DEVIATE highlander User manual

Product Manual
28/05/2020
Contents
•Safety
•Assembly
•Maintenance
•Parts List
•Diagrams

Product Manual
28/05/2020
Safety
WARNING:
- 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 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 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.
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 entrapment of 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.

Product Manual
28/05/2020
Assembly
Below is a list of the specific “standards” that parts fitted to the Highlander frame must adhere to. You must
refer to the specific product instructions provided with any parts you fit to the Highlander.
Interface Standard/Information
Rear Wheel: 29”, Boost: 148mm x 12mm
Fork Compatibility: 29” 150-160mm (42mm and 51mm offset) single crown forks only.
Fork crown interference 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 depending 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: Medium:- 300mm, Large:- 330mm
Seat Collar: 34.9mm (supplied with frame)
Max Tyre Size: 2.8”
Deviate Cycles recommends this bike is assembled by a competent bike mechanic.
The following tips may help with assembly:
Seat Post Dropper Cable:
The frame houses an internal tube which guides the dropper post cable inside 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.
Top Tube Cable Guides: The purpose of the top tube profile is to maintain the sleek look of internal cable routing, while stiffening the top tube. There are a
number of cable clamps along the length of the tube. These provide clamping for the cables, but also serve as tool fixing points, Di2 or additional bottle
mounting.
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 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.

Product Manual
28/05/2020
Maintenance
Service Intervals:
Action
Ever
y
ride
Ever
y 50
hour
sNotes
Clean and lube chain ◆We recommend to refrain from wax chain lubricants
Check tire pressures ◆
Clean worst of mud/debris ◆
Check brake function ◆
Clean stanchions ◆
Check brake pad wear ◆
Check shock pressure ◆Pressure set according to riders preference (25-30%
sag typical)
Check for loose bolts ◆Refer to diagrams in this manual or manufacturers
guidelines
Lube grease ports ◆Use of needle grease ports on all pivots
Check tyres for wear ◆
Check spoke tension ◆
Check drivetrain for 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
Part Torque (Nm)
Main Pivot Bolt 30
Pull Link to Rocker Bolt 30
Pull Link to Rear Triangle Bolt 20
Shock Extender to Rocker Bolts 20
Shock Extender to Shock Bolt 20
Shock Mount Bolt 10
Rear Axle 10
Idler Cover Bolts 2
Drop Out Bolt 2
Bottle Cage Bolts 3
If a bolt is found to be loose it should be
removed and the relevant thread lock should
be applied as detailed in the product
diagrams.
Bolt torque summary:

Product Manual
28/05/2020
Parts List
The following 3 sheets contain the assembly drawings and parts
lists for the Highlander.
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 1
Insert –Rear Axle TRP04-D9-009 1
Idler –18T TRP04-D9-006 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 TC 10
Rear triangle inner seal SEAL –16x22x4TC 2
Cable Grommet TRP04-F9-026 3
Deviate Cycles can happy to 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.

Product Manual
28/05/2020
Front Triangle Assembly
ITEM
PART NUMBER
NAME
NOTES
QTY
1
TRP04
-F9-XXX
FRAME
- CARBON 1
2
TRP04
-F9-010
CLAMP
- CABLE GUTTER 4
3
TRP04
-F9-011
TOP HAT
- PIVOT 4
4
TRP04
-S9-035
SPACER TUBE
- MAIN PIVOT 1
5
TRP04
-F9-016
SLEEVE
- FRAME BOLT 1
6
TRP04
-F9-017
BOLT
- SLEEVE FRAME
TORQUE TO 10 Nm
1
7
TRP04
-F9-015
AXLE
- BOTTOM BRACKET
FITTED FOR SHIPPING
1
8
3802LLUMAX
ENDURO BEARING 3802 LLU MAX
2
9
BTN HEAD M5X18
BUTTON HEAD
- M5 X 18
TORQUE TO 4.5 Nm
4
10
DIN988
–8x14x0.5
WASHER
- DIN988 –8x14x0.5 2
11
SEAL 20x26x4 TC
SEAL
–20x26x4 TC
APPLY GREASE TO LIPS
2
12
O
-RING 15x1.5
O
-RING –15x1.5MM
PREPARE WITH GREASE
2
13
SEAT CLAMP 34.9
AS PER AMP03
NOT SHOWN
1
14
TRP04
-F9-024
WASHER
-BB
REPLACES 2.5MM SPACER WITH
BB
1
15
TRP04
-F9-030
PROTECTION
- DOWNTUBE -
MOULDED
BONDED TO DOWNTUBE
1
16
TRP04
-F9-026
GROMMET
1
Cross section on Main
Pivot bearings
Align flats during
assembly
12
Loctite 243
Loctite 638
Greas
e

