Hey everyone, I'm pretty sure I just blew up my controller by crossing the red and black wires accidentally because when I hooked it up the right way my motor started to run full speed uncontrollably, not to mention the huge spark when I crossed the wires and the puff of smoke, so I guess its time to buy a new controller. My first question is do I have to purchase the exact same controller as the one I currently have? I haven't been able to find the same one so far. I have a 36 volt 500 watt brushed hub motor so I'm wondering if I can buy any controller that is designed for a 500 watt 36 volt brushed motor. Most other controllers don't look like they'd be compatible with my throttle either, it has 4 wires going into a plug that goes to the controller. If I were to guess i'll probably have to change to a new throttle because I don't think any controllers would be compatible with mine. The actual throttle is a push thumb with 3 lights, one for power, one for battery full, and one for battery empty. Any help would be much appreciated as I am sort of new to working on these bikes, I did have a gas bike for a while but I've been working on small engines my whole life so that was easy for me. Thanks!
e-bike controller questions...
- Thread starter dmurtagh
- Start date
AussieRider
1 kW
Hi dmurtagh, welcome to the forum.
With a brushed motor, that is, one with only 2 wires coming out of it you can use pretty much any brushed controller as long as it's up to the job. Your choice of 36V / 500 watt controller for a 36v / 500 watt motor should cause no problems. As for the throttle, you may not need to replace it. The throttle uses 3 wires, the 4th is for the power indicator. Colour codes vary from one to the other. For example, my controller throttle has red, black & blue. Red & black match red & black as in positive & negative. Blue is the signal wire. The fourth wire in my setup is yellow.
BUT! I've seen controllers with other colours as well like green signal, brown for ground & so on.
Hope this helps & we've all released magic smoke as we've learned.
AussieRider.
With a brushed motor, that is, one with only 2 wires coming out of it you can use pretty much any brushed controller as long as it's up to the job. Your choice of 36V / 500 watt controller for a 36v / 500 watt motor should cause no problems. As for the throttle, you may not need to replace it. The throttle uses 3 wires, the 4th is for the power indicator. Colour codes vary from one to the other. For example, my controller throttle has red, black & blue. Red & black match red & black as in positive & negative. Blue is the signal wire. The fourth wire in my setup is yellow.
BUT! I've seen controllers with other colours as well like green signal, brown for ground & so on.
Hope this helps & we've all released magic smoke as we've learned.
AussieRider.
Thank you so much, I bought a new controller that is actually much better than my old one because it supports brake lights and I can also hook my charger right up to the controller instead of having to hook the charger up to the battery pack. I think it should be a little more reliable too since its not one of the cheap Chinese controllers. Hopefully it has reversed polarity protection 
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