How to: Replace S18 control board
How to:
Replace S18 Controller
- Remove the left-side shell(screw locations are colored dots in the picture below):
- On the left side of the unit pop off the rear outer plastic cover by carefully levering out the 2 plastic clips. The clips are located on the widest part of the rear plastic cover. Repeat for the clips on the right side.
- Unscrew the small screw holding the mud-guard in, the 2 long screws holding the back of the inner-shell to the right side inner-shell, and the 3 screws securing the shell to the left-rear battery(yellow).
- Remove the 2 screws beneath the foam on the front of the unit that secures the front outer plastic cover to the shell (green).
- The front plastic cover has clips on the front to attach it to the shell. Carefully pop off and remove the front outer plastic cover.
- Remove the 4 screws holding the inner-shell to the front battery (blue).
- Finally, remove the black screw towards the top in the foam gap, and the silver screw underneath the foam at the top of the shell(cyan).
- Pull away and remove the left-side shell.
- Remove the motor wire cover:
- Remove the 6 screws securing the motor wire cover.
- Under the cover, silicone is used to waterproof the compartment. Sometimes the silicone can stick to the wiring and cover. Carefully remove the motor wire cover so as not to damage the wiring. You may need to cut the cover away from the silicone.
- Remove the 2 screws on the grey slider above the wiring compartment.
- Above that, you'll see a 90-degree wire protector. Remove the 4 screws securing the plastic 90-degree protector. Remove the wire protector.
- Disconnect the power and hall wires. Carefully thread these wires up through the hole where they enter the wiring compartment so that the wires are free from the cavity.
- Remove the 6 screws securing the motor wire cover.
- Remove top panel:
- Remove the 2 rubber covers, located at the top front of the unit. They sit on the left and right sides, jammed between the top panel and front plastic panel.
- The top cover is secured by 8 screws, 4 on each side. Remove the left side screws first. Remove the 2 self-tapping screws located at the front of the top panel, behind the previously removed rubber covers. Repeat for the other side.
- Remove the 2 machined screws ¾ of the way towards the rear of the top panel on the left side.
- On the right side, remove the 2 cyan screws securing the shell. Bend the outer panel to access the 2 machined screws in the step above on the right side.
- Remove the top panel.
- Disconnect batteries:
- Note: Be very careful to not touch any board components with metal as the board is still energized.
- Disconnect the front batteries by carefully pulling the connectors free of the controller.
- Remove the screw on the rear battery wire guide. Repeat for the other side.
- Disconnect the rear batteries by carefully pulling the connector free. Using a flathead, or equivalent, to tap down on the ridge of the connector can help prevent excess wire tension.
- Discharge the board by holding the power button down for 10 seconds.
- Remove the controller:
- Remove the 10 screws on the top that secure the board to the frame. There are 8 screws in a 2x4 grid at the rear of the controller, and 2 screws towards the front, located by the trolley arms. These screws are indicated in the picture below.
- Remove the 2 screws at the rear of the unit that secures the tail light plastic. Remove the tail light plastic.
- Carefully pop the board free of the frame and pull it up. Remove the wire cover next. Note: Kingsong has gone through 3 different iterations so far of the wire cover.
- The most recent version has 2 screws from above that secure the wire cover. The intermediate version has 2 screws from above that thread into tiny nuts under the wire cover. The first version has 2 screws that come up from the bottom of the frame. Remove the screws/nuts and remove the wire cover.
- Chase the wire up and out the top of the frame. The controller should now be fully removed.
- Remove the 10 screws on the top that secure the board to the frame. There are 8 screws in a 2x4 grid at the rear of the controller, and 2 screws towards the front, located by the trolley arms. These screws are indicated in the picture below.
- Install the replacement controller:
- Thread the new motor wire down the hole in the frame and install the wire cover.
- With the rubber pad between frame and controller, set the controller down onto the frame. Carefully position the buzzer and wires so as not to be crushed. Note: The buzzer location has changed several times with different board versions, and so the buzzer may be in a different place than on the previous controller.
- Secure the board down with the 10 screws.
- Reinstall the taillight plastic.
- Chase the motor wires into the motor wire compartment. Lead with the hall wires(white connector). You may need to carefully push on the back of them to get them into the compartment. You may also need to cut away some of the silicone to fit the wires in.
- Attach the controller wires to the motor wires.
- Reinstall the 90° cover and the 2 screws in the slider.
- If necessary, apply additional silicone for waterproofing. Secure the motor wire compartment cover with the 6 large screws.
- Plugin both rear batteries and secure the guides on both sides. Plugin both front batteries. A small pop may occur, this is normal as the batteries drop the voltage to the capacitors.
- At this point, test that the unit is fully functional before continuing. You may need to unlock the controller with the Kingsong or 3rd party app on your phone. Test motor function, charge ability, BT connectivity, lift sensor, and lights.
- Reinstall all panels:
- Reinstallation is the same process as removal but backward. Reinstall the top panel with the 4 self-tapping screws in the front and the 4 machined screws in the back.
- Reinstall the left-side shell. Fit the front of the shell on first and work your way towards the rear. Don't secure the yellow or cyan screws yet.
- Install the mudguard: The large yellow dot screw fits through the left-side shell, through the mudguard top hole, and into the right-side shell. Reinstall the small screw for the mudguard and secure the rest of the yellow screws.
- Install the front left panel. It clips on the front of the unit and is secured by 2 green screws.
- Install the top front rubber inserts, sliding them from rear to front to align them. Press them down between the top and front panels so that they fit correctly.
- Install the cyan screws, on both sides. Make sure that the back of the side shells fit under the top panel.
- Install the tail/rear panel. Pop the tabs in on the right side first and then the left.