X1 Pro Gen 4: Freewheel & Torque Sensor Disassembly Guide

Overview

This guide outlines the disassembly and reassembly procedures for the Gen 4 freewheel & torque sensor assembly.

Tools Needed

• Hex wrenches
• Bottom Bracket cup tool
• Rubber or plastic mallet
• Bearing press (recommended)
• Clean cloth

Disassembly Instructions

Step 1: Remove the Bearing Cover

1. Unscrew and remove all bearing cover screws.
2. Carefully lift off the bearing cover and set it aside.

Step 2: Remove Motor Axle Screw

1. Unscrew the bolt that secures the motor axle to the freewheel assembly.
2. Keep the bolt in a safe place for reassembly.

Step 3: Loosen the Freewheel Housing

1. Thread the Bottom Bracket cup tool into the freewheel housing.
2. Gently tap both ends of the freewheel axle using a rubber or plastic mallet.
   • This will separate the freewheel housing from the motor axle.
   • ⚠️ Avoid using excessive force to prevent damage.

✅ You now have access to the torque sensor and sprag clutch inside the freewheel housing.

Reassembly Instructions

Step 1: Install the Sprag Clutch

1. Place the sprag clutch into the freewheel housing.
2. Make sure it is oriented correctly (see image guide for reference).

Step 2: Align Components

1. Carefully align the torque sensor and motor axle assembly with the freewheel housing.
2. Ensure the outer bearing sits flush against the housing edge.

Step 3: Press or Tap Components Together

Preferred method:

• Use a bearing press to evenly rejoin the components until the outer bearing race is flush with the housing.

Alternative method:

• Use a rubber or plastic mallet to gently tap the assembly together.
• Apply even pressure—do not strike the bearing directly.
• Confirm the bearing race is fully seated and flush.

Step 4: Secure the Assembly

1. Reinstall and tighten the motor axle screw.
2. Place the bearing cover back onto the housing.
3. Tighten all bearing cover screws securely.

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