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Throttle Replacement Guide

The throttle, when engaged by being twisted toward the rider, uses power assistance from the motor to propel the bike forward. In the unlikely event your throttle is damaged or determined to be non-functional by Rad Power Bikes Product Support, you will need to replace it.

This guide shows a throttle replacement on a model released in 2020, but the steps can be used as a guide to replace the throttle on a model released in 2019 or earlier.

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

Tools Needed:

  • Flat head screwdriver
  • Isopropyl alcohol
  • Paper towel
  • Flat side cutters
  • 3 mm and 5 mm Allen wrench
  • Torque wrench with a 3 mm Allen bit
  • A few zip ties
Remove the Throttle
  1. Prepare the bike for maintenance. Press and hold the MODE button on the LCD display remote (or the power button on the LED display) until the display turns off. Remove the battery, then press and hold the MODE button (or the power button on the LED display) until the display turns off to discharge remaining power.

    Prepare_bike_for_maintenance.PNG
  2. Remove the handlebar grip end cap. Locate the handlebar grip with the throttle and use a flat head screwdriver to carefully  pry the end cap off the handlebar end.

    End_cap.PNG
  3. Remove the handlebar grip. Carefully insert the screwdriver between the handlebar tubing and the grip and pry the grip away from the handlebar. Use a paper towel or squeeze bottle to apply a small amount of rubbing alcohol in between the grip and the handlebar as temporary lubrication. Twist and pull the grip off the handlebar end.

    Rubbing_alcohol.PNG
  4. Unplug the throttle connector. Trace the cable coming out of the throttle on the handlebar to the connector at the front of the bike. Use flat side cutters to snip any zip ties preventing the connector from being unplugged. Unplug the connector by pulling each side directly apart without twisting.

    Unplug.PNG
  5. Loosen the throttle clamp bolt. Use a 3 mm Allen wrench to loosen the throttle clamp bolt, located beneath the throttle. If needed, use a 5 mm Allen Allen wrench to loosen the brake lever clamp bolt, then rotate the brake lever up or down to allow throttle bolt access.

    Loosen_throttle_clamp_bolt.PNG


  6. Remove the spacer and then the throttle. Slide the spacer and throttle off the handlebar end, making note of the spacer orientation, which is critical for reinstallation.

    Orientation.PNG
  7. Discard the throttle. Follow local electronics recycling regulations to dispose of the throttle.
Install the New Throttle
  1. Install the new throttle and spacer. Slide the new throttle onto the handlebar end. Slide the spacer onto the handlebar end and push it toward the throttle until it is seated fully underneath the throttle. The throttle and spacer must be oriented and reinstalled properly for the bike to operate safely.

    Spacer_orientation.PNG
  2. Position and secure the throttle. Rotate the throttle so the power switch (on models released in 2019 and earlier) is easily accessible by the rider. Use a 3 mm Allen wrench to tighten the throttle clamp securely. Torque the bolt to 3 Nm. Do not overtighten.

    Tighten_bolt.PNG
  3. Plug in the throttle connector. Carefully align the internal notch and pins (and external arrows) and press each side directly together, without twisting, to fully seat the connection.

    Trace_cable.PNG
  4. Replace zip ties that were removed. Secure cables with zip ties to keep cables clear of any moving parts. Snip zip tie excess so the cut is flush and smooth.

    Snip_zip_ties.PNG
  5. Orient the grip so the narrower end points toward the center of the bike.

    Orient_grip.PNG
  6. Reinstall the handlebar grip and end cap. Apply a small amount of rubbing alcohol to the handlebar. Twist the handlebar grip into place and reinstall the end cap. Once the alcohol dries, the handlebar grip should be firm on the handlebar and should not easily move.

    Twist_grip_into_place.PNG
  7. Reinstall the battery and test the bike fully before riding.

    Reinstall_battery.PNG

Warning_-_Transparent.png Do not use the throttle unless you are on the bike. On models released in 2020, the throttle is active when the bike is on. On models released in 2019 and earlier, the throttle is active when the bike is on and the throttle button is pressed. Always keep one hand on the brake lever and be prepared to squeeze the lever to cut off power assistance if needed, or turn off the bike to prevent accidentally engaging the throttle.

 

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