Shifter Replacement

mceclip34.png Read through these 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 certified and reputable local bike mechanic.

 

1. Gather the tools you will need: Flat head screwdriver, isopropyl alcohol, a paper towel, flat side cutters, 5 mm Allen wrench, 3 mm Allen wrench, a torque wrench (with 3 mm and 5 mm Allen bits and a flat head bit), replacement zip ties, cable cutters or needle nose pliers, cable end crimp, Phillips head screwdriver (optional).

 

2. Turn off the bike. Press the MODE button until the bike and LCD Display turn OFF. 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 (it may flash on). This will ensure the electrical system is fully off and safe for maintenance activities.

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3. Slide the handlebar grip off the handlebar. The grip can be pulled directly off the handlebar end, so first try rotating and pulling to remove. If stuck in place, use the techniques below to remove the grip more easily:

a. Use a flat head screwdriver to pry off the handlebar grip end cap and set aside.

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b. Apply a small amount of isopropyl rubbing alcohol to a paper towel. 

c. Use the flat head screwdriver to carefully pry the handlebar grip away from the handlebar so there is a small gap between them.

d. While keeping the screwdriver in place, squeeze the paper towel against the top of the screwdriver so a small amount of rubbing alcohol drips in between the interior of the grip and exterior of the handlebar to temporarily lubricate those surfaces. Repeat squeezing rubbing alcohol between the grip and handlebar as needed. 

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e. Twist and pull the grip to slide it off the handlebar end and set aside. (If still stuck, mix a small amount of dish soap with a small amount of water and apply a couple drops at a time between the interior of the grip and exterior of the handlebar to lubricate. Once removed, use a clean damp cloth to remove all liquid and soap residue to prevent the handlebar grip(s) from moving while riding, which could cause a dangerous situation.)

 

4. Remove the spacer and set aside. Take note of the orientation of the spacer for reinstallation.

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5. Unplug the throttle-wiring harness connector. Trace the cable coming out of the throttle to the bulge in the cable (the connector). If needed, use flat side cutters to snip the zip tie(s). Grab the connector housing and pull directly apart without twisting to disconnect.  

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6. Remove the throttle. Use a 3 mm Allen key to loosen the throttle clamp bolt, the bolt under the throttle and perpendicular to the throttle power switch (1, below). If needed, move the brake lever out of the way of the throttle bolt by loosening the brake lever clamp bolt (2, below) with a 5 mm Allen wrench and rotating the lever up or down to allow throttle bolt access. Once the throttle is loose, slide it off the handlebar end.

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Notice: To access the throttle clamp bolt (1), it may be necessary to first loosen the brake lever clamp bolt (2) (using a 5 mm Allen wrench) and rotate the brake lever out of the way.

 

7. Remove the brake lever. Depending on the brake cable length, it may be possible to slide the brake lever off the handlebar end while keeping the cable attached to the rear brake caliper and brake lever. To do this: 

a. If necessary, snip the zip ties holding the brake cable housing to the wiring harness and cable guides on the bike. 

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b. Use a 5 mm Allen wrench to loosen the brake lever bolt. 

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c. Rotate the handlebar to the left, to add cable slack, and slide the brake lever off the handlebar end. Set aside for reinstallation.

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d. If more brake cable slack is needed, first unplug the brake-wiring harness connector and attempt to slide the brake off the handlebar end.

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e. If still more brake cable slack is needed, loosen the brake cable pinch bolt on the rear brake caliper using a 5 mm Allen wrench until the cable can move through the bolt, then slide the brake lever off the handlebar. 

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8. Remove shifter cable crimp. At the derailleur on the right side of the rear wheel, locate the shifter cable end, which should have a small metal crimp as an end cap. Use pliers to un-crimp, remove the cable crimp from the shifter end, and set aside.

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9. Add shifter cable slack. Use a 5 mm Allen wrench to loosen the cable pinch bolt just enough to slide the shifter cable end out of the pinch bolt towards the back of the bike. 

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Notice: Loosen the cable pinch bolt about one turn at a time. Do not allow the hardware to come fully off the derailleur. Contact Product Support if the hardware does accidentally come off. 

 

10. Ensure the bike has been shifted into gear 7 and if not, press the shifter button until the dial reads it is in gear 7.  

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11. Remove the shifter cable. 

a. Locate where the cable housing meets the shifter and pull the housing away from the shifter and towards the center of the bike to expose some of the cable near the shifter. 

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b. Push the cable through the shifter and towards the handlebar end. Grab the shifter cable end and gently pull the shifter cable fully out of the cable housing and shifter and discard the old cable.

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12. Remove the old shifter. Use a Phillips or flat head screwdriver to loosen the shifter clamp bolt on the underside of the shifter. 

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mceclip34.png Apply constant pressure to maintain firm contact between the screwdriver and the bolt and prevent the bolt head from stripping, especially if using a Phillips head screwdriver. 

