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Rocky Mountain Maxxis Technical Manual

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TECHNICAL MANUAL
ALTITUDE

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  • Page 1 TECHNICAL MANUAL ALTITUDE...

  • Page 2: Table Of Contents

    Altitude Powerplay Technical Manual Contents Table of Contents Frame Assembly Main Pivot Bearing Installation   3 Chain Stay Bearing Installation   4 Link Bearing Installation   4 Chain Stay Installation   5 Link Installation   6 Seat Stay Installation   8 Shock Installation   10 Powerplay Assembly Bottom Bracket Installation 24MM   11 Bottom Bracket Installation 30MM   12 Spider Removal   13 Crank and Spider Installation Aeffect   14 Crank and Spider Installation Turbine   15 Battery Case Assembly   17 Battery Case Removal   20 Battery Case Installation ...

  • Page 3: Frame Assembly

    Altitude Powerplay Technical Manual Frame Assembly FRAME ASSEMBLY Main Pivot Bearing Installation PA RTS NE E DE D Item Part No. Revision Description BEARING 1807042 ENDURO BEARING 6900 2RS MAX TYPE, 22x10x6 SIZE SPACER, MP 1807038 MAIN PIVOT CENTER SPACER, ID:10, L:48 TOOL S NE E DE D 6900 Bearing Press or suitable Arbor Press A SSE MBLY U sing 6900 Bearing Press, install non-drive-side Enduro S lide Main Pivot Spacer (1807038), slide into main pivot.

  • Page 4: Chain Stay Bearing Installation

    Altitude Powerplay Technical Manual Frame Assembly Chain Stay Bearing Installation PA RTS NE E DE D Item Part No. Revision Description BEARING 1807042 ENDURO BEARING 6900 2RS MAX TYPE, 22x10x6 SIZE CHAINSTAY 1057400CBN/ E-ALT CARBON/ALUMINUM CHAINSTAY 1057410 TOOL S NE E DE D 6900 bearing press or suitable arbor press Link Bearing Installation PA RTS NE E DE D Item Part No.

  • Page 5: Chain Stay Installation

    Altitude Powerplay Technical Manual Frame Assembly INSTA LL ATION a.  G rease top link bearing bores. U sing 6900 Bearing Press, install I nspect bearings for proper seating Enduro 6900 2RS MAX (1807042) against component. b.  D o not grease chain stay bearing Bearings into each pivot. bores. Note: Bearings press into chain stay from inboard side. Chain Stay Installation PA RTS NE E DE D Item Part No. Revision Description AXLE, MP...

  • Page 6: Link Installation

    Altitude Powerplay Technical Manual Frame Assembly A SSE MBLY a.  G rease outside of main pivot S lide chain stay over front triangle a.  I nstall Main Pivot Bolt. bearing inner races, and outer main pivot. b.  T orque to 17 Nm. surface of Main Pivot Bolt (1807029). b.  A pply Loctite 243 (blue) to female threads on the drive-side of the chain stay yoke. Link Installation PA RTS NE E DE D Item Part No.
  • Page 7 Altitude Powerplay Technical Manual Frame Assembly TOOL S NE E DE D • Hex Keys • Loctite 243 • Grease INSTA LL ATION a.  G rease outside of TL-FT Pivot Bolt (1807060), small faces I nsert 6900 Bearing Spacers so that small faces contact of 6900 Bearing Spacers (1807044), and small inner face the inboard inner races of the top link bearings. of 6900 Bearing Cap (1807043). b.  A pply Loctite 243 (blue) to M6-1.0 x 12mm SS Screw (180566-012 FBY) threads. S lide top link and 6900 Bearing Spacers over front triangle. a.  P ass M6-1.0 x 12mm SS Screw through 6900 Bearing Install TL-FT Pivot Bolt. Cap, and thread into TL-FT Pivot Bolt.

  • Page 8: Seat Stay Installation

    Altitude Powerplay Technical Manual Frame Assembly Seat Stay Installation PA RTS NE E DE D Item Part No. Revision Description BOLT, M10x78 1807061 BOLT, 10MM x 78MM, M6x1 INT., AL 7075 T-6, HARD BLACK ANO BOLT 1807046 BOLT, 10MM x 15MM, M10x1 EXT., AL 7075 T-6 HARD BLACK ANO BEARING SPACER 1807044 6900 BEARING SPACER BEARING CAP 1807043 6900 BEARING CAP, AL 7075 T-6, HARD BACK ANO SCREW M6x12 180566-012 FBY FLAT HEAD C'SUNK SOCKET SCREW, M6-1.0 x 12MM, A4/316 SS, 55060.060.012 SEATSTAY 1057401CBN/ E-ALTITUDE CARBON/ALUMINUM SEATSTAY...
  • Page 9 Altitude Powerplay Technical Manual Frame Assembly INSTA LL ATION a.  G rease outside of TL-SS Pivot Bolt (1807061), small I nsert 6900 Bearing Spacers so that small faces contact faces of 6900 Bearing Spacers (1807044), and small the inboard inner races of the top link bearings. inner face of 6900 Bearing Cap (1807043). b.  A pply Loctite 243 (blue) to M6-1.0 x 12mm SS Screw (180566-012 FBY) threads. S lide seat stay around the seat tube, and into top link. a.  P ass M6-1.0 x 12mm SS Screw through 6900 Bearing Install TL-SS Pivot Bolt. Cap, and thread into TL-SS Pivot Bolt. b.  T orque to 8 Nm. A pply Loctite 243 (blue) to inside of threaded seat stay a.  P ass Dropout Pivot Screws (1807046) through chain stay inserts. bearings, and thread into seat stay. b.  T orque to 17 Nm.

