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Bafang BF1808H66200-1 36V 250W Rear Hub

Has your bike lost it’s Oomph, does it now feel like it does 0.0mph extra to your effort?

Do you know how your hub looks on the inside? You can’t tell what lurking in there from the outside…

Has your bike sat for a long time? Has somebody said it’s your battery but you don’t want to believe them?

Does it still make a noise like it want to move but doesn’t? This is your biggest clue maybe, how does it sound?

Did it stop working with no clues or did it give up whilst riding?
The later means you may have damaged something, the former is an indicator of this issue maybe, you see grease ages, it gets old and sticky and parts eventually stop moving, if they do so for long enough then you’ll end up with no drive if your clutch seizes open, or perhaps it’ll jam on and not release, you may hear the motor whir whilst you spin the wheel by hand if it’s still engaged.

The Customer phrased this as

“it just doesn’t do anything on full power, all the lights are on, but there’s no discernible difference between settings anymore, it just stopped working one day, maybe it hadn’t been used for a couple of months. The batteries charged and all the lights come on, but it’s useless on a hill!”

This had me stumped for a bit, but I had a hunch, the strange thing was I’d have assumed and tested further for electrical errors and faults except for the fact the hub made noises like it was still doing something… Just zero discernable torque added with pedal assist at it’s highest level, you could feel a little boost on the flat, but on a hill you’d get zero benefit.

So, what to check first, is it switched on, well yes of course, full battery indicator, all visibly operational, no damaged connectors or wires and some form of response from everything except the power output of the Hub in Assisted Drive modes.

So the strip down begins, the battery removed and voltage checked at 42V so that’s well charged, and looks like it’s not suffering, but I’ve not load tested it or worked out any internal resistance yet, I would almost instinctively think of this to be an issue, it seems odd that the battery level doesn’t drop on the indicator in use. We know therefore the charger also is good. The bike had been left standing in the shop whilst they tried and failed to fault find the issue, so a dud cell could be suspected, but that’s not it.

Hub internals removed, time for inspection…

The wheel has been rebuilt and installed with the axle cutout facing downwards which isn’t ideal, so I go to great lengths to check the continuity of the leads from the 9-pin Juliet Plug to the circuit board solder joints, which appear good, I’m more hesitant of the multimeter I’m using giving false negatives, but it doesn’t appear to be damaged. I’ve full disassembled the hub now and also have the planetary gears visible, these are in good shape although looking a little dry the grease is old and grey but it’s not the issue, it does point towards the age of the hub.

The gears are stuck on the axle shaft and I use a 3-arm puller to remove them along with the clutch, and loose the small woodruff key as I do (easily found, but watch out for it) the twirling and inspecting probably shifted it loose, so be careful as the clutch may float but still need persuading off the axle it gives enough space for it to fall out. Had I realised sooner I might have caught this quicker, but the clutch was off, at this point I’m still running blind, it didn’t function like a clutch should an I just span it and span it, one way then the other, nice and freely it span, little to no real resistance. I secretly knew this was a bit off, but as things were still covered in crap old grease and every part of this hub spins around itself rather freely it wasn’t as obvious to me until I caught a video of someone hacking one apart and I thought all of a sudden about that old grease again.

The sticky old grease in the clutch rollers was holding them back? Maybe, but that leaves one of two options of which either could end in failure, but worth a shot. It’s not an available spare, none of the internals strictly are, it’s sealed and riveted shut in production.
After some moderate cleaning and a blunt tickle it hadn’t got much better but had changed a bit, it got put down and I came back to it and low and behold it jammed on and wouldn’t release, once it released under much load, the was game on!
The second option would involve cutting it open, grinding off the rivets and possibly just riveting it back up afterwards, but I don’t favour the gear shafts staying put for too long, it may become an option next time.

Lot’s of GT85 and a little bit of “engine oil” later, it moves and lives, albeit sporadically operational, it does catch and release, not every time but it’s viable almost, when it grabs though it’d strip the gears so not good enough.
Next come out the big persuader and the flying anvil, oscillating almost syncopated blows on opposing sides whilst giving it a small degree of rotation slowly and then going back to working it round slowly, like checking a bearing for smoothness, or a freehub for engagement.

