Need help adapting my e-bike cable system to a new controller.

[Hugo289234]

m trying to upgrade my e-bike controller, but my current setup uses a different wiring layout and I’m not sure what kind of adapters I need to make it work. I’ll include photos of the controller that came with my kit and the new one I’m trying to switch to.

My current setup:

The motor connects using one large round plug that carries both the phase wires and hall sensor wires together in a single cable.

• There’s another large round connector (Bottom connector 1st image) that comes from the bike’s harness and carries:
  • Display
  • Throttle
  • Brake sensors

I’ll mostly just be using the throttle and display, but I’m fine leaving the other plugs connected — I just won’t be using them.

The new controller:

• Has separate connectors for everything:
  • I don't really know if its really everything.

What I’m looking for:

I need help finding the right adapters (or extension cables) to:

Convert the motor plug into separate phase + hall sensor wires that match the new controller.

1. Convert the main signal plug into individual connectors for throttle and display (or all four, doesn’t matter).

Not sure of the connector names, so any help identifying them or pointing me to the right parts (Amazon, Aliexpress, etc.) would be awesome.


(1st image(Top wire is for the hub motor-Bottom wire is for the display, throttle, brake sensors that runs to the handlebars.

2nd image is my current controller-(I don't use the 2 white wires as well as the 2 small wires on the right.)

3rd image is the controller I want.)

 

[Diggs]

Have you done the obligatory Google review of pin-outs on different controllers. They are relatively the same.

 

[E-HP]

Convert the main signal plug into individual connectors for throttle and display (or all four, doesn’t matter).

You need a new display if you’re swapping out the controller.

 

[docw009]

Ignore the small controller sizes, but you want to go from the modular connectors on the right to the jumbled rats nest on the left? That's a lot of connectors to splice in, and you'll need to run separate harnesses for each handlebar component to the controller. It can be done, but most people come here with questions about a plug and play solution. Ypu will want to buy a controller that fully documents the connectors.

Your old controller has a bigger high current connector, so that may be difficult to find. That means a pain-in-the-butt solder job if you must switch. I'd remove the cable/connector from the old controller and attach it ti the new one on the inside. That's a easier solder job.

Any controller change, unless it is made by the same manufacturer, will require a matching display.

 

[fill]

Most controllers will come with both the julet waterproof connectors OR the more automotive electrical feel connector options. if your selected seller isnt doing so check out a few alternatives..

If your bike is fitted with special bespoke branded connectors then you may find it necessary to build diy connectors from kits google for automotive jst connector kits might be known as something else too?
However if weather sealing is a requirement you may as well solder wire to wire. any effective weather sealing will effectively glue connectors into place so..

+1 to the above get a matched display WITH any replacement controller comments..

 

[Hugo289234]

Most controllers will come with both the julet waterproof connectors OR the more automotive electrical feel connector options. if your selected seller isnt doing so check out a few alternatives..

If your bike is fitted with special bespoke branded connectors then you may find it necessary to build diy connectors from kits google for automotive jst connector kits might be known as something else too?
However if weather sealing is a requirement you may as well solder wire to wire. any effective weather sealing will effectively glue connectors into place so..

+1 to the above get a matched display WITH any replacement controller comments..

Thanks, I really still dont know what to look for. I have searcher everywhere and I still haven't found one that will work that is 40a.

 

[Hugo289234]

Hey, I was wondering if anyone had any suggestions of specific controllers that will work with my current config and wiring setup?

I dont need the 2 white wires on my current controller or the 2 small black wires on the far right hand side of the first image.

Only the power cable and the 2 thick black wires. (The top cable is for my motor and the bottom one splits into the screen, throttle, brake sensors.)

 

[E-HP]

Hey, I was wondering if anyone had any suggestions of specific controllers that will work with my current config and wiring setup?

I dont need the 2 white wires on my current controller or the 2 small black wires on the far right hand side of the first image.

Only the power cable and the 2 thick black wires. (The top cable is for my motor and the bottom one splits into the screen, throttle, brake sensors.)

Why not just replace it with the same controller? No adapter needed.

 

[Hugo289234]

Why not just replace it with the same controller? No adapter needed.

My current controller is designed for a 1000w motor, it pushes 26a. My battery has a Bms of 40a (2000w). I want an upgrade. Would you recommend any specific controllers?

