Battery Fuse Replacement Guide

Follow the steps below to replace a fuse on your battery. This procedure applies to 2018 and newer batteries only.

Caution.png If you are not confident in your ability to successfully and safely perform all steps, we recommend having the work performed or checked by a local, certified, and reputable bike mechanic.

Tools Needed:

  • Small flat head screwdriver or an awl
  • Small needle nose pliers or a fuse puller
  • A replacement 5A and 40A blade fuse (these can be purchased at your local automotive store)
  • Electrical tape
  • Replacement fuse covers from Rad Power Bikes (if using an awl)
Caution.png Using an awl or another sharp tool to remove a battery fuse cover can cause irreparable damage to the fuse cover. If using an awl, please contact us to request a set of replacement fuse covers.  Do not operate the battery or bike without fuse covers properly  installed. Riding without fuse covers properly installed can lead to battery damage caused by water intrusion, or lead to serious injury or death.
Remove the Old Fuse
  1. Get the bike ready for maintenance. Turn off the bike, remove the battery, and press and hold MODE (or the power button) to discharge remaining power.
  2. Set the battery on a solid surface with the side with the fuse covers facing upward.
  3. Turn the battery key to the off and unlocked position ("C" in the illustration below).

    Battery_and_key_positions.PNG
    Caution.png Do not touch the "+" and "-" terminal contacts on the bottom of the battery. Keep the terminal contacts clear of debris, and do not drop or damage the battery. If the battery is damaged, discontinue use and contact Rad Power Bikes Product Support immediately. Never open the battery housing, which will void the warranty and can result in battery damage. It can also expose you to caustic substances and electrical shock or it could create a fire hazard, which can lead to serious injury or death.
  4. Identify the fuse that needs to be removed. The fuse rating is stamped into the battery housing just below the fuse cover. The 40A fuse is on the left and the 5A fuse is on the right.
  5. Remove the fuse cover. Use a small flat head screwdriver or an awl to carefully pry out the fuse cover. Set the fuse cover aside.

    Using a flat head screwdriver

    Remove_5A_cover1.gif

    Using an awl
    Using_an_awl1.jpg

    Caution.png Use caution when using a tool to remove a fuse cover from the battery housing. Position your body so the tool points away from your body to reduce the risk of injury if the tool slips. Use caution to avoid damaging the fuse and battery casing when using a tool to remove a fuse cover from the battery housing. Insert the tool at a shallow enough angle to avoid damaging the fuse and casing near and underneath the fuse cover.
  6. Remove the fuse. Use needle nose pliers to grip the fuse housing and pull the fuse directly outwards. If the fuse is difficult to pull, use the awl to pry each side of the fuse to rock it out the housing. Recycle the fuse according to local rules.

    Using a flat head screwdriver
    Remove_5A_fuse.gif

    Using an awl
    Rock_it_out.JPG

    Continue to the next section to install the new fuse.
Install the New Fuse
  1. Install the replacement fuse. Place the fuse in position and press it into the battery housing fully.

    Install_5A_fuse__2_.gif
  2. Reinstall the fuse cover if it is in good condition, or install the replacement fuse cover. Ensure the battery, the fuses, and the fuse covers are dry and free from debris.

    Tip

    If the fuse cover is damaged, contact us to order a replacement fuse cover. In the meantime, you can install the existing fuse cover and place a small strip of electrical tape over the fuse cover as a temporarily solution to prevent water or debris from entering the fuse port. Install the replacement fuse cover as soon as possible.

    Install_5A_cover.gif
    Caution.png Do not operate the battery or bike without fuse covers properly installed. Riding without fuse covers properly installed can lead to battery damage and result in serious injury or death.
  3. Reinstall the battery, test the bike fully before riding, and ride Rad!

Need more assistance?  Submit a request