TABLE OF CONTENTS
Overview
A step-by-step guide for replacing the wire hub in the handlebar stem attachment assembly, typically because one of the connector pins has been damaged 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
Replacement instructions
- Unplug the bike.
Make sure the bike is unplugged at the lower stabilizer, not just from the wall.
- Unplug the shift lever plugs.
- Remove both shifter cable plugs by pulling the plug away from the center of the bike.
- Remove both shifter cable plugs by pulling the plug away from the center of the bike.
- Remove the stem cap and handlebars.
- Use a 4 mm hex key to remove the three screws on the back of the stem plate.
- Set aside stem cap, screws, and handlebars for reassembly later.
- Use a 4 mm hex key to remove the three screws on the back of the stem plate.
- Remove the stem base.
- Use a 4 mm hex key to remove the 4 screws in the stem baseplate.
- Set screws and base plate aside for reassembly later.
- Use a 4 mm hex key to remove the 4 screws in the stem baseplate.
- Remove the plastic cover.
- Use the 2.5 mm hex wrench to remove the 2 screws in the picture below:
- Set cover and screws aside for reassembly later.
- Use the 2.5 mm hex wrench to remove the 2 screws in the picture below:
- Remove the 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:
- Use the Phillips screwdriver to remove the plastic cover on the back of the wire hub assembly:
- Remove the existing wire hub PCB.
- With the plastic housing rotated towards you, use the 2.5 mm hex key to pry the connector out:
- With the plastic housing rotated towards you, use the 2.5 mm hex key to pry the connector out:
- Connect the 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 2.5 mm hex key to assist:
- 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:
- Replace the cover.
- Use the Phillips screwdriver to replace the back cover:
- Use the Phillips screwdriver to replace the back cover:
- Reassemble the bike.
- Replace the housing cover.
- Use the 2.5 mm hex key to replace the housing cover with the 2 screws set aside from before:
- Replace the stem plate.
- Use the 4 mm hex key to replace the stem plate with the 4 screws removed earlier.
- Install the handlebars and stem cap.
- Place the handlebar in place, then use the 4mm hex key to install the 3 screws removed earlier.
- Use the 4 mm hex key to replace the stem plate with the 4 screws removed earlier.
- Plug in the shift cable plugs.
- Make sure that the flat spot is oriented correctly on the shift cable plugs before pressing them in to the center ports.
- Press cable plugs into ports.
- Make sure that the flat spot is oriented correctly on the shift cable plugs before pressing them in to the center ports.
- Check all connections and plug the bike back into the power adapter.
- Check that both shifters are installed correctly, then plug the bike back into the power supply. Connect to the Stages Cycling app and use the Data tab to confirm that the gears are shifting as expected.
- Check that both shifters are installed correctly, then plug the bike back into the power supply. Connect to the Stages Cycling app and use the Data tab to confirm that the gears are shifting as expected.