DEVIATE Highlander II User manual

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Deviate Highlander II User Manual v1.2 12.12.23
User Manual:
2023

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Deviate Highlander II User Manual v1.2 12.12.23Deviate Highlander II User Manual v1.2 12.12.23
SAFETY INSTRUCTIONS
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 often 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 inspection. 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 racing and tracks. 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
responsibility and helps reduce the risk of injury, death, or damage to your bicycle.
ENVIRONMENTAL
High or low temperature exposure may result in damage to components. The safe operating
temperature is between -10°C and +50°C.
PROTECTIVE EQUIPMENT
The use of a bicycle helmet and gloves are recommended as well as other protective gear
appropriate to the terrain – for example knee guards, elbow guards or a spine protector.
WARNING
TABLE OF CONTENTS
SAFETY INSTRUCTIONS ......................................... 3
Bicycle Safety .............................................................3
Usage ...................................................................3
Environmental .............................................................3
Protective Equipment .......................................................3
Suspension ...............................................................4
Pre-ride Checks............................................................4
Entrapment ...............................................................4
Luggage and Child Seats or Carrier ...........................................4
Permissible 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 .....................................................14-15
Functioning of Warranty ....................................................15

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SAFETY INSTRUCTIONS (CONTINUED)
SUSPENSION
Suspension set-up and adjustment should be carried out according to the manufactures
recommendations. Please refer to the suspension manufacturers product instructions.
PRE-RIDE CHECKS
All bolts and fasteners should be checked before according to the recommendations in the
Maintenance section of this manual or the manufactures recommendations. Brake function and
tyre pressure, wheel fitment and the functioning of the suspension should be checked before
every ride. Additionally, normal functioning of pedals and drivetrain should be checked.
ENTRAPMENT
There is a risk of trapping body parts during maintenance and normal use. Care should be
taken when maintaining moving parts and appropriate 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
SEAT POST DROPPER CABLE
Scan below for video guidance
TOP TUBE CABLE GUIDES
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
mounting.
ASSEMBLY
PARTS SPECIFIC STANDARDS
Interface Specication
Fork Compatibility 29” 160mm 44/42mm offset
Bottom Bracket 73mm BSA Threaded
Headset ZS44/ ZS44/28.6 upper and a ZS56/40 lower headset
cup
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 depending on
design but check for interference before riding)
Shock Size Metric 210*55mm (coil or air)
Shock Hardware Front: 40*8mm | Rear: Eyelet bushing
Shock Average Leverage Ratio 2.54 mm/mm
Brake Mount Post Mount 180mm (Max 203mm Disc Size Rear)
Seatpost Compatibility Internal dropper routing with internal cable routing.
34.9mm, Minimum Insertion Depth: 150mm.
Maximum Insertion Depth: Medium:- 300mm,
Large:- 330mm, XL:- 360mm
Seat Collar 38.5mm (supplied with frame)
Max Tyre Size 2.8”
Deviate Cycles recommends this bike is assembled by a competent bike mechanic.

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BOTTOM BRACKET WASHER
Provided in the box is a BB washer (part number 14 on Front Triangle Assembly). 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 Bolts • Refer to diagrams on page (xxx)
Lube Grease Ports •See diagrams for port locations
(Pages 10, 12)
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
recommendations
Shock Service Refer to shock manufacturers
recommendations
GREASE PORTS
After locating the grease ports (see diagrams on pages 10 & 12) use a Deviate Cycles Dualco
grease gun to insert Peaty’s speed grease into the specified port. Ensure any excess grease is
cleaned and removed prior to using the bike.
PARTS LIST
QUICK REFERENCE SPARES
The following table is a quick reference for typical spares you might need over the life of the bike:
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 (Large) G10 RCS60-00-45 2
Cable Grommet (Small) G10 RCS50-00-35 3
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.
BOLT TORQUE SUMMARY
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
Sleeve - Shock 20
Sleeve - Frame Bolt 10
Rear Axle 10
Idler Cover Bolts 2
Drop Out Bolts 2
Bottle Cage Bolts 3
If a bolt is found to
be loose it should be
removed and the relevant
thread locktite should be
applied as detailed in
the product diagrams on
pages 8, 10, 12.

