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Back to Kit Instruction Index

Zappy-Dual Hawker Battery 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 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!


Zappy-Dual Hawker Battery Pan Installation

Remove the deck and battery from your scooter. Disconnect and re-
move all wires from controller circuit board. (label wires first) Remove
the battery tray. In early models, you must disconnect the brake cable
before removing the plastic tray.

Place the new aluminum battery tray in the empty Zappy frame.


***NOTE: In some earlier models, the kick-stand may prevent the
                   pan from seating properly in the frame. If you find this
                   to be the case, you must relocate the kick-stand bolt
                   about 1/2" to the left of its present location.

Wiring will be for 12 volt operation. That is, the 2 positive battery
terminals will be wired together and continue through to the
controller positive terminal. The 2 negative battery terminals will
be wired together and continue to the controller negative terminal.

Stand batteries in pan and install cables, beginning with the front-
most battery. Be VERY careful to prevent the ends of the wires
coming in contact with any metal object or each other!!

Lay the front battery down in the tray with its terminals UP away from
the bottom of the pan. Lay the rear battery in position (terminals up)
and complete the wiring. When laying in the pan, the batteries must
be positioned as shown below.

                    (batteries are NOT wired in the above pictures)

In order to complete the installation, the original plastic pan must be
cut to remove the forward half. Only the rear fender and controller
area will remain. Be sure to leave enough of the support tabs on the
left and right side of the plastic pan to rest on the chassis rails for

The exact location of the cut depends on the specific model Zappy
in question, but the general location is shown by the heavy white
stripe in the picture below. When cut correctly, the front of the plastic
pan will just contact the rear of the new aluminum pan. Sealing com-
pound or tape should be placed at the joint.

                                  (view from bottom of scooter)

Place the cut and fitted rear plastic fender in place. Install and re-
connect the control circuit board to the new battery and motor. In-
stall the deck.