devox AERO-TRI BAR User manual

AERO-TRI BAR
FELT CARBON FIBER AEROBAR
INSTRUCTION MANUAL

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aerobar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 1: Stack Height & Riser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 2: Armrest Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 3: Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Step 4: Cable Routing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes & Dimension Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4 & 5
6 & 7
8
8 & 9
9 & 10
10 & 11
12
12
13
TABLE OF CONTENTS
2

AERO-TRI BAR
Thank you for purchasing the Felt aerobar system. Like all Felt products, this aerobar is engineered to offer maximum adjustability
and dependability while being easy to use and service. Because this is a precision engineered product we ask you to take great care
in its installation and use. Please apply quality grease to all bolts and always use a torque wrench when tightening all fasteners.
If you are unsure about anything during the installing of this product, please seek the assistance of a qualified bicycle mechanic which
you can find at any Felt Authorized dealer. For your local Felt dealer listings please consult our website.
Limited Warranty: Handlebars
Subject to the terms, conditions and limitations set forth below, Felt products are guaranteed against defects in materials and workmanship for one year from date of purchase from an authorized Felt Dealer. This warranty
applies only to the original owner of Felt products and is not transferable to subsequent owners. This warranty does not cover a cracked handlebar or other damage due to crashes or other similar impacts. Felt alloy
Handlebars have no implied lifespan due to the many variables that affect them, including the amount and type of use, as well as other conditions. It is the owner’s responsibility to have his/her Felt products including the
handlebar inspected by a technician at an authorized Felt Dealer on a regular basis to detect any damage that may have occurred during normal use and immediately after a crash or other impact even if there is no visible
damage. Limited Warranty Service: To obtain service under this warranty, the original purchaser must present the product along with the original, dated proof of purchase to an authorized Felt Dealer.
Limit of Warranty: During the duration of this warranty, Felt Bicycles, LLC, will—at its sole discretion—either repair or replace any Felt product deemed by Felt to be defective. All Felt products should be regularly inspected
by a technician at an authorized Felt Dealer for indications of potential failures. These are important safety checks and may help prevent accidents, bodily injury to the rider, and shortened product life cycles of Felt products.
Not covered under limited warranty:
• Normal wear and tear.
• Any product improperly installed, assembled or maintained.
• Any product that Felt determines has been modified or used with neglect to maintenance.
• Any product used for stunt riding or similar activities, racing, commercial purposes or in any other manner for which they were not designed.
• Damage, failure or loss resulting from causes other than manufacturing defects. This may include but is not limited to: theft, nonstandard or unapproved use, rider error, accident, abuse, neglect, or failure to follow
applicable instructions or warnings.
• Finish blemishes or damage due to exposure to the weather or to a chemical or other similar environment.
• Labor costs associated with servicing, repairing or replacing the product.
Felt Bicycles, LLC, makes no other warranties express or implied by operation of law or otherwise, including the warranties of merchantability and fitness for a particular purpose,
which are limited in duration to those of the express warranties stated herein.
Felt Bicycles, LLC, shall not be liable or responsible for direct, incidental or consequential damages including but not limited to damages for personal injury, property damage or
economic losses, whether based on contract, warranty, negligence, product liability or any other theory.
Some states do not allow the exclusion or limitation of damages or how long an implied warranty lasts so the above limitation/exclusion may not apply to you.
INTRODUCTION

PARTS LIST
QTY. SIZE - PART NAME PART
M6 x 35mm - Bolt4
M6 x 40mm - Bolt4
M6 x 45mm - Bolt4
M6 x 30mm - Bolt8
M6 x 20mm - Bolt4
M5 x 12mm - Bolt4
Bracket Spacer2
M6 x 25mm - Bolt4
M6 x 15mm - Bolt2
Fit Washer40
Armrest Washer2
M6 x 50mm - Bolt4
M6 x 55mm - Bolt4
Threaded Lower Nut2
4
Armrest2

AERO-TRI BAR
QTY.
QTY.
SIZE - PART NAME
SIZE
PART
PART
Narrow Fixed Bridge
Wide Fixed Bridge
1
1
Basebar1
Extension2
Extension Plug
2
Extension Bracket2
Armrest Bracket2
2
40mm
Non-Threaded
Spacer
Non-Threaded
Spacer
Threaded Spacer Threaded SpacerThreaded Spacer
2
20mm
2
10mm
4
5mm
2
30mm

OVERVIEW
The below reference highlights the five main areas of adjustment that can be manipulated to achieve the desired
configuration.
6
The below box illustrates the range of common positions that can be achieved with the Felt aerobar system.
Adjustment field
1. Armpad position & angle
2. Armpad fore & aft
3. Arm pad width
4. Extension width & angle
5. Extension fore & aft
6. Stack height
7. Basebar orientation

AERO-TRI BAR
OVERVIEW
For riders who prefer a narrower position, further adjustment can be achieved by flipping the extension brackets 180
degrees to position the extensions closer together. See two images below for demonstration.
71mm Stack Height (narrow configuration)
Shown below is an example of a high-stack configuration with a narrow arm pad and extension position which
utilizes a narrow fixed bridge for stability.
Shown below is an example of a low-stack configuration with a wide arm pad and extension position.
22mm Stack Height (wide configuration)

