Intense Cycles ACV User Manual

user manual ACV

AT INTENSE, WE HAVE ONE GOAL - TO PROVIDE THE RIDE OF YOUR LIFE //

Our team of designers, engineers and product experts are focused on one thing every day: your experience on the bike. We build bikes that are as thrilling to look at as they are to ride, and we build them for the select few of you who understand the difference and refuse to settle for anything else.

From the early days of Intense, when founder Jeff Steber worked alone in his garage to today, where a crew of talen ted peo ple work in a Teme cula, CA factory, Intense has bee n a brand built on passion by forward thinkers who, even today, love nothing more than to throw a leg over a sweet bike and head out for a rip. We’re so glad you’ve joined us.

Welcome to Intense, enjoy your experience.

THE 27.5+ ACV //

ACV = Air. Cushioned. Vehicle..…and that’s how it rides. This Enduro minded ride is Intense Cycles first offering with a 1X specific frame design. We’ve eliminat ed the front derailleur for those of you who are honch enough for single ring up front. This allows us to increase stiffness by having symmetrical, vertical struts on the rear triangle and clears some room for the wide, 27.5+ tires.

The adjustable travel ( 4.5” or 5”) is enough to fine tune your ride for any trail and the full carbon monocoque front and rear triangles keep things nimble and light for the climb. This vehicle is a ripper of a ride.

registration

WWW.INTENSECYCLES.COM/WARRANTY-CARD/

contact customer service

cs@intensecycles.com 951-296-9596

Welcome to the family

2 // ACV user manual

introduction / registration 2

frame features / component spec 4

Geometry 5

exploded view and b.o.m. 6

Assembly 8

torque chart 13

setup 14

maintenance 18

INTENSE CYCLES // 3

4 // ACV user manual

frame features / spec

Frame Features //

• Adjustable Travel: 4.5" to 5" (115mm OR 130mm)

• 27.5+” Wheel size

• 5.3 lbs / 2,420 grams = Standard frame w/ alloy link, no shock, size m

• Tapered He ad Tube

• Monocoque front triangle

• Integrated BOOST 148 x 12 dropouts

• Internal Brake and Derailleur Cable Routing System

• Internal Seat Tube Cable Routing for dropper posts

• Angular Contact/Collet Bearing System with replaceable Grease Zerks

• Flack guard Downtube and Chainstay protection

• H20 Bottle Fitment

Component Spec //

• Fork – 1.5” tapered steer, 150mm Travel, 561mm lower leg length, 51mm offset

• Shock – 200mm x 50.8mm (7.875” x 2”), 22mm x 6mm and 30mm x 6mm reducers

• 1x gearing only

• Seat post – 31.6mm

• Headset – zero stack 44 upper / external cup 49 lower

• Bottom bracket - Press Fit BB92

• Rear Axle – BOOST 148 x 12 T/A

• Brake Mount – post mount for 160mm rotor

• Crank set - BOOST 148 Compatible - single ring only

• Rear Wheel - BOOST 148 Compatible

INTENSE CYCLES // 5

Geometry

GEOMETRY NOTEs

GEOMET RY TAKEN AT TOP OUT WITH 561MM FORK LENGTH AND 51MM FORK OFFSET.

Component spec NOTE

the Acv is designed around the use of single chain ring. Use of a double or triple ring set will not allow proper clearance with the frame.

SMALL MEDIUM LARGE XLarg e

Wheel Base: 1146 mm/ 45.1” 1172 mm/ 46.1” 1199 mm/ 47.2” 1225 mm/ 48.2”

Top Tube Length: 573 mm/ 22.6” 599 mm/ 23.6” 624 m m/ 24.6” 651 mm/ 25.6”

Chain St ay Lengt h: 438 mm/ 17.25” 438 m m/ 17.25” 438 mm/ 17.25” 438 mm/ 17.25”

Head Tube Length: 94 mm/ 3.7” 102 mm/ 4” 114 mm/ 4.5” 119 mm/ 4.7”

Head Tube Angle: 66.25˚ 66.25˚ 66.25˚ 66.25˚

Reach: 394 mm/ 15.5” 416 mm/ 16.4” 438 mm/ 17.25” 463 mm/ 18.2”

Stack: 620 mm/ 24.4” 628 mm / 24.7” 640 mm/ 25.2” 645 m m/ 25.4”

BB Height: 334 mm/ 13.15” 334 mm/ 13.15” 334 mm/ 13.15” 334 mm/ 13.15”

Seat Tube Angle (Effective): 73.8˚ 73.8˚ 73.8˚ 73.8˚

Seat Tube Angle (Actual): 71˚ 71˚ 71˚ 71˚

Seat Tube Length: 433 mm/ 17” 458 mm/ 18” 484 mm/ 19” 509 mm/ 20”

Standover Height: 801 mm/ 31.55” 805 mm/ 31.68” 810 mm/ 31.9” 813 mm/ 32”

6 // ACV user manual

exploded view

and b.o.m.

