Rocky Mountain Instinct / Pipeline Alloy Frame Assembly Guide Date: April 7, 2017 1
Table of Contents Front Triangle Preparation... 4 Parts Needed... 4 Instructions... 4 Chain Stay Preparation... 6 Parts Needed... 6 Instructions... 6 Shock Preparation... 7 Parts Needed... 7 Instructions... 7 Link Preparation... 9 Parts Needed... 9 Instructions... 9 Frame Assembly...10 Chain Stay to Front Triangle...10 Parts/Materials Required...10 Instructions...10 Seat Stay to Chain Stay...12 Parts/Materials Required...12 Instructions...12 Link to Front Triangle and Seat Stay...14 Parts/Materials Required...14 Instructions...14 Shock to Link...17 Parts/Materials Required...17 Instructions...18 Shock to Front Triangle...21 Parts/Materials Required...21 Instructions...21 Suspension Pivot Torque Guide...23 Hanger and Rear Axle Attachment...24 Parts/Materials Required...24 Instructions...24 2
Frame Protector Installation...27 Parts/Materials Required...27 Instructions...27 Chain Guide Assembly...28 Parts/Materials Required...28 Instructions...28 Cable Routing and Plastic Part Installation...29 Parts/Materials Required...29 Instructions...30 Small Parts Torque Guide...33 3
Front Triangle Preparation Parts Needed Front Triangle (1068140ALU-1068144ALU) 2x Enduro 6900 2RS MAX bearings (1807042) 1x Spacer, MP (1807038) Grease Instructions 1. Grease the Main pivot bores, both sides on the front triangle 4
2. Press in drive side Main pivot Bearing. The bearings outer surface should be flush with the Alloy surface. 3. Place the spacer in the main pivot 4. Press in the non-drive side bearing. The bearings outer surface should be flush with the Alloy surface. 5
Chain Stay Preparation Parts Needed Chain stay (1058140ALU) 2x Enduro 6900 2RS MAX bearings (1807042) Grease Instructions 1. Grease the both bearing bores in the chain stay 2. Press in the bearings into the bores. Ensure the bearings are pressed all the way in. The bearings should sit 0.5mm below the alloy surface. If the bearings press in without much force, remove the bearing, measure the bearing bore diameter and compare to the Chain Stay Drawing. 6
Shock Preparation Parts Needed Shock (210x55) 2x Enduro 698 LLU MAX bearings (1807036) 2x BRG Cups (1807026) 1x Bearing ID Sleeve (1807028) Instructions 1. Grease the inside of the BRG Cups (area in red) 2. Press the bearings into the BRG Cups. Ensure the bearings are pressed firmly against the bearing seat. 7
3. Grease the Shock bare Eyelet (area in red) 4. Press in one of the BRG cups into the Shocks Greased Eyelet 5. Place the Bearing ID Sleeve in the shocks eyelet 6. Press in the second BRG Cup to the shocks eyelet 8
Link Preparation Parts Needed Link (1098101) 4x Enduro 6900 2RS MAX bearings (1807042) Instructions 1. Grease all 4 bearing bores (areas in red) 2. Press in the bearings into the bores. Ensure the bearing is pressed all the way in. The bearing should sit 0.5mm below the aluminium surface 9
Frame Assembly Chain Stay to Front Triangle Parts/Materials Required Prepared Front Triangle Prepared Chain Stay Axle, MP (1807029) Loctite 243 Grease 10mm drift tool Instructions 1. Apply 2 clicks of Loctite 243 from the Loctite applicator to the threads on the Chain Stay (blue) 10
2. Slide the Chain Stay on to the Front Triangle. To make sure the paint doesn t get scratched, flex open the Chain Stay yoke by pushing the ends of the Chain Stays together slightly with your hands. 3. Align the Chain Stay and Front Triangle using a 10mm drift tool 4. Apply grease to the Axle, MP. Make sure not to get grease on the threads of the bolt (green area only) 5. Install and tighten the Main Pivot Bolt to 175 kgcm 11
