Ebike Controller Replacement _ The Easy Way
What’s happening everybody welcome back to the channel so today uh we’re going to replace the controller in a h bike now uh this bike and one of my other bikes started to have a problem uh in this particular one the throttle stopped working and then the um the the bike was
Shut off uh roughly at about 46 volts or 47 volts when really it should uh you know drain the battery down to about 40 volts so there was a couple of problems with this one and uh the other one also had a similar problem where it was
Registering the battery uh but it wasn’t sending any power to the motor so we had decided that it was best to uh replace the controller I have it right here uh this was sent to me from Hadi bike it was custom made with the pigtails uh properly at the proper length and now
We’re going to install it now this this one is not for this particular hottie bike it’s for that one okay the fat bike now I’ve already got it halfway taken apart so in order for me to show you actually what it takes to put this controller in I’m going to pull a
Battery off of that one and show you basically what it looks like when you first take it apart and then we’ll proceed to this bike to install the new controller so let’s dive into this okay so the first thing that you’ll notice when working on a Hadi bike is that you
Can’t you can’t see the controller it’s hidden normally in a lot of bikes you’d see the controller mounted down here you know back behind the seat post down in this area or you might see one down in this area here but in the case of a high
Bike the controller is hidden it’s up in this area here so when you take the battery off uh you can get up in there and see where the controller is so let me show you that now okay so once you got the key it’s hard to do this
One-handed but once you turn the key and get this loose you pull the battery out like so all right the battery just comes right out okay so with the battery removed you’ll see in this case the battery terminals are here uh two positives and two negatives there’s two screws one
Here one here and it pulls this locking piece out okay and then the controller slides out from in here you’ll see the wires are tucked in this little channel here along along the bottom of this kind of box type post how they got this bike constructed and then there’s another kind
Of plastic piece covering back here and behind here or the other connections that uh you know send power to your control you know to your display and to your motor and uh some other things some lights back here some wires for the for the lights and that’s how uh
This hotti bike is basically constructed right so I’m not going to take this one apart any further I’m just going to take you over to this one and show you you I’ve got the the connector out and the controller is tucked away in here right just kind of pull that
Out and there she is that’s one of the nice things about AI bike is that the controller is hidden the bike is very well constructed so that you don’t actually see the controller in the case of the mount bike you know it doesn’t even look like an ebike you have to look
Kind of close because it doesn’t look much like an ebike this one’s got a large battery in it and um so you can clearly see it’s an ebike but from here it’s easy you just take these connectors off right unplug everything unplug these connectors down here drop the new
Controller in and put it back in place so let’s get to it okay so it’s really easy to take these off guys you can see in here you just press in on this pull that one out same thing in the case of that one you can see that
Just press in and then pull them apart and then there’s a couple others here they all come apart the same way all right just press in on the one little tab there and it should come out it’s just a little tough to do this onehanded so let me put this camera down
And I’m going to disconnect them all okay so with most of the small connectors disconnected okay they were they were a snap to take them off uh these the high powerered wires that power up the motor well they’re connected a little bit different okay they’ve got a connection that looks like
This right so I got to get some tools and pull them apart and then uh this seea way to come with this kind of a sophan type tape on it don’t know exactly what kind of tape that is but uh we’ll try to figure something out there
So let me get some tools we’ll take this one apart okay so this little nut right here has to come off and it’s an 8 mm uh really don’t have what it takes to show you this to take this apart with one hand so I’m just
Going to take these AP right here and then pull this old controller out like I say guys um I don’t know what kind of tape this is right here but uh you can see I got the other two taken off already one here and one here uh
It’s really nothing you put an 8 m 8 mm wrench or socket on that you know with a Philips head on that side right so uh we’ll just take the tape off of this one disconnect that disconnect this yellow wire and then uh we’ll pull the controller out okay with
These three power wires disconnected we can pull the controller right out okay so it’s at this point generally when I’m replacing something I will put the uh old part next to the new part to make sure that what I’m replacing is is the same as what I’m taking out right
Now this one here is the old one and here’s the new one uh I’ve checked all the lengths I’ve checked all the connectors and they’re all the same but there is one difference this one I don’t know if that’s something that you can see but um the new one says Max current
17 plus or minus 1 amp and the old one is 18 plus or minus 1 amp I don’t know if that’s going to make any difference in the per performance of the bike um Hadi bike says it should perform about the same you know um so
I’m just going to go with it I also want to say that um this new controller was ordered directly from Hadi bike and um they were actually pretty good I mean here I am in the United States and uh I had to email them from China I took all
The measurements because those long pigtails are 61 mm from the controller and they custom made this one to the exact specifications that I gave them so it took a while it took about um 10 days for them to build it and another 12 days for it to get here but it’s here and
