How to Upgrade Your Pre-2019 Voltbike Hub Motor to a New Electrical System

Update your old VoltBike Hub Motor to a new Electrical System

for: Pre-2018 Voltbikes that use JST style electrical connectors, Black plug
screens 6 Pin Display Screens and cable harnesses, old style controllers , old PAS sensors, and older light systems.

Tools/ parts required:

- Phillips screwdriver
- Zip tie cutter / zip ties
- Square taper crank puller ( for axle mount PAS sensor)
- Metric Hex tools

WARNING

Installation of the 48V battery and/ or electrical components should only be done by a qualified person. Incorrect installation or failure to follow this warning may result in personal injury or death, and/or loss of property.

Introduction

Pre-2018/2017 Voltbikes typically use JST clip style electrical connectors for controllers and other electrical components. It uses a LCD screen with a round black plug, an older style PAS sensor, and an older light system using a variety of connectors. Some old bikes may also use a large plug controller or larger plug motor which is also considered obsolete.

Post 2019 models and all new modern bikes use round Higo style connectors which tend to be more durable and water resistant. These include green plug screens and cable harnesses, yellow round plug axle mount PAS sensors, throttles, and red/blue plug light systems.

Check the current system

To determine what style of parts your older bike has: the controller, screen plug, and motor plug all need to be examined. Photos can be sent to Voltbike to confirm. A check of the male/female black/red power connectors should also be checked to ensure they match.

The customer can look for old style controllers and electrical parts on Amazon or Ebay. Votlbike can provide support on purchases of older electrical parts but the responsibility lies with the customers to ensure the correct part is purchased.

Option to Upgrade to a new Electrical System

Once the current style of electrical parts and connectors has been confirmed there may be an option to upgrade the entire electrical system of the bike. This typically requires a new internal or external controller, a green plug cable harness, green plug 860 screen, throttle, and yellow plug axle mount PAS Sensor, The front and rear light may also not work so you may want to upgrade the lights, but it's not critical to make the bike work. If the battery is old, depleted, or bike damaged the customer may be advised to purchase a new bike instead of attempting an upgrade.

As long as the motor is fully functional the bike will work if these parts are replaced:

Internal Controller  or External Controller 

Cable Harness 
Throttle 
PAS Sensor 
860C screen (5-pin, green plug) 
Rear Light with blue plug cable 
Front Light with cable harness 

Contact us for a full-package price of $599

Adapter cables may be available to convert older LG 3-prong plug controllers or motors
to newer 9-pin small plug controllers and hub motor plugs. Please contact us if your motor cable has a 3-pin connector. 

Note: see other articles in our HELP CENTER related to installing new
controllers or electrical parts.

https://voltbike.com/a/support/support-repairs-and-service/external-controller-installation