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FRONT TRIANGLE ASSEMBLY - DIAGRAM
View page 9 to see the corresponding parts table.
Loctite 243
Loctite 638
Grease
Align flats
during assembly
Cross section on Main Pivot bearings
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FRONT TRIANGLE ASSEMBLY - PARTS TABLE
View page 8to see the corresponding diagram.
Item Part Number Name Notes QTY
1 TRP08-F9-XXX Frame - Carbon 1
2TRP04-F9-010-B Clamp - Cable Gutter 4
3TRP04-F9-011-B Top Hat - Pivot 4
4TRP04-S9-035-C Spacer Tube - Main Pivot 1
5AMP06-F9-013-A Sleeve - Frame Bolt 1
6TRP04-F9-017-A Bolt - Sleeve Frame 1
7TRP04-F9-015-C Axle - Bottom Bracket 1
83802LLUMAX Enduro Bearing 2
9BTN_HEAD_M5x18 BUTTON HEAD - M5x18
- SS A2/A4
Torque to 4.5 Nm 4
10 WASHER_
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 grease 2
13 / / Not shown /
14 TRP04-F9-024 Washer - BB Replaces 2.5mm
spacer with BB
1
15 TRP08-F9-007-A Protection - Downtube 1
16 G10_RCS50-00-35 Grommet (Small) 1
17 CL-FJ21-1 Deviate Seat Clamp Apply grease prior to
seat post installation
1
18 WAFER_HEAD_
M6x16
WAFER HEAD M6x16 2

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REAR TRIANGLE ASSEMBLY - DIAGRAM
View page 11 to see the corresponding parts table.
Cross section on
link bearings
Loctite 243
Loctite 638
Grease
Grease Port
REAR TRIANGLE ASSEMBLY - PARTS TABLE
View page 10 to see the corresponding diagram.
Item Part Number Name Notes QTY
1 TRP08-S9-XXX Rear Swing Arm 1
2TRP04-S9-029-F Axle - Main Pivot Loctite Threads w/243 1
3TRP04-D9-007-J 52mm Idler Cover 55mm Idler Cover =
AMP06-D9-011-A
1
4 TRP04-S9-063-B Chain stay protector 1
5TRP04-D9-008-C Drop Out - 12x148 UDH Hanger =
411H0300001
1
6TRP04-D9-009-B Insert - Rear Axle 1
7TRP04-S9-022-A Rear Axle 148x12 UDH Axle =
411L12B2000003
1
8AMP06-F9-020 Top Hat - Pivot Small Fit o-ring 12x1.5 w/grease 2
9TRP04-D9-006-D 52mm Idler - 18T 55mm Idler = AMP06-D9-
012-B
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 grease 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 - M4x18
- SS A2/A4
Torque to 2 Nm 1
16 CAP_M5x16 CAP HEAD - M5x16
- SS A2/A4
Loctite 243, Torque 2Nm 3
17 WASHER_
DIN988_15x21x1
WASHER - DIN988
- 15x21x1 - SS
1
18 GRUB_SCREW-M5x5 GRUB SCREW - M5x5
- SS A2/A4
Loctite Threads w/243 1
19 ZERKS_FITTING 10-32 UNF Flush Straight
Slotted
Loctite Threads w/638 2
20 G10_RCS50-00-35 Grommet (Large) 2
21 G10_RCS60-00-45 Grommet (Small) 2

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ROCKER - DIAGRAM
View page 13 to see the corresponding parts table.
Loctite 243
Loctite 638
Grease
Grease Port
ROCKER - PARTS TABLE
View page 12 to see the corresponding diagram.
Item Part Number Name Notes QTY
1TRP08-S9-002 Rocker - 145mm 1
2TRP08-S9-004 Link - 145mm 1
3TRP04-F9-011-B Top Hat - Pivot 4
4TRP04-F9-013-B Top Hat - BB 2
5TRP04-S9-045-D Axle Bolt - Swingarm Link Tighten to 20Nm 2
6TRP04-S9-030-F Axle - Swing Arm Link Tighten to 30Nm 1
7TRP04-S9-036-C Spacer Tube - BB 1
8TRP04-S9-037-C Spacer Tube Rocker 1
9TRP08-S9-003 Shock Extender - 145mm 1
10 TRP04-S9-046-A Sleeve - Extender Tighten to 12Nm 1
11 TRP04-S9-049-B Sleeve - Shock Fitted for transport 1
12 6808LLUMAX Enduro Bearing 6808 LLU MAX 2
13 3802LLUMAX Enduro Bearing 3802 LLU MAX 3
14 SEAL_20x26x4_ Seal - 20x26x4 VC Apply grease to lips 4
15 SEAL_45x52x4_ Seal - 45x52x4 VC Apply grease to lips 2
16 O-RING_15x1.5 O-RING - 15x1.5MM - NITRILE Prepare w/grease 4
17 O-RING_40x1.5 O-RING - 40x1.5MM - NITRILE Prepare w/grease 2
18 WASHER_
DIN988_15x21x1
WASHER - DIN988 - 15x21x1 -SS 1
19 ZERKS FITTING 10-32 UNF Flush Straight Slotted 6
20 GRUB_M5X5 GRUB SCREW - M5x5 - 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 casing
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 14).
WARRANTY EXCLUSIONS
• 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 incompatible, 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 insufficient
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-
torquing, 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.
• 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 warranty claims please
email [email protected]

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Deviate Cycles Limited,
Main Street, Kinbuck, Dunblane, FK15 0NQ
tel. [phone]
email. [e-mail]
web. deviatecycles.com
Deviate Highlander II User Manual v1.2 12.12.23