Specialized SHIV User manual

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USER MANUAL - ENGLISH
SHIV

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THIS BRIEF USER MANUAL CONTAINS IMPORTANT
INFORMATION. PLEASE READ CAREFULLY AND STORE IN A
SAFE PLACE.
This user manual is specific to your Specialized Shiv. It contains important
safety, performance and technical information, which you should read
before your first ride and keep for reference. You should also read the entire
Specialized Bicycle Owner’s Manual (“Owner’s Manual”), because it has
additional important general information and instructions which you should
follow. If you do not have a copy of the Owner’s Manual, you can download
it at no cost at www.specialized.com, or obtain it from your nearest
Authorized Specialized Retailer or Specialized Rider Care.
Additional safety, performance and service information for specific
components such as seatpost or pedals on your bicycle, or for accessories
such as helmets or lights, may also be available. Make sure that your
Authorized Specialized Retailer has given you all the manufacturers’
literature that was included with your bicycle or accessories. If there is a
difference between the instructions in this manual and the information
provided by the component manufacturer, please refer to your Authorized
Specialized Retailer.
When reading this user manual, you will note various important symbols
and warnings, which are explained below:
WARNING! The combination of this symbol and word
indicates a potentially hazardous situation which, if not
avoided, could result in serious injury or death. Many of the
Warnings say “you may lose control and fall.” Because any
fall can result in serious injury or even death, we do not
always repeat the warning of possible injury or death.
CAUTION: The combination of the safety alert symbol
and the word CAUTION indicates a potentially hazardous
situation, which, if not avoided, may result in minor or
moderate injury, or is an alert against unsafe practices.
The word CAUTION used without the safety alert symbol
indicates a situation which, if not avoided, could result in
serious damage to the bicycle or the voiding of your warranty.
INFO: This symbol alerts the reader to information which is
particularly important.
GREASE: This symbol means that high quality grease should
be applied as illustrated.
CARBON FRICTION PASTE: This symbol means that carbon
friction paste should be applied as illustrated to increase
friction.
TORQUE: This symbol highlights the correct torque value
for a specific bolt. In order to achieve the specified torque
value, a quality torque wrench must be used.
TECH TIP: Tech Tips are useful tips and tricks regarding
installation and use.
INTENDED USE
The Shiv is intended and tested for Road Riding only (Condition 1). For more
information on intended use and structural weight limits, please refer to the
Owner’s Manual.
WARNING! The Specialized carbon components on the Shiv
bicycle are designed for a maximum rider weight of 240
lb (109 Kg). Do not ride these components if your weight,
including any gear and accessories you are wearing, exceeds
this weight limit. Failure to follow this warning may result in an
accident, which can cause serious injury or death.
GENERAL NOTES ABOUT ASSEMBLY
This manual is not intended as a comprehensive assembly, use, service,
repair or maintenance guide. Please see your Authorized Specialized
Retailer for all service, repairs or maintenance. Your Authorized Specialized
Retailer may also be able to refer you to classes, clinics or books on bicycle
use, service, repair, and maintenance.
WARNING! Due to the high degree of complexity of the Shiv,
proper assembly requires a high degree of mechanical expertise,
skill, training and specialty tools. Therefore, it is essential that the
assembly, maintenance and troubleshooting be performed by an
Authorized Specialized Retailer.
WARNING! Many components on the Shiv, including, but not
limited to, the seatpost, headset and cockpit components, are
proprietary to the Shiv. Only use originally supplied components
and hardware at all times. Use of other components or
hardware may compromise the integrity and strength of the
assembly. Shiv specific components should only be used on the
Shiv and not on other bicycles, even if they fit.
WARNING! Never modify your frame or components in any
way. Do not sand, drill, file, or remove parts. Do not install
incompatible forks or components. An improperly modified
frame, fork, or component, can cause you to lose control and fall.
In order to successfully build the Shiv bicycle, it is very
important to follow the order of operations as outlined in this
manual. Modifying the order of assembly will result in a longer
build process.
TOOLS / TORQUE SPECS
WARNING! Correct tightening force on fasteners (nuts, bolts,
screws) on your bicycle is important for your safety. If too
little force is applied, the fastener may not hold securely. If
too much force is applied, the fastener can strip threads,
stretch, deform or break. Either way, incorrect tightening force
can result in component failure, which can cause you to lose
control and fall.
Where indicated, ensure that each bolt is torqued to
specification. After your first ride, and consistently thereafter,
recheck the tightness of each bolt to ensure secure attachment
of the components. The following is a summary of torque
specifications in this manual:
TABLE OF CONTENTS
INTENDED USE .........................................................................................................................................3
GENERAL NOTES ABOUT ASSEMBLY................................................................ 3
TOOLS / TORQUE SPECS ........................................................................................................................ 3
GENERAL NOTES ABOUT MAINTENANCE.......................................................... 4
REPAIR STAND.......................................................................................................................................... 4
WARRANTY ............................................................................................................................................... 4
ASSEMBLY ....................................................................................................... 6
REAR BRAKE - FRAME.............................................................................................................................6
Di2 WIRE ROUTING - FRAME..................................................................................................................6
BOTTOM BRACKET ..................................................................................................................................7
FORK / HEADSET ASSEMBLY................................................................................................................. 7
SEATPOST / SADDLE ASSEMBLY.......................................................................................................... 8
SEATPOST INSERTION ............................................................................................................................9
BASEBAR ASSEMBLY.............................................................................................................................. 9
Di2 WIRE ROUTING - BASEBAR.............................................................................................................10
FRONT BRAKE ROUTING - FORK...........................................................................................................11
BRAKE ROUTING - BASEBAR................................................................................................................. 11
SPACER STACK / TOWER STUD LENGTHS...........................................................................................12
SPACER STACK / BASEBAR ANGLE....................................................................................................... 13
EXTENSION SOCKET ASSEMBLY...........................................................................................................14
Di2 WIRE ROUTING - COCKPIT...............................................................................................................15
RESERVOIR / FUELCELL DRINKING TUBE ...........................................................................................16
NUTRITION FUELCELL REMOVAL ..........................................................................................................17
BETWEEN-THE-ARMS (BTA) MOUNT INSTALLATION .........................................................................18
COCKPIT REMOVAL FOR TRAVEL.......................................................................................................... 18

