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I know this is the DIY forum but I thought the folks here might have some experience with this. As a result of poor cord routing I broke a couple of wires right where the cord enters the battery pack. I didn't have enough cord exposed to splice the wires so I pried off the plastic grommet @ the battery pack. I ended up breaking that too because I thought it was a press-in type grommet but it ended up being a threaded grommet w/nut so when I got it pried off it pulled all the wires away from their connections inside the battery. Now I need to figure out how to open the battery container and reconnect all the leads. As far as I can tell the top & bottom caps are pressed & glued so I really have now idea how to proceed from this point. The light is only a year old and works quite well so I would like to get it up & working again but I can't see that it would be worth buying a new battery pack since they are > $200 and the MagicShines are only $90 for a complete light (I already bought a MagicShine and it is comparable to the Nite Flux although I still like the Nite Flux a little better if I can get it working again).<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>
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i think that before you proceed, it would be worth posting some close up pics
of the damage to the wiring and batterys/case
you will have to extract the batteries and discard the broken case anyway
 

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Hi Ive taken apart a photon max before ,the bottom cap is very well glued and doesnt
need to be taken out ,you need to grip the top plastic diameter in a vice or round lathe chuck
or similiar for better grip and gently rotate and pull at the same time to break the glue seal.
Be carefull when you pull the top off as the round cicrcuit board is screwed straight on to it.
You can then access the wire and disconnect the four 18650 batterys as there a connector between battrey and boad,you can then slide these out.
Hope this helps.
Regards Solarbake
 

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very helpful..a few questions

Hi This is very helpful..I got a battery that will not charge and not light up the bike light, and am getting ready to take it apart.

Do you have to disconnect (unscrew) the power cable that goes to the light (its got a plastic nut)?

I am hoping it is the batteries, and not the circuitry, should I get 18650 batteries, with or without protection? Can I get higher capacity batteries?

thanks

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solarbake said:
Hi Ive taken apart a photon max before ,the bottom cap is very well glued and doesnt
need to be taken out ,you need to grip the top plastic diameter in a vice or round lathe chuck
or similiar for better grip and gently rotate and pull at the same time to break the glue seal.
Be carefull when you pull the top off as the round cicrcuit board is screwed straight on to it.
You can then access the wire and disconnect the four 18650 batterys as there a connector between battrey and boad,you can then slide these out.
Hope this helps.
Regards Solarbake
 

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Hi Do not unscrew the plastic nut else the wires will twist and break,
you need to grip the ali can and pull of the cap in a straight direction,Use
a large flat bladed screwdriver if you hav to.
 

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Thanks Solarbake your suggestions were on the spot. Got the lid cracked open, the connector was (got?) disconnected, I am trying to figure out which way it gets back on, we tried it both ways...

seeing red light on the LED....once we figure out the connector, I have to identify the culprit (loose connection, circuitry, switch or battery). The battery registered 16.7 volts :)
 
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