Seat Stay to Chain Stay Parts/Materials Required Prepared Front Triangle Chain Stay Assembly Seat Stay (1058142ALU) 2x Bolts (1807046) Loctite 243 Grease Instructions 1. Apply 1 click of Loctite 243 from the Loctite applicator to the threads on both sides of the Seat Stay (area in blue) 12
2. Slide the Seat Stay around the seat tube and spread it over the Chain Stay pivots. 3. Lightly grease the Bolts (area in green) but ensure the threads do not get greased 4. Install and tighten the Bolts to 175 kgcm 13
Link to Front Triangle and Seat Stay Parts/Materials Required Prepared Front Triangle, Chain Stay, Seat Stay assembly Prepared Link Bolt (1807060) Bolt (1807061) 4x Bearing Spacers (1807044) 2x Bearing Caps (1807043) 2x screw (180487-012) Loctite 243 Grease 10mm drift tool Instructions 1. Apply grease to the backside of each bearing in the link and both bolts.(areas in green) 14
2. Place a bearing spacer on each of the greased bearings, the narrow face should touch the bearing race 3. Slide the link on to the top tube pivot 4. Use the 10mm drift tool the align the link and washer with the Front Triangle 5. Slide the top link bolt (1807060) through the link washers and Front Triangle 15
6. Apply Loctite to both screws (area in blue) 7. Use the Bearing Cap and one Screw to tighten the Top link Bolt to 80 kgcm 8. Align the Seat Stay and the bottom of the link and washer using the 10mm drift tool. 9. Slide the lower link bolt (1807061) through the link washers and Seat Stay 10. Use the Bearing Cap and one Screw to tighten the lower link bolt to 80 kgcm 16
Shock to Link Parts/Materials Required Prepared Front Triangle, Chain Stay, Seat Stay, Link assembly Prepared Shock 1x Screw (180487-012) 2x Flip Chip (1807003) 2x Flip Chip (1807004) 2x Bearing Spacer (1807099) 1x Bolt (1807049) Loctite 243 Grease 17
Instructions 1. Apply grease to the inside of the link s ride 9 holes and the bolt (1807049) (areas in red) 2. Place an outer Flip Chip on either side of the link (1807003) 3. Apply grease to the inside of the Flip Chips (area in red) 18
4. Place the inner Flip Chip (1807004) inside the outer flip chips in the orientation shown. 5. Apply grease to either side of the shock eyelet bearings (area in red) 6. Place a Bearing Spacer on either side of shocks greased bearings 19
7. Slide the shock into the link 8. Slide the greased Bolt through the link, flip chips, and shock. 9. Apply Loctite to the screw (area in blue) 10. Tighten the bolt using the Screw to 80 kgcm 20
Shock to Front Triangle Parts/Materials Required Prepared Front Triangle, Chain Stay, Seat Stay, Link, shock assembly Bolt Shk (1807062) Washer (1807064) Screw (180566-016) Loctite 243 Grease Instructions 1. Apply grease to Bolt Shk (1807062) (area in red) 2. Apply Loctite to the Screw (180566-16) (area in blue) 21
3. Rotate the shock into position and put the Bolt Shk. Through the Front triangle and the shock 4. Tighten the shock bolt using the Screw and washer to 80 kgcm 22
Suspension Pivot Torque Guide Note: All Torque values are +/-- 10% Description Part # Location Tool A B Shock Bolts & Screws Top Link Bolts & Screws 1807049 & 180566-016 FBY 1807062 & 180566-012 FBY 1807060 & 180566-012 FBY 1807061 & 180566-012 FBY Top Link Front Triangle FT-TL Pivot SS-TL Pivot 5mm & 4mm Hex Keys Two 4mm Hex Keys 6mm & 4mm Hex Key Torque kg-cm Nm lb-in 80 8 70 80 8 70 Notes Torque only with correct shock and hardware installed. Apply grease to shock bolts, and Loctite 243 (blue) to screw threads. Apply grease to pivot bolts, and Loctite 243 (blue) to screw threads. C Dropout Pivot Screws 1807046 Dropouts 6mm Hex Key 175 17 152 Apply Loctite 243 to female seat stay threads. D Main Pivot Bolt 1807029 Main Pivot 6mm Hex Key 175 17 152 Apply grease to inner bearing races and Loctite 243 to female chain stay threads. A B C D 23