 

13. Install the new shifter. Slide the new shifter onto the handlebar and align for ease of use by the rider. Use a flathead screwdriver, applying constant pressure, to tighten the shifter clamp bolt. Torque to 6 Nm. 

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14. Install the new shifter cable. Ensure the new shifter is in gear 7 for access to the cable opening in the shifter body. Insert the end of the shifter cable into the cable opening (circled below) and carefully push the cable through the shifter body. 

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15. Pass the new shifter cable through the cable housing. 

a. Thread the cable end into the cable housing nearest the shifter. If necessary, remove the cable housing end cap, pass it over the cable end, and then pass the cable end through the opening at the cable housing end. 

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b. Press the end of the housing into the opening at the shifter body. Push the cable through the remainder of the housing, through the frame. 

Notice: on most of our bike models, there are two sections of cable housing (approximate location in orange) and one section of exposed cable near the chainstay of the frame (in blue). When the cable is removed, it is possible the small section of housing at the back of the bike may fall off, and it may be easier to reinstall the cable with that section of housing removed from the frame. 

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The 2019 RadWagon has a continuous cable housing.

c. Pass the cable through the first cable guide following the instructions depicted below:

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First cable guide (circled, above)   

 

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i. Remove housing from guide           ii. Pass cable through opening

 

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iii. Pass cable through cable stop    iv. Fully seat cable stop in first cable guide

d.  Pass cable through second cable guide following the instructions depicted below:

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Second cable guide (circled, above)

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Remove the cable housing, pass the cable through the housing and seat housing in cable guide

 

16. Install the shifter cable at the derailleur.

a. Ensure the chain is located on the smallest sprocket (7th gear) and the shifter is in 7th gear.

b. Pass the cable end through the barrel adjuster and the small opening and notch between the cable pinch bolt and backing nut. 

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c. Pull the cable so there is no slack, but not so tight that the cable moves the derailleur body in towards the wheel, and use a 5 mm Allen wrench to tighten the cable pinch bolt.

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17. Ensure the cable housing is seated in the cable guides on the frame. Once the cable has passed though that section, ensure the cable housing ends are fully seated in the cable guides on the frame.

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18. Adjust the derailleur and take out cable slack if needed. With the rear wheel off the ground, rotate the pedals forward by hand and shift through the gears. Adjust the derailleur if needed.        

mceclip34.png If you do not have the tools, skills, or experience to properly install the shifter cable and adjust the derailleur, work with a certified, local bike mechanic to install, adjust, and tune these and other components on your bike. Improper installation of the shifter, cable, and derailleur adjustment can result in unsafe operating conditions, damage to the bike, property, serious injury, or death. 

 

19. Cut the cable to size. Once the cable housing is fully seated in the cable guides on the frame, and the derailleur is adjusted and shifting properly, use cable cutters to trim off excess shifter cable. Ensure there is around 3” of cable after the cable pinch bolt on the derailleur. 

mceclip34.png Cable ends are extremely sharp, especially when the cable has frayed. Use caution to avoid sharp and frayed cable ends or injury could occur. 

 

20. Install the cable crimp. Pass a new cable crimp onto the cable end and use the crimp portion of the cable cutters or needle nose pliers to secure the crimp at the end of the cable.  

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21. Reinstall the brake lever. Pass the brake lever back onto the handlebar end and use a 5 mm Allen wrench to tighten the brake lever bolt. Torque to 6 Nm.

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22. Reinstall the throttle. Slide the throttle onto the handlebar end. Rotate the throttle to the throttle power switch is easily accessible by the rider. Use a 3 mm Allen wrench to tighten the throttle bolt. Torque to 3 Nm.  

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23. Reinstall the spacer onto the handlebar so the narrow end tucks between the handlebar and the throttle body and the wider end is toward the handlebar end.

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mceclip34.png The spacer must be properly installed between the throttle and the handlebar grip for the bike to operate safely.

24. Reinstall the handlebar grip. Apply a small amount of isopropyl rubbing alcohol or water to the top of the handlebar end and then slide and twist the grip into place. Reinstall the handlebar grip end cap. Once the alcohol or water dries, the handlebar grip should not move or twist easily.

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Notice: Ensure the grip end is flush with the handlebar end and the spacer and throttle are aligned as shown (below, at right).

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25. Reconnect the brake-wiring harness connector and the throttle-wiring harness connector. Find the match for each of these connectors, align the internal notches and pins and external arrows and press directly together to full seat the connections.

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Brake-wiring harness        Throttle-wiring harness

 

26. Reinstall zip ties. Organize cables as they were before removing components and replace the zip ties holding them neatly together. Use flat side cutters to snip the zip excess.

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27. Reinstall the battery, test the bike fully, and have your work inspected by a certified, reputable bike mechanic. 

 

For questions or assistance, please contact Rad Power Bikes Product Support by email to support@radpowerbikes.com or by phone to (800) 939-0310 x 2.