72V ONYX RCR Kelly Controller Guide

This is the definitive technical reference for the stock Kelly KLS7230S controller used on the 72V ONYX RCR. It explains how power really moves through the bike, how the Kelly controller shapes that power, where heat and voltage become the true limits, and how to tune, diagnose, and upgrade the system without damaging the controller, motor, or battery.

This guide is written for riders who want to understand what the bike is doing electrically and mechanically, not just copy settings. It walks through battery vs phase current, back EMF, field weakening, regen behavior, throttle mapping, controller fault codes, wiring, speed limiting, stock ONYX settings, and realistic upgrade paths based on temperature, voltage, and battery health.

Quick Overview

If you remember nothing else, remember this:

• Voltage sets your speed ceiling
• Phase amps create launch torque
• Battery amps create heat, sag, and battery stress
• Battery amps and phase amps are not the same
• Back EMF is why acceleration dies at high speed
• Field weakening raises top speed but adds heat fast
• Regen strength is entirely software-controlled
• The stock Kelly is reliable but intentionally conservative
• Proper throttle setup dramatically improves control and usability
• Real performance gains start with the battery, wiring, and cooling
• Continuous power is limited by temperature
• Short bursts are limited by controller protection

Everything else in this guide explains why these rules exist and how to work within them safely on a real ONYX RCR.

Connect Android to AC Aduser

• Inexpensive Android Phone

To program the Kelly controller with the AC Aduser app, you need either an Android phone paired to the Kelly Bluetooth module or a Windows laptop connected with a USB-to-RS232 cable. ONYX bikes built before summer 2022 (V1.0 and V1.2) typically use the older white Bluetooth EDR module, which does not work with iPhones. Newer models like the V1.5, V1.75, and LTD use the black Bluetooth BLE module, which supports both iPhone and Android.

To pair the white Kelly Bluetooth EDR module with Android, turn the bike on, open your phone’s Bluetooth settings, and wait about 30 seconds. The module will appear as an 8-digit number such as 21072647 with no colons. A blinking red light on the dongle is normal. It will not appear as “ONYX RCR” since that name usually belongs to the battery’s Bluetooth, especially if it has been renamed.

• Turn on your ONYX RCR.
• Open the Bluetooth menu in your Android device’s settings.
• Pair your ONYX RCR Bluetooth
• Enter the pairing password: “1234”.
• Launch the Kelly app (AC Aduser).
• At the warning screen, tap “Yes”.
• On the next screen, choose “Bluetooth”.
• Tap the Bluetooth ID you paired earlier.
• Connect: Tap “Connect” on the AC calibration screen.
• Once the status shows “Connected” in green, tap “Read” to load the controller’s data.

Note: Samsung phones on Android. If you see an “Unsafe App Blocked” message, tap “More details” to try bypassing it or adjust Samsung security settings to allow the app. Step-by-step walkthroughs are available on YouTube.

Use the Kelly software to read and write settings.

• AC Aduser Android App Download
• AC Aduser Windows App Download

Supported platforms:

• Android (Bluetooth)
• Windows (USB or Bluetooth)

Connection options:

• White Bluetooth module (older bikes)
• Black BLE module (newer bikes)
• USB to RS232 cable

All use JST SM 4 pin connectors.

Motor Calibration Pairing

Whenever you replace a motor or controller, calibration is required.

Supported pairings:

• Kelly Controller + QS 205
• Kelly Controller + QS 260
• Kelly Controller + QS 268
• Kelly Controller + QS 273

⚠️ Safety Warning

Before calibration:

• REMOVE THE PEDAL CHAIN
• Raise rear wheel at least 6 inches
• Keep area clear

The wheel can spin at full speed during calibration.

Calibration Steps

Change Motor Identify Setting

• Open AC Aduser via Android or Windows software
• Set Motor Identify EN = 170
• Click Write
• Power OFF bike
• Power ON -> motor calibrates (~60 sec)
• Power OFF, then ON again
• Confirm Motor Identify EN reset to 85

Default:

• Normal: 85
• Calibration: 170

Common Motor Problems

If the bike clicks and won’t exceed ~10 mph:

Likely a hall sensor issue.

