Material & Rating
- Connector — M8 2–6 pin and 8-pin 1T4 waterproof circular connectors, plug or receptacle, straight or right-angle
- Contacts — brass, gold-plated or tin-plated, selected by current rating
- Conductor — stranded copper 26–18 AWG, PVC or XLPE insulation
- Jacket and overmold — PVC or TPU, black or custom colour, molded strain relief at each connector
- Voltage — 24 V, 36 V, 48 V and 60 V e-bike systems as specified on the drawing
- Temperature — 80 °C with PVC insulation, 105 °C with XLPE or TPE
- Ingress protection — mated M8 and 1T4 pairs sealed per drawing; level verified on the sample
Certification
Cactus Electronics is certified to ISO 9001, IATF 16949 and UL and manufactures to the IPC/WHMA-A-620 workmanship standard. Raw materials comply with RoHS. Every assembly passes 100 % electrical testing - continuity, insulation resistance and withstand voltage - before packing, and the QC-to-production personnel ratio is 1:3.
Application
E-bike harnesses connect the drive system and rider interface on two and three-wheeled light electric vehicles.
- Hub motor and mid-drive motor connections
- Battery to controller power leads
- Handlebar display, throttle and brake cut-off wiring
- Speed, torque and cadence sensor leads
- Front and rear light and indicator wiring
- E-scooter, e-trike and light EV wiring
Custom Options
- Connector series and pin count: M8 2–6 pin, 8-pin 1T4, or per sample
- Cable length from 0.3 m, wire gauge and current rating per circuit
- Jacket colour, overmold shape and moulded strain relief length
- Waterproof version with sealed mated pair, or standard version with heat-shrink boots
- Samples in 3–7 working days; MOQ confirmed per project
- Customer carton marking and DDP delivery on request
FAQ
What is the operating temperature rating of this harness?
Standard PVC-insulated assemblies are rated to 80 °C; XLPE or TPE insulation raises the rating to 105 °C. Cables routed along the frame are normally PVC; motor and controller leads exposed to heat are quoted with XLPE or TPE insulation. The exact operating range for a part number is stated on its drawing and confirmed in the sample test report.
Is this overmolded harness waterproof?
The M8 and 1T4 builds are overmolded, so a mated pair keeps water and road spray out of the contact area, which is what e-bike harnesses need for year-round riding. The ingress protection level (typically IP67 for a mated pair) is specified on the drawing and verified during sample validation. Non-overmolded assemblies can be supplied with heat-shrink or grommet sealing instead.
Can I customize the pinout and connector type?
Yes. Pinout, connector series and gender, cable length, wire gauge, jacket colour and overmold shape are all customer-defined. Pin count, pinout, connector gender and cable length are all defined by your motor and controller interface. Send a drawing, a sample, or a pinout table and we return a 2D/3D drawing prepared to IPC/WHMA-A-620 for approval before tooling.
What is your MOQ for custom cable?
MOQ is confirmed per project and depends on harness complexity, connector cost and tooling. Prototype and pilot batches are accepted before mass production, so a new programme can start with sample quantities. Samples are produced in 3–7 working days and mass production runs 20–30 days after approval.
What testing standards do you apply for harness?
Production follows IPC/WHMA-A-620. Every assembly is 100 % electrically tested for continuity, insulation resistance and withstand voltage; the in-house lab adds temperature and humidity cycling, salt spray, connector insertion and withdrawal force, and cable bending tests. Inspection records are kept in the ERP system.