27 7

INTENSE CYCLES // 7

ITEM

NO.

ITEM

PART

NUMBER

DESCRIPTION QTY. TORQUE SPEC.

Bearing Spacer 130759 Top Lin k Bearing Spacer (Lo wer) 1 N/A

Top Lin k 130762 Forge d Top Link 1 N/A

Box Link 130764 Forge d Lower Link 1 N/A

Bearing Cap

24mm OD

130765 Top Link Bear ing Cap (Lower) 2 N/A

Bearing Cap 130778 Box Link Be aring Ca p 4 N /A

Axle Upper 130780 Top Link Pivot A xle 1

20 Nm /

175 in-lbs

Bolt Shoulder 13 0785 Top Link P ivot Bol t 1

20 Nm /

175 in-lbs

Spacer 130789 Box Link Bearin g Space r 2 N/A

Hanger 130790 Derailleur Hanger Forged 1 N /A

Bolt Ma in Pivot 130791

Bolt Ma in Pivot 1.5t

Expander Blk

7 Nm /

60 in-lb s

Hanger Bolt 130792 Derailleur Hanger Bolt 1

11 Nm /

100 in-lbs

Rear Axle 130799

148 x 12mm

Boost Wheel Axle Kit

11 Nm /

100 in-lbs

Cone Adjuster 130807 Pivot Axle Expander Cone 3 N /A

Bolt Ma in Pivot

C/G

130819

Bolt Ma in Pivot 1.5t Expan der,

w/int. Threads for Chain Gui de,

Silver

7 Nm /

60 in-lb s

Bumper 140006 Box Link Bumper 1 N /A

O-Ring 140 013 Seat Clamp o-ring 1 N /A

Plug 140038 B ox Link P ivot Plu g 3 N/A

Cable Guide

Gromet

140039 C able Gui de Grom et 1 N /A

Cable Guide Plug 140040 Cab le Guide Plug 6 N /A

Seat Collar 346941 Bol t-on 36.1 1 N /A

ITEM

NO.

ITEM

PART

NUMBER

DESCRIPTION QTY. TORQUE SPEC.

Zerk Fitt ing 401011 M6 x 1.0 2

5 Nm /

40 in-lb s

SHCS M6 x 22 410009

Cone Adjuster Bo lt,

Socket Head, M6 x 22

14 Nm /

125 in-lbs

BHCS M5 X 12 410010

Water Bo ttle Bo lt,

Button Head, M5 X 12

6 Nm /

54 in-lb s

SHCS M6 x 40 41005 3

Shock Bolt, Front,

Socket Head, M6 x 40

7 Nm /

60 in-lb s

SHCS M6 x 45 410054

Shock Bolt, Rea r,

Socket Head, M6 x 45

7 Nm /

60 in-lb s

Bearing 7902 430007

15 x 28 x 7 2RS MAX Angular

Contact Bearing

4 N /A

Bearing 6802 430008

15 x 24 x 5 2RS

MAX Radial Bear ing

4 N /A

Guard Flack Rear

Strut

500260 Flac k Guard ACV Rear St rut 1 N/A

Guard Flack DT 500262 Flac k Guard A CV Down Tube 1 N/A

Guard Flack CS 500266 Flack Guard ACV Chainstay 1 N /A

Guard Flack SS 500267 Flack Guard ACV Seatstay 1 N /A

Chain St ay

Protector

500268 Chain Sta y Prote ctor, ACV 1 N /A

Decal California

Bear

500300 Decal California Bear 1 N/A

Head Badge 500335 Head Badge Flame Logo 1 N /A

Front Triangle

Fron t

Triangle

Carbon, 4 Size s 1 N /A

Front Triangle

Rear

Triangle

Carbon, 1 Size 1 N /A

Shock Shock

Rear Shock, 7.875” x 2”

(200mm x 50.8 mm)

1 N /A

8 // ACV user manual

Assembly

Tools needed

• High Grade, waterproof grease (Maxima Waterproof Grease recommended)

• Blue Loctite® #243

• 5mm HEX wrench x2

• 8mm HEX wrench

Recommendation

use Grease on lower linkage bolts only. use loctite on upper linkage bolts, dropout bolts and hanger bolt.

PREFA C E //

Service and maintenance on an Intense bicycle requires special tools, abilities and knowledge of working on bicycles. It is always recommended to use an authorized Intense dealer for service and maintenance. Always wear eye protection. It is critical to use the proper tools, loctite, grease and torque specs during assembly. Failure to follow these instructions may result in serious bodily injury or death.

