Part 1 - Locating and Installing the Controller

Original Controller's Location

New Controller's Location

These 2 pictures show the 2 different controllers in their locations, along with the relative location of the other components mounted.

The new controller is noticeably larger than the original one. This necessitated the repositioning of the Throttle Position Sensor (TPS) and the voltage regulator to accommodate the new controller as seen in the picture. BTW, I have no idea what Daymak officially calls these components so I picked generic descriptive names.

Note 1: The throttle position sensor is the black square unit that the throttle cable goes into on the left side and an electrical connector coming from the right side. The signal provides the proper throttle position information to the controller.

Note 2: The voltage regulator takes the high voltage from the battery pack and regulates it down to 12 volts so the accessories such as lights, horn etc can function properly.

The TPS had to be moved down one row of slots and over to the right to clear the chain guard. This however causes the body of the TPS to overhang unsupported which would likely cause it to break. So I added a metal plate to the back, connecting the top bolts to the bottom of the TPS. If you look carefully at the picture you'll see the strap extending from the bottom. This provided the needed support for off-road driving.

I mounted the controller in such a way that the top mounting holes were above the slotted mounting plate. To make this secure, I put two metal plates behind the mounting plate that reached above and allowed for secure mounting. (See pic below).

Notice the 2 vertical metal straps added to secure controller

I had to position the Voltage Regulator below the controller next to the TPS. It was mounted after the controller was mounted, and overlapped part of the controller. I used self tapping screws to secure it.

My goal was to set this up in such a way that the original controller cover would fit properly back into place. To do this, the new controller had to be positioned properly so the right side of the controller was butted up to the installed cover. This worked fine, with room to spare on the left side for the wiring.

The Bluetooth module was located on the top of the controller using 3M double sided mounting tape. This provided an area high on the bike and out of the way. I wire tied the wires coming from the Bluetooth module to keep them secured.

Completed installation of components. Ready for wiring

Note 3: The TPS needs to have freedom of rotation, so be aware of how the wiring is routed around it, especially with the large cables coming from the battery pack.

Now that we have the controller installed, we need to wire it properly. This proved to be a bit of a challenge. This will be the subject of Part 2.