TABLE OF CONTENTS

Overview

A step-by-step guide for replacing the wire harness from the lower board to the nose cap connection location, typically because there is a damaged connector pin on the female side of the nose cap connector.


Tools required

  • 3 mm hex key
  • 5 mm hex key
  • 6 mm hex key
  • #0 Phillips screwdriver
  • Electrical tape
  • Pull wire for threading wire through the frame (optional)
  • Clippers for zip ties
  • 1 small zip tie

Replacement parts required


Replacement instructions

  1. Unplug the bike.
    Make sure the bike is unplugged at the lower stabilizer, not just from the wall.
  2. Remove the nose cap.
    1. Use the 3 mm hex key to remove the 2 screws on either side of the nose cap; set aside for reassembly later.
  3. Check the replacement part functionality.
    1. Before starting, check the 6-pin connector of the replacement harness to ensure that it clips into the upper harness easily.
  4. Remove the existing wire harness.
    1. Once you confirm the new lower harness will properly work with the existing upper harness, remove the existing wire harness by following these steps:
    2. Cut the small cable tie that retains the harness to the frame
    3. Use a clipper to remove the zip tie and dispose of the zip tie.
  5. Remove the rear flywheel cap closest to the rider.
    1. Use the 3 mm hex key to remove the 2 screws pictured below, gently pull the plastic cover away towards the back of the bike, and set aside for reassembly later.
  6. Remove the harness from the lower PCBA (6-pin).
    1. Use your thumbnail to pull on the connector, not the wires, to remove the 6-pin connector pictured below:
  7. Remove lower PCB screws to free PCB from flywheel.
    1. Use the small Phillips screwdriver to remove the 4 screws that hold the PCB to the flywheel; set aside for reassembly.
  8. Remove the stator stay.
    1. Using 6 mm hex key, loosen the M8 cap screw in the bracket above the black part from above. This screw only needs to be loosened enough for the stator stay to be removed.
    2. Use of a cheater bar/tube is needed on the short-end of the hex key when loosening.
    3. Use the 5 mm hex key to unscrew the 2 screws in the black bracket near the PCB and remove the screws completely from the bracket.
      Warning: Be careful not to damage the PCB
    4. Move the PCB out of the way and pull the stator stay out of its location.
  9. Attach the feed wire to the harness at the lower connector.
    Tip: You can use the existing wire harness as the feed wire to save time, if desired.
    1. The lower harness wire should now be disconnected from the bike and still routed through the left leg.
    2. Hold the feed wire parallel to the lower part of the wire and use electrical tape to adhere the feed wire to the existing harness. Be sure to overlap at least 3 inches of wires to prevent the feed wire and harness from becoming disconnected while pulling through the frame.
    3. Pull the harness out of the fork from the top hole, being careful that the feed wire remains connected.
    4. Using both hands, push on the lower part of the wire as you pull on the upper part of the wire. Once the connector gets to the top of the frame, it will require some gentle manipulation to pull through the hole. 
    5. Pull the feed wire through the hole enough that it is exposed on both sides for use on the new harness.
  10. Install the new wire harness.
    Note: If you used the existing harness as the feed wire, this step is not necessary as the new harness is already installed.
    1. Once the feed wire is threaded through the left leg of the bike, follow the steps below to install the new harness:
    2. Attach the new harness to the feed wire.
    3. Align the replacement harness so that the black connector overlaps the bottom end of the feed wire.
    4. Use electrical tape to cover the connector and adhere the new harness to the feed wire.
      1. Newly taped replacement harness and the lower end of the feed wire
      2. Clean end of the replacement harness
      3. Top end of the feed wire
    5. Pull the feed wire and the new harness through the fork, being careful that they do not separate.
    6. Use both hands to push on the lower end of the wire and pull on the upper end of the wire to gently guide the new harness through the left leg of the bike. Once the connector reaches the top hole in the frame, you will need to use your fingers to gently guide the connector through the hole, finishing with the new harness coming out of the top of the legs.
    7. Carefully remove the electrical tape without damaging the connector. Measure the amount of wire to pull through the leg by placing the wire against the zip tie mount and making sure the connectors can be connected.
    8. Attach a zip tie to the mount, fixing the new harness to the frame, then trim the excess end of the zip tie with clippers. Connect the upper and lower harnesses by aligning the black connectors so the clip side meets the side with the notch.
  11. Reattach the stator stay. 
    1. Carefully move the PCB out of the way and replace the stator stay into the flywheel.
      Note: The flywheel can rotate slightly, which is necessary for aligning the screw holes on the stator and flywheel properly.

    2. Tighten screws on the stator stay first.
    3. Then tighten the set screw on top.
  12. Remount the PCB. 
    1. Use a Phillips #0 screwdriver and finger to guide and install 4 screws to mount PCB back to the flywheel.
      Warning: Do not over-tighten! Once these screws are holding the PCB against the plastic bosses, they do not need further tightening.
  13. Attach the 6-pin connector.
    1. Pay attention to the cutout in the receiving end of the 6-pin plug to ensure the 6-pin connector is oriented correctly. Push on the connector until fully inserted.
       
  14. Reinstall the flywheel rear cap. 
    1. Place the cap back into position and use the 3 mm hex key to reinstall the 2 screws pictured below.
  15. Reinstall the nose cap.
    1. Replace the nose cap and use the 3 mm hex key to secure the 2 screws on either side.
  16. Plug in the bike and test. 
    1. Plug the bike back into the power supply.
    2. Get on the bike and start pedaling.
    3. Pull the brake levers and verify that resistance is applied to the brake. 
    4. Use the Stages Cycling app to search for a “Stages Bike” in the room.
    5. Confirm the bike can successfully connect to the app.