Quote from: needabreak on April 07, 2022, 06:32:04 PM
Hey guys. I followed the procedure show in one of the posts where you only cut a slit in blue plastic on the one end that has the 10 amp fuse. Unfortunately I cut just a hair two far to right with razor blade and cut into ribbon wire 1/8 inch. So although with the new fuse installed and the charger light now showing red instead of the previous green, and the charger itself heating up like normal, the battery is still cold after several hours of charging. It appears I cut 2 or 3 wires of ribbon necessary for circuitry to allow incoming charge to actually charge battery. There is also no response to pushing button on battery to see charge level. Any ideas on ribbon wire replacement or patching it? Thought I might scrap insulation back on both sides of the three cut ribbon wires and try to solder small wires across to bridge but will be difficult with such thin ribbon.

There was another person on this post that cut the ribbon completely. His battery charged up fine but the charge level indicator did not work at all like yours. You may have to live without the indicator lights on the battery. I think the battery level will still be visible on the LCD panel on your handlebar. As far as charging a long time, when I repaired mine it charged 4 hours to go from 9 bars to 10. But it works fine now. Maybe your battery will eventually charge to full if you give it more time.

First time I've heard of a waxy material on the fuse. Mine did not. I put nothing on the new fuse. It's working great now.

I also touched my key to the charger port. The battery was 9/10s charged but the charger indicated it was fully charged with a green light. I read on this forum that some had admitted to Rads tech support that they had touched the port with the key causing the fuse to short but still received a replacement battery at no charge. I chose to be honest with them and I contacted tech support yesterday and explained exactly what I did. In my case the battery was dropping in power before I ever touched the key to the charge port. I had charged my battery and my wife's at the same time for the same amount of time. Even though I had not used the bike it dropped one bar. That is what prompted me to remove the battery and put it back on the charger. I explained all this to tech support and they had me submit a video showing all parts of the battery, bike connections and the charger attached. They denied my claim under warranty. Funny thing was even the tech guy said it was a confusing placement of the key hole and charge port. He admitted he's had to stop himself from putting the key in the charge port several times. Rad has some redesign to do.
Since the battery warranty was now void, I performed the fuse replacement like many of you have and it went well. Thank you GSC for suggesting to use a small wood chisel to remove the plastic trim. I used a 1/2 inch chisel and lightly tapped the plastic trim off both ends. No damage whatsoever to the trim. The screws came out easily. I cut around the battery edges to loosen it so I could slide it forward an inch to get to the fuse better. I used a Bussmann brand 10A fuse. With the new fuse in place, I plugged in the charger and the light was now red indicating it was charging again. Great. I covered the cut in the blue wrap with electrical tape and then sealed the whole thing with liquid electrical tape. I sealed it all up and plugged the charger in to raise it to 10 bars. It reached the 10 bars but the red light remained on. I left it for almost an hour and the charger became very warm. The light never turned to green. I plugged the same charger into my wife's fully charged battery and it turns green. I have a second charger as well and the red light stays on connected to my battery. So something is still not right with the battery even though it charges. I questioned if there is another 10A fuse I could have used but all of one ones I found regardless of brand had the same specs. The fuses were purchased at Walmart. $3.50 for a 5 pack. I'll run the battery down a ways and try charging it again. If the green light ever comes on, I'll update this post.


Update: I ran the battery down on a 10 mile ride. After leaving the charger on for about 4 hours it finally showed a green light! It took that long for the last 3 bars to fully charge. Like it never happened.