  • Page 10: Shock Installation

    Altitude Powerplay Technical Manual Frame Assembly Shock Installation PA RTS NE E DE D TOOL S NE E DE D • Hex keys • 2x 4mm Hex key • Grease • Blue Loctite SHOCK INSTA LL ATION a.  G rease outside of Link (1807049) and FT (1807062) S lide shock, with correct hardware (see exploded diagram) Shock Bolts, Bearing Spacers (1807099), and the outside into front triangle, slide in FT Shock Bolt from the drive-side.

  • Page 11: Powerplay Assembly

    Altitude Powerplay Technical Manual Powerplay Assembly POWERPLAY ASSEMBLY Bottom Bracket Installation 24mm PA RTS NE E DE D Item Part No. Revision Description RACE FACE 24MM BB TOOL S NE E DE D • BB press suitable for 89.5mm shell and 24mm Bearing ID • Grease INSTA LL ATION Ensure the outer faces of the BB shell are free from Paint and faced perpendicular to the cylinder. The BB width should be 89.5mm, and the drive side face is 37.9mm from the frame centre line. On the Race face 24mm BB, remove the red anodized 2.5mm spacer from the plastic centre sleeve assembly. Press BB in as per Race Face instructions, ensuring that it is flush with the outer faces of the BB shell.

  • Page 12: Bottom Bracket Installation 30Mm

    Altitude Powerplay Technical Manual Powerplay Assembly Bottom Bracket Installation 30mm PA RTS NE E DE D Item Part No. Revision Description RACE FACE 30MM BB TOOL S NE E DE D • BB press suitable for 89.5mm shell and 30mm bearing ID • Grease INSTA LL ATION Ensure the outer faces of the BB shell are free from Paint and faced perpendicular to the cylinder. The BB width should be 89.5mm, and the drive side face is 37.9mm from the frame centre line. On the Race face 24mm BB, remove the red anodized 2.5mm spacer from the plastic centre sleeve assembly. Press BB in as per Race Face instructions, ensuring that it is flush with the outer faces of the BB shell.

  • Page 13: Spider Removal

    Altitude Powerplay Technical Manual Powerplay Assembly Spider Removal Remove cranks as per manufacturers instructions. Using a 16 notch external bottom bracket cup tool, remove the clutch bearing lock ring from the drive side crank arm. Remove the clutch bearing and spider from the drive side crank arm’s splines.

  • Page 14: Crank And Spider Installation Aeffect

    Altitude Powerplay Technical Manual Powerplay Assembly Crank and Spider Installation Aeffect PA RTS NE E DE D Item Part No. Revision Description CRANKSET RACE FACE AEFFECT CRANK SET CLUTCH BEARING CLUTCH BEARING SPIDER ASSEMBLY WITH 34T RING CLUTCH BEARING 1347010 LOCKRING CLUTCH 24MM LOCK RING TOOL S NE E DE D •...

  • Page 15: Crank And Spider Installation Turbine

    Altitude Powerplay Technical Manual Powerplay Assembly Thread in the clutch bearing lock ring to the drive side Aeffect arm. Torque to 40Nm. Crank and Spider Installation Turbine PA RTS NE E DE D Item Part No. Revision Description CRANKSET RACE FACE TURBINE CRANK SET CLUTCH BEARING CLUTCH BEARING SPIDER ASSEMBLY WITH 34T RING CLUTCH BEARING 1347006 LOCKRING CLUTCH 30MM LOCK RING TOOL S NE E DE D •...
  • Page 16 Altitude Powerplay Technical Manual Powerplay Assembly A SSE MBLY Place BB cup tool in the vise and secure tightly. Liberally apply grease to the inside of the spline pattern on the clutch bearing/spider assembly. Install the clutch bearing/spider onto the spline of the drive side Turbine arm. Thread in the clutch bearing lock ring to the drive side Turbine arm. Torque to 40Nm.

