Difficulty

Moderate

Steps

7

Time Required

                          1 hour

Sections

1

  • Fuse
  • 7 steps

Flags

2

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  • BackRad Bikes Semi-Integrated Battery

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Introduction

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 If it’s wrapped in black plastic, you may have a newer version of the battery with the fuse soldered on.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

Step 1

              Fuse
  • 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.)

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.)

1024

Step 2

              Remove torx screws
  • 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.

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.

Step 3

              Make sure fuse is accessible
  • 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.

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.

Step 4

              Make a slit in blue plastic
  • 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.

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.

Step 5

              Remove fuse
  • You will see a red fuse with the number 10. You can pull it out using needle nose pliers.

You will see a red fuse with the number 10. You can pull it out using needle nose pliers.

Step 6

              Replace fuse
  • 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!

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!

Step 7

              Tape it up
  • 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.

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.

To reassemble your device, follow these instructions in reverse order.

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                    Eve

Member since: 08/01/2022

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harvey - Jan 11, 2023

Reply

Very good information! I had to slide out the battery also to get to the fuse. They probably changed the design so it was harder to change the fuse ourselves.