Puch Wiring Diagram

When it comes time for rewiring a Puch Maxi Moped, the task seems a bit daunting.  Even with a wiring diagram, you can get lost among all the symbols, switches, grounds, and whatever else is on that page.  With zero electronics experience, I was the same way.

Luckily Clint, a fellow Tom Cruiser, came to the rescue with his black belt in the art of electrons. He’s our electrical dude in the crew, so we got down to business documenting the fastest/easiest way to wire a Puch Maxi.

DISCLAIMER UNO: I am in no way proclaiming the following to be the best way to accomplish this task. What it does illustrate is a quick and simple way to get the bike’s electronics running.

DISCLAIMER DOS: This setup has front and rear lights as well as a kill switch; no turn signals, brake light, hi beams, etc.  If that’s your steez than look elsewhere for help.

WHAT YOU NEED

Come correct with some 16 gauge wire, a wiring block (at least 3×2), a pack of wire connectors, some pliers for crimping, and optionally, solder and resin.

LOOKING AT THE STATOR

Puch Stator

An insect from the year 2090

The stator has six different colored wires coming from it.  Here’s what they do:

Grey – Originally this would power your tail light. For this installation you can leave it alone.

Green – This would power the break light.  Once again, leave this out.

Green & Black – This is to be grounded to the frame.

Blue – This goes into the wiring block and then to the ignition coil.

Blue & Black – This is also to be grounded to the frame.

Yellow - This goes into the wiring block and is split into two wires – one for the head light and one for the tail light.

HOOKIN IT UP

Puch Wiring Block

Click to Biggie size

First, I’ll assume the stator is in place with the wires threaded through the little rubber guy on top.  Take the Yellow, Blue, and Green & Black wires and attached them to one side of the wiring block.  Next, attach the Blue & Black wire to the same terminal as the Green & Black.

Now for the other side of the block.  Stick the Blue wire and a Black wire in the same terminal across from the Blue wire.  The Black wire will run to your kill switch and the Blue wire will connect to the ignition coil.

Across from the Yellow wire, stick in two wires (in the picture they are both blue).  One will run to your headlight and one will go to the tail light.

For the headlight, run the wire under the gas tank up to the headlight, put a female connector on it and attach to the male end in the headlight.  This particular headlight is already grounded inside the assembly.

Headlight Female Wire Connector

Headlight Female Connector

For the taillight, run the wire under the rear fender, connect a female connector and attach it to the correct male prong on the assembly.  It is usually marked, but just use your eyes to see which prong leads to the main bulb.  Then, take a short piece of brown wire and put a female connector on one end and a round connector on the other.  Connect the female end to the ground prong (probably marked with a “G” or look for the prong that leads to nowhere) and the round end to one of the bolts that hold the light to the frame.  You will probably need to sand off some paint where this touches to ensure a good ground.

Tail Light Connections

The connections in the taillight assembly

Taillight Ground

You’re grounded

Sanded Frame

Don’t worry it’ll be hidden

Back to the wiring block.  Across from the Green & Black and the Blue & Black wires, stick in a Brown wire and ground that somewhere, but the easiest is to ground it where the ignition coil is grounded.

Grounded

Both grounds hooked together

And that’s it!  Start that Maxi up and starting fixing something else that’s wrong with it.

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