INTENSEcycles ACV User manual

user manual ACV

AT INTENSE, WE HAVE ONE GOAL - TO PROVIDE THE RIDE OF YOUR LIFE //
Our team of designers, engineers and product experts are focused on one thing every
day: your experience on the bike. We build bikes that are as thrilling to look at as they
are to ride, and we build them for the select few of you who understand the difference
and refuse to settle for anything else.
From the early days of Intense, when founder Jeff Steber worked alone in his garage to
today, where a crew of talented people work in a Temecula, CA factory, Intense has been
a brand built on passion by forward thinkers who, even today, love nothing more than
to throw a leg over a sweet bike and head out for a rip. We’re so glad you’ve joined us.
Welcome to Intense, enjoy your experience.
THE 27.5+ ACV //
ACV = Air. Cushioned. Vehicle..…and that’s how it rides. This Enduro minded ride is
Intense Cycles first offering with a 1X specific frame design. We’ve eliminated the front
derailleur for those of you who are honch enough for single ring up front. This allows
us to increase stiffness by having symmetrical, vertical struts on the rear triangle and
clears some room for the wide, 27.5+ tires.
The adjustable travel ( 4.5” or 5”) is enough to fine tune your ride for any trail and
the full carbon monocoque front and rear triangles keep things nimble and light for
the climb. This vehicle is a ripper of a ride.
registration
WWW.INTENSECYCLES.COM/WARRANTY-CARD/
contact customer service
[e-mail]
951-296-9596
Welcome to
the family
2// ACV user manual

introduction / registration 2
frame features / component spec 4
Geometry 5
exploded view and b.o.m. 6
Assembly 8
torque chart 13
setup 14
maintenance 18
INTENSE CYCLES // 3

4// ACV user manual
frame
features /
spec
Frame Features //
• Adjustable Travel: 4.5" to 5" (115mm OR 130mm)
• 27.5+” Wheel size
• 5.3 lbs / 2,420 grams = Standard frame w/ alloy link, no shock, size m
• Tapered Head Tube
• Monocoque front triangle
• Integrated BOOST 148 x 12 dropouts
• Internal Brake and Derailleur Cable Routing System
• Internal Seat Tube Cable Routing for dropper posts
• Angular Contact/Collet Bearing System with replaceable Grease Zerks
• Flack guard Downtube and Chainstay protection
• H20 Bottle Fitment
Component Spec //
• Fork – 1.5” tapered steer, 150mm Travel, 561mm lower leg length, 51mm offset
• Shock – 200mm x 50.8mm (7.875” x 2”), 22mm x 6mm and 30mm x 6mm reducers
• 1x gearing only
• Seat post – 31.6mm
• Headset – zero stack 44 upper / external cup 49 lower
• Bottom bracket - Press Fit BB92
• Rear Axle – BOOST 148 x 12 T/A
• Brake Mount – post mount for 160mm rotor
• Crank set - BOOST 148 Compatible - single ring only
• Rear Wheel - BOOST 148 Compatible

INTENSE CYCLES // 5
Geometry
A
B
C
F
E
D
G
H
L
K
I
J
GEOMETRY NOTEs
GEOMETRY TAKEN AT TOP OUT WITH 561MM
FORK LENGTH AND 51MM FORK OFFSET.
Component spec NOTE
the Acv is designed around the use of
single chain ring. Use of a double or
triple ring set will not allow proper
clearance with the frame.
SMALL MEDIUM LARGE XLarge
AWheel Base: 1146 mm/ 45.1” 1172 mm/ 46.1” 1199 mm/ 47.2” 1225 mm/ 48.2”
BTop Tube Length: 573 mm/ 22.6” 599 mm/ 23.6” 624 mm/ 24.6” 651 mm/ 25.6”
CChain Stay Length: 438 mm/ 17.25” 438 mm/ 17.25” 438 mm/ 17.25” 438 mm/ 17.25”
DHead Tube Length: 94 mm/ 3.7” 102 mm/ 4” 114 mm/ 4.5” 119 mm/ 4.7”
EHead Tube Angle: 66.25˚ 66.25˚ 66.25˚ 66.25˚
FReach: 394 mm/ 15.5” 416 mm/ 16.4” 438 mm/ 17.25” 463 mm/ 18.2”
GStack: 620 mm/ 24.4” 628 mm / 24.7” 640 mm/ 25.2” 645 mm/ 25.4”
HBB Height: 334 mm/ 13.15” 334 mm/ 13.15” 334 mm/ 13.15” 334 mm/ 13.15”
ISeat Tube Angle (Effective): 73.8˚ 73.8˚ 73.8˚ 73.8˚
JSeat Tube Angle (Actual): 71˚ 71˚ 71˚ 71˚
KSeat Tube Length: 433 mm/ 17” 458 mm/ 18” 484 mm/ 19” 509 mm/ 20”
LStandover Height: 801 mm/ 31.55” 805 mm/ 31.68” 810 mm/ 31.9” 813 mm/ 32”

