DEVIATE highlander 150 User manual

User Manual:
cycles
2022
150

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TABLE OF CONTENTS
SAFETYINSTRUCTIONS..........................................................................................3
Bicycle Safety ......................................................................................................3
Usage ...................................................................................................................3
Enviornmental .....................................................................................................3
Protective Equiptment ........................................................................................3
Suspension ..........................................................................................................4
Pre-ride Checks ..................................................................................................4
Entrapment ..........................................................................................................4
Luggage and Child Seats Or Carrier ........................................................... 4
Permissable Weight ...........................................................................................4
Public Roads .......................................................................................................4
ASSEMBLY...............................................................................................................5
Parts Specific Standards ...................................................................................5
Seat Post Dropper Cable .................................................................................5
Top Tube Cable Guides ....................................................................................5
Shock Fitment ......................................................................................................6
Bottom Bracket Washer ....................................................................................6
MAINTENANCE.......................................................................................................6
Service Intervals .................................................................................................6
Bolt Torque Summary ........................................................................................7
PARTS LIST.............................................................................................................7
Quick Reference Spares ....................................................................................7
DIAGRAMS.............................................................................................................8
Front Triangle - Diagram ...................................................................................8
Front Triangle - Parts Table ..............................................................................9
Rear Triangle - Diagram ...................................................................................10
Rear Triangle - Parts Table ...............................................................................11
Rocker Diagram .................................................................................................12
Rocker Parts Table .............................................................................................13
WARRANTY...........................................................................................................14
Warranty Exclusions ...................................................................................15-16

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SAFETY INSTRUCTIONS
WARNING
BICYCLE SAFETY
�As with all mechanical components, the bicycle is subjected to wear and
high stresses. Different materials and components might react to wear or stress
fatigue in different ways. If the design life of a component has been exceeded,
it may suddenly fail, possibly causing injuries or death to the rider. Any form
of crack, scratches, or change of colouring in highly stressed areas indicate
that the life of the component has been reached and it should be replaced.
Additionally, after a crash or impact even without visible damage – affected
components should be replaced or a professional opinion should be sought.
�For composite components for example the frame, impact damage is of-
ten invisible to the user. In the event of any impact you should stop using the
bicycle immediately and return affected components to the manufacturer for in-
spection. Failure to do so may result in catastrophic failure and injury or death.
USAGE
�This product is intended for off road use on trails and tracks. It is not designed
for use on Downhill style tracks or competitive racing. The use of this product
in downhill bike parks including jumps or drops is not recommended. The use
of any bicycle on or off-road, even the best circumstances, is dangerous and
may result in injury or death. Correct set-up and maintenance is your respon-
sibility and helps reduce the risk of injury, death, or damage to your bicycle.
ENVIORNMENTAL
�High or low temperature exposure may result in damage to components. The
safe operating temperature is between -10°C and +50°C.
PROTECTIVE EQUIPTMENT
�The use of a bicycle helmet and gloves are recommended as well as oth-
er protective gear appropriate to the terrain – for example knee guards, elbow
guards or a spine protector.
WARNING

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SAFETY INSTRUCTIONS
SUSPENSION
�Suspension set-up and adjustment should be carried out according to the man-
ufactures recommendations. Please refer to the suspension manufacturers product
instructions.
PRE-RIDE CHECKS
�All bolts and fasteners should be checked before according to the rec-
ommendations in the Maintenance section of this manual or the manufac-
tures recommendations. Brake function and tyre pressure, wheel fitment and
the functioning of the suspension should be checked before every ride. Ad-
ditionally, normal functioning of pedals and drivetrain should be checked.
ENTRAPMENT
�There is a risk of entrapment of body parts during maintenance and
normal use. Care should be taken when maintaining moving parts and ap-
propriate protective equipment should be worn. During normal use care
should be taken to prevent loose clothing catching in the moving parts.
LUGGAGE AND CHILD SEATS OR CARRIER
�The bicycle is not suitable for the fitment of any luggage carrying device or any
child seat or carrier.
PERMISSIBLE WEIGHT
�The total permissible weight of a rider including gear is 120kg.
PUBLIC ROADS
�If used on public roads it is your responsibility to ensure your bike is legal and
roadworthy

