Profile Design AERIA1 EVO User manual

AERIA¹EVO AEROBAR
REVISION 01-02-28-2019

2
AERIA¹ EVO Aerobar
Thank you for purchasing this Profile Design bar. These instructions apply to the Aeria¹ Evo complete bar with Ergo armrests and 35a extensions.
Please read these instructions thoroughly before attempting to install this item. Proper installation is required for compliance with Profile Design's
warranty policy. If you are not familiar with the installation of aerobars or their accessories, please seek the assistance of your local Profile Design dealer
by logging on to www.profile-design.com and using "Dealer Locator" or by calling Profile Design's customer service number p.# 888.800.5999.
INTRODUCTION
Tools and materials required:
• 5mm Hex Wrench
• 4mm Hex Wrench
• Torque Wrench with a 4mm and 5mm Hex fitting
• Assembly compound
• Lithium grease
• Isopropyl alcohol
• Cutting guide and hacksaw (18T blade for Aluminium, 32T for Carbon) Or a pipecutter for aluminium
• Half round file
• Electrical/Insulation tape
• Clean, lint free cloth
Note to Dealers: If you install this product for the consumer, please provide him/her with this owner’s manual after installation.

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AERIA¹ EVO Aerobar
If anything is missing from the aerobar kit please contact your dealer.
Please note that threaded areas have been pre-treated by Profile Design during production with a special blue thread locking compound. This special
compound is easy to detect on the threads of all bolts provided. If you cannot detect this thread locking compound or you are re-installing the bolt, re-apply
a suitable blue thread locking compound as available from Loctite® or another company before assembly.
Optional accessories compatible with this aerobar:
• Profile Design Aeria riser kit
• Boom or Race armrests
• Other extensions from the Profile Design range – 45/25a and 50a
• Older generation armrests – F35, F22, F19
• Older generation extensions – T1, T2, T3, T4, T5 add V2, V4 extensions in carbon and aluminium
Periodically check the aerobars for damage, particularly for scratches through the anodised coating that could lead to oxidation and
weakening of the aluminum. Replace your aerobars if you notice any damage from use or accident.

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AEROBAR COMPONENTS PARTS
A B
01 05 06
02 03
35 36
0407 0910
08 3711
34
AERIA¹ EVO Aerobar

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17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
12
13 14 15 16
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Ref.#Part#
QTY.
Req. Part Description
1 852254 1 Basebar - Aeria1 EVO 42cm Carbon UD-Matte BK w/UV BK Logo
2 189370 1Bracket - Aeria EVO Top bracket Flat BK w/UV BK Logo Left
3 189371 1Bracket - Aeria EVO Top bracket Flat BK w/UV BK Logo Right
4 189372 2Bracket - Aeria EVO Bottom bracket Flat BK
5 852245 1 Extension - 35a 340mm Side A Black Logo
6 852246 1 Extension - 35a 340mm Side B Black Logo
7 313511 4 Bolt-M6*20 SHB Half thread
8 313573 2 Bolt- M5*14SHB
9 274461 4Pin new RM1 System w/ Groove
10 275674 4Washer - 6*12*1.5 UCP
11 275565 2Washer-M5 Silver
12 683189 1Riser-Aeria Bridge 5mm Flat Black
13 293120 2Riser-5mm Aeria Flat Black
14 293121 2Riser-10mm Aeria Flat Black
15 293122 2Riser-20mm Aeria Flat Black
16 293123 2Riser-40mm Aeria Flat Black
17 313525 4 Bolt-M6x15mm SHB
18 313528 4 Bolt-M6x20mm SHB
19 313531 4 Bolt-M6x25mm SHB
20 313532 4 Bolt-M6x30mm SHB
21 313530 4 Bolt-M6x35mm SHB Half thread
22 313533 4 Bolt-M6x40mm SHB Half thread
23 313534 4 Bolt-M6x45mm SHB Half thread
24 313535 4 Bolt-M6x50mm SHB Half thread
25 313537 4 Bolt-M6x55mm SHB Half thread
26 313538 4 Bolt-M6x60mm SHB Half thread
27 313539 4 Bolt-M6x65mm SHB Half thread
28 313540 4 Bolt-M6x70mm SHB Half thread
29 313541 4 Bolt-M6x75mm SHB Half thread
30 313542 4 Bolt-M6x80mm SHB Half thread
31 313543 4 Bolt-M6x85mm SHB Half thread
32 313544 4 Bolt-M6x90mm SHB Half thread
33 313548 4 Bolt-M6x95mm SHB Half thread
34 685215 2PAD - RACE/ERGO 10mm L/R
35 200062 1 Armrest - ERGO W/Hook Sticker Side A
36 200063 1 Armrest - ERGO W/Hook Sticker Side B
37 313593 4 Bolt - M6x12 FHB Stainless (SUS304)
AERIA¹ EVO Aerobar

