Photon: Replacements & Servicing

In some cases, it may be needed to replace the components of the kit. Below, you will find guidelines on how to perform these replacements using standard tools as well as the CYC Official Distributors & OEM Tool Kit.

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Table of Content

Distributors & OEM Tool Kit - Photon Tear Down 
(Including the Stage 1 gear assembly) 

Tool Kit & tear Down

*Please note that although the distributors & OEM Tool Kit is designed for resellers of CYC products, any user may request for a tool kit or specific tools within the tool kit. Contact CYC: https://www.cycmotor.com/contact-us

Replacing the X6P

If you need to replace the X6P controller on a CYC Photon unit, kindly follow the steps below.

1. Remove the controller bolt under the chainring using a 2.5mm hex key.
2. Use a heat gun around the edges of the controller cover. This softens the glue to make it easier to remove. Then, a cutter with a soft-tip hammer to separate the glue from the cover and the motor body. 
   *Always start from the lower corner and go along the edges of the controller cover.
   *Heat-gun temperature should be less than 350°C.
3. Now that there's a gap, use a slight ticker tool to open the gap further.
   *Be careful not to use too much force.
4. Remove the controller cover by pushing the motor body away from the controller cover using your hands as shown.
5. Now that the controller has been removed, use a thin cutter to remove the remaining glue along the edges of the controller housing. You may also use tissue paper and wipe along the edges and inside the controller housing. Please note to take out as much glue as you can to make it easier to install the replacement controller.
6. Add the glue provided with the new controller to the edges of the controller housing as well as to the edges of the replacement controller. 
   *Do not use too much glue as it may interfere with the controller's connectors.
   *Not using enough glue may leave the controller subject to water ingress.
7. Install the replacement controller by aligning the edges of the replacement controller to the controller housing.
8. Tighten the bolt under the chainring.
   *Torque spec is 5Nm
9. Wipe down any excess glue and let the glue dry for 24 hours.
10. Turn on the unit to ensure that it is functioning correctly before sending it off to a user.
    

If you need to replace a Photon's torque sensor, kindly follow the steps below.

1. Remove the Photon's chainring retaining cover.
2. Remove the torque sensor housing and the sprag clutch.
   *You may place the components onto tissue paper to avoid oil leakage & clean the excess grease in the module housing with tissue paper.
3. Undo the 4x bolts from the torque sensor and remove them with care.
4. Insert the new bolts provided through the new torque sensor module and line up the torque sensor to ensure that the pins match up to the housing.
5. Tighten the torque sensor module.
   *Torque spec is 2Nm.
6. Reinsert the sprag clutch, torque sensor housing, and chainring retaining cover.
   *Torque spec is 30Nm for the chainring retaining cover.
7. Test that the torque sensor is working and that the readings via app and display are accurate before sending it off to a user.

Follow the video for more details

Photon TS Replacement Video

Replacing the Photon Motor

If you need to replace the motor on a CYC Photon unit, kindly follow the steps below.

1. The controller needs to be removed. You can remove the controller by following the steps in the "Replacing the X6P" section.
2. Loosen the countersink screws accessible from the controller housing with a 5mm hex key. Once all 4x screws are loosened, remove them completely which will free the motor housing from the rest of the assembly. 
3. Separate the motor housing by gently pulling the motor housing off. The motor will now be exposed.
4. Separate the motor from the controller by pulling the motor and the assembly apart. You can twist (or wiggle) the motor slightly to help with the separation. 
5. Add the grease provided with the replacement motor into the motor gear chamber as shown.
6. Take the replacement motor and place the custom seal onto the replacement motor. 
   *Ensure that none of the pins are not blocked by the seal.
   *Ensure that the seal sits neatly around the edges.
7. Line up the motor gear and install the replacement motor onto the controller module with your hands by pressing them together. You may use a soft-tip hammer to ensure that the gap between the motor and controller housing is fully closed.
8. Insert the motor housing over the motor and take note to ensure that the 4x o'rings around the holes for the countersunk screws stay in position when putting the assembly back together.
9. Insert and tighten the 4x countersunk screws through the controller housing and ensure that there's no gap between the motor housing and controller housing.
   *Torque spec is 6-7Nm

Follow the video for more details

Photon Motor Replacement Video

Replacing the Photon Torque Sensor Connection: PCB Wire 

Tools needed: 

• 19mm Wrench
• Philips screwdriver 
• CYC Distributor & OEM Tool Kit

If you need to replace the PCB wire on a CYC Photon unit, kindly follow the steps below. 

1. Slot in the flat tool over the bearing, and slot in the two crescent tools under the bearing.  
2. Turn in the big screw to lift the large bearing; you can use a wrench to help you. 
3. Place the large bearing removal tool on top of the bearing and tighten it. 
4. Attach the hammer tool to the top of the bearing removal tool. 
5. Pull the hammer tool upwards to remove the bearing. 
6. Use a Philips screwdriver to remove the screws on the PCBs. 
7. Pull out the socket joining the two PCBs and unplug them, then take out the two PCBs. 
8. Remove the longer wire PCB and wrap the wire in a coil. 
9. Use a flathead screwdriver to pick out the connector on the bottom side of the body, then connect the two PCBs. 
10. Put the screws back on to secure the PCBs. 

*Take care when threading the wire to not damage the PCB connections and wires.
*When using the hammer tool, use adequate force when pulling it upwards.  

Follow the video for more details

PHOTON PCB WIRE REMOVAL VIDEO

Grease Types & Application

Grease Types for Sprag Clutches

IMPORTANT: Avoid using Extra Pressure additive (EP) greases as this is normally only used for gear application and not for sprag clutches. 

Re-greasing the Stage 1 Gear Assembly

Add Grease to parts #4 and #5

Add Multitop KP2N-40 DIN 51825 grease to the sprag clutch.

Bolts and Screws

O'ring Specs and Placement

Bottom Bracket Threads

M28*1