Crankbrothers Highline Seatpost User manual

TECHNICALMANUALS
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WARNING!
WARNING!
Tool List:
Shop Rag
24mm Open Face Wrench
2.5mm Hex Key
3mm Hex Key
5mm Hex Key
Tape
Loc-tite 242
Highline Refresh Kit (99151)
Box Cutter
Rubber (optional)
450 Hour Maintenance / Overhaul
Highline Refresh Kit Contents: Part No. 99151
Rev. A - 3.7.18
Highline Seatpost
Seal / Collar
Assembly
Upper Igus Bearing
Grease Packet
x1
x1
x1 x1
x2
Igus Guide
Blocks Lower Igus Bearing
parts + accessories

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Disassembly
Loosen the front and back bolts of the quick release head
assembly using a 5mm hex wrench.
Swing the back bolt out of the slot
in the head of the quill, and then
rotate the saddle forward to remove
it.
Remove the lower cradle, clean
and set aside.
Prior to starting, note the saddle position on the rails and seatpost height in frame.

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Remove the cartridge screw from the top of the quill head using a
2.5mm hex wrench. Clean and set aside
Turn the barrel adjuster in at the
lever to remove cable tension.
Using a 3mm hex wrench, unthread
the remote lever clamp screw and
open the lever’s hinge to remove it
from the handlebars.

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Slide the post out of the frame while pushing the housing through
the frame at the same time.
Apply a large piece of tape to
the cable housing. This will hold
the actuator housing lockring in
place and prevent it from
dropping into the frame when
it is removed in the next step.

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Using your hand, unthread the actuator housing lockring from the
bottom of the outer body. Do not use pliers for this step! If necessary,
use a piece of inner tube to achieve better grip on the lockring.
The tape will hold the lockring in place as the service is performed
Wiggle and pull down on the
actuator housing to remove it
from the bottom of the seatpost.
Be careful not to twist the
actuator housing as this can
damage the cartridge or affect the
clocking. Again, use a piece of
inner tube to obtain a better grip
on the actuator housing. Do not
use pliers for this step!
Unthread the base cap of the
seatpost using a 24mm or
adjustable wrench.

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Push down on the quill head to expose the cartridge for removal.
Wiggle and pull down on the cartridge to remove it from the quill.
You may experience some resistance which is normal.
Remove the bottom out O-ring from the cartridge or outer body.
Clean and set aside.

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Unthread the seal ring assembly
from the outer body. If necessary,
use a piece of inner tube for
better grip. Do not use pliers
for this step!
Pull the quill assembly out of the
outer body.
Using a flat blade knife, gently
pry out both Igus keys from the
channel and discard.
Remove the lower Igus bushing.

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Remove the upper Igus bushing. Slide the seal ring assembly off
the quill and discard.
Wipe off the quill and the inside of the outer body using a cleaning
rag. Never use solvents or degreasers on these parts in order to
prevent damage to the anodized finish.

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Gently install the new seal ring assembly. Be careful not to force the
seal over the lower bushing channel. Walk the seal lip over the edge
at an angle to prevent damage to the seal.
Using the provided grease (Slick Honey works as well) apply small
amount to the lower bushing channel. Install the new upper and
lower Igus bushings.
Assembly
Prior to starting, make sure all parts are clean of dirt and debris.

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Apply a small amount of grease to the two key channels of the quill. Insert the new Igus keys into the channel and if necessary, tap lightly
with a hammer to fully seat the keys into the groove.

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Using the remaining grease in the packet, coat evenly the lower surface of the quill, bushings and keys approximately 10mm above the keys.

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Insert the quill assembly into the outer body. Be sure to align the
Igus keys with the alignment channels inside the outer body before
applying force. Note: The orientation of the body graphics is not
critical but the height markings are intended to face forward. The
slotted portion of the quill head will face the rear when installed
onto the bike.
Lower the seal ring on the quill
and lightly thread the assembly
onto the outer body. Do not
tighten firmly at this time!
Install the bottom out O-ring over
the cartridge and position evenly
on the top of the base cap.
Alignment
Channel

Thread the cartridge base cap into the outer body; be careful not to
damage the bottom out O-ring. Tighten the base cap to 12 Nm using
the 24mm or adjustable wrench.
Apply one drop of 242 (blue) threadlocker to the cartridge screw
threads. Install the cartridge screw into the quill head and thread
into the cartridge with the 2.5mm hex wrench. Tighten to 2Nm.
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Lightly grease the actuator O-ring. Align the actuator screw with the
cartridge valve adapter (figure A) and insert the actuator assembly into
the base cap of the seatpost by wiggling and pressing inward. Be
careful not to twist the actuator housing as this can damage the
cartridge or affect the clocking. Again, use a piece of inner tube to
obtain a better grip on the actuator housing. Do not use pliers for
this step!
Lightly rotate the actuator body so the ledge on the actuator lines up
with the arrow on the base cap decal. Note: Adjusting the actuator
correctly is very critical. If the actuator is not clocked properly, the post
may not function as intended. (Figure B)
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Figure A
Figure B

Thread the actuator lockring onto the base cap and tighten
firmly by hand. Make sure the actuator is locked into position
and cannot move if twisted. If the actuator can still move, use
the piece of inner tube to grab the lockring and tighten securely.
Do not use pliers for this step. Note: Be careful not to rotate
the actuator housing while tightening the lockring!
Remove the tape on the cable housing.
Insert the seatpost into the frame while simultaneously moving the
cable housing in the same direction. Be sure to move them evenly
to prevent kinks or sharp bends in the housing. Lower the post to
the height as noted prior to removal.
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Tighten the seatpost collar per
manufacturer’s instructions.
Never exceed 7Nm!
Position the upper cradle above the saddle rails. Place and hold the lower cradle on the quill head so that
the longer section of the cradle faces the rear of the bike. Rotate the saddle onto the lower cradle and swing
the back bolt into the slot of the quill head.
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Secure the saddle into the position as noted prior to removal. Make
sure the cradle washers are aligned with the cupped section of the
quill head. Using the 5mm hex, tighten each bolt evenly to 7Nm.
Install the remote lever onto the
handlebar into the desired
position. With the 3mm hex,
tighten the clamp screw to
2.5Nm.
Activate the remote lever and
lower the saddle half way down.
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While remaining compressed, tighten the seal ring assembly firmly by
hand. If necessary, use a piece of inner tube for better grip on the
collar. Do not use pliers for this step!
Test the post for proper function. If you experience any malfunction,
refer to our Troubleshooting Guidelines for assistance.
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