Today, we’re going over how we reverse engineer an ebike to wire in a custom controller. When you’re building a custom powertrain, it’s cleaner to use stock parts where possible instead of starting over with new wiring. This is the process we use to create aftermarket kits. You don’t need anything besides a multimeter, some bike tools, and your controller programming tools.
1. WHAT AND WHY
To achieve the OEM+ standard (rather than completely gutting a vehicle and rebuilding it), we want to use as many stock parts as possible. The most critical of these parts to be reused is the wiring harness - it’s already built for you by the factory and is perfectly reusable for your upgraded controller. On top of that, by doing as little custom wiring as possible, you reduce the number of potential failure points in your build.
As a result, our upgraded controller kits will almost always plug directly into your stock wiring harness.
2. MAP IT OUT
The first step is to just check continuity on every pin of every connector. Your goal is to know where each and every pin connects, between your inputs and your outputs.
This is made easier by removing all the wire harnesses from your vehicle, and drawing out each connector. You can see the main harness demonstrated in the video (there are usually two or three harnesses per vehicle.
3. PIN IT
After we know where each pin leads, we need to know what each pin does. Since all ebikes generally work the same way, we can take what we know about each input and use the multimeter (and a power supply sometimes) to determine what each pin represents. General guidelines below:
Throttle - GND, +5V, SIGNAL
Pedal Assist Sensor - GND, +5V, SIGNAL
Display - GND, B+, B-, COMM1, COMM2
Brake sensor - GND, SIGNAL
Motor phases - U, V, W
Motor halls - GND, +5V, U, V, W
Motor sensors - TEMP, SPEED
We demonstrate how we think about the throttle functionality in the video, and need to apply this thinking to every one of the inputs and outputs. This tells us exactly which pin to connect to our new controller, and ultimately informs the final wiring that we create.
4. END RESULT
In the end, we know where each pin goes and what it needs to do. After we have that knowledge, it’s just a matter of creating a custom harness for that purpose.
We’re left with a custom controller kit whose harness plugs directly into the stock wiring harness. There’s no need to create a more complex harness, and this method of mapping/pinning is exactly the same thing as measuring mounting holes for custom accessories (for example) - just in an electrical sense.
On top of that, since we’re implementing our own communication protocols, most stock vehicle communications (which are sometimes proprietary and protected) are replaced. This gives us control over the system, and we don’t need to hack or piggyback into anything.
Go build your ebikes!
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