The wiring harness is a part that connects various electrical components on ebikes by Rad Power Bikes, and runs through the downtube of the frame on the RadRover. Overall, replacing this part involves unplugging the connections, pulling it out of the frame/ pulling the new one through the frame, and plugging in all of the connections.
Read through these instructions, watch the video, and contact Rad Power Bikes Product Support if you have questions. If you are not confident in your ability to successfully and safely perform all steps, we recommend having the work performed by a local, certified, and reputable bike mechanic.
1. Power off the bike. Ensure the bike is in the off position and use the key to remove the battery. Once removed, press and hold the “MODE” button on the LCD Display Remote until the display remains off for about two seconds (it may flash on briefly). This ensures the power is fully discharged from the bike and it is safe to work on.
2. Unplug the wiring harness from the controller. The connection is located underneath the bottom bracket. The connector may be partially inside the frame of the bike (within the downtube). Turn the handlebars all the way to the right to provide extra slack if needed. Hold both sides of the connector body and pull directly apart without twisting to unseat the connection.
Fig. 1 Wiring Harness connection
Fig. 2 10 pins
3. Verify that you have unplugged the correct connector by examining the inside of each side; the wiring harness connector is black on the inside and has a 10 pin connection.
4. Disconnect the electrical connectors near the handlebars. These connections include those coming from the LCD display, both brake levers, the headlight ,and throttle. It will be necessary to snip the zip ties that organize the wires.
Fig. 3 In order from the top (left brake connection, LCD display, right brake connection, throttle connection)
5. Remove the old wiring harness. Pull the wiring harness up through the frame of the bike. To make it easier to reroute the new wiring harness, tie a string (about 4' long) to the old wiring harness. Thread the sting through the downtube as you remove the old wiring harness so you can untie it from the old harness, tie it to the new harness, and pull the string to more easily install the new wiring harness.
Fig. 4 A string looped to old wiring harness.
6. Install the new wiring harness. Pass the wiring harness controller-connector end through the upper cable opening or tie the string to that end and pull the string from the cabel opening at the bottom bracket to pull the wiring harness through the downtube of the frame. Ensure the connector is through the rubber grommet. Align the internal pins and external arrows on the connector housing and press the two sides together without twisting to fully seat the connection.
7. Reconnect the connectors near the handlebars. Each connection is color coded so you know you are connecting each connection to its appropriate mate. When each is matched to its mate, align the internal notches and pins and external arrows and press the connector ends directly together without twisting to fully seat the connection.
Fig. 5 Red connections are brake connections, yellow connection is throttle, silver connection is LCD display.
8. Reinstall the battery, test the bike fully, and have your work inspected by a certified, reputable bike mechanic.
For questions, contact Rad Power Bikes Product Support by email to firstname.lastname@example.org or by phone to (800) 939-0310 x 2.