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36 Volt/Long Range Battery Upgrade Pan Installation
Please read before attempting this procedure!
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 36 volt 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 motor warranty will be voided. If you decide to proceed with this modification, do so at your own risk!
NOTE: This custom battery pan is sized to hold 3 12V-12A/hr
NOTE: This pan will also
accommodate 2 Hawker 13A/hr batteries for
1) Remove 8 bolts holding deck and fender. Lift off deck and fender and set aside.
2) Stand batteries on end and carefully remove the 4 push-on terminals.
3) Remove batteries and wires from pan, then remove pan from frame.
4) Identify the 8 cables/wires as shown below.
Wire and cable identification:
Lower 36 volt pan into frame. Being careful not to damage the insulation,
NOTE: The mechanical brake cable should be routed along the left chassis
6) Install a 3/4" rubber grommet
or plastic strain relief in both holes where the wires
6a) Cut and install a thin layer (1/16"-1/8") of
padding in the bottom of the new
batteries are to be installed on their sides to eliminate the possibility
Be sure you understand the proper positioning of the batteries before
7) Connect the negative (black) battery lead (#1)
to the negative (black)
8) Cut two wood spacer blocks and place in the front and rear of
9) Route the mechanical brake cable along the left side chassis.
****For 24 volt operation using Hawker G13EP batteries.