BEFORE BEGINNING ASSEMBLY OF AEROBAR, READ THE CHART AND NOTES ON STACK HEIGHT BELOW.
If you know the dimensions that you require while riding a TT/TRI bicycle, the chart below will help you quickly identify the
hardware required to achieve your desired stack height.
If you do not know the dimensions you require, Felt recommends getting fitted by a qualified fit specialist.
CONFIGURATION REFERENCE CHART
Note: the chart to the
left and all supporting
figures relate only to
the stack height when
using the narrower
(inner), configuration
on the basebar.
tt
An assembly with stack
height of 53mm will be
used as an example
in the following
instructions.
Threaded Spacer
Inner Stack Height (c-c) Outter Stack Height (c-c)
Fit Washers
Top Bolts (mm)
Bottom Bolts (mm) Threaded lower nut
Non-threaded config.
X
2520 X5mm 445 X 1
5050 20 Fixed Bridge + 5mm 830
4540 20 420 30
6560 40 Fixed Bridge 635 30
7065 40 Fixed Bridge + 5mm 835 30
3025 X10mm 450 X 1
50
45 20 20 5mm Fixed Bridge 6
625 25 30 30
7570
75 80 40
40 Fixed Bridge + 10mm 8
10 40 45 30 30
3530 X5mm + 10mm 655 X 1
6055 30 Fixed Bridge + 5mm 835 30
5550 30 Fixed Bridge 630 30
5050 30 X425 30
Fixed Bridge + 10mm + 5mm
30
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Before beginning assembly, choose your preferred
orientation of the base bar. The diagram to the left shows
the base bar orientation upward (for rise) +20mm and
downward (for drop) -20mm.

AERO-TRI BAR
- One extension
- Two top bolts (55mm)
- One extension bracket
- One bracket spacer*
- Stack height spacers (5mm + 10mm)
- Fit washers (6)**
- One threaded lower nut
Fixed Bridge
Option A. The diagram to the left is a low-stack configuration
and does NOT require the narrow fixed bridge. Use this
example to assist in building low-stack assemblies. Tighten
the 2 bolts to 6Nm.
Step 1: Stack Height & Riser Assembly
Option A
X
36 X5mm +10mm 455 1
Threaded Spacer
Inner Stack Height (c-c)
Fit Washers Top Bolts (mm) Bottom Bolts (mm) Threaded Lower Nut
Non-threaded Config.
Option B. The diagram to the left is a high-stack configuration
and does require the narrow fixed bridge and a total of
4 bolts. 2 of the bolts enter the underside of the basebar
and thread into the threaded spacer, and 2 top bolts enter
the extension bracket and thread into the threaded spacer.
Tighten all 4 bolts to 6Nm.
- One Extension
- Two top bolts (30mm)
- One bracket spacer *
- One extension bracket
- Narrow fixed bridge
- Fit washers (6)**
- Threaded spacers (30mm)
- Bottom bolts
Threaded Spacer
Inner Stack Height (c-c)
Fit Washers
Top Bolts (mm)
Bottom Bolts (mm)
Non-threaded Config.
56 30 630 30
Option B
X
Threaded Lower Nut

To complete the arm rest assembly, you will need the following:
- Two 12mm arm rest bolts
- One arm rest washer
- One arm rest
- One arm rest bracket
- One 15mm bolt
Begin by taking an arm rest bracket and thread a 15mm bolt into the
underside and finger-tighten to keep in place. Place the arm rest washer and
use two arm rest bolts to fasten in desired position. Finally, slip the arm rest
assembly over the extension and tighten the 15mm bolt to 7Nm.
See diagram on following page for the four acceptable configurations.
Step 2: Arm Rest Assembly
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*BRACKET SPACER
Insert the bracket spacer into the slot located on the extension bracket, making
sure to align the holes and leave the long, curved edge flush with the edge of
the extenion bracket slot as shown in the illustration to the right.
**FIT WASHERS
Begin with pressing the fit washers into the recessed holes.
Sandwich the fit washer between the
bolt, spacer/bridge and a threaded
spacer. Tighten the bolt until the fit
washer is pressed in. Unthread the
bolt and assemble.
Threaded spacer
Threaded lower nut

AERO-TRI BAR
Notice that the diameters of the six holes in the arm rest are each larger than
the diameter of the bolt shaft. This allows for fine-tuning to achieve desired
arm pad angle. See below for illustrations.
Possible armrest configurations
Counter-Clockwise Rotation Clockwise Rotation
The image to the left shows the stack assembly and armrest
assembly properly mounted on an extension (actual placement
of assemblies in relation to the extension will vary).

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**If using electronic shifters, this is when you
route the wire. If necessary, use the steel brake
cable to guide the wire through by temporarily
attaching the shifter wire to the brake cable.
2. Route the steel inner cable though the bar
until it exits the appropriate hole. This steel
cable will be used to guide the shifter wire and
the brake housing through the bar.
Step 3: Cable Routing
Routing the brake and shifter cables can be
made easier by following these suggested steps:
*Note- when using electronic shifters, be sure
to route the electronic wire before inserting the
brake housing.
1. Insert the steel inner cable, starting at the
rear of the bar.
3. Starting at the end nearest the grip area of
the bar, slip the cable housing over the cable
and continue to advance the cable housing
through the bar (using the cable as a guide)
until it exits the hole you inserted the cable into.

AERO-TRI BAR
Notes & Dimension Log
Your Dimensions:
Name ______________________ Date __________ Stack height __________mm Arm pad width __________mm
Extension width __________mm Stem Length/rise __________mm/__________degrees Frame______________________
Your dimensions:
Name ______________________ Date __________ Stack height __________mm Arm pad width __________mm
Extension width __________mm Stem Length/rise __________mm/__________degrees Frame______________________
Notes:
Notes: