Wiring Harness Guide

The wiring harness is a component made of wires that connects the electrical components on the KG4.

On the KG4, the wiring harness can be found at the front of the bike and runs through the downtube to connect to the controller near the seat tube.

The wiring harness can be replaced in the unlikely event it is damaged or determined to be non-functional by Keego. The process to replace the harness involves unplugging the connectors, removing the harness from the downtube and replacing it with a new one, then plugging in the connectors.

Tools needed:

• Flat side cutters
• Flat head screwdriver
• String (a few inches longer than the length of the downtube)
• Electrical tape
• A few zip ties
• The replacement wiring harness from Keego

Remove the Old Wiring Harness

• Get the ebike ready for maintenance. Turn off the bike, remove the batteries, and press and hold MODE on the display to discharge any remaining power.
• Locate the wiring harness at the front of the bike
• Unplug the display (green) from the wiring harness. Trace the cable from the remote on the left side of the handlebar to the harness box, and then pull the connectors directly apart without twisting to unplug.
• Unplug the throttle (orange) from the wiring harness. Trace the cable from the throttle on the right side of the handlebar to the harness box, and then pull the connectors directly apart without twisting to unplug.
• Unplug the front brake (red) from the wiring harness. Trace the cable from the brake lever on the left side of the handlebar to the harness box, and then pull the connectors directly apart without twisting to unplug.
• Unplug the headlight (red) from the wiring harness. Trace the cable from the headlight to the wiring harness box, and then pull the connectors directly apart without twisting to unplug.
• Locate and unplug the wiring harness connector. Trace the long cable from the harness box to the frame connection point under the downtube. The wiring harness connector ends have a grey stripe on them. Snip the zip ties on the three mounting bosses on the downtube, and then pull the wiring harness connectors directly apart without twisting to unplug.

Install the New Wiring Harness

• Locate the new wiring harness
• Gently insert the connector through the grommet and into the upper cable opening of the downtube.
• Route the wiring harness cable along the trike downtube. Take up any cable slack and use a zip tie to secure the cables to the three mounting bosses on downtube. Use the flat side cutters to cut off any excess from the zip ties, and ensure the cuts are flush and smooth with no sharp points.
• Plug in the headlight. Connect the red connector at the bottom of the wiring harness to the headlight connector and press directly together without twisting to connect.
• Plug in the throttle. Connect the orange connector to the throttle connector and press directly together without twisting to connect.
• Plug in the brake. Connect the red connector to the brake connector and press directly together without twisting to connect.
• Plug in the display. Connect the green connector to the display connector and press directly together without twisting to connect.
• Check that all cables are free from any moving parts. Rotate the handlebar to ensure it can move freely and that there is enough cable slack. Replace the neoprene sleeve around the cables, and secure the cables to the handlebar with the Velcro straps

Where & How to Buy a New Wiring Harness

If want to buy a new wiring harness, please contact your Keego Mobility service or sales team.