ALTITUDE - CHRIS sports

TECHNICAL MANUAL

ALTITUDE

2Altitude Powerplay Technical Manual Contents

3 Frame Assembly

MainPivotBearingInstallation 3 ChainStayBearingInstallation 4 LinkBearingInstallation 4 ChainStayInstallation 5 LinkInstallation 6 SeatStayInstallation 8 ShockInstallation 10

11 Powerplay Assembly

BottomBracketInstallation24MM 11 BottomBracketInstallation30MM 12 SpiderRemoval 13 CrankandSpiderInstallationAeffect 14 CrankandSpiderInstallationTurbine 15 BatteryCaseAssembly 17 BatteryCaseRemoval 20 BatteryCaseInstallation 21 ChargePortInstallation 22 FrameCabling 24 PowerplayDriveRemoval 29 TorqueSensorReplacement 30 PowerplayChainReplacement 31 PowerplayInstallationPreparation 34 PowerplayDriveInstallation 37 LowerBashBracketAssembly 38 LowerBashInstallation 39

42 Torque Arm Removal

TorqueArmInstallation 43 MotorCaseFinalTorqueing 45 ChainstayPulleyAssembly 46 ChainstayPulleyInstallation 47 MidDrivePulleyInstallation 48 RearWheelAssembly 50 CassetteInstallation 50 RearAxle&RearDerailleurHanger 51 RearDerailleurInstallation 52 ChainInstallation 54 SpeedSensorInstallation 56 OtherBicycleComponents 57 HeadsetInstallation 57 ForkInstallation 58 iWocRemoteInstallation 59 WireConnections 60

65 iWoc Functionality

FunctionalCheck 66 TorqueSensorCalibration 67 CoverInstallation 69

70 Suspension Pivot Torque Guide

71 Powerplay Torque Guide

74 Contact Information

Table of Contents

3Altitude Powerplay Technical Manual Frame Assembly

Main Pivot Bearing Installation

PARTS NEEDED

TOOLS NEEDED

1. 6900BearingPressorsuitableArborPress

ASSEMBLY

FRAME ASSEMBLY

Qty Item Part No. Revision Description

2 BEARING 1807042 NIL ENDUROBEARING69002RSMAXTYPE, 22x10x6SIZE

1 SPACER,MP 1807038 B MAINPIVOTCENTERSPACER,ID:10,L:48

1. Using6900BearingPress,installnon-drive-sideEnduro69002RSMAX(1807042)Bearing.

2. SlideMainPivotSpacer(1807038),slideintomainpivot.

3. Using6900BearingPress,installdrive-sideEnduro69002RSMaxBearing.

4. Inspectbearingsforproperseatingagainstframe.


Chain Stay Bearing Installation

PARTS NEEDED

TOOLS NEEDED

1. 6900bearingpressorsuitablearborpress

Link Bearing Installation

PARTS NEEDED

TOOLS NEEDED

• 6900bearingpressorsuitablearborpress

• Grease



1 CHAINSTAY 1057400CBN/1057410

D E-ALTCARBON/ALUMINUMCHAINSTAY



1 LINK 1097182 A ALTITUDELINK,85MMLONG,RIDE9,AL7075-T6,HARD BLACK ANO


INSTALLATION

Chain Stay Installation

PARTS NEEDED

TOOLS NEEDED

• Hex Keys

• Loctite

1. a. Greasetoplinkbearingbores.

b. Donotgreasechainstaybearingbores.

2. Using6900BearingPress,installEnduro69002RSMAX(1807042)Bearingsintoeachpivot.

Note: Bearings press into chain stayfrominboardside.

3. Inspectbearingsforproperseatingagainstcomponent.


1 AXLE,MP 1807029 A SLAYERMPAXLE,M10x1.25,L:84MM, AL7075-T6HARDBLACKANO


ASSEMBLY

Link Installation

PARTS NEEDED

1. a. Greaseoutsideofmainpivotbearinginnerraces,andoutersurface of Main Pivot Bolt (1807029).

b. ApplyLoctite243(blue)tofemalethreadsonthedrive-sideofthechainstayyoke.

2. Slidechainstayoverfronttrianglemainpivot.

3. a. InstallMainPivotBolt.

b. Torqueto17Nm.


1 BOLT 1807060 NIL BOLT,10MMx54MM,M6x1INT.,AL7075-T6, HARD BLACK ANO

1 LINK 1097182 A ALTITUDELINK,85MMLONG,RIDE9, AL7075-T6,HARDBLACKANO

2 BEARING SPACER 1807044 NIL 6900BEARINGSPACER

1 BEARING CAP 1807043 NIL 6900BEARINGCAP,AL7075T-6,HARDBACKANO

1 SCREWM6x12 180566-012FBY NIL FLATHEADC'SUNKSOCKETSCREW, M6-1.0x12MM,A4/316SS,55060.060.012


TOOLS NEEDED

• Hex Keys

• Loctite243

• Grease

INSTALLATION

1. a. GreaseoutsideofTL-FTPivotBolt(1807060),smallfaces of6900BearingSpacers(1807044),andsmallinnerface of6900BearingCap(1807043).

b. ApplyLoctite243(blue)toM6-1.0x12mmSSScrew(180566-012FBY)threads.

2. Insert6900BearingSpacerssothatsmallfacescontact theinboardinnerracesofthetoplinkbearings.

3. Slidetoplinkand6900BearingSpacersoverfronttriangle.InstallTL-FTPivotBolt.

4. a. PassM6-1.0x12mmSSScrewthrough6900BearingCap,andthreadintoTL-FTPivotBolt.

b. Torqueto8Nm.

