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Replacing the internal cables (requires soldering)

What you need

  1. Replacing the internal cables (requires soldering), Tools and Material: step 1, image 1 of 3 Replacing the internal cables (requires soldering), Tools and Material: step 1, image 2 of 3 Replacing the internal cables (requires soldering), Tools and Material: step 1, image 3 of 3
    • First of all: This is what the defect looks like

    • The tools: knife, lighter, soldering iron, solder, screwdriver(+) and optionally: lubricant (e.g. Silicone grease or Silicone oil spray), pliers

    • Cable you need (copper wire 0,14mm² / AWG26): 9 pieces of wires, with each 30cm length. AND a single short wire (≈7cm length).

    • if you do not have different colored cables: Simply mark the cables accordingly.

    • Heat-shrink tubing 2:1 for isolation: ≈1,6mm (18*2cm length) and ≈6,4mm (5cm length) ((or alternative use insulating tape))

  2. Replacing the internal cables (requires soldering), Open case: step 2, image 1 of 2 Replacing the internal cables (requires soldering), Open case: step 2, image 2 of 2
    • dissolve screw

    • take out case part in strait-up direction

  3. Replacing the internal cables (requires soldering), Wheel-Cap front open: step 3, image 1 of 3 Replacing the internal cables (requires soldering), Wheel-Cap front open: step 3, image 2 of 3 Replacing the internal cables (requires soldering), Wheel-Cap front open: step 3, image 3 of 3
    • Carefully use a knife. Maybe press short with the other hand (finger) down. Part by part. Carefully.

    • do not break the three retainer tab.

    • The knife makes some little scatches.

  4. Replacing the internal cables (requires soldering), Wheel unscrew: step 4, image 1 of 2 Replacing the internal cables (requires soldering), Wheel unscrew: step 4, image 2 of 2
    • dissolve screw

    • the cables are oily.

  5. Replacing the internal cables (requires soldering), Wheel-case open: step 5, image 1 of 3 Replacing the internal cables (requires soldering), Wheel-case open: step 5, image 2 of 3 Replacing the internal cables (requires soldering), Wheel-case open: step 5, image 3 of 3
    • dissolve screw

    • dissolve screw from knob

  6. Replacing the internal cables (requires soldering), strain relief remove: step 6, image 1 of 3 Replacing the internal cables (requires soldering), strain relief remove: step 6, image 2 of 3 Replacing the internal cables (requires soldering), strain relief remove: step 6, image 3 of 3
    • dissolve screw

    • take out part

  7. Replacing the internal cables (requires soldering), cable remove: step 7, image 1 of 3 Replacing the internal cables (requires soldering), cable remove: step 7, image 2 of 3 Replacing the internal cables (requires soldering), cable remove: step 7, image 3 of 3
    • cut the USB-cable

    • open the cable tie (best: to be reused ; look at last photo)

    • pull out plugs

  8. Replacing the internal cables (requires soldering), Shield solder: step 8, image 1 of 3 Replacing the internal cables (requires soldering), Shield solder: step 8, image 2 of 3 Replacing the internal cables (requires soldering), Shield solder: step 8, image 3 of 3
    • A new very short cable is required (approx. 7cm?).

    • Twist the short cable with the shielding from the USB cable

    • Solder the other side of the cable to the black cable (black cable from the USB cable).

    • Pull the heat-shrink tubing over the repair apply heat to shrink it.

    • This only needs to be done once (only for the USB cable). (If necessary, this entire step could also be skipped).

  9. Replacing the internal cables (requires soldering), Colder cable: step 9, image 1 of 2 Replacing the internal cables (requires soldering), Colder cable: step 9, image 2 of 2
    • solder

    • Heat-shrink tubing over it (or adhesive tape)

    • (unimportant) technical background: The USB cable actually needs shielding and the cable pair for the data should be slightly twisted. In fact, USB usually works like this and is simply slower. This should be sufficient for our device.

  10. Replacing the internal cables (requires soldering), Result: step 10, image 1 of 2 Replacing the internal cables (requires soldering), Result: step 10, image 2 of 2
    • When assembling: If necessary, grease the cables at the pivot point with lubricant (e.g. silicone oil / grease).

    • use cable tie

  11. Replacing the internal cables (requires soldering), Pedal: plug replace (if necessary): step 11, image 1 of 3 Replacing the internal cables (requires soldering), Pedal: plug replace (if necessary): step 11, image 2 of 3 Replacing the internal cables (requires soldering), Pedal: plug replace (if necessary): step 11, image 3 of 3
    • If a pedal creaks or squeaks: oil the springs

    • The following is only necessary if the pedal also has another defect. So first check whether the previous repair may have helped.

    • In case one or both pedals are not working: The connector ( jack / plug ) might be defect.

    • Material: A cable from Telephone earphone capsule is a good replacement. Cut out some part (with some cable) and solder it. The plug jack is called 4P4C (or „RJ-9“, „RJ-10“, „RJ-22“).

Conclusion

Work through the steps in reverse order to reassemble your device.

(Lubricate the cables at the pivot points).

The three screws on the front of the steering wheel (behind the horn) should be screwed in straight and completely.

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Joe Musters

Member since: 07/02/20

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