  • Page 17: Battery Case Assembly

    Altitude Powerplay Technical Manual Powerplay Assembly Battery Case Assembly PA RTS NE E DE D Refer to the Battery BOM for all parts: Item Part No. Revision Description BATTERY 1977060CPS BATTERY, 634W, 48V, LI-ION WITH BALANCING PCM BATTERY, CAP 1997063 BATTERY CAP BATTERY, 1997060 BATTERY COVER, LEFT COVER LT BATTERY, 1997061 BATTERY COVER, RIGHT COVER RT BATTERY, PIN 1997062 BATTERY PIN, 68MM, 6061-T6, HARD BLACK ANODIZE...
  • Page 18 Altitude Powerplay Technical Manual Powerplay Assembly Secure the top end of the battery using the spacer (1997064), 56mm bolt (1807139), and a M6 Screw. Secure the bottom end of the battery with the 72mm bolt, and a M6 Screw.
  • Page 19 Altitude Powerplay Technical Manual Powerplay Assembly Torque the M6 screws to 4Nm. Place the steel plate on the top of the battery as shown using double sided adhesive, ensuring that it is centered and firmly pressed down.

  • Page 20: Battery Case Removal

    Altitude Powerplay Technical Manual Powerplay Assembly Battery Case Removal TOOL S NE E DE D • Hex Key set RE MOVA L Remove Powerplay Drive (See section Powerplay Drive Removal). Unscrew grub screw between bottle bosses on down tube. Unscrew M6 screw and remove battery pin from down tube. Slide battery out of down tube.

  • Page 21: Battery Case Installation

    Altitude Powerplay Technical Manual Powerplay Assembly Battery Case Installation PA RTS NE E DE D Item Part No. Revision Description BOLT, BATTERY 1807127 E-MTB BATTERY BOLT, 8MM OD x 81MML. 81MM AL7075-T6 HARD BLACK ANO SCREW, M6x12 180566-012 FBY FLAT HEAD C'SUNK SOCKET SCREW, M6-1.0 x 12MM, A4/316 SS, 55060.060.012 WASHER 1807064 C'SUNK WASHER: (FOR M6 SCREW) ID:6 X OD: 14.6 x 3.25MM THK. SET SCREW, 1808024 SET SCR., FLT. PT., M5 x 0.8 x 20MML. M5x20 ZINC PLATED. 07860.040.020 BATTERY BATTERY ASSEMBLY ASSEMBLY TOOL S NE E DE D •...

  • Page 22: Charge Port Installation

    Altitude Powerplay Technical Manual Powerplay Assembly Charge Port Installation PA RTS NE E DE D Item Part No. Revision Description CHARGE PORT 1977005 CHARGE PORT SCREW, M3x12 1807117 C'SUNK SOCKET SCREW, M3-0.5 x 12MM TORX TORX, STAINLESS STEEL W/BLUE LOCTITE CHARGE PORT 1997079 CHARGE PORT RUBBER CAP, BLACK RUBBER COVER TOOL S NE E DE D •...
  • Page 23 Altitude Powerplay Technical Manual Powerplay Assembly Torque M3 bolts to 2Nm. Make sure the rubber cap stays in the closed position, protecting the charge port.

  • Page 24: Frame Cabling

    Altitude Powerplay Technical Manual Powerplay Assembly Frame Cabling PA RTS NE E DE D Item Part No. Revision Description CONNECTOR 1977012 DOWN TUBE CABLE JOYSTICK CABLE REAR BRAKE REAR BRAKE WITH ASSOCIATED HYDRAULIC HOSE AND FITTINGS SHIFT CABLE SHIFT CABLE HOUSING FOR REAR DERAILLEUR HOUSING DROPPER CABLE DROPPER POST CABLE HOUSING HOUSING TOOL S NE E DE D...
  • Page 25 Altitude Powerplay Technical Manual Powerplay Assembly RE A R BR A KE HOSE Install the rear brake on the seat stay. Loosely cable tie the hose to the Left side of the chain stay (x3). Do not place the forward-most cable tie at the main pivot. Insert the hose up the Left forward motor mount port to the Left Head tube port. Retrieve the hose end from the head tube port using the J-bend of a spoke. Pull the hose through. Place the rubber cover, olive, and end fitting on the hose. Insert end fitting if needed (Sram). Connect the rear brake lever to the hose as per manufacturer’s instructions. Bleed brake as per manufacturer’s instructions. DROPPE R POST C A BLE Insert the housing up the Left forward motor mount port to the Right Head tube port. Retrieve the housing end from the head tube port using the J-bend of a spoke.
  • Page 26 Altitude Powerplay Technical Manual Powerplay Assembly Pull the housing through. Insert the other end up the Left rear motor mount port at the seat tube: Feed it up until it appears at the seat collar. Making sure a seat collar has been placed on the frame, install dropper post as per manufacturer’s instructions.
  • Page 27 Altitude Powerplay Technical Manual Powerplay Assembly RE A R DE R A ILLEUR C A BLE Route the derailleur housing into the Right side of the chain stay near the main pivot. This housing should slide through a tunnel in the carbon.
  • Page 28 Altitude Powerplay Technical Manual Powerplay Assembly Feed the other end up the right forward motor mount port up to the Left Head tube port. Retrieve the housing end from the head tube port using the J-bend of a spoke. The rear derailleur and shifter installation is as per manufacturer’s instruction.

