Things You Will Need
Assembly time, approximately 15 minutes. Difficulty: Easy.
All dropper posts require key way clearance. With so many different frames, clamps and ride heights it's not possible to ship play-free without running the risk of binding. The kit is meant to remove additional play that might develop over time or to tune the play out for a specific bike.
Start with the 3 pins (19) marked with 2 lines. If play still exists move to the 3 pins (20) marked with 4 lines.
With the post still installed on bike complete the following steps
STEP 1: SEAT CLAMP ASSEMBLY
Unthread rear clamp bolt (4) using your 5mm hex key. Remove clamp nut (1) & upper clamp (2). You can then remove your saddle & the lower clamp (3). Clean assembly and put aside until you have check the air pressure at the end of this service.
TIP: Leave front clamp bolt (4) & dont adjust it. When you reinstall the seat, torque the rear clamp bolt to 8Nm (70 in-lbs) and your seat angle will remain correct.
STEP 2: CLEAN & COMPRESS
Wipe away any dirt or debris from the Upper tube (7). Lower the post to mid travel.
STEP 4: MID CAP ASSEMBLY
Unscrew the mid cap assembly (8) by hand or using a strap wrench and slide it up towards the seatpost head.
STEP 5: CARTRIDGE LOCKRING REMOVAL
Remove Cartridge valve cap (5) & lockring (6) with needle nose pliers.
STEP 6: REMOVE UPPER TUBE
With the lockring (6) removed, the upper tube (7) will now slide out from the lower tube (12). Remove slowly, making sure the three original guide pins (10) dont fall back into the open lower tube. Please keep in mind the cartridge (14), without the upper tube and lockring is now fairly loose within the lower tube. Be careful not to knock or apply pressure to it.
STEP 8: GUIDE PIN REPLACEMENT
If grease is anything other than new, wipe it away with a clean cloth. Replace guide pins (10) with oversized guide pins (19) or (20). Grease lower bushing (11), around the guide pins with slickoleum or a light suspension grease.
Remember, Start with the 3 pins (19) marked with 2 lines. If play still exists after assembly, move to the 3 pins (20) marked with 4 lines.
STEP 9: INSTALL UPPER TUBE
Align the guide pins (10, 19 or 20) with the machined grooves in the lower tube (12). The lasered logoing on the lower tube should line up front to back. For reference, the forward facing guide pin slot should line up with the center of the forward facing ONE lasered logo, as pictured below. Push lower tube past guide pins (9) carefully to ensure they do not bend or jam. This action should feel smooth.
Push upper tube down until the cartridge air valve is exposed at the top of the upper tube.
STEP 10: MID CAP ASSEMBLY
If you use travel pins (18) in your post, Now is the best time to install them into the guide slots.
Seat the upper bushing (9) into the top of the lower tube (12). Thread the mid cap assembly (8) into the lower tube and tighten by hand or with strap wrench for added security.
STEP 11: CARTRIDGE LOCKRING & PRESSURE CHECK
Install & tighten cartridge lockring (6) using your needle nose pliers. You can now safety actuate the post to max extension. Attach Shock pump to valve. Inflate post to 250-300psi in the fully extended position. Thread valve cap (5) back down onto the valve.
Note: These cartridges are high pressure in a small volume. The pressure loss during removal of the pump & equalization of the pump upon installation & will produce a lower pressure reading than what was originally in the cartridge. This pressure loss can be as much as 50psi depending on the pump size and quality.
STEP 12: SEAT CLAMP ASSEMBLY
Place lower clamp (3) into the cradle of the upper tube (7). Make sure the arrow is pointing forward. Place your saddle on the lower clamp. Holding your saddle, slide the upper clamp (2), arrow forward, under the front clamp nut (1) and place it on top of the saddle rails. You can then drop the rear clamp nut into its seat at the back of the upper clamp. Thread rear clamp bolt (4) into nut and tighten to 8Nm.
Congratulations, you have now successfully completed the V2 dropper oversized pin installation.
NOW GO RIDE!
If you are having any problems please first double check that you have correctly completed each of the above steps.
If you are still having trouble please email us at firstname.lastname@example.org for help. Please include a detailed description of your issue. Photos are often helpful.