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Rad Power Bikes Production Site

RadWagon 5 controller replacement guide

If Rad Power Bikes Product Support determines your RadWagon 5 has a defective controller, use the following procedure to remove and replace the controller.

Incorrect assembly, maintenance, or use of your ebike can cause component or performance failure, loss of control, serious injury, or death. Ebikes have parts that non-motorized bikes do not have, and neither the assembly steps and/or assembly videos cover all potential aspects of ebike configuration, maintenance, and repair, which can require specialized tools and skills. We strongly recommend you consult a professional, reputable bike mechanic to assist in the assembly, repair, and maintenance of your ebike, or inspect your work if you choose to do it yourself.

Tools needed:

  • 4 mm Allen wrench
  • Torque wrench with Allen bits
  • Flat-side cutters
  • Extra zip ties
  • Bike stand (optional)
  • Nitrile gloves (optional)

Take pictures of cable connections, cable routing and controller placement before you start removing these items, as once you replace the controller you will reinstall everything in its original position.

  1. Get the ebike ready for maintenance. Turn off the ebike, remove the battery, and press and hold the Power button to discharge remaining power.
  2. Use a 4 mm Allen wrench to remove the three bolts securing the battery tray. Remove the battery tray and then pull the battery cable out of the downtube and disconnect by pulling the connectors apart, without twisting, to unplug. Set the battery tray aside for later.
    WAGON5_Controller_Fig2.png
  3. Use the Allen wrench to remove the four bolts that secure the controller to the frame. 
    WAGON5_Controller_Fig2.png
  4. Trace the taillight cable from the top of the controller to the taillight connector mounted the rear rack tubing. Use flat-side cutters to cut the two zip ties securing the cable, and disconnect the cable by pulling the connectors apart, without twisting, to unplug.
    RADWagon5_ControllerConnections.png
  5. Unplug the motor cable mounted on the chain stay by using flat-side cutters to remove the two zip ties securing the cable to the chain stay, and then unscrew the connectors and pull apart.
  6. Carefully pull the PAS and Wiring Harness cables out of the downtube opening and disconnect the cables by pulling the connectors apart, without twisting, to unplug. Pull the cables on the bottom of the controller to remove them from the downtube.
  7. Remove the old controller and recycle according to local rules (if possible). 
  8. Use the Allen wrench to reinstall the new controller in the original location. Use a torque wrench to torque the bolts to 3 Nm.
  9. Feed the Battery, PAS and Wiring Harness cables through the frame opening until the cable ends reach the downtube opening. 
  10. Reconnect the PAS and Wiring Harness cables by lining up the internal notch and pins and the external arrows of each cable, and press together without twisting.
  11. Retrieve the battery tray and reconnect the cable by lining up the internal notch and pins and the external arrows, and press together without twisting.
  12. Carefully feed the extra controller cable lengths into the downtube opening until they are secure.
  13. Use the Allen wrench to re-install the battery tray mounting bolts. Use a torque wrench to tighten the mounting bolts to 5 Nm.
  14. Use new zip ties to secure the taillight and motor cables, and use flat side cutters to snip off any excess from the zip ties to ensure the ends are flush and smooth with no sharp points.
  15. Reinstall the battery, test the bike fully, and ride Rad!
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