What are the Basic Steps to Change My Main Wire Harness?Updated 18 hours ago

Replacing the main wire harness on your electric bike requires careful preparation and attention to detail. Follow these step-by-step instructions to ensure a safe and successful replacement.

Safety Preparation

Before beginning any work on your bike's electrical system, it's crucial to eliminate all power sources:

1. Turn off all power to the bike and remove the battery completely
2. Power cycle the bike to dissipate any remaining energy in the controller system
3. Disconnect all cablesconnected to the main wire harness, including:
   • Display unit
   • Throttle
   • Headlight
   • Combination switch (for bikes with turn signals)
   • Motor cut-off switches

For detailed instructions on safely dissipating controller energy, refer to our power cycling tutorial.

Locating the Controller Connection

The connection point between your controller and wire harness varies by bike model. Locate the multi-pinned round connector based on your specific model:

X-Class (pre-2025 models): Inside the controller box located in the down tube

Grizzly Gen 2 & 3: Inside the cable box positioned under the saddle

Kepler: Near the bottom bracket inside the frame

X-Class 60V: On the underside of the frame, under the saddle, covered by the controller cover

Preparing the Guideline

A guideline will help you thread the new harness through your bike's frame without getting stuck:

1. Select appropriate guideline material such as:
   • Paracord
   • High-test fishing line
   • Old shifter cable
2. Secure the guidelineto the end of the existing wire harness using electrical tape, ensuring a tight, secure connection
   1. Tie off the end of the guide line near the controller mounting location so that the guide line does not pull into the frame.
3. Use adequate length - approximately 4 feet provides sufficient slack for maneuvering

Important: Avoid using baling wire, as it may damage cables during the threading process.

Removing the Old Wire Harness

1. Move to the front of the bike
2. Carefully pull the wire harness through the frame until it emerges completely
3. Keep the guideline attached and in place for the next step

Installing the New Wire Harness

1. Attach the controller end of your new wire harness to the guideline
2. Slowly feed the new cableinto the frame from the front:
   • If the cable becomes stuck, gently pull it back slightly
   • Push forward again to navigate around frame obstructions
   • Take your time to avoid forcing the cable through tight spaces
3. Once the harness is fully threaded through, connect it to the controller
4. Reconnect all peripheral cables in reverse order of disconnection

Final Steps

After installation is complete:

• Reinstall your battery
• Test all electrical components to ensure proper functionality
• Secure any loose cables with appropriate cable management

Need additional assistance? Contact our support team if you encounter any issues during the wire harness replacement process.