Replacing a PWM controller

There are two methods to mount a PWM controller. One methods uses a bracket to hold the controller to the mounting plate. The other uses four screws to hold the controller to the mounting plate. Check which method your Pukka uses by removing the black battery cover and looking at the controller located in front of the batteries.

Click here for Mounting Bracket Method

Screwed to Mounting Plate Method

Replacing the PWM controller by this method involves removing the battery, disconnecting the components that plug into the controller, and installing the new controller.

Remove the battery cover by loosening the bolts on the bottom of the battery tray.

Raise or remove the seat to allow access to the battery cover. Slide the battery cover to the rear and lift the cover.

Remove the two metal brackets that hold the batteries in place.

Disconnect the charger wires (thin red and black wires from the charger port) and controller wires (yellow and green wires from the controller) from the red and black terminals at the front of the batteries. Then, remove the batteries from the tray. It is not necessary to disconnect the fuse harness on the back terminals.

Four screws hold the PWM controller to the mounting plate. Remove these screws and the controller will hang free.

Disconnect all wires that plug into the controller. There will be four wires at the bottom of the controller for the throttle, ignition switch, Parental Speed Control (PSC) switch, and the brake shut off. The two sets of thicker wires on the top are for the motor and the battery.

Install the new controller by connecting the components. The wire connectors should only match with the appropriate component. The yellow and green wires connect to the battery. The yellow wire is the positive (red terminal on the battery) and the green wire is the negative (black terminal on the battery).

NOTE Remember to connect the thin red and black wires that come from the charger port on the side of the Pukka to the positive and negative terminals of the batteries. Without them, your Pukka will not charge.

Attach the controller to the mounting plate.

Replace the batteries and secure them with the two metal brackets.

Replace the battery cover and seat.