6// ACV user manual
exploded view
and b.o.m.
20
19
34
35
2
27
6
27 7
36
31
30
11
12
9
4
8
22 13
5
3
26
5
17
15
33
19
21
25
24
23
19
10
37
14
10
17
23
19
27
18
22 13
4
17
27
19
32
29
16
19
28
1

INTENSE CYCLES // 7
ITEM
NO. ITEM PART
NUMBER DESCRIPTION QTY. TORQUE SPEC.
1Bearing Spacer 130759 Top Link Bearing Spacer (Lower) 1N/A
2Top Link 130762 Forged Top Link 1 N/A
3Box Link 130764 Forged Lower Link 1 N/A
4Bearing Cap
24mm OD 130765 Top Link Bearing Cap (Lower) 2 N/A
5Bearing Cap 130778 Box Link Bearing Cap 4 N/A
6Axle Upper 130780 Top Link Pivot Axle 1 20 Nm /
175 in-lbs
7Bolt Shoulder 130785 Top Link Pivot Bolt 1 20 Nm /
175 in-lbs
8Spacer 130789 Box Link Bearing Spacer 2 N/A
9Hanger 130790 Derailleur Hanger Forged 1N/A
10 Bolt Main Pivot 130791 Bolt Main Pivot 1.5t
Expander Blk 27 Nm /
60 in-lbs
11 Hanger Bolt 130792 Derailleur Hanger Bolt 111 Nm /
100 in-lbs
12 Rear Axle 130799 148 x 12mm
Boost Wheel Axle Kit 111 Nm /
100 in-lbs
13 Cone Adjuster 130807 Pivot Axle Expander Cone 3N/A
14 Bolt Main Pivot
C/G 130819
Bolt Main Pivot 1.5t Expander,
w/int. Threads for Chain Guide,
Silver
17 Nm /
60 in-lbs
15 Bumper 140006 Box Link Bumper 1N/A
16 O-Ring 140013 Seat Clamp o-ring 1N/A
17 Plug 140038 Box Link Pivot Plug 3 N/A
18 Cable Guide
Gromet 140039 Cable Guide Gromet 1 N/A
19 Cable Guide Plug 140040 Cable Guide Plug 6 N/A
20 Seat Collar 346941 Bolt-on 36.1 1N/A
ITEM
NO. ITEM PART
NUMBER DESCRIPTION QTY. TORQUE SPEC.
21 Zerk Fitting 401011 M6 x 1.0 2 5 Nm /
40 in-lbs
22 SHCS M6 x 22 410009 Cone Adjuster Bolt,
Socket Head, M6 x 22 314 Nm /
125 in-lbs
23 BHCS M5 X 12 410010 Water Bottle Bolt,
Button Head, M5 X 12 26 Nm /
54 in-lbs
24 SHCS M6 x 40 410053 Shock Bolt, Front,
Socket Head, M6 x 40 17 Nm /
60 in-lbs
25 SHCS M6 x 45 410054 Shock Bolt, Rear,
Socket Head, M6 x 45 17 Nm /
60 in-lbs
26 Bearing 7902 430007 15 x 28 x 7 2RS MAX Angular
Contact Bearing 4N/A
27 Bearing 6802 430008 15 x 24 x 5 2RS
MAX Radial Bearing 4N/A
28 Guard Flack Rear
Strut 500260 Flack Guard ACV Rear Strut 1 N/A
29 Guard Flack DT 500262 Flack Guard ACV Down Tube 1 N/A
30 Guard Flack CS 500266 Flack Guard ACV Chainstay 1 N/A
31 Guard Flack SS 500267 Flack Guard ACV Seatstay 1 N/A
32 Chain Stay
Protector 500268 Chain Stay Protector, ACV 1 N/A
33 Decal California
Bear 500300 Decal California Bear 1N/A
34 Head Badge 500335 Head Badge Flame Logo 1N /A
35 Front Triangle Front
Triangle Carbon, 4 Sizes 1 N/A
36 Front Triangle Rear
Triangle Carbon, 1 Size 1 N/A
37 Shock Shock Rear Shock, 7.875” x 2”
(200mm x 50.8mm) 1N/A

