2019 RadRover Wiring Harness Connector Check

Accessing the 2019 RadRover wiring harness connector is slightly different than on previous models. These instructions are designed to make that process as clear as possible.

mceclip0.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 local, certified, and reputable bike mechanic.

1. Power off the bike. Ensure the bike is in the off position and use the key to remove the battery. Once removed, press and hold the “MODE” button on the LCD Display Remote until the display remains off for about two seconds (it may flash on briefly). This ensures the power is fully discharged from the bike and it is safe to work on. 

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2. Carefully snip the two zip ties holding the cables in a bundle at the bottom of the bike. Locate one zip tie below the controller and the other under the bottom bracket. Use flat side cutters to snip the zip ties using caution to not damage the cable housing or wires.

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3. Carefully unseat the downtube grommet. Use a flat head screwdriver to carefully unseat one side of the grommet, taking care not to damage the cable housing, wires, or frame paint. Remove the grommet from the opening, sliding it down the cables.

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4. Unplug the battery connector, which runs from the bottom of the battery mounting tray, through the frame, cable opening in the downtube, below the bottom bracket, and to the bottom of the controller. Pull on the connector body (not wires) directly apart without twisting to unplug this two pin connector.

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5. Pull the battery connector out of the way, almost completely out of the cable hole/grommet on the battery mounting tray side of the downtube. This step will free up space in the downtube and make it easier to pull the wiring harness connector out of the cable opening on the bottom of the downtube. Note: in most cases pulling the connector body into the seated grommet provides enough clearance for the wiring harness connector to slide down past the battery connector. It may be necessary to push the connector back in, unseat the upper grommet carefully, and fully remove the battery connector from the upper cable opening.

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6. Rotate the handlebar completely to the right and push the thickest cable into the upper cable opening in the downtube to provide wiring harness cable slack. 

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7. Pull the thick wiring harness cable down through the lower cable opening on the downtube until the bulge of the cable connector comes out (below, left). 

Notice: if the wiring harness connector is or becomes unplugged with the upper end in the downtube, unseat the upper grommet, fully remove the battery connector, and carefully use a screwdriver, from the upper opening down, to push the wiring harness connector down to the lower opening. Do not insert any tool from the lower opening upwards, as that can damage the pins of the connector.

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8. Check the connector (above, right). Unplug the connector and inspect the pins inside. Align the pins and notch and press the connector together to fully seat the connection.

 

9. Insert the wiring harness connector through the cable opening and into the downtube. Rotate the handlebar to the center to remove cable slack if necessary.

 

10. Reconnect the Battery connector. Push the battery connector end directly through the downtube and out through the cable opening (a) and pass the end through the grommet (b). Align the flat sides of this connector (c, d) and press the ends directly together to fully seat the connection (e).

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                   a                                              b                                                       c            

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                         d                                                    e

 

11. Reseat the downtube grommet by aligning one side and then pressing it into place. Repeat with the upper grommet (if necessary). 

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12. Use two zip ties to secure the cabling below the bottom bracket and controller.

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13. Reinstall the battery and lock it onto the frame in the on position, aligned with the open circle icon depicted below.

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

 

Contact Rad Power Bikes Product Support if you have any questions!

By email: support@radpowerbikes.com

By phone: (800) 939-0310 x2