Current Charge Port Install

Objective:
To install the Current Charge Port.

Equipment Needed:

1. 2mm hex wrench
2. 2.5mm hex wrench
3. 3mm hex wrench
4. 5mm hex wrench
5. 18mm open end wrench
6. Torque wrench

1. Power Off the Bike

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

      

2. Open the Lower Motor Cover

   1.  With the bike inverted, use a 3mm hex wrench to remove the center lower motor cover bolt. Tilt the lower motor cover open.

      

   2.  Use a 2mm hex wrench to remove the two side motor cover bolts. Remove the side cover.

      

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

      

3. 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.

      

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

      

4. Remove the Charge Port

   1. Open the charge port and use a 2.5mm hex wrench to remove the 4 charge port mounting bolts.

      

   2. Use an 18mm open end wrench to loosen and remove the lock nut on the backside of the charge port.

      

5. Swap the Charge Port Assembly.

   

6. Install the Charge Port

   1. Take the new charge port assembly and use the 18mm open end wrench to loosen and remove the lock nut to separate the charge port from the housing.

      

   2. Lift up the motor and feed the new assembly into the frame access hole, entering from the inside.

      

   3. Reassemble the charge port with the charge port housing as shown and carefully thread on and tighten the lock nut to secure it in place.

      

   4. Reconnect the charge port plug to the motor.

      

   5. Rearrange the cables and carefully press the motor back into place in the frame, enough to align the mounting holes. Position the new charge port into the frame and reinstall the 4 mounting bolts using a 2.5mm hex wrench.

      

7. 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.

      

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

      

8. Install the Lower Motor Cover

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

      

      

9. Install the Side Motor Cover

   1. Ensure the side cables are properly installed. Replace the side motor cover and hardware using the 2mm hex wrench.

      

   2. Slightly rock the derailleur cage forward to allow the locking button to disengage. Slowly release the cage to re-tension the chain.

      

10. Power On the Bike

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