NuVinci N360 User manual

EN
NuVinci®N360 Technical Manual
NL
Technisch Handboek
EN
Technical Manual
DE
Technisches Handbuch
DK
Teknisk Håndbog
FEB 2012

EN
1. THE NUVINCI®N360 SYSTEM
2
NuVinci N360 Shifter
Controlling the ratio of the N360
is simply a matter of rotating the
shifter grip. The shifter display
indicates ratio as a simple
graphic; a hill for slower speeds
and a at for faster speeds.
Since there are no xed gears,
the exact ratio is determined by
your comfort level. Ratio changes
can be made even while pedaling
under high torque.
NuVinci N360 CVP
Ratio changes occur within the
hub, smoothly and easily via
internals that are sealed for life
and maintenance-free. The hub is
compatible with rim, disc, or roller
brakes, and has an integrated
high-quality freewheel that is
serviceable.
The NuVinci N360 is the third
generation continuously variable
drivetrain from Fallbrook
Technologies. The N360 is a
light-weight and durable drivetrain
that shifts smoothly and seamlessly
across the full ratio range
without steps or gaps.
TABLE OF CONTENTS
1. The NuVinci®N360 System .........................2
2. Assembly of Components
Wheel Building ..............................3
Installing the Sprocket..........................4
Hub Interface Orientation and Installation Angle . . . . . . .5
Installing the Hub Interface ......................5
Assembly of Shifter ...........................7
Installing Shift Cable Housing ....................8
Installing Shift Cables and Hardware ...............9
3. Rear Wheel Installation / Removal
Fitting the Rear Wheel ........................11
Disconnecting the Rear Wheel...................12
4. Basic Maintenance & Care
Adjusting Cable Slack ........................13
Cleaning..................................13
Lubrication ................................13
5. Service Instructions
Replacing Shift Cables ........................14
Adjusting Shifter Resistance.....................15
Resetting CVP to Full Overdrive ..................15
Servicing or Replacing Freewheel ................18
Removing the Brake Conguration ................19
Installing the Brake Conguration ................19
6. Technical Data
N360 Specications .........................20
Exploded View .............................21
N360 CVP and Shifter Dimensions ...............23
7. Intellectual Property Notice.........................24
8. Warranty......................................25
1
EN

EN
Installation and repairs must be made by a qualied bicycle mechanic. This manual assumes a level of knowledge and skill consistent with that of an experienced bicycle assembler or bicycle mechanic.
2. ASSEMBLY OF COMPONENTS
Installing the Sprocket Remove the anti-shift retainer (1) by pulling rmly away from the NuVinci CVP. Install a standard 9-spline, 3/32 inch (2.3mm) sprocket (2), followed by the supplied sprocket spacer (3, if required), and secure with the sprocket snap ring (4). fThe sprocket spacer is intended
for sprockets that are 3/32 inch (2.3mm) thick at the inner diameter. If the inner diameter is 0.17- 0.18 inch (4.3-4.5mm) thick, the spacer should not be used.
fThe N360 is compatible with
16 to 22 tooth sprockets.
fInstall the sprocket for a
chainline closest to the CVP.
If hub interface is not installed immediately following the sprocket, replace the anti-shift retainer (1).
The NuVinci N360 is incompat- ible with 1/8 inch (3.18mm) single-speed chains and sprock- ets. Use 3/32 inch (2.3mm) chains and sprockets only. Use of incompatible chains can result in interference with the hub interface and damage to N360 components and may result in a dangerous condition for the rider.
If the sprocket is asymmetric, incorrect installation can result in interference with the hub interface and damage to N360 components and may result in a dangerous condition for the rider. See Section 6 “TECHNICAL DATA” for Sprocket Ratio requirements.
2. ASSEMBLY OF COMPONENTS
34
EN
2.1
2.2 2.3
1
2
3
4
2.2 2.3
1
135mm
2.1
1
Wheel Building
The anti-shift retainer (1)
provides 135mm spacing, and should remain on the CVP during lacing and wheelbuilding.
fMaximum spoke diameter is
#13 / 2.34mm.
fMinimum spoke diameter is
#14 / 2.00mm.
Suggested lacing is a 2-cross pattern for 26-inch and 700c wheels.
fUse a 2-cross pattern only if
the rim allows the nipples to be effectively in-line with the spokes.
For 24-inch or smaller wheels a 1-cross pattern is suggested. Radial lacing is not recommended.

