Re-Assembling The Rear Suspension; Re-Assembly Of The Rear Suspension; Re-Assembly Of Chain-Stays & Bearings Onto Main Frame - Whyte E-180 S MX Supplementary Service Manual

6.3: RE-ASSEMBLING THE REAR SUSPENSION

6.3.1: Re-assembly of the Rear Suspension

Tools Required: 5mm AF Allen Keys (2 off, 1 fitted to a 5Nm to 25Nm Torque Wrench)
6mm AF Allen Key (2 off, 1 fitted to a 5Nm to 25Nm Torque Wrench)
T-25 Torx® Keys (2 off, 1 fitted to a 5Nm to 25Nm Torque Wrench)
The re-assembly of the rear suspension is essentially the reverse of the dis-assembly procedures 6.1.1, 6.1.2 &
6.1.3.
6.3.2 Re-Assembly of Chain-stays & Bearings onto Main Frame
Before inserting the bearings, make sure all the components are clean from dirt and have been thoroughly de-greased. Apply a
small amount of Loctite 638 to the outside diameter of the bearing and to the inside mating bore of the main Frame (15). Using
the press tools shown in Figure 7, insert the bearings (20) into both sides of the Main Frame (15). Ensure the spacer (21) is
located between the bearings (20).
Referencing figure 3, apply either SKF LGAF 3E or Castrol Optimol T paste to all faces of the shield washers (19), Pivot Pin (12)
and Screw (10). Place the Shield Washers (19) alongside the Bearings (20). Insert & align the Chain-Stays (14) between the
Washers (19). Insert the Pivot Pin (12) from the left side of the Chain-Stays (14). Screw the Pivot Pin (12) io the thread in
the drive-side of the Chain-Stays (14). Insert the Tapered Sleeve (11) and screw in the M6 x 20 long Capscrew (10).
Using a 6mm Socket, first torque tighten the drive-side of the Pivot Pin (12), to the recommended torque settings (refer to the
Tightening torque settings in Section 10.0). Then tighten the M6 x 20 long Capscrew (10), again to the recommended torque
settings (refer to the Tightening torque settings in Section 11.0). Wipe off any excess grease from around the chain-stays and
seat-stays.
6.3.3: Re-Assembly of Link, Shape-It Link & Seat-Stay onto the Main Frame
IMPORTANT: Prior to Re-Assembly of the Seat Stay to the Link, make sure the seat tube of the main frame is inside of
the assembly. Also make sure all suspension components and linkages are the correct orientation and the correct side facing
upwards.
Referencing Fig. 1 and . Starting with the Seat-stay (3) and the Link (4), first check that the shield washers are in place in the
Link and apply either SKF LGAF 3E or Castrol Optimol T anti-fret paste to the contacting faces between the shield washers and
Seat-stay (3). Then ensure that the shield washers in the Link (4) are not pushed out, as you place the seat-stay (3) inside it.
Then pass an M15 x 28 long flanged alloy screw (17) through the right side of the seat-stay (3), the adjacent shield washers
and the bearing in the Link (4). Using the 5mm A/F Allen Key, torque tighten the M15 screw (17) to the recommended torque
settings (refer to the Tightening torque settings in Section 10.0). Repeat that task to assemble the left side of the seat-stay (3)
to the Link (4), also ensuring that the other shield washer in the Link (4) is not pushed out.
Next, to assemble the Shap-It Link (5) and the Link (4), reference figure 2 (Main Frame (1) not shown for clarity), first check
that the shield washers are in place in the Link and apply either SKF LGAF 3E or Castrol Optimol T anti-fret paste to the
contacting faces between the shield washers and Shape-It Link (5). Then ensure that the shield washers in the Link (4) are not
pushed out, as you place the shock extender (7) inside them. Then pass an M15 x 20 long flanged alloy screw (16) through
the Link (4), the bearing in Link, the adjacent shield washer, & into the thread of one arm of the Shape-It Link (5). Using a
6mm A/F Allen Key, torque tighten the M15 Flanged Screw (17) to the recommended torque settings (refer to the Tightening
torque settings in Section 10.0). Repeat that task to assemble the other arm of the Shape-It Link (5) to the Link (4), also
ensuring that the other shield washer in the Link (4) is not pushed out.
Next, to assemble the Link (4) to the Main Frame seat tube (1), check that the shield washers are in place on the inside of t he
bearings that are installed in front of the Link (4) and apply either SKF LGAF 3E or Castrol Optimol T anti-fret paste to the
contacting faces between those shield washers and the link mounting on the main frame seat tube (1). Insert the Link (4)
between the Main Frame seat tube (1). Then pass an M15 x 28 Long Flanged Alloy Screw (15) through the Link (4), the bearing
in Link, the adjacent shield washer & screw into the Main Frame link mounting (1). Screw in an M15 x 28 Long Flanged Alloy
Screw (15) from the left side of the link (4) . Using a 6mm A/F Allen Key, torque tighten the M15 x 28 Long Flanged Alloy
Screws (15) to the recommended torque settings (refer to the Tightening torque settings in Section 10.0). Wipe off any excess
grease.