All of this working it free was done in the vice whilst it was mounted on an old 9mm axle using the cone nuts to centre it with a good clamping force. Using a bar between the planet gear pegs to free it up when stuck again success was judged in the torque required to release it again.

Did it work…

The hub was reassembled with new bearings in the disc / non-drive side and in the planet gears too and low and behold worked as desired first time back on the bike. Sounds good as new, or as good as it’s going to for a hub that’s probably done a good few miles now… Whilst everything looked in almost tip top condition once cleaned up to service it’s not got any noticeable wear except the bearing all feeling like they’d like to have failed a while ago.

Servicing is an important part of keeping your eBike running and we can help you do that, get in touch if you’d like to find out more.

Bike Summary

Bike: Halfords Carrera Crosscity E Folding Bike 250W

Hub Motor: Bafang BF1808H66200-1
Hub Motor Circuit Board:
Planetary Clutch Model: BF180704YA
26T-40T Reduction / 12mm Axle / 9.2mm x 72mm Case x 34mm Total depth / 3x 7.9mm x 20mm Planetary Gear Shafts running twin 688Z Bearings on 17.8mm of shaft.
Bearings (not including Cassette Body freewheel): 6001-2RS for Disc-side x1, 688zz x6 for Planetary Gears

Battery: Reention Rapier IR-III
Li-Ion 36v / 8.7AH / 313.2Wh


Spare Parts available through Halfords, although supply may be currently limited the products you may need are available as;

Spare Battery Product Code: 321489 – £300
Spare Speed Controller: Model Year Variants possible; 321885 Battery Controller Unit – £50
Torque Sensor: 299468 – £15
Spare Wheel: 321406 – £150
Handlebar control: 299500 – £25

The Batteries are also offered by a third party on ebay based out of Bristol with a 10.5Ah Upgrade for £359 link here

Fitted to a Carrera Crosscity E Folding Bicycle, it’s built into a 20″ Rear Wheel, powered by a Reention Battery which is honestly worth getting upgraded if it’s the problem unless you really want to avoid the small weight penalty for the gained range.

Some useful videos on similar hubs

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What goes into your bike when it’s “Serviced”…

Here’s a bike that looked a little worse for wear, it wasn’t very old or very used, just neglected and very poorly built and adjusted from when it was new. Here’s how it’s looked before work started, lost of rust and a chain that’s solid! The Freewheel looks worse than it is actually, everything moves except the cables look like they shouldn’t they do a little, it’s got a bit of promise!

Challenge Sceptre 24" 18 Speed Dual Suspension Mountain Bike Blue 16"
Challenge Sceptre 24″ 18 Speed Dual Suspension Mountain Bike Blue 16″

Why choose this bike, for the purposes of this article, well it was simple, it’s getting a lot of hits! So it seemed like simple exposure, if you are thinking of buying this bike you’re in for a little treat as the labour alone would normally cost you more than this bike would brand new…
As the level of work and parts count goes up so will the price, so here’s some of what you can expect now it’s going to be serviced it’s basically being stripped to component form and rebuilt.

Maybe the wheel’s got pinched for another bike too, so we’re rebuilding them with some bits left around, it’s getting the works treatment, or at least a lot more than it was going to originally. Seeing as the wheels are apart, the freewheels removed, it’s time to give everything a clean.

Dismantled Freewheel
Dismantled Freewheel with two cogs and freehub already cleaned up.

Watch this space to find out how the cranks turned out, the shock spring was pretty orange too, and I’ll show you the secret hidden under the rusty chain and why it’s always worth having a look and checking a bike over before you ride off on it.

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Cycling, Exercise & CORONAVIRUS COVID-19

  • If you can run you can ride, balance isn’t your problem… & Loo Roll isn’t the answer
  • Fear is a really powerful motivator, are you that sick already?

If you’re thinking of getting a bike for any reason, now is a great time to accelerate that decision and reap some healthy & financial rewards as the weather improves or local transport closes down

In 2015, dementia overtook heart disease and stroke as the UK’s biggest cause of death. This graph shows the percentage of all UK deaths from the top four leading causes in 2017. These were dementia, heart disease, stroke and lung cancer.

It won’t be much surprise to you that compared to other ailments and things that might kill you, we’ve faced worse, and there are still bigger issues to consider going forward through this crisis, as a nation are we fit enough to survive, I’m not intending on spending it all sat down that’s for sure.

A new study from Imperial College London found the death rate from heart disease fell dramatically between 2005 and 2015, from 80 deaths per 100,000 people to 46 per 100,000.

Experts said fewer people smoking had fuelled the drop but warned that obesity, Type 2 diabetes and high blood pressure kept the death rates too high.

Heart disease still caused double the deaths from lung cancer (the second biggest killer) in 2015 and 18 times the number of deaths caused by road traffic accidents.

– Press Association

Whilst Self Isolation may be vital for the coming weeks, it’s not for everybody, and won’t be forever, but in the short term it will prove successful if people take the time to consider their actions wisely. If your plan is to eat yourself into a food coma with netflix for a companion for 14 days it’s not going to make you any less mortal than surviving a game of cluedo, however if you get your heart racing against a competitor in a game it’s actually proven to help boost your bodies systems and prove to be a great distraction from time for a while at least,but too much of a good thing can also be bad; so don’t forget to get up and stretch, eat sleep etc… Try a little socialising with those folks called your family, even if it is just a video or phone call.

CYCLING: The Tour de Yorkshire, scheduled to take place between 30 April and 3 May, is postponed with no new date yet announced.

Feeling a little lonely I posted this the other day encouraging people not to forget about the power of hugging, and we’re not all in the at risk groups but to some of us this isn’t appropriate for now, but there are going to be loads of people feeling strained over this and we spend so much of our time trying to distance ourselves that we may forget this is only a brief period. But if tensions are running high and you’re all couped up for a long period you’d be surprised what a hug can fix, you don’t have sneeze all over them though to pass it on so use some judgement and be considerate.

Please use your time and body wisely for the next few weeks it's crucial to keep a bit of distance, consider keeping a diary of anybody you can name as being close to you in the last few weeks before now if you can, you never know who it may help in the future. 

Getting back to the point of all this, it’s a great time to consider giving up a few unhealthy habits, dusting off that exercise bike or treadmill you put away 2 weeks into the New Years Resolution and work off those snacks you’ve already depleted (from what it turns out was meant for week two rations… Am I right?) Let’s face it the gym is out of the question for now, and if you’re stuck inside so is actually cycling for your average person.
Take a look around the world at what’s happening right now, if you’ve not been glued to it already, it’s quite simply amazing to see how fast nature can recover from humans malpractice in our own environments, theirs too mind you!

There’s a story gone viral about the canals in a certain Venetian setting, created for self amusement in India, and I hate to drop the spoiler alerts but it’s fake news, debunked, there are no Dolphins there, and the swans live there anyway, the fish are now visible but the water’s by no means clear…

National Geographic, Fake animal news abounds on social media as coronavirus upends life

There’s exciting things on the horizon don’t forget, we all have things we wanted to do, but plans change, develop further and change again and we do it all the time year on year keeping the machine running, until you guessed it!

This will and already is the year for Electricity, cars bikes and even now scooters and the likes so if you’re scared of putting in too much effort (good if you’ve been told not to over exert yourself by a physician), fancy a little luxury or new technology there will be something to get you interested, if you’re in certain zones around the world there are grants and loans to convert you to e-bikes for both business and personal reasons, there are more benefits than than I could squeeze into a thesis or dissertation and there are enough people who’ve already done that…

If 2020 is anything it’s been long predicted to be then we are in for some change!

If you’ve been paying attention to the state of the planet none of this should surprise you, XR gave shot across the bow of the commercial world, and TESLA going from strength to strength, some things will change, we can now ride small electric scooters in certain parts of the UK and with cities around the world shutting down for the longest sustained periods in modern history urban people have seen pollution drop considerably in certain locales, if we can sustain this change alone the air quality will improve many peoples chances of surviving this and many other viruses to come (and believe me there will be more and more if we don’t)…

People are by and large it seems trying to adopt a work from home or more localised approach to solving this problem, and it’s going to have many benefits for some, for others I can safely assume you don’t get out for much in the way of exercise and your commute was never of the active sort to raise that heart rate at all, well some of the younger generations didn’t have your youthful pursuits of yesteryear and have already grown fat and in active with more years of screen time in their youth than some of these middle aged types have in their working lives, so you have to wonder where is your health heading?