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CAUTION: Ensure that all contact surfaces are clean and bolt
threads are greased or have a threadlocking compound (refer
to the instructions for each bolt) prior to installation.
The following tools are required for installation of this product:
2, 2.5, 3, 4, 5, 6mm socket-style Allen keys
Custom 3mm extended Allen hex (Crossbar)
8mm open wrench (Tower Studs)
Torque wrench
High-quality grease
Cable housing cutters
Carbon assembly compound (fiber paste)
Blue threadlocker
GENERAL NOTES ABOUT MAINTENANCE
The Shiv is a high performance bicycle. All regular maintenance,
troubleshooting, repair and parts replacement must be performed by
an Authorized Specialized Retailer. For general information regarding
maintenance of your bicycle, please refer to the Owner’s Manual. In addition,
routinely perform a mechanical safety check before each ride, as described in
the Owner’s Manual.
Great care should be taken to not damage carbon fiber or composite
material. Any damage may result in a loss of structural integrity, which
may result in a catastrophic failure. This damage may or may not be
visible in inspection. Before each ride, and after any crash, you should
carefully inspect your bicycle for any fraying, gouging, scratches through
the paint, chipping, bending, or any other signs of damage. Do not ride
if your bicycle shows any of these signs. After any crash, and before you
ride any further, take your bicycle to an Authorized Specialized Retailer
for a complete inspection.
While riding, listen for any creaks, as a creak can be a sign of a problem
with one or more components. Periodically examine all surfaces in bright
sunlight to check for any small hairline cracks or fatigue at stress points,
such as welds, seams, holes, and points of contact with other parts. If you
hear any creaks, see signs of excessive wear, discover any cracks, no
matter how small, or any damage to the bicycle, immediately stop riding
the bicycle and have it inspected by your Authorized Specialized Retailer.
Lifespan and the type and frequency of maintenance depends on
many factors, such as frequency and type of use, rider weight, riding
conditions and/or impacts. Exposure to harsh elements, especially salty
air (such as riding near the ocean or in the winter), can result in galvanic
corrosion of components such as the crank spindle and bolts, which
can accelerate wear and shorten the lifespan. Dirt can also accelerate
wear of surfaces and bearings. The surfaces of the bicycle should
be cleaned before each ride. The bicycle should also be maintained
regularly by an Authorized Specialized Retailer, which means it should be
cleaned, inspected for signs of corrosion and/or cracks and lubricated.
If you notice any signs of corrosion or cracking on the frame or any
component, the affected item must be replaced.
Regularly clean and lubricate the drivetrain according to the drivetrain
manufacturer’s instructions.
Do not use a high pressure water spray directly on the bearings. Even
water from a garden hose can penetrate bearing seals and crank
interfaces, which can result in increased bearing and crank wear, which
can affect the normal function of the bearings. Use a clean, damp cloth
and bicycle cleaning agents for cleaning.
Do not expose the bicycle to prolonged direct sunlight or excessive heat, such
as inside a car parked in the sun or near a heat source such as a radiator.
WARNING! Failure to follow the instructions in this section may
result in damage to the components on your bicycle and will
void your warranty, but, most importantly, may result in serious
personal injury or death. If your bicycle exhibits any signs of
damage, do not use it and immediately bring it to your Authorized
Specialized Retailer for inspection.
REPAIR STAND
Due to the Reservoir positioned behind the seatpost, use of a standard
clamping style repair stand should not be used. Specialized recommends
using a fork-mount style work stand which supports the bottom bracket (e.g.
Park PRS-22.2 Team Issue Repair Stand).
CAUTION: Use of an incompatible repair stand may cause
damage to the frame and/or components.
WARRANTY
Warranty information is available from your Authorized Specialized Retailer.
It is also available for download at www.specialized.com.
We may occasionally issue updates and addendums to this document. Please periodically check www.specialized.com or contact Rider Care
to make sure you have the latest information .
Info: [email protected] / 877-808-8154
SPECIALIZED BICYCLE COMPONENTS
15130 Concord Circle, Morgan Hill, CA 95037 [phone]
0000139205_UM_R2, 07/19