8Altitude Powerplay Technical Manual

Seat Stay Installation

PARTS NEEDED

TOOLS NEEDED

• Hex Keys

• Loctite243

• Grease

Frame Assembly


1 BOLT,M10x78 1807061 NIL BOLT,10MMx78MM,M6x1INT., AL7075T-6,HARDBLACKANO

2 BOLT 1807046 NIL BOLT,10MMx15MM,M10x1EXT., AL7075T-6HARDBLACKANO

2 BEARING SPACER 1807044 NIL 6900BEARINGSPACER

1 BEARING CAP 1807043 NIL 6900BEARINGCAP,AL7075T-6,HARDBACKANO

1 SCREWM6x12 180566-012FBY NIL FLATHEADC'SUNKSOCKETSCREW, M6-1.0x12MM,A4/316SS,55060.060.012

1 SEATSTAY 1057401CBN/ NIL E-ALTITUDECARBON/ALUMINUMSEATSTAY


INSTALLATION

1. a. GreaseoutsideofTL-SSPivotBolt(1807061),smallfacesof6900BearingSpacers(1807044),andsmallinnerfaceof6900BearingCap(1807043).

b. ApplyLoctite243(blue)toM6-1.0x12mmSSScrew(180566-012FBY)threads.

2. Insert6900BearingSpacerssothatsmallfacescontact theinboardinnerracesofthetoplinkbearings.

3. Slideseatstayaroundtheseattube,andintotoplink. InstallTL-SSPivotBolt.

4. a. PassM6-1.0x12mmSSScrewthrough6900BearingCap,andthreadintoTL-SSPivotBolt.

b. Torqueto8Nm.

5. ApplyLoctite243(blue)toinsideofthreadedseatstayinserts.

6. a. PassDropoutPivotScrews(1807046)throughchainstaybearings,andthreadintoseatstay.

b. Torqueto17Nm.


Shock Installation

PARTS NEEDED

TOOLS NEEDED

• Hex keys

• 2x4mmHexkey

• Grease

• Blue Loctite

SHOCK INSTALLATION

1. a. GreaseoutsideofLink(1807049)andFT(1807062)ShockBolts,BearingSpacers(1807099),andtheoutsideofOuter(1807003)andInner(1807004)Ride-9Chips.

b. ApplyLoctite243(blue)toM6-1.0x16mm(180566-016FBY)andM6-1.0x12mm(180566-012FBY)SSScrewthreads.

2. Slideshock,withcorrecthardware(seeexplodeddiagram)intofronttriangle,slideinFTShockBoltfromthedrive-side.

3. SelectRide-9PositionusingtheOuterandInnerRide-9Chips.

4. a. Seatbearingspacerswithnarrowinnerfacesagainstbearings,andslideshockintolink.

a. PassLinkShockBoltthroughRide-9Chips,toplink,andshockfromthedrive-side.

Note:Iftheshockisatightfit,loosentheTL-SSandTL–FTPivotBoltspriortoinsertingtheshock.Re-torquethePivotBoltsafterinstallingtheshock.

5. a. PassM6-1.0x16mmSSScrewthroughM6Counter-SunkWasher(1807064),andthreadintoFTShockBolt.

b. Torqueto8Nm.

6. a. PassM6-1.0x16mmSSScrewthroughnon-drive-sideRide-9Chip,andthreadintoLinkShockBolt.

b. Torqueto8Nm.

11Altitude Powerplay Technical Manual Powerplay Assembly

Bottom Bracket Installation 24mm

PARTS NEEDED

TOOLS NEEDED

• BBpresssuitablefor89.5mmshelland24mmBearingID

• Grease

INSTALLATION

1. EnsuretheouterfacesoftheBBshellarefreefromPaintandfacedperpendiculartothecylinder.

2. TheBBwidthshouldbe89.5mm,andthedrivesidefaceis37.9mmfromtheframecentreline.

3. OntheRaceface24mmBB,removetheredanodized2.5mmspacerfromtheplasticcentresleeveassembly.

4. PressBBinasperRaceFaceinstructions,ensuringthatitisflushwiththeouterfacesoftheBBshell.

POWERPLAY ASSEMBLY


1 BB NIL N/A RACEFACE24MMBB


Bottom Bracket Installation 30mm

PARTS NEEDED

TOOLS NEEDED

• BBpresssuitablefor89.5mmshelland30mmbearingID

• Grease

INSTALLATION

1. EnsuretheouterfacesoftheBBshellarefreefromPaintandfacedperpendiculartothecylinder.

2. TheBBwidthshouldbe89.5mm,andthedrivesidefaceis37.9mmfromtheframecentreline.

3. OntheRaceface24mmBB,removetheredanodized2.5mmspacerfromtheplasticcentresleeveassembly.

4. PressBBinasperRaceFaceinstructions,ensuringthatitisflushwiththeouterfacesoftheBBshell.


1 BB N/A NIL RACEFACE30MMBB


Spider Removal

1. Removecranksaspermanufacturersinstructions.

2. Usinga16notchexternalbottombracketcuptool,removetheclutchbearinglockringfromthedrivesidecrankarm.

3. Removetheclutchbearingandspiderfromthedrivesidecrankarm’ssplines.


Crank and Spider Installation Aeffect

PARTS NEEDED

TOOLS NEEDED

• Grease

• Shimano bb cup tool

• Vise

ASSEMBLY

1. PlaceBBcuptoolintheviseandsecuretightly.

2. Liberallyapplygreasetotheinsideofthesplinepatternontheclutchbearing/spiderassembly.

3. Installtheclutchbearing/spiderontothesplineofthedrivesideAeffectarm.


1 CRANKSET N/A NIL RACE FACE AEFFECT CRANK SET

1 CLUTCH BEARING N/A A CLUTCHBEARINGSPIDERASSEMBLY WITH34TRING

1 CLUTCH BEARING LOCK RING

1347010 A LOCKRINGCLUTCH24MM


4. ThreadintheclutchbearinglockringtothedrivesideAeffectarm.

5. Torqueto40Nm.

Crank and Spider Installation Turbine

PARTS NEEDED

TOOLS NEEDED

• Grease

• Shimano bb cup tool

• Vise


1 CRANKSET N/A NIL RACE FACE TURBINE CRANK SET

1 CLUTCH BEARING N/A A CLUTCHBEARINGSPIDERASSEMBLY WITH34TRING

1 CLUTCH BEARING LOCK RING

1347006 A LOCKRINGCLUTCH30MM


ASSEMBLY

1. PlaceBBcuptoolintheviseandsecuretightly.

2. Liberallyapplygreasetotheinsideofthesplinepatternontheclutchbearing/spiderassembly.

3. Installtheclutchbearing/spiderontothesplineofthedrivesideTurbinearm.

4. ThreadintheclutchbearinglockringtothedrivesideTurbinearm.

5. Torqueto40Nm.


Battery Case Assembly

PARTS NEEDED

RefertotheBatteryBOMforallparts:

TOOLS NEEDED

• Hex Key set

• Double sided adhesive tape(VHB5952???)

