E Bike Disassembly Of Frame For Painting Model Hnf Ud1 Repair Guide

Difficulty

Moderate

Steps

Time Required

                          1 - 3 hours

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E-bike Disassembly of frame for painting (model: HNF UD1)
55 steps

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Introduction

I had two identical bikes, and learned a lot along the way. I documented everything along the way, and applied some optimizations to the process afterwards, thus the images often contain parts, that are not there by the time (since this last order of actions is the best). Hope you still find it helpful!

What you need

Step 1

              Remove E-bike Battery

Unlock the battery
Remove the Battery
You may fetch a box to store all the parts of the bike while it is taken for painting
Great videos about dissasembly of Bosch ebike parts can be found here: https://www.e-bikeshop.co.uk/Bosch-eBike…

Unlock the battery

Remove the Battery

You may fetch a box to store all the parts of the bike while it is taken for painting

Great videos about dissasembly of Bosch ebike parts can be found here: https://www.e-bikeshop.co.uk/Bosch-eBike…

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Step 2

              Remove the Seatpost and seatpost clamp

If you use a bike stand, this may rather be the last step!
Unscrew the seatpost clamp screw with the 5mm hex key
Remove the seat and seat post
Pull off the seatpost clamp

If you use a bike stand, this may rather be the last step!

Unscrew the seatpost clamp screw with the 5mm hex key

Remove the seat and seat post

Pull off the seatpost clamp

Step 3

              Remove Crank arm

Remove the crank arm bolt with 8mm allen key completely
A significant amount of pressure may be needed at the beggining. You may hold the crank arm for better force
Before removeing the drive unit its best to check this video for a general overview: https://www.e-bikeshop.co.uk/Bosch-eBike…

Remove the crank arm bolt with 8mm allen key completely

A significant amount of pressure may be needed at the beggining. You may hold the crank arm for better force

Before removeing the drive unit its best to check this video for a general overview: https://www.e-bikeshop.co.uk/Bosch-eBike…

Step 4

Install Crank extractor tool
screw the extractor tool gently in
it is designed to go in nice and smooth, by hand!
hand tighten the rear portion of the crank extractor
With the 16 mm wrench rotate clockwise
Remove the extractor tool
Repeat on the other side

Install Crank extractor tool

screw the extractor tool gently in

it is designed to go in nice and smooth, by hand!

hand tighten the rear portion of the crank extractor

With the 16 mm wrench rotate clockwise

Remove the extractor tool

Repeat on the other side

Step 5

              Remove Chain ring - not necessary

Hold the back brake (or hold it in place with a zip tie)
So the back wheel cant move, and the carbon belt holds the chain ring in place
with the Bosch chain ring lock ring removal tool on a 1/2" ratchet loosen the lock ring on the chain ring
To loosen one needs to turn it to the right! (clockwise) [it is the opposite direction than usual]
A significant force is needed to loosen the lockring
In a later step, after the carbon belt is removed, the chain ring can easily be pulled down too
The text must face outwards both on the chainring and the lockring

Hold the back brake (or hold it in place with a zip tie)

So the back wheel cant move, and the carbon belt holds the chain ring in place

with the Bosch chain ring lock ring removal tool on a 1/2" ratchet loosen the lock ring on the chain ring

To loosen one needs to turn it to the right! (clockwise) [it is the opposite direction than usual]

A significant force is needed to loosen the lockring

In a later step, after the carbon belt is removed, the chain ring can easily be pulled down too

The text must face outwards both on the chainring and the lockring

Step 6

              Remove Belt guide

With the help of a Philips 1 screwdriver remove the tiny screw holding the plastic guide in place
After the screw is removed the plastic can be slid off to the side

With the help of a Philips 1 screwdriver remove the tiny screw holding the plastic guide in place

After the screw is removed the plastic can be slid off to the side

Step 7

              Remove Chain ring

Loosen the back wheel bolts with the 15mm wrench on both sides of the rear axel and move the rear wheel out vertically for a few centimeters
Thus no tension is on the belt
slide the belt and chain ring off the drive train axel
Do not put too big force on belt (bending etc)
Slide the remaining double metal ring off
Slide the underlying black sealing ring off

