How to Wire a Scooter Battery

Scooters didn't use batteries for electrical power until the late 1960s.

Wiring a scooter battery is not a complicated procedure if you have some general know-how about electrical systems; it requires some level of understanding electrical connections and positive and ground wiring, as well as being able to identify potential short circuits. Batteries provide somewhat tricky situations because, if wired wrong, they will cause the electrical system to fail, in a best-case scenario, and could even explode, in a worst-case scenario.

Things You'll Need

• Screwdrivers
• Wire crimper
• Wire cutter
• Battery tester
• Crescent wrench set (metric sizing)
• Wire stripper tool
• Wiring plan for your scooter model
• Trickle battery charger
• Pliers
• Needle-nose pliers

Instructions

1. Locate the wiring plan for your scooter. Pull the new battery out of its shipping box. Wet the battery down by adding water, as instructed in the manufacturer's instructions. Allow a dealer to wet the battery, if you are not sure how to proceed. Remove the water plugs on the top of the battery, as it charges. Charge the battery sufficiently, using a trickle charger. Remove the battery from the charger. Re-insert the water plugs and attach the drain hose that comes with the battery.

2. Locate the terminal hardware in the battery shipping box (two screws with two matching nuts). Take the battery and place it in the battery holder in the scooter. Confirm that the battery seats properly, without any imbalance. Find the battery elastic strap and hook it to the scooter; wrap it around the battery and hook the other strap end to the scooter frame, as well. Confirm that the battery sits tightly.

3. Take the black wire coming from the scooter wiring system and make sure that the wiring end has the proper connector. Remove the wrong connector, if it exists, by snipping it off at the base, then use a wire stripper to remove the insulation on the cut end. Take a new connector and place it on the end of the bare black wire. Insert the bare wire into the connector and squeeze the connector tight on the end, using a crimper tool. Line up the new connector end to the negative battery terminal (symbolized by a "-" sign). Connect it with the hardware and screw it tight with a screwdriver and crescent wrench. Repeat the same process for the red wire.

4. Make sure that the fuse in the scooter wiring system shows no burn-out signs. Find the "On" switch and turn the scooter's electrical power on only--not the engine. Confirm that there are no short circuits by testing the electrical switches. Find the short in the system, if the fuse burns out, replacing the fuse when fixed.

5. Turn on the scooter engine and test the electrical switches with the engine running. Confirm a second time that the battery sits securely, and then shut down the scooter's engine. Take it for a test ride to confirm everything works properly.

Tips & Warnings

• Make sure to disconnect the battery if your scooter is going to sit for an extended period of time. This prevents the battery from draining quickly. Re-charge the battery monthly with a trickle charger if the sitting period lasts for a few months.

• Avoid any sparks on or near the battery. The battery acid gas from the battery cells inside can ignite and explode.

• Any battery work should be done wearing eye goggles or similar protection at all times.

References

• Vespa Maintenance: Battery Service
• GS Motor Works: Easy Scooter Assembly
• I Scoot NY: Scooter FAQ

Resources

• Bajaj: Bajaj Scooter Wiring Diagrams
• Scooter Help: Vespa and Lambretta Scooter Wiring Diagrams
• Electrical Wiring Diagrams: Vespa P200 Wiring Diagram