Battery Connectors - Replacement

Battery Connectors Spacer Installation (to be used when only adding a spacer and not replacing the connectors)

Rear wheel - Replacement - Video can also be used for: 

• Belt tightening (just skip everything in the middle)

• Rear wheel inner tube replacement (once the rear wheel is replaced, repair/replace the inner tube like on any bike. This tutorial can be used if needed)

Headset bearings - Replacement

Seat clamp - Replacement

Front Light - Replacement

Brake Bleeding

Olives and Inserts replacement

You can also find more explanations on the tutorial for 'Fork replacement'. 

Grease the crank arm

Straighten/Untrue a wheel - A few additional comments: 

• You'll need:

  • • An adequate spoke wrench that matches the size of the spoke nipple. Nipple size is 3.6 mm on Cowboy 3 (this tool will work) and 3.23 mm on Cowboy 2 (this tool will work).

    • A way to check the position of the rim compared to the frame - We recommend using zip ties.

• On Cowboy 2 and Cowboy 3, the tension of the spokes is different on each side of the rear wheel (due to the integration of the torque sensor in the motor hub). You'll feel that the spokes feel tighter on one side then on the other, this is perfectly normal. Make sure you don't over-tighten the spokes on one side (this could damage the rim) or don't leave the spokes too loose on the other side.

• It can happen that the spokes on the loose side become very loose (to the point where you can turn the nipple by hand). If that's the case, start by tightening all spokes with little to no tension, then true the wheel as explained in the video above.

• We use disc brakes rather than rim brakes - This provides us with a slightly larger margin of error when truing the wheel. Any left-right movement of a few millimeters won't affect the bike's functionality in any way.

Replace a Spoke

• Note that we also have a rim tape inside the rim. The rim tape should be removed to access the spoke from inside the rim (simply push it aside with a small pointy tool), then be reinstalled before remounting the tire. 

Replace the fork

This tutorial is meant to fill the gaps of other existing tutorials, so the full repair is as follows:

• Remove the old fork from the bike (info available in other tutorials, eg. headset bearing replacement)

• Connect the brake set on the new cable -> Focus of this tutorial.

• Reconnect the new fork (same steps as #1 in reverse)

• Bleed and calibrate the front brake (separate tutorial available).

"Floating Saddle" Fix - Helicoil installation(Cowboy 2 only - Cowboy 3 bikes already have a helicoil preinstalled)

Puncture - Front wheel

Belt - Replacement (Cowboy 2 only)

Bottom Bracket - Replacement

Brake Pads - Replacement

• After removing the pads, check if the pistons are sticking out. If they are, clean them with WD40 Specialist PFTE Spray and a clean cloth. (Make sure that the PFTE spray doesn’t come in contact with the disc or pads!)
  Lastly, push the pistons back into place using a new tire lever or tool such as the “BTL-115 Piston tool from BBB”, then install the pads and wheel.

Bike General Maintenance

Brake Discs - Replacement

Brake Discs - Cleaning

Mudguards - Installation

Comm module back-up Cell removal

Cowboy Backoffice App

Comm Module - Replacement. Note: Before the customer can connect from the main Cowboy app, he will have to log out and log in from the app on his phone.

Controller - Replacement

Note that every time you do a controller replacement, you NEED to do a controller update to make it work. It might happen that after installation, it’s not working. It’s because we MUST update the controller before using the bike. 

Rear wheel Repairs (torque sensor, motor cover, torque cable, motor) - Instructions with updated freewheel mounting as from 10:42 (click me)

Torque sensor bearing replacement with the specific tool 

Torque sensor bearing replacement without the specific tool