Cannondale CY22 Mavaro Neo Owner'S Manual Supplement Download

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CY22 Mavaro Neo, Tesoro Neo X, Trail Neo

Replacement Parts

Service Kits

138689 Rev 1 (06/22)

Replacement Parts

Service Kits

Item

Kit #

Kit Description

K33002

Derailleur Hanger QR SS SS 088

K33012

Derailleur Hanger QR ST SS 087

K22002

Hardtail Neo Belt Tensioner

K34002

Hardtail Neo Skid Plate

K14021

Mavaro Headtube Light

K34211

Neo Key Cover

K32040

DT Adhesive Cable Guide Qty 3

K76002

Hardtail Neo Motor Mount Brackets

K76032

Hardtail Neo HT Accessory Mounting Kit

K34012

Battery Cover DT Bottom Exit 750wh

K32002

Hardtail Neo Frame Cable Guides

K76012

Neo Latching Charge Port Holder

K76022

Neo 750 DT Bottom Exit Batt Rail

K34022

DT Bolt On Scuffguard

K34032

Hardtail Neo

STD/RMX

Motor Cover

K34052

Hardtail Neo

Step-Thru

Motor Cover

K11002

Hardtail Neo Chainguard

K32012

HT Internal Cable Clips Qty2

K34042

Hardtail Neo CS Protector

KP312/

Open Oval Grommet x10

K35062

HT Internal Routing Sleeve

HeadShok

K35052

HT Internal Routing Sleeve

1.8

K13002

Hardtail Neo

Rear Rack

K13012

Hardtail Neo

MD/LG/XL

Rear Rack

Summary of Contents for CY22 Mavaro Neo

Page 1: ... THIS SUPPLEMENT AND YOUR CANNONDALE BICYCLE OWNER S MANUAL Both contain important safety information Keep both for future reference CY22 Mavaro Neo Tesoro Neo X Trail Neo English Owner s Manual Supplement ...

Page 2: ...be taken to avoid damage SYMBOLS NLGI 2 NGLI 2 synthetic grease Apply NGLI 2 synthetic grease ANTI S Anti Sieze Lubricant Apply Permetex Anti Sieze Lubricant 2 Medium strength removable thread lock Apply Loctite 242 blue or equivalent N m Tightening torque in Newton meters ILLUSTRATIONS Throughout this manual all product images graphics and figures shown are for illustration purposes only and may ...

Page 3: ...ls or supplements from our website http www cannondale com Contacting Cannondale Cannondale USA Cycling Sports Group Inc 1 Cannondale Way Wilton CT 06897 USA 1 800 726 BIKE 2453 CSG Europe Woudenberg Cycling Sports Group Europe B V Geeresteinselaan 57 3931JB Woudenberg The Netherlands International Distributors Consult our website to identify the appropriate Cannondale Dealer for your region Your ...

Page 4: ...nd bike types Likewise there are various drive assist system manufacturers Shimano BOSCH Bafang Yamaha etc How does the Drive System work It is important to know that when the drive assist system is turned ON the drive unit engages to provide power only while you are pedaling The amount of power provided by the drive unit depends on your pedaling force and on the assistance mode level you set with...

Page 5: ...lways have mechanical work done by an Authorized Cannondale Dealer No Modification DO NOT MODIFY THIS BICYCLE DRIVE SYSTEM IN ANY WAY FOR ANY REASON Doing so can result in severe damage in faulty or in dangerous operating conditions or in violation of local laws Dealers and Owners MUST NOT change alter or modify in any way the original components of the bicycle or drive assist system e g the speci...

Page 6: ... and react appropriately depending on the riding conditions such as on slippery trails tight turns or unstable or uneven surfaces Set assistance level to eco lowest assist or to off before descending technical trails e g tight downhill switchbacks When not riding Turn the drive system off to prevent unauthorized use Do not ride the e bike without the battery Make sure the battery is fully charged ...

Page 7: ...this bicycle To determine if coverage is provided you should contact your insurance company or agent Also make sure your speed e bike is insured and registered according to the local laws Ride sensibly and safely around others the application of power by means of the electric motor assist means that riders can reach high speed Riding faster increases the risks of serious accidents Watch out for ot...

Page 8: ...s before packaging Package the battery inside a shipping container to prevent damage The battery must be removed before flying and may be subject to special handling by the air carrier CHARGING Bring the battery and charger indoors and allow to reach room temperature before charging Make sure charger and A C outlet are the same voltage Locate both charger and battery indoors in a clean dry area wi...

