Pro-SS Controller Installation Guide

Complete Step-by-Step Installation Instructions

Safety Precautions ⚠️

IMPORTANT: Read all safety instructions before beginning installation

• Always disconnect the battery before starting installation
• Wear safety glasses and insulated gloves
• Work in a well-ventilated area
• Keep tools and workspace clean and organized
• Never work on live electrical systems
• If unsure about any step, consult a qualified electrician

Tools Required

• Wire strippers and crimpers
• Multimeter
• Screwdrivers (Phillips and flathead)
• Allen wrench set
• Cable ties and zip ties
• Heat shrink tubing
• Electrical tape
• Torque wrench (for motor connections)

Package Contents Checklist

Before starting, verify you have all components:

• [ ] Pro-SS Controller unit
• [ ] Wiring harness
• [ ] Mounting brackets
• [ ] Hardware kit (screws, bolts, washers)
• [ ] User manual and wiring diagram
• [ ] Throttle connector (if applicable)
• [ ] Display connector (if applicable)

Pre-Installation Planning

Step 1: Choose Installation Location

Controller Placement Requirements:

• Dry, well-ventilated area
• Away from direct heat sources
• Accessible for maintenance
• Protected from water and debris
• Minimum 2 inches clearance on all sides for cooling
• Secure mounting surface that can support controller weight

Recommended Locations:

• Under seat compartment
• Battery box (if space permits)
• Frame-mounted enclosure
• Dedicated controller compartment

Step 2: Plan Wire Routing

• Route high-power cables (motor, battery) separately from signal cables
• Avoid sharp edges and moving parts
• Plan for service loops at connections
• Consider wire protection (conduit, cable management)

Installation Process

Step 3: Mount the Controller

1. Position the controller in chosen location using mounting brackets
2. Mark mounting holes with pencil or marker
3. Drill pilot holes if necessary (avoid drilling into frame tubes)
4. Secure with provided hardware

• Use thread locker on bolts
• Torque to manufacturer specifications

1. Verify secure mounting – controller should not move when gently shaken

Step 4: Battery Connection

⚠️ CRITICAL: Battery must be disconnected during this step

1. Identify battery terminals (positive and negative)
2. Connect battery cables to controller:

• Red wire to positive (+) terminal
• Black wire to negative (-) terminal

1. Use proper torque specifications (typically 8-12 Nm)
2. Apply dielectric grease to connections
3. Secure cables with zip ties to prevent strain on terminals

Battery Wire Specifications:

• Use minimum 10 AWG wire for 5kW systems
• Maximum cable length: 3 feet
• Use quality MC4 or Anderson connectors

Step 5: Motor Connection

1. Locate motor hall sensor connector (smaller connector)
2. Connect hall sensor cable to controller hall sensor port
3. Connect motor power cables (typically U, V, W phases):

• Yellow → U phase
• Green → V phase
• Blue → W phase

1. Verify connections are tight and properly seated
2. Secure motor cables to prevent vibration damage

Step 6: Throttle Connection

1. Identify throttle connector (usually 3-pin or 5-pin)
2. Match connector to controller throttle port
3. Ensure proper pin alignment before connecting
4. Test throttle movement – should move smoothly without binding
5. Secure throttle cable to handlebars with cable management

Throttle Types Supported:

• Hall effect throttle (0-5V)
• Potentiometer throttle (1-4V)
• Twist grip or thumb throttle

Step 7: Additional Connections

Display/Dashboard (if equipped):

• Connect display cable to designated controller port
• Mount display in easily visible location
• Secure display cable routing

Brake Switches:

• Connect brake switch wires to brake input terminals
• Test brake switches activate properly
• Both front and rear brake switches recommended

Additional Features:

• Reverse switch (if applicable)
• Key switch/ignition
• Turn signals and lighting
• Horn and other accessories

Step 8: System Wiring Verification

Before powering up, double-check:

• [ ] All connections are secure and properly terminated
• [ ] No exposed wires or loose connections
• [ ] Proper wire routing away from moving parts
• [ ] All mounting hardware is tight
• [ ] Battery connections have correct polarity
• [ ] Motor phase wires are properly connected

Initial System Testing

Step 9: Power-Up Sequence

1. Connect battery (controller should power on)
2. Check for error codes on display
3. Verify throttle response (motor should not run without throttle input)
4. Test brake switches (motor should stop when brakes applied)
5. Check all functions before first ride

Step 10: Parameter Configuration

Basic Settings to Configure:

• Maximum speed limit
• Acceleration curve
• Regenerative braking level
• Battery voltage settings
• Motor direction (if incorrect)

Use controller programming interface or app to adjust:

• Speed settings
• Power output levels
• Safety parameters
• Custom riding modes

Troubleshooting Common Issues

Controller Won’t Power On

• Verify battery voltage and connections
• Check main fuse (if equipped)
• Test with multimeter for proper voltage

Motor Runs Backwards

• Swap any two motor phase wires (U, V, or W)
• Or use controller software to reverse direction

Throttle Not Responding

• Check throttle cable connections
• Verify throttle voltage range in controller settings
• Test throttle with multimeter (should show 0.8V to 4.2V typically)

Overheating Issues

• Verify adequate ventilation around controller
• Check for proper heat sink mounting
• Reduce power settings if necessary

Final Installation Steps

Step 11: Cable Management

1. Secure all cables with zip ties or cable clamps
2. Protect cables from chafing and sharp edges
3. Create service loops at connections for future maintenance
4. Apply protective covering where cables may contact frame

Step 12: System Documentation

• Record all settings and configurations
• Take photos of installation for future reference
• Keep warranty information and receipts
• Create maintenance schedule reminder

Post-Installation Checklist

• [ ] All connections secure and properly terminated
• [ ] Controller securely mounted with adequate cooling
• [ ] All cables properly routed and protected
• [ ] System powers on without error codes
• [ ] Throttle responds smoothly and proportionally
• [ ] Brakes function properly and cut motor power
• [ ] No unusual noises or vibrations during operation
• [ ] All safety systems functional
• [ ] Performance meets expectations

Maintenance Schedule

Weekly:

• Visual inspection of connections
• Check for loose hardware

Monthly:

• Clean controller heat sink
• Inspect cable routing and protection

Quarterly:

• Verify torque on all power connections
• Update controller firmware if available

Annually:

• Complete system inspection
• Replace consumable components as needed

Warranty Information

Installation must be performed according to this guide to maintain warranty coverage. Improper installation may void warranty. Contact technical support if you encounter any issues during installation.

Technical Support Contact:

• Email: [support email]
• Phone: [support phone]
• Online: [support website]

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Note: This guide provides general installation procedures. Always refer to your specific controller manual for model-specific requirements and specifications. When in doubt, consult with a qualified technician.