TABLE OF CONTENTS

Overview

Step by step guide for replacing the wire hub in the handlebar stem attachment assembly, typically because a user has damaged one of the connector pins by plugging in the shift lever plugs incorrectly.


Tools required



  • 2.5 mm hex key
  • 4 mm hex key
  • Small Phillips head screwdriver


Replacement parts required  

(000-8008) - Handlebar Wire Hub 



 

Replacement instructions


Unplug bike


1. Make sure the bike is unplugged at the lower stabilizer, not just from the wall.



2. Unplug shift lever plugs


Remove both shifter cable plugs by pulling on the plug away from the center of the bike.



3. Remove stem cap and handlebars


Use a 4mm hex key to remove the three screws on the back of the stem plate.




Remove stem cap and screws; set aside for reassembly later.



4. Remove stem base


Use a 4mm hex key to remove the 4 screws in the stem baseplate.



Set screws and base plate aside for reassembly later.



5. Remove plastic cover


Use the 2.5mm hex wrench to remove the 2 screws in the picture below:



Set cover and screws aside for reassembly later.


6. Remove plastic wire cover


Use the Phillips screwdriver to remove the plastic cover on the back of the wire hub assembly:



This will expose the connector on the back of the broken assembly:



7. Replace wire hub


8. Remove existing wire hub PCB


With the plastic housing rotated towards you, use the 2.5mm hex key to pry the connector out:



9. Connect new wire hub PCB


Once the wire hub is free, dispose of it and install the replacement hub by lining up the male and female ends indicated by slots on the short edges of the connectors:



Align the connectors and lightly push on the connector until you feel a very slight click, or you are confident it is installed as far as possible. This should not take much force, similar to the amount of pressure required to install the cap on a sharpie marker. You can use the 2.5mm hex key to assist:



10. Replace cover


Use Phillips screwdriver to replace the back cover:



11. Reassemble bike


Replace housing cover


Use 2.5mm hex key to replace the housing cover with the 2 screws set aside from before:



12. Replace stem plate


Use 4mm hex key to replace the stem plate with the 4 screws removed earlier.



Install handlebars and stem cap


Place the handlebar in place, then use the 4mm hex key to install the 3 screws removed earlier.



13. Plug in the shift cables


Make sure that the flat spot is oriented correctly on the shift cable plugs before pressing them in to the center ports.



Press cables in to ports.


14. Check all connections and plug bike in


Check that both shifters are installed correctly, then plug the bike back into the power supply. Ask user to test the bike with the Stages Cycling app to see if gears now change.