Page 9: ...ot rely on this marking as an indication of the proper minimum seat post insertion depth You can be severely injured paralyzed or killed in an accident if you ignore this warning Maintaining Your Bike s Drive System NOTICE Drive assist system components must only be serviced at an authorized service center This will ensure the quality and safety of the drive assist system Never attempt to open or ...

Page 10: ...enter of the fork axle From bottom of frame head tube Maximum fork length You must select a replacement fork not only based on head tube diameter but the critical factor of frame maximum fork length Do not exceed maximum fork length Exceeding the MAXIMUM FORK LENGTH limit can overload the frame causing it to break while riding Your retailer MUST follow and observe this specification for your bike ...

Page 11: ...ed in any way PERIODIC INSPECTION REQUIRED The rack and frame mounting points must be periodically inspected for damage as part of your routine bicycle maintenance SECURE RACK CONTENTS You must make sure that all items placed in the rack are secure and cannot be thrown out or shifted in the rack while riding You must prevent any parts of the contents the straps or the tie downs used to secure the ...

Page 12: ...dset ACROS 1 5 1 8 Integated w Internal Cable Routing K35012 1 5 1 8 Int Hdset 28 6 52 60 45 83 Bottom Bracket Type Width Bosch Drive Unit Front Derailleur N A Seat Post Dia Binder 31 6mm 36 4mm Min Seat Post Insert 100mm Tire Size x Max Tire Width SM 27 5x2 5 MD LG XL 29x2 5 Max Fork Length SM 495mm MD LG XL 505mm Rear Brake Mount Type Min Max Rotor Dia IS 180mm 203mm Rear Axle Type Length 135x9m...

Page 13: ...69 2 69 2 69 2 E Seat Tube Angle Effective 74 8 75 2 75 2 75 2 F Standover 74 4 77 4 79 7 81 9 G Head Tube Length 14 0 13 0 14 0 15 5 H Wheelbase 116 3 117 6 119 6 121 9 I Front Center 68 9 70 6 72 6 74 8 J Chain Stay Length 48 0 48 0 48 0 48 0 K Bottom Bracket Drop 5 8 7 5 7 5 7 5 L Bottom Bracket Height 29 2 29 5 29 5 29 5 M Fork Rake 5 5 5 5 5 5 5 5 N Trail 7 7 8 2 8 2 8 2 O Stack 61 6 62 6 63 ...

Page 14: ...Fork Rake 4 4 4 4 4 4 4 4 N Trail 9 6 10 3 10 3 10 3 O Stack 62 4 63 7 64 7 66 0 P Reach 40 0 41 6 43 3 45 0 Head Tube Height 49 5 50 5 50 5 50 5 Tesoro Neo X Standard Size S M L XL Wheel Size in 27 5 29 29 29 A Seat Tube Length 40 0 43 5 47 0 50 0 B Top Tube Horizontal 57 9 59 9 61 8 63 9 D Head Tube Angle 68 0 68 0 68 0 68 0 E Seat Tube Angle Effective 74 0 74 0 74 0 74 0 F Standover 75 0 78 4 8...

Page 15: ... Top Tube Horizontal 57 9 61 8 D Head Tube Angle 68 8 69 2 E Seat Tube Angle Effective 74 8 75 2 F Standover 43 4 43 5 G Head Tube Length 14 0 14 0 H Wheelbase 116 3 119 6 I Front Center 68 9 72 6 J Chain Stay Length 48 0 48 0 K Bottom Bracket Drop 5 8 7 5 L Bottom Bracket Height 29 2 29 5 M Fork Rake 5 5 5 5 N Trail 7 7 8 2 O Stack 61 6 63 5 P Reach 41 2 45 0 Head Tube Height 48 0 48 0 ...

Page 16: ...Tube Horizontal 57 9 61 8 D Head Tube Angle 68 0 68 0 E Seat Tube Angle Effective 74 0 74 0 F Standover 44 0 44 5 G Head Tube Length 14 0 14 0 H Wheelbase 115 6 119 8 I Front Center 68 1 72 5 J Chain Stay Length 48 0 48 0 K Bottom Bracket Drop 5 2 6 5 L Bottom Bracket Height 29 9 30 5 M Fork Rake 4 4 5 1 N Trail 9 4 9 4 O Stack 62 4 64 4 P Reach 40 0 43 3 Head Tube Height 49 5 50 5 ...

