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EVO ALLOY

USER MANUAL

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Summary of Contents for EVO ALLOY

Page 1: ...EVO ALLOY USER MANUAL ...

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Page 3: ...P I V O T A S S E M B LY 1 1 5 1 BEARING ASSEMBLY 11 5 2 PIVOT ASSEMBLY 13 5 3 SUSPENSION TORQUE SPECIFICATIONS 17 6 I N T E R N A L R O U T I N G 1 7 6 1 DROPPER SEATPOST 17 6 2 REAR DERAILLEUR AND REAR BRAKE 19 6 3 REAR BRAKE CABLE BAT 22 7 F L I P C H I P S H E A D S E T C u p s 2 2 7 1 ADJUSTING THE HORST PIVOT FLIP CHIP 23 7 2 ADJUSTING THE HEAD TUBE ANGLE 23 8 A I R S H O C K S E T U P 2 7 8...

Page 4: ... 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 always repeat the warning of possible injury or death CAUTION The combination of the safety alert symbol and the word CAUTION indicates a potentially hazardous ...

Page 5: ...A D S E T The headset uses a 1 1 8 41 8 mm x 30 5 x 8 mm 45 x 45 Campagnolo Standard compatible upper bearing and a 1 5 52 mm x 40 x 7 mm 45 x 45 lower bearing Ensure that replacement bearings are compatible with the Specialized headset specification No tools are needed for installation or removal of both bearings Grease bearing surfaces before installation 2 2 S E A T P O S T SEATPOST MINIMUM INS...

Page 6: ... E U R H A N G E R TheStumpjumperEvoAlloyframeusestheSRAMUDH UniversalDerailleurHanger attherear dropout ThishangermustbeinstalledfollowingSRAM sinstallationinstructions Pleaserefertothe installationstepsinsection9 orrefertotheSRAMUDHUserManual 2 6 S T E M Some Stumpjumper Evo Alloy models are equipped with an Alloy Trail Stem WARNING The trail stem is designed with no gap between the stem body an...

Page 7: ...hipping bending or any other signs of damage Do not ride if your bicycle shows any of these signs After any crash and before you ride any further take your bicycle to an Authorized Specialized Retailer for a complete inspection While riding listen for any creaks as a creak can be a sign of a problem with one or more components Periodically examine all surfaces in bright sunlight to check for any s...

Page 8: ... WARNING Failure to follow the instructions in this section may result in damage to the components on your bicycle and will void your warranty but most importantly may result in serious personal injury or death If your bicycle exhibits any signs of damage do not use it and immediately bring it to your Authorized Specialized Retailer for inspection WARNING When placing the frame and or bicycle in a...

Page 9: ... as shipped Visit www specialized com for all possible geometry configurations 4 2 G E N E R A L S P E C I F I C A T I O N S ITEM PART SPECIFICATION HEADSET S182500005 SPECIALIZED INTEGRATED 1 1 8 UPPER 1 1 2 LOWER SEAT COLLAR S184700004 SPECIALIZED SL SEAT COLLAR KCNC SPL SC02 38 6 SEAT COLLAR DIAMETER 38 6 MM SEATPOST DIAMETER 34 9 MM DERAILLEUR HANGER S202600002 SRAM UDH 00 7918 089 000 BOTTOM ...

Page 10: ...ermarket parts may negatively impact geometry and or ride quality and in some circumstances may result in a catastrophic failure of the frame or its components Please check with your Authorized Specialized Retailer or suspension manufacturer regarding aftermarket fork compatibility 4 3 S H O C K C U S T O M I Z A T I O N Specialized frames are generally designed and tested to work with the suspens...

Page 11: ...R INSIDE DO PIVOT SPACER GEO ADJ M6 X 1 G 4 HORST PIVOT OUTER SPACER HORST PIVOT OUTER SPACER ASSY 12 X 21 X 2 5 H 2 HORST PIVOT CENTER SPACER SPCR STEP 6 MM ID X 16 MM OD X 16MM W 7075 T6 I 2 MAIN PIVOT SPACER SPCR 15 1 ID X 21 5 OD X 2 5 W FSR AL7075 J 1 MAIN PIVOT BOLT DS LEFT HAND THREAD SCR ASSY CUST OD 15 X M14 X 1 7075 LH BLK 6 MM HEX 210 24 K 1 MAIN PIVOT BOLT NDS SCR ASSY CUST OD 15 X M14...