Start here:

• Inspect motor wires near axle
• Check brake drag
• Torque axle nuts to 80 Nm
• Check phase wire junction box
• Inspect controller LED
• Trace internal harness

Hall Sensor Quick Test (John Angel Method)

• Power on bike
• Lift rear wheel
• Spin wheel by hand
• No speed reading -> hall or controller issue
• Switch to backup hall connector and repeat

Multimeter Hall Sensor Test

Tools:

• Digital Multimeter
• Hall Tester

Procedure:

• Red = +5V
• Black = Ground
• Yellow/Green/Blue = signals
• Voltage should toggle 0V ↔ 5V while wheel spins

Simple Overview: How Power Flows

ONYX uses a three phase motor system:

Battery (DC) to controller to motor (AC phases)

What each part controls:

• Battery voltage is top speed headroom
• Battery current is battery stress and voltage sag
• Phase current is launch torque
• The controller shapes how safely power is delivered

Horsepower, Torque, and Speed

1 kW is about 1.34 HP
Stock RCR is about 7.2 kW

Battery Amps vs Phase Amps

Example:

72V × 100A is 7.2 kW input
Phase current during launch can be much higher than battery current

Back EMF: The High Speed Wall

As RPM increases:

• The motor generates voltage
• Available current drops
• Torque falls off

When back EMF is close to battery voltage:

Acceleration stops

The two real ways around it:

• Higher battery voltage
• Field weakening

Field Weakening

Field weakening changes timing so the motor can spin higher at the same voltage.

It works, but it costs heat.

Results:

• Higher top speed
• Better high speed pull
• More heat

Typical gain:

about 20 to 30 percent

Kelly field weakening setting

Parameter: Min Excitation

Monitor motor temperature closely.

Regenerative Braking

Regen is controlled by the parameter:

RLS_TPS Brk Per%

This defines how strong braking is when the throttle is released.

Recommended tuning:

• Adjust in steps of 5 to 10
• Test ride after each change
• Higher regen means more braking and more motor heat

Cruise Control

Cruise Control can’t be programmed. It activates automatically every time you hit 30 mph and hold the throttle steady for 5 seconds, as long as it is enabled.

Boost Feature

Avoid enabling the boost feature. It can weaken the controller. Activating boost requires additional physical modifications, which are not recommended.

ONYX 72V RCR Kelly Controller Settings

This is the full stock settings list.

Aftermarket Controllers: When to Upgrade

Benefits:

• Higher current limits
• Better cooling
• Faster acceleration
• Higher top speed
• Advanced tuning

Popular 72V Controller Options

ONYX Left Handlebar Controls

Always use stock controls when possible. Aftermarket controls require rewiring.

Purchase Links:

• Stock Left Controls
• Aftermarket Left Control

Aftermarket Left Control Wiring

The ONYX Blocker Matrix (Speed Limiter)

Newer ONYX bikes include a plug in speed limiter called the Blocker Matrix.

How to Disable It

• Open battery cover
• Find the green single pin connectors
• Disconnect the paired plugs
• Reconnect matching colors together

Your bike will immediately return to full speed.

Removing the Module

• Remove side panel
• Unplug the module between throttle and harness
• Store it if needed

Completely plug and play.

Kelly controller LED codes

This section explains how to read the small lights on the Kelly controller when something goes wrong. The green light shows if the controller has power and is working normally, while the red light flashes in patterns to tell you what problem it has detected. Each flash pattern matches a specific issue, such as a battery voltage problem, wiring or sensor problem, throttle issue, overheating, or an internal fault. By counting the flashes and checking this table, you can quickly figure out what is wrong and what to look at first, instead of guessing.

There are no user serviceable parts inside the controller.

• Green LED off usually means power, fuse, or wiring issue
• Green on is normal operation
• Green and red on together often means software or voltage problem
• Red blink codes point to wiring, voltage, temperature, or throttle faults
• Auto Identify failures are commonly hall or phase wiring related

Green LED Codes

Red LED Codes

These are shown in the manual as code pairs like 1,1.

Stock Throttle Setup

Most ONYX bikes only use about 60% of their throttle travel by default.

That causes:

• Jerky low-speed control
• Accidental over-throttling
• Reduced range
• Poor power modulation

By adjusting TPS dead zones and the throttle curve, you can unlock nearly the full throttle range and dramatically improve how the bike rides.

Throttle Dead Zones (TPS Dead Low / High)

By default, the controller ignores large portions of your throttle movement.

Default values

What this means

• First 20% = no response
• Last 20% = full throttle
• Only 60% actually controls speed

Optimized Dead Zone Settings

Results:

• Bike responds almost immediately
• Maximum speed only at the very end
• 90% of throttle travel becomes usable
• Much smoother control

Stock Throttle

• TPS Dead Low usually cannot go below 18%
• TPS Dead High can safely be raised to 95%

This still improves usable travel significantly.

TPS Forw MAP (Throttle Sensitivity)

This setting controls where power is concentrated in the throttle range.

Recommended:

• 50% for linear daily riding
• 30-40% for smooth city control
• 70% only for aggressive riding

Throttle Curves Explained

Throttle curves reshape how fast power ramps in.

Stock / Logarithmic Curve

• Big torque immediately
• Fun but inefficient
• Drains battery faster
• Weak at high speed

Exponential Curve (recommended)

• Gentle low-speed power
• Strong mid-to-high speed pull
• Better range
• More precise control

This is ideal for Sport Mode and high-power setups.

