Ranger: Double battery pack installation manual (upgrade from single pack)

WARNING!

If You don’t have sufficient mechanical knowledge, experience and proper tools, we strongly recommend, that You have these operations done by Your selling dealer or at Your local motorcycle service center! Making mistake during the disassembly or assembly of the electric system will void the warranty and may cause a hazardous situation, resulting in fire, severe injury or death and damage to property.
For safety reasons it is strongly recommended to leave the battery discharged before handling any component of the motorcycle's electrical system!
Do not let the battery to stay fully discharged, as it may have a negative impact on its capacity. Charge the battery after each ride.

Follow these steps to remove the original single battery pack:

Required tools:

hex wrench #3
hex wrench #5
wrench #13
cutting plier
Torx wrench #T25

Make sure, that the magnetic kill switch is in OFF position (magnet NOT attached) and the battery state of charge is very low.
Engage the motorcycle stand.
Using the hex wrench #3 loosen and remove the 2 bolts holding the inspection lid (from below the frame, just above front fender).
Disconnect the two main red and black power connectors from the battery.

WARNING:
Ensure, that the main red and black power connectors are separated and can NOT get in contact with each other or with the frame!
Disconnect the yellow charge port connector and the small black connector for the main ON/OFF kill switch from the battery.
Using the hex wrench #3 loosen and remove the 3 bolts from the left controller cover and remove the cover from the motorcycle.
Repeat the same for the right controller cover with the charge port. Be extra carefull and do NOT damage any cables.
Cut the upper zip tie on the right side (if necessary), install the supplied C-clip nut according to the picture and put new zip tie to fix cables to the frame.
Using the hex wrench #5 and the wrench #13 loosen and remove the 4 bolts and 2 nuts, that hold the foot rail to the frame, and remove the foot rail from the motorcycle.
Using the hex wrench #5 loosen and remove 2 bolts from the right lower battery holder and remove the holder from the motorcycle.
Repeat the same for the left lower battery holder.
With the same hex wrench loosen and remove the bolt altogether with the battery pressure pad. This bolt is visible only when the reclining seat is engaged.
With the help of another person gently remove the battery out from the frame. Be extra careful to the wires and connectors.

WARNING!
Ensure, that the main red and black power connectors are separated and can NOT get in contact with each other or with the frame!

Follow these steps to install the new double battery pack:
With the help of another person gently install the new battery into the frame. Be extra careful to the wires and connectors.

WARNING!
Ensure, that the main red and black power connectors are separated and can NOT get in contact with each other or with the frame!
Install the right lower battery holder on the frame with 2 bolts, removed during step #10 and #11. Use a small ammount of a threadlock with medium strength (blue) on each thread. Using the hex wrench #5 tighten the bolts (18 - 20 Nm).
Repeat the same for the left lower battery holder.
Reinstall the battery pressure pad and its bolt, removed during step #12. Using the hex wrench #5 tighten it gently (5 - 6 Nm).
Using the supplied Torx bolts M5x6 and a small ammount of a threadlock with medium strength (blue) assemble the right plastic bodywork with both side pannel holders according to the picture. Using the Torx wrench #T25 tighten the bolts (5 - 6 Nm).
Install the right plastic bodywork on the frame. Be very carefull and do NOT damage any cables. Pull the charge port cable through the frame first and then slide the upper side of the plastic bodywork in the frame.
Install 1 of the 2 supplied Torx bolts with countersunk head (M5x16) to the upper hole on the right plastic bodywork and using the Torx wrench #25 tighten it just slightly. Then install 2 of the supplied Torx bolts with countersunk head (M5x6) to the lower holes on the right plastic bodywork. Using the Torx wrench #25 tighten all bolts (5 - 6 Nm).
Connect the main red power connector from the battery to the red connector from the controller. Double check, that the wiring is correct!
Connect the main black power connector from the battery to the black connector from the controller. Double check, that the wiring is correct!
Connect the yellow charge port connector from the battery to the yellow connector from the controller. Double check, that the wiring is correct!
Connect the last small black connector from the battery to the black connector of the main ON/OFF kill switch. Double check, that the wiring is correct!
Gently allign all the wiring cables to fit into the frame.
Install the 4 remaining Torx bolts with countersunk head (M5x6) from the lower side of the left plastic bodywork and using the Torx wrench #25 tighten them (5 - 6 Nm).
Put the inspection lid back on its place, install the 2 bolts, that were removed in step #3, and using the hex wrench #3 tighten them (2 - 3 Nm).
Unpack the footrail from the packing foil and unscrew the 2 side bolts from the front U-bracket. Using the hex wrench #5 and wrench #13 loosen and remove the 2 rear bolts and 2 nuts.
Install the new and wider footrail onto its place. Use a small ammount of a threadlock with medium strength (blue) on each thread and hand tighten a few threads on each of 4 bolts. Using the hex wrench #5 tighten all 4 bolts (18 - 20 Nm). Then install the 2 nuts and using the hex wrench #5 and the wrench #13 tighten them (18 - 20 Nm).
Double check, that all bolts and nuts are properly tightened.

If Your motorcycle is under warranty, please register it on our website, if You have not already done so:
https://www.kuberg.com/en/bike-registration

If the problem persists, please contact Your dealer or KUBERG customer service (support@kuberg.com). For the fastest possible resolution please send:

VIN of Your motorcycle (it is stamped on the right side of the steering column).
Detailed information on actions taken so far, a few photos and preferably a video.

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Ranger: Double battery pack installation manual (upgrade from single pack)

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