Manual 601 Mk3 Please look for the newest update of this manual on http://www.liteville.com/t/25_36.html
Build restrictions for the Liteville 601 frame Please be aware, not all parts available on the market can be used on the Liteville 601 frame and some parts simply should not be used! Following are components of which we already know that there are restrictions: Suspension forks Ensure, that when the fork is fully compressed, the fork brace does not touch the head tube. Take special note when using the 1.5 headset cups in the slack setting. Forks we are aware of with restricted compatibility are Fox 32 (all year models / 26 ) check space The factory travel setting of the 601 is 190mm. Recommended are suspension forks of at least 160mm travel. The Liteville 601 has no restrictions for use with triple crown forks. Note: we have built a fork stop into the inside of the down tube. This fork stop protects the down tube against dents from the triple crown fork in case of a crash. Cranks / bottom bracket look for space Not all available crank/bottom bracket units can be used. The bottom bracket shell uses a BSA thread and 73mm width. Make sure the cranks do not collide with the chain stays and with the SCS chain guide on the right hand side. When using a Shimano front derailleur, ensure it is an E-Type derailleur and an E-Type compatible BB is used. 2
Seatpost All Liteville frames have an inner seat tube diameter of 34.9mm. To avoid any frame damage, following minimum insert depths apply: Up to 200mm extension length = 120mm min. insert depth Over 200mm extension length = 140mm min. insert depth The extension length is measured from the end of the seat tube to the top of the saddle. The factory black anodised frames have a laser etched mark on the back of the seat tube to indicate this (minimum seatpost insert). This mark indicates the 140mm insert length. Works Finish frames do not have a laser etching. Nevertheless, you are required to adhere to the before mentioned requirements. What is the minimum length of a seat post adapter shim? Here, the above mentioned min. insert requirements also apply: Up to 200mm extension length = 120mm min. insert depth Over 200mm extension length = 140mm min. insert depth The use of a seatpost adapter shim does not make the minimum insert depth of the seatpost redundant! Tip: if you are unsure, choose the longer seatpost shim and double check for compatibility and good quality (such as the Syntace Post Shim Light 31.6 / item no. 113299 and Syntace Post Shim 30.9 / item no. 114203). Tires The Liteville 601 frame is compatible with tires up to 2.5. This refers to tyres with inside diameter of 559mm (26 ). Take note that upon full compression of the rear shock the tyre is allowed to contact the seat tube as an upper limit. Please also check the fork manufacturer s requirements. Note: A brushing of the rear wheel on the seat tube upon full compression when riding will, other than producing a wear mark on the seat tube, not cause any damage. Seatpost clamp We recommend the use of our SuperLock2 seatpost clamp. In case you want to use another seatpost clamp, you will need a clamp with a inside diameter of 38.0mm. Gear cable Only use gear cable outer housing with an outer diameter of 4.0mm. for example Shimano SIS-SP41. 3
Rear shock / shock mounts Do not use a shock with an eye-to-eye length greater than 241mm. The stroke must not exceed 76mm. Tip: The 601 frame is designed with specific kinematics and hence does not harmonise with all shocks available. In order to achieve optimal suspension characteristics our factory supplied shocks have been set up to suit. If you want to run a shock with a different stroke, you will need to check all moving parts (incl. shock) for interference-free movement when mounted in the frame and at selected front shock mount position. This must be checked for the entire suspension travel! To do this, release all air from the shock and fully compress the frame. Tip: Due to the large travel and variety of setup options, it is necessary to check your specific setup for collision-free performance, as not all possible combinations can be guaranteed to be collision-free. This means, depending on tyre choice and wheel diameter, frame size, position of the front shock mount, choice of shock and relevant tolerances in the combination of components it is possible that two components contact each other. Please avoid such a suspension setting or do not use relevant parts as such a setup can lead to damage of frame and components. Geometry fine tuning Bolt right at the top means: steepest head angle setting and high bottom bracket. Of course you can not only use the geometry fine tuning option for general geometry adjustments. You can also use it to adjust the sag, without changing the geometry. Bolt right at the bottom means: slackest head angle and low bottom bracket. 4