With the youngest victim being only 21 in Spain and 45 in the UK for the Coronavirus and the larger at risk group being not too far ahead of that, there could be a lot of children growing up without parents and grandparents sooner than expected so this change of habits could really last a lifetime if we take the time of consideration before we start to spring from our nests, which could by a short stretch take us well into the summer as schools start closing for unknown periods and exams, and most reasons to leave the house get cancelled…

The lists of cancellations now stretching further and further ahead the events industry is being obliterated taking many sports out of play and I’m hoping at a long shot maybe that this might actually promote more active participations in activities linked to all these events you love to watch… It’s going to take a while to master it for sure but it’s the taking part that really counts in heart beats not points or prize cups but tangible improvements with less pollution could be easy to achieve with a bit more cycling in our lives.

Why start cycling now?

The health benefits of getting out are hardly understated, by the time you’ve realised it’ll already be the summer, and then what are you going to do with all that sun and no cheap flights… This is a great activity for the family to enjoy, it could probably cost less to buy some bikes rather than pay for a summer holiday that might be spent at school anyway at this rate…

If you have a bike, it’ll probably work given a little wash and some air in the tyres, a drop of oil on the chain, etc etc if that sounds like to much trouble you could always get in touch with your local bike shop and see what they can do to help you or take a little time to learn how to fix it yourself.
Your local bike shop may even offer collections or delivery for your repairs at this time to help keep movement outside the house to a minimum, if they don’t please suggest it to them…

Fixing what you’ve got already can be a great way to get back into something with little outlay, a second hand bike with a bit spent on it can be upgraded and given a new lease of life. It’s won’t cost the earth, it’s an investment in it and in your future health too. Simple Services often range from a simple check over to full replacements of parts like the complete drive train and will make your bike feel like new.

Consider selling your old bike now, it’ll help someone in need, apart from the famous n+1 paradox your average person doesn’t really need or want to keep the old bike they’ve grown out of and probably won’t return to using it but someone else out there will still love it for years to come possibly getting a great deal more from it than you did.
If your confining yourself to the house, it might be a good time to start sorting out things like that pile covering everything in the garage, the shed you can’t get in, maybe with Spring here your garden’s overgrown the bike storage, it’s time for clean anyway whilst your going around disinfecting indoors (is anyone?) take the time to if you’re not, stop worrying about somebody else’s sh!t unless your sewers blocked with it that is (don’t flush those wipes & kitchen roll etc)…

If you’re thinking of getting a bike for any reason, now is a great time to accelerate that decision and reap some healthy & financial rewards as the weather improves or local transport closes down (I wonder which happens first, TFL is already reducing services) . They have more payoffs than I can be bothered to get into right now and if you’re not convinced already just even a little bit more not even for your kids sake (if they don’t have one, they’re gonna want one if they’re kept off school for the next 12 weeks and you’re stuck in a bed!)

Kids bikes are actually getting a whole load better, the more ergonomically designed ones cost a bit more but they pay off in miles of enjoyment you’d never have thought possible on a basic model you maybe grew up with.

Adults bikes are more amazing than ever the more you spend the more you get certainly applies to the quality of metals and workmanship available these days.
If you’re lucky enough to qualify for a discount like cycle to work or the cargo bikes loan in Scotland it’d be worth taking the option.

I’m going to write a post about what I think is reasonable to spend on a new bike, it will vary, there are scales of difference but for a guide your average MTB or Road Cyclist may ascribe to the following rule of x=20% of salary or +£100 p/year of age, x=n+1, but for commuting or simple exercise this isn’t necessarily a good formula for those on a pushed budget or space constraint.

Other Stuff

So what on the way then? Here’s a few things to keep you excited for 2020 there’s enough gloom for most to survive with for a while…

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Smart Superflash 1/2 Watt Rear LED Light – Fix intermittent and Dim Lights

Push switch is mounted too close to the case, this will need gently bending to move it inwards.

