So I blew out my last controller by hitting a bump...
Now I started having some issues with my new one (no shunt mod and no 100V caps either). I'm running at 60V, but saw similar problems when i went back to stock 48V. Basically, if I hit a sizeable bump and then hit the throttle some weird stuff occurs. The motor seems to miss. I also noticed that the voltage gauge plummets. It's a bit scary because this is exactly how my last controller died and that ended with me pushing the bike 8 miles.
I'm just wondering if anyone had any thoughts or had seen this before. My initial feeling is that something is shorted and hitting a bump is causing something in the power lines from the controller to the motor to short to the chassis. That would certainly explain why the voltage meter plummets for a second. A huge amperage spike would cause the battery voltages to sag immensely. I have an ammeter installed, so I'll try to catch a reading on that the next time it happens. Note that the 30A fuse hasn't burned out yet either.
My other thought is that hitting the bumps is causing a problem with the hall sensors in the motor. That would be affirmed by the fact that the motor will seem like it only sags the voltage/misses every other cycle or so. Though, thinking about it, the hall sensors would cause 1/3 of the revolution to miss, not 1 part in every 2 or so revolutions.
I checked the hall connector from the motor to the controller and made sure it was tight. I also wrapped some tape around my 3 power lines from the controller to the motor hoping (where the bullet connectors are, since the green insulation looked a bit blackened) that will prevent any shorting. We'll see how riding goes tomorrow.