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Current Dropper Post Cable & Housing Install

Objective:
To install the Current Dropper Post Cable & Housing.
Equipment Needed:

  1. 2mm hex wrench
  2. 2.5mm hex wrench
  3. 3mm hex wrench
  4. 5mm hex wrench
  5. Cable cutters
  6. Crimping tool
  7. Torque wrench

 

 

  1. Power Off the Bike 

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

       

    2. Remove the cable crimp on the end of the dropper cable. 

       

    3. Use a 2.5mm hex wrench to loosen the cable pinch bolt on the dropper lever. Remove the cable from the lever assembly. 

       

  2. Remove the Right Side Frame Grommet

    1. Use a 2mm hex wrench to remove the right side frame grommet bolt and then remove the frame grommet. 

       

  3. Remove the Dropper Post

    1. Use a 5mm hex wrench to loosen the seat post clamp bolt.
       

       

    2. Lift the dropper post and cable out of the frame.

       

  4. Remove the Display

    1. Use a 2mm hex wrench to remove the two display mounting bolts and lift up the display. 

       

  5. Open the Lower Motor Cover 

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

       

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

       

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

       

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

       

  7. Remove the Dropper Post Cable and Housing 

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

       

    2. Twist the cable housing ferrule off of the lever end of the housing and pull the rest of the dropper housing with insulator out of the frame.


       

    3. Remove the dropper cable from the bottom of the dropper post. 

       

  8. Swap the Dropper Cable and Housing 

    1. Ensure the new housing is cut to the same length as the original housing. 

       

  9. Install the Dropper Cable 

    1. Install the bushing end of the new cable into the bottom assembly of the dropper post as shown. 

       

    2. Remove the ferrule on the new housing and then feed it into the battery compartment from the bottom of the bike and out of the right side cable port. Replace the housing ferrule and and the insulator. 

       

    3. Press the insulator over the housing and inside of the frame as shown.  

       

    4. Lift up the motor and feed the opposite end of the cable housing into the seat tube until it exits the frame.

       

    5. Rearrange the cables and carefully press the motor back into place in the frame, enough to align the mounting holes. (do not crush the wires)

       

  10. Install the Mid Drive Motor
    1. Use a 5mm hex wrench and reinstall the 4 motor mounting bolts that were removed earlier. 


       

    2. Torque the bolts to 25Nm. 

       

  11. 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. 

       

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

       

  12. Install the Lower Motor Cover 

    1. Close the lower motor cover and reinstall the single center bolt using a 3mm hex wrench. Ensure the lower motor cover sits flush to the motor and side cover.

       

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

       

  13. 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.   

       

  14. Install the Dropper Post

    1. With the cable bushing installed into the bottom of the post, feed the new dropper cable into the housing and continue feeding it until the housing fully seats into the bottom of the dropper post. The cable should exit the top end of the housing.

       

    2. Lower the seat post into the frame while pulling the cable on the opposite end. This will ensure the housing stays seated while the post is moving.

       

    3. Position the seat post to the desired height and then use a 5mm hex wrench to snug the seat clamp bolt. Torque to 7Nm. 

       

  15. Install the Right Side Frame Grommet
    1. Replace the right side frame grommet and use a 2mm hex wrench to reinstall the cable grommet bolt. 
    2. Feed the new cable into the dropper lever assembly until the housing is fully seated into the barrel adjuster. Pull the cable tight while holding the dropper lever forward, as shown. 
    3. Use a 2.5mm hex wrench to tighten the cable pinch bolt until snug (2-3Nm)
    4. Trim the excess cable leaving about 40mm of cable remaining and cap it off by installing a new cable crimp.  
    5. Test the dropper lever for proper function. Make tension adjustments as needed, using the barrel adjuster.