RadWagon front fork replacement guide

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The RadWagon front fork can be replaced if instructed to do so by Rad Power Bikes Product Support. Follow the steps below to replace the front fork.

Tools Needed:

A 4 mm Allen wrench
A 5 mm Allen wrench
Flat side cutters or wire cutters
Needle nose pliers
A Phillips head screwdriver
The replacement fork from Rad Power Bikes.

Remove the Old Fork

Get the bike ready for maintenance. Turn off the bike, remove the battery, and press and hold MODE to discharge remaining power.
Remove the headlight and front fender. Use a 4 mm Allen wrench to remove the bolt holding the headlight and top fender mount to the frame and set aside. Use a 4 mm Allen wrench or Phillips head screwdriver (depending on model year) to remove the bolts holding the fender mounting bracket to each side of the front fork lowers. Pass the fender between the tire and fork to remove and set aside.
Remove the front wheel. Open the quick release lever and remove the front wheel from the front fork dropouts.
Remove the brake caliper from the front fork. Use a 5 mm Allen wrench to loosen the two bolts holding the caliper to the fork lower and set aside.
Remove the brake cable from the caliper. Use a 5 mm Allen wrench to loosen the cable pinch bolt enough to allow the brake cable to slide out of the caliper arm. If there is a cable crimp installed on the end of the cable, use wire cutters to snip off the crimp. Loosen the barrel adjuster and slide the brake cable out of the caliper.
Slide the brake cable up and out of the front fork cable guide.
Remove the deflopilator spring. Use an Allen wrench or screwdriver shaft, perpendicular to the spring, to leverage the spring off of one of the mounting point eyelets and set aside.
Remove the top cap and bolt. Use a 5 mm Allen wrench to remove the bolt at the top of the steerer tube.
Loosen the steerer tube clamp bolts. Use a 5 mm wrench to loosen the two bolts on the clamp.
Remove the steerer tube clamp, handlebar, and spacers from the bike.
Remove the front fork from the frame. Recycle the part according to local rules.

Continue to the next section to install the new fork.

Install the New Fork

Install the new front fork to the frame.
Install spacers, handlebar, and steerer tube clamp bolts. Use a torque wrench to torque bolts to 10 Nm.
Install the bolt and top cap. Thread the bolt into the top of the steerer tube carefully by hand. Use a 5 mm Allen wrench to tighten securely. Install the top cap.
Install the deflopilator spring. Hook one end of the deflopilator spring to the eyelet on the downtube of the frame by passing it up from the bottom and through the eyelet. Straddling the bike frame, pass an Allen wrench or screwdriver shaft through the other hook at the end of the spring and leverage the hook onto the front fork eyelet. Keep fingers (and everything) clear of the spring coils during installation.
Pass the brake cable through the front fork cable guide.
Reinstall the brake cable into the caliper. Pass the cable end down through the top of the barrel adjuster. Pass the cable down through the top of the cable pinch bolt, pull the cable taut, and use a 5 mm Allen wrench to tighten the cable pinch bolt to secure. Slide the cable crimp onto the raw cable end and use needle nose pliers to flatten the crimp to secure.
Install the brake caliper to the front fork. Use a 5 mm Allen wrench to tighten the two bolts and secure the caliper to the fork lower.
Install the front wheel. Ensure the front wheel quick release is fully open, and lower the fork onto the wheel so the brake disc slides into the caliper and the axle goes into the dropouts fully. Ensure the wheel is centered in the dropouts and fully seated. Tighten the adjustment nut until the quick release lever is held in line with the axle and use the palm of your hand to fully close the lever. Take care to not touch the brake disc.
Reinstall the battery, test the bike fully, and have your work inspected by a certified, reputable bike mechanic.