Throttle wire splicing

[bolt]

Hi folks,
I have a BL-36 (aotema) brushless kit. The connector between my 4 wire thumb throttle and my controller box was carelessly crushed, so I am now trying to figure out how to connect the wires without the helpful connectors. On the throttle end I have black, white, red and blue, and on the controller end I have black, white, red and purple-ish. When I connect like colors, because that is how I figured it should work, and try the throttle it doesn't engage, but the LED's are working for "power" and "full" battery. I can get the motor to engage when different connected colors touch one another, but that just bypasses the throttle without control. I am so clueless about what is supposed to connect to what and what wires should not connect. Any low tech explanations out there? I would be very appreciative.

 

[chisixer6]

I believe the red goes to red and black goes to black. This leaves white & blue and white & purple. I left the blue off on mine, so try white and white. I take it that the connector is 3 pins and the other 1 pin goes for the LED's. maybe some one else will chime in...

 

[Rassy]

I've had several of their brushed (BD36) kits a few years ago. Your first guess was correct. The running when touching two wires does happen. That is why a short in the throttle wires will sometimes put you in wide open throttle (WOT) mode.

So, you have basically proved that the motor and probably the controler are working. My guess would be a bad throttle wire or a bad throttle. The WOT was probably caused by touching the red to the white. Use your multimeter to check the voltage between the red and black (don't touch these two together). You should get about 5V. If the above is true, then with the wires hooked to the throttle, check the voltage between the red and white as you apply the throttle. It should vary between a little over 0V and a little under 5V.

 

[d8veh]

The connections are red to red (5v); black to black (0v); white to white (throttle signal); blue to purple (battery voltage for LEDs).
If you short white to red, you get a throttle signal of 5v, which gives full throttle.
If, when it got crushed, the blue wire touched the red or white, or if you did it during testing, you've blown the hall sensor in the throttle and you'll need to replace it.
You can check all this with a voltmeter: Between red and black there should be 5v and beteen white and between about 1v and 4v depending on throttle position.

 

[dogman dan]

Correct. If you choose to replace the throttle with one with three wires, the purple/blue would be the one you no longer connect. It has full pack voltage for the led meter in the Aotema type throttles.

Typically a generic replacement throttle will have red and black, then white or some other color. In such cases, red to red, black to black, then white to the other color on three wire throttles.