]

If the wire gauge difference isn't the problem, and the pin connections are correct and no wires are touching, what else could cause the motor to start and stop when you use the thumb throttle.

[Bikemad]

You can easily check that the motor side of your throttle wiring is working correctly by doing a simple test with the harness disconnected.
A small piece of wire (reshaped paper clips work well for this) inserted between pins no 4 and 6 on the motor socket should make the motor run at full speed:



Make sure the wheel is raised off the ground and that the power is switched ON before you insert the wire.

Just push the clip in enough to make contact with the outer end of both connectors.  If the clip/wire diameter is too large and you press it in too far it can open out the contacts inside the connector too much so they will no longer grip the pins of the corresponding plug.

Be very careful to only put it into the correct two holes or you could end up damaging the controller or wiring harness.

If your motor runs continually during the test, you will probably need to double check the throttle connections and try and measure the voltage on the throttle signal wire as the throttle is operated. You may need to solder some temporary wires to make it easier to connect the voltmeter.

Alan
 

[ElectricStreet]

I was surprised to discover that the battery had gone dead in the past two days.  That news led me to realize that a short had occurred.  Apparently, the two wires not being used (the reverse and/or the pedelec) were touching and causing the motor to shut down.  Now it's fixed and runs again.  Horray!  Thanks for the input. 

[Bikemad]

Double check that the wiring is correct and that no two wires are touching each other.

The two wires not being used (the reverse and/or the pedelec) were touching and causing the motor to shut down.

I'm glad you've managed to sort the problem, but you really shouldn't leave the battery connected when not in use as it will slowly drain itself over time.
In fact, the battery should always be turned off or disconnected when the bike is not being used predominantly for safety reasons, in addition to prolonging the battery life.

Alan