VELOCITY/OSET Lithium Battery upgrade conversion instructions
CAUTION MUST BE TAKEN TO PREVENT PERSONAL INJURY, BATTERY OR MOTORCYCLE DAMAGE DURING THE CONVERSION PROCESS.
THE VELOCITY LITHIUM BATTERY IS A POWERFUL ELECTRICAL BATTERY SYSTEM PRODUCING FROM 24 TO 58+ VOLTS AS WELL AS 17 TO 30 AMPS OF POWER.
THE VELOCITY BATTERY PACK COMES WITH THE ANDERSON TYPE PLUG INSTALLED ON THE BATTERY LEADS TO PROTECT THE USER FROM POSSIBLE ELECTRICAL CONTACT WITH THE BATTERY, BUT CARE AND ATTENTION MUST BE TAKEN TO CONVERT THE OSET MOTORCYCLE POWER SUPPLY WIRE SYSTEM TO THE ANDERSON TYPE PLUG SUPPLIED IN THE BATTERY KIT.
ALWAYS MAKE SURE THE RED (+) AND Black (-) WIRES OF THE MOTORCYCLE CORRESPOND TO THE RED (+) AND BLACK (-) WIRE FEEDS OF THE VELOCITY BATTERY UPGRADE.
DO NOT DISASSEMBLE OR ALTER THE ANDERSON TYPE PLUG SUPPLIED ON THE VELOCITY BATTERY FOR ANY REASON.
IF YOU HAVE ANY QUESTIONS CONCERNING INSTALLATION OF THE VELOCITY BATTERY UPGRADE IN THE OSET MOTORCYCLE PLEASE CONTACT THUMBS UP TRIALS SUPPLY PRIOR TO INSTALLATION.
Following are some guidelines for converting the OSET Electric motorcycles with Sealed Lead Acid (SLA) battery power systems, to the Velocity lithium battery upgrade system.
In the event that a stock OSET lithium battery found in the OSET 20 MKII, 24 Race or MX10 needs to be replaced, the Velocity lithium battery is a good replacement option for these lithium battery systems.
The Velocity battery kit includes a completely sealed lithium battery, from the 24 volt system used in the OSET 12.5 Race and Eco models to the most powerful 48V/30Ah lithium kit designed to upgrade the stock OSET lithium power plant supplied in the 20 MKll, 24 Race and MX10 models.
The following narration converts an SLA power supply to a Velocity lithium power supply. The same steps can be followed with any of the OSET models with the difference being the motorcycle power plugs supplied on the lithium OSET powered model(s).
The conversion is a very simple process of changing the OSET battery plug(s) to the supplied Anderson type power plug. Anderson type plugs can be found in different colors for different applications, the supplied Anderson type plug will be gray in color.
The conversion can be completed in 30 minutes or less.
The Velocity kit includes all parts needed to upgrade any OSET to the Velocity lithium system, including the Velocity lithium battery, a lithium battery charger, and the wiring conversion plug.
The provided Anderson type plug consists of 2 silver spades, these spades will be connected to the OSET motorcycles’ power wires and then inserted into the gray Anderson type plastic plug body that has the + and - symbols, the wires slide into the respective slots once the OSET wires have been attached to the supplied silver plug spades.
NOTE: For these installation instructions a Red Anderson type plug was used to better distinguish between the OSET bike wiring plug, Red, and the Velocity battery plug, Gray.
Tools you will need to complete the upgrade;
Wire insulation stipper
Wire terminal crimpers or pliers for crimping and/or a soldering iron/gun to solder the spades to the OSET wires.
Remove the left and right side panels from the OSET so that you have access to the battery compartment.
Disconnect the power wires, Red (+) Black (-) from the OSET motorcycle that connect to the SLA batteries. If the Velocity upgrade is being installed in an OSET lithium battery powered bike the OSET screw-in battery connector will need to be removed.
With a set of wire cutters, cut the OSET spade plugs or OSET screw-in plug (depending on the OSET model), from the OSET motorcycle power wires, Red (+) and Black (-).
(Cut the plugs as close to the plug ends as possible, leaving as much OSET Red (+) and Black (-) wire length as possible)
Once the stock OSET spades or lithium screw-in plug has been removed, strip about ⅜” (10mm) of insulation from the Red (+) and Black (-) OSET wires.
Connect the provided Anderson type spade connections.
The new spade terminals can be crimped or soldered to the OSET motorcycle power wires.
Depending on the method used to connect the supplied wire spades to the OSET wires pay special attention making sure the new connections are securely attached to the wires.
Once the new Anderson type plug spades are connected, securely, to the Red (+) and Black (-) wires on the OSET bike, insert the new spade terminal ends into the plastic body of the Anderson plug plastic casing.
