Whyte 146, Supplementary Service Manual

Page 1: ...146 T 120 E 120 Supplementary Service Manual Edition 1 August 2010 ...

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Page 3: ...r T 120 6 1 2 From 146 6 2 Stripping and Re assembling Front and Rear Quad Links 6 2 1 From E 120 or T 120 6 2 2 From 146 6 2 3 Extraction of KP Bearings 6 2 4 Insertion of KP Bearings 6 2 5 Re Assembly of Quad Links 6 3 Re assembling the Rear Suspension 6 3 1 Correct Orientation of Front and Rear Quad Links 6 3 2 Re Assembly of Rear Suspension E 120 or T 120 6 3 3 Re Assembly of Rear Suspension 1...

Page 4: ...rd may be obtained from the Whyte Bikes Brochure or alternatively from the Whyte Bikes website www whytebikes co uk Please remember if you are in any doubt about your ability to safely service or repair your Whyte bike do not ride it and instead arrange for a professional bicycle mechanic at your local Whyte dealer to do the job correctly Bundled with this manual are the respective manufacturers i...

Page 5: ...Page 5 2010 Edition 1 WHYTE Service Manual 2 0 GEOMETRY Fig 1 Geometry ...

Page 6: ...hieve the correct sag of the fork and rear damper BB height with Ø686mm tyres fitted 2 5 60 559 2 2 Whyte T 120 Geometry Frame Size X Small Medium Large Head Angle A 68 0 68 0 68 0 Seat Angle B 73 0 73 0 73 0 Top Tube C 578 7mm 598 2mm 610 8mm BB Height D 341 5mm 336 5mm 334 5mm Stand Over E 756m 777mm 800mm Wheel Base F 1093 4mm 1119 3mm 1135 1mm Chain Stay G 425mm 425mm 425mm Seat Post H 27 2mm ...

Page 7: ...mm Chain Stay G 420mm 420mm 420mm 420mm Seat Post H 30 9mm 30 9mm 30 9mm 30 9mm 2 4 Whyte E 120 Geometry with 130 Fork Notes Geometry shown here is Showroom i e without rider aboard the bicycle With Sag geometry is with rider after correct sag is set at front and rear Please refer to suspension set up for information on how to achieve the correct sag of the fork and rear damper BB height with Ø673...

Page 8: ...tments to the components fitted to your Whyte 3 2 WHYTE GETTA GRIP SEAT CLAMP 3 2 1 WHYTE GETTA GRIP SEAT CLAMP SADDLE HEIGHT ADJUSTMENT The Getta Grip seat clamp design is present on all models of Whyte full suspension moun tainbikes It is a patented design to allow adjustment of the saddle height by either the use of a QR Lever or bolt up method This manual covers both of those styles of clamp d...

Page 9: ...o the QR Lever 4 from the Closed position to the Open position Next adjust the height of the Seat Pin to the desired level and close the QR lever 4 to the from the Open position to the Closed posi tion The QR closing force can be adjusted by turning the QR Adjuster Bobbin 8 clockwise or anti clockwise before closing the QR Lever 4 3 2 2 WHYTE 146S T 120S COCKPIT ADJUSTMENTS Please refer to the spe...

Page 10: ...tions Rebound Damping adjustment This adjustment fine tunes the speed at which the wheel returns to its normal ride height after hitting a bump Refer to the relevant manufacturers instructions to find out how to adjust the rebound damping To demonstrate the effect of this function turn the adjuster to its slowest setting Press down on the handlebars to compress the forks then release the load The ...

Page 11: ... the relevant Shock manufacturers technical information to find out how to adjust the Shock To demonstrate the effect of this turn the adjuster to its slowest setting Press down on the saddle to compress the suspension then release the load The suspension recovers very slowly to its original position Repeat the above with the adjuster turned to the fastest setting and the difference will be seen i...

Page 12: ...stress fatigue in different ways If the design life of a component has been ex ceeded it may fail suddenly causing possible injury to the rider Any form of crack scratches and decolouring in highly stresses areas are showing that the component has exhausted its life time and has to be replaced If you are in any doubt about one or more components on your Whyte DO NOT RIDE YOUR BIKE Consult the spec...

Page 13: ...anufacturers detailed instructions bundled with this man ual or for further information visit the specific manufacturers website Fig 5a Bolt up Style Lubrication Fig 5b QR Style Lubrication Point Lubricant Lubrication Interval 1 Castrol LM or equivalent Once a Month Description M6 x 30mm Fastener Point Lubricant Lubrication Interval 1 Castrol LM or equivalent After Every Ride 2 Castrol LM or equiv...

Page 14: ...r Suspension Assembly Item Description 1 Screw in Bearing Cap 19mm A F 2 M8 Aerospace Nut 10mm A F 3 M8 x 100mm long Stud 3 indicates 90mm long in T 120 4 E 120 or T 120S Main frame 5 Front 75mm centres Carbon Fibre Link Assembly 6 Rear 50mm centres Carbon Fibre Link Assembly 7 E 120 or T 120S Swinging Arm ...

Page 15: ...ospace Nut 10mm A F 3 M8 x 100mm long Stud 4 M8 x 90mm long Stud 5 M6 x 12 long Countersunk Capscrew 8 Front 80mm centres Y Link Assembly 9 Rear 55mm centres H Link Assembly 10 146S Swinging Arm 7 146S Main frame 6 Ø9 5mm x 25 long Hollow Pin M6 internal threads Fig 8 Whyte 146 Rear Suspension Assembly ...

