Parts:

  • Replacement Charge Port
  • Tube of Thread Lock


Tools:

  • 3mm Allen T-Handle
  • Utility Knife
  • #2 Phillips Screwdriver
  • 14mm Wrench 
  • Heat Gun (Optional)


Process:


Place the board on a riser that hangs the wheels off the table. A small box works well.





Use the 3mm Allen T-Handle to remove the 6 screws holding on the battery box. Put the 6 screws to the side.


  




Grab around the board while supporting the unattached battery box. Carefully flip it over. 








Flip over the battery box.







Notice that the motor wires coming out of the battery box will now be crossed.





Use the #2 Phillips Screwdriver to remove the 6 screws that hold the lid onto the battery box.



 




There may be a light bead of silicon holding the lid to the battery box. Gently grab the motor wires near the back of the battery box and lift up to dislodge the lid. Lift the lid off of the battery box.



 



Disconnect the battery from the motor controller before working on anything inside the battery box.






Find the red charge port connector. Unplug the battery from the charge port.


 



Use the 14mm wrench to remove the charge port nut. Turn the nut counter clockwise until it releases from the threads. As the clearance is very tight you will have to place the wrench, turn, then replace the wrench head several times.

Optional: You may use a heat gun on low heat setting or hair dryer to heat and soften the glue that holds this nut in place.  Be careful not to apply too much heat to the wall of the battery box, or it will soften and break.
 





You may need to hold the outside of your charge port with your other hand, while turning the charge port nut counter-clockwise.





Remove the charge port nut and washer.





Pull out the charge port.





Grab the new the charge port.


Remove the charge port nut and lock washer.  Insert the charge port into the side wall of the battery box, making sure its rubber cover sits between the charge port and the outside of the wall.





Use thread lock on the threads of the charge port. Replace the washer and begin to hand tighten the nut.





Continue to tighten by hand until you feel too much resistance.  Then use your off hand to hold the charge port while tightening the nut with the 14mm wrench.


Continue tightening until the charge port is firmly in place and the rubber gasket of the charge port cover is tightly compressed.






Plug the charge port's red connector to the battery's red connector. Make sure the two are lined up so that the wire colors match. Do not force them if they are not lined up.




 

Reconnect the battery to the motor controller.





Put the lid back into place. Notice that the countersinks are only on one side. This side should be facing up.


Use the #2 Phillips Screwdriver to tighten the six screws that hold the lid on.

 






Flip the battery box over.







Grab the board so that you are supporting the unattached battery box.  Carefully flip it back over and set it back on top of the riser box used earlier. 

 






 
Use the 3mm Allen T-Handle to secure the battery box to the deck with the six battery box mount screws. Put a drop of thread lock onto the threads near the end of each screw. 

 






  

Ready to ride!







achargeport

acharge

aport


Charge Port Replacement Kit

"Charge Port Replacement Kit"