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Current Rear Brake Assembly Install

Objective: To install the Current Rear Brake Assembly.
Equipment Needed:
  1. 2mm hex wrench
  2. 2.5mm hex wrench
  3. 3mm hex wrench
  4. 4mm hex wrench
  5. 5mm hex wrench
  6. 6mm hex wrench
  7. 8mm open end wrench
  8. Brake hose cutter
  9. Torx T25
  10. Torque wrench
 
 

 
 

  1. Remove the Display

    1. Press and hold the power button to turn off the bike.

    2. Use a 2mm hex wrench to loosen and remove the two display mounting bolts. Lift the display out of the way.

       

    3. Carefully pedal the bike and shift to the highest gear or smallest cog. (Note: Current EXP requires the bike to be powered on to shift the bike's derailleur.)

  2. Remove the Rear Brake Lever

    1. Use a torx t25 to loosen the rear brake lever clamp bolt. Remove the lever assembly from the handlebar.

         

  3. Open the Lower Motor Cover

    1. Use a 3mm hex wrench to remove the center lower motor cover bolt. Tilt the lower motor cover open.

       

  4. Remove the Mid Drive Motor

    1. Use a 5mm hex wrench to loosen and remove 4 of the motor mounting bolts, excluding the two rear most bolts. Turn the chainring to access the center driveside bolt.

     

  5. Remove the Battery

    1. Turn the terminal plug lock clockwise and unplug the power cable from the battery.

       

    2. Use a 5mm hex wrench to remove the two battery mounting bolts from the downtube of the bike.

    3. Locate the strap on the bottom of the battery and use it to pull the battery up and out of the bike frame.

         

    4. Tilt back the derailleur cage and engage the lock button to relieve the chain tension.

       

  6. Remove the Rear Wheel

    1. Use a 6mm hex wrench to loosen and remove the rear thru axle. Remove the rear wheel from the bike.

         

    2. With the bike inverted or in a work stand, place a thick piece of foam or shop towell in between the upper linkage and the seat tube of the frame.

    3. Loosen and remove the upper shock mounting bolt using a 4mm hex wrench. Lift the top of the shock out of the frame and allow the rear triangle to rest on the foam block or towel. Note: Some variations may us a 6mm hex wrench for the upper bolt.

       

    4. Use a 2.5mm hex wrench to remove the inner chainstay cable tab and bolt.

       

    5. Use a 2mm hex wrench to remove the left side frame grommet bolt and remove the grommet from the frame.

  7. Disconnect the Rear Brake Hose

    1. Slide the rubber hose grommet off the brake lever and then use an 8mm open end wrench to fully loosen the brake hose compression bolt. Remove the brake hose from the lever assembly.

       

    2. Use a brake hose cutter tool to trim off the old barb and olive from the end of the hose.

       

    3. Remove the compression bolt and hose grommet from the brake hose. Insert a plug into the end of the hose.

       

    4. Remove the brake hose insulator from the frame.

       

    5. Proceed to remove the brake hose from the frame by pulling it towards the rear of the bike until it is completely out of the frame.

  8. Remove the Rear Brake Assembly

    1. Use a 5mm hex wrench to loosen and remove the two rear caliper mounting bolts. Remove the rear brake assembly from the bike.

  9. Swap the Rear Brake Assembly

     

  10. Install the New Rear Brake Assembly

    1. Insert the new brake hose into the routing hole in the chainstay of the rear triangle. Guide it forward until it enters the main frame.

         

    2. Move it through the motor compartment and then the battery compartment until the brake hose can exit out of the left side of the headtube, as shown. Reinstall the brake hose insulator and press it into the frame.

           

    3. Reinstall the left side frame grommet using a 2mm hex wrench.

         

    4. Install the rear brake caliper using a 5mm hex wrench. Thread in the bolts but do not tighten them fully just yet.

         

    5. Capture the new brake hose and replace the inner chainstay cable tab using a 2.5mm hex wrench.

           

  11. Install the Rear Shock

    1. Install the upper end of the shock into the mount in the frame. Ensure the bushings and spacers are installed and create a proper fit with no side to side movement.

       

    2. Install the upper shock mounting bolt and thread it in using a 4mm hex wrench. Torque both shock bolts to 10Nm. If the upper bolt uses a 6mm hex wrench, torque to 15Nm.

         

    3. Remove the foam block from the frame.

       

  12. Install the Rear Wheel

    1. Remove the pad spacer from the rear brake caliper. Replace the rear wheel into the frame dropouts. Ensure the rotor goes in between the brake pads and the cassette captures the chain on the smallest cog

           

    2. .Apply grease to the threads of the rear thru axle and then reinstall the axle to capture the wheel.

       

    3. Tighten the rear thru axle using a 6mm hex wrench. Torque to 10-16Nm.

         

  13. Install the Motor

    1. Use a 5mm hex wrench and reinstall the 4 motor mounting bolts that were removed earlier. Torque the bolts to 25Nm

       

  14. Install the Battery

    1. Carefully guide the battery into the frame using the attached strap. Ensure the bolt holes are facing upward. Align and center the threaded holes on the battery to the corresponding holes in the bike frame.

       

    2. Use a 5mm hex wrench to reinstall both of the battery mounting bolts to secure the battery. Thread both in before fully tightening. Torque each bolt to 10-12Nm. (Note: For EXP models, ensure the spacer/bolt is used on the lower battery bolt location, closest to the mid drive motor.)

           

    3. Plug the terminal cable back into the battery port and then lock it in place by turning the terminal lock counterclockwise.

       

  15. Install the Lower Motor Cover

    1. Close the lower motor cover and reinstall the single center bolt using a 3mm hex wrench.

          

    2. Tilt back the derailleur cage and engage the lock button to relieve the chain tension.

       

  16. Install the Display

    1. Replace the display into the frame until flush. Align the mounting holes and press the display down.

    2. Reinstall the 2 display mounting bolts using a 2mm hex wrench.

           

  17. Install the Rear Brake Lever

    1. Replace the rear brake clamp and assembly on the handlebar. Keep the clamp loose enough to adjust the position.

  18. Connect the Rear Brake Hose

    1. Install the hose grommet and compression bolt onto the brake hose. Unthread the metal cap on the end of the brake hose insert by turning clockwise. Install the SRAM olive onto the end of the hose fitting by threading it on, turning counterclockwise. Thread it on until snug. (It is reverse threaded)

       

       

    2. Insert the brake hose with the barb and olive into the lever assembly. Thread the compression bolt into place and tighten with an 8mm open end wrench. Torque to 5-7Nm. Slide the hose grommet into place.

    3. Position the brake lever to the desired position and tighten the assembly in place using a Torx t25. Torque the clamp bolt to 5-6Nm.

       

    4. Align the rear brake caliper so that it is centered over the brake rotor. Tighten the bolts in place ensuring that the rotor is not rubbing on either brake pad. Torque the caliper bolts to 9-12Nm.

       

    5. Press and hold the power button to turn the bike on and test for proper operation.

         

    6. Ensure the brake is properly bled and the brake pads are properly bedded in before use.