Hanger and Rear Axle Attachment Parts/Materials Required Frame assembly Hanger Bolt (3227001) Hanger (1097132 or 3227002) Axle 12MMx173MM (3227009) Axle Washer (3227006) Loctite 243 Grease Instructions 1. Apply Loctite to Hanger bolt external threads (area in blue) 2. Grease the back side of the correct hanger (Standard vs Shimano Direct mount) where it contacts the frame (area in red). Ensure there is no grease on the internal threads of the hanger. 24
3. Place hanger on the seat stay 4. Tighten the Hanger Bolt (left hand thread) to approximately 200 kgcm (tight!) 5. Apply Loctite to the m10x1 threads in the hanger (area in red) 6. Grease the Axle Washer and Axle Threads (areas in red) 25
7. Slide the Axle Washer onto the Axle 8. Thread in the Axle to the Hanger Bolt 26
Frame Protector Installation Parts/Materials Required Frame Assembly Chain Stay Protector (3708005) Seat Stay Protector (3708008) Isopropyl Alcohol Instructions 1. Clean all of the carbon surfaces where the protectors will be applied with Isopropyl Alcohol. 2. Remove the backing of the Chain Stay protector and place it in the correct spot 3. Press down on the protector, ensuring all of the edges are stuck down firmly and there aren t any air bubbles under the protector 4. Repeat steps 2 and 3 with the Seat Stay Protector 27
Chain Guide Assembly Parts/Materials Required Frame assembly with cranks and chain installed Chain Guide (3398001) 3x Chain Guide Spacers (3398002) 2x Screw (1807132) Washer (1807133) Loctite 243 Instructions 1. Shift the bike into the largest cog on the Cassette 2. Apply Loctite to the threads of the screws (area in blue) 3. Determine the amount of Chain Guide Spacers required and place them under the Chain guide. Put the rest in the spare parts box (total of 3 spacers). a. 0 spacers for 28T Chain Ring b. 1 spacer for 30T Chain Ring c. 2 spacers for 32T Chain Ring d. 3 spacers for 34T Chain Ring 4. Use the washer and screws to secure the chain guide in place, making sure the guide does not rub when in the largest cassette cog, or smallest cassette cog. Adjust the position if necessary. 28
Cable Routing and Plastic Part Installation Parts/Materials Required Frame assembly 1x Grommet (YF-W13-2) 3x Grommet (1807078) 3x Plug (1807077) 2x Plug (1808034) Cable Port (1807066) Cable Port (1807067) 1x Screw (1807068) Foam tubes Isopropyl Alcohol grease 29
Instructions 1. Place the 2 plugs in the seat stay chain stay pivot. 2. Grease the holes in the frame where the grommets are inserted. (areas in red) 30
3. Route all the cables through the frame and appropriate grommets at the head tube and Seat tube (see images below). Use a foam tube on each cable routed through the down tube of the frame. If it is difficult to slide the foam tube on the cables, pour a small amount of Isopropyl Alcohol down the foam tube to lubricate it before sliding it on the cable. 4. Install the Cable Port Parts in the orientation shown 31
5. Set the correct cable length for the rear of the bike and tighten the Screw (1807068) to clamp the cables 6. Push the Cable Port parts into the Port Cover 7. Push in all of the grommets into the frame. Pull the cables taught to ensure they won t rattle in the frame 32
Small Parts Torque Guide Note: All Torque values are +/-- 10% E Description Part # Location Tool Rear Axle Nut 1807046 F Rear Axle 1807045 Drive-Side Dropout Non- Drive-Side Dropout 6mm Hex Key 6mm Hex Key Torque kg-cm Nm lb-in 204 20 177 104 10 90 Notes Left hand thread, apply Loctite 243 (blue) to male threads. Apply grease to axle shaft and threads. Use Stainless Steel Washer (3227006) on non-drive-side. E, F 33