Rocky Mountain Element User manual

1
Rocky Mountain
Element
Technical Manual
Date: August 17th, 2016
Rev B

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Table of Contents
Materials Required..................................................................................................................... 3
Suspension Pivot Torque Guide................................................................................................. 4
Small Parts Torque Guide.......................................................................................................... 5
Assembly Instructions................................................................................................................ 6
1) Bearing Installation.......................................................................................................... 6
1.1 Main Pivot..................................................................................................................... 6
1.2 Top Link & Chain Stay .................................................................................................. 6
2) Frame Assembly ............................................................................................................. 7
2.1 Chain Stay Installation .................................................................................................. 7
2.2 Top Link Installation...................................................................................................... 8
2.3 Seat Stay Installation .................................................................................................... 9
2.4 Shock Installation.........................................................................................................10
3) Plastic Component Installation .......................................................................................11
3.1 Downtube Cable Port...................................................................................................11
3.2 Head Tube Cable Ports................................................................................................11
3.3 Chain Stay Protector....................................................................................................12
3.4 Seat Stay Protector......................................................................................................12
4) Rear Axle & Rear Derailleur Hanger...............................................................................13
5) Cable Routing.................................................................................................................14
5.1 Internal Cable Noise Damping Hose............................................................................14
5.2 Head Tube Port Cable Routing ....................................................................................15
5.3 Frame Cable Routing...................................................................................................15
6) Bearing Removal............................................................................................................16
6.1 Main Pivot....................................................................................................................16
6.2 Top Link & Chain Stay .................................................................................................16

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Materials Required
-Rocky Mountain Element MY 2017 Frame
-6900 Bearing Tool
-Loctite 243 (blue)
-Grease
-Torque Wrench
o3mm, 4mm, and 6mm Hex Key Bits
-4mm and 5mm Hex Keys
-Isopropyl Alcohol
-Clean Rags
-Blind Puller (10mm OD)

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Suspension Pivot Torque Guide
Note: All Torque values are +/-- 10%
Description
Part #
Location
Tool
Torque
Notes
kg-cm
Nm
lb-in
A
Shock
Bolts &
Screws
1807049 &
180566-016 FBY
Top Link
5mm &
4mm Hex
Keys
80
8
70
Torque only with
correct shock and
hardware installed.
Apply grease to
shock bolts, and
Loctite 243 (blue) to
screw threads.
1807062 &
180566-016 FBY
Front
Triangle
Two 4mm
Hex Keys
B
Top Link
Bolts &
Screws
1807047 &
180566-012 FBY
FT-TL
Pivot
6mm &
4mm Hex
Key
80
8
70
Apply grease to
pivot bolts, and
Loctite 243 (blue) to
screw threads.
1807048 &
180566-012 FBY
SS-TL
Pivot
C
Dropout
Pivot
Screws
1807046
Dropouts
6mm Hex
Key
175
17
152
Apply Loctite 243 to
female seat stay
threads.
D
Main
Pivot
Bolt
1807045
Main
Pivot
6mm Hex
Key
175
17
152
Apply grease to
inner bearing races
and Loctite 243 to
female chain stay
threads.
A
B
C
D

5
Small Parts Torque Guide
Note: All Torque values are +/-- 10%
Description
Part #
Location
Tool
Torque
Notes
kg-cm
Nm
lb-in
E
Counter
Sunk M5-
0.8x16mm
1806009
Head Tube
Cable Port
3mm Hex
Key
<9
<1
<8
Loctite 243 (blue).
Tighten until snug.
Downtube
Cable Port
F
Rear Axle
Nut
1807046
Drive-Side
Dropout
6mm Hex
Key
204
20
177
Left hand thread,
apply Loctite 243
(blue) to male
threads.
G
Rear Axle
1807045
Non-Drive-
Side Dropout
6mm Hex
Key
104
10
90
Apply grease to
axle shaft and
threads. Use
Stainless Steel
Washer (3227006)
on non-drive-side.
E
F, G