EN
Hub Interface Orientation and Installation Angle
Use the uninstalled hub
interface (1) to determine the desired orientation. fTypical orientation is forward,
parallel to the chain stay or seat stay cable routing.
fMove the hub interface along
the dropout to ensure clearance at different axle positions.
With the hub interface
oriented correctly inside the right dropout, the installation angle (2) is the indicated angle of the drop- out (20 degrees in this example). fUse the markings on the hub
interface to determine your approximate installation angle.
Installation Angle:__________ 2. ASSEMBLY OF COMPONENTS
5
Prior to installation, set the hub interface to the full overdrive (H) position (4). Suspend the hub interface over the right hand axle, and align the axle ats (5) with the installation angle from Step 2.5.
fAlternatively, a no-turn
washer (6) can be installed over the hub interface to align the installation angle.
When the installation angle is aligned, ensure the hub interface is set to full overdrive (H) and seat the hub interface fully onto the shift driver and the spline nut until it is ush with the spline nut, as shown.
Thread the RH Nut (7), serrations facing outward, onto
the axle and tighten to 10-15 Nm (7-11 ft-lbs). Install the rear wheel per Section 3.
2. ASSEMBLY OF COMPONENTS
6
2.4 2.5
2.7 2.8 2.9
2.10
Installing the Hub Interface Remove the anti-shift retainer, if installed (reference Step 2.2).
Ensure that markings between
the splined nut (2) and the shift driver (3) are aligned. If not, refer to Step 5.6.
2.6
1
2
0º
2.4
2.5
20º
2
3
2.6
4
2.7
6
5
20º
2.8
2.9
7
2.10
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EN
EN
Assembly of Shifter Install right brake lever according to the manufacturer’s instruction.
Slide the shifter (1) onto the
handlebar.
fInstall the right hand grip (2)
onto the handlebar according to the manufacturer’s instruc- tions.
Position the shifter such that
the display (3) is visible to the rider and the cables will be unobstructed.
fTighten the clamp bolt to
2.0-2.5 Nm (18-22 in-lbs).
Never use lubricants or solvents to install handlebar grips. Make sure that the shifter and the brake lever function properly and are unobstructed (re-adjust if necessary). Never ride without the handlebar grips. The turning grip of the shifter could become loose. This can result in a severe injury.
2. ASSEMBLY OF COMPONENTS 2. ASSEMBLY OF COMPONENTS
Installing Shift Cable Housing
Route cable housing as shown
from the shifter to the hub interface.
Measure, cut and install the
appropriate length cable housing (4) for the bicycle.
fFull-length housing is recom-
mended for both shift cables.
fMake sure that the cable
housing lengths are sufcient to allow an extreme turning angle. Also consider the inu- ence of adjustable handlebars and stems on the cable housing lengths.
Secure cable housing to the frame.
fThe cable housing must remain
moveable for axle adjustments.
fAvoid tight bends when install-
ing the shift cable housing.
fLeave at least 150mm of hous-
ing unsupported at the hub interface (5) to ease installation and removal of the shift cable hardware.
With housing length correct, install end caps (6) at both ends of each housing.
78
2 .18
1
3
2
2.11 2.12
150mm
4
5
6
4
2.13 2.14
2.11 2.12
2.13
2.14

