Yeti Cycles 2011 DJ User manual

YETI CYCLES
600 CORPORATE CIRCLE, UNIT D
GOLDEN, CO 80401
888.576.9384
USA
2011 DJ OWNER’S MANUAL

Table of Contents
Brand Overview 6
Frame Features 8
Geometry 10
Maintenance Schedule 12
Bike Setup
ūCable Setup 14
ūDropout Adjustment 16
Warranty 18
Contact Information 19

6
OVERVIEW
Overview
WELCOME TO THE TRIBE
Congratulations on your purchase of a new
Yeti bicycle and welcome to the Yeti Tribe. We
are confident your new bicycle will exceed your
expectations for value, performance and ride quality.
Each frameset and component has been custom
specified and designed to enhance your riding
experience. Whether you are a beginner cyclist or
a seasoned-pro, Yeti bicycles will provide endless
hours of two-wheeled fun.
GENERAL INFORMATION
This model-specific manual is designed to be
used in conjunction with the general Yeti Owner’s
Manual and the manuals supplied by the suspension
manufacturers. If you did not receive the Yeti
Owner’s Manual or the manual provided by the
suspension manufacturer, download the materials
off the Internet, or contact you dealer.
Bicycling can be a hazardous activity even under
the best of circumstances. Proper maintenance of
your bicycle is your responsibility and when done
properly helps reduce the risk of injury and damage
to your bicycle. This manual outlines basic setup
and maintenance recommendations of your new
Yeti. Because it is impossible to anticipate every
situation or condition that may occur during the
assembly, setup and maintenance of your bicycle,
Yeti recommends that all service and repairs be
performed by an authorized Yeti dealer.
Warning: Make sure you review and understand the warnings, instructions and content of this manual and
accompanying manuals for your bicycle.
Warning: Technological advances have made bicycles and bicycle components more complex and the pace of
innovation is increasing. It is impossible for this manual or accompanying manuals to provide all the information
required to properly repair and maintain your bicycle. In order to help minimize the changes of injury, it is critical for you
to have work performed by an authorized Yeti dealer.
This manual contains many “Warnings” and
“Cautions” concerning the consequences of failure
to maintain or inspect your bicycle. The combination
of the safety alert symbol and the word “Warning”
indicates a potentially hazardous situation in which,
if not avoided, could result in serious injury or death.
The combination of the safety alert symbol and the
word “Caution” indicates a potentially hazardous
situation in which, if not avoided, may result in minor
injuries or damage to your bicycle or a component
of your bicycle. Be sure to read and understand all
“Warnings” and “Cautions”.

8
Frame Features
FEATURES
1. HEADTUBE
The DJ utilizes a tapered headtube for added stiffness with no
weight penalty.
2. TUBING
Oversized custom hydroformed tube set with integrated yokes
3. SQAURE LOOPSTAYS
Singular square loopstays provides added stiffness and a sleek
aesthetics. Accommodates a 2.5’’ tire.
4. BOTTOM BRACKET
73mm shell, for use with a 113mm spindle.
5. ISCG ‘05 MOUNTS
ISCG tabs are machined into the bottom bracket. This is far
superior than flimsy welded tabs. These ISCG tabs allow a chain
guide to be bolted directly to the frame, which eliminates the
twist and shift of the guide.
6. DROPOUTS
Adjustable sliding dropouts that allow for 25mm of adjustment.
Optional single-speed specific dropout
1
4
3
2
5
6

10
Geometry
GEOMETRY
*All measurements are in inches.
C
K
F
E
G H
I
B
A
D
J
GEOMETRY DJ
100 MM FORK
SM MD LG
A13.8 13.8 13.8
B22.6 23.6 24.6
C68.5 68.5 68.5
D70.5 70.5 70.5
E15.6-16.1 15.6-16.2 15.6-16.3
F40.4-41.0 41.4-42.0 42.4-43.0
G12.5 12.5 12.5
H27.1 26.9 26.7
I4.50 4.50 4.50
J18.5 18.5 18.5
K1.5 1.5 1.5