  • Page 29: Powerplay Drive Removal

    Altitude Powerplay Technical Manual Powerplay Assembly Powerplay Drive Removal TOOL S NE E DE D RE MOVA L Disconnect all 4 electrical cables: Speed sensor connector Battery connector iWoc connector Charge port connector Remove torque arm (see section Torque Arm Removal). Remove lower bash bracket countersunk & upper rear motor mount M8 screws. Slide motor out the left side of the bicycle.

  • Page 30: Torque Sensor Replacement

    Altitude Powerplay Technical Manual Powerplay Assembly Torque Replacement Sensor Remove Powerplay drive. Unscrew 2x M4 screws holding sensor bracket in place. Gently pull sensor bracket away from Powerplay drive case. Disconnect 3 pin connector on sensor from drive. Separate sensor from sensor bracket by loosening grub screw (fig 10) and prying apart. With new sensor connect 3 pin connector. Gently feed connector into slot in Powerplay drive case. Apply hot glue to underside of sensor tray and place in position on Powerplay drive case. Install 2x M4 screws and torque to 3Nm.

  • Page 31: Powerplay Chain Replacement

    Altitude Powerplay Technical Manual Powerplay Assembly Powerplay Chain Replacement On left side of drive, with the motor cover removed, unscrew three M4 screws securing transfer chain cover & remove cover. Locate master link on chain, clean grease off. Using needle nosed pliers, carefully leverage the master link clip off the pins of the master link and remove link. Remove chain. Remove O-rings from motor drive pinon using a pick, and replace with new.
  • Page 32 Altitude Powerplay Technical Manual Powerplay Assembly Install new chain by wrapping it around motor pinion then the driven gear, so that the two ends meet at the centre of the driven gear. Using needle nosed pliers, carefully install the master link, from the backside, so the master link clip is accessible. Cover transfer chain with grease.
  • Page 33 Altitude Powerplay Technical Manual Powerplay Assembly Install transfer chain cover. 10. Install three M4 screws and torque to 2Nm.

  • Page 34: Powerplay Installation Preparation

    Altitude Powerplay Technical Manual Powerplay Assembly Powerplay Installation Preparation PA RTS NE E DE D Item Part No. Revision Description COG, 12T 1347016 TRANSFER DRIVEN COG, 12T, MR.CONTROL P/N: TRSK-TY (WITH FLANGER) LOCKRING, 12T 1347008 CASSETTE LOCKRING, FOR 12T COG. MR CONTROL P/N: M-HUB-12T CLAMP 1997081 CABLE CLAMP, M5 CSUNK. AL6061-T6, HARD BLACK ANO. SCREW, M5x10 180475-010 C'SUNK SOCKET SCREW, M5-0.8x10MM. ZINC PLATED 10.9 STEEL TOOL S NE E DE D •...
  • Page 35 Altitude Powerplay Technical Manual Powerplay Assembly Install the 9T cog on the Torque arm in the orientation shown above. Use blue Loctite on the M5 bolt, and torque to 6Nm.
  • Page 36 Altitude Powerplay Technical Manual Powerplay Assembly DRIVE COG RE MOVA L Using the Shimano splined tool, and chain whip, remove lock ring DRIVE COG INSTA LL ATION L ocate the 12T cog on the Powerplay motor output shaft spline, making sure the shoulder is inboard, and bottomed out on the spline shoulder Apply a small amount of grease to the lock ring threads. Using the Shimano splined tool, and chain whip, torque the drive cog to 40 Nm.

  • Page 37: Powerplay Drive Installation

    Altitude Powerplay Technical Manual Powerplay Assembly Powerplay Drive Installation PA RTS NE E DE D Item Part No. Revision Description SCREW, M8x30 1807121OVT C'SUNK SOCKET SCREW, M8-1.25x30MM, STAINLESS STEEL TOOL S NE E DE D • Hex keys • Loctite A SSE MBLY The motor is installed on the left side of the bicycle. Hold the base of the motor in the palm of your hand, and locate it towards the motor mounts of the bicycle. Pull the rear brake hose, and dropper housing out of the way, and insert the motor into position.

  • Page 38: Lower Bash Bracket Assembly

    Altitude Powerplay Technical Manual Powerplay Assembly Insert the upper rear motor mount bolt first and hand tighten it to hold the motor in position. NOTE: Final torquing steps to follow in section Motor Case Final Torqueing on page 45. Lower Bash Bracket Assembly PA RTS NE E DE D Item Part No. Revision Description BRACE, MOTOR 1997021 DYNAME LOWER MOTOR BRACE AND BASH MOUNT. AL6061-T6 HARD BLACK ANO. BASH GUARD 1997058 RMB BASH GUARD SCREW,...