Loosen the back wheel bolts with the 15mm wrench on both sides of the rear axel and move the rear wheel out vertically for a few centimeters

Thus no tension is on the belt

slide the belt and chain ring off the drive train axel

Do not put too big force on belt (bending etc)

Slide the remaining double metal ring off

Slide the underlying black sealing ring off

Step 8

              Remove Bosch Drive unit Cover

On the right side:
Remove the 2 screws closer to the front with the help of a 3mm hex key
When the plastic is a bit loose, a black plastic distance holder can be slid out from between the frame and plastic cover

On the right side:

Remove the 2 screws closer to the front with the help of a 3mm hex key

When the plastic is a bit loose, a black plastic distance holder can be slid out from between the frame and plastic cover

Step 9

Proceed using a T25 torx screwdriver to remove the 2 screws holding the plastic cover in place on the right side of the frame
approximately where earlier the belt placeholder was
After all these screws (4 in total on this side) are removed, the plastic cover can be lifted and removed
Proceed to the other side

Proceed using a T25 torx screwdriver to remove the 2 screws holding the plastic cover in place on the right side of the frame

approximately where earlier the belt placeholder was

After all these screws (4 in total on this side) are removed, the plastic cover can be lifted and removed

Proceed to the other side

Step 10

On the left side of the frame:
Using the 3mm hex key, remove the small screw in the deep hole
This screw has a length of 11,5mm

On the left side of the frame:

Using the 3mm hex key, remove the small screw in the deep hole

This screw has a length of 11,5mm

Step 11

Remove the two (identical) lower screws with the 3mm hex key
On this bike type, the frame could take bigger screws, thats why the first screw has a longer “neck”. In one case this came out directly, when unscrewing the screw.
If this extra does not come out, then it can be removed with a big flat head screwdriver (size 8) later on, but must not necessary be removed
These screws are 17,5 mm long
Lift off the plastic cover

Remove the two (identical) lower screws with the 3mm hex key

On this bike type, the frame could take bigger screws, thats why the first screw has a longer “neck”. In one case this came out directly, when unscrewing the screw.

If this extra does not come out, then it can be removed with a big flat head screwdriver (size 8) later on, but must not necessary be removed

These screws are 17,5 mm long

Lift off the plastic cover

Step 12

              Remove Bosch Drive unit holder

Since the frame holds the unit in place, the drive unit holder screws can be removed before the cables are
However, make sure, the drive unit does not fall out of place!
Remove the two torx screws with a T30 torx screwdriver

Since the frame holds the unit in place, the drive unit holder screws can be removed before the cables are

However, make sure, the drive unit does not fall out of place!

Remove the two torx screws with a T30 torx screwdriver

Step 13

Remove the two nuts with a 13mm socket and ratchet

Remove the two nuts with a 13mm socket and ratchet

Step 14

              Disconnect Bosch drive unit cables

Never pull directly on the cables!
Remove the biggest cable, the battery cable:
Using a flat head screwdriver loosen the catch 1-2mm
Using pliers disconnect the plug of the powerpack

Never pull directly on the cables!

Remove the biggest cable, the battery cable:

Using a flat head screwdriver loosen the catch 1-2mm

Using pliers disconnect the plug of the powerpack

Step 15

These images show how the original cableing was and serves as a reminder of all 4+1 plugs in place (battery pack plug is disconnected already)

These images show how the original cableing was and serves as a reminder of all 4+1 plugs in place (battery pack plug is disconnected already)

Step 16

              Remove plug and cable of back lamp

Located in 3. place from the left is the back lamp’s cable and plug
It runs directly to the back of the bike and exits the drive units frame part on a hole around the kickstand just below the rear fender
The cable runs through the inner side of the rear fender and ends in the back lamp