Product Manual
28/05/2020
Rear Triangle
ITEM
PART NUMBER
NAME
NOTES
QTY
1
TRP04
-S9-014
REAR SWING ARM
1
2
TRP04
-S9-029
AXLE
- MAIN PIVOT
LOCTITE THREADS WITH 243
1
3
TRP04
-D9-007
IDLER
- SIDE PLATE 1
4
TRP04
-S9-020
INSERT
- M15
LOCTITE OUTER FACE WITH 638
1
5
TRP04
-D9-008
DROP OUT
- 12X148 1
6
TRP04
-D9-009
INSERT
- REAR AXLE 1
7
FB1890BK001
REAR AXLE
- 148 x 12
TORQUE TO 10 Nm (MAX)
1
8
TRP04
-F9-012
TOP HAT
- PIVOT SMALL
FIT O
-
RING 12x1.5 WITH GREASE
2
9
TRP04
-D9-006
IDLER
-18T 1
10
61803
-2RS
BEARING
- 61803 2RS 2
11
3802LLUMAX
ENDURO BEARING 3802 LLU MAX
2
12
SEAL
- 20X26X4TC
SEAL
- 20X26X4 TC 4
13
SEAL
- 16X22X4TC
SEAL
- 16X22X4 TC 2
14
O
-RING - 12x1.5
O
-RING - 12X1.5MM 2
15
CAP M4X16
CAP HEAD
- M4 X 16
TORQUE TO 2 Nm
1
16
CAP M5X16
CAP HEAD
- M5 X 16
LOCTITE 243,
TORQUE TO 2Nm 3
17
DIN988
- 15X21X1
WASHER
- DIN988 - 15X21X1 1
18
GRUB M5x5
GRUB SCREW
- M5 X 5
LOCTITE THREADS WITH 243
1
29
ZERKS
ZERKS FLUSH GREASE NIPPLE
LOCTITE THREADS WITH 638
2
20
TRP04
-S9-063
PROTECTION
SELF ADHESIVE (NOT SHOWN)
1
21
TRP04
-S9-026
GROMMET
NOT SHOWN
2
Cross section on link
bearings
15
8
13
12
Loctite 243
Loctite 638
Greas
e

Product Manual
28/05/2020
Rocker
ITEM
PART NUMBER
NAME
NOTES
QTY
1
TRP04
-S9-016
ROCKER
- 140MM
1
2
TRP04
-S9-015
LINK
- 140MM
1
3
TRP04
-F9-011
TOP HAT
- PIVOT
4
4
TRP04
-F9-013
TOP HAT
-BB
2
5
TRP04
-S9-019
AXLE BOLT
- SWINGARM LINK
TIGHTEN TO 20Nm
2
6
TRP04
-S9-030
AXLE
- SWING ARM LINK
TIGHTEN TO 30Nm
1
7
TRP04
-S9-036
SPACER TUBE
-BB
1
8
TRP04
-S9-037
SPACER TUBE
- ROCKER
1
9
TRP04
-S9-044
EXTENDER
- 140MM
1
10
TRP04
-S9-045
SLEEVE
–EXTENDER
TIGHTEN TO 20Nm
1
11
TRP04
-S9-046
BOLT
–EXTENDER
1
12
TRP04
-S9-049
SLEEVE
–SHOCK
FITTED FOR TRANSPORT
1
13
6808LLUMAX
ENDURO BEARING 6808 LLU MAX
2
14
3802LLUMAX
ENDURO BEARING 3802 LLU MAX
3
15
SEAL 20x26x4TC
SEAL
–20x26x4 TC
APPLY GREASE TO LIPS
4
16
SEAL 45x52x4TC
SEAL
–45x52x4 TC
APPLY GREASE TO LIPS
2
17
O
-RING 15x1.5
O
-RING –15x1.5MM
PREPARE WITH GREASE
4
18
O
-RING 40x1.5
O
-RING –40x1.5MM
PREPARE WITH GREASE
2
19
DIN988 15x21x1
WASHER
- DIN988 –15x21x1
1
20
ZERKS
ZERKS FLUSH GREASE NIPPLE
6
21
GRUB M5x5
GRUB SCREW
- M5 x 5
4
Loctite 243
Loctite 638
Greas
e