  • Page 39: Lower Bash Installation

    Altitude Powerplay Technical Manual Powerplay Assembly TOOL S NE E DE D • Hex keys A SSE MBLY Locate the Bash Guard on the bracket fingers. Insert the custom Hex SS M5 screws and torque to 6Nm. Lower Bash Installation PA RTS NE E DE D Item Part No. Revision Description SCREW, M8x25 1807123OVT C'SUNK SOCKET SCREW, M8-1.25x25MM, STAINLESS STEEL SCREW, M8x65 1807122OVT C'SUNK SOCKET SCREW, M8-1.25x65MM, STAINLESS STEEL SCREW, M8x50...
  • Page 40 Altitude Powerplay Technical Manual Powerplay Assembly TOOL S NE E DE D • Hex keys • Loctite 243 INSTA LL ATION Apply blue Loctite to the three countersunk M8. Locate the bash bracket assembly below the Powerplay Motor casing.
  • Page 41 Altitude Powerplay Technical Manual Powerplay Assembly Insert the 30mm M8 countersunk bolt through the forward most hole. Hand tighten the bolt to hold the bracket in position for the remaining two bolts. Insert the 50mm bolt in the rearmost position on the bracket, hand tighten. Insert the 65mm bolt in the middle position on the bracket, hand tighten. NOTE: Final torquing steps to follow in section Motor Case Final Torqueing on page 45.

  • Page 42: Torque Arm Removal

    Altitude Powerplay Technical Manual Torque Arm Removal TORQUE ARM REMOVAL TOOL S NE E DE D • Hex keys RE MOVA L Unscrew 3x countersunk screws and remove drive side motor cover. Disconnect chain quick link and remove chain, or move chain off drive pinion. Unscrew derailleur cable hold down clamp, and move cable up and out of the way. Unscrew 2x screws on torque arm. Unscrew 3x countersunk screws and remove non drive side motor cover. Unscrew forward motor mount bolt so it is clear of torque arm, but drive stays installed.

  • Page 43: Torque Arm Installation

    Altitude Powerplay Technical Manual Torque Arm Removal Rotate the torque arm forwards to clear the drive pinion, and pull away from motor. Torque Arm Installation PA RTS NE E DE D Item Part No. Revision Description TORQUE ARM 19970203 TORQUE ARM ASSEMBLY-DYNAME 3 ASSEMBLY SCREW, M6x30 180359FBY-030 C'SUNK SOCKET SCREW, M6-1.0 x 30MM, STAINLESS STEEL W/BLUE LOCTITE SCREW, M6x16 180566FBY-016 FLAT HEAD C'SUNK SOCKET SCREW, M6-1.0 x 16MM, A4/316 STAINLESS STEEL M8x60 BOLT 1808023OVT SOCKET HEAD CAP SCREW; M8x60, STAINLESS STEEL TOOL S NE E DE D •...
  • Page 44 Altitude Powerplay Technical Manual Torque Arm Removal INSTA LL ATION CAUTION: Ensure Powerplay drive power is OFF L ocate the torque arm in position against the right side of the motor, moving the rear derailleur cable out of the way if needed. The spring portion of the arm must be tucked behind the teeth of the 12T cog A pply Loctite to the two M6 bolts. P lace the two bolts and hand tighten with an Hex key while pressing down on the torque arm lightly Apply Loctite to the socket head shoulder screw. C arefully feed the screw past the brake, dropper and Higo cables, and into the upper front motor mount location on the left side of the front triangle. Hand tighten with a 6mm hex key NOTE: Final torquing steps to follow in section Motor Case Final Torqueing on page 45.

  • Page 45: Motor Case Final Torqueing

    Altitude Powerplay Technical Manual Torque Arm Removal Motor Case Final Torqueing TOOL S NE E DE D • 4, 5, 6 mm Hex Key • Torque wrench with 4, 5 and 6mm bits PROCE DURE Once all five M8 motor bolts are in place, the final torqueing can occur. First, torque the two torque arm M6 counter sunk bolts to 10Nm while pushing down on torque arm. Torque the bolts first to 10Nm, then to 14Nm in the following sequence: Upper rear Upper front Bb front (middle bash bracket) Front bash bracket Rear bash bracket...

  • Page 46: Chainstay Pulley Assembly

    Altitude Powerplay Technical Manual Torque Arm Removal Chainstay Pulley Assembly PA RTS NE E DE D Item Part No. Revision Description 11T COG 1347012 11T COG, FOR 19MM BEARING BEARING, 698 1807036 ENDURO 698 LLU 19X8X6 BOLT, M8x18 1807126 BOLT M8x18MM CUSTOM 6061 HARD BLACK ANO. CHAIN GUIDE ARM 1397004 E-ALTITUDE CHAINSTAY PULLEY GUIDE SCREW, M5x12 1807152 C’SUNK SOCKET SCREW, M5-0.8x12MM STAINLESS STEEL SPACER, 1347013 CHAINSTAY PULLEY GUIDE SPACER...

  • Page 47: Chainstay Pulley Installation

    Altitude Powerplay Technical Manual Torque Arm Removal A SSE MBLY Install the bearing in the 11T pulley using an arbor press. Locate the pulley and spacers within the bracket and align all bores concentrically. Apply blue Loctite to the Axle bolt. Install axle bolt through assembly and tighten to 12Nm. Chainstay Pulley Installation PA RTS NE E DE D Item Part No. Revision Description LOWER IDLER LOWER IDLER ASSEMBLY ASSEMBLY SCREW, M5x12 1807152 C'SUNK SOCKET SCREW, M5-0.8x12MM. STAINLESS STEEL...

  • Page 48: Mid Drive Pulley Installation

    Altitude Powerplay Technical Manual Torque Arm Removal TOOL S NE E DE D • Loctite • Hex Keys A SSE MBLY Locate the chain stay pulley assembly underneath the right side of the chain stay. Install screws with Loctite and hand tighten both. Torque both screws to 6Nm. Mid Drive Pulley Installation PA RTS NE E DE D Item Part No. Revision Description AXLE, MID DRIVE 1457014 MID DRIVE PULLEY AXLE, M11x1MM 40MM, AL7075-T6 HARD BLACK ANO...
  • Page 49 Altitude Powerplay Technical Manual Torque Arm Removal INSTA LL ATION Press the DR11197 bearing into the mid drive pulley. Press the spacer into the mid drive pulley bracket. Locate the mid drive pulley bracket upon its support on the Front triangle. Install the countersunk M5 bolt in the upper corner of the bracket to hold it in place. Hand tighten so the bracket can still be aligned. Apply grease to the M11x1 threads of mid drive pulley axle. Install M11 bolt without the pulley, and ensure the bracket and Front triangle bore are aligned. Torque the M5 countersunk bolt to 4Nm. Remove the M11 bolt. Place the pulley in location on the bracket, concentric with the pulley spacer. 10. Install the M11 bolt and torque to 10Nm.

  • Page 50: Rear Wheel Assembly

    Altitude Powerplay Technical Manual Torque Arm Removal Rear Wheel Assembly PA RTS NE E DE D Item Part No. Revision Description MAGNET 1997068 SPEED SENSOR MAGNET SPEED SENSOR 1977007 SPEED SENSOR CBLE R WHEEL D3 SPEED SENSOR 1997069 SPEED SENSOR MAGNET HOLDER SCREW 1808028 DOME HEAD SCREW, M5x12MM, GRADE 10.9 STEEL, BLACK OXIDE, TORX TOOL S NE E DE D •...

  • Page 51: Rear Axle & Rear Derailleur Hanger

    Altitude Powerplay Technical Manual Torque Arm Removal INSTA LL ATION Apply grease to lock ring threads. Torque no less than manufacturers suggestion of 40Nm. Rear Axle & Rear Derailleur Hanger PA RTS NE E DE D Item Part No. Revision Description AXLE WASHER 3227006 WASHER, 12x19x0.5MM, 304 SS AXLE, 3227009 2017 ELEMENT REAR AXLE 12MM x 173MM, 12MM x 173MM HARD BLACK ANO HANGER 1097132 REAR DER. HANGER, INT. LH THREAD,...

  • Page 52: Rear Derailleur Installation

    Altitude Powerplay Technical Manual Torque Arm Removal Apply Loctite 243 (blue) to Hanger Bolt threads. a.  P ass Hanger bolt through seat stay, and thread into derailleur hanger, turning counter clockwise Note: Axle Nut and derailleur hanger are left hand (reverse) threaded! Turn counter-clockwise to tighten. b.  T orque to 20 Nm. G rease Rear Axle (3227009) body and threads. a.  P ass Rear Axle through Stainless Steel Washer, left seat stay, hub, and thread into the hanger bolt. b.  W ith hub installed, torque to 10 Nm. Rear Derailleur Installation PA RTS NE E DE D Item Part No. Revision Description SCREW, M5x10 180475-010...
  • Page 53 Altitude Powerplay Technical Manual Torque Arm Removal TOOL S NE E DE D • Hex keys INSTA LL ATION W ith the motor in place on the front triangle, and the rear derailleur cable passed through the Chain stay and the front triangle, observe the small M5 tapped hole on the right side of the motor case. Install a cable retainer clip on this location with an M5 countersunk screw. Torque to 4Nm.