ASSEMBLY

1. Locatethetwosidecoversonbothsidesofthebattery.AspertheBOMdiagram.

2. Locatetheendcapinplaceatthelowerendofthebattery,ensuringthecablecomesoutandgoesoutthereliefintheleftsideofthecap.

3. Slidethebatterypinthroughtheassemblytolocatetheendcaptothesideplates.


1 BATTERY 1977060CPS NIL BATTERY,634W,48V,LI-IONWITH BALANCING PCM

1 BATTERY,CAP 1997063 C BATTERYCAP

1 BATTERY, COVER LT

1997060 A BATTERYCOVER,LEFT

1 BATTERY, COVER RT

1997061 A BATTERYCOVER,RIGHT

1 BATTERY,PIN 1997062 NIL BATTERYPIN,68MM,6061-T6, HARDBLACKANODIZE

1 BOLT,SLEEVE56 1807139 A SLEEVEBOLT,M8X56MMALLOY7075-T6.

1 BOLT,SLEEVE70 1807141 NIL SLEEVEBOLT,M8X70MM.ALLOY7075-T6.

1 PLATE,BATTERY 1997067 NIL BATTERYSTEELPLATE

2 SCREW 180191FBY-016 NIL FLATHEADC'SUNKSOCKETSCREW, M6-1.0x16MM,A4/316STAINLESSSTEEL

1 SPACER,BATTERY 1997064 NIL BATTERYSLEEVESPACER,44MM,6061-T6, HARDBLACKANODIZE


4. Securethetopendofthebatteryusingthespacer(1997064),56mmbolt(1807139),andaM6Screw.

5. Securethebottomendofthebatterywiththe72mmbolt,andaM6Screw.


6. TorquetheM6screwsto4Nm.

7. Placethesteelplateonthetopofthebatteryasshownusingdoublesidedadhesive,ensuringthatitiscenteredandfirmlypresseddown.


Battery Case Removal

TOOLS NEEDED

• Hex Key set

REMOVAL

1. RemovePowerplayDrive(SeesectionPowerplay Drive Removal).

2. Unscrewgrubscrewbetweenbottlebossesondowntube.

3. UnscrewM6screwandremovebatterypinfromdowntube.

4. Slidebatteryoutofdowntube.


Battery Case Installation

PARTS NEEDED

TOOLS NEEDED

• Hex Key set

ASSEMBLY

1. Slidethebatteryupthedowntubeuntiltheplasticendcapalignswiththelowerportionofthecarbononthedowntube.

2. Insertthebatteryboltthroughtheframe.

3. InstalltheM6screwandwasher.

4. Torqueto4Nm.

5. InstalltheM5x20mmsetscrewinthemiddledowntuberiv-nut,Torqueto2Nm.


1 BOLT,BATTERY81MM

1807127 NIL E-MTBBATTERYBOLT,8MMODx81MML.AL7075-T6HARDBLACKANO

1 SCREW,M6x12 180566-012FBY NIL FLATHEADC'SUNKSOCKETSCREW, M6-1.0x12MM,A4/316SS,55060.060.012

1 WASHER 1807064 NIL C'SUNKWASHER:(FORM6SCREW)ID:6XOD: 14.6x3.25MMTHK.

1 SETSCREW,M5x20

1808024 NIL SETSCR.,FLT.PT.,M5x0.8x20MML. ZINCPLATED.07860.040.020

1 BATTERYASSEMBLY

N/A NIL BATTERYASSEMBLY


Charge Port Installation

PARTS NEEDED

TOOLS NEEDED

• Hex Keys

ASSEMBLY

1. Locatetherubbercapontothechargeportcableassemblybyfeedingthewirethroughthehole.

2. FeedtheBatterychargeport2pinconnectordowntheseattube,andouttheportneartheupperrearmotormountlocation.

3. Makingsuretherubberflapisalignedwiththeholes,inserttheM3torxscrewsintotheirlocations.


1 CHARGE PORT 1977005 NIL CHARGE PORT

4 SCREW,M3x12TORX

1807117 NIL C'SUNKSOCKETSCREW,M3-0.5x 12MM TORX,STAINLESSSTEELW/BLUELOCTITE

1 CHARGE PORT COVER

1997079 B CHARGEPORTRUBBERCAP,BLACKRUBBER


4. TorqueM3boltsto2Nm.

5. Makesuretherubbercapstaysintheclosedposition,protectingthechargeport.


Frame Cabling

PARTS NEEDED

TOOLS NEEDED

• Wire feed tool

• Wirecollectingtool(spoke)

• Flashlight

JOYSTICK HIGO CABLE

1. Thiscableshouldbeinstalledfirst,fromHeadtubetoLeftforwardmotormountport,beingpulledthroughwithawirefeedtool, asshownbelow:

a. Ensure female end of Higo cable goes towards the motor


1 CONNECTOR CABLE

1977012 NIL DOWNTUBECABLEJOYSTICK

1 REAR BRAKE N/A NIL REARBRAKEWITHASSOCIATEDHYDRAULIC HOSE AND FITTINGS

1 SHIFT CABLE HOUSING

N/A NIL SHIFT CABLE HOUSING FOR REAR DERAILLEUR

1 DROPPER CABLE HOUSING

N/A NIL DROPPER POST CABLE HOUSING


REAR BRAKE HOSE

1. Installtherearbrakeontheseatstay.

2. LooselycabletiethehosetotheLeftsideofthechainstay(x3).

3. Donotplacetheforward-mostcabletieatthemainpivot.

4. InsertthehoseuptheLeftforwardmotormountporttotheLeftHeadtubeport.

5. RetrievethehoseendfromtheheadtubeportusingtheJ-bendofaspoke.

6. Pullthehosethrough.

7. Placetherubbercover,olive,andendfittingonthehose.Insertendfittingifneeded(Sram).

8. Connecttherearbrakelevertothehoseaspermanufacturer’sinstructions.

9. Bleedbrakeaspermanufacturer’sinstructions.

DROPPER POST CABLE

1. InsertthehousinguptheLeftforwardmotormountporttotheRightHeadtubeport.

2. RetrievethehousingendfromtheheadtubeportusingtheJ-bendofaspoke.


3. Pullthehousingthrough.

4. InserttheotherenduptheLeftrearmotormountportattheseattube:

a. Feeditupuntilitappearsattheseatcollar.

b. Makingsureaseatcollarhasbeenplacedontheframe,installdropperpostaspermanufacturer’sinstructions.