8// ACV user manual
Assembly
Tools needed
• High Grade, waterproof grease
(Maxima Waterproof Grease
recommended)
• Blue Loctite® #243
• 5mm HEX wrench x2
• 8mm HEX wrench
Recommendation
use Grease on lower linkage bolts
only. use loctite on upper linkage
bolts, dropout bolts and hanger bolt.
PRE FA CE //
Service and maintenance on an Intense bicycle requires special tools, abilities and
knowledge of working on bicycles. It is always recommended to use an authorized
Intense dealer for service and maintenance. Always wear eye protection. It is critical
to use the proper tools, loctite, grease and torque specs during assembly. Failure to
follow these instructions may result in serious bodily injury or death.

INTENSE CYCLES // 9
5
2
1 4
3
CONNECTING TOP LINK TO FRONT TRIANGLE //
A Holding top link (#130762) with
shock mount pointed forward, hold
upper spacers (#130789) against inside
of bearing race (IMAGE #1).
B Match upper link to top tube, making
sure that spacers do not fall out.
C Using upper pivot axle (#130780),
insert through non-drive side of top link
bearing and push through to drive side
bearing, making sure spacers do not fall
out (IMAGE #2). Install shoulder bolt
(#130785) into drive side of top link
pivot, and tighten to 20 NM or 175 in/
lbs (IMAGE #3).
CONNECTING BOX LINK TO FRONT TRIANGLE //
A Hold bearing caps (#130778) with
rounded ends facing outwards against
bearings on box link (#130764) (IMAGE
#4), (note box link orientation in image
#4, with rubber bumper facing upward
and rearward on box link).
B Match link to front triangle and from
non drive side, insert greased main pivot
bolt (#130819) through the non-drive
side of frame (IMAGE #5).
C Use 8mm HEX to install, then torque
pivot bolt (#130819) to 7 NM or 60 in/lbs.

10 // ACV user manual
7
68
9
CONNECTING REAR TRIANGLE
TO BOX LINK //
A Follow previous step to connect rear
triangle to box link (IMAGES #6 & 7).
B Use 8mm HEX to install, then torque
pivot bolt (#130791) to 7 NM or 60 in/lbs.
CONNECTING REAR TRIANGLE
TO TOP LINK //
A Hold spacers (#130765) with squared
edges against the bearing and the rounded
edges facing outward (IMAGE #8), Swing
the seat stays up and align with the lower
spacers. From the non drive side of top
link, install greased pivot bolt (#130791)
(IMAGE #9).
B Use an 8mm HEX to install. Torque
main pivot bolt (#130791) to 7 NM or
60 in/lbs.

