Controller (Porteur) Replacement

Install Guide

 

Tools Needed:

  • Flush cut clippers
  • Electrical tape
  • 2mm hex key
  • 2.5 mm hex key
  • 3mm hex key
  • 5mm hex key
  • Needle Pliers
  • Water proof bicycle grease
  • Small Zip ties (2)

 

Procedure:

Step 1 Remove the zip ties securing the motor cable to the fork (1.1, 1.2) and disconnect the motor cable from the front wheel (1.3).

Step 2 Use strips of electric tape to protect the motor cable housing from damage.

Step 3 Remove the seat tube access cover (3mm hex key) (3.1, 3.2, 3.3) and disconnect all three cables (3.4, 3.5).

Step 4 Remove the seatpost (4.1) the seatpost clamp (4.2) and use pliers to remove the seat tube liner insert (5mm bolt) (4.3, 4.4)

Step 5 Remove the side plates from the controller housing (2mm hex key).

Step 6 Disconnect the controller housing bracket from the frame (2.5 hex key).

Step 7 Carefully uncoil the cables from the controller housing.

Step 8 Disconnect the gray headlight/selector cable (8.1) by pushing against the latch clip with a small hex key.

Step 9 Remove the battery cable and bottom bracket cable from the seat tube.

Step 10 Remove brown, yellow and green motor cables from top tube. At the front of the bike (10.1) guide the motor cable into the frame while at the same time removing the cable from the back of the bike. (10.2, 10.3)

Step 11 Stop removing the motor cable when the motor cable connector is accessible (11.1). Twist motor cable connector to detach motor cable (11.2)

Step 12 Now the old controller housing is completely detached. Set it aside and return to Faraday Bicycles.

Step 13 Feed the taped seat tube cables from the new controller housing into the rear of the top tube (13.1) and down the seat tube (13.2).

Step 14 Excess cable will come out the seat tube access panel. This excess should be long enough to reach the top of the kickstand mount.

Step 15 Connect the motor cable.

Step 16 Connect the headlight/selector cable.

Step 17 Slide the motor cable into the rear of the top tube (17.1) and out the front of the frame (17.2). Stop when the taped portion of the motor cable has been fully removed from the frame.

Step 18 At the rear of the top tube, separate the three cables which run through the frame. The taped battery and bottom bracket cable should run down the seat tube. The motor cable (brown, yellow and green) and the headlight/selector cable (gray) run on the right and left sides of the top tube
(18.1).

Grease the seat tube liner and align so that the longer leg is oriented to the
drive side of the bike. (18.2)

Insert the seat tube liner into the seat tube. Ensure the cables are routed to the sides of the seat tube, between the seat tube liner and the seat tube. Check that the cables are in the correct location and not being pinched or sheared as the seat tube liner is inserted.

There should be little to no resistance as the seat tube liner is being inserted. If the seat tube liner is difficult to insert remove the liner, check cable location and insert again.

Insert the seat tube liner fully into the seat tube. The bump on the seat tube will slip into the notch of the seat tube.


Step 19 Fold excess cable into the controller bracket; re-attach bracket to frame with bolts (2.5 mm hex key).

Step 20 Connect the three plugs at the seat tube access panel (20.1, 20.2, 20.3, 20.4). Reinsert all the cables into the seat tube (20.5). Replace seat tube access panel cover (3mm hex key) (20.6).

Step 21 Reattach side plates to the controller housing (2mm hex key).

Step 22 Replace seat tube clamp (22.1) and seat post (22.2).

Step 23 Route the motor cable through the drive side of the fork from front to rear. Remove tape from motor cable. Reconnect motor cable to motor. (23.4)

Step 24 Use small zip ties to attach the motor cable to the two cable brackets on the fork.

Step 25 Turn on the bike and spin the wheel to make sure it’s working. Finally, take it for a test ride. You may need to update the motor parameters depending on the bottom bracket version.