RadCity 5 Plus Assembly Guide

Assembly instructions for the RadCity

The following steps provide an overview of how to assemble your RadCity 5 Plus from Rad Power Bikes. They are not a complete or comprehensive manual of all aspects of assembly, maintenance, and repair, which involve specialized tools and skills.

We recommend you consult a certified, reputable bike mechanic to assist in the assembly, repair, and maintenance of your RadCity.

Please note that your RadCity may include components that look different from those in the illustrations above and elsewhere in this manual. Such changes help ensure uninterrupted shipping. RAD engineers rigorously test each component to guarantee quality and compatibility.

WARNING: Incorrect assembly, maintenance, or use of your e-bike can cause component or performance failure, loss of control, serious injury, or death. Even if you’re an experienced bike rider, you must read and understand the entire manual and any documentation provided for subcomponents or accessories before riding. If you are not sure you have the experience, skills, and tools to correctly perform all assembly steps in the manual and the assembly video, consult a local, certified, reputable bike mechanic.

1. Unpack the Bike

Open the bike box and, with the help of another person capable of safely lifting a heavy object, remove the ebike from the bike box, placing it upright on the back wheel and front fork protector plate. Carefully remove the packaging material protecting the bike frame and components, and keep the packaging materials in case you want to ship the bike. Otherwise, recycle these materials, especially cardboard and foam, wherever possible. Remove the small box from the
bottom of the bike box and carefully set out the contents. Ensure all of the following pieces are included with the bike:

• Front-wheel
• Front fender
• Charger
• Headlight
• Fender
• Mounting Hardware
• Pedals (left and right)
• Keys
• Manual(s)
• Front-wheel quick release (in fork protector plate)
• Stem bolt-hole cover
• Assembly toolkit

If anything is missing, please contact Rad Power Bikes.
We also recommend the following (not included) for assembly and maintenance:

• A strong friend
• Flat-side cutters
• 15 mm pedal wrench
• Bicycle grease
• Clean shop towel or paper towel for cleaning excess grease
• Bike pump with Schrader valve and pressure gauge
• Torque wrench (3 Nm-60 Nm) with Allen bits (Torque and Tool Information)

2. Install the Handlebar

1. Determine whether you can reach the internal top-cap bolt with the long 5 mm Allen wrench, shown as “C” in the illustration “Stem/handlebar installation” on the next page. If the top-cap bolt is not visible, loosen the side stem angle adjustment bolt (see “Stem angle adjustment bolts” on the next page) and remove the other stem angle adjustment bolt (on the underside of the stem). Rotate the stem until the top cap bolt can be reached with the long 5 mm Allen wrench.
2. Orient the handlebar so the brake levers face forward and the shifter is on the rider’s right side. Trace the brake housing from the left brake lever to the brake caliper and make sure the bundle of cables is not twisted.
3. Center the stem and handlebar assembly onto the steerer tube. Slide the stem onto the tube fully. If the stem does not slide down easily, loosen the stem clamp bolts (see “B” in “Stem/handlebar installation” on the next page) by about two turns and try again (5 mm Allen wrench).
4. Tighten the internal top cap bolt using the long 5 mm Allen wrench. Insert the long end of the tool into the top of the stem and into the top cap bolt head (see “C” in “Stem/handlebar installation below” on the next page). Turn clockwise just until the wrench becomes a bit harder to turn, and then turn the wrench another half-turn more.
5. Check that the headset is tight enough. Press on the back or side of the stem and try to move it back and forth. There should be no movement inside the stem indicating the headset is tight enough for the next assembly steps. Later in the process, you will test and fine-tune the headset tightness for riding.
6. Tighten the stem clamp bolts evenly (Allen wrench). Orient the handlebar so that it is perpendicular to the frame. Tighten the stem clamp bolts one-quarter turn at a time, alternating between bolts until torqued evenly to the value in Tools and recommended torque values.

Stem/handlebar installation
A: Stem angle adjustment bolt (side)
B: Stem clamp bolts
C: Long 5 mm Allen wrench just above the top cap bolt.

7. Position the handlebar correctly on the stem. Your handlebar came loosely attached to the stem of your bike, so before you secure it, make sure it’s centered on the stem and that the handlebar grips will be approximately parallel to the ground when the front wheel is installed. (You can fine-tune the positioning later.)

8. Tighten the stem faceplate bolts. Use an Allen wrench to tighten each of the faceplate bolts by a quarter turn, following an “X” pattern. Repeat until the handlebar is secure. Ensure the gap between the faceplate and stem is even. Torque the bolts evenly to the value listed in the tools and torque guide.

3. Install the Front Wheel onto the Front Fork

1. Locate and remove the quick-release skewer from the front fork protector plate. Open the lever, remove the thumbnut and cone spring on the opposite side, and remove the skewer. Keep the washer and the other cone spring in place on the lever side.
2. Lightly grease the quick-release skewer. Place about half of a pea-size amount of bicycle grease onto the threaded end of the skewer and then wipe it across the rest of the skewer.
3. Install the skewer through the front wheel hub, starting from the brake-rotor side. Make sure to not touch the brake rotor. Reinstall the cone spring on the skewer. Ensure both cone springs point inward. Keep the lever open and thread on the thumbnut a couple of turns, leaving enough room for the fork dropouts.
4. Remove the hydraulic brake pad spacer from the brake caliper on the front wheel.

