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ViAS VENGE, Instruction Manual

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ViAS VENGE Instruction Manual Download Page 15

12

A. INSTALLING BRAKE / SHIFTER HOUSINGS IN FRAME (

electronic)

ELECTRONIC WIRING LENGTH CHART

WIRING LOCATION

WIRING LENGTH

WIRING LOCATION

WIRING LENGTH

Front Derailleur

500mm

Shifters (x2)

350mm

Rear Derailleur

700mm

Down Tube

1200mm

Battery (Seatpost)

1000mm

 

„

FACTORY ROUTING: 

Junction B inside handlebar, junction A under bottom bracket 

A

.

1

BROWN: 

Electric wiring (ED)

A

RED: 

Rear Brake (RB)

B

 

„

Fig.1:

 Install a section of brake housing 

B

 (see chart on page 10 for specific housing 

length), starting at the rear brake exit port. It helps to give the cable housing a slight bend 
before feeding it into the seat tube exit port. Continue to run the housing into the frame until it 
becomes visible at the head tube, then guide it out the top of the head tube.

2

C

D

E

F

G

Fig.1 & 2:

 Route the wires through the chainstay 

C

, seat tube (battery 

D

 and front derailleur 

E

) 

and down tube 

F

, over/in front of the bottom bracket, then connect the wires to the junction A box. 

Use the BB guide door 

G

 designed specifically to contain the junction A box.

Summary of Contents for VENGE

Page 1: ......

Page 2: ......

Page 3: ...enance When reading this instruction guide you will note various important symbols and warnings which are explained below WARNING The combination of this symbol and word indicates a potentially hazardous situation which if not avoided could result in serious injury or death Many of the Warnings say you may lose control and fall Because any fall can result in serious injury or even death we do not ...

Page 4: ...EMBLY 19 A PREPARING FACEPLATE 19 MECHANICAL SHIFT SETUP 20 B INSTALLING HOUSINGS IN HANDLEBAR mechanical 20 C CONNECTING HANDLEBAR TO STEM mechanical 21 D INSTALLING STEM ON STEERER TUBE mechanical 23 ELECTRONIC SHIFT SETUP 24 B INSTALLING STEM ON STEERER TUBE electronic 24 C INSTALLING HOUSINGS IN HANDLEBAR electronic 25 D CONNECTING HANDLEBAR TO STEM electronic 26 E ROUTING BRAKE CABLES TO BRAK...

Page 5: ...orce on fasteners nuts bolts screws on your bicycle is important If too little force is applied the fastener may not hold securely If too much force is applied the fastener can strip threads stretch deform or break Either way incorrect tightening force can result in component failure which can cause you to lose control and fall Where indicated ensure that each bolt is torqued to specification Afte...

Page 6: ...t sunlight to check for any small hairline cracks or fatigue at stress points such as welds seams holes and points of contact with other parts If you hear any creaks or discover any cracks no matter how small immediately stop riding the part and have it inspected by your Authorized Specialized Retailer WARNING Great care should be taken to not damage carbon fiber or composite material Any damage m...

Page 7: ...k options 6 5 75 5mm in 5mm increments Stem length 7 options 70 85 95 105 115 125 135mm Handlebar rise 8 options 0 25mm rise x 38 40 42 44cm width Seatpost length setback 6 options 330 380mm length x 0 20 35mm setback STEM TOP CAP S164800008 VENGE STEM 70mm S164800013 85mm S164800014 95mm S164800015 105mm S164800010 115mm S164800011 125mm S164800012 135mm S164800016 STEM SHIM MECHANICAL SHIFT S164...

Page 8: ...EIGHT 16 5mm S162500010 VENGE AEROFLY HANDLEBAR 0mm RISE 38cm S160800008 40cm S160800001 42cm S160800002 44cm S160800003 VENGE AEROFLY HANDLEBAR 25mm RISE 38cm S160800007 40cm S160800004 42cm S160800005 44cm S160800006 LOW STACK Choose the LOW STACK TOP CAP S162500022 6 5mm tall Add either one or two 5mm low stack spacers HIGH STACK Choose the HIGH STACK TOP CAP S162500010 16 5mm tall and the HIGH...

Page 9: ...on the fork Fig 2 Install the fork in the head tube Fig 3 Install the upper bearing B S162500005 Fig 3 Install the compression ring C S162500002 or S162500004 Brake guide back Mechanical S164800001 Electronic S164800002 Shim slot front 4 Fig 4 Install the stem shim D S164800001 or S164800002 into the stem Make sure the etchings are on top and the arrow is pointing toward the front of the bike ...

