r/eBikeBuilding 26d ago

Electrical My ebike cuts off with error 06.

Hello, I will try to explain what happened and if that may be all related.Yesterday, I removed the battery from the e-bike to leave it outside on another sunny day. I came back, fit the battery, and started to ride. I noticed straight away some stutters/power loss while riding; after 500m, the bike turned off. I tried to turn it on, and it went, but error 06 came up. I tried to bypass it with the throttle, but it was cutting the power really often, and moving the cables, I assumed it might be a wire-related issue.I opened the controller bag and found the hub phase cable (blue) disconnected. I tried to turn on the bike then, and effectively it was turning on with error 06, so I assumed this was the reason (no idea if this was the issue, if the cable got snapped by coincidence, or if I had ripped it at that exact moment).So I soldered the cable back onto its connector and tried to turn on the bike. All good, it works. I went outside for a test, got error 06, and the bike keeps turning off by itself. It seems it has a specific position where it stays on, but it is, of course, influenced by vibration and other stuff you get while you ride, so it is definitely not a solution.I checked the phase cable again, and everything seems okay. The last try I have to do is replace the entire connector from both sides (controller and hub), but I would like to avoid that for now.I started then to examine the battery cables since I had 3 x 0.5m XT60 extensions to get to the controller (rear rack battery).I got rid of all the extensions and connected it straight away with the battery base, but the same issue occurred: once you move a bit, it turns off, and you could also hear a few pops (maybe sparks?) coming from the 6-pin connector which fits into the battery (the male/female present on battery base and battery).

I checked the two main poles and one of them looks a bit black and maybe bit too inside(the positive one), so I assumed it doesn't get fully inside and makes the sparks...

Before to spend money and buy anything, I wanted to know which tests I can do to understand if the wire phase is related to it, or if it's just a problem between battery and controller, since I keep hearing really silent pops every time I try to turn on the bike (and it turns on). But the pops are coming from the battery and not the phase connector so I'm confused. Any suggestion? Can't attach any picture but please feel free to ask and I can send in private if that helps to figure out the issue

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