This guide will show you how to connect the second battery plate with the wires of the bike. To do this, it is necessary to remove the connector that is currently installed on the headtube and install a new one close to the motor on the downtube to support both batteries.
You will find the Steps to this Guide are Underlined. Image descriptions are Italicized and appear under every photo.
Please reach out to our support if you have any questions regarding this guide.
Important note: This guide is only for Juggernaut HD Duo Downtube battery installation and is not for converting an HD to HD DUO
You only need to follow this guide if your second battery plate is not mounted and installed on the down tube of your bike AND the necessary connector is not already located in the downtube. This is for headtube connector and uninstalled/unmounted secondary battery plate ONLY!
If you are not sure, please contact us.
- Wear proper clothing to protect your face, hands, and body.
- Make sure the work area is dry and clean.
- Make sure the battery is NOT connected to the bike.
- Side cutter
- Insolation tape
- Hot air-gun
Step 1: Remove the primary battery in the hidden downtube of the bike. Use the keys to unlock the battery lock. After put your hand below the battery and turn the battery holder. Now the battery will fall off the bike. The battery must NOT be connected to the bike.
Step 2: Remove the battery holder that protects the battery from falling out of the tube.
Picture 1 shows the battery holder.
Step 3: Remove the 3 screws that hold the battery lock in place.
Picture 2 shows the 3 screws that have to be removed to remove the battery lock.
Step 4: Remove the battery lock by pushing the keyhole inside that you can remove it out of the frame. Locate the wiring and the dualiser (black plate) that is behind the battery lock.
Picture 3 shows the inner frame and the dualiser that is located behind the battery lock.
Picture 4 shows the dualiser that is located behind the battery lock.
Step 5: Use about 64cm/25.5inch of the long black cable we send you (hereafter referred to as cable (A)). Push the cable (A) through the tube that is located inside the frame of the bike into the direction of the green arrow. Sometimes it's easier to push from the top to bottom, sometimes bottom to top.
Picture 5 shows cable A and the tube inside of the frame.
Step 6: Strip the insolation of cable (A) carefully without cutting the wires inside the two wires inside. Cut the filling material so that only the grey and beige wire are left. Remove a bit of the insolation of these two wires and twist the material inside.
Picture 6 shows what's inside of cable (A). Two wires and two strings of filling material.
Picture 5 shows cable A after the filling material is cut.
Step 7: Remove the yellow connector that is wired to the dualiser. Do not cut both wires at the same time. Cut the wires one at a time. Start with the black wire. Then cut the blue wire. The connector is no longer needed. Strip the insolation of the two wires and twist the material inside.
Picture 8 shows the cutting of the black cable that is connected to the dualiser.
Picture 9 shows the cutting of the blue cable that is connected to the dualiser.
Picture 10 shows the two stripped wires that are connected to the dualiser and the two stripped wires of cable (A).
Step 8: Add a butt connector to the wires of the cable (A) by using a side cutter to squeeze one side of the butt connector.
Picture 11 shows how the black wire of cable (A) gets connected with a butt connector.
Picture 12 shows how the beige wire of cable (A) gets connected with a butt connector.
Step 9: Connect wires from the dualiser with the wires of cable (A). Note: Pull a heat shrink tube over each wire before connecting them. Connect the black wire from the dualiser with the black/grey wire from cable (A).
Picture 13 shows the black wire covered with a heat shrink before connecting.
Picture 14 shows how to connect the black wire of the dualiser with black/grey wire of cable (A).
Picture 15 shows how to connect the two wires by squeezing the butt connector.
Step 10: Connect the blue wire from the dualiser with the beige wire of cable (A).
Picture 16 shows how to connect the blue wire of the dualiser with beige wire of cable (A).
Picture 17 shows how to connect the two wires by squeezing the butt connector.
Picture 18 shows the final connections of all four wires. The connections are covered by a black heat shrink.
Note: We will heat up the tubes after we checked that everything is working. We are done with the part on the top.
Step 11: Strip the insolation of the cable (A) at the bottom and twist the material inside. Add a butt connector on each end of the wire.
Picture 19 shows cable (A) and the two stripped two wires inside of it.
Picture 20 shows how the butt connector is connected to the black wire.
Picture 21 shows how the butt connector is connected to the beige wire.
Step 12: Cut the cable (B) to a length of 10cm/4inch (like in the picture). Strip the insolation of cable (B) carefully without cutting the two wires inside. Strip the insolation of the two wires inside cable (B) and twist the material inside.
Picture 22 shows cable (B) with the yellow connector before stripping the insolation.
Step 13: Connect the two wires of cable (B) with the two wires of cable (A). Pull a heat shrink tube over the wire before connecting them. First, connect the black wire of cable (B) with the grey wire of cable (A). After that connect the red wire from the connector with the white/beige cable.
Picture 23 shows the wires of cable (B) and cable (A). The black wire of cable (B) is fitted in the butt connector of the black wire of cable (A). Note: It looks like the beige wire goes into the heat shrink, but it's actually behind it.
Picture 24 shows how to connect the beige wire of cable (A) with the red wire of cable (B).
Picture 25 shows the final connections of all four wires.
Step 14: Connect the second battery with the newly installed connector. Turn on the bike to check if everything is connected properly. The display should turn on. Is that the case, turn off the bike and disconnect the battery again.
Picture 24 shows how to connect the second battery with the newly installed connector.
Picture 25 shows the turned on display of the bike.
Step 15: Melt all the heat shrink tubes to protect the connections between the wires.
Picture 28 shows how to heat up the heat shrinks to protect the connections on the bottom of the bike.
Picture 29 shows how to heat up the heat shrinks to protect the connections on the top of the bike.
Step 16: Add insolation tape to protect all the connections between the wires.
Picture 30 shows how to use insolation tape to protect the connections.
Step 17: Mount the battery plate on top of the downtube by using the 4 screws that are present. Lead the cable from the battery plate through the hole into the frame.
Picture 31 shows the location of the hole in the frame and how to lead the yellow connector through it.
Picture 32 shows how to mount the battery plate by using the 4 screws that are tightened into the frame.
Step 18: Connect the yellow connector from the battery plate with the yellow connector that was installed earlier.
Picture 33 shows how to connect the battery plate with the newly installed yellow connector.
Step 19: Fit the dualiser and back into the frame. Push it into the direction of the headtube. Ensure that the cables are not under tension or bent, and there is enough space for the battery lock.
Step 20: Reinstall the battery lock by following steps 2 and 3 in reverse order.
When everything is back in place and sits tightly you can put the batteries in place and start riding your bike!