Replacing the brake lever

The brake lever is attached to the brake cable and a motor cut off that cuts the power to the motor when the brake lever is pulled. To you replace the brake lever, you will need to disconnect the brake cable and motor cut off wire, and remove the brake lever from the handlebar.

Disconnect the brake cable

Loosen the brake cable from the brake. You do not need to pull the brake cable out of the brake or out of the cable sheath.

Position the barrel connector at the brake lever end of the brake cable so that the slot in the connector, the lock nut, and the brake lever are aligned. Pull the brake cable out of the barrel connector and through the slot.

The end of the cable has a cylinder that fits in the lever itself. Remove the cable end from the lever.

Disconnect the brake lever from the handlebar

Remove the hand grip from the handlebar.

Use a hex wrench to loosen the brake lever and slide it off the handlebar.

Disconnect the motor cut off wire from the PWM controller

Raise or remove the seat to allow access to the battery compartment.

Remove the two bolts at the bottom of the battery tray.

To remove the battery cover, slide the cover to the rear and lift.

Between the batteries and the seat post tube is the PWM controller. It is encased in an aluminum box that is mounted to the plate that separates it from the batteries. Locate the connector with red and black wires. Disconnect this plug.

Cut the connector off of the brake wire (be careful not to cut the connector off the wire coming from the PWM controller) and feed the wire through the rubber grommet at the bottom of the battery tray.

Feed the wire through the rubber grommet at the bottom of the motor mount on the swing arm.

Feed the wire through the eyelets on the frame.

Connect the new motor cut off wire to the PWM controller

Before placing the connector on the wire, feed the wire through the eyelets in the frame, up through the grommet of the mounting plate on the swing arm, and up through the grommet in the battery tray.

Put the new connector into the connector on the PWM controller. Insert the red and black wires into the new connector opposite the wire of the same color. Be sure that the wires snap in place and do not come loose. Then, replace the battery cover.

Slide the brake lever onto the handlebar and tighten it with a hex wretch.

Insert the brake cable into the brake lever and slip the cable into the groove and position the metal end into the barrel connector.

Adjust the brake.