REAR DERAILLEUR CABLE

1. RoutethederailleurhousingintotheRightsideofthechainstaynearthemainpivot.

2. Thishousingshouldslidethroughatunnelinthecarbon.


3. FeedtheotherenduptherightforwardmotormountportuptotheLeftHeadtubeport.

4. RetrievethehousingendfromtheheadtubeportusingtheJ-bendofaspoke.

5. Therearderailleurandshifterinstallationisaspermanufacturer’sinstruction.


Powerplay Drive Removal

TOOLS NEEDED

REMOVAL

1. Disconnectall4electricalcables:

1. Speedsensorconnector

2. Batteryconnector

3. iWocconnector

4. Chargeportconnector

2. Removetorquearm(seesectionTorqueArmRemoval).

3. Removelowerbashbracketcountersunk&upperrearmotormountM8screws.

4. Slidemotorouttheleftsideofthebicycle.


Torque Replacement Sensor

1. RemovePowerplaydrive.

2. Unscrew2xM4screwsholdingsensorbracketinplace.

3. GentlypullsensorbracketawayfromPowerplaydrivecase.

4. Disconnect3pinconnectoronsensorfromdrive.

5. Separatesensorfromsensorbracketbylooseninggrubscrew(fig10)andpryingapart.

6. Withnewsensorconnect3pinconnector.

7. GentlyfeedconnectorintoslotinPowerplaydrivecase.

8. ApplyhotgluetoundersideofsensortrayandplaceinpositiononPowerplaydrivecase.

9. Install2xM4screwsandtorqueto3Nm.

Powerplay Assembly


Powerplay Chain Replacement

1. Onleftsideofdrive,withthemotorcoverremoved,unscrewthreeM4screwssecuringtransferchaincover&removecover.

2. Locatemasterlinkonchain,cleangreaseoff.

3. Usingneedlenosedpliers,carefullyleveragethemasterlinkclipoffthepinsofthemasterlinkandremovelink.

4. Removechain.

5. RemoveO-ringsfrommotordrivepinonusingapick,andreplacewithnew.

Powerplay Assembly


6. Installnewchainbywrappingitaroundmotorpinionthenthedrivengear,sothatthetwoendsmeetatthecentreofthedrivengear.

7. Usingneedlenosedpliers,carefullyinstallthemasterlink,fromthebackside,sothemasterlinkclipisaccessible.

8. Covertransferchainwithgrease.


9. Installtransferchaincover.

10. InstallthreeM4screwsandtorqueto2Nm.

Powerplay Assembly


Powerplay Installation Preparation

PARTS NEEDED

TOOLS NEEDED

• Chain whip

• Shimano Splined lock ring tool

• Arbor press

• Hex keys

• Blue Loctite

TORQUE ARM ASSEMBLY

1. Pressthebearingintothe9Tcogusinganarborpressorvise.

2. PresstheMagnetintotorquearm,beingwaryofmagneticfieldorientation.

NOTE:Useaknowngoodtorquearmtogaugewhichorientationthemagnetshouldgo.Itishelpfultousefelttippedmarkertocolourtheoutwardfacingendofthemagnetduringthisprocess.


1 COG,12T 1347016 A TRANSFERDRIVENCOG,12T,MR.CONTROLP/N:TRSK-TY(WITHFLANGER)

1 LOCKRING,12T 1347008 A CASSETTELOCKRING,FOR12TCOG. MRCONTROLP/N:M-HUB-12T

1 CLAMP 1997081 A CABLECLAMP,M5CSUNK.AL6061-T6, HARDBLACKANO.

1 SCREW,M5x10 180475-010 NIL C'SUNKSOCKETSCREW,M5-0.8x10MM. ZINCPLATED10.9STEEL


3. Installthe9TcogontheTorquearmintheorientationshownabove.

4. UseblueLoctiteontheM5bolt,andtorqueto6Nm.

Powerplay Assembly


DRIVE COG REMOVAL

1. UsingtheShimanosplinedtool,andchainwhip,removelockring

DRIVE COG INSTALLATION

1. Locatethe12TcogonthePowerplaymotoroutputshaftspline,makingsuretheshoulderisinboard,andbottomedoutonthesplineshoulder

2. Applyasmallamountofgreasetothelockringthreads.

3. UsingtheShimanosplinedtool,andchainwhip,torquethedrivecogto40Nm.


Powerplay Drive Installation

PARTS NEEDED

TOOLS NEEDED

• Hex keys

• Loctite

ASSEMBLY

1. Themotorisinstalledontheleftsideofthebicycle.

2. Holdthebaseofthemotorinthepalmofyourhand,andlocateittowardsthemotormountsofthebicycle.

3. Pulltherearbrakehose,anddropperhousingoutoftheway,andinsertthemotorintoposition.

4. ApplyblueLoctitetothemotormountbolt.


1 SCREW,M8x30 1807121OVT NIL C'SUNKSOCKETSCREW, M8-1.25x30MM,STAINLESSSTEEL


5. Inserttheupperrearmotormountboltfirstandhandtightenittoholdthemotorinposition.

NOTE: Final torquing steps to follow in section Motor Case Final Torqueingonpage45.