NOTICE: If the front wheel is not installed or if the hydraulic brake pad spacer is missing, do NOT squeeze the brake levers. Doing so can cause the brake pads to clamp together too much and prevent the brake rotor from fitting between the pads. If this happens to you, install the brake pad spacer back between the pads to create more space between the brake pads for the brake rotor. More information can be found in the RadCity 5 Plus Owners Manual.

5. Carefully lift the front of the bike and lower the fork onto the wheel so that the brake rotor
enters the caliper, between the brake pads, and the axle enters the fork dropouts fully. If installing the front wheel is difficult, reinsert the pad spacer to create more space between the brake pads for the brake rotor.

Then remove the spacer and install the wheel. If installing the front wheel is difficult, use a 5 mm Allen wrench to turn the inner pad adjustment dial counterclockwise one or two clicks to increase the space between the brake pads. Try to install the wheel again.

6. Check that the wheel is fully seated in the dropouts, that the wheel axle is level and parallel to the ground, and that the wheel is centered.

7. Hold the quick-release lever in line with the axle and tighten the thumbnut until the lever can stay parallel to the floor without being held. Use the palm of your hand to close the lever fully, without touching the brake rotor. The quick-release lever secures the front wheel to the bike, so it’s important that the thumbnut is tight enough that the closed lever has an adequate clamping force to keep the axle and wheel firmly in place. When you close the lever, there should be enough resistance that it leaves an imprint in your hand.

8. Prop the bike on the kickstand.

9. Check the security of the front wheel and quick-release lever. If it’s too easy or too difficult to close, adjust the lever tension by turning the thumbnut one turn, then close the lever. Check the front wheel security on a regular basis: the front wheel should always be fully seated in the dropouts of the front fork, and the quick-release lever should always be properly secured.

4. Check the Security of the Rear Wheel

Check the security of the rear wheel. The rear wheel security and hardware torque should also be checked on a regular basis, refer to the torque chart to confirm that everything is secured.

5. Install the Front Fender and Headlight

a. Remove the front fender from the rear of the bike.
b. Locate the bag with the fender and headlight mounting hardware.
c. Pass the fender from the back of the front wheel, under the fork arch, as shown below.

d. Install the fender/headlight mounting hardware through the headlight bracket, fender, and fork (5 mm Allen wrench and 10 mm wrench).
e. Plug in the headlight connector. Line up the internal notch and pins and external arrows, and press directly together without twisting.

f. Locate the fender bracket and mounting bolts. If needed, thread in the bolt to attach the fender mounting bracket to the mounting point on the back of the fork, then tighten securely (Allen wrench). Repeat with the other bracket on the other fork lower.

g. Ensure the fender mounting bracket is oriented properly on the mounting point on the fork lower as shown in the illustrations.

h. Secure the fender mounting arms. Pass a split washer and then a flat washer onto the bolt end. Place the fender arm over the mounting hole on the outside of the bracket. Thread the bolt through the fender mounting arm. On the other side of the bracket, thread on a washer and locknut by hand as shown in the “ fender mounting hardware” illustration. Tighten securely (4 mm Allen wrench and 8 mm wrench).

i. Check that the fender and headlight are centered, then torque the fender mounting arm bolts according to the value in “Tools and recommended torque values” on page 8. Headlight pointing slightly downward to not blind others

j. Adjust the headlight angle slightly downward so it will not blind oncoming traffic. Use the tools listed in “Tools and recommended torque values” on page 8 to loosen the angle adjustment bolt and locknut, angle the headlight downward, then tighten securely. Do not over-tighten.

6. Install the Pedals

a. Locate the right-side pedal, which is marked “R,” should have an “R” sticker attached, and has a smooth pedal axle. The right pedal goes on the crank on the drivetrain side of the bike, which has the chain and is the same as a rider’s right side when seated on the bike.

b. Place a pea-size or slightly smaller amount of bicycle grease onto the threads of the right pedal.

c. Carefully thread the right pedal onto the right crank by turning clockwise (toward the front of the bike). Do so slowly and gently by hand. Do not cross thread or damage the threads. See the “Right pedal installation” illustrations.

d. Place a pea-size or slightly smaller amount of bicycle grease onto the threads of the left pedal.

e. Carefully thread the left pedal onto the left crank by turning counterclockwise (toward the front of the bike). The reversethreaded left pedal is marked with an “L,” should have an “L” sticker attached, and has notches on the pedal axle. Thread slowly and gently by hand without cross-threading or damaging the threads. See the “Left pedal installation” illustrations.

f. Tighten each pedal using a pedal wrench to avoid damage caused by wider wrenches, as shown in the assembly video at www.radpowerbikes.com/assemble.

g. Torque each pedal to 35 Nm. h. Wipe off any excess bicycle grease.

7. Inflate Tires

Check that the tire beads and tires are evenly seated around the rims. Use a pump with a Schrader valve and pressure gauge to inflate each tire to the recommended PSI (pounds per square inch) indicated on the tire sidewall. Do not overinflate or underinflate tires.

8. Prepare Your Ebike’s Power System For Use

Prepare your e-bike’s power system for use. Your bike has been configured to ensure power isn’t deployed to the motor during shipping. To ensure your e-bike is ready for use, you will need to do one or both of the following:

• Plug in the display connector. Your display connector may come unplugged. If it does, you will find one of the cables at the front of the bike disconnected (it will have green connector ends). Line up the internal notch and pins, and external arrows, and press together without twisting.
• Take your battery out of ship mode. If your display connector comes connected, your battery is probably in ship mode to prevent accidental activation prior to assembly. To take it out of ship mode, press and hold the battery button for at least three seconds.

RadCity 5 Plus Owners Manual