there is 2 possible problems. 1. please check the connection, ensure the power can really give you true 48volt if you are using. 2nd, it could be the controller is faulty. is your motor is 1500watts type. ? to my understanding, 1500watts cannot match well with cyclone headline controller, it can blow the spoil something inside the controller. but as for the smaller motor like 900watts, or 1200 watts, it works perfertly. NO problem since the day i have used it. i have used many hundreds trips there is no problem from the controller or the motor. i have the 1000 watts/1500watts motor this one can be used with the kelly controller. if you are getting a new headline controller for the 1500watts, i suggest if i am you, i will get the kelly one.
i have 2 controller at that time. 900watts and 1000/1500watts. i ON my 1000watts 48v controller with the BIG motor, it give a green light and later flash with red light. It fails to work. then i changed my controller to the 900watts, it can run the motor 1000watts. so i know i have blew the 48v controller. it simply cannot match with the big motor. It need kelly controller to feed the power and speed. now i am running the 900watts kit, very happily after that, ya.. until now. i need it to run all over cities and park anywhere i like it.
if you are sending the controller back and back to your country it might cost you a total USD100, i will rather buy one kelly controller USD180+ or minus. finally to compare which product is better the smaller motor or the bigger one? to me, it seem the smaller one is better one, much more waterproof, better troque, smaller, better range. for speed is just only slightly slower compare to the bigger motor.
cheers!