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Long Range Hawker Upgrade (prior to 2002 Flyer)
Please read before attempting this procedure!
WARNING
The batteries utilized in this mod can produce very large and dangerous currents if metallic objects such as screwdrivers or wrenches contact the terminals accidentally! These currents can cause serious burns and other personal or property damage!
Only an experienced mechanic, familiar with high current battery circuits, should attempt to assemble this kit. If you have the slightest concern regarding your ability to handle this project, I recommend securing the services of such a professional to aid in the assembly.
Remove all metal object such as wrist watches and other jewelry before beginning work. Use insulated tools to prevent accidental contact with exposed terminals or connectors. Eye protection is required!
**Disclaimer:
The following battery modification was undertaken
as an experiment. While providing the reader with details (below)
of my installation, I make NO claims as to its safely, reliability,
advisability, or efficacy! Obviously, your scooter warranty will
be voided. If you decide to proceed with this modification, do so at your own
risk!
Installation
Line the bottom of the enclosure with a pad of cork, thin foam, felt, or other suitable material to provide a cushion for the batteries. Attach this material with hot glue.
Measure and cut the wooden blocks necessary to keep your batteries in position before assembling the electrical components. Depending on the batteries you choose, these blocks will vary in size and position. The illustration below, shows the arrangement for a pair of Hawker G13EP batteries positioned lengthwise in the enclosure.
The picture below shows the battery orientation ( Hawker G13EP) within the box. ***Do not use wooden blocks thicker than 1/2", as they will block access to the electrical switch, pilot light, and charger port openings.
When the battery positioning blocks are complete, set them in place with hot
glue. Remove the batteries, and install the battery pan in place between the
chassis rails of the Currie scooter. ***In some models of the Currie scooter,
there are metal strengthening pads welded in place between the rails. Grind
these sufficiently to allow the pan to slide loosely into place. Mark the
position of the 4 holes where bolts pass through the scooter deck and frame.
These holes are not pre-cut in the new battery pan because they are not consistent
across all Currie production runs. Remove the pan and drill and file
the holes large enough to allow some adjusting of the battery box position.
Re-install the pan in the scooter, and begin installing the switch, pilot light, and charger port as show below.
NOTE: The picture above shows the electrical
parts installed outside the scooter. Actual installation of these parts
MUST be done while the battery pan is installed between the chassis rails.
The existing wiring harness may require one or two of the cables be lengthened to complete the installation. Be sure to use #10 or #12 insulated stranded wire and the proper crimp splices to extend these cables. Pull the motor power cable and polarized plug through the hole provided near the rear of the pan. Install the plastic feed-through from the original battery box.
Replace the push on connectors (if necessary) with the appropriate type for your
particular batteries. Before connecting and installing the batteries, be sure to
remove all metal objects from the immediate area. An accidental short circuit
across the terminals of a battery can cause SEVERE burns or possible explosion
of the batteries! Unless you are thoroughly familiar with battery handling
procedures, bring the assembly to a qualified mechanic for the final battery
installation!