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RadRover Wiring Harness Replacement Guide

The wiring harness on the RadRover runs through the downtube and connects various electrical components. The wiring harness can be replaced in the unlikely event it is damaged or determined to be non-functional by Rad Power Bikes Product Support.

You will need:

  • Flat side cutters
  • Flat head screwdriver
  • String a few inches longer than the length of the downtube
  • Electrical tape
  • A few zip ties
  • The replacement wiring harness from Rad Power Bikes
    1. Get the bike ready for maintenance. Turn off the bike, remove the battery, and press MODE to discharge remaining power.
    2. Unplug the connectors at the front of the bike.
      1. Snip zip ties securing the cables.
      2. Start with the silver metal display connector and untwist the metal portion of the connector, then pull each side directly apart, without twisting, to unplug.

        Display_connector.gif
      3. Pull each remaining connector directly apart, without twisting, to unplug.
    3. Turn the handlebar and feed the wiring harness into the downtube. Locate the wiring harness cable at the front of the bike and gently feed the cable into the upper cable opening of the downtube.

      Create_slack.gif
    4. Unseat the rubber grommets. Use a flat head screwdriver to carefully unseat the rubber grommet at the upper and lower cable openings.

      Remove_grommets.gif
    5. Access the wiring harness connector. At the bottom of the downtube, carefully pull the wiring harness cable until the connector is out of the lower cable opening. Use caution to avoid unplugging the connector while inside the downtube. Once the connector is out of the downtube, pull each side of the connector directly apart, without twisting, to unplug.

      Access_connector.gif
    6. Secure the string to the connector end. Tie and tape the string to the wiring harness connector end at the bottom of the downtube (the string will be used to pass the new wiring harness through the downtube). Insert the connector end into the downtube.

      Insert_connector_into_downtube.gif
    7. Remove the wiring harness through the top of the downtube. Carefully pull the wiring harness out of the upper cable opening, ensuring the string comes out of both cable openings and remains inside the downtube.

      Remove_harness.gif
    8. Pass the upper grommet off the wiring harness and onto the string.
    9. Remove the string from the wiring harness. Allow the string to hang outside of both cable openings. Recycle the old wiring harness according to local rules.
    10. Secure the string to the new wiring harness. Tie and tape the string coming out of the upper cable opening to the single-connector side of the new wiring harness.

      Secure_string.gif
    11. Pass the connector through the downtube. Pass the connector end through the rubber grommet at the upper cable opening and gently push the connector into the downtube. At the same time, gently pull on the string at the lower cable opening until the connector moves out of the opening.

      Install_new_harness.gif
      Caution.png Do NOT use any tools (other than the string and tape) to assist in directing the connector end out of the lower cable opening. Tools like pliers, screwdrivers, etc. can easily damage the connector pins and housing, especially when inserted from the lower cable opening upwards into the downtube. 
    12. Connect the wiring harness to the controller. Remove the tape and untie the string from the connector end. Locate both connector ends and ensure the connector end passes through the grommet. Line up the internal notches and pins (and external arrows) and press directly together, without twisting, to connect.

      Reconnect.gif
    13. Insert the connector into the downtube. Double-check that the connection is secure and gently place the connector into the downtube through the lower cable opening. Reinstall the rubber grommet.

      Insert_connector.gif
    14. Adjust the wiring harness at the front of the bike. At the front of the bike, gently pull the wiring harness cable to add cable slack, then reinstall the rubber grommet.
    15. Plug in the display connector. Line up the internal notches and pins (and external arrows) and press directly together, without twisting, to connect. Then twist the metal portion together fully.

      Plug_in_display.gif
    16. Plug in the headlight connector. Trace the cable coming from the bottom of the wiring harness junction, and locate the matching connector end coming out of the headlight. Line up the internal notches and pins (and external arrows) and press directly together, without twisting, to connect.
    17. Plug in the remaining connectors. Plug in all other connectors at the front of the bike.
      1. Locate the wiring harness connector ends and the matching connector ends. Trace the cable from the part to the connector end and ensure the connectors match.
      2. Line up the internal notches and pins (and external arrows) and press directly together, without twisting, to connect.
        Caution.png Do not plug in a connector to the wiring harness if it does not match in color and shape. Doing so could cause irreparable damage to the connector, the part, or the wiring harness.
    18. Secure cables with zip ties. Trim the zip ties to be flush and smooth.

      Zip_ties.gif
    19. Reinstall the battery and test the bike fully before riding.
Caution.png If you are not confident in your ability to safely and successfully perform all steps, we recommend having the work performed or checked by a local, certified, and reputable bike mechanic.

 

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