The wiring harness connects various electrical components and can be replaced in the unlikely event it is damaged or determined to be non-functional by Rad Power Bikes Product Support.
We recommend using two people in order to safely replace the wiring harness.
Read through the instructions 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.
- Flat head screwdriver
- Flat-side cutters
- String or paracord (about 4’)
- Electrical or masking tape (about 3”)
- Replacement zip ties
- A friend to help hold the bike in place
- The replacement wiring harness from Rad Power Bikes
- Turn OFF the bike. Use the battery key to unlock and remove the battery from the bike.
Once the battery is removed, press and hold the MODE button on the LCD Display
Remote until the LCD Display has remained off for a few seconds, to ensure the
electrical system is fully off and safe for maintenance activities.
- Snip relevant zip ties. Locate the zip ties that bundle the wiring harness and other
cables together near the handlebars and end of the downtube of the frame. Use flat-side
cutters to carefully snip each zip tie. See the images below identifying the location of
these zip ties. Use caution to protect all cables and cable housing; snip only the zip tie using
a flat-side cutters.
- Remove the Downtube Grommet. At the left side of the bike, locate the cable opening
at the back of the end of the downtube and the black, oval-shaped, rubber grommet
installed around the edge of the opening. Use a flat head screwdriver to carefully unseat
the grommet (see below).
- Expose Downtube Connectors. Use the handlebars to turn the bike wheel to the right,
which will provide slack necessary to expose the connectors that are housed inside the
bottom of the downtube near the cable opening. Unlock the hinge latch and partially
open the folding mechanism hinge. Have a friend hold the handlebars of the bike
keeping the frame and hinge steady, and the front wheel turned to the right. Then,
starting near the handlebars, gently push the wiring harness cable into the cable opening
of the head tube. Gently pull on the cable through the opening at the front of the hinge
and push the cable through the opening at the back of the hinge. Then, return to the
cable opening at the bottom of the downtube and gently pull out the cable connectors.
Note: Pull directly on the connector body, not on the cable directly whenever
- Unfold and lock the frame. Close the folding mechanism and secure the latch to lock
out the frame properly.
Note: whenever closing the folding mechanism, use caution to keep clothing and body parts clear of the folding hinge. Ensure there is no slack in the internally routed
cables and take care to never pinch cables (or anything) with the hinge.
- Identify the connectors that will need to be unplugged. The two connectors pulled
from the downtube with the largest diameter cables are the wiring harness (1 orange,
below) and the battery connector cable (2 blue, below).
- Unplug the Wiring Harness Connector (1 orange, below). Grab each side of the
connector body and carefully pull the connector apart without twisting or tugging directly
on the cable. The inside of the wiring harness is a black, 10-pin connection (see image
below at right) (note: double check the unplugged connector is correct. The battery
connector is a black, 2-prong connection, which remains plugged in throughout this
- Prepare to simultaneously remove the old wiring harness and thread the new
wiring harness through the downtube. Locate the new wiring harness and tie one end
of an approximately 4’ long piece of string or paracord to the end that will plug into the
connector at the head tube of the bike. Tape the string to the connector body to prevent
the connector body from bending and getting caught in the downtube (see below). Tie
the other end of the string to the bottom connector of the old wiring harness.
- Remove the old wiring harness. Starting at the wiring harness connectors at the Head
Tube, unplug the connectors (to the two brake levers, throttle, and display) and carefully
pull the old wiring harness out of the downtube.
- Thread the new wiring harness through the downtube. Feed the taped connector through the hole at the back of the downtube and allow the pulling of the old wiring harness out to thread the new harness through the downtube.
- Plug in the new wiring harness near the head tube. Once the connectors for the new
wiring harness have been pulled through the opening near the head tube of the bike,
remove the tape and untie or cut the string. Match the connectors by color, align the pins
and the notches in the connector body, and carefully plug in the new wiring harness to
each corresponding connector (to the two brake levers, throttle, and display).
- Thread the wiring harness connector through the grommet. Locate the connector
end for the new Wiring Harness near the base of the bike and the other side of the
connection. Ensure the other side of the connection is threaded through the rubber
- Plug in the wiring harness near the bottom of the downtube. Align the pins and the
notch in the connector housing, and carefully plug in the new wiring harness connector
to the other connector that has been threaded through the grommet.
- Push the connectors into the cable opening at the downtube end. Ensure all wires
and brake/shifter cables that come out of the cable opening also run through the
grommet, then carefully push the wiring harness and battery connectors back into the
cable opening at the downtube end.
- Replace the rubber grommet at the cable opening at the downtube end. Grab the
oval-shaped rubber grommet and while pinching the long sides together, seat the top of
the grommet at the top of the cable opening. Work each side of the grommet onto the
sides of the metal cable opening.
Once only a small amount of the grommet is unseated from the rim of the cable opening,
use a flat head screwdriver to very carefully press the grommet back onto the opening so
the entire grommet is properly seated.
Note: Use extreme caution to press only on the grommet and avoid damage.
- Replace the zip ties at the front and bottom of the bike. Gather the cables at the front
of the bike near the head tube, zip tie them together, and use flat-side cutters to snip
away excess. Repeat for the cables near the Downtube end.
- Test the bike for safe operation. Mount the bike onto a bike maintenance stand, power
the bike ON, test all electrical and mechanical components for safe and proper
operation. Have the bike inspected for safety by a certified, reputable bike mechanic.
Questions or comments? Contact us!
Phone: (800) 939-0310 x 2