This document is a supplementary service manual for Whyte eMTB full suspension bicycles, specifically covering the 2022 Edition 1 models. It provides detailed instructions for setup, maintenance, and servicing procedures unique to these electric mountain bikes.
Function Description:
The Whyte eMTB full suspension range is designed for typical mountain biking use, offering advanced design and engineering for an enhanced riding experience. These bikes feature full suspension systems, including both front forks and rear shock absorbers, to manage varied terrain and provide comfort and control. The "MX" designation indicates models that utilize a 29" front wheel and a 27.5" rear wheel, optimizing handling and traction characteristics. The bikes are equipped with Bosch e-bike systems, including a battery and charge port, integrating electric assistance into the riding experience. The manual emphasizes safety and proper maintenance to ensure the longevity and safe operation of the bicycle.
Important Technical Specifications:
- eMTB Gravity Enduro Suspension Models: E-180 S MX, E-180 RS MX, E-180 WORKS MX.
- eMTB Trail Enduro Suspension Models: E-160 S MX, E-160 RS MX, E-160 S 27.5", E-160 RS 27.5".
- eMTB Trail Enduro 29ER Suspension Models: E-160 S 29ER, E-160 RS 29ER.
- Maximum Weight Limit: 18 stone / 114 kg (including rider's equipment).
- Suspension Sag Settings:
- E-160 (29"): Shock Stroke 57.5mm, Sag (25% Firmer) 14.5mm, Sag (30% Plusher) 17.25mm.
- E-160 MX: Shock Stroke 57.5mm, Sag (25% Firmer) 14.5mm, Sag (30% Plusher) 17.25mm.
- E-160 (27.5"): Shock Stroke 57.5mm, Sag (25% Firmer) 14mm, Sag (30% Plusher) 17.25mm.
- E-180 MX: Shock Stroke 65mm, Sag (25% Firmer) 16.25mm, Sag (30% Plusher) 19.5mm.
- Torque Settings (Min-Max):
- M5 Socket-head Cap Screw (T-25 Torx) (Rear Suspension): 5.0-6.0 Nm (3.7-4.4 lbs.ft).
- M15 x 20 long Alloy Flanged Screw (Rear Suspension): 15.0-17.0 Nm (10.5-12.5 lbs.ft).
- M15 x 28 long Alloy Flanged Screw (Rear Suspension): 22.0-26.0 Nm (16.2-19.2 lbs.ft).
- M15 x 87 long Pivot Pin (Rear Suspension): 9.0-11.0 Nm (6.1-7.5 lbs.ft).
- M6 x 20 long Socket Head Capscrew (Rear Suspension): 9.0-11.0 Nm (6.1-7.5 lbs.ft).
- 8mm Sram UDH Fixing Bolt (Rear Dropout Assembly): 21.0-25.0 Nm (15.4-18.4 lbs.ft).
- M5 Cap Screw (Seat Post Clamp): 6.0-8.0 Nm (4.4-5.9 lbs.ft).
- 5mm Socket Head M10 screw (DownTube Lower Cover): 9.0-10.0 Nm (6.6-7.4 lbs.ft).
- SRAM UDH (Universal Derailleur Hanger) System: Features a left-hand thread for the fixing bolt.
- Whyte 12mm QR Shaft: Requires a minimum hand-force of 15 Nm for tightening.
- Bearings: 3802V2RD (MN) KR-BOLU.
- Shield Washers: O.D. 20mm and O.D. 23mm.
- Internal Spacer: 49mm long.
- Compliance: Designed, tested, and complies with ISO 4210-2 & EN-15194-2017 Safety Standards.
Usage Features:
- Adjustable Suspension: Both front forks and rear dampers are adjustable for sag and rebound damping. Sag adjustment ensures the suspension is set correctly for the rider's body weight. Rebound damping fine-tunes the speed at which the wheel returns to its normal ride height after hitting a bump.
- Platform Damping: Rear shocks may feature a "platform" facility (e.g., Fox "3pos w/Adj" or SRAM RockShox "Motion Control") to adjust slow-speed compression damping, which influences pedaling efficiency.
- Whyte Seat Clamp Adjustment: Allows for easy adjustment of seat post height using a 5mm Allen key and torque wrench.
- SRAM UDH System: Provides a universal derailleur hanger system for compatibility and easy replacement.
- Whyte 12mm QR Shaft: Facilitates tool-free installation and removal of the rear wheel.
- Internal Cable & Hose Routing: Designed for a clean aesthetic and protection of cables and hoses, with specific methods for replacement.
- Bosch Battery System: Integrated electric assistance with a removable battery and a charge port located in the motor mount.
Maintenance Features:
- Detailed Disassembly and Reassembly Instructions: The manual provides step-by-step guidance for servicing the rear suspension, including removing the rear shock, links, swinging arm, and bearings. It also covers the dropout system.
- Bearing Extraction and Insertion: Specific tools and procedures are outlined for removing and inserting bearings, including the use of a bearing press tool and Loctite 638 for secure insertion.
- Shield Washer/Spacer Re-assembly: Instructions for proper placement and lubrication of shield washers and spacers using SKF LGEP2 or Castrol Spherol AP3 grease and anti-fret pastes (SKF LGAF 3E or Castrol Optimol T).
- Torque Settings Table: A comprehensive table lists recommended torque values for various components, crucial for safe and correct reassembly.
- Lubrication Guidance: Refers to the Whyte General Instruction Manual and specific component manufacturers' instructions for proper lubrication regimes.
- Battery Removal and Installation: Detailed steps for safely removing and reinstalling the Bosch battery, emphasizing adherence to Bosch's documentation.
- Internal Cable/Hose Replacement: A method is provided for replacing internal cable and hose outers, particularly for the rear derailleur cable in the chain-stay.
- Suspension Tuning Log: A blank table is included for riders to record their optimal suspension settings, aiding in consistent setup after servicing or adjustments.
- Safety Warnings: Numerous "CAUTION!" and "WARNING!" notes highlight critical safety considerations, such as avoiding over-tightening, ensuring correct component orientation, and consulting a professional mechanic if uncertain.
- Manufacturer Resources: Encourages users to consult specific component manufacturers' manuals and websites for detailed information on adjustments, servicing, and safety.
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