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R
O
Q
P
T
U
V
Z
Y
X
AA
W
JJ
II
E
F
G
L
K
M
I
H
S
N
D
B
ACC DD
FF
GG
HH
EE
BB
C
J
DESCRIPTION TOOL SIZE in-lbf Nm
A FRAME
B FORK
C BASEBAR
D BASEBAR SPINDLE 5/6mm (one bolt / nut per spindle)
E BASEBAR WEDGE 5mm 120 13.5
F BASEBAR HOOD
G NOSECONE CLIP
H NOSECONE BRACKET 3mm 22 2.5
I TOWER STUDS 4mm hex / 8mm open 35 4.0
J SPACER STACK
K EXTENSION SOCKET 3mm 22 2.5
L TOWER NUTS 5mm 80 9.0
M BTA MOUNT
N CROSSBAR 3mm 22 2.5
O ARM CUPS
P ARM CUP WEDGE
Q ARM CUP BOLTS 3mm 45 5.1
R ARM CUP PLATES
DESCRIPTION TOOL SIZE in-lbf Nm
S EXTENSIONS
T SEATPOST (SADDLE CLAMP) 5mm 120 13.5
U SEATPOST WEDGE 5mm 55 6.2
V SEATPOST WEDGE COVER
W NUTRITION FUELCELL
X HYDRATION FUELCELL
Y RESERVOIR
Z RESERVOIR UPPER BOLT 5mm 35 4.0
AA RESERVOIR LOWER BOLT 5mm 35 4.0
BB HEADSET RUBBER COVER
CC HEADSET WEDGE CAP 5mm (reverse thread) 22 2.5
DD HEADSET WEDGE BOLT 4mm 26.5 3.0
EE HEADSET WEDGE
FF HEADSET STEERER SHAFT
GG UPPER HEADSET BEARING
HH LOWER HEADSET BEARING
II JCT A BRACKET 2mm 13 1.5
JJ JCT A COVER 2mm 13 1.5

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ASSEMBLY
REAR BRAKE - FRAME
Fig.1: Route the rear brake hose through the frame, starting at the
chainstay port, under the bottom bracket shell, up the down tube and
under the non-drive side of the Nutrition Fuelcell shelf. Continue routing
the hose up the down tube until it exits the port below the head tube.
In order to reduce resistance during installation, we
recommend waiting until the rear brake hose is routed before
installing the junction A bracket in the down tube.
Di2 WIRE ROUTING - FRAME
Fig.1: The following are the recommended routing instructions for Shimano
Di2 wiring on the Shiv. Use the Park IR-1 Internal Cable Routing Kit to
simplify installation of shift wires or cable housings and brake housings.
All wires go over the bottom bracket shell, through the front of the
bottom bracket shell and out the side. The cranks must not be installed
until after the wiring routing is complete.
Make sure the junction A bracket (in front of the SWAT down tube box) is
removed from the down tube.
The frame has a permanently integrated guide tube for the
hydration system. Internal routing will run on either side of this
feature. It is normal to experience some resistance during the
routing process as a result.
Route the wires through the frame.
• Rear derailleur wire: Through the chainstay, starting at the rear
dropout port.
• Front derailleur wire: Down the seat tube, starting at the seat tube port.
• Battery wire: Down the seat tube, starting at the top of the seat tube.
• Lower down tube wire: Under the Nutrition Fuelcell shelf (on the
drive side) and down to the bottom bracket, while leaving the upper
plug dangling out of the Nutrition Fuelcell cavity.
• Upper down tube wire: Down through the port below the head tube
until it exits at the upper opening of the Nutrition Fuelcell cavity.
Guide four wires through the forward facing access hole in the bottom
bracket shell, and out of the frame.
Plug the wires into a Junction B box (SM-JC41), then place the junction
B box and wires back into the down tube, in front of the bottom bracket
shell.
Install the Junction A box (EW-RS910) into the Junction A bracket.
Torque the Junction A box cover bolts to 13 in-lbf / 1.5 Nm.
Di2 WIRE LOCATIONS/LENGTHS
LOCATION QTY TYPE LENGTH (mm)
REAR DERAILLEUR 1 EW-SD50-1 700
FRONT DERAILLEUR 1 EW-SD50-1 300
BATTERY 1 EW-SD50-1 700
DOWN TUBE (LOWER) 1 EW-SD50-1 600
DOWN TUBE (UPPER) 1 EW-SD50-1 300
BASEBAR 2 EW-SD50-1 500
EXTENSIONS 1 EW-JC130 (split wire) 50 / 550 / 550 FRONT
DERAILLEUR
BATTERY
BRAKE UNDER BB
JCT B BOX
(SM-JC41)
JCT A BOX
(EW-RS910)
LOWER
DOWN TUBE
UPPER
DOWN TUBE
REAR
DERAILLEUR
1
DRINKING
TUBE
LOWER DOWN
TUBE WIRE
REAR BRAKE
FUELCELL
SHELF
JCT A BOX
(EW-RS910)