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EN
2. ASSEMBLY OF COMPONENTS 2. ASSEMBLY OF COMPONENTS Installing Shift Cables and Hardware Pass the shift cables through the appropriate cable housing and ensure the housing is seated completely into the shifter.
fThread both barrel adjusters
completely clockwise (in) to provide maximum installation slack.
Pull the underdrive shift cable
(1) rmly at the rear axle location until it stops, checking to make sure that the NuVinci shift indica- tor (2) goes completely at.
Pass the underdrive shift cable
(3) through the UD cable stop (4) and secure the UD cable stop at the distance shown while pulling the cable rmly.
fEnsure that the cable housing
is seated fully at the shifter.
fUsing a 2mm allen, secure the
cable and torque to 1.5-2.0 Nm (13-18 in-lbs).
fCut the excess cable at a
maximum of 2.0mm from the end of the UD cable stop (5).
Pull the overdrive shift
cable (6) rmly at the hub interface until it stops, checking to make sure that the NuVinci shift indicator goes into a steep hill (7).
fMake sure the underdrive shift
cable and UD cable stop are free and unobstructed.
Pass the overdrive shift
cable (8) through the OD latch (9) and secure the OD latch at the distance shown while pulling the cable rmly.
fEnsure that the cable housing
is seated fully at the shifter.
fUsing a 2mm allen, secure the
cable and torque to 1.5-2.0 Nm (13-18 in-lbs).
fCut the excess cable at a the
OD latch marking (10), and tuck the remaining cable length into the OD latch as shown (11).
The cable hardware should
appear as shown. Assemble to CVP per Step 3.2 and adjust cable slack with barrel adjusters per Step 4.2.
910
2.15 2.16
2.17
2.18
2.19
1
2
3
4
5
120mm
2.15 2.16
7
6
2.17
8
9
10
11
111mm
2.18 2.19

EN
EN
Install the shift cable hardware
following steps A, Band C.
3. REAR WHEEL INSTALLATION/REMOVAL Fitting the Rear Wheel
fPlace the rear wheel into the
rear frame, making sure not to obstruct shift cables.
Slide one no-turn washer (1) each onto each axle end. The serrations of the no-turn washer must bear against the dropout of the frame. The rectangular boss must engage in the dropout of the frame.
fMount the axle nuts (2).
Tightening torque 30 – 40 Nm (266-350 in-lbs).
fFor rim and roller brake appli-
cations, connect the rear brake according to the manufacturer’s instructions.
Improper installation of the no-turn washer will result in damage to the dropout and the hub. Over-tightening may damage parts. Under-tightening can result in the axle sliding in the dropouts.
3. REAR WHEEL INSTALLATION/REMOVAL
Disconnecting the Rear Wheel
fShift to a position that allows
easy access to the shift cable hardware.
Remove shift cable hardware
following steps A, Band C. Loosen and/or remove the axle nuts (3) and the no-turn washers (4).
fFor rim or roller brake applica-
tions, disconnect the rear brake according to the manufacturer’s instructions.
fRemove the rear wheel.
11 12
3.1
3.2
3.3
3.4
1
2
Boss
1
A
B
C
3
3.1
3.2
A
B
C
3.3
3
4
3
4
3.4

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EN
Replacing Shifter Cables Remove cable hardware from both cables and remove shift cables from housing.
Adjusting Cable Slack Cable slack can be adjusted
with the barrel adjusters (1) at the
shifter. Cable slack can be determined by pulling lightly on the cable housing (2) at the shifter and noticing any slack.
f
0.5mm of slack is ideal. Cable slack of more than 2.0mm may cause decreased shift perfor- mance and shift cable durability.
fFor rear wheel removal, ad-
ditional cable slack may be desired to ease shift cable hardware removal, which can be obtained with the barrel adjusters.
4. BASIC MAINTENANCE AND CARE
Lubrication
fThe NuVinci N360 CVP is
provided with permanent lubrication and the CVP internals are maintenance-free for the life of the product.
fThe NuVinci N360 internal
freewheel mechanism is serviceable.
fRegular lubrication will extend
the chain’s service life.
13 14
Cleaning
fYour NuVinci N360
components are sealed and well protected from the external environment. However, do not use water under pressure (such as pressure washers or water jets) for cleaning to prevent malfunctions due to water penetration.
fDuring the winter season, you
should clean your bicycle in shorter intervals so that winter road salt cannot cause any damage.
fDo not use aggressive cleaners.
5. SERVICE INSTRUCTIONS
Remove the Phillips screw
(1) on the bottom of the NuVinci shifter and remove the bottom cover by pulling lightly on the access tab (2).
Using a small at screwdriver
or pointed object, extract the cable anchors (3) and shift cables (4) from the grip pulley. fRotate the grip to access
individual cable anchors.
Install one shift cable, allowing
the shifter housing (5) to guide the cable around the internals until it comes out the other side. Guide the cable through the closest barrel adjuster (6).
Pull the cable through the
barrel adjuster until the cable anchor seats fully into the grip pulley (7).
fRotate the grip to position the
next cable for installation and repeat 5.3 and 5.4.
Reinstall the bottom cover and screw (1). Torque to 0.2-0.3 Nm (2-3 in-lbs).
4.1
4.2 5.1
5.2 5.3 5.4
2
1
4.1
4.2
1
2
3
4
5
6
7
5.1
5.2
5.3
5.4

