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Rad Power Bikes Production Site

RadRover Step-Thru Controller Replacement Guide

The RadRover Step-Thru controller can be replaced if you are instructed to do so by Rad Power Bikes Product Support.

Watch the video below and follow the instructions to replace the controller on your RadRover Step-Thru.

Tools needed:

  • 4 mm Allen wrench
  • Phillips head screwdriver
  • Flat head screwdriver
  • Flat side cutters
  • A few zip ties
  • The replacement controller from Rad Power Bikes
Remove the Old Controller
  1. Get the bike ready for maintenance. Turn off the bike, remove the battery, and press and hold the MODE button to discharge remaining power.
  2. Locate the battery tray and remove the mounting bolts. Use a 4 mm Allen wrench to remove the three battery tray mounting bolts. Set the bolts aside and tilt the tray away from the seat tube to allow access the controller mounting bolts.
    Move battery tray.gif
  3. Locate the controller and remove the mounting bolts. Use a Phillips head screwdriver to remove the four controller mounting bolts. Set the bolts and mounting brackets aside.
    Remove mounting bracket.gif
  4. Unplug the wiring harness connector from the controller. The wiring harness connector is located inside the downtube.
    1. Create cable slack. Turn the handlebar to the rider’s right side. Gently feed the wiring harness into the top of the downtube to create cable slack.
      Create cable slack.gif
    2. Unseat the rubber grommet at the bottom of the downtube. Use a flat head screwdriver and gentle pinching movements to carefully unseat the rubber grommet. Be careful not to damage the grommet or nearby cables.
      Remove grommet.gif
    3. Feed cable into the top of the downtube while gently pulling the wiring harness connector out of the lower cable opening. Be careful not to unplug the connector while it is inside the frame.
      Access connector.gif
    4. Unplug the connector. Pull each side directly apart, without twisting, to unplug.
      Unplug connector.gif
  5. Unplug all remaining connectors from the controller. Snip zip ties as needed, and pull each side of the connector directly apart, without twisting, to unplug.
    Unplug all connectors.gif
  6. Remove the old controller and recycle it according to local rules.
    Recycle.gif
    Continue to the next section to install the new controller.
Install the New Controller
  1. Locate the new controller and orient it so the mounting holes face the front of the bike and the single cable is pointed upward.
    Orient cables.gif
  2. Place the new controller on the frame where it will be installed. Pass the cables coming out of the bottom of the controller through the opening between the frame tubing.
    Put cables into position.gif
  3. Install the controller on the frame. Pass a mounting bracket through the top mounting hole on the frame and thread in the bolts by hand. Repeat with the other bracket, tightening partway.
    Install controller on bike.gif
  4. Center and secure the controller. Ensure the controller is centered and use a Phillips head screwdriver to tighten the four bolts evenly and securely, alternating between bolts in an “X” pattern.
    Center controller.gif
  5. Plug in the wiring harness connector. Pass the connector end through the grommet at the bottom of the downtube. Locate the other connector end. Align the internal notch and pins (and external arrows), and press directly together, without twisting, to connect.
    Connect wiring harness.gif
  6. Insert the wiring harness connector into the downtube. Double-check that the wiring harness connector is fully secure, then pass the connector into the lower cable opening and into the downtube.
    Insert connector.gif
  7. Reinstall the grommet. Place the long side of the grommet at the top or bottom of the opening, then gently work the grommet around the opening until fully seated.
    Install grommet.gif
  8. Create cable slack at the front of the bike. At the top of the downtube, gently pull the wiring harness cable to create cable slack at the front of the bike.
    Create cable slack (2).gif
  9. Plug in the remaining connectors. Locate the matching connector ends. Align the internal notch and pins (and external arrows), and press directly together, without twisting, to connect.
    Plug in connectors.gif
  10. Replace any snipped zip ties and trim them to be flush and smooth.
    Replace zip ties.gif
  11. Secure the battery tray. Reposition the battery tray against the front of the seat tube. Thread in the three bolts by hand, then use a 4 mm Allen wrench to evenly tighten the bolts. Check that the battery tray is secure.
    Install battery tray.gif
  12. Check that all cables are free from any moving parts. Rotate the handlebar to ensure it can move freely and that there is enough cable slack.
  13. Reinstall the battery, test the bike fully before riding, and ride Rad!

 

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