Tools required
Long nose pliers
Stanley Knife
2d or 2p to open the case
Drinks can, or suitably small thin washers
Cut a small chip from the top of a drinks can, you need to size this to fit behind the batteries positive contact to force it forward towards the battery.

You’ll need to use the knife to move the contact forward to give you space.

Here I used a chip from the can
Here I used a washer, but I only had the one…

Next you’re going to need to close up the gaps a little and use the pliers to crimp the battery terminals a little tighter to give the +ve terminal a bit of room to make contact without binding on the case

The switch will need gently bending to move it over just enough to stop it automatically triggering on the case.
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Thief attempts to take a woman’s bike, but then a cowboy rides up on a horse to lasso him

Sophie Sanders

This article owes it’s credit to; The
the original story comes from a CBS report back in 2016…

Sophie Sanders | The BL 10/08/19, 12:38

Robert Borba (R) with lassoed suspect. (LAWNS OF MEDFORD)

After moseying over to the Walmart for some dog food and on the way out, 28-year-old Robert Borba heard a woman screaming.

“Stop him! Stop him! He stole my bike! He stole my bike!” The cowboy from Oregon recalled the situation to CBS News. “And I kind of look around and all of a sudden this guy goes whizzing by me on a bicycle.”

As security cameras show, there was no way to catch him on foot. So the cowboy did what cowboys do. He saddled up to save the day, armed with little more than a lasso.

“A couple of swings and then I threw it at him, just like I would a steer,” Robert said. 

“He’s like, ‘What are you doing, man? You got a badge?’ And I’m like, ‘No, I ain’t got a badge,’” he said.

Eagle Point Police Officer Chris Adams was called to the scene by Borba. He was fascinated by what he saw—The suspect was lying on the ground, roped and tied like steer headed for the pen. 

“I’d take him by my side any day,” Adams said.

“I told the cop, I said, ‘Man, you guys ought to pick up a rope and throw that gun away. You might have better luck with it.’ He started laughing,” Borba said.

He said taking action to stop a thief was just the right thing to do.

“If it was my wife or my little girl, I would hope somebody would help her if I wasn’t around,” he said.

When it was over, police said all Borba asked for was his rope back. He coiled it up, tipped his hat, and then rode off into the sunset.

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Listings, the Before and After: Cleaning & Servicing

Bike servicing made easy, looks simple doesn’t it… So why does it more often than not look like this…

Do you have a cloth and a can of oil? Got an old tooth brush, better a brass one though!

Cleaning goes a long way to making a bike rideable and pleasantly doing so, but a dirty bike falls short and grinds it’s way around lacking in stopping power and pulling efficiency too, you’ll put more power in to move a dirty bike. Over zelouly using a Hose or Jetwash will only aid corrosions access to those impossible to see areas inside your bearings driving in dirt whilst it washes out your grease.

Before… (or as listed)

We quite often list bikes on ebay and our website before we’ve even done more than a cursey clean, sometimes not even that and this is one of those examples.

Here’s a list of typical faux pas of your Halfords Apollo specials, this also applies to most bikes built from a box at home, this is only going of whats in front of me with this bike so it’s not comprehensive but actually quite minimal.

  • No Grease used, so a rusty seatpost / stem and pedals that would’ve either rusted in place but most likely fallen out as loose…
  • Loose B/B & Headset bearings, these are not fully adjusted often from the factory and also require bedding in (ergo your 6 week service)…
  • Stiff Brakes due to low manufacturing tolerances and corrosion due to no grease!
  • Little to no oil on the chain, it’s got nothing left of the factory oil.

This one sold locally so we treated it to the service it doesn’t deserve, and just started with a wire brush, slowly addressing the debris, dirt and corrosion goes a long way we came across most problems you’ll regularly see above, the adjustments in all honesty were not as bad as they could be.

After Servicing

Find out about our service prices here

Servicing starts with a good clean and that’s half the battle with bikes, they’ve got so many angles dirt can get in and stop everything running smoothly, now it’s looking good it runs better too.
Knocking noises dealt with in simple adjustments, and stiff brakes aided with modifications to the finish, the bike’s sounding solid again like it should do.

