Broke Bafang G60 Motor?! Repair Attempt w New Bearings. Maybe Janked

My Bafang G60 hub motor is broke! The rotor magnets are scraping on the stator again! I take the motor apart, and ATTEMPT to fix it with new bearings, but that doesn't resolve the problem! The rotor wobbles untrue as it spins on the axle! I think the big metal shell of the rotor might be bent or warped?? Let me know in the comments what you think!
0:00 Wobbly Rotor
0:14 Intro
0:45 Noise Demonstration
1:30 Opening Motor
3:25 Disassembling Motor
8:34 Looking at Magnets
10:20 Gear Puller
14:58 Looking at Bearings
18:32 Scrapes on Magnets
19:13 First Bearing Removal
22:24 Bearing Install 6902RS
29:51 Second Bearing Removal
32:06 Bearing Install 6002RS
34:43 Rotor Is Not True
36:10 Wobbly Rotor Slams On
37:59 Looking at Magnets
39:20 Comment What Do You Think??
Let Me Know In The Comments What Do you Think Is Wrong With the Motor??
Also Please Leave A Comment About Wired Ebikes and Your Wired Freedom 2024.
JFly is Steve !

[@fredflintstone2077]

If you don't want to spend lots of money you could always skim a bit off the areas that are rubbing. It may reduce the power by a small amount but probably not be noticeable.

[@velotaf484]

I’m repairing mine from flushed motor. I didn’t make video of but some pictures. I will remplace all Hall sensors, remaking the electronic card (I have to find the capacitors information and I will put them near the controller), remplacement of all bearings…. And I hope I didn’t screw when disassembling, everything apart.

[@kmtnbike1117]

I’ve seen videos where guys replacing bearing on freehubs just use a socket that is the size of external ring of bearing to pound them in. Just a thought!

[@EBikeBuilder_]

that metal piece, i think its called the "sun gear" , worked great to pound the bearings in with a rubber mallet. the back of the sun gear presses against the external rings of the bearings nicely

[@velotaf484]

For that you can use the old bearing, he is the same diameter. 😉

[@fredflintstone2077]

You did not appear to check for free play in the bearings. Without it, the bearings were not going to be your issue. Also, you never, NEVER hit a bearing in from the middle race. All that does is stress the bearing and cause damage that will lead to premature wear or possibly destroy it before you even use it. You press or tap them in by the outside race. Use a socket, tube or similar. You could have even used the old bearing to tap in the new one

[@maniakfps249]

Replacing a bearing for the first time is always a bit difficult. ps. don't break the hammer

[@stuartleslie1988]

Also it would be a good idea to always match parts with replacement after disassembly. Just because parts have same numbers some clearances may differ. Not trying to be rude or criticize just trying to share some knowledge

[@EBikeBuilder_]

yea its a chinese motor who knows what bearings they use, they are fairly standardized , in terms of inner and outer diameter , it may have been slightly taller or something but almost identical. That rotor shell was all bent up , a new rotor fixed it

[@maximumchargeEV]

Great video man, sorry about the motor. Hopefully the new one will work even better. Those windings look REALLY clean considering how much power you were running through it.

[@EBikeBuilder_]

Yeah the windings seem OK, they look darker / dirty in some areas but its magnet dust. Im gonna try to fix this motor with a new rotor- I found one for 50$ worth a try. Hopefully the rotor scraping on the stator didn’t bend the whole damn stator up too. But it may have, in which case i have a front g61.1000 coming, same one you have on the psycho cycle !! I think i might have to rebuild the whole wheel if that axle is a different size though Lol… that would be a project. But yeah this is fun, typical ebikebuilder stuff 🤣😂🤙

[@EddieRodriguez-yu4ft]

You have to check the magnet not lose from the roller if they lose you have to glue then the roller.that is what I think it is.