Everything looks okay so we’re going to put it in okay at this point this is actually quite simple just lay this one in here lay the controller in there set these two wires to the side because they lay on top of the controller like that right and we’ll hook up the proper ones
We’ll slip the controller in there then I’m going to do the high powerered wires first to make sure that all works and then we’ll plug in the rest of them okay so we’re almost there now uh you can see these little three little um connectors I got all of them together
With the little nuts and bolts all right so we’re just going to put a little electrical tape on them all right to keep them safe and then uh we have these ones up in here now this red one here is the power main power wire for the
Battery which connects down here once we put the battery on these three little black ones they also connect up in there too but you have to be a little careful with them because even though you know you can’t plug in the wrong one uh it’s
Easy to try to mix them up and then damage them as you’re realizing that you’ve got the wrong ones there so um I would advise just being real careful with these guys as you put them in make sure you got the right ones matched up
And then plug them in and we should be all hooked up here okay so it is very important to watch these two connections right here because they will interchange so in my case I did have them wrong uh I reached out to hotti bike cuz at first everything didn’t work and they spotted
It uh so you got to watch to make sure that the you know the the wires are are matching before you put these two together cuz you can mix them up the the connections are the same so if you cross them it won’t work but right now we have
Everything right everything’s on and everything is working I’ll hit the throttle and we have power there and we also have see the brake lights work and we also have Cadence see that so everything’s working perfectly excellent all right so with everything hooked up right uh you got a lot of
Wires here to work with so basically in this case now you got to tuck as much of this wire down in this direction and up in here cuz there’s a lot of space up in the top part to get this tucked away so that uh we can put these end caps on and
Then we can slip the battery in so let’s get to it so with the bottom plate on now these wires all have to be tucked in this channel right and then tucked up in here and then this plate goes on and you can see the terminals for the battery there
Uh on this bike those terminals are not used because the battery hooks up to a pigtail down here all right so even though that they’re there they don’t work they’re dead there’s nothing to that so we’ll stretch these wires out get them in the channel nice and tight
And uh get this piece on and at that point we’re ready to put the battery on one interesting thing happened here guys uh from tugging on all the wires while you know um maneuvering the new controller in somehow it pulled on all of this all through these zip ties and
Disconnected one of the connections here on the on the uh front display so when you’re doing a job like this and uh you’re ready to go you think you got everything hooked up and it doesn’t work check stuff that you didn’t even touch because I never touched any of this and
Uh I just by chance came over here and looked at it and found that this was disconnected so have to pull this up a little bit to get this to connect because see it won’t even connect that’s why it’s it’s been pulled through a little bit and just got disconnected so
Anything could happen when doing a job like this all right that should just about do it just lay a piece of tape on top of the wires to protect them all right and we’re all hooked up now uh you can see this like I say these terminals are not
Used but this is basically here to lock the battery in you know with its lock all the wires are protected in that channel everything’s closed up let’s put the battery on all right guys here’s our battery and this is really hard to do one-handed so uh you can see the pigtail from the
Battery there it Cooks up over there you just kind of lay the back of the battery in and then Notch it in over there I can’t do this one-handed so let me shut this camera off and drop this battery in all right there she is we should just snap this right
In okay now it work all hooked up let’s see how everything works and there you have it everything looks good our battery voltage is at 53.8 volts that’s about right for a 48 volt system and uh we’re good to go uh I have nothing but good things to say about HEI
Bike uh sometimes things go wrong with the bikes you just never know but uh they help me diagnose the problem uh we narrowed down to the controller took a little while but I got a controller couple hours worth of work we got it all set up and we’re ready to ride the bike
Again I’d also like to note that if you look at this H bike right these are 70 mm rims here right and they enable me to run a 3-in tire and I kind of like that that like that bike look nice so anyway guys thanks for watching
Uh pay attention to the channel here I got a lot going on uh we do we bike content we do a lot of different content my wired Freedom Bike here has a problem right look at that I got a flat tire that’s the second time that that’s
Happened now these um tires that I have on here are 3 and 1/2 in V Tire speedsters they did a lot for this bike uh I ride it mostly on pavement and very low noise and very low rolling resistance the only problem is these tires are very thin because they’re very
Light and they’re very prone to getting a flat this isn’t even a piece of metal this is a piece of a tree or a shrub or something that I um you know ran over and it punctured the tire so what I have is one of these inserts and a tube to
Match that okay and uh we’re going to have a video on this one soon so anyway thanks again for watching and we’ll see you in the next one
How to install a Brushless DC Controller. This video applies to any Electric Bike. weather is be a Senada Herald or Saber, Philodo, Nakoto, A20, Aostirmotor, Lectric XP, Velowave, Hotebike, Shuangye
GoTrax Mokwheel Himiway Aventon Velotric
Most E-Bike Controllers are replaced this way
#ebike #bike #cycling
