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Nukeproof MEGAWATT 297 2021, Manual, Page: 65 / 78

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Nukeproof MEGAWATT 297 2021 Manual Download Page 65

M E G A W AT T   B I K E   G U I D E   2 0 2 2   |  

6 5 

T O R Q U E   A N D   G R E A S E   D I A G R A M S

Note:

 Use medium strength threadlock

We recommend Loctite 243

Recommended Torque Values  Torque

Battery Door Bolts

2Nm

Battery Mount Bolts

7Nm

Cable Guide Bolts

3Nm

Torque

Summary of Contents for MEGAWATT 297 2021

Page 1: ...B I K E M A N U A L...

Page 2: ...ou get familiar with your Megawatt its Shimano STEPS EP8 system and a helpful resource for maintaining and setting up your bike Please read this manual carefully to help look after and enjoy your Mega...

Page 3: ...m S e c t i o n 4 S h i m a n o E T u b e S e c t i o n 5 S u s p e n s i o n s e t u p S e c t i o n 6 M a i n t e n a n c e a n d C a r e S e c t i o n 7 S p e c i f i c at i o n s S i z i n g G e...

Page 4: ...ss valves reflectors SW300 tool additional items will depend on the dealer you have purchased the bike from Some Nukeproof dealers will provide pedals and basic tools with the bike on delivery typical...

Page 5: ...elp at this point from another person to hold the box If your dealer has stapled the box please ensure they are removed to prevent paint damage 5 The bike will be carefully wrapped before shipping to...

Page 6: ...onent manuals basic tools fork tokens depending on the make and model of fork and spare cable ties for cabling 2 Basic tools for assembling bike pedals and tools supplied are at the discretion of the...

Page 7: ...M E G AWAT T B I K E G U I D E 2 0 2 2 7 5 The Shimano STEPS charger is supplied with plugs to suit the country the bike is purchased in or delivered to...

Page 8: ...face plate and bolts set aside safely for installing later 2 Place bars to stem using the set up lines to position the bars centrally Ensure cables and brake lines are not tangled at this point 3 Tigh...

Page 9: ...lay socket until there is a noticeable seating click 6 Repeat install with 2nd SD50 wire 7 You can adjust the roll of the bars back or forward at this point to your personal preference Ensure the bars...

Page 10: ...ll of your bars the controls can be changed to suit rider preference 1 The angles of the brakes gear shifter dropper lever Shimano STEPS display and mode selector can be changed 2 The controls can be...

Page 11: ...ant failure to install the pedals on the correct side of the bike will cause irreparable damage your crank and pedal Alloy pedals Alloy pedal axles are marked L indicating the left pedal non driveside...

Page 12: ...AWAT T B I K E G U I D E 2 0 2 2 1 2 Left Pedal Right Pedal Left Axle Right Axle F i t t i n g 1 Check the threads on your crankarm are clean and have no damage 2 Take your RIGHT pedal and grease the...

Page 13: ...t force the pedal into the crank 4 Take your LEFT pedal and grease the axle 5 Line the pedal up to the non driveside crank place your 8mm hex key through the non driveside crank and into the back of t...

Page 14: ...n 2 To get a starting point for your saddle height stand beside your bike and adjust the height to your hip bone 3 Sit on the bike with assistance from another person or leaning against a secure struc...

Page 15: ...each rider Good starting point is to have the saddle at horizontal and adjust as you spend more time on your bike 2 To lower the nose of the saddle loosen the rear bolt and tighten the front bolt To r...

Page 16: ...ed forward and backwards to suit the rider preference To adjust the saddle position the two clamp bolts need loosened Start in the middle of the adjustment range and with time on the bike move forward...

Page 17: ...h your authorised Nukeproof dealer to complete the work 1 Loosen and remove top cap bolt and cover with a 5mm Allen Key 2 Loosen both stem steerer clamp bolts with a 4mm Allen Key 3 Remove stem and pl...

Page 18: ...imple This guide will take you through the steps to make your bike tubeless Items Required Tubeless pump Tubeless Sealant Tubeless valves Tools to remove wheels Usually 5mm 6mm hex for thru axles Tyre...