Lower Bash Bracket Assembly

PARTS NEEDED


1 BRACE,MOTOR 1997021 NIL DYNAMELOWERMOTORBRACEANDBASHMOUNT.AL6061-T6HARDBLACKANO.

1 BASH GUARD 1997058 A RMB BASH GUARD

2 SCREW,SHOULDER M56x8

1807125 NIL CUSTOMHEXSOC.HD.SHLD.SCR., 303SS,M56x8


TOOLS NEEDED

• Hex keys

ASSEMBLY

1. LocatetheBashGuardonthebracketfingers.

2. InsertthecustomHexSSM5screwsandtorqueto6Nm.

Lower Bash Installation

PARTS NEEDED



1 SCREW,M8x65 1807122OVT A C'SUNKSOCKETSCREW, M8-1.25x65MM,STAINLESSSTEEL


1 LOWER BASH BRACKET

N/A NIL LOWERBASHBRACKETASSEMBLY


TOOLS NEEDED

• Hex keys

• Loctite243

INSTALLATION

1. ApplyblueLoctitetothethreecountersunkM8.

2. LocatethebashbracketassemblybelowthePowerplayMotorcasing.


3. Insertthe30mmM8countersunkboltthroughtheforwardmosthole.

4. Handtightenthebolttoholdthebracketinpositionfortheremainingtwobolts.

5. Insertthe50mmboltintherearmostpositiononthebracket,handtighten.

6. Insertthe65mmboltinthemiddlepositiononthebracket,handtighten.


42Altitude Powerplay Technical Manual Torque Arm Removal

TOOLS NEEDED

• Hex keys

REMOVAL

1. Unscrew3xcountersunkscrewsandremovedrivesidemotorcover.

2. Disconnectchainquicklinkandremovechain,ormovechainoffdrivepinion.

3. Unscrewderailleurcableholddownclamp,andmovecableupandoutoftheway.

4. Unscrew2xscrewsontorquearm.

5. Unscrew3xcountersunkscrewsandremovenondrivesidemotorcover.

6. Unscrewforwardmotormountboltsoitisclearoftorquearm,butdrivestaysinstalled.

TORQUE ARM REMOVAL


7. Rotatethetorquearmforwardstoclearthedrivepinion,andpullawayfrommotor.

Torque Arm Installation

PARTS NEEDED

TOOLS NEEDED

• Loctite

• Hex keys


1 TORQUE ARM ASSEMBLY

19970203 NIL TORQUEARMASSEMBLY-DYNAME3

1 SCREW,M6x30 180359FBY-030 NIL C'SUNKSOCKETSCREW,M6-1.0x 30MM,STAINLESSSTEELW/BLUELOCTITE

1 SCREW,M6x16 180566FBY-016 NIL FLATHEADC'SUNKSOCKETSCREW, M6-1.0x16MM,A4/316STAINLESSSTEEL

1 M8x60BOLT 1808023OVT NIL SOCKET HEAD CAP SCREW; M8x60,STAINLESSSTEEL


INSTALLATION

CAUTION: Ensure Powerplay drive power is OFF

1. Locatethetorquearminpositionagainsttherightsideofthemotor,movingtherearderailleurcableoutofthewayifneeded.Thespringportionofthearmmustbetuckedbehindtheteethofthe12Tcog

2. ApplyLoctitetothetwoM6bolts.

3. PlacethetwoboltsandhandtightenwithanHexkeywhilepressingdownonthetorquearmlightly

4. ApplyLoctitetothesocketheadshoulderscrew.

5. Carefullyfeedthescrewpastthebrake,dropperandHigocables,andintotheupperfrontmotormountlocationontheleftsideofthefronttriangle.

6. Handtightenwitha6mmhexkey



Motor Case Final Torqueing

TOOLS NEEDED

• 4,5,6mmHexKey

• Torquewrenchwith4,5and6mmbits

PROCEDURE

1. OnceallfiveM8motorboltsareinplace,thefinaltorqueingcanoccur.

2. First,torquethetwotorquearmM6countersunkboltsto10Nmwhilepushingdownontorquearm.

3. Torquetheboltsfirstto10Nm,thento14Nminthefollowingsequence:

a. Upperrear

b. Upperfront

c. Bbfront(middlebashbracket)