INTENSE CYCLES // 1 1
TIGHTENING SEATSTAYS TO TOP LINK //
A Grease and install adjuster cone
(#130807) into head of main pivot bolt
(#130791) and greased M6x22mm bolt
(#410009) through the adjuster cone
into the main pivot bolt (IMAGE #14).
B Using hand pressure, squeeze the top
of seat stay together at the lower top
link location to eliminate side to side
play (IMAGE #15) then use a 5mm HEX
to make snug.
C Torque M6x22mm (#410009) to 14 NM
or 125 in/lbs (IMAGE #16).
INSTALLING REAR SHOCK //
A Holding the rear shock in one hand, match the forward end to the foward shock
mount on the frame and install greased M6x40mm bolt (#410053) through drive side
of frame (IMAGE #10). Do not tighten.
B Match rear end of shock to desired travel setting (see below) on upper link and
install greased M6x45mm bolt (#410054) through non-drive side of link (IMAGE #11).
C Torque shock bolts (#410053 & #410054) to 7 NM or 60 in/lbs (IMAGES #12 & 13).
adjustable travel NOTE
the top link of the Acv features dual mounting positions. The Upper shock mounting
hole on top link is for LONG travel, the lower hole is for SHORT travel. for more
information see the set up guide on page 14.
1510 12
14 1611 13

12 // ACV user manual
INSTALLING ADJUSTER CONES ON LOWER LINK //
A Grease and install adjuster cone
(#130807) into head of main pivot
bolt (#130819 / #130791) and greased
M6x22mm bolt (#410009) through the
adjuster cone into the main pivot bolt
(IMAGES #17 & 18).
B Torque M6x22mm (#410009) to 14 NM
or 125 in/lbs (IMAGE #19).
INSTALLING DERAILLEUR HANGER //
A Grease outer edges of derailleur hanger
(#130790) and loctite derailleur bolt
(#130792) (IMAGE #20).
B Insert hanger (#130790) into back
of frame opening and match derailleur
bolt (#130792) from outside of frame,
threading bolt into hanger (IMAGE #21).
C Torque derailleur bolt (#130792) to
11NM or 100 in/lbs (IMAGE #22).
2017
19 2118
22

torque
Achieving proper torque is vital to
ensuring the safe performance and
function of the Acv carbon frame.
Failure to do so could result in sub-
optimal performance of your frame
as well as premature wear and tear
of individual parts.
additional reference
In addition to this chart, all torque
values are laser etched onto
corresponding hardware for your
reference.
INTENSE CYCLES // 1 3
torque chart
20 Nm / 175 in/lbs
7 Nm / 60 in/lbs
7 Nm / 60 in/lbs
M8 HEX 7 Nm / 60 in/lbs
M5 HEX 14 Nm / 125 in/lbs
M8 HEX 7 Nm / 60 in/lbs
M5 HEX 14 Nm / 125 in/lbs
M8 HEX 7 Nm / 60 in/lbs
M5 HEX 14 Nm / 125 in/lbs
11NM or 100 in/lbs

seatpost
make sure to insert seat post at least
4” into the main frame. Anything less
than this amount could cause damage
to the frame or even failure.
14 // ACV user manual
set up
adjustable travel
upper mount: 130mm
lower mount: 115mm
upper mount
lower mount
4”

INTENSE CYCLES // 1 5
shock setup
rock shox monarch rt3 200x51mm
set up and tune
proper set up and tuning can
vary from shock to shock. Please
consult the rockshox manual
included with your bike for complete
information about set up, tuning
and general maintenance or visit
www.sram.com/rockshox/products
Travel 112 mm 125 mm
Shock Stoke 51 mm
Shock Sag 20% when sitting on the bike
Fork Sag 25-30% when sitting on the bike
SHOCK: ACV Pro Rock Shox Monarch RT3 200x51 mm DB2 MM S 320
SHOCK: ACV Foundation Rock Shox Monarch R 200x51 mm DB2 MM S 320
RIDER WEIGHT (LBS/KGS) SPRING (PSI) REBOUND (clicks out) SPRING (PSI) REBOUND (clicks out)
100 lbs / 45 kgs 89
2 to 3
99
2 to 3
110 lbs / 50 kgs 104 114
120 lbs / 54 kgs 120 130
130 lbs / 59 kgs 136 146
140 lbs / 63.5 kgs 151 161
150 lbs / 68 KGS 167
3 to 4
177
3 to 4
160 lbs / 73 kgs 182 192
170 lbs / 77 kgs 198 208
180 lbs / 82 kgs 213 223
190 lbs / 86 kgs 229 239
200 lbs / 91 kgs 244 254
210 lbs / 95 kgs 260 270
220 lbs / 100 kgs 275 285
230 lbs / 104 kgs 291
5 to 6
301
5 to 6
240 lbs / 109 kgs 306 316
250 lbs / 113 kgs 322 332
260 lbs / 118 kgs 337 347
270 lbs / 122 kgs 353 363
280 lbs / 127 kgs 368 378
290 lbs / 131.5 kgs 384 394
300 lbs / 136 kgs 399 409