Tip: Take a good days time to find your individual setup preference. The variety of shock settings allows a multitude of different suspension setups. Brakes The Liteville 601 frame has been designed exclusively for use with disc brakes. The frame comes with 7 PM tabs allowing the use of PM disc brake callipers directly in combination with a 7 rotor without the necessity for an adapter. For the use of rotors greater than 7 /180mm, please contact your respective brake manufacturer. The minimum rear rotor diameter is 180mm and the maximum diameter is 210mm. For use of brake rotors larger than 180mm please contact your brake manufacturer reg. required adapter. Assembly Frame preparation The contact and bearing contact surfaces (head tube, bottom bracket, drop outs and brake tabs) have already been faced at the factory and are ready for assembly. Should you still have any assembly issues despite careful frame preparation, please contact Syntace directly. Headset / fork The frame comes with the 0 Syntace VarioSpin headset cups factory pressed in. In case you need to change/remove the bearing cups, do not forget to use grease on the contact surfaces upon re-assembly. Ensure the bearing cups are pressed in evenly, completely and squarely. When using the VarioSpin tuning bearing cups, ensure the cups are aligned correctly in the frame. Please take note of the respective assembly instructions. It is best to use a special tool for disassembly and assembly of the bearing cups, such as the VarioSpin assembly tool (item no. 115125) Headangle The Liteville 601 Mk3 is equipped with the Syntace VarioSpin headset. By changing the headset cups, the head angle can be changed and fine tuned according to your needs. Supplied with the frame are concentric (0 ) bearing cups. The separately available Vario-headset cups (as indicated in blue, see below figure) allow the head angle to be changed +/- 1.5. 5
Headangle -1.5 Headangle +1.5 Frame size Art. Nr. XS 114951 S 114944 M 114906 L 114913 XL 114920 XXL 114920 Fork installation Supplied with the frame are all headset components required for a tapered steerer fork (bottom 1.5, top 1 1/8 ). First, install the lower (larger) slotted ring onto the fork s steerer tube. It should be flush against the top surface of the fork crown. Now slide the fork into the frame. Then, install the upper (smaller) slotted 1 1/8th ring onto the steerer tube from the top and install the black headset cover plate. Note: the reduction kit for 1 1/8th steerer forks can be ordered separately (item number: 114593). This will create a different assembly process for the lower half of the headset. When using 1 1/8th forks, the lower reduction ring (grease lightly) needs to be placed between the lower headset cone and the lower headset bearing. The assembly of the upper headset half remains the same. Note: When combining the Syntace MegaSpacer with a Liteville 601 a silver 0.6mm washer is required between the SuperSpin headset and the MegaSpacer. This spacer is included with the MegaSpacer set (from 06.2013 onwards) or can be ordered separately from Syntace. 6
SuperSpin tapered unten 1.5, oben 1 1/8 Tip: Make your first test ride with un-cut steerer tube. You would not be the first to be beating your head against a wall because you have cut the steerer of your brand new fork too short in the rush. Tip: Before installing the cover plate, grease bearing. It will keep moisture away and aid free rotation. Tip: Pull the headset tight with the adjustment bolt, then loosen the bolt again (about ¾ of a turn). Only now make final bearing play adjustment. With this procedure you can ensure that the bearings have been seated correctly and will spin freely. You may need to make a final headset bearing play adjustment on your first ride. Make sure the fork crown (single crown forks) does not hit the down tube when turning the bars. Bar/stem Install bar and stem according to manufacturer s instructions onto the steerer tube. Gear and brake levers Install levers according to manufacturer s specifications. Tip: Use a low torque on brake and shift levers so that they can turn in case of a crash. Bottom bracket / crank & front derailleur When using an E-Type front derailleur, check the derailleur plate does not contact the swingarm pivot point (see photo). It may be necessary to slightly modify the derailleur plate so it does not contact the swing arm. This is not a design error, but a deliberate positioning of the main pivot for best kinematics and stiffness properties. Proceed as follows: Simply pre-mount the derailleur and mark the interference area. Now remove the marked area of material from the plate. This can be done for example with a file. Liberally grease contact surfaces for the bottom bracket. Fix the E-Type derailleur with the bolt (supplied by Shimano). Important: Do not use a spacer between frame and derailleur. Tip: Now install both BB bearing cups according to installation instructions. Don t forget grease! Now tighten the Allen key screw of the derailleur according to manufacturer s specifications and install cranks. Make sure there is enough room (as described on page 2) for rotation between crank arms and chainstay or 7
SCS chainguide test for enough clearance. Tip: Supplied is a derailleur pad which can be applied to the front derailleur. Assemble as shown below to reduce chain noise. Assembly gear outer housing / brake line on down tube The outer housing for the rear derailleur and the brake line are attached with cable guides on the cable pads which have been factory attached to the down tube. This ensures a perfect cable routing. Note: Please only tighten the clamp bolts lightly. They only need to locate the cables in their position. If they are tightened too much, then the outer housing and brake line can be deformed which can compromise their function. Note: The rear brake line and the rear derailleur outer housing are routed under the rocker link. If the rear brake line needs to be shortened, then the brake line can be routed under the rocker link after the brake line is cut. The same goes for the gear outer housing. If you don t need to shorten the brake line, you will need to fully remove the shock from the frame. Then, remove the M15 alloy bolts (Allen key size 8mm) which connects the rocker link with the down tube. Please take note that all bolts are factory fitted with a thread locker. To remove, release the thread locker with for example a soldering gun (See FAQ). 8
Now, the brake line assembly with brake calliper and also gear cable outer housing can be routed. To finish off, re-assemble the rocker link and shock. When assembling, take note to use the correct thread locker and let it set sufficiently. Please also check the torque used. We recommend routing the gear cable and brake line around the left of the head tube as shown in the figure. This reduces cable rub on the frame and ensures you can freely turn the bars. Cable routing for front derailleur To attach the cable housing, you will find special mounting tabs on the bottom of the top tube. Proceed as follows: Sharply bend a zip tie about 10 15mm behind the tip to create a shape close to a hook. Now insert the hooked zip tie into the cable mounting tabs. Make sure you insert only far enough so the tip just snaps over the cross bridge. By pulling and pushing, you can direct the zip tie all the way through until the head contacts the top tube. Now you can install the cable housing (and the optional cable housing for an adjustable seat post). Note: Only pull the zip tie tight by hand! 9
Cut (with a precision side cutter) the zip tie right at the head and turn the heads all the way to the top tube so they do not point down. The shifter cable housing for the front derailleur should neither run in a large arch nor in a very direct way to ensure good function. Cable routing for the rear derailleur The shifter cable for the rear derailleur is to be routed directly through the seat tube and into the chain stay. To protect the cable even better from corrosion, we use an additional, flexible tube. Note: Do not remove the black plastic tube. In case you did remove it, re-install it by pushing it thoroughly into its seat and do NOT use any type of lubrication. The exit for the shifter cable is at the lower end of the right chainstay. 10
Changing the shifter cable housing Leave the black tube in place. Cut the new cable housing with a 45 cut as shown. Spray some silicon spray into the black tube. Guide the outer housing through the black tube until it stops at the entry to the right hand chainstay. Now, make a loop with the remaining length of outer housing and use this loop as leverage. Now turn and push the outer housing until it finds its way into the chainstay. Tip: It will be easier for the cable to find its way if you move the rear end up and down approx. 1-2cm. To do this, you will have to disconnect the shock at the rear shock mount. Continue pushing the outer housing through the chainstay until it stops at the exit. By turning and pushing, let the outer housing find its way out. To finish off, cut the end as usual. Done. Alternative method Cut off the head of an old shifter cable. Insert the old shifter cable through the plastic tube and through the chainstay and ensure it exits at the rear. Now, slide the outer housing onto the old shift cable from the front, and guide through the frame. By turning and pushing of the outer housing let the housing end find its way through the plastic tube and through the chainstay until it appears from the exit in the chainstay. Remove old shift cable and cut outer housing to length as usual. Done. 11
Routing of brake line Please be aware that the brake line shortens during compression of the rear suspension. Ensure you leave it long enough! Use the included clips for mounting the brake line on the left chainstay. If you still decide to use zip ties, ensure they are loose enough, so that the brake line can still slide through easily when the rear suspension moves through its travel. If the zip ties are over-tightened, they may make unwanted squeaky noises. line towards the rear. The routing may vary with other brake models. Attention: The routing pictured is for brake callipers where you can turn the 12
Rear derailleurs from Shimano Please only use Shimano derailleurs with Shadow technology. Installation of older derailleurs (with the large housing bend) is not recommended because they do not harmonize well with our new, low-profile routing through the chain stay. Assemble and adjust rear derailleur according to manufacturer s owner s manual. Rear derailleurs from SRAM You can use SRAM XX1, X01, X0, X9 and X7 rear derailleurs. Reasons for why the Shimano Shadow and SRAM derailleurs are particularly suitable: Direct cable routing without unnecessary tight bends No friction loss due to tight radii No banging derailleur against chainstay, chain movement is minimised Better protection against branches Reduced noise and wear Assemble and adjust rear derailleur according to manufacturer s owner s manual. Saddle, seat post and seat tube Check the inside of the seat tube for sharp edges and burrs before inserting the seatpost. Remove any burrs with fine sanding paper (such as grit 180). Please take note of the respective min. seatpost insert length as described in section Seatpost. Now assemble the saddle according to the saddle s and seatpost s manufacturer s specifications Tip: Only cut the seat post to the minimum insert dimension