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CAUTION: Ensure that none of the Di2 wires are protruding
into the bottom bracket shell. Any wires protruding into the
shell area can drag on the crank spindle, which can cause
damage to the components.
Plug the upper and lower down tube wires into the Junction A box.
Install the bracket and junction A box into the upper area of the Nutrition
Fuelcell cavity, then install and torque the mounting bolt to 13 in-lbf / 1.5
Nm.
2
SLIDE BATTERY
IN SLEEVE
SPLIT ON
DRIVE SIDE!
PULL ON STRAP TO
REMOVE BATTERY
SEATPOST SLIDES
UP AND DOWN
OVER SLEEVE
SLEEVE SNUG
INSIDE FRAME LOWER
RESERVOIR
BOLT
Fig.2: Install the sleeve over the battery and plug the wire into the
battery. Slide the battery in the seat tube, with the pull tab sticking out
the top. Use the pull tab to remove the battery if needed.
Though the sleeve is triangular, it follows the aero profile of
the seatpost and seat tube, and can only be installed in one
orientation. The shape of the sleeve is designed to hold the
battery inside the seat tube, while allowing the seatpost to
be raised and lowered over the battery and sleeve without
interfering with it.
The split on the side of the sleeve MUST face toward the drive
side of the bike. If the sleeve is oriented any other way, it will
not allow the seatpost to slide over it without interference.
If the lower Reservoir bolt is not installed and the sleeve is
oriented incorrectly, installing the seatpost will force the
battery and sleeve too low into the seat tube, making battery
removal extremely difficult.
Make sure the lower Reservoir bolt (doubles as the upper bottle
cage bolt) is installed prior to inserting the battery in the seat
tube. If the battery is seated too low, it can interfere with the
installation of the bottle cage bolt, and the battery or wire can
be damaged by the bolt.
When installing the bolt, ensure it does not interfere with the
wire coming up the seat tube.
BOTTOM BRACKET
The Shiv is equipped with an OSBB/BB30 spec bottom bracket
shell, with an alloy bearing interface and circlips. A number of
OSBB/BB30-compatible bottom bracket options are available
to work with the Shiv in order to use your preferred OSBB/
BB30-compatible crankset. Please consult with your local
Authorized Specialized Retailer for additional information.
Install the chosen OSBB/BB30-compatible bottom bracket, then install
the matching cranks according to the manufacturer’s specifications.
CAUTION: Do not face or ream the bottom bracket shell!
This can prevent proper installation of the crank. Your
Specialized frame does not require any bottom bracket
shell pre-installation preparation, as all surfaces have been
precisely machined to specific tolerances at the factory for
a proper interface with OSBB/BB30-compatible bottom
brackets and cranksets.
FORK / HEADSET ASSEMBLY
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Fig.3: Position the rear bracket portion of the nosecone between the
fork legs.
The rear bracket portion of the nosecone must be installed
before routing the front brake through the fork. The front brake
routing can be performed with the fork on or off the frame.
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Fig.4: Install the lower nosecone bolts and washers. Torque the bolts to
22 in-lbf/2.5 Nm.

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5
Fig.5: Grease, then install the upper (small) and lower (large) headset
bearings in the frame’s headset cups.
Use of a marine grade grease can help reduce bearing
corrosion.
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A
B
C
D
E
REVERSE
THREAD
Fig.6: Install the fork on the frame.
• Place the fork’s upper and lower crown over the head tube, engaging
the lower bearing on the lower crown. While installing the fork, guide
the Di2 wire and rear brake hose between the lower fork bridge and
the nosecone bracket.
• Grease the head and threads of the steerer shaft (A). Install the
steerer shaft through the upper crown and headset bearings, then
thread into the lower crown.
• Once the headset is adjusted, grease then install the headset wedge
assembly (wedge (B), wedge bolt and spacer (C), wedge cap (D)).
Torque the wedge bolt to 26.5 in-lbf / 3.0 Nm. The wedge locks the
steerer shaft in place.
To perform future adjustments of the headset, loosen the
wedge bolt (C) and remove the wedge assembly from the
steerer shaft. Using a 6mm Allen key, adjust the steerer shaft
position, then re-install the wedge assembly as described in
Fig.6. Ensure that the steerer shaft doesn’t turn and tighten the
headset while tightening the wedge bolt.
There will be significant movement between the fork and head
tube until the steerer shaft is installed and adjusted.
Headset bearing adjustment is performed the same way as
a standard headset, gradually tightening the headset while
rocking the headset back and forth until the movement is
gone, and rotation is smooth and free.
The headset adjustment and steerer shaft wedge installation can
be done later in the assembly, once the front brake is installed.
The wedge cap has a reverse thread, and is for steerer shaft
extraction to remove the fork. It is not to adjust the headset
preload.
• Fig.6: Install the rubber headset plug (E). Align the plug so the shaft
of the plug aligns with the hole and the top is aligned with the crown.
Once properly aligned, the “S” logo will be oriented so as to be
readable when sitting on the bike. Press the plug in so the post at the
base of the plug goes into the headset wedge cap.
SEATPOST / SADDLE ASSEMBLY
ALIGN ARROWS
TAB INTO GROOVE
A B
C
C
DD
E
F
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Fig.7: Install the saddle on the saddle clamp.
• Grease the inboard rail clamp contact surfaces (D), then install them in
the seatpost head assembly (F).
• Position the saddle rails on the inboard rail clamps.
• Position the outboard rail clamps (C) over the saddle rails. Use
7x7mm clamps for alloy rails or 7x9mm clamps for carbon rails.
• Insert the female bolt (E) through one of the outboard rail clamps and
key the bolt tab in the outboard rail clamp groove.
• Apply loctite to the bolt threads (A) and grease to the bolt head and
washer (B), then place the washer on the male bolt.
• Install the bolt in the opposing outboard rail clamp, then thread it into
the female bolt.