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Assembly Instructions
1) Bearing Installation
1.1 Main Pivot
1) Using 6900 Bearing Press, install non-
drive-side Enduro 6900 2RS MAX
(1807042) Bearing.
2) Grease exterior of Main Pivot Spacer
(1807051), slide into main pivot.
3) Using 6900 Bearing Press, install drive-
side Enduro 6900 2RS Max Bearing.
4) Inspect bearings for proper seating
against front triangle.
1.2 Top Link & Chain Stay
1) Grease top link
bearing bores.
Do not grease
chain stay bearing
bores.
2) Using 6900 Bearing Press, install
Enduro 6900 2RS MAX (1807042)
Bearings into each pivot.
Note: Bearings press into chain
stay from inboard side.
3) Inspect
bearings for
proper seating
against
component.

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2) Frame Assembly
2.1 Chain Stay Installation
1) Grease outside of main pivot
bearing inner races, and outer
surface of Main Pivot Bolt
(1807045).
Apply Loctite 243 (blue) to female
threads on the drive-side of the
chain stay yoke.
2) Slide chain
stay over front
triangle main
pivot.
3) Install Main Pivot
Bolt.
Torque to 17 Nm.

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2.2 Top Link Installation
1) Grease outside of TL-FT Pivot Bolt
(1807047), small faces of 6900 Bearing
Spacers (1807044), and small inner face
of 6900 Bearing Cap (1807043).
Apply Loctite 243 (blue) to M6-1.0 x
12mm SS Screw (180566-012 FBY)
threads.
2) Insert 6900 Bearing Spacers so that
small faces contact the inboard
inner races of the top link bearings.
3) Slide top link and 6900 Bearing Spacers
over front triangle. Install TL-FT Pivot Bolt.
4) Pass M6-1.0 x 12mm SS Screw
through 6900 Bearing Cap, and
thread into TL-FT Pivot Bolt.
Torque to 8 Nm.

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2.3 Seat Stay Installation
1) Grease outside of TL-SS Pivot Bolt
(1807048), small faces of 6900 Bearing
Spacers (1807044), and small inner face
of 6900 Bearing Cap (1807043).
Apply Loctite 243 (blue) to M6-1.0 x
12mm SS Screw (180566-012 FBY)
threads.
2) Insert 6900 Bearing Spacers so that
small faces contact the inboard
inner races of the top link bearings.
3) Slide seat stay around the seat tube, and
into top link. Install TL-SS Pivot Bolt.
4) Pass M6-1.0 x 12mm SS Screw
through 6900 Bearing Cap, and
thread into TL-SS Pivot Bolt.
Torque to 8 Nm.
5) Apply Loctite 243 (blue) to inside of
threaded seat stay inserts.
6) Pass Dropout Pivot Screws
(1807046) through chain stay
bearings, and thread into seat stay.
Torque to 17 Nm.

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2.4 Shock Installation
1) Grease outside of Link (1807049) and FT
(1807062) Shock Bolts, as well as the
outside of Outer (1807003) and Inner
(1807004) Ride-9 Chips.
Apply Loctite 243 (blue) to M6-1.0 x
16mm (180566-016 FBY) and M6-1.0 x
12mm (180566-012 FBY) SS Screw
threads.
2) Slide shock, with correct hardware
(see exploded diagram), into front
triangle, slide in FT Shock Bolt from
the drive-side.
3) Select Ride-9 Position using the Outer
and Inner Ride-9 Chips.
4) Slide shock into link, and pass Link
Shock Bolt through Ride-9 Chips,
top link, and shock from the drive-
side.
Note: If the shock is a tight fit,
loosen the TL-SS and TL –FT Pivot
Bolts prior to inserting the shock.
Re-torque the Pivot Bolts after
installing the shock.
5) Pass M6-1.0 x 16mm SS Screw through
M6 Counter-Sunk Washer (18067064),
and thread into FT Shock Bolt.
Torque to 8 Nm.
6) Pass M6-1.0 x 12mm SS Screw
through non-drive-side Ride-9 Chip,
and thread into Link Shock Bolt.
Torque to 8 Nm.

