Housing Replacement


Getting ready

It is advised to wear suitable protective personal equipment (PPE) and be in safe working environment. Before starting this maintenance process, below tasks must be completed:

  • Disconnect the battery/power supply
  • Kickstand Removal
  • Removing Cranks
  • Removing Brake Pads

Tools required

Torque Driver
Loctite 2701
or any equivalent thread-locker fluid

Parts required

You will need to prepare the listed parts for this maintenance procedure.

Replacement Right Housing
x 1 unit
Replacement Left Housing
x 1 unit
Replacement Right Rear Housing
x 1 unit
Replacement Fork Cover Left 
x 1 unit
Replacement Fork Cover Right 
x 1 unit

Steps to follow

Step 1 Crank Removal

Crank Removal


Step 2 Kickstand Removal

Kickstand Removal


Step 3 Removing Fork Cover Left

3.1

Using a torque driver, unscrew 1 unit of Flat Head Cap screw on the Fork Cover Left.
3.2

Continue to remove 2 more units of Socket Head Cap screws on the lower side of the Fork Cover Left.
3.3

Once all screws has been removed, carefully remove the Fork Cover Left from the bike.

Gently slide out the Fork Cover Left through the Brake Caliper & set it aside.

Step 4 Removing Fork Cover Right

4.1

Using a torque driver, unscrew 2 units of Socket Head Cap screws on the Fork Cover Right.
4.2

Once all screws has been removed, carefully remove the Fork Cover Right from the bike.

Gently slide out the Fork Cover Right through the Brake Caliper & set it aside.

Step 5 Removing Right Rear Housing

5.1

Using a torque driver, start unscrewing the Socket Head Cap screws on the Right Rear Housing.
5.2

Continue to remove the rest of the Socket Head Cap screws.

Total 4 units of Socket Head Cap screws must be removed from the Right Rear Housing.
5.3

Once all screws has been removed, carefully remove the Right Rear Housing from the bike.

Gently slide out the Right Rear Housing through the brake caliper and set it aside.

Step 6 Unscrewing Right Housing from Left Housing

6.1

Using a torque driver, start unscrewing the Socket Head Cap screws on the Right Housing.
6.2

Continue to remove the rest of the Socket Head Cap screws.

Total 20 units of Socket Head Cap screws must be removed from the Right Housing.

Step 7 Removing Left Housing

7.1

Using a torque driver, unscrew the Socket Head Cap screws on the rear side of the Left Housing.
7.2

Continue to remove the rest of the Socket Head Cap screws.

Total 2 units of Socket Head Cap screws must be removed from the rear side of the Left Housing. 
7.3

On the front side of the Left Housing, continue to unscrew 3 units of Socket Head Cap screws.
7.4

Once all screws has been removed, carefully remove the Left Housing from the bike.

Gently pull out the Left Housing until the housing is completely removed.
 

Step 8 Removing Right Housing

8.1

Using a torque driver, unscrew the Socket Head Cap screws on the front side of the Right Housing.
8.2

Continue to remove the rest of the Socket Head Cap screws.

Total 3 units of Socket Head Cap screws must be removed from the the front side of the Right Housing. 
8.3

On the other side of the Right Housing, remove 1 unit of Socket Head Cap screw on the Gearbox Module.
8.4

Once all screws has been removed, carefully remove the Right Housing from the bike.

Gently pull out the Right Housing until the housing is completely removed from the bike. 

Step 9 Installing new Right Housing

9.1

Collect 1 unit of new Right Housing and install it onto the bike by aligning to the BB Shaft’s hole & Seat Frame.
Make sure that the installed Right Housing is correctly installed & perfectly aligned.
9.2

On the bottom side of the Right Housing, ensure that the cable is perfectly routed & slotted into its correct cable slot.
9.3

On the other side of the Right Housing, insert & firmly tighten 1 unit of Socket Head Cap screw to the Gearbox Module.
9.4

Using a torque driver, insert and firmly tighten the Socket Head Cap screws on the front side of the Right Housing.
9.5

Continue to remove the rest of the Socket Head Cap screws.

Total 3 units of Socket Head Cap screws must be removed from the the front side of the Right Housing. 

Step 10 Installing new Left Housing

10.1

Collect 1 unit of Left Housing and install it onto the bike by aligning to the BB Shaft’s hole and Seat Frame.
Make sure that the installed Left Housing is correctly installed & perfectly aligned.
10.2

On the front side of the housing, check the alignment with Front Logo and ensure that the Right Housing is fully flushed with the Front Logo.

Make sure that all cables are perfectly aligned into the cable holes and not stuck in between the housing before securing Left & Right housing.
10.3

On the other side of the Right Housing, insert & firmly tighten 1 unit of Socket Head Cap screw to the Gearbox Module.
10.4

On the bottom side of the Left Housing, ensure that the cable is perfectly routed and slotted into its correct cable slot.
10.5

Using a torque driver, insert and firmly tighten 3 units of Socket Head Cap screws on the front side of the Left Housing.

Apply Loctite on each screw before inserting into screw hole. 

Step 11 Installing new Right Rear Housing

11.1

Collect 1 unit of new Right Rear Housing subassembly.

Start installing the Right Rear Housing by sliding it in between the brake caliper.
11.2

Make sure that the Right Rear Housing is fully flushed with Gearbox Module & perfectly aligned with the Left Housing.
11.3

Using a torque driver, insert and firmly tighten 4 units of Socket Head Cap screws into its respective screw holes.

Apply Loctite on each screw before inserting into screw hole. 

Step 12 Installing new Fork Cover Right

12.1

Collect 1 unit of new Fork Cover Right and ensure that the orientation is correct. 

Start installing the Fork Cover Right by sliding it between the Front Caliper from the top side.
12.2

Make sure the Fork Right Cover is fully flushed with the Front Wheel casing.
12.3

Using a torque driver, insert and firmly tighten 2 units of Socket Head Cap screws into its respective holes.

Apply Loctite on each screw before inserting into screw hole. 

Step 13 Installing new Fork Cover Left

13.1

Collect 1 unit of new Fork Cover Left and ensure that the orientation is correct. 

Start installing the Fork Cover Left by sliding it between the Front Caliper from the top side.
13.2

Make sure the Fork Right Cover is fully flushed with the Front Wheel casing.
13.3

Using a torque driver, insert and firmly tighten 1 unit of Flat Head Cap screw on the Fork Cover Left.

Apply Loctite on each screw before inserting into screw hole. 
13.4

Continue to insert and tighten 2 more units of Socket Head Cap screws on the lower side of the Fork Cover Left.

Apply Loctite on each screw before inserting into screw hole. 

Step 14 Re-installing Kickstand

Kickstand Installation


Step 15 Re-installing Crank

Crank Installation


End of Article

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