How to replace hub motor cable in e-bike?

Question

The hub motor wires are cut from near the axle and looks like I can't repair it without completely replacing it. The motor is similar to this one on Ali Express. I failed  to open the motor because the screws are so tight and rusted. I am thinking of cutting some part of the rod and join the wires. This seems an easier but not a good solution. Any advices?
Update:
I was able to get my motor working by cutting the cable from near the sensor board, pulling the cable inside the motor through the shaft and rejoining/soldering from where it was originally cut. This shortened my cable few inches and it was barely reachable to the controller. See the picture below. I wanted to know if the cable can be completely replaced with no need for these joins but it's not easy as the cable was the part of the motor coil itself.

Marras93 · Answer

I had a similar problem with a motor broken during shipment (luckily the manufacturer sent me a new one). I tried to fix the broken one by replacing the cable, but it's quite hard to do, because the space inside the housing is quite small, and when I tested the motor it worked for a while until the housing, by rubbing the cable, shortened the sensor cable, and broke the sensor board in the motor. I could reasonably run it sensorless, but you need a sensorless controller if this happen. Long story short is not easy at all, I'm quite good in soldering but failed in this regard. And disassembling the motor, at least with my geared unit, is not so easy as well, so if you have nothing to lose you might try it, but be prepared for a long evening of struggling.

Answered by Marras93 on March 13, 2021

How to replace hub motor cable in e-bike?

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