Page 10: ...X X X X X 70 5mm X X X X X 75 5mm X X X X X X Specialized recommends using a stationary trainer and working with an experienced fit professional Since the fork must be cut to the correct height before the bike can be built and ridden determining the proper fit is more important than with a traditional bike To help transfer measurements from a current bike use the Venge ViAS Sizing tool located at ...

Page 11: ...ired position rotate the faceplate downward so that there is no gap between the faceplate and the stem body at the underside of the stem The gap should only be above the handlebar Torque the stem bolts to 100 in lbf 11 3 Nm If the faceplate is not bottomed against the lower edge of the stem the faceplate and handlebar can rotate downward under rider weight until the faceplate bottoms out against t...

Page 12: ...pposite side outer cap and thread into the nut Tighten lightly Remove all burrs and square edges from the seat tube and seatpost surfaces in contact each other These edges and burrs can dig into the material compromising the strength of the carbon Remove any grease from the internal surface of the seat tube Composite seatposts are non metallic and cannot seize in the seat tube Applying grease redu...

Page 13: ...nue to run the housing up the down tube until it exits at the head tube Fig 1 REAR DERAILLEUR Slightly curve the leading edge of a section of shift housing B see chart above for recommended housing length then insert the housing into the chainstay Route the housing over the bottom bracket shell and up the down tube until it exits at the head tube Fig 1 FRONT DERAILLEUR Install a section of shift h...

Page 14: ...o the upper headset bearing then seat the compression ring into the upper bearing Fig 5 Trim the front derailleur housing A so that 105 115mm of housing exits at the bottom bracket cable guide port Fig 5 Insert the front derailleur housing into the housing guide B at the bottom bracket Avoid tugging on the housings to seat the compression ring Fig 4 Too hard of a tug will pull the housings out of ...

Page 15: ... of brake housing B see chart on page 10 for specific housing length starting at the rear brake exit port It helps to give the cable housing a slight bend before feeding it into the seat tube exit port Continue to run the housing into the frame until it becomes visible at the head tube then guide it out the top of the head tube 2 C D E F G Fig 1 2 Route the wires through the chainstay C seat tube ...

Page 16: ...the bottom bracket then connect the wires to the junction B box Place the junction B box into the down tube then install the BB door 5 Fig 5 Apply grease as illustrated to the upper headset bearing then seat the compression ring into the upper bearing Fig 5 Place the brake housing and shift wire into their respective slots in the compression ring Fig 5 Grease then place the compression ring into t...

Page 17: ...en place a barrel adjuster C onto the exposed section of housing Fig 2 Insert another section of cable housing into the barrel adjuster then trim the housing so that the overall length exiting the seat tube exit port is 130mm Fig 2 Install a brake cable sheath D into the housing slot of the non drive side brake arm Fig 2 Insert the end of the brake cable housing into the brake arm s housing slot M...

Page 18: ...that when installed the top of the expander plug is 0 3mm C below the top of the shim The expander plug lip is 1mm thick B If the steerer tube extends above the shim it can result in contact between the expander plug and the stem cap which can prevent proper headset adjustment Inspect the fork and stem to ensure that there are no burrs or sharp edges that can damage the surfaces in contact with ea...

Page 19: ...to the fork starting at the exit port hole at the drive side front brake mount location Work the cable up into the fork crown and up the steerer tube Fig 2 Once the cable exits the fork out the top of the steerer tube pull on the cable exiting the top of the steerer tube to pull the housing into the fork Fig 3 Once the housing extends past the top of the steerer tube remove the cable from the insi...

Page 20: ...the expander plug into the cut steerer tube Fig 7 While pressing the expander plug into the steerer tube lightly pull on the cable housing from the brake exit port to help guide the housing through the fork and prevent any kinks from forming in the housing 8 Align PointR tool toward front of bike E F G 9 Align PointR tool toward front of bike The PointR tool E is a long custom Allen key designed t...

Page 21: ...nder plug bolt The PullR tool is a custom tool designed to thread into and remove the expander plug Thread the PullR tool into the upper wedge until it bottoms out in the expander plug then turn the lever clockwise to pull the upper wedge out of the expander body Once the upper wedge is removed the expander sleeve can be removed as well If the system is fully installed and the steerer tube needs t...

Page 22: ...unt bracket S169900005 Fig 1 or with a flush mount faceplate cap Fig 2 1 Garmin mount Garmin bracket Faceplate Standard bracket Di2 bracket 2 Faceplate Faceplate cover The Garmin mount can be installed with or without a Shimano Di2 junction box When using a Shimano Di2 junction box use the Di2 bracket To install the Garmin mount bracket unscrew the two screws on the inside of the faceplate then re...