EN
EN
If the spline nut (3) and
shift driver (4) markings are not aligned, full overdrive will need to be reset.
fIf the markings are not obvious,
full overdrive should result in the hub/wheel rotating 1.8-2 times for every 1 rotation of the CVP sprocket.
Set the hub interface to the full
underdrive (L) position (note this is opposite of normal installation). Reinstall the hub interface (angular position is unimportant), leaving the RH Nut uninstalled.
fThe hub interface will be
used to shift the CVP into full overdrive by hand in the following steps.
5. SERVICE INSTRUCTIONS 5. SERVICE INSTRUCTIONS
15 16
Resetting CVP to Full Overdrive The NuVinci N360 CVP is shipped
in full overdrive with an anti-shift retainer installed (reference Step 2.2).
fIf the hub interface is incorrectly
installed, full ratio range of the CVP may be unavailable, and full overdrive will need to be reset.
If installed on the bicycle, shift the CVP into overdrive (H) as far as possible, and remove the rear wheel per Section 3.
Remove the RH Nut (2) that
secures the hub interface (3), then remove the hub interface by lifting carefully from underneath.
H
2
3
5.5
5.5
5.6 5.7
4
3
5.6 5.7 L

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EN
Install the NuVinci N360 CVP
into a vice or xture as shown, clamping on the left hand axle ats.
fIf a vice is not available,
installation in the bicycle frame is possible, tightening only the left hand side no-turn washer and axle nut to allow rotation of the hub interface.
While driving the CVP clockwise
with the sprocket (1), rotate the hub interface (2)
counter-clockwise
toward
the full overdrive (H) position
until a rm stop is felt. Repeat this rotation 2-3 times by driving the CVP clockwise and rotating the hub interface back and forth, ending at a rm stop toward (but likely not at) the full overdrive (H) position.
fThe indicated position of the
hub interface is unimportant in this step.
fWhen in full overdrive, the
hub/wheel should rotate approximately 1.8-2 times for every 1 rotation of the CVP sprocket.
When full overdrive is found, remove the hub interface per Step 5.5. Check to make sure the mark on the spline nut and shift driver align per Step 5.6. Install hub interface per Steps 2.4 through 2.10.
At all times while rotating the wheel, sprocket, or hub interface, be careful not to catch or pinch ngers.
5. SERVICE INSTRUCTIONS
Remove the rear wheel per Section 3. Remove the hub interface per Step 5.5. Reference the Exploded Diagram on Page 22. Remove the sprocket snap ring (12), sprocket spacer (13, if installed), and sprocket (14).
Remove the snap ring (15) on
the shift driver, and remove the freewheel assembly (16).
fIf servicing or replacing,
use a medium-weight oil or lightweight water-resistant grease and check function.
Remove the interior snap ring
(17), needle bearing (18), and RH shield (19) if these components are being replaced.
Install the serviced / new free- wheel components according to the Exploded Diagram on Page 22. Install sprocket and hub interface per Section 2. Install the rear wheel per Section 3. Servicing or Replacing Freewheel
Set the NuVinci N360 CVP in full overdrive with the front shifter or hub interface prior to removal.
5. SERVICE INSTRUCTIONS
17 18
5.8
5.9
5.10 5.11
17
18
19
16
15
5.10 5.11
5.8
5.9
1
2
fReference Exploded Diagram P.21