RadRover 6 Plus Controller Replacement Guide

Follow this guide to replace the controller on your bike in the unlikely event the controller becomes damaged or is determined to be non-functional by Rad Power Bikes Product Support.

The following videos are for the RadCity 5 Plus bikes, but the steps are the same for the RadRover 6 Plus High-Step and Step-Thru bikes. 

  Notice

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:

  • Phillips head screwdriver
  • Flat head screwdriver
  • T8 Torx screwdriver
  • T9 Torx screwdriver
  • Flat-side cutters
  • A few zip ties
  • 3 mm Allen wrench
  • 2.5 mm Allen wrench
  • String a few inches longer than the length of the downtube
  • Electrical tape
  • The replacement controller from Rad Power Bikes

ControllerPlus.jpg

  Notice

Hardware may vary (bolt head style) and/or require different tools. Use the appropriate head size and type of tool for your bolts. Ensure the tool is pressed firmly into the bolt head and turn slowly to prevent stripping.

The illustrations below will highlight where the controller is located within the downtube for each version of the RadRover 6 Plus:

RRHSControllerLocationCropped.jpg RadRover High-Step
RRSTControllerLocationCropped.jpg RadRover Step-Thru
Remove the Old Controller
  1. Start by getting the bike ready for maintenance. Turn off the bike, remove the battery, and press the power button to discharge remaining power.
  2. Remove the internal cable cover. Use your Phillips head screwdriver to loosen and remove all four bolts. Set the internal cable cover and hardware aside.

    InternalCableProtectorBoltsCircled.png

  3. Remove the battery mount. Use your Phillips head screwdriver to remove the two bolts on the battery mount. Set the bolts aside for later, and unplug the battery mount connector.

    BatteryMountBoltsCircled.jpg

      • RadRover High-Step: The battery mount connector is directly underneath the internal cable cover in the battery slot. Pull both sides apart, without twisting, to unplug.

        HSCablesClean.jpg

      • RadRover Step-Thru: The battery mount connector is inside the downtube, below the battery mount. Gently pull the battery mount until you can see the battery connector. Pull both sides apart, without twisting, to unplug.

        IMG_1441.jpg

    Pull the battery mount out of the downtube and set it aside.

    Tip

    The bolt at the top of the battery mount has a flat head and the bolt at the bottom has a round head. Make sure that each bolt is in the correct orientation when reinstalling the battery mount.

  4. Remove the lock core (RadRover High-Step only). 
    1. Remove both bolts from the lock core. The bolt head style and size may vary.

      LockCoreCad.png

    2. Insert your key into the lock core. Turn your key clockwise toward the rear of the bike until the key hits the side of the lock core opening.

      IntegratedBattery_KeyPosition_edited.png

    3. Remove the key and pull the lock core out of the downtube. Set the lock core and the bolts aside.

      Tip

      The bolt at the top of the lock core has a flat head and the bolt at the bottom has a round head. Make sure that each bolt is in the correct orientation when reinstalling the lock core.

  5. Remove the external cable cover. Use your 2.5 mm Allen wrench to remove the four bolts underneath the downtube. Set the bolts and the external cable cover aside.

    ExtCableCoverBolts.png

  6. Unplug the motor connector. Use flat-side cutters to snip the zip tie on the chainstay to free the motor cable. Pull both ends of the connector apart, without twisting, to unplug.

    MotorConnectorZoom.PNG

  7. Unplug the wiring harness connector. Use flat-side cutters to snip the zip tie on the seat tube to free the wiring harness cable. Pull both sides of the connector apart, without twisting, to unplug.

    WiringHarness_ControllerConnectorZoom.PNG

  8. Remove the controller mounting bolts. Use your 3 mm Allen wrench to remove the controller mounting bolts. The location of these bolts differs between the RadRover High-Step and the RadRover Step-Thru.
    • RadRover High-Step: 

      RRHSControllerMountingBolts.png

    • RadRover Step-Thru:

      STControllerMountHoles.jpg

  9. Remove the controller. Pull the controller out from the downtube. Set the bolts aside and recycle the controller according to local rules.
Install the New Controller
  1. Prepare the new controller. 
    • RadRover High-Step: Insert the controller into the top of the downtube. Ensure the controller holes are facing downward and the cables are facing the rear of the bike.