Page 12: ...9 M N R R N B M N B B A I A I N M B M B G C C G H G C H C G B 4 1 EXPLODED VIEW BEARINGS SPACERS ...

Page 13: ...10 Q S V P L P O L U V T O Q J K D E F F E D 4 2 EXPLODED VIEW BOLTS ...

Page 14: ...inst the frame or stay Check the expiration date on your Loctite Do not use expired Loctite Apply green Loctite 603 to all the bearing bore interface surfaces then press all the bearings into their respective pivot locations Even though all pivot bolts are factory treated with a blue threadlocker band make sure to complete the following steps in this order Apply and spread a thin layer of liquid b...

Page 15: ...ND SPACERS Fig 5 3 Place the spacer into the bearing hole from the outer side of the chainstays Insert the bearings from both sides of the chainstay sandwiching the spacer in the center N M B B M M B B M R B R B N N 5 2 LINK BEARINGS AND SPACERS ...

Page 16: ...e a 6 mm hex key to torque the bolts to 180 in lbf 20 Nm During assembly place a folded paper towel or clean rag between the link and the frame to prevent damage 5 2 P I V O T A S S E M B L Y EXTENSION SHOCK V V U T 5 4 Fig 5 4 Insert the top hat spacers into the rear shock eyelet Align the shock eyelet with the extension hole then install the bolt Do not torque the lower shock eye bolt until the ...

Page 17: ...y to torque the bolts to 90 in lbf 10 Nm LINK EXTENSION P N N O N N P 5 7 Fig 5 7 Grease then place the extension spacers into the link bearings Align the extension with the extension bearings Grease then insert the extension axles into the pivot bore Grease then thread the extension bolts into the extension axles Use a 5 mm and 4 mm hex key to torque the bolts and axles to 60 in lbf 7 Nm ...

Page 18: ... DROPOUT D D E G G F F G G E 5 8 Fig 5 8 Grease then place all the inner spacers x4 against the Horst link bearings tapered surface against the bearing Align the flip chip spacers in either high or low position and place them against the frame The chainstay protector must be assembled prior to installation With the flip chips assembled install the bolts Make sure both drive side and non drive side...

Page 19: ... the pivot bolts Use a 6 mm hex key to torque the bolts to 210 in lbf 24 Nm The drive side bolt is a left hand thread LOWER SHOCK EYELET BOLT T 5 11 Fig 5 11 Once all pivot locations are assembled and torqued to specification torque the lower shock eyelet bolt Use a 6 mm hex key to torque the bolts to 180 in lbf 20 Nm When torqueing the rear shock eye bolt use a long reach hex bit to avoid damagin...

Page 20: ...and ICR tube that is long enough to reach from the headtube guide to the top of the seattube when routed through the frame 5 3 S U S P E N S I O N T O R Q U E S P E C I F I C A T I O N S 6 7 2 1 3 4 5 5 12 NON DRIVE SIDE DRIVE SIDE PIVOT LOCATION TOOL in lbf Nm 1 MAIN PIVOT 6 mm HEX 210 24 2 LINK SEAT TUBE 6 mm HEX 180 20 3 LINK SEATSTAY 6 mm HEX 180 20 4 LINK EXTENSION 4 5 mm HEX 60 7 5 DROPOUT H...

Page 21: ...ube If the brake and shift housings are already installed make sure to route the seat post tube toward the drive side of the cable funnel Once the housing sticks out of the top of the seat tube grab both ends of the housing and gently work the nylon tube through the frame until the cable guide is in place Remove the section of scrap housing Using a 2 5 mm hex key install the cable guide screw to 1...

Page 22: ...ainstay Gently push and twist the housings until they exit the chainstay near the main pivot Wind the end of the housing not being inserted into the frame into a loop to help twist it through the chainstay A B C D 6 4 Fig 6 4 Assemble SWAT door Insert the foam gasket A into the bezel B so the inner lip of the bezel is fully visible and the gasket is fully seated Install the bezel onto the frame In...