Page 17: ... 68 0 E Seat Tube Angle Effective 74 0 74 0 74 0 F Standover 66 6 66 9 66 2 G Head Tube Length 14 0 13 0 14 0 H Wheelbase 115 6 117 8 119 8 I Front Center 68 1 70 5 72 5 J Chain Stay Length 48 0 48 0 48 0 K Bottom Bracket Drop 5 2 6 5 6 5 L Bottom Bracket Height 29 9 30 5 30 5 M Fork Rake 4 4 5 1 5 1 N Trail 9 4 9 4 9 4 O Stack 62 4 63 5 64 4 P Reach 40 0 41 7 43 3 Head Tube Height 49 5 50 5 50 5 ...

Page 18: ... is located on the bottom bracket It is a 7 character barcode See inset _____________________________________ Frame Serial Number Bike Registration To register your bike Go to the Product Registration section of our website at www cannondale com Actual bike appearance will differ 1 Drive unit 2 Drive Controls Display 3 Internal Battery 4 Charge port 5 Wheel Sensor 6 Serial number Identification ...

Page 19: ...the lock then remove and wipe the key clean Record Key Number Be sure to write down the key serial number a on the line below The serial number is required to order spares and replacements Replacement keys are obtained from the key manufacturer _____________________________________ ___ Key Serial Number 2 c 1 3 a b The key 2 unlocks the internal battery mount mechanism See Downtube Battery To acce...

Page 20: ...ng cable into the socket connector 3 Follow the manufacturer s charging instructions for the duration of charging 4 Disconnect the charger cable from the port connector and close the cover and close the cover latch 5 Disconnect the charger from its source of power Follow the drive system manufacturer s instructions for charging and handling the battery Be sure to inspect the condition of the batte...

Page 21: ...re the bike upright to prevent it from falling over 2 Turn the key clockwise to release the battery frame latch 3 Insert the lower part of the battery so that the battery socket engages with the frame connector 4 4 Press in on the top of the battery causing the ramp and lock to engage fully 5 Remove the key 6 Install the battery cover 1 and secure it with the cover knob 2 NOTICE Do not ride the bi...

Page 22: ...esoro Neo X Trail Neo Technical Information Battery Charging Port 138689 Rev 1 06 22 1 2 3 4 6 5 7 8 1 Battery Cover 2 Cover Knob 3 Battery 4 Battery frame connector 5 Ramp 6 Retention lock 7 Key 8 Key Cover Identification ...

Page 23: ...0 25mm of the bottom of the upper headtube bearing as shown by the gap above NOTICE The sleeve is required Do not remove the sleeve Periodic inspection required See Maintenance in this manual Correct installation Use degreaser and a clean cloth to make the complete steerer tube of the fork free of oil and grease Push the sleeve onto the steerer tube by hand It should be hard to push it down by han...

Page 24: ...t be possible to turn the sleeve on the steerer tube 1 1 8 fork The sleeve needs to be pushed down to the tapered section of the fork to create a close contact Headshok Position sleeve down to the step of the Headshok steerer to create close contact Close contact can be checked through the 4 little holes of the sleeve The sleeve should sit firmly on the steerer tube It should not be possible to tu...

Page 25: ...ame 6 14 4 2 1 3 5 9 7 8 11 12 13 10 1 Speed sensor 2 ABS sensor rear 3 Rear brake 4 Rear derailleur 5 Dropper post 6 Rear light 7 Sleeve Headshok 8 Sleeve 1 8 9 Front brake 10 Charge port 11 ABS power 12 ABS sensor 13 Front light 14 Power Identification ...

Page 26: ...ion Routing Headtube 138689 Rev 1 06 22 Routing Headtube 8 9 10 1 4 3 2 7 6 5 1 Charge port 2 Human Machine Interface HMI 3 Rear derailleur 4 Brake light 5 Electrical cable 6 Rear brake 7 Dropper post 8 ABS power 9 ABS sensor front 10 Front light Identification ...

Page 27: ...al Information Routing Chainstays Routing Chainstays 1 6 2 8 7 a 2 4 5 3 1 Dropper post 2 Rear derailleur 3 Grommet 4 Rear brake 5 Speed sensor 6 Rear light 7 Washer 8 Retaining screw a Entry hole Identification ...

Page 28: ...gain The method for inspecting and setting the tension of the belt is defined by the belt manufacturer Adjustment 1 See gatescarbondrive com for correct belt tension measurement setting 2 Loosen mounting bolts 6 3 Turn adjust screw 9 to set belt tension Turn clockwise to increase tension Turn counter clockwise to decrease tension 4 Tighten the counter nut 8 5 Tighten bolts 6 to specified torque Re...

