TABLE OF CONTENTS

Overview

Overview

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
Small Phillips screwdriver
Tape (electrical tape preferred)
Pull wire for threading wire through frame
Clippers for zip ties
1 small zip tie

Replacement parts required

000-7870 - HARNESS E, LOWER

Replacement instructions

Unplug bike

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

Remove nose cap

Use the 3 mm hex key to remove the 2 screws on either side of the nose cap; set aside for reassembly later.

Check replacement part functionality

Before starting, check 6-pin connector of replacement harness to ensure that it clips in to upper harness easily.

Remove existing wire harness

Once you confirm the new lower harness will properly work with the existing upper harness, remove the existing wire harness by following these steps:

Cut small cable tie that retains the harness to the frame

Use a clipper to remove the zip tie and dispose of the zip tie.

Remove flywheel rear cap closest to rider (M3 Hex Key)

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.

Remove harness from lower PCBA (6-pin)

Use your thumbnail to pull on the connector, not the wires, to remove the 6-pin connector pictured below;

Remove lower PCB screws to free PCB from flywheel

Use the small Phillips screwdriver to remove the 4 screws that hold the PCB to the flywheel; set aside for reassembly.

Remove Stator Stay

Use a 6 mm hex key to 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.

Use of a cheater bar/tube is needed on the short-end of the hex key when loosening.

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

Move the PCB out of the way and pull the stator stay out of its location.

Attach feed wire to harness at the lower connector

Tip: You can use the existing wire harness as the feed wire to save time, if desired.

The lower harness wire should now be disconnected from the bike and still routed through the left leg.

Hold 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.

Pull harness out of fork from the top hole, being careful that feed wire remains connected

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. Pull the feed wire through the hole enough that it is exposed on both sides for use on the new harness.

Install 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.

Once the feed wire is threaded through the left leg of the bike, follow the steps below to install the new harness:

Attach new harness to the feed wire

Align the replacement harness such that the black connector is overlapping the bottom end of the feed wire.

Use electrical tape to cover the connector and adhere the new harness to the feed wire.

Newly taped replacement harness and lower end of the feed wire
Clean end of the replacement harness
Top end of the feed wire

Pull Feed wire and new harness through fork being careful that they do not separate

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.

Carefully remove 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.

Attach zip tie to the mount, fixing the new harness to the frame, then trim excess end of 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.

Reassemble bike

Once the the new wire harness is installed and upper connection is made, reassemble the bike following the steps below:

Reattach Stator Stay

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.

Tighten screws on stator stay first.

Then tighten the set screw on top.

Mount PCB

Use a Phillips 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.

Attach 6-pin connector

Pay attention to the cut out 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.