PIVOT SHUTTLE Maintenance Procedure This maintenance guide provides detailed instructions to replace the dropper post cable housing on the Pivot Shuttle should something malfuction or break. If these steps are followed, the procedure can be completed without having to remove any of the components associated with the Shimano Steps E8000 E-bike system. All of the necessary steps are outlined below and accompanied with pictures to help explain each step. 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.
1 2 Using a 2mm allen wrench, remove the DS cable port cover at the head tube. Using a 4mm allen wrench, loosen the seat post collar. 3 4 Using a 2mm allen wrench, loosen the pinch bolt at the dropper remote to release the cable end. Cut the cable crimp off the dropper post cable. 5 6 Remove the seat post and unclip the head of the cable from the actuation cradle at the bottom of the seat post. Pull the cable out through the seat tube leaving the housing in the frame. 2
7 8 Remove the ferrules from both ends of the dropper post housing. To route the dropper post housing, use the Brake Routing Cable (BRC) from the Park Tool Internal Routing Kit (IR-1.2). 9 10 Attach the BRC to the free end of the current dropper post housing where it exits the head tube. Pull the dropper post housing and the BRC attached through the frame and out the seat tube, leaving the BRC inside the frame. 11 12 Remove the current dropper post hosing from the BRC and use it to cut new dropper post housing to the correct length. Attach the new dropper post housing to the BRC at the end left hanging out of the seat tube. 3
13 14 Route the new dropper post housing through the front triangle by pulling the BRC back through the frame and out through head tube. Remove the BRC from the dropper post housing and put the ferrules on each end of the housing. 15 16 Remove the metal cable bushing from the cable head and feed the new cable through the hole in the bushing. Make sure the bushing is oriented so the cable head will sit in the bushing's counterbore. Feed the new cable through the housing starting from the end sticking out of the seat tube. 17 18 Seat the cable bushing into the actuation cradle and push the housing up to the housing stop on the bottom of the seat post. Grease the seat post. Do not use carbon paste; it can cause the seat post to seize in the seat tube. 4
19 20 Before installing the seat post, apply grease to the inside of the seat tube as well. This ensures proper coverage of grease between the seat post and seat tube. Install the seat post. Tighten the seat post collar to 3-5 Nm. Hold the cable and push on the housing to ensure it is properly seated on the base of the seat post. 21 22 Route the cable through dropper remote. Make sure to route the cable through the noodle as well, if you are using a remote that has one. Seat the housing into the remote and pull the cable tight. Tighten the pinch bolt using a 2mm allen wrench to 1.2 Nm. 23 24 Cycle the remote 15-20 times to remove any slack from the cable. Loosen the pinch bolt and pull the cable tight. Retighten the pinch bolt to 1.2 Nm. Cut the cable to length, leaving 8mm past the pinch bolt. 5
25 26 Put a cable crimp on the cable end and tuck the cable end under the remote. Replace the cable port clamp on the head tube with the wire on top of the dropper post housing. Tighten the bolt so the wire and housing are held firmly in place. 27 Make sure there is enough slack in the housing outside the frame to allow the handle bars to turn freely. Loosen the clamp and adjust the slack as needed. 6