Located in 3. place from the left is the back lamp’s cable and plug

It runs directly to the back of the bike and exits the drive units frame part on a hole around the kickstand just below the rear fender

The cable runs through the inner side of the rear fender and ends in the back lamp

Step 17

              Remove plug and cable of Bosch sensor

From the 4. socket remove the plug of the bosch sensor
The cable goes directly inside the left back fork and exits just before the sensors place

From the 4. socket remove the plug of the bosch sensor

The cable goes directly inside the left back fork and exits just before the sensors place

Step 18

              Remove Plug going to intuvia board computer

Remove the flat plug and unwind the cables
The cable enters the inside of the frame in the middle and exits on the left side on the biggest hole, runs up the frame and to the board computer mount

Remove the flat plug and unwind the cables

The cable enters the inside of the frame in the middle and exits on the left side on the biggest hole, runs up the frame and to the board computer mount

Step 19

              Remove the plug of the front light

The first socket is for the front light and goes straight throw the middle of the frame, and out on the biggest whole
Runs along the fork and up to the light

The first socket is for the front light and goes straight throw the middle of the frame, and out on the biggest whole

Runs along the fork and up to the light

Step 20

              Remove Drive Unit

When all plugs are unplugged, the last nut can also be loosened with the 13mm socket
The drive unit can be shifted horizontally to the other side.

When all plugs are unplugged, the last nut can also be loosened with the 13mm socket

The drive unit can be shifted horizontally to the other side.

Step 21

              Drive unit removal

Keep the long place holder on the two long screws on top of the drive unit
Keep small place holder on the lower long screw as well!

Keep the long place holder on the two long screws on top of the drive unit

Keep small place holder on the lower long screw as well!

Step 22

              Remove the black design cover

Remove the screw next to the battery charging port with a PH1 Screwdriver [marked with red circle]
This screw is the smallest of the three types
Remove the upper screw with a 3 mm hex key on both sides. (2x in total) [marked with blue circle on this side]
These screws are slightly longer and thinner, than the lowest screws

Remove the screw next to the battery charging port with a PH1 Screwdriver [marked with red circle]

This screw is the smallest of the three types

Remove the upper screw with a 3 mm hex key on both sides. (2x in total) [marked with blue circle on this side]

These screws are slightly longer and thinner, than the lowest screws

Step 23

Remove the lower screw on one side.
This lower screw is thicker and shorter, than the upper hex screw
The screw on the other side can also be removed, however its better left and simply shifted to the side (there is a spacer inbetween held in place with these two screws)!
After the 4 screws are removed, the black cover can be taken off (comes in two pieces) sideways

Remove the lower screw on one side.

This lower screw is thicker and shorter, than the upper hex screw

The screw on the other side can also be removed, however its better left and simply shifted to the side (there is a spacer inbetween held in place with these two screws)!

After the 4 screws are removed, the black cover can be taken off (comes in two pieces) sideways

Step 24

              Remove Battery Mounting Cover

For removing the plastic cover of lower battery holding part
Remove the two black screws from the black plastic with a T15 torx screwdriver
Release the catch on the lower side (facing the back fork/drive unit)
By taking the plastic parts apart, the outer shell can be removed

For removing the plastic cover of lower battery holding part

Remove the two black screws from the black plastic with a T15 torx screwdriver

Release the catch on the lower side (facing the back fork/drive unit)

By taking the plastic parts apart, the outer shell can be removed

Step 25

              Remove the battery plug

First remove the cables with smaller plugs through the rectangular hole
Carefully, not to bend (and break) cables and plugs
After all other cables removed, the battery plug fits the big hole on its own

First remove the cables with smaller plugs through the rectangular hole

Carefully, not to bend (and break) cables and plugs

After all other cables removed, the battery plug fits the big hole on its own

Step 26

Remove the two torx screws with a T25 torx screwdriver

Remove the two torx screws with a T25 torx screwdriver

Step 27

For the upper cover
Using the T15 torx screwdriver remove the black screw from the low end
lift the cover gently (lift outwards around the lock)
after fidgeting around, lifting the right side helped

