Important Before working on your Optibike always turn off the main power switch located on the battery. Tools in this guide 5mm Allen/Hex Wrench 3mm Allen/Hex Wrench Piece of rigid wire from coat hanger or similar, at least 24″ length Side cutters Removing Remove battery Remove bolts shown above, using a 5mm and 3mm allen wrench. The mid/center bolt on the battery is a shorter bolt. Also remove the motor wire cover and set aside. Pull the battery out at the top enough to access the connector, make sure the battery doesn’t fall out. Rotate the connector lock counter-clockwise, and then pull the connector backwards. Giving it a little wiggle can help here. Now remove the battery entirely and set aside.
Disconnect Motor Gently pull the motor wires out from the frame to expose the connectors. The connectors can catch on the frame a bit and may need some re-alignment. Disconnect both connectors. The 8 pin connector has a latch you’ll need to press (shown by arrow). The 3 pin connector simply pulls apart.
Remove Controller from Frame Using a 5mm allen wrench, remove the 2 bolts holding the controller in place. Next you’ll need to pull out the head cable, as shown by the arrow it’s tucked into the side of the frame, grab the cable and start pulling it up out of the frame.
Now grab the controller and move it back towards the opening in the frame, it may catch on the insert where the battery bolts to, but just needs to be moved around it. Pull out the remaining motor cables from the frame. Remove the controller fully from the frame.
Remove Controller Connector Cut the 2 zip ties on the controller, take care that you don’t damage the wires. Disconnect the white connector from the controller, as shown by the arrow there is a tab that needs to be pressed to remove it. Inspect both sides of the controller connector for signs of any damage or corrosion. Also look at the cable side of the connector and inspect the pins, make sure none are falling out or damaged. Installing If needed, swap the heatsink on to the new controller using a 3mm allen wrench. Connect Head Cable Connect the white controller connector, the tab needs to be on the correct side as shown here. Add new zip ties to the controller mount, this provides strain relief for the wires. Pull Wires through Frame and Install Controller Feed a length of stiff wire from the bottom to the top of the frame. A coat hanger can work well for this. Bend the end of the wire at the top into a hook. Take the motor wires and tape them to the stiff wire you fed through the frame, start by taping the 3 pin connector. And then tape the 8 pin on after.
Pull the wires down through the frame until they come out the opening near the motor. Place the controller back into the upper area of the frame for now. Take the head cable and feed the extra length into the back of the frame as shown in the next few images.
With one hand on the controller, line up the holes in the mounting plate with the frame, and re-install the M5x10 button head bolts. Connect Motor and Install Battery Reconnect the motor wires. Feed the extra wire and connectors back inside the frame. Make sure your battery switch is in the “OFF” position. Seat the battery in the frame, with the top leaning out so you can access the connector. Line up the connector and push it together, the arrows in the image point to the detents in the connector housing that align it. You may need to rotate the outer ring as you push the connector together. Push the battery all the way back into the frame, taking care that the power wires don’t get caught and pinched. Install the battery bolts, with the shorter of the 3 going in the middle position. And re-install the motor wire cover. Align the motor wire cover with the frame.
Turn the switch on the battery to the ON position, wait a few seconds, then press the power button on the handlebar and check that everything functions properly (Display turns on, throttle works, and no errors are shown on the display).