d. Frontbashbracket

e. Rearbashbracket

a

d c e

b


Chainstay Pulley Assembly

PARTS NEEDED

TOOLS NEEDED

• Arbor press

• Loctite

• Hex Keys


1 11TCOG 1347012 NIL 11TCOG,FOR19MMBEARING

1 BEARING,698 1807036 NIL ENDURO698LLU19X8X6

1 BOLT,M8x18 1807126 NIL BOLTM8x18MMCUSTOM6061 HARDBLACKANO.

1 CHAIN GUIDE ARM 1397004 B E-ALTITUDECHAINSTAYPULLEYGUIDE

2 SCREW,M5x12 1807152 NIL C’SUNKSOCKETSCREW,M5-0.8x12MMSTAINLESS STEEL

2 SPACER, PULLEYGUIDE

1347013 A CHAINSTAYPULLEYGUIDESPACER


ASSEMBLY

1. Installthebearinginthe11Tpulleyusinganarborpress.

2. Locatethepulleyandspacerswithinthebracketandalignallboresconcentrically.

3. ApplyblueLoctitetotheAxlebolt.

4. Installaxleboltthroughassemblyandtightento12Nm.

Chainstay Pulley Installation

PARTS NEEDED


1 LOWER IDLER ASSEMBLY

N/A NIL LOWERIDLERASSEMBLY

2 SCREW,M5x12 1807152 NIL C'SUNKSOCKETSCREW,M5-0.8x12MM.STAINLESS STEEL


TOOLS NEEDED

• Loctite

• Hex Keys

ASSEMBLY

1. Locatethechainstaypulleyassemblyunderneaththerightsideofthechainstay.

2. InstallscrewswithLoctiteandhandtightenboth.

3. Torquebothscrewsto6Nm.

Mid Drive Pulley Installation

PARTS NEEDED

TOOLS NEEDED

• Loctite

• Hex Keys


1 AXLE,MIDDRIVE 1457014 A MIDDRIVEPULLEYAXLE,M11x1MM40MM,AL7075-T6HARDBLACKANO

1 BEARING, DR11197

1807034 NIL SLAYERREARPIVOTSBEARING, DR11197LLUMAX,ENDURO

1 PULLEYBRACKET 1997059 A MIDDRIVEPULLEYPLATEANDGUIDE

1 PULLEY, MID-DRIVE

1347014 A MIDDRIVEPULLEY,12T,BLACKDELRINPLASTIC

1 SCREW,M5x20 1807151 NIL C`SUNKSOCKETSCREW,M5-0.8x20MM.A2SS.

1 SPACER 1808022 NIL MID-DRIVEPULLEYSPACER.6061-T6. HARD BLACK ANO


INSTALLATION

1. PresstheDR11197bearingintothemiddrivepulley.

2. Pressthespacerintothemiddrivepulleybracket.

3. LocatethemiddrivepulleybracketuponitssupportontheFronttriangle.

4. InstallthecountersunkM5boltintheuppercornerofthebrackettoholditinplace.Handtightensothebracketcanstillbealigned.

5. ApplygreasetotheM11x1threadsofmiddrivepulleyaxle.

6. InstallM11boltwithoutthepulley,andensurethebracketandFronttriangleborearealigned.

7. TorquetheM5countersunkboltto4Nm.

8. RemovetheM11bolt.

9. Placethepulleyinlocationonthebracket,concentricwiththepulleyspacer.

10. InstalltheM11boltandtorqueto10Nm.


Rear Wheel Assembly

PARTS NEEDED

TOOLS NEEDED

• Arbor press

• T25Torxdriver

INSTALLATION

1. InstallMagnetintomagnetholderusinganarborpress.

2. Installrotoraspermanufacturer’sinstructions,Magnetorientationisnotcritical.

3. Makesuretousethetwolonger12mmscrewstogothroughthespeedsensorholder.

Cassette Installation

PARTS NEEDED

TOOLS NEEDED

• Vise

• ShimanosplineLock-ringtool


1 MAGNET 1997068 NIL SPEED SENSOR MAGNET

1 SPEED SENSOR 1977007 NIL SPEEDSENSORCBLERWHEELD3

1 SPEED SENSOR 1997069 A SPEED SENSOR MAGNET HOLDER

1 SCREW 1808028 NIL DOMEHEADSCREW,M5x12MM,GRADE10.9STEEL,BLACKOXIDE,TORX


1 CASSETTE N/A NIL SRAMEX1CASSETTE


INSTALLATION

1. Applygreasetolockringthreads.

2. Torquenolessthanmanufacturerssuggestionof40Nm.

Rear Axle & Rear Derailleur Hanger

PARTS NEEDED

TOOLS NEEDED

• Loctite243

• 6mmHexkey


1 AXLEWASHER 3227006 B WASHER,12x19x0.5MM,304SS

1 AXLE, 12MMx 173MM

3227009 B 2017ELEMENTREARAXLE12MMx 173MM, HARD BLACK ANO

1 HANGER 1097132 A REARDER.HANGER,INT.LHTHREAD, STANDARDMOUNT(USEFORSRAM)

1 HANGER 3227002 F REARDER.HANGER,INT.LHTHREAD, SHIMANODIRECTMOUNT(SHOWN)

1 HANGER BOLT 3227001 E HANGERBOLT,EXT16MMLHTHREAD,AL6061-T6,HARDBLACKANO.


Rear Derailleur Installation

PARTS NEEDED

1. ApplyLoctite243(blue)toHangerBoltthreads.

Note: AxleNutandderailleurhangerarelefthand(reverse)threaded!Turncounter-clockwisetotighten.

2. a. PassHangerboltthroughseatstay,andthreadintoderailleurhanger,turningcounterclockwise

b. Torqueto20Nm.

3. GreaseRearAxle(3227009)bodyandthreads. 4. a. PassRearAxlethroughStainlessSteelWasher,leftseatstay,hub,andthreadintothehangerbolt.

b. Withhubinstalled,torqueto10Nm.


1 SCREW,M5x10 180475-010 NIL C'SUNKSOCKETSCREW,M5-0.8x10MM. ZINCPLATED10.9STEEL

1 CLAMP 1997081 A CABLECLAMP,M5CSUNK.AL6061-T6, HARDBLACKANO.

1 REAR DERAILLEUR 1807125 NIL SRAMEX1

1 HOUSING N/A NIL 4MMSHIFTHOUSING,WITHENDFERRULES,___CM

2 CABLE TIES N/A NIL BLACK


TOOLS NEEDED

• Hex keys

INSTALLATION

1. Withthemotorinplaceonthefronttriangle,andtherearderailleurcablepassedthroughtheChainstayandthefronttriangle, observethesmallM5tappedholeontherightsideofthemotorcase.

2. InstallacableretainercliponthislocationwithanM5countersunkscrew.

3. Torqueto4Nm.


Chain Installation

PARTS NEEDED

TOOLS NEEDED

• Notoolsrequired.

INSTALLATION

CAUTION: Verify on iWoc remote that Powerplay drive is OFF

1. Routethechaininthefollowingorder:

a. UndertheMiddrivePulley,throughitsguide

b. OvertheDrivesprocket

c. Overthetorquearmsprocket

d. Underthechainring,ensuringthatthenarrowandwideteethalignwiththechain

e. Overthelowerchainstaypulley


1 CHAIN N/A NIL SRAMEX1CHAIN,62COMPLETELINKS,INCLUDING QUICK LINK


2. Leavealengthofchainhangingfromthelowerchainstaypulley(approx.5completelinks).

3. Routetheotherendofthechainoverthesmallestcassettecog,thenthroughthederailleurcage.

4. Oncethechainishangingthroughthederailleurcage,theendscanbeconnected.

5. Usinganappropriatequicklink,jointhechain.

6. Rotatethecranksforward,sothequicklinkisonthetop(tensionside)ofthechain.

7. Usethecrankarmtolockthequicklinkinitsextended/closedposition.


Speed Sensor Installation

PARTS NEEDED

TOOLS NEEDED

• Hex keys

ASSEMBLY

1. Locatethespeedsensorinthecradle.

2. InstallM5x10countersunkscrewwithblueLoctite,Torqueto4Nm.


1 CLAMP 1997081 A CABLECLAMP,M5CSUNK.AL6061-T6,HARDBLACKANO.

1 SPEED SENSOR 1977007 NIL SPEEDSENSOR,CABLE,2PINCONNECTOR

2 SCREW,M5x10 180475-010 NIL C'SUNKSOCKETSCREW,M5-0.8x 10MM. ZINCPLATED10.9STEEL


Other Bicycle Components

ThesepartsareOEMcomponentsandareinstalledusingtraditionalmethods.ThissectionisintendedasaguidetoshowhowAltitudePowerplayassemblydiffersfromthatofaregularbicycle