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ASSEMBLY
Deviate Cycles recommends this bike is assembled by a competent bike mechan-
ic.
� There are a number of cable
clamps along the length of the top
tube. These provide clamping for the
cables, but also serve as tool fixing
points, Di2 or additional bottle mount-
ing.
� The frame houses an internal tube
which guides the dropper post cable in-
side the frame to the bottom of the seat
tube. To reduce water ingress and protect
the paint, ensure to fit the grommet to the
cable before inserting into the frame.
Interface Specification
Fork Compatibility 29” 150-160mm (42mm and 51mm offset)
single crown forks only. Fork crown inter-
ference with downtube MUST be checked
before fitting forks.
Bottom Bracket 73mm BSA Threaded
Headset ZS44/ZS56
Chainline 52mm (any deviation from this will cause
increased idler wear)
Chain Length 126 links (widely available, no need to join
chains)
Max Chainring Size 36t round (oval chainrings may fit depend-
ing on design but check for interference
before riding)
Shock Size Metric 210x55mm (coil or air)
Shock Hardware Front: 30x8mm | Rear: bushing
Shock Average Leverage Ratio 2.54 mm/mm
Brake Mount Post Mount 180mm
Seatpost Compatibility Internal dropper routing with internal cable
routing. 31.6mm, Minimum Insertion Depth:
100mm. Maximum Insertion Depth: Medi-
um:- 300mm, Large:- 330mm
Seat Collar 34.9mm (supplied with frame)
Max Tyre Size 2.8”
PARTS SPECIFIC STANARDS
SEAT POST DROPPER CABLE TOP TUBE CABLE GUIDES

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SHOCK FITMENT
� Ensure the air valve and any parts of the shock do not interfere with the frame
before you ride. Check the full range of suspension motion.
BOTTOM BRACKET WASHER
� Provided in the box is a BB washer (part number 14 on Front Triangle Assem-
bly). Please ensure this is fitted when installing the BB between the frame and BB. It
replaces the 2.5mm spacer found with BB’s to achieve a 52mm chainline. Additional
spacers may be required for certain BB’s.
MAINTENANCE
Service Intervals:
Action Every Ride 50hrs Notes
Clean/Lube Train •Not wax chain lubricants
Check Tyre Pressures •
Clean Mud/Debris •
Check Brake Function •
Clean Stanchions •
Check Brake Pad Wear •
Check Shock Pressure •See manufacturer guidelines (25-
30% sag)
Check For Loose Bols •Refer to diagrams on page (xxx)
Lube Grease Ports •
Check Tyre Wear •
Check Spoke Tension •
Check Drivetrain Wear •Replace chain before 0.75% wear
Check Bearing Wear •Check for play in pivots and idler
Rebuild Linkages As Required
Fork Service Refer to fork manufacturers recom-
mendations
Shock Service Refer to shock manufacturers rec-
ommendations

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If a bolt is found to be
loose it should be re-
moved and the relevant
thread locktite should be
applied as detailed in
th product diagrams on
pages 8,10,12.
PARTS LIST
QUICK REFERENCE SPARES
� The following table is a quick reference for typical spares you might need over
the life of the bike:
� Deviate Cycles can happily supply any spares that you may need for your bike,
but some items such as bearings and seals can be sourced from you local bearing
dealer.
� For all other frame related spares please contact us or check the online store.
The use of non-genuine parts is not recommended and would void the warranty
associated with Deviate products.
Part Torque (Nm)
Main Pivot Bolt 30
Pull Link to Rocker Bolt 30
Pull Link to Rear Triangle Bolt 20
Shock Extender to Rocker Bolt 20
Shock Extender to Shock Bolt 20
Shock Mount Bolt 10
Rear Axle 10
Idler Cover Bolts 2
Drop Out Bolts 2
Bottle Cage Bolts 3
Bolt Torque Summary:
Part Part Number Quantity Per Frame
Dropout TRP04-D9-008-C 1
Rear Axle TRP04-S9-022-A 1
Idler TRP04-D9-006-D 1
Idler Bearings 61803-2RS1 2
Main Pivot, Rear Links,
Extender Bearing
3802 LLU MAX 7
Rocker Bearing 6808 LLU MAX 2
Idler Seals, Main Pivot Seals SEAL - 20x26x4 VC 10
Rear Triangle Inner Seal SEAL - 16x22x4 VC 2
Cable Grommet TRP04-F9-026 3

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FRONT TRIANGLE ASSEMBLY - DIAGRAM
� View page 9 to see the corresponding parts table.
Loctite 243
Loctite 638
Grease
17