after being sure to have found your optimal seat height. Don t forget that shoe sole thicknesses vary and that different saddle may have different build heights. That way you can lower the seat post to the max. Shortening to the minimum required length ensures you can drop the seatpost to the max. and you get some additional weight savings at zero additional cost. Attention: When a seatpost is fully inserted, it can potentially, depending on frame size and length of the seatpost, contact the recess on the lower right hand side of the seat tube. If you try to force the seatpost past this point, the seatpost can be damaged. Please also take note of the seatpost s wear limit. When frequently adjusting the height of your seatpost in muddy or dusty conditions, material wear actually takes place on the surface of both the seat tube and seatpost. The wear on carbon seatposts is much higher than on alloy seatposts due to the coated resin matrix/ fibers used. To keep this wear to a minimum, we re commended removing the seatpost from the frame after every ride in wet/muddy conditions and then give it a good clean. The inside of the seat tube should also be cleaned with a clean rag. Check the diameter of the seatpost from time to time. At no position along the post, the diameter is allowed to become less than 34.7mm! If the seatpost continues to be used with a diameter below the wear limit, then the frame can be crushed in the seatpost clamping area and be deformed to an unrepairable extend. In an extreme case cracks could be caused. 13
Syntace X-12 thru-axle The Syntace X12 through axle system is the only through axle system that allows adjustment of track and camber. The Allen key bolt (size: 5mm hex key) on the right hand drop out is purely for attachment of the derailleur hanger and to clamp the thread insert. It does not require removal when removing the rear wheel! Note: The axle insert has been adjusted to your specific frame. This can be seen by the alignment of mark and clamping slit when 0.5mm and 0.1mm eccentrical inserts are used. Suspension setup Adjusting shock preload For optimal performance we highly recommend spending some good time to set the suspension up correctly. Proceed as follows: Push the O-ring on the shock body right back against the shock seal. Now, place one foot on the first step of some stairs and carefully get on the bike with your full riding outfit (including helmet, riding shoes, full backpack etc.) without any unnecessary weight shifting or bouncing. Carefully get off the bike without any further compression of the shock and check where the O-ring is. Measure the the distance between O-ring and shock seal. Depending on riding style, shock used and personal preference, the O-ring should be 20-40% of thew stroke away from the shock seal (see diagram). If the distance is greater, add some air into the shock. If the distance is less, release some air from the shock. Caution: Even a backpack or hydration backpack will change the applied load on the suspension setup to the extend that it will require re-adjusting of the shock s air pressure. 14
Setting rebound speed Ride off a kerb at average speed while seated. After the initial impact, the suspension should only oscillate once. If the suspension is too fast (the suspension oscillates multiply after initial impact) then increase the rebound dampening. Most shocks indicate this direction with a + or a turtle. The adjusting dial is usually red. Please take note: The suspension should also not rebound too slowly, otherwise the suspension will harden or pack up while riding over many fast consecutive bumps. If necessary, adjust the rebound setting. Most shocks indicate this direction with a - or a rabbit. Please also take note of the shock manufacturer s owner s manual. Built-in interfaces Height adjustable seatpost with remote The Liteville 601 Mk3 has been prepared for installation of the Rock Shox Reverb Stealth. The entry to the seat tube can be found on the left lower end of the seat tube. Assemble the seat post remote cable according to seatpost manufacturer s manual. Tip: Of course you can also use a dropper post with external remote routing. To use such a post, you will find an elongated hole in the top of the top tube just in front of the seat tube (Figure 1.) and one elongated hole in the bottom of the top tube and near the head tube (Figure 2.). Fig. 1 Fig. 2 15
Syntace SCS Chain Guide Integrated connections for the patented Syntace SCS chain guide are standard at the Liteville 601. The tabs can be round on the right hand chainstay yoke and under the right hand chainstay yoke (see figure). The Syntace SCS chain guide offers low weight and a to date unknown precise function coupled with reliability for double and triple cranks. Syntace RockGuard Integrated connection tab for the patented Syntace RockGuard derailleur guard. Caution: Due to a change in design of the rear derailleurs / derailleur hangers, RockGuard TypeI and TypeII will no longer fit on the Liteville 601 MK3. The MK3 uses the RockGuard Type III. Instead of continuous trouble with mis-adjusted gears, and every so often bent soft derailleur hangers, you have the choice of a superbly reliable function 365 days a year. Enclosed are two different derailleur hangers. Shimano direct mount Standard derailleur hanger 16
