RadExpand and RadMini Step-Thru hinge replacement guide

Use this procedure to replace the hinge on folding ebike models if instructed to do so by Rad Power Bikes Support. The steps below show the RadExpand, but the process will be similar for RadMini Step-Thru models.

Tools needed:

• 2 mm Allen wrench
• 5 mm Allen wrench
• 10 mm wrench

1. Get the bike ready for maintenance. Turn off the bike, remove the battery, and press and hold the POWER or MODE button to discharge remaining power.
2. Open the quick release lever.
   1. Press down on the small locking clasp and pull the quick release lever out and toward the back of the bike.
      
   2. Unhook the back of the locking lever to release the frame hinge lock from its locking position on the frame
3. Remove the adjustment bolt.
   1. Locate the adjustment bolt that connects the frame hinge lock to the quick release lever.
   2. Use a 5 mm Allen wrench and a 10 mm wrench to loosen the adjustment bolt.
      
   3. Remove the adjustment bolt, nut, internal pin, spring mechanism and frame hinge lock. Take a picture of these items while still in place, as you will need to assemble them in the same position when installing the new hinge.
      
4. Remove the quick release lever.
   1. Open the quick release lever fully and locate the small hole beneath the hinge pin.
      
   2. Use a 2 mm Allen wrench to remove the set screw inside this hole.
   3. Remove the hinge pin by feeding it down through the bottom of the quick release lever.
      
   4. Remove the quick release lever.
      
5. Install the new hinge.
   1. Place the new quick release lever in place and feed the hinge pin back in place through the bottom of the frame. You may need to use an Allen wrench to push the hinge pin all the way back in place.
      
   2. Use the 2 mm Allen wrench to screw the new set screw in place to secure the hinge pin.
   3. Reassemble the new frame hinge lock, spring mechanism, and internal pin within the quick release lever opening and hold in place with your fingers (see below). Make sure the spring mechanism is in the correct position so that it provides resistance when the lever is closed.
      
   4. Insert the new adjustment bolt through the quick release lever and internal pin. Use a 5 mm Allen wrench and nut to secure this bolt, and adjust the tension as necessary according to the Hinge Adjustment Guide.

       Do not overtighten the adjustment bolt, as this can result in another broken hinge.

6. Check that the lever closes fully and the frame is secure.
7. Reinstall the battery, test the bike fully, and ride Rad!