Page 23: ... the base of the side arm B and guide it out with a hook or L pick through the hole in the base of the side arm A B 6 7 Fig 6 7 Guide the shift housing and brake hose up the side arm through the sidearm loop B and into the top tube Remove the non drive side ICR cable guide A from the ICR port near the head tube with a 2 5 mm hex key Guide the shift housing and brake hose out of the non drive side ...

Page 24: ...8 MM 6 8 Fig 6 8 Slide an 8 mm foam rattle prevention tube onto the shift housing A and an 11 mm foam rattle prevention tube onto the brake hose B then slide them individually into the frame Slide the cable guide onto the shift housing and brake hose in any orientation you prefer Press the guide in the port and insert the screw Using a 2 5 mm hex key torque the bolt to 13 2 in lbf 1 5 Nm Apply a s...

Page 25: ...ore making any modifications For information on the geometry when adjusting the flip chips visit www specialized com 6 3 R E A R B R A K E C A B L E B A T 6 10 Fig 6 10 OUTSIDE BANJO CALIPERS Position the seat stay brake housing clip so that it is perpendicular to the tube and the housing is above in front of the bolt Ensure that the housing has a natural loop curvature between the seat stay and c...

Page 26: ... via adjustable headset cups The bike ships with the zero offset cup A installed and a 1 degree headset cup B ships in the small parts box 7 1 A D J U S T I N G T H E H O R S T P I V O T F L I P C H I P A B A B 7 1 LOW HIGH Fig 7 1 Remove the Horst pivot bolt from the frame A Remove all four flip chips B and align the Horst pivot spacer in the slot to either high or low position When replacing the...

Page 27: ...ree headset cup A D E C A B 7 3 Fig 7 3 Loosen the stem bolts A that attach it to the fork steerer Loosen and remove the top cap bolt B Remove the stem C from the fork steerer tube D and remove the fork from the frame E Choose the headset cup and position Fig 7 2 for the rider s desired geo ...

Page 28: ...n aligning the headset cup the etching that is at the front of the bike indicates which setting you are in Make sure the head tube and headset cup are free of dirt and debris when changing the upper cup angle Lubricate all the parts with high quality waterproof grease The bottom headset cup is used for all options of adjustability The cup has a spherical interface with the headtube and will move w...

Page 29: ...round pull the front brake and rock the bike back and forth to ensure the headset is fully seated and that there is no looseness in the system Recheck the system to ensure it is assembled per the above instructions then torque the stem to the manufacturer s recommendations Wipe off any excess grease and clean with isopropyl alcohol to prevent dirt accumulation ADJUSTMENT POINT CHAINSTAY LENGTH BOT...

Page 30: ... RING Fig 8 1 To check the sag push the o ring against the seal A then mount the bicycle while propped up against a wall and sit in the saddle in a normal riding position without bouncing the suspension Do not set sag while riding Check the sag by measuring the distance between the shock seal and the o ring B Once the sag is close to the desired setting increase or decrease the pressure as needed ...

Page 31: ...tab Do NOT apply grease to the frame UDH hanger or UDH bolt threads Apply grease ONLY to the thru axle threads The hanger must be completely seated in the hanger pocket or against the frame stop tab when tightened to the specified torque 8 MM 9 3 9 4 Fig 9 3 InstalltheUDHwasher thenthreadtheUDHboltthroughthewasherandintothehanger Fig 9 4 Tighten the bolt to 221 in lbf 25 Nm The UDH hanger bolt is ...

Page 32: ...ROTECTOR S206500014 CBG MY21 SJ ALLOY SIDEARM WITH BOLTS S206500012 CBG MY21 SJ ALLOY CABLE FUNNEL AT BB AREA AND CHAINSTAY WITH BOLTS S206500013 CBG MY21 SJ ALLOY HEADTUBE ICR CLIP WITH BOLTS S200600004 BRG MY21 SJ ALLOY BEARING KIT S201500007 CHS MY21 SJ ALLOY CHAINSTAY SATIN BLACK SMOKE S205000004 STS MY21 SJ ALLOY SEATSTAY SHORT FOR S1 S4 SATIN BLACK SMOKE S205000003 STS MY21 SJ ALLOY SEATSTAY...

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