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18.5 mm
15.0 mm
23.0 mm 100.0 mm 67.0 mm
129.4 mm
15.0 mm
10.0 mm
4.6 mm
18.5 mm
87.5 mm
108.4 mm
57.0 mm
22.4 mm
157.5 mm
420.0 mm
19.4 mm
22.2 mm
35.0°
340.0 mm
35.5 mm
100.0 mm
60.0 mm
19.4 mm
28.0 mm
AERIA¹ EVO Aerobar
PART DRAWINGS

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18.5 mm
15.0 mm
23.0 mm 100.0 mm 67.0 mm
129.4 mm
15.0 mm
10.0 mm
4.6 mm
18.5 mm
87.5 mm
108.4 mm
57.0 mm
22.4 mm
AERIA¹ EVO Aerobar

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430mm
AERIA¹ EVO Aerobar
MAXIMUM EXTENSION LENGTH
Please note that the maximum length from the rear of the bracket to the tip of the extensions is 430mm.
Minimum insertion - the extension must completely fill the window in the bracket.
•
No sight line through the bracket is permitted.

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Ref.# Location Bolt Size Torque
1Basebar mount M6x15mm 6Nm (53 inlbf)
2Barrel mount M6x20mm 6Nm (53 inlbf)
3Extension clamp M5x14mm 5Nm (44 inlbf)
4Armrest Bolts M6x13mm CS 4.7Nm (42 inlbf)
5 Stem Clamp 6Nm Max
TORQUE SETTINGS
1.
3.
2.
4.
AERIA¹ EVO Aerobar

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BOLT LENGTHS
Height : 10mm Height : 20mm Height : 40mmSPACER Height : 5mm
Only use Profile Design supplied bolts.
!
35MM 40MM 45MM 50MM 55MM 60MM 65MM 70MM 75MM 80MM 85MM 90MM 95MM 30MM25MM20MM15MM
AERIA¹ EVO Aerobar
• Aerobar Stack is the height of the top of the pads above the centre of the basebar including the cushion.
• Note that the bridge, if used, counts as a 5mm spacer.
• The Bridge should be used for spacer heights above 40mm
• The table shows the aerobar stack with different armrest choices:

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BOLT LENGTHS
Aerobar Stack Spacer Height
(mm) Spacers Used Bolt Length (mm)
Ergo/Race
10mm
Ergo/Race
5mm
57 52 0 0 15
62 57 5 5 20
60 55 10 10 25
65 60 15 5, 10 30
70 65 20 20 35
75 70 25 5, 20 40
80 75 30 10, 20 45
85 80 35 5, 10, 20 50
90 85 40 40 55
95 90 45 40, Bridge 60
100 95 50 5, 40, Bridge 65
105 100 55 10, 40, Bridge 70
110 105 60 5, 10, 40, Bridge 75
115 110 65 20, 40, Bridge 80
120 115 70 5, 20, 40, Bridge 85
125 120 75 10, 20, 40, Bridge 90
130 125 80 5, 10, 20, 40, Bridge 95
Height over 40mm
The Bridge should be used
for spacer heights above 40mm
BRIDGE
HEIGHT : 5MM
AERIA¹ EVO Aerobar

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AERIA¹ EVO Aerobar
1. Apply a thin coating of assembly compound to the
surface of the stem clamping area on the basebar.
2. Fit the stem to the basebar, torquing the bolts evenly
to 5Nm.
3. Apply a thin coating of lithium grease to the surface of the bracket mount
on the basebar.
4. Mount the lower bracket and risers using the bolt lengths (with washers)
specified in the bolt lengths table. (Refer to page 11.)
5. Use the Torque wrench with 5mm Hex to tighten the bolts to 6Nm.
6. If you will be using the AeriaRiser Kit
apply lithium grease to all of the faces of
the risers.
INSTALLATION INSTRUCTIONS

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10º
0º
ASSEMBLY COMPOUND THREADLOCKER LITHIUM GREASE
AERIA¹ EVO Aerobar
7. Apply lithium grease to the upper surface of the
lower bracket.
8. Mount the upper bracket on the lower bracket by
carefully threading the M6x20mm bolts through
the washers and both brackets into the locator
barrels.
9. Adjust the angle of the bracket by altering the depth of the bolts
in the barrels.
10.
Once you are satisfied with the angle and have matched both
sides, use the Torque wrench with 5mm Hex to tighten the bolts
to 6Nm.

