Hardwiring a Puch

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IMPORTANT Safety notice and Legal disclaimer :: OFF-ROAD USE ONLY!

The modifications discussed in this article are neither designed nor intended for vehicles which will be operated on public roadways. The simplified electrical system presented here will completely disable the function of the vehicle's brake light, horn and turn signals. Operation on public roadways without a working brake light, horn and/or turn signals is extremely dangerous and this article shall in no way be construed as to encourage such illegal and/or dangerous acts. This information is presented here for educational purposes only, and Mopedarmy.com ("MA") and the authors / editors of this article explicitly disclaim any and all liability for the actions of others deriving solely or partially from the contents of this article.

Hardwiring a Puch moped

In the Puch service manual, pages 118 through 121 contain the actual wiring diagrams which can be a helpful reference. It can be viewed here or downloaded (in PDF) here.

All of the following information was found on http://www.MopedArmy.com.

Here's a topic addressing the horn issues in the Magnum stock wiring.

Hardwiring.jpg Note: Headlight is yellow, taillight is gray, and coil is blue

Basic instructions (edited somewhat):

Remove the whole wiring harness. Have some ring connectors and female spade connectors on-hand. You'll also want wire cutters, and crimpers for the connectors.

Dissect the harness by pulling the wires out of all the tubing (re-use tubing as well) and lay it all out. Follow this to get it running and later clean up all the “too long” length of wires:

yellow wire from statorrun to headlight and ground headlight nearby (brown wire)
green wire from statorrun up to one brake light switch and blue/green back to junction block and blue/green wire from stop light
gray wire from statorgray of taillight (make sure taillight is grounded)
green blackground to frame
blue/blackground to frame
blue wire from statormeets blue from coil and coil should already be grounded

Put another short blue wire into same terminal as blue coil wire. use this and touch to anything metal to kill the bike. Later you can run this wire to a kill switch and ground the switch.

click the number next to this to see an example uploaded by Cory on how to hardwire--> [[1]]

p.s. the brown wires are ground wires