Headset Introduction, Adjustments and Good Practices

The headset of your ebike is located inside the headtube and allows the fork steering column and front wheel to rotate and turn.

Headset Adjustments

The headset can loosen over time with normal use, so it is important to periodically check the headset tightness and to tighten it properly when necessary. A headset that is too loose can cause an accident and a headset that is too tight can cause premature wear on components, so it is important to tighten properly and to the correct amount of tightness. With periodic checks and tightening when needed, you can keep your ebike safe, fun to ride and increase the lifespan. Follow the steps below to check headset tightness and perform an adjustment on the KG4 headset.

Tools Needed:

• 5 mm or 6mm Allen wrench
• Torque wrench with a 5 mm or 6 mm Allen bit

1. Get the ebike ready for maintenance. Turn off the bike, remove the batteries, and press and hold the power button (or MODE on the LCD display remote) to discharge any remaining power.
2. How to check if the headset needs to be adjusted
   1. Check if the headset is too loose. Place one hand over the spot where the top of the front fork meets the bike’s headtube. At the same time, use your other hand to squeeze the left brake lever, and gently rock the ebike front to back.
      If you feel a knocking sensation under your hand or hear a “clunking” or rattling sound, the headset is likely too loose.
   2. Check if the headset is too tight. Lift the front wheel off the ground slightly. Stand clear of the handlebars and carefully tilt the bike slightly to one side to check if the front wheel “flops,” or easily and quickly turns to the side.
      If the front wheel will not flop to the side, the headset is likely too tight.
3. Adjust the headset
   1. Loosen the stem clamp bolts. Use a 5mm or 6mm Allen wrench to loosen (but not remove) the two stem clamp bolts, until the handlebar stem can move independently of the front wheel.
   2. Loosen or tighten the headset. Remove the top cap cover and set aside. Use a 5 mm Allen wrench to turn the top cap bolt 1/4 turn clockwise to tighten or counterclockwise to loosen. Do not make the headset too loose or over-tighten.
   3. Check the headset tension. Repeat step 2 to see if the headset needs to be adjusted further. Perform another adjustment, if needed. Reinstall the top cap cover once the adjustment is complete.
4. Align the handlebar
   1. Adjust the front wheel so it points directly forward and is in line with the frame. Rotate the handlebar stem independently of the wheel so the handlebar is centered and perpendicular to the wheel direction. To ensure proper alignment, use the center of the tire or wheel as a reference point for the handlebar alignment (not the fender).
   2. Evenly tighten the stem clamp bolts. Once the handlebar is aligned, use a 5 mm Allen wrench to tighten the bolts 1/2 turn starting with the top bolt, and alternating between each bolt to ensure they are tightened securely. Torque the bolts to 8 Nm.
   3. Check that the stem is secure. Stand over the front wheel and hold it in place between your legs. Place one hand on each handlebar grip, and try to turn the handlebar from side to side. Push forward with one hand with approximately 20 lb of force, while pulling backwards with the other hand with approximately 20 lb of force. The stem must be tight enough that it does not turn independently of the wheel.
   4. If the stem turns independently of the wheel, loosen the stem clamp bolts and repeat step 4 to make sure the headset is properly aligned and secure.
   5. Once properly secured, reinstall the battery and test the bike fully before riding.