Page 29: ...nsioner 3 2 4 5 1 8 7 6 9 8 N m Loctite 242 blue 10 12 11 13 14 1 Bracket 2 Roller assy 3 Bolt 4 Shim 5 Nut 6 Mounting bolts 3X 7 Barrel 8 Counter nut 9 Tensioning screw 10 Belt 11 O Ring 2X 12 Roller wheel 13 Bearing 14 Clip Identification ...

Page 30: ...er M4 3xD 5 Guard 6 Guard spacer 2X 7 Guard bracket 8 Screw M4x16 2X 9 Screw M5x16 2X Identification The guard must be securely in place at all times to prevent contact with drive belt or drive chain Inspect the guard condition frequently It should not be loose or damaged e g cracked broken dented or missing any part Replace the guard with a new one if damaged Tighten all hardware securing the rac...

Page 31: ...seatstay and chainstay should be carefully cleaned and checked for any damage anytime the parts are disassembled Do not allow dirt or contamination A film of bearing grease can be applied to mating surfaces to inhibit corrosion and minimize creaking Clean the area with isopropyl alcohol and alloy to dry before applying fresh Loctite to the bolt threads Tighten all the hardware evenly to the specif...

Page 32: ...other lights on the bicycle Headlight a high intensity light DAYTIME RUNNING LIGHT Comes on only during daytime Intended to be used at daytime to increase rider visibility to other cyclists to pedestrians and to motorists Not intended to illuminate the road road hazards or use at night It is not a bright high intensity cycling light intended to illuminate the road or hazards in the road Please rea...

Page 33: ...tion Routing Daytime Running Light 4 1 5 3 2 7 6 M5 3 N m 2 Sleeve not shown Routing Daytime Running Light 1 Daytime Running Light DTRL 2 DTRL wire 3 Guide 2X 4 Clip 4X 5 Thread boss 4X 6 Cable guide 7 Screw Identification ...

Page 34: ... locations for the frame fasteners bolts screws nuts on your bicycle Setting the correct torque is very important to your safety and to the durability and performance of your bicycle Always use a calibrated torque wrench Follow the manufacturer torque instructions for all the components of your bike Some fasteners have a pre applied thread locking patch Its effectiveness is reduced after repeated ...

Page 35: ...33 Technical Information Tightening Torques M5 5 N m M5 5 N m M4 2 N m M8 20 N m M4 2 N m M6 1st time 10 N m 2nd time 9 5 N m M5 5 N m M8 6 N m 2 2 2 2 2 2 2 2 Loctite 242 Blue ...

Page 36: ...ets I K76032 Hardtail Neo HT Accessory Mounting Kit J K34012 Battery Cover DT Bottom Exit 750wh K K32002 Hardtail Neo Frame Cable Guides L K76012 Neo Latching Charge Port Holder M K76022 Neo 750 DT Bottom Exit Batt Rail N K34022 DT Bolt On Scuffguard O K34032 Hardtail Neo STD RMX Motor Cover P K34052 Hardtail Neo Step Thru Motor Cover Q K11002 Hardtail Neo Chainguard R K32012 HT Internal Cable Cli...

Page 37: ...35 Replacement Parts Service Kits wb cage X A B S C D E F J U V R Q N M L T H O P G I rack K ...

Page 38: ...ts taillights and or number plate illumination ensure each light functions properly Check for proper function of the front and rear brakes Brake pad and rotor wear is typically greater on e bikes than on pedal only bikes requiring more frequent inspection and replacement Check tire pressures and the condition of the wheels Ensure the tires are not damaged and do not have excessive wear Ensure no w...

Page 39: ...essure to clean Power washing will force contaminants into parts where they will promote corrosion immediately damage or result in accelerated wear DO NOT use compressed air to dry DO NOT use abrasive or harsh chemical cleaner solvents which can damage the finish or attack and destroy both the outside and internal parts When rinsing avoid directing the spray directly at shock fork adjusters or bea...

Page 40: ...nnondale Way Wilton CT 06897 USA 1 800 726 BIKE 2453 www cannondale com CSG EUROPE Cycling Sports Group Europe B V Geeresteinselaan 57 3931JB Woudenberg The Netherlands service cyclingsportsgroup com CANNONDALE UK Cycling Sports Group Vantage Way The Fulcrum Poole Dorset BH12 4NU 44 0 1202732288 sales cyclingsportsgroup co uk ...

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