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Help with battery to controller connection

Old 06-04-21, 03:29 PM
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jojimbo
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Help with battery to controller connection

I'm just about finished with my build but unfortunately the wires for power coming from the battery base and the ones coming out of the controller don't match. Am I SOL or is there anything I can do?

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Old 06-04-21, 04:12 PM
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2old
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Very easy solution. Just procure a connector set (I use XT-90's with spark arrest; got mine with "pigtails" from Luna Cycle, but they're everywhere) and solder or use crimp connectors to join. If you get them with "pigtails" you don't need to worry about the plugs, just connect the wires. Experts like DY probably don't need to do this.

Took a second look and if you can find the appropriate "bullets", you only need to put them on the bare set; however, I'd get a more durable system.
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Old 06-04-21, 04:20 PM
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jojimbo
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Originally Posted by 2old View Post
Very easy solution. Just procure a connector set (I use XT-90's with spark arrest; got mine with "pigtails" from Luna Cycle, but they're everywhere) and solder or use crimp connectors to join. If you get them with "pigtails" you don't need to worry about the plugs, just connect the wires. Experts like DY probably don't need to do this.
You're a lifesaver, so a connector isn't necessary? I can just connect them directly, solder and put a sleeve over the connection? Alternatively I do have a few of these connectors from a fuse kit, i'm not sure what they're called though.
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Old 06-04-21, 04:30 PM
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FME, with the high voltage going through the wires, I would use good connectors. Also, you can, but i wouldn't connect them directly because you'll want to separate the battery from the controller IMO. See what others have to say. I'm a Chemist not an EE or anything close.
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Old 06-04-21, 08:10 PM
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Originally Posted by 2old View Post
FME, with the high voltage going through the wires, I would use good connectors. Also, you can, but i wouldn't connect them directly because you'll want to separate the battery from the controller IMO. See what others have to say. I'm a Chemist not an EE or anything close.
Gotcha, thanks again, really appreciate the help
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Old 06-05-21, 07:43 AM
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Don't use the squeeze connectors in the picture. They will get hot and melt.

Go to the automotive store and buy some crimp-on bullet connectors, and a suitable crimp tool. Pliers don't work very well, You could also crimp the wire together directly if you never plan to disconnect the controller.

Or if you can solder, use XT60's or XT90's. Better solution.
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Old 06-07-21, 12:48 PM
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The only good solution is XT90.

Any other connector will spark when connecting and that can cause long term problems. If you only disconnect the battery once a year, it may not be a problem, but if you regularly take the battery off the bike, solder in some xt90's.

Bullet or other connectors don't seem to make a very solid connection in my experience. I've done it, but it didn't work out well.
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Old 06-14-21, 09:55 PM
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Skotchlok is a definite NO! Cannot handle any current.

XT90's are great and can easily be soldered.

If you have a good shop they can crimp on a set of andersons OR the bullet connectors like in your pic.

I use and do them all.

-SP
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Old 06-15-21, 07:28 AM
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I use the XT 60's and solder the connections, and cover the soldered connection with shrink wrap plus a bit of electrical tape for good measure. But all the batteries i use have an on/off switch built in.so when a battery gets removed I just switch it off. The one battery that does not have a switch just gets removed from it's cradle before being disconnected.
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