Page 16: ...he main frame 4 To Remove the Rear Link Assembly 6 from the bike using the 10mm Sockets undo the M8 Aerospace nuts 2 on the M8 shaft 3 or 3 that passes through the Rear Link Assembly 6 and the Main Frame 7 and remove the M8 shaft 3 or 3 and the Rear Link Assembly 6 from the Main Frame 4 In E 120 models made before 2011 be careful to retain all the shield washers that fit into the Quad Link as semb...

Page 17: ...From the E 120 or T 120 Item Description 1 KP5AX bearing 2 Middle shield washer note only fitted to pre 2011 E 120 3 Front 75mm Carbon Fibre E 120 or Alloy T 120 Quad Link Body 4 Rear 50mm Carbon Fibre E 120 or Alloy T 120 Quad Link Body Fig 9 Link Assembly for both front and rear Quad Links E 120 or T 120S ...

Page 18: ...l 6 2 2 From the 146 Item Description 1 KP5AX bearing 3 Outer stepped shield washer 4 Front 80mm Y Quad Link Body 5 Rear 55mm H Quad Link Body 2 KP6AX bearing Fig 10 146 Link Assemblies for front 80mm Y link above and rear 55mm Quad Link below ...

Page 19: ... WHYTE Service Manual Item Description 1 M8 Nut 2 KP5AX or KP6AX Tool 1 3 Link Body 4 KP5AX or KP6AX Bearing 5 KP5AX or KP6AX Tool 2 6 M8x65mm Socket Head Cap Screw Fig 11a KP Bearing Extraction Fig 11b KP Bearing Insertion ...

Page 20: ...and 10mm Span ner until you can see the KP bearing 5 being pressed squarely into the Link Body 4 Once the KP bearing is fully seated an you can no longer tighten the M8 Socket Head Cap Screw further undo the nut and bolt and remove any excess Loctite from around the KP Bearing particularly in any internal threads Repeat for the remaining KP Bearings Important note the single KP6AX bearing in a Y l...

Page 21: ...e that upon assembling the Quad Links to the mainframe that the links are orientated as shown in Figures 13 14 Both figures show E 120 but the link orien tations also apply to T 120 and 146 as well Fig 13 Correct Installation of Carbon Fibre Quad Links onto E 120 Main Frame Correct Installation of Front Link Correct Installation of Rear Link ...

Page 22: ...Page 22 2010 Edition 1 WHYTE Service Manual Fig 14 Correct Orientation for Front 75mm Quad Link Swinging Arm Side Main Frame Side Longer Distance Shorter Distance ...

Page 23: ...Page 23 2010 Edition 1 WHYTE Service Manual Fig 15 Whyte E 120 T 120 Rear Suspension Assembly ...

Page 24: ...aft 3 or 3 through the front Quad Link 5 the Mainframe 4 and through the front of the Rear Shock until the M8 Shaft 3 or 3 is showing out the other side of the front Quad Link 5 You should now have both front and rear Quad Links assembled onto the Mainframe 4 with the Rear Shock in position Next lower the Swinging Arm 7 onto the rear suspension assembly and position the Swinging Arm 7 onto the fro...

Page 25: ...efer to Fig 16 Tighten all M8 AeroSpace Nuts 2 to the recommended settings Refer to the Tightening torque settings in Section 7 0 Next make sure that there is still a substantial amount of Molykote 111 Silicon covering all the KP5AX Bearings Lastly refit the Link Bearing Caps 1 by carefully screwing them into the link body Take care not to cross thread the fine thread Tighten all Link Bearing Caps...

Page 26: ...ow pin 6 through the front of the Swinging Arm 10 the stepped shield washers 3 figure 10 and the front Y Link 8 until it has passed though the other side Next rotate the Swinging Arm 10 down to attach it to the rear Quad Link 9 and the rear of the Rear Shock Once you have the Swinging Arm 10 in the correct position make sure that the rear Quad Link 9 the Swinging Arm 10 and the Rear Shock though h...

Page 27: ... THE WHYTE MODULAR DROPOUT SYSTEMS Fig 18 Exploded view of E 120 Dropout Assembly Item Description 1a Chain ring Bolt Male 1b Chain Ring Bolt Female 2 Dropout Q R Modular Type Derailleur side 3 Swinging Arm Mounting Point 4 Dropout Q R Modular Type Disc side ...

Page 28: ...WHYTE Service Manual Fig 19 Exploded view of T 120 146 Dropout Assembly Item Description 1 M6 x 16 long Cap Screw 2 Dropout Q R Modular Type brake side 3 Dropout Q R Modular Type derailleur side 4 Swinging Arm Mounting Point ...

Page 29: ...re 7 2 Assembling the Rear Modular Dropouts onto the Swinging Arm Tools Required 5mm Allen Key 6mm Allen Key Torque Wrench Loctitie 638 retaining compound 7 2 1 To E 120 Reference figure 18 It is important to make sure the Swinging Arm 3 and Dropouts 2 4 are clean and free from mud grease and other dirt which could prevent the Dropouts 2 4 and Swinging Arm 3 from fitting together perfectly Before ...

Page 30: ...ufacturers information bundled with this manual or alternatively refer to the specific manufacturers website for further information 9 0 NOTES Rear Quad Link Suspension Nm lbs ft Link Outer Bearing Caps 2 0 Min 3 0 Max 1 5 Min 2 2 Max M8 AeroSpace Nuts 17 0 Min 19 0 Max 12 5 Min 14 0 Max Rear Dropout Assembly Chain ring Bolts E 120 Dropout 15 0 Min 25 0 Max 11 0 Min 25 0 Max M6 cap screws T 120S o...

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