Page 19: ...by taking the bead over the rim 7 Push the valve through the rim and remove the inner tube 8 Get your tubeless valve and get it ready to install At this point also double check that the tubeless tape...

Page 20: ...yre leave 1 4 open 13 Add tubeless sealant as per sealant manufacturer recommended amount 14 Finish fitting tyre Make sure the bead is pushed to the centre of the rim as this will make it much easier...

Page 21: ...instructions A couple of points to note It can take a couple of rides for the sealant to get fully around the tyre settle Don t be alarmed if you need to top up the air pressure a couple of times betw...

Page 22: ...G AWAT T B I K E G U I D E 2 0 2 2 2 2 likely to be an issue with the tape If the air is escaping at the valve then its getting past the tape somewhere and you will need to check your tape is not dama...

Page 23: ...d hubs until axle cannot be pushed further Tighten the Through Axle clockwise to the Nm found on the axle if no Nm is displayed please consult with your Nukeproof Dealer If the Through Axle is stiff w...

Page 24: ...n in the assembly guide Brake performance will vary with riding terrain and weather conditions familiarise yourself with your brakes performance in different conditions The gears on the bike are opera...

Page 25: ...familiarised with the controls and display H o w t o s w i t c h yo u M e g awat t O n O f f This part of the manual details how to operate the Shimano STEPS EP8 system installed to your Megawatt The...

Page 26: ...ss and hold the power switch until the screen goes blank Note It is good practice to turn the bike on with out having your foot on the cranks If you have your foot on the crank this can cause an error...

Page 27: ...and look under the downtube 2 Loosen the bottom left bolt on the battery door 1 full turn with your 4mm hex key 3 Loosen the bottom right bolt on the battery door 1 full turn using your 4mm hex key 4...

Page 28: ...M E G AWAT T B I K E G U I D E 2 0 2 2 2 8 7 The battery should be fully seated after you hear two clicks 8 Push the silver clip down to fully release the battery 9 Lift the battery out of the frame...

Page 29: ...condition and there is no damage to any part of it 11 Rotate the battery so that the locating plastic part on the mount lines up to the hole in the battery casing 12 Line the battery up and push into...

Page 30: ...2 0 2 2 3 0 15 Tighten the top bolt first using a 4mm hex key 16 Tighten the lower left bolt using a 4mm hex key 17 Tighten the lower right bolt using your 4mm hex key Your battery has now been refit...

Page 31: ...screen will turn on briefly load the Shimano STEPS logo and turn off Your Nukeproof Megawatt can be charged in two ways Battery in the bike Battery removed from the bike C h a r g e w i t h t h e b at...

Page 32: ...l socket and remove the charger 6 Ensure the charging port is in good condition 7 Refit the cover ensuring it is fully closed There is a separate how to guide showing the steps to removing your batter...

Page 33: ...e the light on the battery is illuminated When the battery is fully charged you can unplug everything then follow our separate how to guide to reinstall your battery Troubleshooting If you are having...

Page 34: ...ss can be done in reverse if you wish to go from 630WH to 504WH Tools required 3mm hex key 4mm key hex 6mm hex key Removal 1 Remove the top bolt on your battery door 2 Loosen the two bottom bolts 1 fu...

Page 35: ...the downtube 6 The battery mount can now be fully re moved from the frame 7 Turn the battery mount on its end and undo the 4 bolts highlighted in the photo 8 Remove this part of the bracket and keep b...

Page 36: ...he mount back in place 13 Refit the 4 bolts to resecure the bracket 14 Your mount should now be fully rebuilt and look like the photo 15 Put the battery mount back into the frame and loosely insert bo...

Page 37: ...T B I K E G U I D E 2 0 2 2 3 7 17 Insert the new battery ensuing that the battery is tight in the mount 18 Refit battery door by sliding over the two bolts and tightening then reinsert the top bolt a...

Page 38: ...G AWAT T B I K E G U I D E 2 0 2 2 3 8 H o w t o c h e c k b at t e ry l e v e l Switch on E Bike Battery level will be displayed on screen Number of Bars Range 5 100 81 4 80 61 3 60 41 2 40 21 1 20 1...