Page 23: ...e clean cut with no metal burrs and that the inner sheaths have been fully opened using a pick or other narrow object Move the levers back into the desired position seat the housings in the levers then tighten the levers to the manufacturer s torque specification Fig 1 Trim each section of exposed cable housing E F according to the housing length chart below Install the brake and shifter cables in...

Page 24: ...rt each brake cable and housing into the cable guide assembly until fully seated 3 Fig 3 Run the cables into the stem body then guide the cables through their respective channels stem shim channels Fig 6 page 22 until the shift cables exit the bottom of the stem and the brake cables exit the top of the stem Gradually guide the stem over the cable guide assembly and the cable housings As the guide ...

Page 25: ...lebar The bolts can be positioned above or below the housings Fig 5 Before tightening the bolts align the handlebar rotation position as outlined in Chapter 1 Section A DETERMINING FIT page 6 and make sure it s centered left to right then tighten the stem faceplate bolts to 100 in lbf 11 3 Nm 6 Sheath flange Sheath Fig 6 Once the handlebar and stem are assembled the shift cable sheaths will extend...

Page 26: ...e steerer tube The spacers are keyed to ensure alignment with the compression ring and the stem Fig 1 Guide the shift cables coming out the bottom of the stem through the opening between the spacers and the steerer tube and into the two outer holes in the compression ring Continue to guide the shift cables down into the cable housings inside the frame until the cables exit at the derailleurs and t...

Page 27: ...sion ring and the stem Fig 1 Place the wire in the shim s wire channel the shim in the stem then the stem on the steerer tube 2 D A B Fig 1 2 Route the wire through the stem hole located above and in front of the shim then out the front of the stem Fig 2 Assemble the shift and brake parts of the cable guide assembly A S164800003 using a M3 x 0 5mm x 8mm countersunk Allen bolt B and 2mm Allen key 3...

Page 28: ... into the handlebar see chart page 12 for wiring lengths until they exit out the front hole of the handlebar FACTORY ROUTING Connect the wires to the Junction B box F in front of the handlebar ALTERNATE ROUTING Route the wires in front of the handlebar but do not plug in yet Route a section of brake housing C D into each side of the handlebar until they exit the slot at the stem clamp area Make su...

Page 29: ...dlebar holes and in front of the handlebar along with the two shift wires Fig 2 Continue pulling the brake cables out the top of the stem while guiding the handlebar toward the stem clamp until the housings are seated into the brake cable guide stops FACTORY ROUTING With the handlebar positioned against the stem place the junction B box inside the handlebar 3 Di2 wires to Junction A box Junction A...

Page 30: ... bolts can be positioned above or below the housings Fig 4 Before tightening the bolts align the handlebar rotation position as outlined in Chapter 1 Section A DETERMINING FIT page 6 and make sure it s centered left to right then tighten the stem faceplate bolts to 100 in lbf 11 3 Nm E ROUTING BRAKE CABLES TO BRAKES 1 B A S160700006 Rear brake noodle Ferrule Sheath flange Into stem cable guide S16...

Page 31: ... rear brake noodle starts to curve downward toward the shim place the ferrule into the channel in the stem shim until it bottoms out against the small step 4 Shim arrow Expander arrow Expander mark Front brake Rear brake A B Fig 4 Guide the front brake cable into the front brake cable guide hole B inside the upper wedge of the expander plug Continue to guide the front brake cable into the correspo...

Page 32: ...que the stem bolts to 45 in lbf 5 1 Nm 5 BRAKE ADJUSTMENT A ADJUSTING FRONT BRAKE FRONT NARROW REAR NARROW FRONT WIDE REAR WIDE S169900003 Left S169900006 Right S169900012 Left S169900011 Right S169900004 Left S169900007 Right S169900013 Left S169900014 Right Rim width 19 26mm Rim width 19 26mm Rim width 24 30mm Rim width 24 30mm Choose the appropriate brake pad holders based on the width of the r...

Page 33: ...ing the brake cable through the non drive side cable retainer loop then guide the brake cable sheath through the drive side cable retainer loop Place the sealing grommet on the sheath Fig 4 Insert the brake cable through the cable pinch bolt E Torx T10 then pull the cable tight so that the brake provides the desired amount of brake lever throw Make sure the cable release dial is in the engaged clo...

Page 34: ...to 45 in lbf 5 1 Nm The headset cable housings and noodles may reseat themselves slightly This may require that the brakes be readjusted several times until everything is fully seated B ADJUSTING REAR BRAKE Follow the same installation steps as in Chapter 5 Section A ADJUSTING FRONT BRAKE page 29 The only difference is how the brake cable is secured to the drive side brake arm 1 Fig 1 Place the ca...

Page 35: ......

Page 36: ...SPECIALIZED BICYCLE COMPONENTS 15130 Concord Circle Morgan Hill CA 95037 408 779 6229 ...

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