  • Page 54: Chain Installation

    Altitude Powerplay Technical Manual Torque Arm Removal Chain Installation PA RTS NE E DE D Item Part No. Revision Description CHAIN SRAM EX1 CHAIN, 62 COMPLETE LINKS, INCLUDING QUICK LINK TOOL S NE E DE D • No tools required. INSTA LL ATION CAUTION: Verify on iWoc remote that Powerplay drive is OFF Route the chain in the following order: Under the Mid drive Pulley, through its guide Over the Drive sprocket...
  • Page 55 Altitude Powerplay Technical Manual Torque Arm Removal Leave a length of chain hanging from the lower chain stay pulley (approx. 5 complete links). Route the other end of the chain over the smallest cassette cog, then through the derailleur cage. Once the chain is hanging through the derailleur cage, the ends can be connected. Using an appropriate quick link, join the chain. Rotate the cranks forward, so the quick link is on the top (tension side) of the chain. Use the crank arm to lock the quick link in its extended/closed position.

  • Page 56: Speed Sensor Installation

    Altitude Powerplay Technical Manual Torque Arm Removal Speed Sensor Installation PA RTS NE E DE D Item Part No. Revision Description CLAMP 1997081 CABLE CLAMP, M5 CSUNK. AL6061-T6, HARD BLACK ANO. SPEED SENSOR 1977007 SPEED SENSOR, CABLE, 2 PIN CONNECTOR SCREW, M5x10 180475-010 C'SUNK SOCKET SCREW, M5-0.8 x 10MM. ZINC PLATED 10.9 STEEL TOOL S NE E DE D •...

  • Page 57: Other Bicycle Components

    Altitude Powerplay Technical Manual Torque Arm Removal Other Bicycle Components These parts are OEM components and are installed using traditional methods. This section is intended as a guide to show how Altitude Powerplay assembly differs from that of a regular bicycle PA RTS NE E DE D Item Part No. Revision Description SCREW, M5x16 1806009 FLAT HEAD C'SUNK SOCKET SCREW, M5-0.8 x 16MM, ALUMINIUM HT PANEL LEFT 1097136 HT PORT PANEL, LEFT HT PANEL RIGHT 1097140 HT PORT PANEL, RIGHT USB HOLDER 1998015 E-ALTITUDE USB HOLDER BRACKET IWOC REMOTE 1977011...

  • Page 58: Fork Installation

    Altitude Powerplay Technical Manual Torque Arm Removal INSTA LL ATION Grease the outside of the upper headset cup. Align the laser etched line on the upper head set cup at the very front of the bike. Use the adapter to align the cup with the headset press in place. Carefully compress the cup into position. Install the lower cup normally. Fork Installation PA RTS NE E DE D Item Part No. Revision Description FORK SUSPENSION FORK STEM STEM HANDLE BAR HANDLEBAR USB HOLDER 1998015 E-ALTITUDE USB HOLDER BRACKET HEADSET FSA KNOCK BLOCK HEADSET •...

  • Page 59: Iwoc Remote Installation

    Altitude Powerplay Technical Manual Torque Arm Removal iWoc Remote Installation PA RTS NE E DE D Item Part No. Revision Description JOYSTICK 1977011 JOYSTICK WITH USB PORT USB HOLDER 1998015 E-ALTITUDE USB HOLDER BRACKET CABLE TIES 4MM CABLE TIES TOOL S NE E DE D • Wire cutters A SSE MBLY...

  • Page 60: Wire Connections

    Altitude Powerplay Technical Manual Torque Arm Removal Route cable tie UP through the two holes, and beside the stem during placement. Once USB-on-Wire is placed in the cradle, rotate the zip ties back towards the front, then around the plastic part. Pull the zip ties snug, and clip the wires. Wire Connections PA RTS NE E DE D Item Part No. Revision Description CABLE TIE 4MM CABLE TIES TOOL S NE E DE D • Wire cutters BLOCK DI AG R A M...
  • Page 61 Altitude Powerplay Technical Manual Torque Arm Removal A SSE MBLY Connect the iWoc remote to the Higo extension cable With Powerplay drive installed in front triangle, and working on the left side of the bicycle: Connect charge port 2 Pin connector, push joined connector in cavity behind Powerplay drive.
  • Page 62 Altitude Powerplay Technical Manual Torque Arm Removal Push dropper post housing into cavity above Powerplay drive. Push Rear brake hose into cavity above Powerplay drive.
  • Page 63 Altitude Powerplay Technical Manual Torque Arm Removal C onnect 5 pin iWoc extension cable and place it next to transfer chain cover. Pull extension cable taut by feeding it back into downtube. Connect 2 pin Speed Sensor connector, and place it in the cavity behind Powerplay drive. Leave wire accessible.
  • Page 64 Altitude Powerplay Technical Manual Torque Arm Removal Connect 3-Pin Battery connector, and place it next to transfer chain cover. CAUTION: The bike power is now live Verify iWoc and motor functionality (see section Functional Check on page 66).

