Introduction
Installing a larger, 52V16Ah or 52V17Ah Range Extender Battery into your Medium Frame Classic Duo eBike can be a bit of a tricky process but with some patience you can get it done!
You will need the following tools to do this:
2.5mm Allen Key
3mm Allen Key
Phillips Screwdriver
Large Adjustable Wrench
Electrical Tape
Box Cutter or Blade to cut electrical tape
You will also need some sort of glue, epoxy, waterproof sealant or waterproof tape to finish and waterproof the installation.
You will also need to use the included Range Extender plate and Handlebar End Cap.
Step 1
Remove the motor covers on both the drive side, and non-drive side of the bike. Do do this, remove all 3 bolts securing the motor cover plate on each side with a 2.5mm Allen Key.
Put motor cover plates and bolts aside, then move onto the next step.
Step 2
Remove the three bolts at the bottom of the underside of the downtube with a 3mm Allen Key. Remove the screws but leave the discharge port in place for the time being!
Gently remove the dualizer from the Non-Drive side of the motor cavity.
The dualizer is highlighted in the second image.
Gently remove the wires from the OUTPUT side of the dualizer so some length of these are exposed to aid in tracking the wires in the next step!
Step 3
Locate each dualizer output connector. Then trace each of them
One will goto the discharge port, the part ee unscrewed in the previous step. Pulling on this set of wires will cause the discharge port to move.
The other wire will goto the existing Range Extender Port on the bike. This is the one we want to work with! It will not have slack, and not move anything on the bike when pulled on.
Remove the electrical tape from the connection leading to the Range Extender Port.
Unplug the connector from which you just removed the electrical tape. Then move to the next step!
Step 4
Go inside the downtube of the bike. We need to find the underside of the Range Extender Port in the frame!
Once you have located this use a large adjustable wrench to loosen the nut on the underside of it. Once you have loosened this by 1-2 turns you should be able to finish unthreading the nut by hand.
With the nut fully unthreaded you can pull the range extender port outside of the bike from the top! Keep track of the nut and don't let it get lost into the bike frame!
Step 5
We now need to plug the hole where the old range extender port was in the bike.
Take the included "Handlebar End Cap" and use this to lug the hole.
Now you will need to seal the hole. There are a variety of ways in which you can do this:
Hot Glue from a hot glue gun
Silicon Caulking
Heavy Duty waterproof tape
A tube of 2-Part Epoxy
Once you have sealed the hole we can advance to the next step!
Step 6
Take the "Range Extender Plate with XT60 connector". Take the XT60 connector end
This is the end with the Yellow, female ended connector
Run the XT60 connector from the drive-side of the bike to the non-drive side of the bike as illustrated in the first two images here.
With the XT60 connector ran to the non-drive side of the frame yo can move to the next step!
Step 7
Remove the 4 bolts on the downtube with the Phillips screwdriver.
Line up the holes on the range extender plate with the holes on the frame.
Install the Range Extender Plate onto the bike frame. Make sure to place the included ABS washers in between the bike frame and the range extender plate.
Work to thread the wire coming from the end of the range extender plate so it's slotted into the cutout previously mentioned. Then loosely install the cover back onto this side to keep this wire in place!
Step 8
Now plug the end of the Range Extender plug you threaded through the frame into the dualizer. This would be the connection from which you previously unplugged the old Range Extender Port.
Use some electrical tape over this to keep the connection secure!
Go to the discharge port of the bike. Re-install the discharge port back into the bike with the 3mm Allen Key.
Step 9
We now need to re-install the dualizer and other wiring back into the motor cavity! This will take some patience, folding and bundling of wires but is very possible! The second image here shows how the wiring on the bike used for this guide was initially positioned for reference!
With the dualizer and other wiring reinstalled into the bike, you can reinstall the motor cover onto this side of the bike with the 2.5mm Allen Key.
Ensure you have fully tightened the drive-side motor cover on the bike with the 2.5mm Allen Key
You have now installed the dualizer plate onto your Classic Duo. Put the battery on and have fun with your extended range!