What connectors and cables are used in e-bikes – Many many of us immediately remove the kit connectors and replace them with our current favorite connectors.
Definitive Guide to Ebike Connectors – These are our favorite connectors for E-bikes. They come in two sizes. We still recommend you buy them with pigtails attached, but they are fairly easy to solder wires to. If you do solder to them, attach a male/female pair to hold the pins in perfect alignment, until the soldering is over. The pins can rotate in the housing (with needle-nose pliers) if you want to lay them flat on their sides and have the solder/wire “cup” facing up. I use these for 14ga/12ga wire, and cover the soldered joint with 5mm heat-shrink. ES – XT-60 looks nice, very handy, but it seems as though you could never make them really weatherproof, and you’d have to use shrink wrap to keep the water out.
XT90 same as XT60, but a little bit larger and doesn’t melt with 90 amps of power. More pricey but worth every penny if you are running high power. Highly recommended. The wire insertion cup fits very fat 10ga wire (or smaller, of course) and I use 6mm heat-shrink tubing to cover the solder joint. “Heat shrink” is dirt cheap from Hobby King. To be used between the battery and the controller. Of course, your life will be easier if you order them with factory installed pigtails.
electricbike.com – Anderson Power Poles (APP) are used a lot on DIY bikes as charging connectors because chargers rarely charge over 7 amps and these connectors are cheap. They are an old technology which I feel has been surpassed by better connectors. Note that this is the mini version of the Anderson connector and shouldnt be confused with its big brother which is much larger.
XT90 same as XT60, but a little bit larger and doesn’t melt with 90 amps of power. More pricey but worth every penny if you are running high power. Highly recommended. The wire insertion cup fits very fat 10ga wire (or smaller, of course) and I use 6mm heat-shrink tubing to cover the solder joint. “Heat shrink” is dirt cheap from Hobby King. To be used between the battery and the controller. Of course, your life will be easier if you order them with factory installed pigtails.
XLR’s have a heavy-duty metal shell with a latch that will prevent them from coming apart by accident. They also score very high for moisture resistance.
ebikes.ca – we have standardized almost all of our ebike parts to use Anderson Powerpole connectors for anything that handles significant current (like the battery and motor phase wires), and JST-SM connectors for any of the small signal wires. Please see our Crimping Guide for details on installing these parts. The 3-pin XLR standard is used on the charging port of our battery packs, and the 5.5×2.1mm DC Plug and Jack are used for small pwer accessories like our Lights and DC-DC converters, where Andersons are a bit too bulky.
The “Amberwolf” method of butt-splicing two wires. Fast simple strong and slim. First, slide on a piece of heat-shrink. After working to two ends into each other, flatten the joint by wrapping it in a bare strand or two from a piece of junk wire. Then just solder and heat-shrink.
Ebike Circuit Protection, Fuses and Circuit Breakers -Electric Bicycles have batteries capable of delivering a lot of current in a short time. Good design calls for a fuse or circuit breaker within a few inches of the battery to protect wiring, batteries and in some cases body parts from becoming damaged. Many common fuses are not up to either the voltage rating or the current rating demanded in electric bicycles. The fuse should be close to the batteries to provide maximum protection. It doesn’t do much good if the protection is downstream of the short. Ideally it should be either in the middle of the battery chain or immediately at one end. Circuit Breakers are another choice. Inexpensive solar circuit breakers with high DC ratings can be found in Solar systems.
XT60 – ieftini și buni. Nu se pot cupla invers, rezistă pînă la 60-65A curent constant. Fabricati din nylon rezistent la temperatura si conectori montati inca din faza de injectare in matrita, XT60 asigura un contact foarte sigur. Contactele sunt arcuite si aurite pentru o rezistenta electrica minima. Usor de utilizat, mai usor de lipit decat Anderson. XT90 rezistă până la 100A curent continuu.
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