12
Maintenance
MAINTENANCE
MAINTENANCE Following these guidelines will help maintain the performance of your bicycle and prevent
more serious problems from arising. It is important to remember that service intervals can vary depending
on climate, trail conditions, and riding frequency.
Caution: The torque specications listed should be used as a guide when performing maintenance. Technological
advances have made bicycles and bicycle components more complex, and the pace of innovation is increasing.
Because of these advances, Yeti recommends that you refer to the torque specications of the manufacture’s component
you are adjusting. In order to help minimize the chances of injury, do not perform any maintenance that you are not
condent can be completed within your abilities.
MAINTENANCE? Not sure how to work on your own bike?
Contact your authorized Yeti dealer or visit www.parktool.com
and check out the repair help section. This section contains
detailed instruction on many of the service items listed in the
maintenance schedule.
TORQUE We have attached a brief list of torque specifications for bolts and components that may need to
be tightened while performing basic maintenance. This is just a guide. For specific torque specifications,
please contact the component manufacturer directly.
TORQUE SPECS
Pivot Bolts 125 -150
Derailleur Hanger Bolts 30 -45
Handlebar Binder Bolt 150 -180
Stem Binder Bolt 175 -260
Seatpost Binder Bolt 150 -180
Saddle Clamp Bolts 175 -250
Rear Derailleur 70 -86
Front Derailleur Clamp 45 -60
Chainring Bolts 88 -132
ACTION WEEKLY MONTHLY 3 MONTHS ANNUALLY
Clean and lube chain x
Check tire pressure x
Clean bike of mud and debris (never
spray water directly into frame or
components)
x
Check brake function x
Check shock pressure, if applicable x
Check for loose bolts and tighten, if
necessary
x
Check headset and tighten / loosen, if
necessary
x
Thoroughly clean pivot points with a
rag (do not lubricate)
x
Replace brake pads, if necessary x
Check tires for wear x
Check spoke tension and retention, if
necessary
x
Check chain for worn, damaged, or
loose links, replace chain if necessary
x
Complete tune-up performed by an
authorized Yeti dealer
x

14
The DJ has full cable housing. By using full cable housing, we have eliminated break points in the line
of your shifter housing. This allows riders to experience better overall shifting performance by reducing
the entrance of unwanted elements such as sweat and sediment. Use of full cable housing helps prevent
corrosion from the elements and keeps the shifting smoother for a longer period of time.
Cable Setup
SETUP HOUSING
Caution: The failure to properly route shifter housing can cause malfunction of the shift mechanism and unexpected
shifting of gears.
REAR DERAILLEUR Fit the housing from the rear shifter along the
head tube and through the bolt-on cable stops on the bottom of the
top tube. There are three bolt-on stop groups on the bottom of the top
tube to which the housing and brake line can be attached, each with two
positions to secure housing. Fit the rear housing line along the top tube
through these stops, using the position closest to the drive side.
Next route the housing around the outside of the seat tube on the drive side
and down the drive side seatstay. Attach the housing using the two bolt-on
cable stops on the top of the seatstay. Loop the housing into the derailleur
to finish.
REAR BRAKE The rear brake line loops across the head tube and runs
through the three bolt-on cable stops on the non drive side of the top
tube. Use the position closest to the non-drive side on the cable guides for
the rear brake line.
Next route the brake line around the seat tube and down the non drive side
seatstay. Use the two bolt-on cable guides on the bottom of the seatstay
to secure the line. Ensure the line is finished on the inside of the seatstay
when attached to the caliper body. This will prevent the brake line from
being compromised if the bike or rider falls.
BOLT-ON CABLE GUIDES 2011 Yeti frames use bolt-on cable
guides for routing brake and shift housing. The guides allow
for clean cable routing and thier two-piece design keeps the
housing from contacting the frame and marring the finish.
1
2

16
DROPOUT ADJUSTMENT
Adjustable Dropouts
DROPOUT ADJUSTMENT Loosen the two M6x34mm tension bolts
located above the back of the chainstay on each side of the bike.
DROPOUT ADJUSTMENT Loosen the four M8x22mm dropout bolts
located at the chainstay and steatstay junction with a 5mm allen key.
DROPOUT ADJUSTMENT Slide the dropouts to the desired chainstay
length. Use the hash marks on the dropouts to ensure both dropouts
are square and the rear wheel is centered in the frame.
DROPOUT ADJUSTMENT Tighten the two M6x34mm tension bolts
on the frame with a 5mm allen key to achieve proper chain tension.
Ensure both sides are tightened equally and the rear wheel stays centered
in the frame.
Torque:10-15 in/LB
DROPOUT ADJUSTMENT Tighten the two M8x22mm dropout bolts
on the drive side of the frame with a 5mm allen key. Repeat for the
non-drive side.
Torque:70-75 in/LB
DROPOUT ADJUSTMENT Double check that the dropouts are square
and the rear wheel is centered in the frame. Ensure that the dropout
bolts are torqued to spec.
Tip: When assembling the DJ for the first time it will be helpful to set the
chainstay to the desired length before measuring and cutting the chain.
This will help ensure proper chain tension for the bicycle. When making a
large adjustment of the chainstay length after the bicycle is fully assembled
be aware that a change to the length of the chain may be necessary.
62
1
3
4
5
The 2010 DJ has adjustable dropouts that allow the chainstay length of the frame to be changed from 395mm
to 410mm. This allows for a total change of 25mm. In addition the wheel can be moved/tensioned with out
affecting the position of the disc brake.