For the upper cover

Using the T15 torx screwdriver remove the black screw from the low end

lift the cover gently (lift outwards around the lock)

after fidgeting around, lifting the right side helped

Step 28

With the help of a T25 screwdriver, remove the two screws holding the upper (locking mechanism) to the frame
When both screws are removed, the lock can be lifted (removed)
The plus is on the upper side
Underlying cable holder plastic can also be lifted
the higher fences show to the upper side, also the narrower side is on the top
There may be a plate under the lower screw between the frame and the lock (10)
But could also be below the upper one (04)

With the help of a T25 screwdriver, remove the two screws holding the upper (locking mechanism) to the frame

When both screws are removed, the lock can be lifted (removed)

The plus is on the upper side

Underlying cable holder plastic can also be lifted

the higher fences show to the upper side, also the narrower side is on the top

There may be a plate under the lower screw between the frame and the lock (10)

But could also be below the upper one (04)

Step 29

              Remove front brake lever for easier handling

Remove grip on right side
Loosen the brake lever and pull it off the handle
Alternatively unscrew the holding part on the fork with 3mm hex key

Remove grip on right side

Loosen the brake lever and pull it off the handle

Alternatively unscrew the holding part on the fork with 3mm hex key

Step 30

              Remove the front fork (and wheel)

Remove - if any - protective/design rubber cap on stem
Loosen the stem with a 5mm allen key.
Loosen the two bolts on the side of the stem with the 5mm allen key

Remove - if any - protective/design rubber cap on stem

Loosen the stem with a 5mm allen key.

Loosen the two bolts on the side of the stem with the 5mm allen key

Step 31

Carefully lift the handle bar off the fork
Lift the two consecutive spacers off
Lift off the bearing cap

Carefully lift the handle bar off the fork

Lift the two consecutive spacers off

Lift off the bearing cap

Step 32

              Remove Front fork bearings

Remove upper bearing
The flat part must be facing upwards, the cornered part downwards into the frame
The lower bearing can be left on the front fork

Remove upper bearing

The flat part must be facing upwards, the cornered part downwards into the frame

The lower bearing can be left on the front fork

Step 33

              Remove Nuvinci shift cables

shift pedals to a position that allows easy access to the shift cable hardware
Remove the shift cable hardware ends
Open the securing closing mechanism on the lower one (open and lift)
Remove the cable end from its socket

shift pedals to a position that allows easy access to the shift cable hardware

Remove the shift cable hardware ends

Open the securing closing mechanism on the lower one (open and lift)

Remove the cable end from its socket

Step 34

Remove the upper cable’s end from its socket
The cable with no closing mechanism comes on the top part, and the closing mechanism closes in from the bottom on the top

Remove the upper cable’s end from its socket

The cable with no closing mechanism comes on the top part, and the closing mechanism closes in from the bottom on the top

Step 35

              Remove rear wheel

Loosen the bolts with the 15mm wrench on both sides of the rear axel
Remove the rear wheel carefully, not to damage the belt!

Loosen the bolts with the 15mm wrench on both sides of the rear axel

Remove the rear wheel carefully, not to damage the belt!

Step 36

              Disassemble the frame

Remove rear facing bolt with 5mm allen key

Remove rear facing bolt with 5mm allen key

Step 37

Slide the black part out of the frame (pointy part faces backwards)

Slide the black part out of the frame (pointy part faces backwards)

Step 38

To remove the bolt that held the long screw and black part in place,
use a small but long tool (nail or screwdriver) and put it in the hole, where the removed screw was previously, but not through the upper part of the frame, but diagonally from the outside - thus the bolt can be slightly pushed out of the frame
Grab this slightly outlying bit with a plier and pull it out

To remove the bolt that held the long screw and black part in place,

use a small but long tool (nail or screwdriver) and put it in the hole, where the removed screw was previously, but not through the upper part of the frame, but diagonally from the outside - thus the bolt can be slightly pushed out of the frame

Grab this slightly outlying bit with a plier and pull it out

Step 39

              Remove Bike rack (after light cable released)

Do not remove the bike rack (the mud guard) while the back light is still attached to the motor!
Loosen the two bolts on the rear part of the frame with 4 mm allen key

Do not remove the bike rack (the mud guard) while the back light is still attached to the motor!