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SEATPOST INSERTION
8A
B
C
D
E
Fig.8: Install the seatpost and wedge assembly.
• Apply grease to the bolt threads, bolt head and washer (A), and the
contact surfaces between the upper (B), middle (C) and lower (D)
wedge parts.
• Install the rubber wedge cover (E) onto the seatpost.
• Apply carbon assembly compound (fiber paste) to the seatpost, then
insert the seatpost into the seat tube. Guide the battery strap (fig.2,
P.3) into the seatpost before installing the seatpost in the seat tube.
• Assemble the seatpost wedge, then insert it into the frame, in front of
the seatpost.
• Once the saddle height is determined torque the seatpost wedge bolt
to 55 in-lbf (6.2 Nm).
• Slide the rubber wedge cover down over the wedge assembly.
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MINIMUM INSERTION:
75mm
SIGHT HOLE
Fig.9: Both the frame and seatpost have minimum insertion requirements.
In addition, the frame has a maximum insertion requirement.
MINIMUM INSERTION: The seatpost must be inserted into the frame
deep enough so the minimum insertion/maximum extension (min/max)
mark on the seatpost is not visible, and/or the seatpost is visible through
the sight hole. Both the frame and seatpost require a minimum of 75mm
of insertion. This hole is only visible when the Reservoir is not installed.
MAXIMUM INSERTION: 200mm.
CAUTION: The Reservoir may limit the seatpost insertion. The
seatpost and/or saddle rails must have enough clearance to
not touch the reservoir.
WARNING! Failure to follow the seatpost and frame insertion
requirements may result in damage to the frame and/or
seatpost, which could cause you to lose control and fall.
WARNING! For general instructions regarding the installation
of the seatpost, refer to the appropriate section in the Owner’s
Manual. Riding with an improperly tightened seatpost can
allow the saddle and seatpost to slide down, which can
damage the frame and cause you to lose control and fall.
WARNING! Inspect the seatpost and seat tube to ensure that
there are no burrs or sharp edges. Remove any burrs or sharp
edges using fine grit sandpaper.
The Shiv seatpost length is 350mm, and is available in two
offsets. If the seatpost is at the maximum insertion and the
saddle is too high, the seatpost can be cut. Once cut, the
minimum insertion line on the seatpost will no longer be accurate.
To ensure adequate insertion, make sure the seatpost has the
required insertion, and/or is visible through the sight hole.
Do not apply grease to the contact surfaces between the
seatpost and the seat tube. Grease reduces the friction, which
is critical to proper seatpost grip. Specialized recommends the
application of carbon assembly compound (fiber paste), which
can increase friction between carbon surfaces. Please visit
your Specialized Authorized Retailer for additional information.
BASEBAR ASSEMBLY
At this time, the rear brake hose and main down tube wire
should be sticking out the port below the head tube, between
the fork legs and below the lower bridge of the fork.
B
A
C
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DO NOT GREASE!
Fig.10: Install the Basebars.
• Grease the inside surface of the four fork lobes.
• Choose the spindles that correspond to the desired Basebar angle (0
or 20 degree position) and orient the spindles accordingly (if using the
+/- 20 position options).
• The Basebars are side-specific. Position a Basebar all the way
against the fork between the lobes, then guide a spindle through a
lobe, through the Basebar and through the 2nd lobe. Make sure the
spindle is centered within the lobes.
• Torque the cinch bolt and cinch nut on each end of the spindles to
50% of the final torque (40 in-lbf / 4.5 Nm), then apply full torque to
the 6mm hex nut side (80 in-lbf / 9.0 Nm) while holding secure the
opposite side from rotation.
• Once the spindle is installed through the Basebar, pull the Basebar
outward to seat it against the spindle.

10
+20°
0°
-20°
+20°
0°
-20°
B
A
C
11
Fig. 11: The 0 degree spindle option orients the Basebars parallel to the
ground (B). The 20 degree spindle option allows the Basebars to be angled
up (A) or down (C).
The 0 degree spindles have no specific orientation. The 20
degree spindles can be flipped according to the desired
Basebar angle (up or down).
The fit between the spindles and the lobes may be tight, and
may require a light tap using a rubber mallet.
The spindles can be installed from front-to-back or
back-to-front. However, if cables and wires have already been
installed, back-to-front is easier.
1
3
2
12
SPINDLE
WEDGE
BASEBAR
Fig.12: Install the wedge assemblies.
• Grease the bolt and the three wedge pieces (do not grease the
surface that interfaces with the spindle), then install each wedge
piece individually inside the Basebar.
The wedge parts are labeled 1, 2 and 3 (see fig.12).
• Once the three wedge pieces are in position, install the wedge bolt.
1
3
2
13
Fig.13: Torque the wedge bolts to 120 in-lbf / 13.5 Nm.
While tightening the wedge bolt, wiggle the Basebar until the
up-and-down slack in the Basebar goes away. Make sure the
interface between the spindle and wedge is complete. Post
tightening, grab the Basebar and forcefully pull up and down to
make sure the wedge is fully seated.
Make sure the Basebars are angled as desired and match each
other. If the angles do not match each other or the Basebars
are angled while using 0 degree spindles, the system may
require re-installation.
Di2 WIRE ROUTING - BASEBAR
The rear portion of the nosecone must be installed before
routing the brake hoses and shift wires.
JCT B BOX
(SM-JC41)
UPPER DOWN TUBE
WIRE (300mm)
BASEBAR WIRE
(500mm)
BASEBAR WIRE
(500mm)
14
Fig.14: Route the Basebar wires.
• Plug the main wire exiting between the fork and the nosecone into a
Junction B box.
• Plug a 500mm length wire into the Junction B box, then route it up
through the port in the underside of the upper fork bridge, and out
one side of the upper fork bridge.
• Route the wire through the Basebar port, and guide the wire through
the Basebar until it exits the front of the Basebar.
• Repeat the process for the other Basebar.
The Di2 wires must be routed through the Basebars before the
brake hoses, otherwise there will not be space to insert the
wires through the ports.