Recommended Throttle Curve Settings

Try this test:

• Cruise slowly in Sport Mode
• Do a few pulls from 25 mph
• Then full throttle from a stop

The difference is immediately noticeable.

Real-World Benefits

After tuning:

• Throttle becomes predictable
• Low-speed riding is easier
• Fewer accidental wheelies
• Longer range
• Better control in high-power modes
• Domino throttle becomes far more usable

This setup is especially important for Sicko Mode.

Domino Throttle Setup

Before touching anything electrical:

• Turn the bike on
• Disconnect the battery
• Wait a few seconds for the system to discharge

This prevents shorts, controller damage, and accidental sparks.

Tools You’ll Need

Mechanical crimps are preferred over solder for reliability and vibration resistance.

• Brass crimp terminals
• Self-adjusting wire stripper
• Wire crimping tool
• Dual-temperature heat gun
• Electrical loom tape
• 30mm heat-shrink tubing

Domino Throttle and Switches

Use these known-compatible parts to match the wiring tables below:

• Domino Twist Full Grip Throttle
• Triple Switch - ON/OFF/ON

If your switch uses different colors, request a wiring diagram before proceeding.

Good Lighting

Work in a bright area. Misreading wire colors can permanently damage the controller.

Mode Switch Wire Warning

The yellow and green wires are both positive on the ONYX RCR.

• Never allow them to touch while powered on
• Doing so will damage the controller instantly

Avoid Soldering

For vehicle wiring:

• Crimping is stronger under vibration
• Handles heat cycles better
• Maintains lower resistance
• Avoids brittle joints

Only solder:

• Battery charge connectors
• Battery discharge connectors

Everything else should be crimped.

Domino Throttle Install Instructions

This install reuses the stock throttle harness. No new wiring runs are required.

Preparation

• Cut the Domino throttle connector off (leave 1 inch)
• Locate the stock throttle cable
• Cut it 2 inches from the throttle housing

Harness Prep

• Slide 5 inches of heat-shrink onto the bike harness
• Strip 2 inches of outer insulation from all bundles
• Strip ½ inch from each individual wire

Wiring

• Match colors using the tables below
• Crimp each joint
• Wrap each joint with 1½ inches of loom tape

Testing

• Reconnect battery
• Power on
• Test throttle
• Test power switch
• Test mode switch

If all works:

• Power off
• Slide heat-shrink over joints
• Shrink evenly using heat gun
• Stop once fully sealed

Domino Throttle Wires

Power Switch Wiring

Triple Switch (Blue, Red, Brown)

Double Switch (Blue, Red)

Mode Switch Wiring

Triple Switch (Blue, Red, Brown)

Triple Switch (Black, Blue, Brown - discontinued)

• Older ON/OFF/ON variant
• Still usable if found

Final Notes

• Double-check wire colors before crimping
• Never test wiring with exposed connectors
• Do not hot-plug switches
• Keep harness strain-free

A clean throttle install improves response, reliability, and long-term controller health.

ONYX 23Ah and 41Ah Battery Aging Limitations

The ONYX 23Ah and 41Ah battery packs are now well into their aging curve and no longer deliver their original capacity or peak discharge performance. In real-world use, this typically appears as a 10 to 20 percent reduction in usable range and roughly a 15 percent drop in maximum output. As the cells age, internal resistance increases, which causes deeper voltage sag under load and noticeably higher battery temperatures during hard acceleration and sustained high power use.

At this stage, both packs have very limited tolerance for being pushed beyond factory limits. Operating above the stock Kelly controller current levels significantly increases the risk of permanent cell damage. High-current modes such as SICKO MODE or FarDriver JAWS MODE can over-stress individual cells, trigger localized overheating and accelerated cell degradation, and cause irreversible capacity loss. In severe cases, this can render the pack partially or fully unrecoverable.

For reliability and long-term safety, these batteries should only be operated within the DC current, DC boost, and AC phase current limits listed below.

ONYX 23Ah DC Current and Phase

• DC Current Amps: 40A to 50A
• DC Boost Current: 55A to 60A
• AC Phase Current: 120A to 150A

ONYX 41Ah DC Current and Phase

• DC Current Amps: 80A to 90A
• DC Boost Current: 90A to 100A
• AC Phase Current: 180A to 240A

Final Advice

Learn voltage, current, and heat before chasing speed.

Tune one setting at a time and log the result.

Respect battery limits, especially on aging 23Ah and 41Ah packs.

Keep regen conservative and temperatures visible.

Never increase controller current without upgrading wiring and cooling first.

Do not enable features you do not fully understand.

And remember:

• Controllers are easy to replace.
• Motors are expensive.
• Batteries are the hardest to recover from damage.

Build in layers. Test between changes. Let temperature be your guardrail.

That is how you get real performance from an ONYX RCR without turning parts into consumables.