Loosen the two bolts on the rear part of the frame with 4 mm allen key

Step 40

The Bolt has multiple plates:
a metal plate below the bolt head
a cornered black plate , then comes the bike rack
one metal between the bike rack and the frame
Main goal is to strip everything from the frame, thus the rest of the bike racks screws do not have to be removed, since the complete bike fender must be removed

The Bolt has multiple plates:

a metal plate below the bolt head

a cornered black plate , then comes the bike rack

one metal between the bike rack and the frame

Main goal is to strip everything from the frame, thus the rest of the bike racks screws do not have to be removed, since the complete bike fender must be removed

Step 41

              Remove The Rear Fender from the frame

Remove the two screws holding it to the frame’s middle (back frame’s triangle’s corners)
There are two (1-1) black plastic/rubber plates between the fender and the frame on the screws
In total the bike rack and rear fender are connected with 4 screws to the frame

Remove the two screws holding it to the frame’s middle (back frame’s triangle’s corners)

There are two (1-1) black plastic/rubber plates between the fender and the frame on the screws

In total the bike rack and rear fender are connected with 4 screws to the frame

Step 42

              Remove Belt

Carefully remove the Belt through the frame
Watch out not to bend the belt, or damage it in any way

Carefully remove the Belt through the frame

Watch out not to bend the belt, or damage it in any way

Step 43

              Storeing the Belt

For storage purpose you can coil the belt by holding it on the two sides, and turning one hand inwards, the other outwards.
If you feel resistance, STOP!
It should coil easily (in three loops)
This video shows the process: https://www.youtube.com/watch?v=VgM-qeHG…
Uncoiling: find the outermost circle, and slowly start to straighten it out. The Belt will uncoil on its own
If you feel resistance, STOP!
Uncoiling the belt: https://www.youtube.com/watch?v=slFf0q1I…

For storage purpose you can coil the belt by holding it on the two sides, and turning one hand inwards, the other outwards.

If you feel resistance, STOP!

It should coil easily (in three loops)

This video shows the process: https://www.youtube.com/watch?v=VgM-qeHG…

Uncoiling: find the outermost circle, and slowly start to straighten it out. The Belt will uncoil on its own

Uncoiling the belt: https://www.youtube.com/watch?v=slFf0q1I…

Step 44

              Remove bike stand

Loosen the two front facing bolts with the 5mm hex key
Curved side must face backwards (obviously, as the stand must look backwards…)

Loosen the two front facing bolts with the 5mm hex key

Curved side must face backwards (obviously, as the stand must look backwards…)

Step 45

              Remove rear wheel holder

Remove the longer front facing screws (with neck) from the rear end on both sides with 4 mm hex key
those setting the tightness of the belt by adjusting the position of the wheel holder

Remove the longer front facing screws (with neck) from the rear end on both sides with 4 mm hex key

those setting the tightness of the belt by adjusting the position of the wheel holder

Step 46

Cut the zip ties holding the brake cable on the frame with a wire cutter or remove other fixating elements
Remove the screws on both sides (2x2) holding the wheel holder in place with 6mm hex key
The plate comes between the bolt head and the frame!

Cut the zip ties holding the brake cable on the frame with a wire cutter or remove other fixating elements

Remove the screws on both sides (2x2) holding the wheel holder in place with 6mm hex key

The plate comes between the bolt head and the frame!