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FRONT BRAKE ROUTING - FORK
FRONT BRAKE
EXIT PORT
FRONT BRAKE
HOSE
15
Fig.15: Route the front brake hose through the fork, starting at the fork
leg port, until it exits the port between the upper and lower fork bridges.
BRAKE ROUTING - BASEBAR
FRONT
BRAKE
FORK BRIDGE
EXIT PORT
16
REAR
BRAKE
HEAD TUBE
EXIT PORT
17
Fig.16/17: Route the front and rear brake hoses.
• Guide the brake hoses up through the opening at the front of the
upper fork bridge port and out the respective sides depending on the
desired placement for the brake levers (front brake on the left or right
side), then through the Basebar ports until they exit the Basebars at
the brake lever ends.
• Install the brake hoses on the levers according to the manufacturer’s
instructions.
• Plug the Di2 wires into the ports in the brake levers, then install the
levers in the Basebars.
• Adjust the housings so the curves through the cockpit, nosecone,
frame and fork are optimized (no sections that are taut or bowing
excessively).
Once the housing length through the frame and fork is set, install
the calipers on the chainstay and fork, to use as guides when
trimming the hoses to their final lengths. Each hose should
have a gradual curve to the caliper. Once trimmed, unmount the
calipers from the chainstay and fork, then install the hoses and
mount the calipers according to the manufacturer’s instructions..
The hose routing through the nosecone area should not
touch the sides of the nosecone bracket (Fig.17). Any contact
between the nosecone bracket and the hoses can make
installation of the nosecone clip more difficult, and cause
damage to components over time.
The frame can handle a bit of excess length. The fork is less
forgiving about excess hose length due to the shorter path.
TRIM HOSE FLUSH
WITH BOTTOM OF
CALIPER HOLE
GRADUAL CURVE
18
Fig.18: Install the brake calipers on the chainstay and fork, then gradually
trim the hoses so when they’re seated inside the calipers, the hoses have
slight curves.
Once the hose lengths are set, install the hoses on the calipers according
to the manufacturer’s instructions.
19
Fig.19: Install the left and right Basebar hoods over the Basebar. Make
sure the hoods are oriented correctly for proper hood fitment. The hoods
side-specific (L/R), and are supplied in three shapes (-20, 0, +20),
depending on the chosen Basebar angle. Please refer to the markings
on the hoods.
Apply the front brake to double-check the headset adjustment and adjust
if necessary.

12
SPACER STACK / TOWER STUD LENGTHS
SPACER STACK 0 5 10 15 20 25 30 35 40 45 50 55
STUD LENGTH 30 40 50 60 70 80 90
SPACER STACK 60 65 70 75 80 85 90 95 100 105 110 115
STUD LENGTH 90 100 110 120 130 140 150
Choose the Spacer Stack (0 - 115mm spacers) to match the Tower Stud lengths (30 - 150mm studs). Tower Studs are marked in 10mm increments
on the wrench flat. E.g. A 40mm Spacer Stack requires a 70mm Stud. Adjust the Basebar angle to match the Spacer Stack (see Spacer Stack /
Basebar Angle table).

13
SPACER STACK / BASEBAR ANGLE
SPACER -20 0+20
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
RECOMMENDED BASEBAR ANGLE
RECOMMENDED BASEBAR ANGLE
RECOMMENDED BASEBAR ANGLE
The table above shows the recommended Basebar angle based on the
desired Spacer Stack.
NO HEX HOLE ON TOP!
FLANGE
AGAINST
FORK!
UP ETCHING
POINTING UP
20
Fig.20: Thread the Tower Stud into the fork. Proper stud orientation
requires that the Allen(hex) hole must be facing down and the wrench
flat flange must be against the fork. The top of the Tower Stud must NOT
have an Allen key hole on it.
WARNING! Tower Studs need to be properly oriented, inserted,
and torqued as described and illustrated above.
Each Tower Stud is etched with the millimeter length and the
word “UP” with an arrow. The Tower Stud must be positioned
so the wording is right side up and the arrow points up.
Make sure the Tower Studs are properly aligned when
threading into the fork.
The bolts must be threaded all the way down until the flange
rests against the top of the fork, then torqued to specification.
USE EITHER A 4MM
ALLEN KEY AND
TORQUE FROM BELOW,
OR USE AN 8MM OPEN
WRENCH AT THE BASE
OF THE TOWER STUD
21
CAUTION: When tightening the Tower
Studs with an 8mm open wrench,
avoid contact between the wrench and
the carbon lip at the top of the fork
tower. Contact between the wrench
and the lip may cause damage.
Fig.21: Torque the Tower Studs to 35 in-lbf/4.0 Nm.
Fig.21: The Tower Studs can be tightened either with a 4mm
Hex key from underneath the upper fork bridge, or with an
8mm open wrench from the upper side.
When threading the Tower Stud into the upper fork bridge, the
threads will have significant resistance during the threading
process. This resistance is normal. Install the Tower Studs
until the flanges are fully seated against the fork and torqued
to specification. If the flange will not seat against the fork,
remove the stud, clean the threads, ensure proper orientation
and reinstall the stud.
22
Fig.22: Install the Spacer Stack that corresponds to the chosen Tower
Stud length (see Spacer Stack/Tower Stud table).

