Need help installing twist throttle to my 48v 1000watt ebike

[Zakaria16]

Hey guys I am having some serious problems installing my throttle to my electric bike. I use the bike as a commuter to work and back and really need it working again and have been struggling with this for a while. I cannot seem to figure out where the wires go. I know my controller has the throttle connector with the three small wires, but where do I connect the two larger wires? I hope there is an easy solution. Thanks so much for the help guys. I attached pictures to help aid the process.

Zack

 

[spdas]

Seems the 2 larger wires are for the key switch to turn the controller on and off. It is red although the diagram says green. One goes to the 48v+ and the other goes to the controller activating wire. (maybe called "Lock wire")

francis

 

[Zakaria16]

Thanks for the help. Are you saying one of the two big wires goes directly into the battery when you say one goes into the 48v?

 

[Zakaria16]

Here is a wire diagram for my controller.

 

[wesnewell]

If you are going to use the key switch, take one of the big wires to battery positive and the other to the red lock cable wire from controller. If you already have an on/off switch, or you already have the lock cable wire wired to positive side of battery, you don't need to hook up the big wires unless you want to. If your original throttle only had the 3 throttle wires, you don't need to mess with the key switch wires.

 

[Zakaria16]

Thanks for the help guys.I went ahead and tried it that way but the bike is still not powering on. I connected the thick yellow wire (48 v output from switch) to the lock cable on the controller and connected the three small wires to the three small throttle cable on the controller. I do not think there is anything wrong with the battery or any other wiring as the vpower lithium is fairly new that I have been using.

I guess to give you some background on the bike... It was working like a charm when it shut off while riding one day. Seemed like I needed a new controller so I got a new one and a new throttle to go with it.

Any idea why it is not working? i also heard that I can connect the other thick cable (48 v input for battery meter/switch) directly to the red wire from the battery but that did not work either and does not seem like a good idea anyway. I am kind of reaching a dead end on this.

Zack

 

[Zakaria16]

There is also a phase cable that includes a small red and a black wire coming from the controller. I wonder if I should try connecting the two bigger wires (48 v input and output) from the throttle to this phase cable?

Zack

 

[amberwolf]

I guess to give you some background on the bike... It was working like a charm when it shut off while riding one day.

With a Vpower battery, even a "new" one, if it's made like the two I've worked on, it could easily have a physical problem inside that causes it to just shut off the BMS to protect the cells.

Cells could just be unbalanced, especially if it gets run down anywhere near empty, in which case you can just put it on the charger for a few days or weeks to fix this (or look up single-cell charging on how to do it a different, faster, way).

Or cells could actuallly be disconnected in the parallel groups, where one or more cells in a group (probably on an end or corner) has broken off the strips at the spot welds, so the rest of the cells in the group are taking the load, and of course they're lower capacity in total without the disconnected cell(s). Sometimes these cells may make intermittent connection, making it harder to troubleshoot.

There's a lot of threads on how to test (and repair) a battery, so I'd recommend following the steps in those, so we can help you figure out if it is or is not caused by the battery, before going any further with the controller stuff (which is less likely to be the cause).

 

[wesnewell]

Thanks for the help guys.I went ahead and tried it that way but the bike is still not powering on. I connected the thick yellow wire (48 v output from switch) to the lock cable on the controller and connected the three small wires to the three small throttle cable on the controller. I do not think there is anything wrong with the battery or any other wiring as the vpower lithium is fairly new that I have been using.

Congratulations. You hooked up half the circuit when you connected the big yellow wire to the lock cable. Now hook up the other half for a complete circuit by hooking the big red wire to Battery positive. If that doesn't work, turn the key on the throttle on.

 

[Tamaranchorider]

You might want to create a shunt on those two wires. I replaced my key throttle with a non-key one and the two wire connector from the controller that is for the key requires a completion in circuit. I completed the circuit by putting a wire into both ends of the connectors and taping it in place. Works fine for me.

 

[wesnewell]

The picture of the lock cable looks like just one wire. if it's 2 wires, you need to connect both big wire from throttle to it.