Introduction
Many people have accidentally stuck their metal key into the charge port of the Rad Power Bikes semi-integrated battery, causing the fuse to blow. This guide will walk you through the steps to replace your fuse. You may also find this video helpful: https://www.youtube.com/watch?v=Q287-kQN...
NOTE: If your battery is wrapped in blue plastic, you should be able to replace your fuse. If it's wrapped in black plastic, you may have a newer version of the battery with the fuse soldered on.
What you need
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Use a flathead screwdriver to pry into the end cap and then tap at an angle with a mallet to knock off end cap. This will reveal the screws underneath. Start with the end cap closest to the charge port. (You may not need to take off the other end, depending on how step 3 goes.)
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There are four torx 10 screws on each side. Two are easy to access, but the other two are buried deep in the recessed opening, so you’ll need a torx 10 screwdriver that can go deep.
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The fuse is at top left corner on charge port end of battery. Pull the blue casing out a bit to access it. If there is a lot of black rubber sealing your battery into place, you may need to open the other side so you can push it out from one end. Your goal is to get top portion of battery sticking out the top, making the fuse accessible.
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Use a utility knife to make a small slit so you can remove the broken fuse. Proceed slowly and carefully. To the right of the fuse there is a flat ribbon that conveys the battery status to the exterior lights. You don't want to accidentally cut through that.
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You will see a red fuse with the number 10. You can pull it out using needle nose pliers.
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Insert the working fuse in the same spot where you removed the broken one. Then, plug in your charger to confirm that both lights are red indicating it is fixed and now charging. If it works now, congrats!
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Use electrical tape to tape where you cut the slit. You could also try liquid electrical tape. Avoid using silicone with acetic acid since it can corrode the electronics in the battery pack.
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To reassemble your device, follow these instructions in reverse order.
To reassemble your device, follow these instructions in reverse order.
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14 Comments
We replaced the fuse, but the battery doesn't charge up. What next?
I have a Rad Rover 6 Plus. Battery wouldn't charge or even show a single bar on display and was not in "transport mode". I followed this guide but had to open BOTH sizes to cut the battery adhesive to be able to slide the batter about 1 or 2 inches as the 10 amp fuse was mounted deeper down on the RIGHT side. Note also that I found a 30amp fuse on the other side (opposite the charge port). It was still okay, but the 10amp fuse was toast. I replaced it and the battery is charging just fine!!!! Why don't they make this any easy fuse replacement. These are $600 batteries that shouldn't be replaced simply due to a 10 cent fuse!
Does that 10amp mini red fuse need to be rated for voltage? Are there specific 10amp mini red fuses for 48v batteries or will any 10amp mini fuse do?
I have the Rad Rover 6 Plus and the battery is dead for some reason in less than a year with under 50 miles rode on it.
I have the type of battery that should be repairable but they put so much silicone around the sides and especially the bottom it is literally welded in there with the silicone. It seems to me like they don't want anyone to be able to fix the battery.