14
MAX:
20mm
MIN:
12mm
22
FIG.23 WARNING!
Always use the proper Tower Stud length that corresponds to
the chosen Spacer Stack shown in the Spacer Stack/Tower
Stud table. When the proper Tower Stud length is used, there
should be approximately 12-20mm of exposed threads above
the installed Spacer Stack. Use of an incorrect Tower Stud
length (either too long or too short) may compromise the
structural integrity of the assembly.
The spacers are keyed to fit only one way. Make sure the stack
spacers are not installed upside down.
EXTENSION SOCKET ASSEMBLY
The Extension Socket is directional, with the pointed end facing
forward, matching the profile of the Spacer Stack. The Internal
Cable Routing (ICR) ports must be facing forward.
If you’re performing a fit, it is recommended to complete the fit
before routing the extension Di2 wires, to prevent unnecessary
disassembly.
24
Fig.24: Install the Extension Socket over the Tower Studs.
25
Fig.25: Install the Tower Nuts on the Tower Studs. Tighten them down
gradually and evenly while alternating between the two Tower Nuts to make
sure the Extension Socket is seated evenly on the Spacer Stack. Once fully
seated, still alternating between the two Tower Nuts, gradually increase the
torque in 20 in-lbf / 2.3 Nm increments, until a torque of 80 in-lbf / 9.0 Nm
is reached.
26
B
A
Fig.26: Determine if the Crossbar will be positioned in front (A) or
behind (B) the Extension Socket, based on fit preference.
27
Fig.27: Grease then install the lockplate inside each Crossbar cavity
prior to installing the extensions.

15
A dab of grease behind the Crossbar Lockplate can help retain
the Lockplate in place while installing the extension. Do not
grease the interface between the Lockplate and the extension.
If the Crossbar will be positioned in front of the Extension
Socket, the extensions need to be installed in the Crossbar first.
If the Crossbar will be positioned behind the Extension Socket,
the extensions need to be installed in the Extension Socket first.
10mm
28
THE MIN/MAX LINES PRINTED
ON THE EXTENSIONS MUST BE
FULLY VISIBLE BEYOND THE
CLAMPS WHEN INSTALLED. DO
NOT CLAMP BEYOND THE LINES
DO NOT CLAMP PAST
FORWARD WINDOW
Fig.28: Position the extensions based on fit preference, then torque the
Extension Socket bolts to 22 in-lbf / 2.5 Nm (fig.29).
WARNING! As illustrated in Fig.28, there is a minimum and
maximum insertion for the extensions. Use as reference the
graduation lines printed on the extensions themselves. The
minimum and maximum lines printed on the extension must be
fully visible beyond the clamps when installed.
The extension must stick out a minimum of 10mm behind the
rear clamp, and the forward window must not be obscured by
the forward clamp. The forward and rearward clamps can be
either the Extension Socket or the Crossbar, depending on the
chosen configuration.
OPTIONAL 10°
WEDGE
29
Fig.29: Position the Crossbar and arm cups based on fit preference.
• The arm cups can be installed in an outboard (fig.30) or inboard
(fig.31) location on the Crossbar. The outboard position has four
lateral options, while the inboard position has two.
• The arm cups also have three fore-aft positions (fig.29/30), in
addition to the Crossbar assembly being able to slide fore-aft.
• The arm cups can also be rotated inward or outward before tightening
the bolts, to fine-tune the arm position relative to the extensions.
30 OUTBOARD SETTING
ARM CUPS ANGLE
IS ADJUSTABLE
THREE (3)
FORE-AFT OPTIONS
FOUR (4)
LATERAL OPTIONS
INBOARD SETTING
31
THREE (3)
FORE-AFT OPTIONS
TWO (2)
LATERAL OPTIONS
Fig.27: Once the Crossbar position is determined, using the provided
50mm long 3mm Hex tool, torque the bolts to 22 in-lbf / 2.5 Nm.
Fig.29: Once the arm cup position is determined, torque the bolts to 45
in-lbf / 5.1 Nm.
Di2 WIRE ROUTING - COCKPIT
EW-JC130
50mm
550mm550mm
32 External
wire
shifters
Fig.32: Install a Y-connector wire (EW-JC130, 50/550/550mm), with