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3) Plastic Component Installation
3.1 Downtube Cable Port
1) Apply Loctite 243 (blue) to Counter Sunk
M5-0.8x16mm (1806009) Screw threads.
2) Pass M5-0.8x16mm Screws through
Downtube Cable Port (1807052)
and thread into front triangle.
Torque to snug (<1 Nm).
3.2 Head Tube Cable Ports
1) Apply Loctite 243 (blue) to Counter Sunk
M5-0.8x16mm (1806009) Screw threads.
2) Pass M5-0.8x16mm Screws through
Drive-Side (1087140) and Non-
Drive-Side (1097136) Head Tube
Cable Ports and thread into front
triangle.
Torque to snug (<1 Nm).

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3.3 Chain Stay Protector
1) Clean drive-side chain stay with isopropyl
alcohol and a clean rag.
2) With the Chain Stay Protector
(3707001) aligned on the chain stay;
mark the leading edge with masking
tape, to use as an installation guide.
3) Remove backing paper from Chain Stay
Protector, and using the masking tape
guide, install the protector on the chain
stay.
Press and hold the Chain Stay Protector
firmly, to ensure proper adhesion.
4) Remove masking tape guide, and
clean any residue with isopropyl
alcohol and a clean rag.
3.4 Seat Stay Protector
1) Clean drive-side seat stay with isopropyl
alcohol and a clean rag.
2) With the Seat Stay Protector
(3708003) aligned on the seat
stay; mark the leading edge
with masking tape, to use as an
installation guide.
3) Remove backing paper from Seat Stay
Protector, and using the masking tape guide,
install the protector on the chain stay.
Press and hold the Seat Stay Protector firmly,
to ensure proper adhesion.
4) Remove masking tape guide,
and clean any residue with
isopropyl alcohol and a clean
rag.

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4) Rear Axle & Rear Derailleur Hanger
1) Apply Loctite 243 (blue) to Axle Nut
(3227001) threads.
Note: Axle Nut and derailleur hanger are
left hand (reverse) threaded! Turn
counter-clockwise to tighten.
2) Pass Axle Nut through seat stay,
and thread into derailleur hanger.
Note: Select the correct rear
derailleur hanger, either Shimano
Direct Mount (3227002) or Standard
Mount (1097132).
Torque to 20 Nm.
3) Grease Rear Axle (3227009) body and
threads.
4) Pass Rear Axle through Stainless
Steel Washer (3227006), seat stay,
hub, and thread into Axle Nut.
With hub installed, torque to 10 Nm.

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5) Cable Routing
5.1 Internal Cable Noise Damping Hose
We recommend our riders install our Foam Tubes to damp cable noise within the frame.
Note: Only the one cable is shown in this image for clarity.
1) Pour isopropyl alcohol
down Foam Tube to
lubricate foam tube.
Foam Tube for 4mm
Housing (3337001).
Foam Tube for 5mm
Housing (3337002).
2) Slide one Foam Tube over each internal cable, prior to
routing cables through frame.
Note: The Foam Tubes do not fit through either the
head tube or down tube cable ports.

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5.2 Head Tube Port Cable Routing
Colour Coding:
Green –5mm Hose (hydraulic lines or smaller)
Blue –4mm Housing (mechanical shift cable housing or smaller)
Red –3mm Cable (electronic cables or smaller)
Note: Use a zap-strap to affix cables before installing port, as shown.
5.3 Frame Cable Routing
Colour Coding:
Green –Brake Hose
Orange –Internal Dropper Post Hose
Purple –Shock Remote
Blue –Side Swing Front Derailleur Cable
Red –Di2 Front Derailleur Cable
Pink –Rear Derailleur Cable

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6) Bearing Removal
6.1 Main Pivot
1) Use a blind puller seated against the bearing inner races to remove main pivot bearings.
6.2 Top Link & Chain Stay
1) Align 6900 Bearing
Press against bearing
inner race (inboard for
link, outboard for chain
stay).
2) Pass bolt through 6900
Bearing Press, and thread into
6900 Bearing Cup.
3) Tighten bolt to
remove
bearing.