Assembling E-Bike Cables
HIGO cables can be assembled yourself with basic tools and some experience. This page explains when self-assembly makes sense, what tools are needed, and walks through a concrete example step by step.
When does self-assembly make sense?
Not every situation requires a custom-made cable. In these three cases, self-assembly is the right choice.
Frame replacement
After a frame replacement, existing cable lengths often no longer fit. An extension with a matching HIGO connector is the cleanest solution.
Defective connector
A damaged or broken connector does not mean the entire cable needs to be replaced. Often, replacing just the connector is sufficient.
Custom cable length
Standard lengths do not always fit. For special installation situations – e.g. cargo bikes or conversions – a custom length is the better choice.
Tools & Materials
The following tools and materials are required for the soldering method.
Soldering iron & solder
Temperature-controlled, ideally 350–380°C. A fine soldering tip is recommended for the delicate wires of e-bike cables.
Wire stripping tool
For clean stripping of wires without damaging the fine copper strands. An adjustable wire stripper is recommended.
Heat shrink tubing
For insulating solder joints. Heat shrink tubing protects against short circuits, moisture and mechanical stress.
Heat shrink tubing in the shop →Potting compound (optional)
For increased protection against moisture and vibration. Especially recommended for outdoor applications and battery connections.
Potting compound in the shop →Side cutters & knife
For cleanly cutting the cable to the desired length. A straight, clean cut makes subsequent stripping easier.
Heat gun
For shrinking the heat shrink tubing. A lighter can be used as an alternative – but keep your distance to avoid burning the tubing.
Soldering procedure
The soldering method is the most common approach for HIGO extension cables. It requires some practice but is achievable with basic tools.
Cut cable to length
Cut both cable ends to the desired extension length. Allow some extra length – approx. 20–30 mm for the connection point.
Thread heat shrink tubing
Before soldering, thread the heat shrink tubing onto one cable end and slide it out of the way. This step is often forgotten – afterwards it can no longer be threaded on.
Strip & tin the ends
Strip approx. 8–10 mm of insulation from the cable ends. Lightly twist the strands and coat with solder (tin). This makes the subsequent soldering considerably easier.
Solder the wires
Bring matching wires together and solder. Solder each conductor individually, never multiple at once. Allow to cool briefly before soldering the next conductor.
Position & shrink the tubing
Slide the heat shrink tubing over the solder joint so that it fully covers it. Shrink evenly with a heat gun or lighter.
Test functionality
Before installation, check the connection with a multimeter for continuity. Also test for short circuits between individual conductors.
Example: Extending a battery cable after frame replacement
An e-bike gets a new frame. The existing HIGO Mini-B 3-pin battery cable is 80 mm too short. Goal: extend by 150 mm using a solder connection.
HIGO Mini-B 3-pin · Extension 150 mm
HIGO Mini-B extension cables are available as ready-made versions – in Standard, Special Type 1 and Special Type 2. Mini-B extension cables in the shop →
Common mistakes & how to avoid them
Wrong pin count or series
Mini-B and Mini-C look similar but are not compatible. Always identify the series and pin count of the existing connector before ordering.
Forgetting the heat shrink tubing
The most common beginner mistake – after soldering, the heat shrink can no longer be threaded on. Always thread it on before soldering and slide it out of the way.
Cold solder joints
Dull, crumbly solder joints have no reliable electrical contact. Cause: too low a temperature or movement during cooling. Reheat the solder joint.
Wrong colour assignment
Swapped conductors can damage the controller or battery. Always document the colour coding and double-check before soldering.
No functional test
A short circuit or break in the connection only becomes apparent during installation – too late. Always test with a multimeter for continuity and absence of short circuits.
Stripped too short
Less than 6 mm of stripped wire makes soldering difficult and increases the risk of a poor connection. Strip at least 8–10 mm.
When is a custom-made cable worth it?
Not every situation is suitable for self-assembly. In these cases we recommend a ready-made custom cable:
Very long cables over 1,000 mm · Multi-pin connections with 6 or more conductors · Cables with factory-filled potting compound · Series production of multiple identical cables · Uncertainty about connector type or pin assignment.
For custom orders simply enquire: Product enquiry →
Overview of all extension cable types – Standard, Special Type 1 and Special Type 2.
FAQ – Cable assembly
Yes – HIGO cables can be assembled yourself with basic tools (soldering iron, wire stripper, heat shrink tubing). The soldering method is the most common approach and is achievable with some practice even for beginners.
For the soldering method you need: a temperature-controlled soldering iron (350–380°C), wire stripper, heat shrink tubing, side cutters and a heat gun. Optional but recommended: potting compound for additional moisture protection.
A ready-made custom cable is recommended for very long cables over 1,000 mm, multi-pin connections with 6 or more conductors, cables with factory-filled potting compound, series production of multiple identical cables, or when there is uncertainty about connector type or pin assignment.
The most common mistakes are: forgetting the heat shrink tubing (always thread on before soldering), wrong colour assignment of wires (document and double-check), cold solder joints due to too low a temperature, and skipping the functional test with a multimeter after soldering.
Yes – absolutely. Before installation, every connection should be checked with a multimeter for continuity and absence of short circuits. An undetected short circuit can damage the controller or battery.