Step 1 – Ensure your scooter is powered off
You need to make sure your scooter is powered off and not charging. This is to make sure that there is no power in the cable whilst we are working on it. If there is power, this could damage the scooter perminantly.
Step 2 – Remove the broken connector
You need to remove the broken connector, you may be able to remove this with the pliers, or you may have to remove the rear mudguard and or wheel to remove this.
Please see our guides here on removing these.
Step 3 – Remove the bottom cover of the scooter
Now we need to remove the bottom cover of the scooter so that we can access the cable on the inside, this involves removing lots of screws using the Torx Screwdriver. You may want to get the scooter setup on a workbench or chair so that you can work on it easier.
Whilst you’re removing these screws, you may notice that some of them are damaged and are hard to remove. You may want to try a smaller screwdriver if they are damaged. Also, you may whish to consider replacing these screws before they become completely damaged and you are unable to remove them.
Scooter sat on a chair for easy access
Cover Removed exposing the inside components
Damaged screws – you may want to look at replacing these with new ones
Step 4 – Remove the old cable
Now remove the old cable, you’ll see here that the connector has completely come off
Now, using the wire cutters and the knife, remove any frayed bits of wire and strip back the outer (black) sheath approximately 2cm
This is the waterproof seal, you need to keep this bit!
Step 5 – Prepare new cable
Now, we need to prepare the new cable. The cables you can buy from us are pre-stripped and tinned ready for soldering, however for ease we will not be soldering so need to remove the exposed wire and strip back the outer black sheath to approx 2cm as we did with the old cable in the last step.
Bare wire cut off and outer sheath stripped to approx 2cm
Now, put the rubber seal back on the wire – this is important to do this now before we connect the two cables together
Step 6 – Connect the wires together
Now, we will connect the old and new cables together, ensure that you connect the matching colours together!
Insert the internal portion of wire and the external portion of wire into the crimps as far as they go
You can confirm that the wires are pushed all the way in by checking round the back of the crimp. If the wires are not long enough, you’ll need to strip away more of the black outer sheath
With your pliers now squeese the waterproof crimp connectors so that the yellow/orange insert is flush with the rest of the connector. This will both connect the wires electrically but also release the waterproof gel.
Repeat the process for the other wire and you’ll be left with a neat looking connection like this
Now plug the connector in and it should lock into place on the existing part of the connector
You can now safely power on the scooter, and test the that the brake light is now working, if it’s not working, then try applying slightly more pressure on the crimp connectors and confirming that the wires have been inserted all the way in.
Step 7 – Putting it back together
Now that you have crimped the wires and tested the brake light now works, you can put the scooter back together.
Tuck the wire and the connectors in the gap between the battery and the chassis. Put the rubber seal with the wire in it back into the chasiss and pull back as much wire inside as you can to avoid the external part of the wire touching the wheel.
Now perform step 3 in reverse to put the bottom cover back on and you’re done!