How to Connect the Brake Cut-off Wire?
2 Answers
The brake lever's cut-off switch has two wires in total. Connect the green wire to the positive terminal of the power indicator on the dashboard. Locate a connector with a black wire, and use a multimeter to measure its voltage, ensuring it is below 12V. Apply power and slowly rotate the throttle to make the motor turn gently. Use a thin wire to short-circuit the two wires of this connector. The wire that causes the motor to stop when shorted is the brake cut-off wire. Connect the black wire from the brake lever's cut-off switch to the brake cut-off wire on the controller.
I've been repairing cars for decades and am very familiar with handling broken brake wires. The connection method for brake wires prioritizes safety first, especially concerning brake lights—it's dangerous if others can't see you braking. Specific steps: First, use wire strippers to strip a section of insulation from both ends of the broken wire, exposing the copper strands. If you have connectors like quick splices, insert the copper strands and crimp them tightly; if not, solder them securely with a soldering iron, but be careful not to burn yourself. After connecting, always wrap the joint with electrical tape or heat-shrink tubing to prevent short circuits. Then, test by pressing the brake pedal to see if the light turns on. If the wiring is aged or damaged, inspect and replace it as needed. The brake system is a lifeline, so I always emphasize these details during repairs to avoid similar issues. Having all tools ready and working in a quiet environment makes the job easier.