Step 47

              Remove Bosch speed sensor

Remove the rubber cap by hand
Remove the locking screw with a T20 torx screwdriver
The speed sensor’s cable is going through the frame

Remove the rubber cap by hand

Remove the locking screw with a T20 torx screwdriver

The speed sensor’s cable is going through the frame

Step 48

              Rear Brake cable

The rear break levers’ “cable” (on the right) is tied together with the Intuvia board computers fat cabel and goes down the frame on the right side
After the Battery, it crosses and exits the black part on the left side (as single cable) and goes on the top part of the rear frame

The rear break levers’ “cable” (on the right) is tied together with the Intuvia board computers fat cabel and goes down the frame on the right side

After the Battery, it crosses and exits the black part on the left side (as single cable) and goes on the top part of the rear frame

Step 49

              NuVinci gear shifter cable setup

The NuVinci gear shifter is on the right side.
The cables are tied together with the supernova lamp’s thin cable (in comparison to Intuvias thicker cable) .
These cables go down on the left side of the frame. Then cross under the black part below the battery and exit on the right side (only the two Nuvinci cables from here). Then it goes down to the inner part of the frame’s back triangle and has three plastic holders.

The NuVinci gear shifter is on the right side.

The cables are tied together with the supernova lamp’s thin cable (in comparison to Intuvias thicker cable) .

These cables go down on the left side of the frame. Then cross under the black part below the battery and exit on the right side (only the two Nuvinci cables from here). Then it goes down to the inner part of the frame’s back triangle and has three plastic holders.

Step 50

Remove the 3x screws, keeping the cable holders in place, with a 3mm hex key
The frame is upside down for easier work conditions on the image

Remove the 3x screws, keeping the cable holders in place, with a 3mm hex key

The frame is upside down for easier work conditions on the image

Step 51

              Remove cable guide and black design cover holder plate

Underlying metal holder (and cable aligner) is held in place by a 3mm hex screw
A big diametered washer is under the screw head
Below is the placeholder

Underlying metal holder (and cable aligner) is held in place by a 3mm hex screw

A big diametered washer is under the screw head

Below is the placeholder

Step 52

              Remove Front fork bearing holders

The one on top has sharper corners
The one on the bottom is fully rounded
They can either be removed with a specific tool, or with a chisel and a hammer (possibly rubber hammer)
Be careful with this step not to damage the rings inner side - might even ask for the help at a local bike shop

The one on top has sharper corners

The one on the bottom is fully rounded

They can either be removed with a specific tool, or with a chisel and a hammer (possibly rubber hammer)

Be careful with this step not to damage the rings inner side - might even ask for the help at a local bike shop

Step 53

              Remove screw hole changers

Before painting the fork these small parts can be removed with a wide flat head screwdriver (8), but do not have to necessarily
This step can be skipped, especially, because these can easily be damaged, and are sometimes difficult to remove

Before painting the fork these small parts can be removed with a wide flat head screwdriver (8), but do not have to necessarily

This step can be skipped, especially, because these can easily be damaged, and are sometimes difficult to remove

Step 54

              Prepare for painting

Check with paint shop if the wholes should be protected
If needed - insert (short) screws in all places, where there were any before, to save their guideway (14 small type screws, 7 bigger type)
And the frame is ready for a fresh new paint!!!

Check with paint shop if the wholes should be protected

If needed - insert (short) screws in all places, where there were any before, to save their guideway (14 small type screws, 7 bigger type)

And the frame is ready for a fresh new paint!!!

Step 55

              Additional empty wholes

There are 2x2 unused bolts on either (inner) side of the frames back triangles top tube
Additional two unused bolts are just over the rear fender facing slightly upward

There are 2x2 unused bolts on either (inner) side of the frames back triangles top tube

Additional two unused bolts are just over the rear fender facing slightly upward

To reassemble your device, follow these instructions in reverse order. Except for the nuvinci cable setting - this has to be adjusted at the end, when the back wheel is set to the right position and belt tension

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                    Bango Bejla

Member since: 11/08/2016

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Rares Alexandru Murza - Apr 20, 2022

Do you have any photos of the frame after it’s been painted?

Bango Bejla - May 4, 2022

Yes, I updated the main picture to show the frame after the paint job :)

Member-Contributed Guide#

Introduction#

What you need#

Member-Contributed Guide

Introduction

What you need