V10 (new 2007) Seasonal Maintenance
(
Recommended every 6-12 months, depending on riding frequency and
conditions. Perform this procedure after the winter or if your bike is
creaking/popping. )
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Tools Required:
(2) 5mm allen wrenches
(2) 6mm allen wrench
8mm allen wrench
242 loctite
Rock and Roll Super Coat grease
242 Loctite
Rock and Roll Super Coat grease
plastic or rubber mallet
punch
1/2" or 13mm box end wrench.
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This is a picture of the V10.3 ( 2007 ) if your frame doesn't look like this, you might want the V10.2 Maintenance Guide |
Step 1: Read the instructions!
It's
the right thing to do, so just go ahead and do it. Understand what you
are about to encounter. Remove rear wheel, crankset, and BB (only if
you have an external bearing bb) from the frame. Clean off the major
dirt so you don't contaminate grease or Loctite later on.
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Step 2: Remove the Upper Link
a) Using your 6mm allen wrench, remove all of the M8 bolts in the upper link.
b)Remove the bearing caps by tapping on them with a punch from the inside of the link.
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Step 3: Remove Shock
a) Use your 6mm allen wrench and 1/2" or 13mm box end wrench to remove both shock bolts
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Step 4: Remove Lower Link
a) Using the 5mm allen wrenches, loosen the two bolts in one of the lower pivot axles. One will come out.
b)
Install the removed bolt back into the pivot axle without its cap. Once
it is fully screwed in, use a punch or 5mm allen wrench and mallet to
tap the axle out.
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Step 5: Clean & Prep
a) Use your 5mm allen wrench, remove all bearing pinch bolts from the lower link pivots.
b) Clean the dirt and dried loctite off of them
c) Apply loctite 242 to all pinch bolts and install loosely in their place.
d) Clean the pivot axles, and remove dried loctite from the bolts.
e) Apply fresh loctite 242 to the pivot bolts, and coat the external surface of the pivot axle with grease
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Step 6: Assemble Lower Link
a) Install lower link to swingarm with a pivot axle.
b) Install the other pivot axle into the mainframe. Make sure both axles are fully engaged in their 2 bearings.
c) Loosen all 4 bearing pinch bolts to allow the bearings to float in the frame.
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| d) Install pivot axle bolts and seal washers with loctite 242. Torque to 115 in/lbs. (Fig. 1 )
e) Tighten all 4 pinch bolts to 65 in/lbs.
f) Check lower link for smooth operation and make sure there is no lateral play.
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Fig. 1 |
Step 7: Install Upper Link
a) Apply loctite 242 to the M8x22 bolts and install all four loosely (3-4 turns in) into the frame. (Fig. 2)
b) Once all four bolts are installed loosely, tighten them to 135 in/lbs.
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Fig. 2 |
Step 8: Install Shock
a)
Install rear shock bolt first, with a washer on each side. The nut
should go on the drive side. Torque nut to 190 in/lbs. (Fig. 3)
b) Repeat for forward shock bolt.
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Fig. 3 |
Step 9: Check Pivot Axles for Proper Function
a)
There is a possibility that your pivot axles may be a little too long
for your slightly worn links. This is a test to make sure your axles
are short enough to properly clamp everything.
b) Make sure all the bolts are torqued to spec. using two allen wrenches (one on each side).
c) Take one allen wrench and try to turn each of the pivots clockwise.
d)
If any of these axles spin, tighten the bolts more and try again. If
you have an axle where the bolts are very tight, but the axle spins
when turned, the bolts are bottomed out on the ends of the axle.
e) Remove any spinning pivot axles and shorten 1-2mm using a file or grinder. Install and re-test.
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Derailleur Hanger Replacement
a) If the bike is assembled, remove the rear derailleur.
b) To remove the rear wheel, loosen the M6 pinch bolt and remove through axle.
c) Using a 5mm allen wrench, remove the derailleur hanger cap on the outside of the swingarm.
d) Using a 2mm allen wrench, remove the set screw from the dropout.
e) Remove hanger, tapping the old one out with a mallet if necessary.
f) Install new hanger.
g) Apply loctite 242 to cap, and tighten to 70 in/lbs. (Fig. 4)
h) Apply loctite 242 to set screw, and tighten to 50-60 in/lbs.
i) Grease through axle and install with wheel. Tighten to 60 in/lbs.
j) Tighten through axle clamp bolt to 70 in/lbs.
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Fig. 4 |
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