BE SURE TO INSERT THE RED WIRE IN THE (+) SLOT IN THE PLASTIC HOUSING AND THE BLACK WIRE IN THE (-) SLOT IN THE HOUSING.
The above pictures show the proper placing of the OSET bike power wires, Red (+), into the corresponding (+) slot of the plastic plug housing and the Black (-), into the corresponding (-) plastic housing slot of the plug housing.
NOTE: The above picture also shows 2 styles of crimping the plug spade terminal to the wires. The top, black wire (-), has a flat crimp that if crimped too wide can make installing the spade terminal into the plastic plug housing more difficult due to the width of the crimp and the plastic hole it must fit in.
A circular or more rounded crimp or soldered connection will slide into the plastic housing easier.
NOTE: The Anderson type plug spade terminals have a top and bottom orientation when installed and need to be installed into the plastic housing correctly. You will notice in the above picture, the spade terminal bottom is relatively flat with a notch at the end of the terminal, while the top side of the terminal has a noticeable ridge towards the end of the terminal.
The spade terminal will only fit into the housing in one orientation and with some pressure will slide into the housing from the rear and be locked in place by the spring loaded flat metal piece at the front of the plastic housing.
MAKE SURE THE SPADE IS INSTALLED COMPLETELY FORWARD IN THE HOUSING AND LOCKED SECURELY OVER THE SPRING KEEPER. IF THE SPADE IS NOT INSTALLED CORRECTLY THE BATTERY WILL SHOW POWER ON THE OSET THROTTLE LIGHT BAR, BUT WHEN POWER IS APPLIED THE LOOSE AND IMPROPER PLUG CONNECTION WILL NOT ALLOW THE NEEDED POWER TO FLOW THROUGH THE PLUG CONNECTION.
A small flat blade screwdriver can help the spade terminal slide over the keeper.
If the spade needs to be removed from the plastic housing for some reason simply apply downward pressure to the spring keeper and pull the spade back out of the plastic housing.
Notice the top spade, in the vertical (left) picture, is installed correctly and the bottom spade has not locked over the keeper spring and will not fit correctly to the other half of the Anderson type plug.
The horizontal picture (right) has both spades installed correctly and is ready to be connected to the Velocity battery Anderson type plug.
This is what the plug should look like after installed on the OSET motorcycle.
Install the Velocity battery into the battery compartment of the OSET.
The Velocity battery housing is directional and should be oriented correctly to fit down into the OSET battery compartment.
Plug the Velocity battery plug to the OSET battery plug, that was just installed by the user.
Use the stock OSET battery holder to secure the Velocity battery. Depending on the model of OSET, the battery keeper will be a metal top strap or a nylon/velcro strap.
Before reinstalling the OSET side panels, route the Velocity battery charging cable to the front of the bike. Front or side mounting of the charging port is preferred due to less water and mud accumulation.
NOTE: It is recommended that the supplied charging port rubber cover always be reinstalled after charging to protect the port against dirt, mud and water.
With the new upgraded Velocity Battery securely in the OSET bike, all wires reconnected and secured, replace and secure the OSET side panels.
Due to shipping regulations the Velocity battery can not be shipped with a full charge.
It is recommended that the battery be charged fully after installing and before riding your OSET bike.
NOTE: The first charge can take up to 6 hours +/-.
NOTE: It is recommended that the Velocity battery be charged after each use. Charge times can be up to 6+ hours depending on the amount of use and discharge of the battery.
NOTE: It is also highly recommended that the Velocity battery be fully charged before long term storage of the bike and battery.
NOTE: While the Velocity battery has built in overcharge protection and the supplied lithium charger is programmed to stop the charging process when the battery has reached a full charge, it is recommended, as with any other battery charger, that the charger be disconnected from the power source.
NOTE: To property attach the supplied lithium charger to the battery;
- Plug the charger to the wall power supply.
- Plug the charger plug to the battery charging port.
NOTE: The charger has a built in charging and status light;
Red light; Charging
Green light; Charged and ready to disconnect from the power supply.
Flashing Green light; possible error in the charging, due to plugging the charger into the battery charging port before plugging the power plug into the electrical supply plug, a power surge or interruption while charging, etc.
NOTE: The Velocity lithium battery upgrade must be charged with the supplied lithium battery charger.
Lithium battery life is shortened if the recharge is too fast, the provided charger is set to maximize the recharge without damage to the lithium battery.
Lithium batteries cannot be charged with SLA battery chargers.
NOTE: This is a very valuable charging tool that is used in the Thumbs Up shop on all OSET charges.
The timer allows the rider to preset a specific charge time for the Velocity lithium or any other battery charger.
After setting the desired charge time the timer will shut off power to the charger.
NEVER LEAVE A LITHIUM BATTERY UNATTENDED WHILE CHARGING. SERIOUS RISK OF FIRE, INJURY OR DEATH COULD OCCUR.