PIVOT SHUTTLE Chain Ring Replacement Maintenance Procedure

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1 PIVOT SHUTTLE Chain Ring Replacement Maintenance Procedure This maintenance guide provides detailed instructions to replace the chain ring of the Shimano Steps E8000 E-bike system should something malfuction or break. This procedure is comprised of multiple subtasks that must be completed in the order listed below. The ordered list below provides the page on which each of the tasks begin. Chain Ring Replacement - Remove Crank Arm and Spider Assembly 2 - Replace Chain Ring 4 - Install Crank Arm and Spider Assembly 5 Maintenance Notes: Doing work on the motor and battery can be performed easier if the bike can be mounted upside down in a work stand. Many of the pictures in this guide will show the bike being worked on in this way. When working on the battery, the battery can be held in the frame by mounting the cover in the frame by the rear bolt with the battery facing outward. Performance. Redefined.

2 SHUTTLE Remove Crank Arm and Spider Assembly 1 2 Using a 4mm allen wrench, remove the chain guide. 3 Loosen the pinch bolts on the drive side crank arm. 4 Remove the crank arm cap using the appropriate crank arm tightening tool (TL-FC16 or TL-FC18). 5 Pull the stopper plate out so the crank arm can be released from the motor spindle. It will not be removed completely, just enough to clear the hole in the spindle. 6 Pull the crank arm off the motor spindle. Wrap a toe strap around the rear wheel and chainstay. 2

3 SHUTTLE Remove Crank Arm and Spider Assembly 7 8 TL-FC36 TL-FC39 Remove the spacer from the motor spindle. Removing the chainring and spider will require a lockring removal tool (TL-FC39) and a lockring wrench (TL-FC36) Remove the lockring with the lockring removal tool and the lockring wrench. The lockring is reverse threaded. It is loosened by turning clockwise. Remove the chain from the chain ring. 11 Remove the chain ring/spider assembly. 3

4 SHUTTLE Replace Chain Ring 1 2 Remove the chain ring nuts with a chain ring nut wrench and a T30 torx wrench. Remove all the hardware. The spider assembly has four bolts, spacers, and nuts. The spacers and chainring nuts are custom Pivot parts for the 157mm rear hub spacing. Replacement parts can be purchased through a Pivot dealer. 3 4 Put the chain ring nut through the spider and place 3mm spacer on the opposite side of the spider. Install the chainring with the tooth count facing outward. 5 6 Apply Loctite 243 (or equivalent) to the threads of the chain ring bolts. Bolt the new chain ring onto the spider with the 3mm spacers between the chain ring and spider. Tighten the bolts to 8 Nm. 4

5 SHUTTLE Install Crank Arm and Spider Assembly 1 2 Apply grease to the spider assembly splines. Apply grease to the motor spindle. Apply to both sides of the motor if both crank arms were removed. 3 4 Install the chain ring/spider assembly on to the motor spindle. Align the cut out in the spider with the wide area on the motor spindle. Screw a long M6 bolt into the unused threads in front of the motor spindle. Thread the bolt into the motor until the bolt bottoms out. This will keep the chain ring from rotating when installing the lockring. 5 6 Wrap the bolt in a cloth to protect the spider from scratches when the spider stops against the bolt. Install the lock ring with the lock ring tool (TL-FC39) and tighten to 45 Nm. The lock ring is reversed threaded and will tighten by turning counterclockwise. 5

6 SHUTTLE Install Crank Arm and Spider Assembly 7 8 Remove the bolt and cloth from the motor. Install the spacer on the motor spindle Before installing the crank arms, check the inside face of the crank arms for the right (R) and left (L) designation to verify that the correct crank arm is mounted on the correct side of the motor. 11 Install the crank arm by aligning the split in the crank arm with the hole in the motor spindle. 12 Tighten the crank arm cap with the appropriate tool (TL-FC16 or TL-FC18). The cap should be torqued to 1.5 Nm. Push the stopper plate into place. 6

7 SHUTTLE Install Crank Arm and Spider Assembly Using a 5mm allen wrench, tighten the crank arm pinch bolts. The bolts should be tightened slowly, alternating bolts. The bolts should be torqued to 14 Nm. Place the chain back on the chain ring Apply Loctite 243 to the threads of the chain guide mounting bolt. Using a 4mm allen wrench, install the chain guide and adjust it so clears the chain ring and the chain through the whole range of gears. Torque the mounting bolt to 4 Nm. 7

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