BMS Replacement Replacement

Start with a clean work bench

Remove all conductive a tools from your work bench

Wear safety glasses

Use a stanley knife to cut though the sealant of the battery case

Use caution when doing this

Slowly lever the case apart.

Start at the bottom and work your way around to the handle

Fully open the case

The glue is quite strong, use you hand inside to seperate the case from the heat shrink

Be careful to not damage the delicate switch wires

Cut off the thick black shrink wrap

The main power cables and switch remain connected to the top cover.

Gently release and remove the switch cables from any adhesive so that they are not under stain when opening the case.

Rest the top cover on a box or similar to prevent staining the cables

Remove the heat shrink from the battery pack.

go slowly at the cable end as to not break or stain any thinn switch cables

Remove the fiberglass sheeting from the pack

Remove the negative terminal

Cover the negative terminal with tape

Unplug the 4 connectors from the BMS. these will all be reused. do not cut.

Cut the large main negative cables from the BMS. There are 3-4 at each end of the BMS.

Cut the black switch light wire as close to the BMS as possible.

A connector is soldered to this in step 14

Fully remove old BMS

Desolder short wires from the main negative

Ensure all old solder locations are smooth

Remove fibreglass from old BMS and install on New BMS

Locate new BMS as shown

Solder main Negatives as shown

The new BMS has all of the connections from one end only.

Arrange as neatly as possible to avoid pinch points

Tape down to secure BMS in place

Solder or crimp the eye terminal to the switch light wire that was cut in step 10

The New BMS has different cable routing than the old one

Cut a slot in the fibreglass for the for the new BMS cables

Wrap the fiberglass sheets back around the BMS

Use duct of fiberglass tape close and seal the fiberglass sheets around the battery pack

Connect the main negative to the terminal on the battery case.

Correct order is Terminal - main negative lug - eyelet - bolt

Turn the switch on and off to check that the red light turns on and off.

Check the BMS app to ensure the all cells and connected to the ballance leads

Use ant BMS V2 app from the app store

Insert wisdom here.