For the lighting and horn system I wanted to keep it pretty simple with a headlight, tail light, brake light, front and rear turn signals and a horn. I also wanted to be able to control everything with handle bar switches. The following is a schematic of how I wanted to lay everything out:
I went ahead and added a 60v to 12v 10a step-down DC converter, to be able to run regular LEDs for my lighting and a 12v horn. I wanted everything to be nice and neat so I ended up running all of my wires for the front lights using the old tachometer as a junction box.
For the right switch, the ON/OFF controls power to both the Headlight and Tail light. The bottom button is the right horn button.
For the left switch, the HI/LO is the Headlight/Daytime Running Light (DRL). The middle 3-way ON/OFF/ON switch is the left and right blinker. The bottom button is the left horn button.
Next up was to tackle the brake light system. This part was a little tricky because I wanted the brake light to be triggered when either of the brake levers were depressed. There are a couple of ways to do this, the easiest is if your motor controller has a brake light output wire. However the controller that I was planning on purchasing did not. I once again scoured the internet looking for options and stumbled upon a great post on Endless Sphere forums that had exactly what I was looking for: https://endless-sphere.com/forums/viewtopic.php?f=2&t=75171&sid=2c7e5bfdad2e249c423274b408d7ed10&start=25 The post uses an octocoupler relay to trigger the brake lights.
I ordered the relay off of Amazon and tied it into my brake levers. The results were great! I now have a working brake light.
At this point, I had already chose the motor controller I was going to be using. The controller was wired for both a standard battery output for lighting and a switched battery outputt controlled by the LCD screen. I was using the standard battery output to run my 12v system and wanted to make use of the switched output. I decided to tie in some led strips to the switched output for some cool under lighting! The only problem was the out put would be too high for standard LEDs, so I chose to run 4 stands of LEDs in series to drop the voltage down to ~12v per strand.
After the wiring and installation was complete, I was able to test all the lighting using a 42v power supply that I had.
With all of the lighting and horn functional, the last steps will be to wire the motor controller, the motor, accessories and battery.
The Electric Moped Project 