16
each 550mm wire going through the center of the Extension Socket, and
routed internally into the top of the Extension Socket, toward the Di2 exit
ports at the front of the Extension Socket (fig.33/34).
THROUGH
EXTENSION
SOCKET
INTO
EXTENSION
33
THROUGH
EXTENSION
SOCKET THROUGH
CROSSBAR
INTO
EXTENSION
34
Fig.33/34: Route the Di2 wires.
• Once the wires exit the ports, they will either go through the Crossbar
wire channels then into the extensions, or straight into the extensions,
depending on the fore or aft position of the Crossbar.
• Connect the Di2 wires to the shifters, then install the shifters
according to the manufacturer’s instructions.
• Fig.32: Route the Y-wire down the center of the Extension Socket
and Spacer Stack until it exits below the upper fork bridge, then plug
the 50mm section of the Y-wire into the remaining hole in the junction
B box in the nosecone.
RESERVOIR / FUELCELL DRINKING TUBE
BOLT TAB KEYS INTO
RESERVOIR BOLT
HOLE GROOVE
35
36
Install the Reservoir.
• To install the Reservoir, position it behind the seat tube, then grease
and loosely install the upper bolt assembly (fig.35), followed by the
lower Reservoir bolt (fig.36). The lower bolt threads into the upper
bottle cage bolt hole and through the seat tube, then threads into
the Reservoir.
Anytime the Reservoir is being installed, to avoid damage to the
battery and/or wire, look through the seat tube to make sure
the bolt path is clear. Once confirmed, install the bolt through
the seat tube.
• Once the Reservoir is held in place with both upper and lower bolts,
torque the bolts to 35 in-lbf / 4.0 Nm.

17
The frame has a permanent guide tube integrated in the frame.
The Hydration Fuelcell drinking tube is routed through this tube.
37
Fig.37: Install the Hydration Fuelcell in the frame.
• During initial installation, guide the plug and tether through the frame
tube, starting at the nosecone. Once the plug exits the tube inside the
reservoir, plug it into the Hydration Fuelcell drinking tube.
• Pull the tether out the front while guiding the Hydration Fuelcell down into
the Reservoir, until the drinking tube exits the port below the head tube.
• Once the drinking tube exits the frame below the lower fork crown,
disconnect the plug and tether from the drinking tube.
38
Fig.38: Install the Hydration Fuelcell in the Extension Socket.
• Remove the plug and tether from the drinking tube, then guide the
drinking tube up through the underside of the upper fork bridge,
through the stack and out the top of the Extension Socket.
• Install the bite valve.
• When removing the Hydration Fuelcell for cleaning, remove the bite
valve, install the plug with tether and pull the Hydration Fuelcell out of
the Reservoir.
Use the integrated pipe cleaner on the end of the tether to
regularly clean the inside of the drinking tube.
When seating the Hydration Fuelcell inside the Reservoir,
make sure it’s properly seated around the cutout for the upper
Reservoir bolt area. Poor fit around the cutout may result in
reduced fluid capacity.
A
B
39
Fig.39: Make sure all the wires, brake hoses and Fuelcell drinking tube
are in their correct locations, then install the Nosecone clip into the
Nosecone bracket. Position the top portion of the Nosecone clip first (A),
then rotate the bottom (B) until it clicks into place.
To remove the Nosecone clip, grip the lower tabs on the Nosecone clip
and pull to disengage from the Nosecone bracket, then rotate the bottom
forward to disengage from the Nosecone bracket.
To prevent cosmetic damage, pay particular attention to the
tabs as they engage the rear portion of the Nosecone bracket.
NUTRITION FUELCELL REMOVAL
40
* CAUTION: Do not pull up on the tab to remove the Nutrition
Fuelcell from the frame. Too much pull force on the tab can
lead to failure.
Fig. 40: To correctly remove the Fuelcell, insert a hand inside
the Fuelcell and pinch the tab toward the Fuelcell. While
pinching, pull and rotate the Fuelcell out of the frame.

18
BETWEEN-THE-ARMS (BTA) MOUNT INSTALLATION
An optional BTA mount can be installed in front of the Extension Socket/
Crossbar assembly for use with a computer display or optional bottle cage.
41
OPTIONAL BOTTLE
CAGE CAN BE
MOUNTED
RAIL CAN SLIDE
FORE-AFT
BARFLY
MOUNT
Fig.41: Install the BTA mount.
• Open the clamps and place the BTA mount in front or behind the
Extension Socket/Crossbar assembly.
• Swing the clamps shut and tighten the clamp bolts to 18 in-lbf / 2.0 Nm.
• The center rail can slide fore-aft to fine-tune the position of the bottle
or computer display. Make sure the rail doesn’t interfere with the
routing of the drinking tube through the Extension Socket.
COCKPIT REMOVAL FOR TRAVEL
The cockpit assembly can be removed for travel with the simple removal
of the Tower Nuts and unplugging a single wire.
• Remove the Nosecone clip and unplug the single Y-wire (EW-JC130)
coming down through the Spacer Stack from the Junction B box.
• Using a 5mm Allen key, remove the two Tower Nuts on top of the
Extension Socket.
• Lift the Extension Socket off the fork.
• I nstall the Tower Nuts to hold the spacers in place.
42
Fig.42: To drop the Basebars down the side, loosen the two wedge bolts
while wiggling the Basebars until they drop down into a vertical position,
then lightly tighten the wedge bolts to hold the Basebars in place.
Failure to tighten the wedges when the Basebars are in travel
position may result in the Basebars rubbing against the fork legs.

19

20