PARTS NEEDED

Headset Installation

PARTS NEEDED

TOOLS NEEDED

• Headset press

• Appropriate adapter to allow upper headset cup to be pressed

• Hex Keys


2 SCREW,M5x16 1806009 NIL FLATHEADC'SUNKSOCKETSCREW, M5-0.8x16MM,ALUMINIUM

1 HT PANEL LEFT 1097136 C HTPORTPANEL,LEFT

2 HT PANEL RIGHT 1097140 C HTPORTPANEL,RIGHT

1 USB HOLDER 1998015 NIL E-ALTITUDEUSBHOLDERBRACKET

1 IWOC REMOTE 1977011 NIL IWOC REMOTE WITH USB PORT

1 FORK N/A NIL SUSPENSION FORK

1 HEADSET N/A NIL FSA KNOCK BLOCK HEADSET

1 STEM N/A NIL STEM

1 BAR N/A NIL HANDLE BAR

CABLE TIE N/A NIL CABLE TIES




INSTALLATION

1. Greasetheoutsideoftheupperheadsetcup.

2. Alignthelaseretchedlineontheupperheadsetcupattheveryfrontofthebike.

3. Usetheadaptertoalignthecupwiththeheadsetpressinplace.

4. Carefullycompressthecupintoposition.

5. Installthelowercupnormally.

Fork Installation

PARTS NEEDED

• Installtheforkasperheadsetmanufacturer’sinstruction.

• IfusinganFSAHBSheadset,besuretoclamptheupperclampoftheheadsetwiththeforkalignedstraight.

• Installonespacerontheupperclamp.

• PlacetheUSB-on-wirebracketonthesteerertube.

• InstallonemorespacerontheUSB-on-wirebracket.

• InstalltheStemonthesteerertube.

• Installremainingspacersandcompressioncap.


1 FORK N/A NIL SUSPENSION FORK

1 STEM N/A B STEM

1 HANDLE BAR N/A NIL HANDLEBAR

1 USB HOLDER 1998015 NIL E-ALTITUDEUSBHOLDERBRACKET



iWoc Remote Installation

PARTS NEEDED

TOOLS NEEDED

• Wire cutters

ASSEMBLY


1 JOYSTICK 1977011 NIL JOYSTICKWITHUSBPORT

1 USB HOLDER 1998015 B E-ALTITUDEUSBHOLDERBRACKET

2 CABLE TIES N/A NIL 4MMCABLETIES


1. RoutecabletieUPthroughthetwoholes,andbesidethestemduringplacement.

2. OnceUSB-on-Wireisplacedinthecradle,rotatetheziptiesbacktowardsthefront,thenaroundtheplasticpart.

3. Pulltheziptiessnug,andclipthewires.

Wire Connections

PARTS NEEDED

TOOLS NEEDED

• Wire cutters

BLOCK DIAGRAM


X CABLE TIE N/A NIL 4MMCABLETIES


ASSEMBLY

1. ConnecttheiWocremotetotheHigoextensioncable

2. WithPowerplaydriveinstalledinfronttriangle,andworkingontheleftsideofthebicycle:

a. Connectchargeport2Pinconnector,pushjoinedconnectorincavitybehindPowerplaydrive.


b. PushdropperposthousingintocavityabovePowerplaydrive.

c. PushRearbrakehoseintocavityabovePowerplaydrive.


d. Connect5piniWocextensioncableandplaceitnexttotransferchaincover.Pullextensioncabletautbyfeedingitback intodowntube.

e. Connect2pinSpeedSensorconnector,andplaceitinthecavitybehindPowerplaydrive.Leavewireaccessible.


f. Connect3-PinBatteryconnector,andplaceitnexttotransferchaincover.

CAUTION: The bike power is now live

3. VerifyiWocandmotorfunctionality(seesectionFunctional Check onpage66).

65Altitude Powerplay Technical Manual iWoc Functionality

IWOC FUNCTIONALITY


Functional Check

WARNING

Ifbicycleisinstand,ensurerearwheelandcranksarecleartomove.

INSTRUCTIONS

1. Withcompletebicycle,poweruptheiWocremote.EnsurebootupsequencehappensonLEDs.

2. Performzerocalibration(seesectionTorque Sensor Calibration).

3. Pressthepowerdownbutton,ensurewalkmodeengages.


Torque Sensor Calibration

CAUTION: Ensurebikeisstaticontheground,withNORIDERWEIGHTonthebike.YoumayperformthisoperationSTRADDLINGthebicycle.

1. Rotatethecranksandshiftthebikeintothelargestrearcassettecog

2. Pressthetwotopbuttons(BUTTONSCANDD)onthejoystickatthesametimetostartthecalibration.YouwillseethepowerLED flashred

3. Gentlytapthepedalwithlittleforcetoensurethatthetorquesensorresetsitselfto‘zero’bythederailleurtension.

4. Withbothfeetonthegroundandnomassonthepedals,PresstheBUTTONBtoenterthisvalue


5. TheLEDwillnowflash2xalternatingRED/YELLOWbeforeexitingcalibrationandreturningtoregularusemode:

Tosavethecalibration,theJoystickmustnowbereset.