INTENSE CYCLES // 9

1 4

CONNECTING TOP LINK TO FRONT TRIANGLE //

A Holding top link (#130762) with

shock mount pointed forward, hold upper spacers (#130789) against inside of bearing race (IMAGE #1).

B Match upper link to top tube, making

sure that spacers do not fall out.

C Using upper pivot axle (#130780),

insert through non-drive side of top link bearing and push through to drive side bearing, making sure spacers do not fall out (IMAGE #2). Install shoulder bolt (#130785) into drive side of top link pivot, and tighten to 20 NM or 175 in/ lbs (IMAGE #3).

CONNECTING BOX LINK TO FRONT TRIANGLE //

A Hold bearing caps (#130778) with

rounded ends facing outwards against bearings on box link (#130764) (IMAGE #4), (note box link orientation in image #4, with rubber bumper facing upward and rearward on box link).

B Match link to front triangle and from

non drive side, insert greased main pivot bolt (#130819) through the non-drive side of frame (IMAGE #5).

C Use 8mm HEX to install, then torque

pivot bolt (#130819) to 7 NM or 60 in/lbs.

10 // ACV user manual

CONNECTING REAR TRIANGLE TO BOX LINK //

A Follow previous step to connect rear

triangle to box link (IMAGES #6 & 7).

B Use 8mm HEX to install, then torque

pivot bolt (#130791) to 7 NM or 60 in/lbs.

CONNECTING REAR TRIANGLE TO TOP LINK //

A Hold spacers (#130765) with squared

edges again st th e bea ring and the rounded edges facing outward (IMAGE #8), Swing the seat stays up and align with the lower spacers. From the non drive side of top link, install greased pivot bolt (#130791) (IMAGE #9).

B Use an 8mm HEX to install. Torque

main pivot bolt (#130791) to 7 NM or 60 in/lbs.

INTENSE CYCLES // 1 1

TIGHTENING SEATSTAYS TO TOP LINK //

A Grease and install adjuster cone

(#130807) into head of main pivot bolt (#130791) and greased M6x22mm bolt (#410009) through the adjuster cone into the main pivot bolt (IMAGE #14).

B Using hand pressure, squeeze the top

of seat stay together at the lower top link location to eliminate side to side play (IMAGE #15) then use a 5mm HEX to make snug.

C Torque M6x22mm (#410009) to 14 NM

or 125 in/lbs (IMAGE #16).

INSTALLING REAR SHOCK //

A Holding the rear shock in one hand, match the forward end to the foward shock

mount on the frame and install greased M6x40mm bolt (#410053) through drive side of frame (IMAGE #10). Do not tighten.

B Match rear end of shock to desired travel setting (see below) on upper link and

install greased M6x45mm bolt (#410054) through non-drive side of link (IMAGE #11).

C Torque shock bolts (#410053 & #410054) to 7 NM or 60 in/lbs (IMAGES #12 & 13).

adjustable travel NOTE

the top link of the Acv fe at ures dua l mounting po sition s. The Upp er shock moun ting hole on top link is for LONG travel, the lower hole is for SHORT travel. for more information see the set up guide on page 14.

1510 12

14 1611 13

12 // ACV user manual

INSTALLING ADJUSTER CONES ON LOWER LINK //

A Grease and install adjuster cone

(#130807) into head of main pivot bolt (#130819 / #130791) and greased M6x22mm bolt (#410009) through the adjuster cone into the main pivot bolt (IMAGES #17 & 18).

B Torque M6x22mm (#410009) to 14 NM

or 125 in/lbs (IMAGE #19).

INSTALLING DERAILLEUR HANGER //

A Greas e outer edges of derailleur hanger

(#130790) and loctite derailleur bolt (#130792) (IMAGE #20).

B Insert hanger (#130790) into back

of frame opening and match derailleur bolt (#130792) from outside of frame, threading bolt into hanger (IMAGE #21).

C Torque derailleur bolt (#130792) to

11NM or 100 in/lbs (IMAGE #22).

2017

19 2118

torque

Achieving proper torque is vital to ensuring the safe performance and function of the Acv carbon frame. Failure to do so could result in suboptimal performance of your frame as well as premature we ar and tear of individual parts.

additional reference

In addition to this chart, all torque values are laser etched onto corresponding hardware for your reference.

INTENSE CYCLES // 1 3

torque chart

20 Nm / 175 in/lbs

7 Nm / 60 in/lbs

M8 HEX 7 Nm / 60 in/lbs

M5 HEX 14 Nm / 125 in/lbs

M8 HEX 7 Nm / 60 in/lbs M5 HEX 14 Nm / 125 in/lbs

11NM or 100 in/lbs

seatpost

make sure to ins ert seat po st at least 4” into the main frame. Anything less than this amount could cause damage to the frame or even failure.

