Do a search in this forum and you will find some helpful information. There have been problems in the past with batteries being too tight as well as too loose.
Thanks, Bruce. I read all the messages related to poor battery connections, and also the extended explanation of Tora Harris regarding this issue, and the promises he made regarding future improvements, but the problem still remains at least in some CCXs. I have to assume that Juiced is working on these problems; my motivation to post again is to keep this issue fresh. Most people read only the first page of websites.
As things are now, even a perfect mechanical engagement of the battery, does not provide a reliable electrical connection. A displacement of a fraction of a millimiter of the battery with respect to the frame results in a connection or no-connection. As time goes, the problem becomes more frequent and I am concerned that very soon, damage to the electrical contacts will result, due to the minimal engagement. When the contact surface is so small, the current concentration in that limited contact surface results in a high temperature spot and/or sparking, finally melting the contacts and the insulation around the female contacts. We have seen pictures of damaged connectors in previous postings. Today solving the problem may require a $20 expense, ignoring the problem may cost much more.
Tightening the nuts that support the connectors could make for a minor temporary fix, which I did not observe. So far this is what the manufacturing support group has suggested, with no benefit to my bike.
I have worked in a project that had exactly the same type of connection problems, even worse, because these electrical connectors had to operate in an ambient of up to 200°C. The only solution I know of, is to make one of the connecting parts "quasi-floating", but kept in place against the other half of the connector by some elastic mean, such as a spring or spring washer. Mechanical tolerances are to be expected, more so when there are injected plastic parts, aluminum parts, working together, manufactured by different vendors.
To aggravate matters, the frame engagement pin diameter is about 0.4", and in the direction perpendicular to the "flat", it is only 0.34", while the diameter of the battery hole is approximately 0.5". Such slack between the pin and the hole diameters has to be taken by other parts, making the whole assembly difficult to manufacture with reliable results.
So, long term I assume that Juiced will be required to improve tolerances, make one of the connectors "quasi-floating". A clamping system to keep the heavy battery in place should also be part of the solution, similar to the quick release of the front wheel. Depending only on a pin and hole engagement to keep parts in place without relative movement is not enough.
Because this forum has a big audience, I wonder if this problem has not been already solved by someone. I knew about the tie-wrap to hold the battery against the frame, it seems a reasonable short term fix. In few words, I want to use my time biking rather than posting in a website forum.
