Front Rack Installation: Brake Cable Rerouting Guide

The front rack accessory ships with a plastic cable guide and two zip ties. These parts are needed to reroute the front brake cable on some models. Rerouting the brake cable will protect the cable housing while installing and using the front rack.  

This guide will show you how to check if your brake cable needs to be rerouted before installing a front rack, and how to reroute the brake cable if needed.

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.

You will need:

  • 3 mm Allen wrench
  • 5 mm Allen wrench
  • Torque wrench with a 5 mm Allen bit
  • Needle nose pliers
  • Isopropyl alcohol
  • A paper towel or a clean shop towel
  • Tape measure or ruler
  • Flat side cutters
  • The cable rerouting hardware included with the front rack accessory:
    • an adhesive cable guide
    • two zip ties; one longer than the other

Follow the steps in the headings below to reroute the brake cable if needed.

Check the Position of the Brake Cable
  1. Get the bike ready for installation. Turn off the bike, remove the battery, and press and hold MODE (or the power button) to discharge remaining power.
  2. Trace the cable coming out of the left brake lever to the caliper near the front wheel.

    If the brake cable runs in between the fork and the wheel and is secured at the front of the fork lower (as shown in the image below), follow the steps in this guide to reroute the brake cable before installing the front rack.

    RadCity_fork_lower.png

    If the brake cable runs over the fork crown and is secured on the rear of the fork lower (as shown in the image below), you do not need to reroute the brake cable. Click HERE to return to the Front Rack Installation Guide and follow the steps to continue installing the front rack.

    RadRover_brake1.png
Prepare the New Cable Guide
  1. Prepare the cable guide and fork lower for installation.
    1. Locate the cable guide and two zip ties included with the front rack accessory.
    2. Orient the longer zip tie so that the raised portion of the locking end points in the same direction as the raised portion of the cable guide (1 in the image below).
    3. Pass the larger zip tie through the cable guide.
    4. Orient the shorter zip tie so the raised portion of the locking end points away from the raised portion of the cable guide and opposite the large zip tie (2 in the image below)
    5. Pass the smaller zip tie through the cable guide.

      mceclip4.png   IMG_3194__1_.jpg
    6. Clean the fork lower. Apply some isopropyl alcohol to a paper towel and wipe the back of the fork lower. Allow the area to dry completely.

      mceclip5.png
  2. Locate the brake caliper at the front wheel and remove the brake cable.
    1. Locate and remove the brake cable crimp. Use needle nose pliers to carefully unbend and remove the cable crimp at the end of the cable. Set the cable crimp aside for reinstallation.

      mceclip6.png   mceclip7.png
      Caution.png Use caution when handling the brake cable end with the cable crimp removed. The end of the cable is sharp and can cause injury if not handled carefully. If the brake cable appears corroded, rusty, or damaged, or if the brake cable housing appears worn or damaged, which can happen over time and with normal use, the cable and/or housing should be replaced by a certified, reputable bike mechanic.
    2. Loosen the cable pinch bolt. Use a 5 mm Allen wrench to loosen (but not remove) the cable pinch bolt on the caliper just enough to allow the cable to pass through the pinch bolt opening.

      mceclip8.png
    3. Remove the brake cable and housing from the caliper. Pull up on the brake cable housing remove the brake cable from the caliper and  barrel adjuster.

      mceclip9.png   mceclip10.png
  3. Remove the brake cable from the old cable guide.
    1. Locate the old cable guide at the front of the fork lower (circled in the image below).

      RadCity_callout.png
    2. Use a 3 mm Allen wrench to remove the cable guide bolt.
    3. Remove the brake cable from the cable guide and reinstall the cable guide bolt.
Install the New Cable Guide
  1. Locate the area where the new cable guide will be installed. The new cable guide should be installed about 2-3" below the top of the fork, centered directly between the outer edge of the fork lower and the inner edge, so it is directly behind the fork lower (as shown in the image below).

    mceclip13.png
  2. Install the new cable guide.
    1. Orient the new cable guide so the longer zip tie is up top.

      mceclip14.png
    2. Ensure that the cable guide will be installed in the correct position, about 2-3" from the top of the fork lower, centered, and vertical.

      mceclip17.png
    3. Remove the adhesive backing cover from the cable guide.

      mceclip16.png
    4. Place the cable guide into position, pressing firmly for a few moments to adhere.
  3. Secure the brake cable in the new cable guide.
    1. Position the brake cable so it passes over the fork crown and behind the fork lower (as shown in the image below).

      RadRover_brake1.png
    2. Press the brake cable into the cable guide. Align the brake cable and housing with the opening of the cable guide and carefully press the cable directly into the guide.
    3. Secure the zip ties. Secure the longer zip tie around the fork and the shorter zip tie around the brake cable so it is out of the way of moving parts. Trim both zip ties to be flush and smooth.

      mceclip23.png   
  4. Reinstall the brake cable.
    1. Pass the brake cable through the barrel adjuster.
      Caution.png If a front fender is installed on the bike, ensure the brake cable passes between the fender mounting arm and the wheel.
      mceclip25.png
    2. Press the housing into the barrel adjuster opening to fully seat the housing.
    3. Pass the brake cable end between the cable pinch bolt and backing nut.

      mceclip26.png
    4. Push the caliper arm forward slightly and pull the brake cable taut.

      mceclip27.png
    5. Use a 5 mm Allen wrench to tighten the cable pinch bolt. Use a torque wrench to torque the cable pinch bolt to 6 Nm.
  5. Check the brakes and perform an adjustment if needed.
    1. Squeeze the brake lever several times to fully seat the cable housing and test the brake.
    2. Adjust the brake if needed. If the brake lever can be easily squeezed more than halfway to the handlebar, it needs to be adjusted. Click HERE for instructions to adjust the brakes.

      mceclip28.png
    3. Reinstall the cable crimp at the end of the brake cable. Pass the cable crimp over the brake cable end and then use needle nose pliers to secure the crimp at the end of the cable.

      mceclip38.png
      Caution.png Cable ends are extremely sharp, especially if the cable has frayed. Use caution to avoid sharp and frayed cable ends or injury could occur.
  6. Check cable slack. Turn the handlebar all the way left and all the way right. Ensure the handlebar has complete range of motion and the cable has enough slack to move as the bike turns without stretching/damaging the cable and without activating the brake pads. If the handlebar cannot turn fully, or the brake activates while turning, click HERE to adjust the brakes as needed.
  7. Click HERE to return to the Front Rack Installation Guide and follow the steps to continue installing the front rack.

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