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Item Part Number Name Notes QTY
1 TRP04-F9-XXX Frame - Carbon 1
2 TRP04-F9-010-B Clamp - Cable Gutter 4
3 TRP04-F9-011-B Top Hat - Pivot 2
4 TRP04-S9-035-C Spacer Tube - Main Pivot 1
5 TRP04-F9-016 Sleeve - Frame Bolt 1
6 TRP04-F9-017 Bolt - Sleeve Frame 1
7 TRP04-F9-015 Axle - Bottom Bracket 1
8 3802LLUMAX Enduro Bearing 2
9 BTN HEAD M5X18 Button Head - M5 X 18 Torque to 4.5 Nm 6
10 DIN988 – 8x14x0.5 Washer - DIN988 8x14x0.5 2
11 SEAL 20x26x4 VC SEAL - 20X26X4 VC - NITRILE Apply grease to lips 2
12 O-RING 15x1.5 O-RING - 15X1.5MM -
NITRILE Prepare with greese 2
13 SEAT CLAMP 34.9 As Per AMP 03 Not shown 1
14 TRP04-F9-024 Washer - BB Supplied with BB 1
15 TRP04-F9-030-A Protection - Downtube Bonded to downtube 1
16 TRP04-F9-026 Grommet 1
17 / Seat Tube Apply grease prior to
seat post installation /
FRONT TRIANGLE ASSEMBLY - PARTS TABLE
� View page 8 to see the corresponding diagram.

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REAR TRIANGLE ASSEMBLY - DIAGRAM
� View page 11 to see the corresponding parts table.
Loctite 243
Loctite 638
Grease

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REAR TRIANGLE ASSEMBLY - PARTS TABLE
Item Part Number Name Notes QTY
1 TRP04-S9-066-A Rear Swing Arm 1
2 TRP04-S9-029 Axle - Main Pivot Loctite Threads
w/243 1
3 TRP04-D9-007-J Idler Side Plate 1
4 TRP04-S9-020-B Insert - M15 Loctite outer face
w/638 1
5 TRP04-D9-008-C Drop Out - 12x148 1
6 TRP04-D9-009-B Insert - Rear Axle 1
7 TRP04-S9-022-A Rear Axle 148x12 Torque to 10Nm 1
8 TRP04-F9-012-B Top Hat - Pivot Small Fit o-ring 12x1.5 w/
grease 2
9 TRP04-D9-006-D Idler - 18T 1
10 61803_2RS1 BEARING - 61803 2RS 2
11 3802LLUMAX Enduro Bearing 3802 LLU
Max 2
12 SEAL - 20X26X4 VC SEAL - 20X26X4 VC - NITRILE Prepare with greese 4
13 SEAL_16X22X4_VC SEAL - 16X22X4 VC - NITRILE 2
14 O-Ring - 12x1.5 O-RING - 12X1.5MM -
NITRILE
Replaces 2.5mm
spacer with BB 2
15 Cap M4X16 CAP HEAD - M4 X 18 - SS
A2/A4 Torque to 2 Nm 1
16 Cap M5X16 CAP HEAD - M5 X 16 SS
A2/A4
Loctite 243, Torque
2Nm
3
17 DIN988 - 15X21X1 Washer - DIN988 - 15X21X1 1
18 Grub M5x5 Grub Screw - M5 X 5 Loctite Threads
w/243 1
19 Zerks 10-32 UNF Flush Straight
Slotted Loctit Threads w/638 2
20 TRP04-S9-063-B Protection Self Adhesive 1
21 TRP04-S9-026 Grommet Not Shown 2
� View page 10 to see the corresponding diagram.

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ROCKER - DIAGRAM
Loctite 243
Loctite 638
Grease
� View page 13 to see the corresponding parts table.

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ROCKER - PARTS TABLE
� View page 12 to see the corresponding diagram.
Item Part Number Name Notes QTY
1 TRP07-S9-002-A Rocker - 150mm 1
2 TRP07-S9-004-A Link - 150mm 1
3 TRP04-F9-011-A Top Hat - Pivot 4
4 TRP04-F9-013-A Top Hat - BB 2
5 TRP04-S9-019 Axle Bolt - Swingarm Link Tighten to 20Nm 2
6 TRP04-S9-030-D Axle - Swing Arm Link Tighten to 30Nm 1
7 TRP04-S9-036-B Spacer Tube - BB 1
8 TRP04-S9-037-B Spacer Tube Rocker 1
9 TRP07-S9-003-A Shock Extender - 150mm 1
10 TRP04-S9-046-A Sleeve - Extender Tighten to 20Nm 1
11 TRP04-S9-049-B Sleeve - Shock Fitted for transport 1
12 6808LLUMAX Enduro Bearing 6808 LLU 2
13 3802LLUMAX Enduro Bearing 3802 LLU
MAX 3
14 Seal 20x26x4VC Seal - 20x26x4 VC Apply grease to lips 4
15 Seal 45x52x4VC Seal - 45 x52x4 VC Apply grease to lips 2
16 O-Ring 15x1.5 O-RING - 15X1.5MM - Prepare w/grease 4
17 O-Ring40x1.5 O-RING - 40X1.5MM -
NITRILE Prepare w/grease 2
18 WASHER_
DIN988_15X21X1
WASHER - DIN988 -
15X21X1 -SS 1
19 ZERKS 10-32 UNF Flush Straight
Slotted 6
20 GRUB M5X5 Grub Screw - M5 x5 - SS
A2/A4
4