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．Torque to 5 Nm
．Torque to 5 Nm
ASSEMBLY COMPOUND THREADLOCKER LITHIUM GREASE
AERIA¹ EVO Aerobar
11. To install the extensions in an aerobar bracket, first apply a light coating of
assembly compound to the inner faces of the extension clamp.
12.
Install the extensions in the desired position and tighten the M5 extension fixing
bolt using the 4mm Hex wrench so they are held snugly.
•
Install the shifters (if using bar end models) as per the shifter
manufacturer’s instructions. We recommend a light coating of
assembly compound on the inside of the extension prior to installing
the shifter.
•
Install the cables as per instructions from the shifter manufacturer.
We suggest routing the cables by pushing through from the cable exit
hole on the bracket.
•
Then use the torque wrench with a 4mm fitting to tighten the extension
clamp to 5Nm.

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40mm
AERIA¹ EVO Aerobar
13.
Carefully determine the required extension length by performing a bike fit or
measuring the existing extensions.
•
The Aeria¹ Evo bracket allows 40mm of extension length adjustment beyond the
minimum insertion. We recommend cutting the extensions 20mm longer than
the minimum insertion point so you have room to both shorten and lengthen the
extensions easily.
•
The windows in the bracket show the minimum insertion – you must not be able
to see through the extension shaft.
14.
Apply a thin layer of lithium grease to the surface of the wing mount.
1. Mark the cut line on the extensions.
2. We recommend checking your measurements after first marking
the cut line to ensure that you do not inadvertently cut the
extensions too short.
3. If using a cutting guide mount it securely in a vice. Then place the
extension in the guide and line up the marked cut line with the slot
in the cutting guide.
•
For aluminium an 18 tooth blade is recommended. Along with
eye protection.
•
For carbon a 32T or carbon specific blade is recommended.
Wrap the extension with insulation tape at the cut line to limit
the risk of splintering the carbon at the blade exit point.
4. If cutting carbon, wear a breathing mask, gloves and eye
protection then dispose of the dust residue carefully. Airborne
dust particles are a respiratory hazard
5. Using the hacksaw, make firm strokes of the blade through the
guide, allowing the blade to do the work. Do not apply excessive
force to the hacksaw as you risk snapping the blade and the
possibility of injury.
6. Alternately, if you are using a pipe cutter (only on aluminium
extensions) – first apply insulation tape either side of the cut line
to protect the finish of the extension from the rotating wheels.
7. Line the cutter up carefully with the cut line then rotate with a
smooth motion, gradually depressing the cutting wheel further as
the cut depth increases.
8. Repeat the process for the second extension.
9. Once you have cut both extensions, use the half round file to
remove any sharp edges from both the interior and exterior faces
of the extension.
How to cut the extensions
•
No sight line through the bracket is permitted.

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．Torque to 4.7 Nm
ASSEMBLY COMPOUND THREADLOCKER LITHIUM GREASE
．Torque to 4.7 Nm
RECOMMENDED
ORIENTATION
PERMITTED
ORIENTATION
AERIA¹ EVO Aerobar
15.
Fasten the armrests to the brackets using the M6x13mm or M6x10mm countersunk bolts, note that the Ergo, Race and
Boom armrests have an offset design so care is required to ensure each side is positioned in the same way.
16.
Apply a light coating of Lithium grease to the surface of the bolts as a protective layer against the effects of sweat.
17. Attach the cushion by placing carefully on hook and loop backing of the armrest and hold firmly for 30 seconds. Repeat
for the other armrest. Note that the cushions on these models of armrest are symmetrical, so it doesn’t matter which
side each cushion is applied to.

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A
A
B
AERIA¹ EVO Aerobar
1. To fit the armrests first ensure the inner face of the armrest is free of lint and
grease, if the armrest has previously had a hook and loop sticker applied the
residue should first be removed either mechanically or with a citrus based
solvent.
2. Before applying the hook and loop sticker, you may choose to wipe down the
surface with isopropyl alcohol to ensure good adhesion. Remove the backing
from the hook and loop sticker and apply it to the armrest, smoothing the sticker
out to ensure there are no air bubbles trapped under it.
3. Allow the sticker 24 hours to cure before use.
How to Install new armrests

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Shifting Cables
Brake Cables
Brake Cables
AERIA¹ EVO Aerobar
CABLE ROUTE MAP

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AERIA¹ EVO Aerobar
W
ARNING
•
Profile Design Worldwide Two Year Limited Warranty.
•
Profile Design, LLC (distributor) warrants to the original retail purchaser ("you") that the Profile Design product for which you received this
warranty is free from defects in material and workmanship for (2) two years from the date of original retail purchase.
For more details on this warranty, its exclusions and/or how to make a claim under the warranty please call +1 310.747.0085 extension 161 or
visit www.profile-design.com/pages/warranty

2677 El Presidio Street
Long Beach, CA 90810
Ph: 310-884-7756
w
ww.profile-design.com
© Profile Design LLC