How to Connect the Brake Cut-off Wire?
3 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.
I'm a car modification enthusiast and have personally worked on brake light wiring repairs. The method isn't difficult: After locating the break point, I prefer using crimping pliers and copper sleeve connectors—strip the insulation from both ends, align the copper wires, and firmly crimp the connection point with pliers. Then test it: press the brake pedal to confirm the light comes on (if it stays dark, check the switch or fuse). Remember to insulate the connection thoroughly—wrap it generously with electrical tape to prevent shocks. Brake light failure is extremely dangerous, especially when driving at night—last time my connection wasn't secure and I nearly had an accident. I also recommend checking all vehicle wiring for aging while you're at it, as modified cars often deal with this issue. DIY saves hassle, but you need complete tools; if unsure, consult a professional to fix it.
