Scootertalk Forums have helped me A TON over the past few years, so I decided to try to give a little tiny bit back to the cause. I noticed a gap in some of the information regarding the Bird 590 Conversion, and this post is only addressing the gap (not the entire conversion - for that, search the forum....) It's nothing new, but here are a few clear images of what a proper BMS Bypass should look like on a Bird 590. After you properly wire the new controller into your 590, this is the last major step to make it run properly, and not cut out power i ntermittently.----- Original Credits to SAMZONE.
1. Open the Battery Compartment ((((CAREFULLY))))
2. Cut the Large Black Wire- Near - to its Connection... on the Circuit Board (its the farthest, closest wire to the edge, the biggest black one)
3. Strip the End of the Wire
4. Find an equally thick, insulated, piece of scrap wire you have, and cut it approximately the length of the battery
5. Solder one end of your scrap wire to the end of the black wire - that is found now dangling free in the tangle of wires
6. Solder the other end of your scrap wire to the far edge of the circuit board, on the B- Contact Square. (I pealed up the metal edge of the plate on top of it, but i'm not entirely sure if you need to, probably not)
Just make sure you have a good solid proper solder joint on that B- Contact Square (See Pictures)
7. Now you have bypassed the BMS
8. Great Job! Share your knowledge.
(The Red wire stretching across the BMS board is my scrap piece of wire (if you havent figured that out..))