How to repair Broken Trail Remote on Specialized Turbo Levo 2018 and the pinout for bonus
Specialized e-bikes utilize control cables with a braided wire construction that exhibit a lower tolerance for mechanical stress and extended vibration compared to more industrial durable options. These cables, specifically those associated with the handlebar-mounted remote buttons, are susceptible to fatigue-induced failure due to their fine gauge and hard braided design. This can manifest as button malfunction after a period of sustained use, as experienced in my case after two to three years of riding.
And now the sad part of the story… Replacement part price. For 130 euros, those buttons better come pre-attached to a small gold-plated unicorn. Four buttons? Absolutely criminal!
Disassembly:
- Housing Access: The remote enclosure utilizes a sonic welding technique, essentially creating a permanent closure between the two halves. Destructive disassembly is required. A thin, flat-head screwdriver can be used to carefully pry open the housing seam, but caution is necessary to avoid damaging the internal flexible printed circuit board (FPCB).
- Cable Removal: Once the housing is breached, the control cable can be severed near the entry point. This allows for the complete removal of the remote unit.
- Sealant Removal: The remaining challenge lies in the removal of the silicone sealant. This process requires meticulous cleaning with a sharp tool to scrape away the adhesive from the wires and FPCB. Special attention should be paid to the vicinity of the soldering pads on the circuit board, as these delicate components are susceptible to damage from excessive force.
The pinout:
1 = “S”, 2 = “+”, 3 = “-“, 4 = Foot, 5 = Common