Maintenance and care Bearings frame / headset All bearings used are greased for life and do not need to be disassembled to be repacked with grease. In case of a defective bearing you can order a new bearing from your dealer or from Liteville. Tip: When cleaning, do not let a strong jet of water enter the bearings (see section washing ). Too much assumed care can reduce the bearing life. Bolts All frame bolts used are high-tensile titanium and alloy bolts. They have been custom manufactured for our Liteville frames. All bolts are factory assembled with appropriate thread locker. Never the less, you need to regularly check them regularly, especially after first assembly of the bike, and ensure they are done up according to specified torque (see page 18). On all black frames, the torque values can be found laser-etched onto the frame at respective locations. In case of loss or damage you can order them through your Liteville WerkStation distributor or from Syntace directly. Ensure you use the correct thread locker and that it sets correctly (see end of this manual). Attention: Look carefully! Should a bolt really move when checking to see if bolts are tightened to specification, then the thread locker bond will be broken and new thread locker needs to be applied. You will find more detailed thread locker information on www.liteville.de -> FAQ. Hint on creaking noises: Sometimes one needs to do the opposite of what one expects for example, if it creaks up front, grease in the rear. The suspected creaking from the bottom bracket might not be caused there at all. You will find more detailed information on www.liteville.de -> FAQ. Washing Never use a high-pressure cleaner, strong water hose beam or similar to clean your frame! The high water pressure will force water into the bearings and premature corrosion and wear will follow. Dirt, blown away by high water pressure, will scratch the surface and mark it permanently. Clean the frame only by pre-cleaning with water from a bucket or a gentle spray from a garden hose and if necessary use a soft sponge or brush. The main clean is best performed with a soft sponge and a bucket of water with a few drops of dishwashing liquid. Dry the frame with a soft cloth so that no water stains appear. To achieve a nice sheen, apply silicone spray to the frame and work in with a soft cloth. Caution: Ensure no silicone spray is brought into contact with the brake rotors or brakes. If this happens you will need new will lose the function of your brakes and will need new brake pads. Just the spray dust can be enough to cause this. 17
Works Finish In addition to the available surfaces race black anodized and your custom colour in powder coat, we offer in every production run a limited edition of Works Finish frames. The new Liteville Works Finish is a genuine raw aluminium surface, no imitation. You can see the irregular marks of the manual work. Changes of surface colour and stains are standard with this finish. Over time it develops the charm of natural patina on the Works Finish frame. The surface can, by the way, be re-worked anytime, either mechanically or chemically for example polished matt or to a mirror finish with Scotch-Brite or it can be coated. You will find two coarse Scotch-Brite pads included with every Works Finish frame. Please try their effectiveness in an area not immediately visible to make sure you will like it. Logos on Works Finish: You will find two logos cut from 3M material with the frame. You can apply them to your frame in a similar fashion to the logos on the regular black anodised frames or in your own fashion it is yours to decide! 18
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Bolts: Maximum torques and thread locker Always use a torque wrench such as the Syntace Torque Tool to tighten any bolts Attention: Look carefully. Should a bolt really move when checking to see if bolts are tightened to specification, then the thread locker bond will be broken and new thread locker needs to be applied. You will find more detailed thread locker information on www.liteville.de -> FAQ. 1Nm bolts are to be done up very lightly only (do not use thread locker) 10 Nm 10 Nm 10 Nm 20 Nm screw 10 Nm 30 Nm insert 20 Nm screw 6 Nm 6 Nm 30 Nm insert 10-20 Nm X-12 Achse 10 Nm 6 Nm 10 Nm 10 Nm 10 Nm screw 10 Nm insert white = no thread locker blue = medium strength thread locker green = high strength thread locker 20
Bearings with Loctite If replaced, the highlighted bearings must be assembled using a high strength loctite (for eg. Loctite, Syntace Bond 48 Hochfest). To do this, degrease the bearing seat with a cleaning alcohol. Then, using a cotton bud apply the loctite bearing race and frame bearing seat sparingly. Please pay special attention so that no loctite flows into the bearing seal. When cleaning, do not let a strong jet of water enter the bearings (see section washing ). Too much assumed care can reduce the bearing life by more than 20 000km of riding. Friction bearings / needle bearings in shock eyelets Bearings seatstay / rocker link Bearings rocker link / downtube Rear and main pivot bearings Horst link bearings white = no thread locker blue = medium strength thread locker green = high strength thread locker 21
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Syntace GmbH Am Mühlbach 5C D - 87487 Wiggensbach Tel. +49 (0)8370 929988 Fax +49 (0)8370 929888 liteville@liteville.de Sales for Germany, Austria and Switzerland: Syntace GmbH Dammweg 1 D - 83342 Tacherting Tel. +49 (0)8634 66666 Fax +49 (0)8634 6365 syntace@syntace.de 24 Current: 04.03.2014