A controller is the brain of every electric bike or electric motorcycle. It connects the battery, motor, throttle, brakes, and other electrical components to ensure smooth performance. The diagram of a 48V controller, like the one shown here, helps in identifying each wire and its function. Knowing these pinouts is very important for troubleshooting faults and performing repairs
The battery connection wires are usually the thickest. The red wire is positive and the black wire is negative If these connections are loose or damaged, the controller will not power on
The motor phase wires are three thick wires in colors like yellow blue and green. These carry current from the controller to the motor If one wire is faulty the motor may vibrate or fail to run smoothly
The Hall sensor wires are a bundle of five smaller wires red 5V supply black (ground), and three signal wires usually yellow green and blue These help the controller detect the motor’s rotor position. If the Hall wires are faulty the motor may not start or may run roughly
The throttle wires generally include red (5V) black ground and green (signal) The signal varies with the throttle twist and tells the controller how much power to send to the motor. A broken throttle wire results in no acceleration
The ignition lock wires allow you to turn the controller on or off using a switch or key If these are disconnected, the bike will not power up even if the battery is connected
The brake wires connect to the brake levers. When brakes are applied, these wires send a signal to cut power from the motor for safety. If they malfunction, the motor may cut off unexpectedly or fail to stop when braking
The charging port wires connect the battery charging system. The positive and negative wires allow safe charging through the controller. A damaged charging wire can stop the battery from charging properly
The charge indicator wires are used to show battery level on the bike’s display or indicator light. They are not directly related to driving but are useful for monitoring battery health
In summary, every wire in the controller plays an important role. By carefully identifying and testing these pinouts with a multimeter, most wiring-related problems in electric bikes and motorcycles can be diagnosed and repaired