Apollo Explore 2.0 Stem Replacement

How to replace the stem on the Apollo Explore 2.0. This is a full job: you'll remove the headset, pull the brake cable and communication cable out through the stem and battery compartment, swap the stem, then reroute everything back through. Includes connector identification and tips for getting cables and rubber seals back in. TOOLS Allen keys: 2.5mm, 5mm, 6mm, plus a small Allen key for fishing wires Large flathead screwdriver (the bigger the better) Rubber mallet Long-nose pliers Electrical tape REMOVE THE HEADSET AND BRAKE CABLE 1. Loosen the brake cable adjustment screw, align the two lines on the adjuster, and pull the cable out. 2. Remove the six headset screws with a 2.5mm Allen key, lift off the headset and unplug the wires. 3. Remove the rubber seal, fold the stem and remove the wire cover. 4. Pull the brake cable out of the stem, pushing on one end while pulling the other. REMOVE THE COMMUNICATION CABLE 5. Flip the scooter over and remove the 10 deck screws to open the battery compartment. 6. Identify and disconnect the three stem connectors: • Stem light: yellow/brown into black/red • Rear light: white/grey into yellow/red • Display: the remaining connector 7. Pull the connectors out of the battery compartment, using long-nose pliers to pry open each rubber seal and pass them through. 8. Push the cable up through the stem and pull it out from the top, one connector at a time. SWAP THE STEM 9. Remove the top bolt and washer with a 5mm Allen key. 10. Remove the stem bolts (one on each side) with a 6mm Allen key. 11. Tap a large flathead screwdriver into the slot with a rubber mallet to spread the clamp, then pull the stem out. 12. With the screwdriver still in, fit the new stem and align it with the wheel. Remove the screwdriver. 13. Reinstall the two stem bolts, then the washer and top bolt. REROUTE THE CABLES 14. Tape the communication cable connectors together with electrical tape and feed them down the left side of the stem. Use a small Allen key to hook them through the opening at the bottom. Leave enough length at the top to connect the handlebar. 15. Thread the brake cable through the rubber seal, then fish it through the dedicated hole in the stem's inner structure. 16. Refit the rubber seals with the holes oriented as shown in the video. Wiggle them in or use an Allen key or flathead to help. Working alone? You can cut a seal to fit it around the cables. It closes back up once seated. 17. Reconnect the stem light (align the arrows on the connectors), then the headset connectors: headlight, red and green. Twist the wires and tuck them into the headset so they don't get pinched. 18. Seat the headset with no gap against the stem and reinstall the six screws. 19. Reinstall the brake cable: squeeze the brake lever, insert the cable, align the two lines and seat the end. CLOSE UP AND TEST 20. Flip the scooter, pull the slack through the last rubber seal into the battery compartment, remove the tape and reconnect the three connectors. Each only fits one way. 21. Before closing, power on and check the stem light, turn signals and headlight, and make sure there are no error codes. 22. Tuck the wires in, refit the battery compartment seal and close the deck without pinching any wires. 23. Refit the cable loom. Leave enough slack to turn the handlebar fully both ways, and stop the loom short so it doesn't restrict steering. 24. Adjust the brakes before riding. Related videos: Explore 2.0 Handlebar Assembly Replacement →    • Explore 2.0: Handlebar Assembly Replacement   Explore 2.0 Stem LED Light Replacement →    • Apollo Explore 2.0 Stem LED Light Replacement   Explore 2.0 Battery Box Replacement →    • Apollo Explore 2.0 Battery Box Replacement   Explore 2.0 Folding Mechanism Replacement + Adjustment →    • Explore 2.0: Folding Mechanism Replacement...   REPLACEMENT PARTS 🇺🇸 US: https://apolloscooters.co/collections... 🇨🇦 Canada: https://apolloscooters.ca/collections... Still stuck? Email our support team: support@apolloscooters.co Questions about this repair? Leave them in the comments below. #ApolloExplore #ApolloScooters #ElectricScooterRepair #EScooterMaintenance