      LockCoreWithCables_edited.png

    • RadRover Step-Thru: Insert the controller into the downtube. Ensure the controller holes are facing downward, and the cables are facing the front of the bike. Orient the battery cable (the shortest cable) so that it points toward the front of the bike. Orient the wiring harness and motor cables so that they face the rear of the bike. 

      IMG_1450.jpg

  2. Prepare the controller carrier (if applicable). Some controllers will come with a controller carrier (pictured under the black controller in the photo below), which helps position the controller in the downtube. If you do not have a controller carrier, skip to the next step.

    Help.00_07_23_15.Still023.jpg

    1. Place the carrier underneath the controller. Face the flat side of the carrier upward and rest the controller directly on top.

      Help.00_05_25_01.Still017.jpg

    2. Align the holes on the carrier with the holes on the controller.

      Help.00_06_22_09.Still019.jpg

  3. Attach the controller. 
    1. Push the ends of the wiring harness and motor connectors through the hole at the bottom of the downtube. Both connectors should hang outside of the frame.

      IMG_1439.jpg

    2. Align the controller holes with the holes in the frame.
    3. If you have a controller carrier, the bolts will thread through the mounting holes in the frame, through the carrier, and into the controller.
    4. Thread in the bolts by hand, then torque to 5 Nm.
  4. Route the cables (RadRover High-Step only).
    1. Route the motor and wiring harness cables along the non-drive side (the side without the chain) of the downtube.
    2. Route the battery cable on the drive side (the side with the chain) of the downtube.

      HSCablesLabeled.jpg

  5. Plug in the motor and wiring harness connectors. At the bottom of the downtube, locate the matching connector ends. The wiring harness connector has 11 internal pins and the motor has 3 internal pins. Align the internal notches and pins and external arrows. Press both ends together, without twisting, to connect.

    MotorConnectorZoom.PNG
    Motor connector (pictured above)

    WiringHarness_ControllerConnectorZoom.PNG
    Wiring harness connector (pictured above)

  6. Plug in the battery mount connector. Locate the battery mount and connect it to the controller inside of the downtube. Line up the internal notches and pins, and external arrows, and press together without twisting.
  7. Install the battery mount. Thread the flat bolt into the top hole, and the round bolt into the bottom hole. Torque to 2 Nm.

    BatteryMountBoltsCircled.jpg

    Tip

    If a bolt slips, you may need to tilt the bike so that the bolt falls out of the battery slot. There is a hole at the bottom of the downtube.

  8. Install the lock core (RadRover High-Step only).
      1. Place the lock core into position. The lock cylinder should face the non-drive side (the side without the chain) of the bike
      2. Thread in both bolts by hand. Thread the round bolt into the bottom hole and the flat bolt into the top hole.

        LockCoreCad.png

      3. Ensure all cables sit flush underneath the lock core. Torque to 2 Nm.

        LockCoreInstall_edited2.png

    Tip

    If a bolt slips, you may need to tilt the bike so that the bolt falls out of the battery slot. There is a hole at the bottom of the downtube.

  9. Install the internal cable cover. Place the internal cable cover into position, making sure not to pinch any cables. Thread in the four bolts by hand, and use a Phillips head screwdriver to evenly tighten the four bolts. Do not overtighten.

    InternalCableProtectorBoltsCircled.png

  10. Replace snipped zip ties. Use flat-side cutters to snip off zip tie excess. Ensure the cut is flush and smooth, with no sharp point.
  11. Install the external cable cover. Place the external cable cover in position underneath the frame. Thread in the bolts by hand, starting with the bolt closest to the bottom bracket. Ensure all cables sit flush underneath the external cable cover. Use a 2.5 mm Allen wrench to evenly tighten the bolts. Do not overtighten.

    ExtCableCoverBolts_edited.png

    Tip

    Route the motor cable on the drive side of the external cable cover bolts. Route the shifter cable and the rear brake cable along the non-drive side of the external cable cover bolts.

  12. Check that all cables are out of the way of moving parts. Turn the handlebar to each side to ensure it can move freely.
  13. Reinstall the battery and test the bike fully before riding.

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