Front Rack Cable Guide Installation

The front rack ships with a plastic cable guide and two zip ties, one small and one large. These components are needed to reroute and protect the front brake cable when the front rack is installed on the 2018 and 2019 RadCity, RadCity Step-Thru, RadMini, and RadMini Step-Thru. 

Notice: the new cable guide is not needed for front rack installation on the RadRover or RadWagon.

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 certified and reputable local bike mechanic.

1. Gather the tools you will need: Needle nose pliers, 5 mm Allen wrench, isopropyl alcohol, a paper towel or a clean shop towel, tape measure or ruler, flat side cutters, and a torque wrench with a 5 mm Allen bit.

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. Set up the cable guide and zip ties. 

a. Orient the larger of the two zip ties so that the raised portion of the locking end points in the same direction as the raised portion of the cable guide (1).

b. Pass the larger zip tie through the cable guide.

c. Orient the smaller 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)

d. Pass the smaller zip tie through the cable guide.

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4. Clean the back of the front fork lower. Apply isopropyl alcohol to a clean paper or shop towel and clean the back of the right front fork lower and allow to dry.

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5. Remove the brake cable crimp. Locate the brake caliper at the front wheel of the bike and the metal brake cable coming out of the end. Use needle nose pliers to carefully unbend and remove the cable crimp at the end of the cable. Set aside for reinstallation.

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Notice: 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.

6. Loosen the cable pinch bolt. Use a 5 mm Allen wrench to loosen the cable pinch bolt on the caliper just enough to allow the cable to pass through the pinch bolt opening. 

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7. Remove the brake cable and housing from the caliper. Pull up on the brake cable housing to pull the housing out for the barrel adjuster and the brake cable end through the cable pinch bolt and the barrel adjuster.

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8. Remove the brake cable and housing from the old cable guide. Pull the brake cable and housing up through the old cable guide at the front of the front fork lower.

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9. Locate the new cable guide placement. At the back of the right side of the front fork lower, use a tape measure or ruler to measure approximately 2 - 3 inches (in) from the top of the fork lower. The new cable guide should be placed in that location, centered directly between the outer edge of the fork lower and the inner edge, so it is directly behind the fork lower (+).

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10. Place the new cable guide. 

a. Orient the new cable guide so the large zip tie is on top and the small zip tie is on the bottom.

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b. Remove the cover of the adhesive backing.

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c. Ensure proper placement: completely vertical, centered at the back of the right fork lower, approximately 2 - 3 in from the top.

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d. Press the new cable guide against the fork to adhere.

11. Secure the large zip tie around the fork. Pass the large zip tie ends around the fork lower. Push the tapered end of the zip tie into the locking mechanism on the other end. Pull as tightly as possible to secure.

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12. Press the brake cable housing 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. 

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13. Secure the small zip tie around the cable housing. Pass the small zip tie ends around the brake cable housing. Push the tapered end of the zip tie into the locking mechanism on the other end. Pull taught to secure.

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14. Snip off zip tie excess. Use flat side cutters to snip off the excess at the end of both zip ties.

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15. Reinstall the brake cable. 

a. Pass the brake cable through the barrel adjuster. 

Notice: If a front fender is installed on the bike, ensure the brake cable passes between the fender mounting arm and the wheel.

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b. Press the housing into the barrel adjuster opening to fully seat the housing.

c. Pass the brake cable end between the cable pinch bolt and backing nut.

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d. Push the caliper arm forward slightly and pull the brake cable taught.

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e. 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.

16. Squeeze the brake lever several times to fully seat the cable housing and test the brake cable adjustment. 

17. Adjust the brakes if needed. If the brake lever can be easily squeezed more than halfway to the handlebar, they need to be adjusted so they will have adequate room between the lever and the grip.

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a. For small brake adjustments and fine tuning, the brake lever feel, add cable tension by using the barrel adjusters located at the brake lever and/or at the caliper. Twist the lock nut to loosen it away from the caliper or brake lever body. Turn the barrel adjuster to add small amounts of cable tension (or cable slack) to dial in your preferred brake lever feel. Once the tension is dialed to your preference, tighten the locknut by twisting it away from the barrel adjusted until it is snug against the caliper or brake lever body. 

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Unlocked at caliper   Locked at caliper     Unlocked at lever          Locked at lever

b. For large brake adjustments, typically to add tension to a brake cable, adjust the cable at the caliper. At the caliper arm, use a 5 mm Allen wrench to loosen the cable pinch bolt just enough to allow the cable to move (but not so loose that the hardware comes off completely) (i). Pull the end of the cable tight, slide the caliper arm slightly away from the cable end (ii), and tighten the cable pinch bolt(111). Test the brake feel and performance; repeat if necessary. When complete, torque the cable pinch bolt to 6 Nm (iv). 

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i. Loosen cable pinch bolt   ii. Pull cable tight          iii. Tighten pinch bolt       iv. Torque to 6 Nm

18. 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. 

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mceclip39.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.

19. Ensure adequate cable slack and tension. Turn the handlebar all the way left and all the way right. Ensure the handlebar has complete range of motion and the cable has adequate slack to move as the bike turns without stretching/damaging the cable and without activating the brake pads. If the handlebar cannot turn fully, of the brake activates while turning, adjust the brakes as needed.

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20. 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.