18
Warranty
WARRANTY
YETI LIMITED (2) TWO YEAR FRAME WARRANTY (applies to 303 DH, 303 RDH, 25TH 303 DH, AS-R 7 > 160MM
Fork, DH-9, AS-X, 4X, DJ, SX)
Yeti Cycles will repair or replace, at its option, any frame it determines to be defective materials and / or
workmanship. The (2) two year limited warranty is conditioned upon the bicycle being ridden under normal
conditions and having been properly maintained. This warranty does not apply to the components attached
to the frameset such as suspension components, wheels, drive train, brakes, seatpost, handlebar and stem.
This warranty applies only to the original owner and is non-transferable. This warranty is void if the bicycle
was not properly assembled by an authorized Yeti dealer.
YETI LIMITED (5) FIVE YEAR FRAME WARRANTY (applies to AS-R 5 Carbon, AS-R 5 Alloy, AS-R Carbon, AS-R
Alloy, AS-R-sl(c), AS-R, AS-R 7 w/160MM Fork, 575, ARC, ARC-X, Big Top 29’R, FRO, Kokopelli)
Yeti Cycles will repair or replace, at its option, any frame it determines to be defective materials and / or
workmanship. The (5) five year limited warranty is conditioned upon the bicycle being ridden under normal
conditions and having been properly maintained. This warranty does not apply to the components attached
to the frameset such as suspension components, wheels, drive train, brakes, seatpost, handlebar and stem.
This warranty applies only to the original owner and is non-transferable. This warranty is void if the bicycle
was not properly assembled by an authorized Yeti dealer.
ADDITIONAL CONDITIONS
These limited warranties do not apply to normal wear and tear, nor to claimed defects, malfunction or
failures that result from abuse, neglect, improper assembly, improper maintenance, alteration, collision,
crash or misuse. The original owner shall pay all labor charges connected with the repair or removal of all
components. Under no circumstances does this limited warranty include of the cost of travel or shipment to
and from an authorized Yeti dealer. In order to exercise your rights under these limited warranties, the bicycle
or frameset must be presented to an authorized Yeti dealer, together with proof of purchase.
ūThe above warranties have been in effect since January 2000. All Yeti frames sold prior to that date
had a limited (1) one year warranty on the frameset.
ūNo Fault Replacement Policy
ūYeti Cycles will make replacement parts available at a minimum charge to the original owner in the
event of a crash or any other non-warranty situation. Yeti Cycles does this at its sole discretion and
reserves the right to refuse this offer.
ūIf you have a warranty concern, please contact your authorized Yeti dealer.
NO FAULT REPLACEMENT POLICY
Yeti Cycles will make replacement parts available at a minimum charge to the original owner in the event of a
crash or any other non-warranty situation. Yeti Cycles does this at its sole discretion and reserve the right to
refuse this offer. If you have a warranty concern, please contact you authorized Yeti dealer.
PRODUCT LIFE CYCLE
Every Yeti frameset has a useful product life cycle. The length of that useful product life cycle will vary
depending on the construction and materials of the frameset, maintenance and care the frameset receives,
and the amount and type of use the frameset is subjected to over its life. Yeti recommends that an authorized
Yeti dealer should inspect the frame for stress annually. Frame stress could cause potential failure and the
signs are usually apparent in the form of cracks, fracture lines, deformation, dents and other visual indicators
of abnormality. These safety checks for frame stress are important to prevent accidents, injury to the cyclist
and product failure of a Yeti frameset.
DISCLAIMER
Yeti Cycles is not responsible for any damages to you or others arising from riding, transporting or other
use of your bicycle. In the event that your frame breaks or malfunctions, Yeti Cycles shall have no liability or
obligation beyond the repair or replacement of your frame pursuant to the terms outline in this warranty.
CONTACT INFO
Yeti Cycles
600 Corporate Circle, Unit D
Golden, CO 80401
(p) 303-278-6909
(f) 303-278-6906
WWW.YETICYCLES.COM
BUSINESS HOURS
Monday-Friday
8AM-11:30AM, 1:00PM-5:30PM
(Mountain Time)