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BionX Smart User Manual

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RL39 - Repair instructions for changing the frame
Version 1.0, last revised 03/2016
1/58
Number of work units required (1WU = 5 minutes = EUR 6.00 net):
46
A. Removing the belt guard (only on models with belt guard)
B. Reducing the belt tension
C. Removing the belt guide
D. Removing the rear wheel
E. Removing the cable outlets
F. Removing the right crank
G. Removing the left crank
H. Removing the kickstand plate
I. Removing the inner bearing
J. Removing the battery nest
K. Removing the rear mudguard
L. Removing the right brake line
M. Removing the rear brake caliper
N. Removing the dropouts
O. Removing the front wheel
P. Removing the front mudguard
Q. Removing the front brake caliper
R. Removing the stem trim
S. Removing the stem
T. Removing the headset
U. Removing the saddle clamp
V. Installing the saddle clamp
W. Installing the fork
X. Installing the stem
Y. Installing the front brake caliper
Z. Installing the front mudguard
AA. Installing the front wheel
BB. Installing the dropouts
CC. Installing the rear mudguard
DD. Installing the battery nest
EE. Installing the inner bearing
FF. Installing the left crank
GG. Installing the right crank
HH. Installing the shift sleeve
II. Installing the right brake line
JJ. Installing the cable outlets
KK. Installing the rear wheel
LL. Aligning the belt
MM. Adjusting the belt tension
NN. Installing the belt guide
OO. Adjusting the headset play
PP. Aligning the front light
QQ. Installing the stem trim
RR. Installing the shift cable
SS. Adjusting the shift mechanism
TT. Preparing the brake caliper
UU. Preparing the brake lever
VV. Filling/ bleeding the brake
WW. Checking the pressure point
XX. Installing the rear brake caliper
YY. Aligning the brake caliper
ZZ. Installing the kickstand plate
AAA. Installing the belt guard (only on models with belt guard)
BBB. Updating the drive system
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BionX Smart Specifications

General IconGeneral
BrandBionX
ModelSmart
CategoryBicycle
LanguageEnglish

Summary

Removing the Belt Guard

Undo Kickstand Plate Bolts

Undo the two rear bolts of the kickstand plate using a size 5 Allen wrench.

Undo Belt Guard Mounting Bracket Bolt

Undo the bolt on the mounting bracket of the belt guard on the rear stay using a T25 angled Torx wrench.

Reducing the Belt Tension

Undo Dropout Bolts

Undo the bolts at the dropouts on both sides using a size 6 Allen wrench.

Adjust Axial Adjustment Nuts

Undo nuts for axial adjustment and loosen the adjusting bolt.

Removing the Rear Wheel

Turn Twist Grip to 1st Gear

Turn the twist grip to 1st gear before removing the rear wheel.

Removing the Right Crank

Use Crank Remover

Grease crank thread and use crank remover tool.

Removing the Inner Bearing

Disconnect Sensor Connector

Carefully pull the rectangular connector out of the frame and unplug it.

Detach Bearing Shells

Detach the plastic shell and remove bearing shells from the axle unit.

Removing the Battery Nest

Remove Battery Nest

Pull the battery nest upwards towards the right side out of the frame.

Removing the Front Wheel

Open Quick-Release Lever

Open the quick-release lever and remove the front wheel from the fork.

Push Transport Lock

Push the transport lock between the brake pads.

Removing the Front Brake Caliper

Undo Caliper Retaining Bolts

Undo the brake caliper retaining bolts using a size 5 Allen wrench.

Removing the Stem

Pull Bowden Cable Out

Pull the Bowden cable with its sheath out of the frame.

Removing the Headset

Drive Out Lower Headset Shell

Drive the lower headset shell out of the head tube using hammer and drift.

Installing the Fork

Push Fork Seat Ring onto Steerer Tube

Push the fork seat ring of the headset onto the steerer tube.

Installing the Front Brake Caliper

Fit Brake Caliper to Mounting

Fit the brake caliper onto the mudguard bracket and brake mounting.

Tighten Caliper Retaining Bolts

Tighten caliper retaining bolts until caliper can still be moved sideways.

Installing the Front Wheel

Install Wheel in Fork

Install the wheel in the fork, ensuring axle is seated in dropouts.

Close Quick-Release Clamp

Close the quick-release clamp by screwing nut and flipping lever.

Installing the Rear Wheel

Guide Rear Wheel into Dropouts

Guide the rear wheel into the dropouts, ensuring belt is not crushed.

Tighten Axle Nuts

Tighten the axle nuts to a torque of 40 Nm.

Aligning the Belt

Check Belt Line While Turning Crank

Turn crank and check belt line against side stop (flange).

Adjusting the Belt Tension

Use Eco Tension Tester

Use Eco Tension Tester to set required belt tension.

Check Tension at One Tooth

Correct tension achieved when belt touches top of chain stay with one tooth.

Filling/ Bleeding the Brake

Press Oil Through Caliper

Use filling syringe to press mineral oil through the brake caliper.

Updating the Drive System

Connect BIB to Computer

Connect the BIB to the data cable and plug USB into computer.

Click 'Update System'

Launch BBI software, click 'Update system' when prompted.

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