Today I had some time left so I took my chance to remove the cables from the headset…
Put the bike in the bikestand and removed the wheels, steer and fork. Removed the switch in the toptube and disconnected the cable from the handlebar switch. The rearbrakeline was next, cut it behind the lever and took both the cable and the brakeline out of the topcap. Installed the plugs in the cableholes.
Then took a good look at the brakeline, there is a liner, but that mostly for noiseprevention, so I decided to make a piece of string at the old brakeline and while removing it pulling the string through the frame. That went according plan…
Started from the rear, it was a bit of a challenge to get the brakeline through the lower rear fork, but thankfully the piece of string helped a lot. The next challenge was the frame, and when inserting the brakeline I pushed the black liner in the frame, bummer….
So decided to loosen the bolts from the engine and take a look from underneath. Left the motor hangina on the rear bolts and I could just reach the liner and put it back through the frame. Second chance, holding the black liner, feeding the brakeline gently in while pulling on the string. Slowly but steady getting there.
Almost…
With some 2 inch to go the string snapped, but thankfully I could push it through and out of the liner. Crisis aboarded. Feeding the brakeline and cable through the port in the frame and installed the cover. The next task was to build everything back, connect everything and fill the rear brake.
And a few hours later no more cables through the headset and a working bike.
What did I learned?
A (Giant) E-bike is not an easy bike to work on and I can understand why the LBS need more time to get some things done. I already asked my LBS (Giant dealer) to do this job and install anonther headset.
They told me that it was not possible to install another headset then the one in the bike and it would take them about 6 to 8 hours to do all the work…
Changing the brakeline took me about 2,5 hours, didn’t change the topside of the headset (yet) and installed the original one for now. I only had to buy a new brakeline sofar, original one was to short to reroute.
So first step, if you want to do this too, check if the length of your rear brakeline is long enough, then you don’t have to change it. Mine was probably shorted by my LBS.
Definitley a job you can do yourself, but not for the faintharted or beginners. Definitely need some experience wrenching on (E-)bikes and brakes and have all the tools needed at your disposal.