As mentioned previously I used the existing cable – just shortening it a bit. The remaining length is ok and I didn’t need to get a cable through the axle from scratch.

I carefully drew a diagram of the colours of the wires and reconnected the new ends to the correct colour. The soldered joints were covered in heat shrink and self-almalgamating tape.

I didn’t use any glue, putty or sealant. I reused the existing wire ties and added another around the omega clip.

Note that the wire exits the axle inside the motor on the same side as the aperture on the end of the axle. This means that if the aperture on the end faces downwards, and any water gets into the axle, it will drain into the motor. Whereas if the aperture on the end faces upwards then water cannot get out of the axle into the motor.

As mentioned in a previous post I damaged the cable for a Bafang BPM front hub motor. I found various instructions on the web for strip-down instructions – notably this strip-down on Endless Sphere.

My motor isn’t exactly the same as any of the stripdowns I’ve seen – mine is a front hub 250W motor without sensors. I’ve put some details here if only for me when I need to do this job again!

The cover plate comes off easily enough and the motor unit can then be pulled out of the hub. Note any washers between the outer hub and the motor unit!

The clutch and planetary gears can be pulled off. The sun gear can then be unscrewed from the motor and the circlip underneath it removed.