6. PressBUTTONBfor2secondstoturnoffthepower.TheJoystickwillcyclecoloursontheLEDandshutdown.

7. Green–blue–green–red–WHITE–OFF.

9. PressBUTTONBtoturntheunitbackonandrunitsbootupsequence,thecalibrationisnowready.


Cover Installation

CAUTION: VerifyoniWocremotethatPowerplaydriveisOFF.

1. InstallLeftmotorcoverbyfirstfeedingrearbrakehoseandspeedsensorwirethroughopenslot.

2. InstalltwoM5x22alloyboltsontoptwoholes,andoneM5x12alloyboltinbottomhole.

3. Torquehandtight

4. InstallRightmotorcoverovertorquearmassembly

5. InstalltwoM5x22alloyboltsontoptwoholes,andoneM5x12alloyboltinbottomhole.

6. Torquehandtight

70Altitude Powerplay Technical Manual Suspension Pivot Torque Guide

Note:AllTorquevaluesare+/--10%

SUSPENSION PIVOT TORQUE GUIDE

Description Part No. Location ToolTorque

Noteskg-cm Nm lb-in

A SHOCK BOLTS & SCREWS

1807049&180566-016FBY

Top Link 5mm&4mmHex Keys

80 8 70 Torque only with correct shock and hardwareinstalled.Apply grease to shockbolts,andLoctite243(blue)toscrewthreads.

1807062&180566-012FBY

Front Triangle

Two4mmHex Keys

B TOP LINK BOLTS & SCREWS

1807060&180566-012FBY

FT-TLPivot

6mm&4mmHex Key

80 8 70 Apply grease to pivotbolts,andLoctite243(blue)toscrewthreads.1807061&

180566-012FBYSS-TLPivot

C DROPOUT PIVOT SCREWS

1807046 Dropouts 6mmHexKey 175 17 152 ApplyLoctite243to female seat stay threads.

D MAIN PIVOT BOLT

1807029 Main Pivot

6mmHexKey 175 17 152 Apply grease to inner bearing races andLoctite243tofemale chain stay threads.

C

B

A

D

71Altitude Powerplay Technical Manual Powerplay Torque Values


Noteskg-cm Nm lb-in

BATTERYCASESCREW,M6x12

180566-012 Battery 4mmhex 40.79 4 35.4 Secures56,70and81mmbatterycasebolts,blueloctite

SETSCREW,M5x20

1808024 Down tube 2.5mmhex 20.395 2 17.7 Ensure set screw bottoms on battery plate

SCREW,M3x12TORX

1807117 Charge port 2.5mmhex 20.395 2 17.7 Tighten four screws evenly

SCREW,M5x10

180475-010 Torque arm pulley

3mmhex 61.185 6 53.1 Blue loctite

LOCKRING,12T

1347008 12Tdrivepinion

Shimano splined cassette lockring tool

407.9 40 354 Grease on threads

SCREW,SHOULDER M5x6x8

1807125 Bash guard 3mmhex 61.185 6 53.1 Grease or loctite

SCREW,M6x30

180359FBY-030

Torque arm 4mmhex 101.975 10 88.5 Loctite,pushdownon torque arm while tightening

SCREW,M6x16

180566FBY-016

Torque arm 4mmhex 101.975 10 88.5 Loctite,pushdownon torque arm while tightening

SCREW,M8x30

1807121OVT Powerplay upper rear frame mount

5mmhex 142.765 14 123.9 Loctite,tightenfirstto10Nminsequence,then14Nmfinal

M8x60BOLT 1808023OVT Powerplay upper front frame mount and torque arm


POWERPLAY TORQUE VALUES, 1 OF 3




Noteskg-cm Nm lb-in

SCREW,M8x25

1807123OVT Powerplay bash bracket


SCREW,M8x65



SCREW,M8x50



BOLT,M8x18 1807126 Chainstay pulley axle

6mmhex 81.58 8 70.8 Loctite,ensureno play and pulley spins freely

SCREW,M5x12

1807152 Chainstay pulley bracket

3mmhex 61.185 6 53.1 Loctite

SCREW,M5x20

1807151 Mid drive pully bracket

3mmhex 30.5925 3 26.55 Loctite,alignpartwith shaft spacer before torquing

AXLE,MIDDRIVE

1457014 Mid drive pully axle

6mmhex 101.975 10 88.5 Loctite,ensureno play and pulley spins freely

CLUTCH BEARING LOCK RING 24MM

1347010 Aeffectcrank 16notchexternal bb cup tool

407.9 40 354 Apply grease to entire clutch bearing spline and threads

CLUTCH BEARING LOCK RING 30MM

1347006 Turbine crank 16notchexternal bb cup tool

407.9 40 354 Apply grease to entire clutch bearing spline and threads

SCREW,M5x10

180475-010 Speed sensor and derailleur housing hold down clamp

3mmhex 40.79 4 35.4





Noteskg-cm Nm lb-in

TORXSCREW,M5x12

1808028 Brake rotor T25Torxdriver

63.2245 6.2 54.87 Loctite,torquerotor as per manufacturers instructions

CASSETTE LOCK RING

N/A Cassette Shimano splined cassette lockring tool

407.9 40 354 Manufacturer specification

HANGER BOLT 3227001 Derailleur hanger

6mmhex 203.95 20 177 Loctite,lefthandthread

AXLE,12MMx173MM

3227009 Rear axle 6mmhex 101.975 10 88.5 Grease threads and axle shaft

SCREW,M5x16

1806009 Head tube panel

3mmhex 15.29625 1.5 13.275 Grease,donotovertighten

SCREW,M5x22

1808037OVT Drivecover,top


SCREW,M5x12

1808036OVT Drivecover,bottom




DE VELOPMENT CENTRE

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1225EastKeithRoad,Unit#10NorthVancouver,BCCanada,V7J1J3

T.604-980-9938F.604-980-9975

HE A D OFFICE

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9095,25thAvenue,St-Georges,QCCanada,G6A1A1T.1-800-663-2512F.1-800-570-8356

Rocky Mountain, its logo and other trade names are registered trademarks.Some technologies on Rocky Mountain products are patented or patent pending.

©Rocky Mountain Bicycles 2017

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