Step 4: Wire Up Good Scooter

Here is where it gets tricky... It's highly likely that your connectors will not match -- mine didn't. The best way to go about this is to start with one connector. See if both sides mate. If they do, more on.

If Not - check the other side of the connector on the other scooter. Then remove the pins from the connector and do a Frankenstein swap. The pins usually have a small tap inside - push it to the side with a small screw driver, then pull the wire/pin out.

Sometimes, there's no remedying it. In cases like these -- you can jam the pin on the wire into the connector, then secure with tape. Be sure they won't short inside the tape as these motor controllers are rather sensitive :/

You absolutely need to connect the following items

1. Hall Effect Throttle
2. Motor
3. Battery

For safety you should also connect the brake switch.


I have a 500w 24v electric scooter, I'm using 2 12v 10ah ub12100-s batteries. I want to add a 3rd battery wired to a button mounted on the handlebars to use the extra power when I need to. My question is how would I go about wiring this and able to use the 24v constantly and able to use the button for 34v?
Does increasing the voltage by 50 percent roughly double the power? For resistive circuits, it generally does---the power is proportional to the square of the voltage, so 3/2 the voltage gives 9/4 the watts. I'm not clear on inductance in electric motors, though. I'd think that if you saturate the flux capacity of the electromagnet cores, the excess power would be converted straight to heat. Does your motor get very hot? I'm wondering if there's a simple test you could do with your multimeters to tell when you're saturating the cores, and limit the power to what actually boosts speed, without wasting more as heat. (BTW, those meters look familiar... and really cheap... I have a yellow one and a red one from Harbor Freight, too.) Also, do you have any links to good instructions for de-sulfating the 12V sealed batteries? I have a couple that need help.
See <a rel="nofollow" href="http://visforvoltage.net/forum-topic/bicycles-and-pedelecs/1040-anybody-use-desulfinator-restore-old-slas">Anybody use a desulfator to &quot;restore&quot; old SLAs?</a><br/>Increasing the voltage by 50 percent will probably smoke your controller before it even gets to the motor.<br/>What motor and controller ar you using?<br/>
A 36v controller from the 36V derelict scooter ;) I used a 24V rated motor - which is still healthy and spinning away :)
K, the motor may take over 24 Volt, but not 36 Volt. Is it a Unite Motor?
Yep, it's a United Motor - it's been taking the 36V and hasn't had a problem yet. On paper, 36V would be bad for it. In reality, it's a hunk of copper, aluminum, steel and plastic. Remember, for this we care what it <em>can</em> do, not what it was intended to do ;) The wire inside is too big for the loads at 24V - so I'm not concerned about a fire or anything of that sort. Switching over to the 36V motor would yield a bit more speed, as it was wound for 36V, but that added complexity to this very short project.<br/>
I tried this... adding 1 more battery to two scooters, one a Razor (250w motor) and the other a cheap Chinese made knock-off (200w motor), both being 24v original to 36v modified. I did not change the controller or anything else. I believe that the permanent magnet scooter motors are more robust than you would expect. Even the controllers rated at 24v running 36v do not get hot. The heavy Razor would go about 13 to 14mph max at 24v, with new SLA's running at 36v it will max out at 19mpg (gps tested). The Chinese knock off is lighter and the 200w motor reacts very well to the additional 12v and this scooter will top out around 22mph. In each scooter, I used 4 dpdt, Bosch relays to make a series/parallel switch, so when the relays are off, all three batteries are in series making 36v. When the relays are energized, The batteries are put in parallel and I can use a common 12v charger. There maybe some resistance in the relay contacts, but they are rated at 40amps at 12v, they too do not seem to mind the additional voltage. I do think think running 48v will fry something, but I have not tried that.
How long did your battery upgrades last? Did anything burn up?
<p>The 24v to 36v battery modification did no apparent harm to the Razor Bistro scooter. But for the 200w Chinese scooter, when the motor is not used for a while, it takes about 45 seconds for the motor to spin up to full speed. After it has done that, everything works as usually. But if you let it sit for a few days, the same thing will happen. These scooters have a current limiting &quot;shunt&quot; on the controller pc board. I am going bypass the shunt to see if more current will go to the motor. When I do this, I think something may break permanently.</p>
<p><a href="https://www.youtube.com/watch?v=j35bCvc2kIY" rel="nofollow">https://www.youtube.com/watch?v=j35bCvc2kIY</a></p>
<p>check this vid out...would you recommend doing what this guy did? with either the original 24v configuratuion or the modded 36v plan with stock motor and controller?</p>
<p>can you please post the wiring schematic you used to mod up your 24v Razor to 36v using the stock motor and controller?? this is precisely what im looking to do and the idea of switching between parallel and series battery configuration is brilliiant</p>
Warning! Crazy back to the future projects MAY send you back in time (financially...!)
Warning! Crazy back to the future projects MAY send you back in time (financially...!)
Warning! Crazy back to the future projects MAY send you back in time (financially...!)
Guess I'm as guilty of risking my motor as you, probs not the speed controller tho' thus my risk is limited, sure don't wanna gut the thing replace all if I can help it...
Guess I'm as guilty of risking my motor as you, probs not the speed controller tho' thus my risk is limited, sure don't wanna gut the thing replace all if I can help it...
Just risking your valuble merchandise seems like a false economy to me. I've replaced the fsla's with two silver 50ah batterries, and it is going great, but I'm gonna swap out for a 350W motor as weight to power is a bit off, and slight over-heating on long runs reduces efficiency. I'll mod a Lipoly conversion next, but I hear the Chinese don't make female connectors for the load balancer but wiring is easy...
how do u dispose the cells
Take them back to the place where you bought the new batteries. I think they are legally required to dispose of them.
how would you fix the batteries?
basically you use a Desulfator (there is one on instructables!) which sends 1ms long 50v pulses.
i broke my scootrer's headtube aswell, but fixed it...
those batteries look like they need to be cleaned or exchanged for new ones
Naw, like many things - it's what's on the inside that counts ;)
My friend and I are going to be converting his older-model Razor E300 to a higher voltage. I'm thinking we could get a new controller and a 48 volt battery pack, and probably a new motor. The batteries will still have to fit in the existing cavity, so they'll each have to be half the size, making the scooter have a much shorter range (oh well). I have a Zivan NG-1 48 volt charger from me and my dad's electric bike conversion. Any advice? Thanks

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Bio: Engineer making renewable energy products for African entrepreneurs.
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