Parts:

  • Replacement On/Off Switch
  • 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.






Identify where the On/Off Switch plugs into the motor controller. Unplug the On/Off Switch connector.


 




Use the 14mm wrench to remove the on/off switch 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.





Remove the nut and pull the wiring and On/Off Switch through the hole.


You may need to hold the outside of the on/off switch with your other hand, while turning the on/off switch nut counter-clockwise.


Grab the new On/Off Switch. 





Make sure the nut is removed. Thread the wiring through the hole until the back of the On/Off Switch is flush with the battery box. 


Use thread lock on the threads of the on/off switch. Place the nut over the wiring and hand-tighten onto the threads. Use the 14mm wrench to tighten the nut.




Plug the On/Off Switch back into the motor controller.  






Tuck the wiring down and into the corner so its not sticking up over the top of the battery box.





Reconnect the battery to the motor controller.





Test the new on/off switch by turning power on, then turn back off using the new switch.



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!





apower

apowerbutton

apowerswitch

aonoffswitch

aonoff