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Sync Ergonomics AEROBAR TWO Assembly Manual

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AEROBAR TWO 2025
SELECTION AND GENERAL ASSEMBLY GUIDELINES
pg. 1

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Summary of Contents for Sync Ergonomics AEROBAR TWO

  • Page 1 AEROBAR TWO 2025 SELECTION AND GENERAL ASSEMBLY GUIDELINES pg. 1...

  • Page 2: Warranty

    Ergonomics components. WARNING: In order to be installed correctly the components of Aerobar Two (AB02) require specialised knowledge of a time trial bicycle. It is recommended that installation should be performed by a qualified bicycle mechanic. Improper assembly of any of the components of AB02 could cause damage to the product(s) and/or bicycle, may lead to loss of control of the bicycle, and may lead to personal injury, or in severe cases even death.
  • Page 3 REQUIRED TOOLS AND PRODUCTS Torque wrench (with Hex and Torx drivers) 4 mm T-Handle Hex key T10 and T25 Torx keys Cutting guide (Park Tool SG-6) Hack saw and a high-quality 32 TPI blade Fine metal file or deburring tool Isopropyl alcohol MOTOREX Bike Grease 222 Loctite...
  • Page 4 INTRODUCTION The Aerobar Two (AB02) ecosystem is an integrated, modular solution designed to facilitate better positioning and aerodynamics on a time trial bike. The AB02 system provides dedicated arm cup angulation (15-degrees) and a more forward arm cup position. There are two categories of AB02 systems – Centre Stack and Dual Stack.
  • Page 5 EXTENSION SELECTION – FOREARM MEASUREMENT Two AB02 extension options are available, MEDIUM and LONG. The difference in length between the two options is 40 mm, with this additional length being added in the mid-section of the Long extensions. The overall height, the clamp end geometry and the grip end geometry are consistent between both the Medium and the Long extensions.
  • Page 6 LENGTH ADJUSTEMENTS The length adjustment range for our Base arm cups is 45 mm, in 15 mm increment. WIDTH ADJUSTEMENT AB02 ecosystems have been configured around an extension clamp spacing of 125 mm (center-to-center). A total of 46 mm of lateral arm cup adjustment is available with our Base arm cups.
  • Page 7 STACK ADJUSTEMENT AB02 2025 Dual Stack systems come with 30 mm of spacers as standard. With basebar adapters, spacers, extension clamps and arm cup installed, this will typically result in about 90 mm stack height, to the surface of the arm cup (basebar adapter dependant). Spacer Kit B can be purchased which provides an additional 30 mm of spacers and allows most Dual Stack systems to be configured at 120 mm of height, from the surface of the basebar.
  • Page 8 DUAL STACK SOLUTIONS Sync offers a range of Dual Stack fit kits, that share the following common design characteristics. Note: Spacer Kit B (+30 mm) is available during checkout and includes Bolt Kit B (for up to 60 mm spacer height). For more information and technical resources, please visit https://www.syncergonomics.com/technical.
  • Page 9 CENTRE STACK SOLUTIONS Sync offers a range of Centre Stack fit kits, that share the following common design characteristics. Note: Centre Stack solutions use the bikes original spacer stack for adjustment to stack height. We do not supply stack spacers for AB02/AB03 Centre Stack Solutions. For more information and technical resources, please visit https://www.syncergonomics.com/technical.
  • Page 10 DUAL STACK SOLUTIONS – BRIDGE Above 30 mm of spacers, we recommend that a support brace (bridge) is used with all Dual Stack solutions. All bikes, with the exception of the Colnago TT1 use our 125 mm (C-C) spacing for extensions. The Colnago TT1 is spaced at 115 mm (C-C) and requires the Colnago TT1 UCI bridge.
  • Page 11 DUAL STACK SOLUTIONS – SPACER KIT AB02/AB03 Dual Stack fit kits are supplied with 30 mm of spacers and Bolt Kit A. This includes M5 x 25-45 mm bolts, which cater for 10-30 mm of spacers being installed. Bolt Kit B and Spacer Kit B are available to purchase during checkout and include an additional 30 mm of spacers and M5 x 55-75 mm bolts, covering up to 60 mm of spacers.
  • Page 12 EXTENSION CLAMP AND CRADLE The extension clamp and extension clamp cradle are components that apply to all Centre Stack and Dual Stack 2025 Aerobar Two ecosystems. Please see the following for assembly noting bolt torque and the use of specific assembly compound.
  • Page 13 AB02 extension clamps are designed to cater for a 22.2 mm round tube. Undersized tubes may not clamp effectively and we strongly recommend you check the tolerances when using extensions other than Sync Ergonomics extensions. Note: When installing carbon tubes, we recommend the use of a fine-grit assembly paste or carbon paste.

  • Page 14: Notes On Wiring

    NOTES ON WIRING Thanks to the connection at the SHIMANO DI2 shifter, you can run the Di2 wires through the spacer stack during assembly, leaving sufficient length to connect the shifters as a final step. The wires will run through the basebar adapter/s, through the spacers, clamp adapter and carbon brace, into the clamp and up and out of the extensions.
  • Page 15 BASE ARM CUP INSTALLATION Base arm cups are directional. Cups should be mounted with the rounded edge of the arm cup facing forward. Use the supplied M5 x 8 mm Torx flanged button head screws for connection to the extension clamp. Note: We recommend the application of MOTOREX Bike Grease for the arm cup screws.