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Log In & Make Your Offers…

Log In & Make Your Offers...

Exciting News for bargain hunters! Back again, in Trial form for now so we’d appreciated a thorough test! Send us your offers now…

Your participation is required as we test this feature out on our website.
We’ve added this to all products starting today in a bid to match our flexible offerings on other sites and boost sales on our existing website.

You’ll first need to be logged in to see the offers button and then you’ll just need to enter a few details to place you offer, we’ll get back to you as soon as we can.

This allows potential buyers to “make an offer” for products on our web site.  You may then accept, decline, or counter the offer we may send, and counters may go back and forth until an agreement is reached.

  • Log In / Create User Account
  • Find your item & click “Make Offer” button
  • Email notifications are sent to both the potential buyer and the store providing details about the offer and updates on the current status.
  • Grab a bargain!!!

Whilst we are trialling this, if you are local and looking for a bargain repair price get in touch… We will be offering discounts on Dr Bike Bookings placed and paid for in advance until 14 April 2019

We are constantly adding to our online catalogue of parts for sale, and looking for new ways to serve our customer base. Using eBay is a great way of reaching people and achieving turn over at prices that work for both of us but outside of that we’ve not had the option until now to accept prices other than as advertised through the website.

This should also allow us to give quantity rate discounts on certain items stock permitting.

Happy Shopping!



Your personal data will be used to support your experience throughout this website, to manage access to your account, and for other purposes described in our privacy policy.

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Samm Henshaw – How Does It Feel?

More… Bikes in Music Videos

Continuing with the Bikes in Music Videos theme, we’ve found a fresh new summer anthem for you…
Including lyrics such as “It goes timeline, swipe right, deep like”, the upbeat track looks into the ways in love is viewed in our culture today

‘How Does It Feel’ is guaranteed to be one that gets you moving, as Henshaw told Hot Press“I just really wanted to start a conversation on what love really is. We talk about love so much in society but are we truly living it?” Iniabasi Samuel Henshaw (born 22 February 1994), professionally known as Samm Henshaw, is a British singer, songwriter and record producer of Nigerian descent, signed to Columbia Records.

Samm Henshaw – How Does It Feel? from Taz Tron Delix on Vimeo.


The video, directed by Taz Tron Delix (who has also worked on Declan McKenna’s ‘Humongous’ music video), has an aesthetically-pleasing retro feel to it. The low contrast, dramatic camera angles and zooms match the mood Henshaw creates with the soulful bluesy song.


Samm Henshaw – How Does It Feel? – Lyrics

How does it feel to be loved?

[Verse 1]
I just landed on this earth today
Heard people acting crazy over something strange
Brothers be paying for diamonds that they can’t afford
Just to keep up the appearance for a polaroid
All I see is something crazy I don’t understand
Ladies making babies just to keep a man
Fellas chasing Stellas when they got a Pam
They go from Stephanie to Bethany
From definitely to never be so

(How does it feel to be loved?)
Oh, how does it feel?
That’s what they say
Ooo, must be insane, oh yeah
(How does it feel to be loved?)
Somebody has gotta tell me, oh yeah

[Verse 2]
It goes time right, swipe right
Deep like five times
Don’t know what it sounds like
But someone told me it’s a little Marvin with some candle light
A little ocean on the weekend with a can of Sprite
I mean I love ’em white
Ooo, love is such a mystery
I’m so perplexed by all the things my eyes have let me see
People think that love is things like physicality
When in reality it’s meant to hold you down like gravity

(How does it feel to be loved?)
How does it feel to be loved?
That’s what they say
Oh my, must be insane, oh yeah
(How does it feel to be loved?)
How does it feel, how does it feel? Yeah

You see now
How am I supposed to find love?
If I don’t understand love
How am I supposed to be loved? ooh
And if I have to buy love
Then I don’t really want love
If this is what it means
The fighting and the screams
You want dependency
I need some therapy, oh
(How does it feel to be loved?)
I gotta know, I ain’t too sure
Somebody tell me how does it feel to be loved?

(How does it feel to be loved?)
I just wanna know, yeah
I just gotta know, yeah
How does it feel?
How does it feel to be loved?
Oh my
(How does it feel to be loved?)

