When you choose to ride an e-bike as a new lifestyle, there will always be some problems during the ride. But thanks to the pedal, you can still reach the end. Sometimes you can fix it by yourself. Start from the easy points.
Check these first:
- Battery voltage and connections
- All wire harnesses and connectors
- Controller housing for damage or water intrusion
- Display unit for error codes
Usually, the controller will work well for at least 3 years.
Here are the checkpoints:
No Power/Dead Controller:
- Test the input voltage at the controller terminals
- Check the main fuse and replace if blown
- Inspect power cables for breaks or corrosion
- Verify the battery management system isn’t in protection mode
Intermittent Power Loss:
- Look for loose connections, especially at controller plugs
- Check for damaged wires that may short intermittently
- Examine solder joints inside the controller (if accessible)
- Test throttle and brake sensor connections
Motor Runs But No Torque:
- Check the phase wire connections between the controller and the motor
- Test hall sensor wires (usually 5-pin connector)
- Verify motor specifications match controller settings
Replace or Repair?
Replace if:
- The controller is water-damaged and corroded
- Multiple internal components have failed
- Housing is cracked beyond repair
- Repair cost exceeds 60% of replacement cost
If not, check the points to see if you can fix it.
Repair Process
Tools needed: Multimeter, soldering iron, heat shrink tubing, electrical tape, replacement fuses
Safety first: Always disconnect the battery before working on electrical components
Step-by-step:
- Document all connections with photos before disconnecting
- Remove the controller from the bike frame
- Open the controller housing carefully (some are potted and non-repairable)
- Identify failed components – look for burnt resistors, blown capacitors, or damaged MOSFETs
- Test components with a multimeter
- Replace damaged parts with exact specifications
- Reassemble and test with low power first
We highly suggest you find a new controller from Amazon and replace it. Make sure the new controller functions and cables are the same as defined. But the controller still can have a spare function, no need to connect cables.
But when you can’t find a match controller and can’t get help from the manufacturer, please try to contact us. We will gladly help you get it.