[@polunu]

Very informative, your perspective is very much appreciated 👍 It seems like the geared hubs really suffer in high speed, high impact situations, after hitting potholes at 35+ mph. I'm trying to keep from abusing my own bike's motor, so I turned down the amp limit and use soft start, but I'm still weary of the plastic in there. The Lightning Rod Big Block kit is probably more suited to the kind of hills I have to contend with around here, but a qs205 would be much more convenient if I can keep using the frame I've got. Any chance that you'll use a different motor?

[@EBikeBuilder_]

I’ll keep the geared hubs on this bike. The geared hubs are fragile apparently i have seen a handful of people break them but i never had any issues till now. I have the 72v bbshd bike i will ride more this year when the weather is better. I want to try a QS motor but they are kinda heavy for bikes, idk. I would prefer to have a QS motor on a bomber frame with suspension or something. I don’t want that big heavy qs motor in a hard tail.

[@paulstir]

check for loose magnets also brother

[@HeroRickyGames]

The motor is laughing.

[@fredflintstone2077]

It must have got pretty hot if the magnets became unbonded.

[@nicod974]

Too much grease, use silicone white grease instead. You can rectify the stator on a cnc machine, you'll have to tropicalize it afterward. You can use the same method for the rotor as long as the bill is not exploding.

[@EBikeBuilder_]

thanks for the suggestions, its good to hear your thoughts and know there is a possiblity of fixing it. Also good to know about tropicalizing the magnets. I thought they might degrade when damaged and exposed to air. Thats a good point. I dont have access to a CNC so for now i have ordered a new rotor, I am hoping the stator is not too messed up and a new rotor will be able to spin freely, we will see in the coming week. And if not, i have a bafang Fm g061 1000w front motor coming from China that can replace it.

[@velotaf484]

I don’t know if the magnets will be operational after that.

[@Naomi_Boyd]

I have this one cookie sheet I use for baking bacon in the morning. I just throw it in there to heat up with the oven. I always know when the oven is hot because of the loud BONG the cookie sheet makes when it deforms from the heat. You need a new rotor my friend. I read through the comments. It's not the axle. If the axle was bent, the rotor would just spin tilted instead of wobbling. The rotor is warped, probably from the heat. You are going to need to true the wheel too. That can't have been good for the spokes.

[@EBikeBuilder_]

Yeah actually, i noticed it had a big lateral deviation that hadn’t been there before. I don’t think its the axle either. The rotor was wobbly AF, regardless of its position along the axle. Someone suggested that banging on the rotor with a rubber mallet might not be ideal, or perhaps i had the gear puller on crooked or something, i agree that’s a possibility, but i never opened it up in the first place till it had a scraping problem. so think this rotor warped out of tolerance slowly over time. At first it would only scrape at maximum RPMS giving it full power. I opened up the motor and the magnets were sliding out along the rotor shell. So i glued them back in and it was a little better. Ride it for a while. Then the other day when i did that video where my bike light got launched off from an impact of my horn bottoming out, something happened and that was it, i thought the brake rotor was just bent at first but then i was riding around the yard and it got totally F’d out of no where. I have a new rotor coming from ebay to try out. I hope the stator didnt get messed up. Or i have a FM g61.1000w (5t) that is coming that should go even faster. 😎

[@hughmcharg111]

Try replacing the axle , bent relative to the stator.

[@EBikeBuilder_]

it could be. That looks like a mess to take apart though, would probably have to take the motor cable out of the axle, and redo it. The new motor itself is like 200$. so they arent often practical to repair, other than the nylon gears and whatnot

[@stuartleslie1988]

OMG that poor mallet. Use a socket that is the same size as the bearing

[@EBikeBuilder_]

i eventually used the sun gear that has a flat. back to it and fits perfect

[@TheIAMINU]

All that beating with a hammer , and it's not true anymore , go figure ....

[@EBikeBuilder_]

It slowly went out of tolerance over time , i never opened it up until it had a problem. I get what you’re saying, i wouldn’t be banging a mallet on a new one