 

[E-HP]

My current controller is designed for a 1000w motor, it pushes 26a. My battery has a Bms of 40a (2000w). I want an upgrade. Would you recommend any specific controllers?

Just to be clear on the requirement. You want a controller, with a compatible display, that supports a throttle input. You need it to have a motor connector that is compatible with your motor. You want the controller to take advantage of the higher current that your battery can provide.

Sound about right?

The second cable and connector will be discarded, since you will be replacing the display. You will reuse the throttle and brake sensors (I don't really think the sensors are necessary) with the new controller.

The battery is used. The controller should be sized at maybe 30A or 35A if the battery is in good shape.

Need the voltage to do anything else.

 

[Hugo289234]

Just to be clear on the requirement. You want a controller, with a compatible display, that supports a throttle input. You need it to have a motor connector that is compatible with your motor. You want the controller to take advantage of the higher current that your battery can provide.

Sound about right?

The second cable and connector will be discarded, since you will be replacing the display. You will reuse the throttle and brake sensors (I don't really think the sensors are necessary) with the new controller.

The battery is used. The controller should be sized at maybe 30A or 35A if the battery is in good shape.

Need the voltage to do anything else.

Thanks, my battery voltage is 52v but a 48v controller should be fine.

 

[E-HP]

Thanks, my battery voltage is 52v but a 48v controller should be fine.

I can't see all of the pins on the motor connector. Can you post of pic of the connector on the motor side? Does it look like the Z910?

Connectors - Learn - Resources

There are lots and lots of connector types used in the ebike industry, so many that it would be a very tall order to try and list them all. In our business, we focus just on aftermarket conversion kits and have tried to keep the connector styles down to a well chosen minimal set. This page...

ebikes.ca

 

[fill]

The 40a capacity of the battery pack while a crucial metric for controller selection, isnt a target. Instead consider it a ceiling and add a margin or safety buffer too so limit your controller peak output to something less 30-35a? perhaps?

Your controller will not be 100% efficient so 35a output will require >35a input..

 

[Hugo289234]

I don't have the bike with me but it's the Z910 connector. Would you have any suggestions?

I can't see all of the pins on the motor connector. Can you post of pic of the connector on the motor side? Does it look like the Z910?

Connectors - Learn - Resources

There are lots and lots of connector types used in the ebike industry, so many that it would be a very tall order to try and list them all. In our business, we focus just on aftermarket conversion kits and have tried to keep the connector styles down to a well chosen minimal set. This page...

ebikes.ca

 

[docw009]

Consider this 22A nominal . 45A peak KT controller. You will need to buy a matching L1121 connector to splice on your motor cable or find a L1121 - Z916 adapter. Also need a KT display. Might need a KT harness to go to the handlebars, depending on whether you have 2 wire or 3 wire brake levers.

Best part, if you speak Canadian, they will tell you what you need.

KT 45A 40-75 Sine Wave WP Brushless Motor Controller (48-60V compatibl

We have requested the best from the KT (Kunteng) Factory! These new controllers are compact, super smooth, and feature rich! Please Note: It seems that BAFANG G063 1000W may not be compatible with this controller. Distinct Features Include - All Waterproof Connections (Uses 1T5 Harness Cable for...

www.affordableebikes.ca

 

[derekderek]

motor cable. Amazon.com : HUDAMZKY Hub Motor Convert Extension Cable 9 Pin Waterproof Connector 36V 48V 52V 250W-1200W Ebike Motor Conversion Line 60cm 130cm 160cm Electric Bike Accessories (60cm Female) : Sports & Outdoors

 

[derekderek]

this might be the cable to rewire the display-controls to a rats-nest controller. Amazon.com: Tomotato Ebike Cable Controller, 1T5 Waterproof Cable Controller, Motor Convert Extension Cable 13 Core Wire Integration Cable Electric Bike Accessories : Sports & Outdoors

 

[derekderek]

this LOOKS like the conversion harness when replacing an all-juliet-waterproof cable controller to standard "rats nest" setup. i am buying one for my BIL's senada herald. they are nice bikes but cust service is slow... https://www.amazon.com/XBERSTAR-Con...g=lMJan&pd_rd_w=lHN0O&pd_rd_i=B0C3CFTKP2&th=1 this says for KT contrpller, but i believe KT and S866-900 use the same 5 pin wiring layout.