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WARRANTY
All of Deviate Cycles frames come with a lifetime warranty. This warranty comes with
some important conditions.
We want you to have peace of mind when purchasing a Deviate. We produce high
end carbon frames and stand behind our product 100% with a lifetime warranty.
Saying that, in return we expect you to maintain your frame and not use it beyond it’s
intended limits.
If our analysis (or your honesty) suggests abnormal loading, for example due to cas-
ing downhill style jumps on a trail bike - then our crash damage replacement policy
will apply. Our engineering team have extensive experience with carbon fibre failure
analysis so their decision is final.
The following conditions apply to the lifetime warranty:
� Lifetime Warranty is only valid for manufacturing defects.
� Applies to frame-set and machined parts.
� Valid for intended and appropriate use only.
� Warranty only applies to the original owner with proof of purchase.
� Does not include any work associated with warranty process (i.e. stripping down
or re-building a replaced frame).
� Does not include import tax or duty when shipping outside the UK.
� If a replacement in required we will endeavour to replace like for like - but if
this is not possible we may offer an alternative.
� Subject to exclusions (see page 15).

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WARRANTY EXLUSIONS
� Wear and tear.
� Paintwork. 2 year warranty applies to paintwork manufacturing defects.
Custom painting voids the frame warranty except where carried out by an
authorised paint-shop or where written authorisation is obtained from us. Where
an authorised paint-shop is used, we take no liability for this work and will be
not liable for any costs incurred due to a separate warranty claim, for example
where re-painting may be required due to a replacement part.
� Where clear protection is applied, this voids any warranty we supply on the
paintwork including any damage to the existing paint occurring during removal
or fitting.
� Cable rub and other friction damage.
� Bearings and other “wear parts” i.e. the idler wheel and seals.
� Damage occurring due to insufficient maintenance or poor treatment. Refer
to the manual for maintenance instructions.
� The fitment of incompatible parts voids the warranty. For the avoidance of
doubt, forks beyond the travel range quoted for a frame are deemed incompati-
ble, as are wheel sized that are not quoted for the frame or 3rd party linkages.
� Damage occurring due to the seizing of bolts or components due to insuffi-
cient maintenance or over-tightening. To be clear if lack of maintenance causes
the linkage or bearings to seize and this results in damage to the frame, this is
not covered.
� Damage occurring as a result of over-torqueing, cross threading or other
mis-fitting of components. Refer to manual for tightening torques.
� Damage occurring due to impact damage of any description.
� Damage occurring where another vehicle or bicycle is involved.

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WARRANTY EXLUSIONS
� Damage occurring where another vehicle or bicycle is involved.
� Damage occurring due to extreme temperature exposure (cold night rides
okay, liquid nitrogen not okay | hot deserts okay, blowtorch not okay).
� Any component not manufactured by Deviate Cycles (i.e. rear shock and
other build parts). Refer to relevant manufacture for warranty details.
� Crash damage (see crash replacement policy) and other damage caused by
the environment (i.e. rock strikes).
� Beyond intended/appropriate use. i.e. using a trail bike for downhill riding.
� Professional competitive use.
� Deliberate damage including attempted theft.
� Damage that occurs during transit (i.e. by an airline or in a vehicle).
� Functioning of Warranty:
It is our decision if either the bike must be returned to us for inspection or photos
must be provided. The frame must be stripped of all non warranty components
and cleaned. You will be charged for the pick up service and if the warranty
is confirmed the shipping cost will be refunded in full. If the warranty case is
declined then you will be charged for return shipping, if required.
Our decision is final on warranty matters. Your statutory rights are not affected.
For questions or to claim on the warranty please email [e-mail].
V1.5 - 21/11/22