- Start by unplugging the wiring harness from the controller. The connection is located underneath the bottom bracket. The joint may be partially inside the frame of the bike (within the downtube). It is helpful to turn the handlebars all the way to the right to provide extra slack. The wiring harness has a 10 pin connection, so once you disconnect the joint please verify that there are 10 pins.
Fig. 1 Wiring Harness connection
Fig. 2 10 pins
- Next, disconnect the electrical connections up by the handlebars. These connections include those coming from the LCD display, both brake levers, headlight and the throttle. It will be necessary to snip the zip ties that organize the wires.
Fig. 3 In order from the top (left brake connection, LCD display, right brake connection, throttle connection)
- Now pull the wiring harness up through through the frame of the bike. To make it easier to reroute the new wiring harness, it is helpful to tie a string to the old wiring harness. Use the string to pull the new wiring harness through the frame and reconnect it back to the controller.
Fig. 4 A string looped to old wiring harness.
- Finally, reconnect the connections at the handlebars. Each connection is color coded so you know you are connecting each connection to its appropriate mate.
Fig. 5 Red connections are brake connections, yellow connection is throttle, silver connection is LCD display