Bike not working after battery replacement...Help please !!

[Deleted member 4366]

All you have to do is ask. I guess you haven't connected the ignition wire, which is next to the thick red battery wire. It has to be connected to the battery positive - normally via a switch so that you can switch the controller on and off.

Don't forget that all the time you're going through this pain, you're improving your knowledge and understanding.

 

[danielrlee]

Try using a short piece of wire and stuff it in the back of the connector so to bridge the thick and thin red wires.

 

[chris301up]

That's 'sods law' isn't it?

I've just removed everything and put the bike back in the garage. I'll give that a go. My original controller didn't have this connection so, like many of the other wires, thought it was redundant.

When I have a bit more time I'll re-connect, including that 'ignition wire' and see what happens?

This may seem like a stupid question. Why would you want to switch the controller on/off when there is an ignition key integral to the battery?

Thanks again

 

[danielrlee]

There appears to be an echo in here and in other threads..... I think I've been added to d8veh's ignore list. I wonder what I did to deserve that?

 

[mw1]

This may seem like a stupid question. Why would you want to switch the controller on/off when there is an ignition key integral to the battery?

Not a stupid question, I have the same thing re a controller I am about to wire up & D8veh pointed me in the right direction. Agree though, when the controller can just take it's power from the main battery feed,as some do.

 

[danielrlee]

Most batteries don't have a separate power switch.

 

[chris301up]

Right. Have just re-connected everything, including the ignition wire as suggested, and I now have voltage at the hall sensors. So a step in the right direction at last.

The motor still refuses to do anything though. Not even if turning it backwards as before ??

Just another question. The wiring is extremely confusing on the new controller though, as the colours do not match the ones on my bike. Most of them I can generally work out what goes where, except for the throttle and PAS as there are two sets of wires which are Green, Red and Black ??

 

[chris301up]

Right. Have just reconnected everything again and am finally getting power to the motor. Turning the throttle works and we can hear the motor spinning, but not the wheel. Any ideas???

 

[chris301up]

Ok.

Left the bike switched off for around 30 minutes and it now seems to work as it should. Have no idea why.?? I have to make good all connections now so lets hope it work once that's done ????

 

[Deleted member 4366]

When the motor was whirring but not turning the wheel, it was spinning backwards. The controller can't see the wheel turning, so it has to make a best guess. Once it has it right, it usually stays right. The motor direction is sometimes worked out in a self-learning procedure that involves connecting a pair of self-learning wires. We'd need to see a photo of all the wires you have that are not motor, throttle or PAS to determine whether yours has them. If it does, they need to be disconnected once you have it right, otherwise it'll repeat the self-learning each time you switch on, with a chance that it'll guess the wrong direction again.

 

[mw1]

Left the bike switched off for around 30 minutes and it now seems to work as it should. Have no idea why.?? I have to make good all connections now so lets hope it work once that's done ????

Glad you had a result Chris

Mark

 

[chris301up]

Right. Just an update.

I have been in touch with the supplier of the controller unit and they have provided details of the wiring. Herewith attached is an image of this which may be useful to someone in the future

I do however, have some questions.

1) There doesn't appear to be any connections for my handlebar displayer,
which on my original controller had an Orange & Black wire?
2) These doesn't seem to be a PAS connection?
3) There doesn't appear to be any handlebar brake connections?
4) What are High Battery & Low Battery brakes?
5) What is 1 + 1 power line?

Any further comments would be greatly appreciated before I continue further

 

[chris301up]

I've finally managed to get the bike up and running but just cannot work out the PAS wiring

Don't know if anyone would know from the image attached?

 

[mw1]

I've finally managed to get the bike up and running but just cannot work out the PAS wiring

What colours are the wires from your pas sensor?

 

[chris301up]

Blue, Red and Black

Here is an image of the old controller

 

[mw1]

I'm fairly sure that what I said in a previous post are the relevant wires. Try blue to blue, black to black & red to green. Pretty sure you can't do any damage, it'll either work or it won't.

 

[chris301up]

Sorry. I must have missed that? You were referring to the Dial 3 Speed Line in the image. Correct? Will give that a go

 

[mw1]

Yes, correct.

 

[Nealh]

Right. Just an update.

I have been in touch with the supplier of the controller unit and they have provided details of the wiring. Herewith attached is an image of this which may be useful to someone in the future

I do however, have some questions.

1) There doesn't appear to be any connections for my handlebar displayer,
which on my original controller had an Orange & Black wire?
2) These doesn't seem to be a PAS connection?
3) There doesn't appear to be any handlebar brake connections?
4) What are High Battery & Low Battery brakes?
5) What is 1 + 1 power line?

Any further comments would be greatly appreciated before I continue further

1) Possible dial 3 spd is for a LED which are only 3 spd/assist. Looks like controller is not LCD compatible.
3) Your old controller is marked low brake so connect up to low.
2/5) 1 + 1 = PAS, looks like R/G/Blk so R/R, G/B & Blk/Blk. Green & Blue being signal.
d8veh should be able to add more light .

 

[mw1]

1) Possible dial 3 spd is for a LED which are only 3 spd/assist. Looks like controller is not LCD compatible.
3 & 4) Not 100% but depending on your brake connector, if you have a 2 wire brake connector plug it in to high if you have 3 wire connector plug it in to low.
2/5) 1 + 1 = PAS, looks like R/G/Blk so R/R, G/B & Blk/Blk. Green & Blue being signal.

Ah yes, I hadn't looked at the diagram properly. Your answer makes far more sense

Mark