16 // ACV user manual

INTENSE CYCLES // 1 7

18 // ACV user manual
maintenance
GENERAL SERVICE AND CARE //
You have purchased a high performance bicycle which requires a certain level of service
and maintenance to sustain the level of performance your frame was designed around.
Proper care will also ensure the bike is safe to ride at all levels. It is important to read
and understand the carbon care information as well as follow the maintenance schedule
and inspect your bicycle before each ride. These will not only help to limit or avoid costly
repairs but will also help to avoid injury due to service neglect and component failure.
carbon care
Intense Cycles employs advanced composite techniques and materials in
our frames which do require a certain level of care and maintenance to
ensure a safe experience at the high level of performance each frame is
designed around. Not following these guidelines will decrease the level
of performance and possibly cause injury or death.
• Use a soft cloth with warm soapy water to clean the carbon surfaces. Do
not use abrasive cloths or cleaners.
• Be sure all frame surfaces in contact with cables are protected. Cable
housing rubbing on carbon can wear over time.
• Be sure brake levers, handle bar ends and the fork crown do not contact
the frame at full rotation.
• Never clamp any part of a carbon frame in a bike stand or car rack.
• Always inspect your frame if you experience any chain suck. Intense
frames come equipped with steel chain suck plates but damage can still
be done in the event of chain suck.
• Always inspect your frame in full after a crash to be sure there is no
damage. Look for cracks, dents or loose fibers. If you discover damage
in any degree it’s best to have your frame inspected by a qualified
Intense Cycles dealer. Any direct impact to the frame can cause serious
structural damage.
• Use high grade waterproof grease on seat post, BB and head set bearing
contact areas with the carbon.
• Never ream or face a carbon frame.
• Be sure to follow all recommended torque settings.

INTENSE CYCLES // 1 9
maintenance Schedule*
Action Every Ride 500 Miles or
1 Month
2000 Miles or 6
Months
4000 Miles or
1 Year
Tires Check air pressure, inspect tread and sidewalls for tears and punctures X
Chain Brush off and lubricate X
Brakes Squeeze brakes and confirm function X
General Clean complete bike of mud and debris X
Headset Check adjustment X
Box Link Add grease thru zerk fittings X
Frame Pivots Check torques X
Spokes Inspect for damage, check tension X
Shock and Fork Check air pressure, inspect for leaks X
Deraileur Cables Inspect and lube X
Seatpost Clean and regrease interface with frame X
Frame Pivots Remove pivot bolts, check bearings for pitting and wear X
Headset Disassemble stem, headset and fork. Check bearings for pitting and wear X
Hubs Pull wheels off, check hub bearings for pitting and wear X
Bottom Bracket Remove crank arms and check BB bearings for pitting and wear X
Brakes Replace brake pads X
Chain Inspect for damage and check for stretching X
General Complete Tune-Up X
Shock and Fork Overhaul See MFG Recommendations
* THE ABOVE MAINTENANCE SCHEDULE IS ONLY A GUIDELINE. refer to COMPONENT MANUFACTURER FOR SPECIFIC INSTRUCTION ON MAINTAINING THEIR PARTS.

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Intense Cycles USA 42380 rio nedo Temecula, Ca. 92590
www.INTENSeCYCLES.com
330014