Page 39: ...select mode Eco Lowest power setting Trail Perfect for general MTB use and safest for steep descents A couple of turns of the cranks are required for the motor to provide assistance Boost Maximum and...

Page 40: ...ill enhance your Shimano STEPS EP8 experience The full manual for the Shimano E Tube app can be found at the following link for reference Shimano E Tube App E T u b e A p p The E Tube Project APP can...

Page 41: ...U I D E 2 0 2 2 4 1 3 You can now search for your Megawatt on the App 4 Once the bike has been found select Register 5 You can now add a 6 digit Passkey for your bike 6 Your bike is now connected and...

Page 42: ...WAT T B I K E G U I D E 2 0 2 2 4 2 7 Register as new bike and it will save your bike to your E Tube App 8 Your bike will now be stored on the E Tube App for firmware updates troubleshooting and adjus...

Page 43: ...e terrain The EP8 system also has two pre set profile assist settings you can choose from The power assist settings for Eco Trail and Boost can be adjusted in both profiles The Profile 1 assist is for...

Page 44: ...d Range Overview and Cadence Automatic Time Setting When turned on time will display as shown on connected phone or computer Manual Time Setting When Automatic Time Setting is off you can manually ent...

Page 45: ...y be cancelled during updates no other operations can be performed Do not update your firmware near other electronic devices to avoid disruption of wireless signal Do not update the firmware in an env...

Page 46: ...on the handlebar display The error codes will also be shown in Maintenance under the Error Log on the Shimano E Tube App The Shimano E Tube App will offer troubleshooting for any issues if an issue ca...

Page 47: ...or more assist switches connected to the system Not possible to shift gears with electronic derailleurs If this error appears consult your dealer W031 Chain tension may not yet be adjusted or installa...

Page 48: ...sist while riding Let your dealer configure motor unit so that total number of gears setting matches number of gears in internal geared hub E031 Chain tension may not yet be adjusted or cranks may not...

Page 49: ...ings as you ride to find what works best for you Before setting up your suspension please read the full manual for your shock and fork FOX provides a 4 digit Tune code or a QR code on their forks and...

Page 50: ...d size for the frame If a bearing end shock can be sourced this would be preferential to ensure the smoothest suspension action H a r d wa r e Front 25x8mm Rear 30x8mm T u n e When purchasing a new sh...

Page 51: ...l bump compliance with a strong Mid Stroke support for optimal cornering and pumping The Mid End of the stroke allows for more tuning options and a wide 30 35 range of usable SAG An Increased end stro...

Page 52: ...re able to do this due to the climbing assistance on an E Bike Higher anti Squat in the climbing gears which drops off to 52 in the descending gears The Megawatt remains true to our belief that a low...

Page 53: ...t of Anti Rise that tails off for bigger hits on the trail This allows some squat in the suspension when breaking hard into a corner allowing the rider to maintain his her position This allows the rid...

Page 54: ...E G U I D E 2 0 2 2 5 4 A x l e Pat h C u r v e The Megawatt s axle path moves rearwards for 50mm of travel SAG This prevents the rear wheel from hooking up on square edges and ultimately will help th...

Page 55: ...etailed as axle to crown A C cannot be exceeded Maximum A C for the Megawatt is 596mm Using a fork that exceeds the A C may lead to frame failure and injury Using a longer axle to crown fork will void...

Page 56: ...ot ride your bike Any unusual noises or creaks please have your bike inspected by a reputable mechanic and escalate to your dealer if needed Check all pivot points and bearings for signs of play any p...

Page 57: ...e bearings have perished or an adjustment is required To adjust the headset loosen the two stem steerer bolts tighten the top cap bolt and then retighten the stem steerer bolts again This will pull th...

Page 58: ...not remove the battery this will protect the connections between the battery and bike S e r v i c e L i f E Your bike is subject to wear and tear normal for all mechanical components The service life...

Page 59: ...ibility Your dealer and Nukeproof Bikes do not have an obligation to keep a record of this number Please take a note of the number for insurances and theft prevention purposes In the unlikely case you...

