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Long Range Hawker Upgrade (prior to 2002 Flyer)
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!
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
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.
Re-install the pan in the scooter, and begin installing the switch, pilot light, and charger port as show below.
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.