Electric Bikes - motor making jerking/rattling noise

Help please!

I have a Crystalyte 408 rear hub setup (36V Li-Ion battery). Recently I damaged the wires leading into the motor. So i opened it up and soldered the wires. I put everything back together and everything seemed to work for awhile. But then yesterday, the motor started making a jerking/rattling noise. I did some testing and narrowed it down to the following:

-assuming the controller is connected to the motor, the jerking/rattling noise only happens when I switch the controller to “ON”. If I switch it to “OFF”, the jerking/rattling noise disappears (also if one or both of the 2 cables that connect the controller to the motor is disconnected, the jerking/rattling noise disappears)
-the jerking/rattling noise only happens at wheel speeds above 10km/h.
-it happens regardless if the battery is or is not hooked up to the controller

Note: the motor still “works” but it is very uncomfortable to ride (and although I don’t have a Cycle Analyst, I am concerned that it may be drawing excessive current)

Based on some research (http://www.ebikes.ca/troubleshooting.shtml), I suspect that there may be a problem with the motor’s Hall Effect sensors. However, there did not appear to be any water/corrosion damage when I opened the motor up. Can anyone advise?

Thanks

hi I had that same problem

the root cause was in the wires leading to the motor. Make sure you have solid connectivity there.
They are three anderson connectors. I removed them and used in place a three prong electrical outlet male female connector (those used say for connecting your computer) and that worked just fine.

Also make sure that none of your throttle wires are pinched. That was also a root cause in my case. The green wire was pinched and i had to cut it and resolder it.

hope that helps. let us know what you find.

thanks alfonsopilato.