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How do you service a BMX? Part 1

Wire Brushed Raw Steel BMX Parts

Servicing a BMX, your step by step go to guide…


So your bikes rattling, and a bit stiff, suffered a bit outside and probably a little worse for wear, does it need servicing and some tlc… Have you got rusty Bolts too?
Simple to do you need a strip down and rebuild, it breath a new lease of life into your steed and give it back that sure footed feeling.

Start by giving it a good wash, it’s easier to work on a cleaner bike, even if the dirt looks thin and dry, it’ll shift quickly with a wash and look better once it’s done.

So, first things first, get busy pulling it apart…

Step-by-Step Strip Down

  • Check the seatpost moves, and adjust it a bit maybe to;
  • Pop it in the workstand…
  • Remove the pedals
  • Disconnect the brakes
  • Loosen the Rear Wheel for chain slackening
  • Remove the cranks and Bottom Bracket
  • Remove the wheels
  • Remove the Brake Cables, then pads, then remove the Brake Calipers
    (take care not to separate the springs from the arms, their asymetrical mix them up and your brakes won’t work, worse still you might break  your brakes…)
  • Remove the Handlebar Stem, and Handlebars together, catching the forks
    (watch out! strap a leg to the downtube with a zip-tie to save yourself some toes)
  • Separate the parts on the bars

You should now be left with an almost bare frame… Maybe headset bearing cups and B/B cups remain, the seatpost can come out last, and go back in first, as will any cups you will need to replace.

The Tools Required

So what tools will you need to get this far? Only a few;

  • 4mm, 5mm, 6mm, 8mm Allen Keys
  • 15mm or 17mm / 19mm Spanners
  • Large Adjustable and or Plate Spanner
  • A small screwdriver / pry lever
  • A Cross Head Screwdriver

Now you’ll need to clean all the grime and muck off it, you’ll be surprised where it’s got to… Good old soapy water isn’t a bad start, but there’s good alternatives and GT85 will gut through most grime and grease a lot quicker at this stage.


Inspecting the damage

Once you’ve got everything cleaned up, you’ll be wondering whats good and what’s worn out, it’s often obvious but if it’s not I’ll cover it all here.

Deep cleaning, and servicing requires some wire wool, and a wire brush for cleaning any stubborn corrosion.

This is the crown race that’s been abused, and this is the good one replacing it.

The bearing surface should be free from pitting and raised bumps, these will feel bad when your steer and may cause further issues as sudden wear can occur at this point.

Anything that can’t be removed with some wire wool will tell you how you’re doing, if the surface wear is extreme or uneven it’s time for a replacement part.

Acceptable level of wear will show now signs of pitting or degraded surfaces, they should show a polish when clean, you should notice a wear path but it should be free from damage.

If your bearings are at all discoloured, pitted, rusty etc… It’s time to change them too, the retaining cage as well if it’s not cleanable, you can remove it adding extra balls to account for the added room and further increasing the life of the cups.


Sealed headsets are a bit different, and will require new bearing sets. These are often one of a few standards so it’s always worth checking the spec properly, they’re often marked with a bearing code for ACB Bearings this is important as the wrong size will damage your frame.



Cleaning for Painting


Wire Brushed Raw Steel BMX Parts
Parts Prepared for painting Wire Brushed Raw Steel BMX Parts












Painting for Finish

You’ll need a clean dust free, still but ideally open warm air environment but lets be too idealistic about what we want and work with what we’ve got.

Finished & Painted Parts for a BMX Rebuild
Finished & Painted Parts for a BMX Rebuild

Painted Bolts in a Wooden holding block
Painted Bolts in a Wooden holding block

A clean & dust free space will mean your parts have a good finish, even and solid paint finish that will stand up to the fresh abuse it will likely receive.

Applying paint in thin layers working you way around in coats will mean a nice consistent glossy (or matt finish) with good coverage and no drips, focusing too much on coverage will mean overspray and drips… In worst cases it will mean nothing works!

Reassembly of Painted Parts


Starting with the Cups if they’ve ben removed, then crowns, the B/B, Headset and Forks are the first things to get installed and we’ll cover that in Part 2, that’s it for now folks…