Page 60: ...6 Recommended Shock Sag 30 35 Measured seated Shock Size 230x62 5mm Shock Hardware F 25x8mm Shock Hardware R 30x8mm Sizing S M L XL XXL Headtube 56 66mm Tapered Semi Intergrated Headset ZS56 28 6 ZS66...

Page 61: ...e Height at Saddle Offset 650 700 750 800 850 H Saddle Offset at Saddle Height 139 98 156 36 163 32 178 84 194 35 I Headtube Length 115 115 120 130 140 J Headtube Angle 64 64 64 64 64 K Chainstay Leng...

Page 62: ...25 10 8 28 9 8 7 28 27 11 7 8 28 28 8 9 10 3 4 5 2 6 27 24 25 12 27 11 13 14 26 26 23 B 32 A Shock Bolt Kit Bearing Kit Horst Link Kit Main Pivot Kit Upper Swing Link Kit Lower Swing Link Kit Cable Gu...

Page 63: ...M E G AWAT T B I K E G U I D E 2 0 2 2 6 3 18 20 22 16 16 15 16 21 19 18 18 17 17 17 17 30 17 31 30 31 33 33 C D E 33 33 33 34 33...

Page 64: ...M11B Battery Mount Bolt 4 18 M4x8L M11B Cable Guide Bolt 3 19 VT9A CGB A Upper Internal Cable Guide 1 20 VT9A CGB B Lower Internal Cable Guide 1 21 VT9A BTH A Upper Battery Mount 1 22 NP9A BTH B R2 L...

Page 65: ...E 2 0 2 2 6 5 T O R Q U E A N D G R E A S E D I A G R A M S Note Use medium strength threadlock We recommend Loctite 243 Recommended Torque Values Torque Battery Door Bolts 2Nm Battery Mount Bolts 7Nm...

Page 66: ...e recommend Loctite 243 Recommended Torque Values Torque Shock Bolts 15Nm Upper Swing Link 14Nm Lower Swing Link 19NM Main Pivot 19Nm Horst Link Bolts 12Nm Cable Guides 3NM Recommended Torque Values T...

Page 67: ...M E G AWAT T B I K E G U I D E 2 0 2 2 6 7 Grease...

Page 68: ...16 https nukeproof com collections bikes spares megawatt products megawatt bat tery door kit Part Shared with Mega 2021 Diagram Number Product Page Horst Link Kit 7 8 9 10 https nukeproof com collect...

Page 69: ...ult please contact an authorised Nukeproof dealer for warranty assistance If any parts are damaged accidentally or the result of a crash a Shimano STEPS dealer can assist with replacement parts Shiman...

Page 70: ...re clearance 2 6 Rockshox ZEB max tyre clearance 2 8 M a x i m u m A x l e t o C r o w n a n d T r av e l o f f o r k The fork length also detailed as axle to crown A C cannot be exceeded Maximum A C...

Page 71: ...liar with your bike its handling and capabilities before riding off road Ensure the location you are riding is legal you have a right to ride there and no laws are being broken Ensure you are wearing...

Page 72: ...se bursting or ignition Do not deform modify disassemble or apply solder directly to the battery Doing so may cause leakage overheating bursting or ignition Do not connect the terminals with metallic...

Page 73: ...se the battery charger at the specified power supply voltage only If a power supply voltage other than that specified is used fire destruction smoke overheating electric shocks or burns may occur Use...

Page 74: ...ginal warranty period and subject to the conditions outlined in the original warranty This limited warranty does not cover items used in rental operations or any defect caused by wear and tear acciden...

Page 75: ...al Nukeproof warranty claim form a letter or suitable document must be provided containing all of the following information Customer details Full name Order reference or copy of shop receipt with stor...

Page 76: ...cut off at 15 5mph E Bike users must be 14 years and over EN15194 bikes are except from MOT Vehicle Tax Licence T h i r d Pa r t y Wa r r a n t y Please familiarise yourself with the respective manufa...

Page 77: ...TA I N I N G R E C O R D S O F T E S T R E S U LT S I S I N C L U D E D B E L O W C O M P L I A N C E D E P T W I G G L E LT D 1 0 0 0 L A K E S I D E S U I T E 3 1 0 T H I R D F L O O R N E W I N G P...

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