  • Page 65: Iwoc Functionality

    Altitude Powerplay Technical Manual iWoc Functionality IWOC FUNCTIONALITY...

  • Page 66: Functional Check

    Altitude Powerplay Technical Manual iWoc Functionality Functional Check WA RNING If bicycle is in stand, ensure rear wheel and cranks are clear to move. INSTRUC TIONS With complete bicycle, power up the iWoc remote. Ensure boot up sequence happens on LEDs. Perform zero calibration (see section Torque Sensor Calibration). Press the power down button, ensure walk mode engages.

  • Page 67: Torque Sensor Calibration

    Altitude Powerplay Technical Manual iWoc Functionality Torque Sensor Calibration CAUTION: Ensure bike is static on the ground, with NO RIDER WEIGHT on the bike. You may perform this operation STRADDLING the bicycle. Rotate the cranks and shift the bike into the largest rear cassette cog P ress the two top buttons (BUTTONS C AND D) on the joystick at the same time to start the calibration. You will see the power LED flash red G ently tap the pedal with little force to ensure that the torque sensor resets itself to ‘zero’ by the derailleur tension. W ith both feet on the ground and no mass on the pedals, Press the BUTTON B to enter this value...
  • Page 68 Altitude Powerplay Technical Manual iWoc Functionality T he LED will now flash 2x alternating RED/YELLOW before exiting calibration and returning to regular use mode: To save the calibration, the Joystick must now be reset. P ress BUTTON B for 2 seconds to turn off the power. The Joystick will cycle colours on the LED and shut down. G reen – blue – green – red – WHITE – OFF. P ress BUTTON B to turn the unit back on and run its boot up sequence, the calibration is now ready.

  • Page 69: Cover Installation

    Altitude Powerplay Technical Manual iWoc Functionality Cover Installation CAUTION: Verify on iWoc remote that Powerplay drive is OFF. Install Left motor cover by first feeding rear brake hose and speed sensor wire through open slot. Install two M5x22 alloy bolts on top two holes, and one M5x12 alloy bolt in bottom hole. Torque hand tight Install Right motor cover over torque arm assembly Install two M5x22 alloy bolts on top two holes, and one M5x12 alloy bolt in bottom hole. Torque hand tight...

  • Page 70: Suspension Pivot Torque Guide

    Altitude Powerplay Technical Manual Suspension Pivot Torque Guide SUSPENSION PIVOT TORQUE GUIDE Note: All Torque values are +/-- 10% Torque Description Part No. Location Tool Notes kg-cm lb-in SHOCK 1807049 & Top Link 5mm & 4mm Torque only with BOLTS & 180566-016 FBY Hex Keys correct shock and SCREWS hardware installed. Apply grease to 1807062 &...
  • Page 71 Altitude Powerplay Technical Manual Powerplay Torque Values POWERPLAY TORQUE VALUES, 1 OF 3 Note: All Torque values are +/-- 10% Torque Description Part No. Location Tool Notes kg-cm lb-in BATTERY 180566-012 Battery 4mm hex 40.79 35.4 Secures 56, 70 and CASE SCREW, 81mm battery case M6x12 bolts, blue loctite SET SCREW, 1808024 Down tube 2.5mm hex 20.395 17.7 Ensure set screw M5x20...
  • Page 72 Altitude Powerplay Technical Manual Powerplay Torque Values POWERPLAY TORQUE VALUES, 2 OF 3 Note: All Torque values are +/-- 10% Torque Description Part No. Location Tool Notes kg-cm lb-in SCREW, 1807123OVT Powerplay 5mm hex 142.765 123.9 Loctite, tighten M8x25 bash bracket first to 10Nm in sequence, then 14Nm final SCREW, 1807122OVT Powerplay 5mm hex 142.765 123.9 Loctite, tighten...
  • Page 73 Altitude Powerplay Technical Manual Powerplay Torque Values POWERPLAY TORQUE VALUES, 3 OF 3 Note: All Torque values are +/-- 10% Torque Description Part No. Location Tool Notes kg-cm lb-in TORX SCREW, 1808028 Brake rotor T25 Torx 63.2245 54.87 Loctite, torque M5x12 driver rotor as per manufacturers instructions CASSETTE Cassette Shimano 407.9 Manufacturer...
  • Page 74 H E A D O FFI C E Rocky Mountain Bicycles Rocky Mountain Bicycles 1225 East Keith Road, Unit #10 9095, 25th Avenue, North Vancouver, BC Canada, V7J 1J3 St-Georges, QC Canada, G6A 1A1 T. 604-980-9938 F. 604-980-9975 T. 1-800-663-2512 F. 1-800-570-8356 Rocky Mountain, its logo and other trade names are registered trademarks. Some technologies on Rocky Mountain products are patented or patent pending. ©Rocky Mountain Bicycles 2017...

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