Post by dan50 on Oct 17, 2013 8:26:15 GMT -5
I came up with an easy way to hook up a battery charger or battery tender without removing any body panels.
It takes about 15-20 minutes per scooter to make and install the wires.
Parts needed per scooter (see 1st picture):
2 female connecters
2 male connecters
2 connecters for the battery posts, either fork type or round type with a hole in the center
2 pieces of wire (desired length) either copper or stainless steel, 1 red (positive) and 1 black (negative)
Soldering gun and solder (optional but recommended)
Electrical tape, black for negative and red or white for positive (to easily identify connections)
I recommend using stainless steel connecters as they will not rust or oxidize. Stainless steel wire is optional but won't rust.
The 1st picture is the parts and the assembled wires.
The 1st set of pictures is installing wires on my Kaliber LS. The battery is on its side over the rear tire/motor and behind the right side cover.
The 2nd set of pictures is installing wires on my SunL passeo. the battery is under the floorboard.
Remove cover to expose battery. Loosen the bolts or screws on the battery posts.
Put the fork or round connecters on the battery posts (red is positive and black is negative) and tighten posts. (Picture is blurry, sorry, but you get the idea).
Replace the side cover.
Push other connecters on the pins. I tape the covers to keep water out and to prevent accidental electrical shorts.
Tuck wires up into side cover (be careful not to put them somewhere they will get into moving parts or hot surfaces).
To hook up battery charger; pull wires out to hang down, remove the caps and connect clamps of battery charger to the pins. (I normally hang the positive over the turn signal stalk to keep the positive from grounding (shorting) out on the muffler).
For scooters with batteries under the floorboard; remove floor mat.
[img src="http://www.49ccscoot.com/pics/membersubmitted/C08-2_zpsfd924c28.jpg" style="max-width:100%;"
Remove battery cover and loosen bolts/screws on battery posts.
Attach fork type or round type connecters to battery posts and tighten.
Replace cover and put caps on pins. (To clear the wire you may have to file clearance holes on battery cover so it lays flat. I did this later).
On my SunL Passeo there are a couple of extra holes in the floorboard. This is where I tuck the wires to keep them secure and out of the way so they don't get damaged. There are no moving parts or hot surfaces to damage the wires.
Replace floor mat and you are ready to go.
To hook up battery charger; remove floor mat, pull wires out of holes, remove caps and hook clamps of battery charger to pins.
I hope you find this idea as useful as I have. No more removing plastic to get to battery posts!
It takes about 15-20 minutes per scooter to make and install the wires.
Parts needed per scooter (see 1st picture):
2 female connecters
2 male connecters
2 connecters for the battery posts, either fork type or round type with a hole in the center
2 pieces of wire (desired length) either copper or stainless steel, 1 red (positive) and 1 black (negative)
Soldering gun and solder (optional but recommended)
Electrical tape, black for negative and red or white for positive (to easily identify connections)
I recommend using stainless steel connecters as they will not rust or oxidize. Stainless steel wire is optional but won't rust.
The 1st picture is the parts and the assembled wires.
The 1st set of pictures is installing wires on my Kaliber LS. The battery is on its side over the rear tire/motor and behind the right side cover.
The 2nd set of pictures is installing wires on my SunL passeo. the battery is under the floorboard.
Remove cover to expose battery. Loosen the bolts or screws on the battery posts.
Put the fork or round connecters on the battery posts (red is positive and black is negative) and tighten posts. (Picture is blurry, sorry, but you get the idea).
Replace the side cover.
Push other connecters on the pins. I tape the covers to keep water out and to prevent accidental electrical shorts.
Tuck wires up into side cover (be careful not to put them somewhere they will get into moving parts or hot surfaces).
To hook up battery charger; pull wires out to hang down, remove the caps and connect clamps of battery charger to the pins. (I normally hang the positive over the turn signal stalk to keep the positive from grounding (shorting) out on the muffler).
For scooters with batteries under the floorboard; remove floor mat.
[img src="http://www.49ccscoot.com/pics/membersubmitted/C08-2_zpsfd924c28.jpg" style="max-width:100%;"
Remove battery cover and loosen bolts/screws on battery posts.
Attach fork type or round type connecters to battery posts and tighten.
Replace cover and put caps on pins. (To clear the wire you may have to file clearance holes on battery cover so it lays flat. I did this later).
On my SunL Passeo there are a couple of extra holes in the floorboard. This is where I tuck the wires to keep them secure and out of the way so they don't get damaged. There are no moving parts or hot surfaces to damage the wires.
Replace floor mat and you are ready to go.
To hook up battery charger; remove floor mat, pull wires out of holes, remove caps and hook clamps of battery charger to pins.
I hope you find this idea as useful as I have. No more removing plastic to get to battery posts!