14 // ACV user manual

set up

adjustable travel

upper mount: 130mm lower mount: 115mm

upper mount

lower mount

4”

INTENSE CYCLES // 1 5

shock setup

rock shox monarch rt3 200x51mm

set up and tune

proper set up and tuning can vary from shock to shock. P lease consult the rockshox manual included with your bike for comp lete information about set up, tuning and general maintenance or visit www.sram.com/rockshox/products

Trav el 112 mm 125 mm

Shock Stoke

51 mm

Shock Sag

20% when sitting on the b ike

Fork Sag

25-30% when sitting on the bi ke

SHOCK: ACV Pro

Rock Sh ox Monar ch RT3 200x51 mm DB2 MM S 320

SHOCK: ACV Foundation

Rock Sh ox Monar ch R 200x51 m m DB2 MM S 320

RIDER W EIGHT (LB S/KGS) SPRING (PSI) REBOUND (clicks out) SPRING (PSI) REBOUND (clicks out)

100 lb s / 45 kgs

2 to 3

110 l bs / 50 kgs

104 114

120 lb s / 54 kgs

120 130

130 lb s / 59 kgs

136 146

140 l bs / 63.5 kgs

151 161

150 lb s / 68 KGS

167

3 to 4

177

3 to 4

160 lb s / 73 kgs

182 192

170 l bs / 77 kgs

198 208

180 lb s / 82 kgs

213 223

190 lb s / 86 kgs

229 239

200 lb s / 91 kgs

244 254

210 lb s / 95 kgs

260 270

220 lbs / 100 kgs

275 285

230 lb s / 104 kgs

291

5 to 6

301

5 to 6

240 lb s / 109 kgs

306 316

250 lb s / 113 kgs

322 332

260 lb s / 118 kgs

337 347

270 lb s / 122 kgs

353 363

280 lb s / 127 kgs

368 378

290 lb s / 131.5 kg s

384 394

300 lb s / 136 kgs

399 409

16 // ACV user manual

INTENSE CYCLES // 1 7

18 // ACV user manual

maintenance

GENERAL SERVICE AND CARE //

You have purchased a high perform ance bicycle which requires a certain level of servic e and maintenance to sustain the level of performance your frame was designed around. Proper care will also ensure the bike is safe to ride at all levels. It is important to read and understand th e carbo n care information as well as follow the mainte nance schedule and inspect your bi cycle before each ri de. These will not only help to limit or avoid costly repairs but will also help to avoid injury due to service neglect and component failure.

carbon care

Intense Cycles employs advanced composite techniques and materials in our frames which do require a certain level of care and maintenance to ensure a safe experience at the high level of performa nce each frame is designed around. Not following these guidelines will decrease the level of performance and possibly cause injury or death.

• Use a soft cloth with warm soapy water to clean the carbon surfaces. Do not use abrasive cloths or cleaners.

• Be sure all frame surfaces in contact with cables are protected. Cable housing rubbing on carbon can wear over time.

• Be sure brake levers, handle bar ends and the fork crown do not contact the frame at full rotation.

• Never clamp any part of a carbon frame in a bike stand or car rack.

• Always inspect your frame if you experience any chain suck. Intense frames come equipped with steel chain suck plates but damage can still be done in the event of chain suck.

• Always inspect your frame in full after a crash to be sure there is no damage. Look for cracks, dents or loose fibers. If you discover damage in any degree it’s best to have your frame inspected by a qualified Intense Cycles dealer. Any direct impact to the frame can cause serious structural damage.

• Use high grade waterproof grease on seat post, BB and head set bearing contact areas with the carbon.

• Never ream or face a carbon frame.

• Be sure to follow all recommended torque settings.

INTENSE CYCLES // 1 9

maintenance Schedule*

Action Every Ride

500 Mil es or

1 Month

2000 Mil es or 6

Months

4000 Mi les or

1 Year

Tires

Check air pressure, in spect tread an d sidewa lls for t ears an d punct ures X

Chain

Brush off and l ubricat e X

Brakes

Squeeze brakes and confirm function X

General

Clean c omplet e bike of mud and debris X

Headset

Check adjustment X

Box Lin k

Add gre ase thr u zerk fittings X

Frame Pivots

Check torques X

Spokes

Inspect for damage, check tension X

Shock a nd Fork

Check air pressure, in spect for leaks X

Deraileur Cables

Inspect and lube X

Seat post

Clean and regrease interface with frame X

Frame Pivots

Remove pivot bo lts, che ck bearings for p itting a nd wear X

Headset

Disass emble s tem, headset a nd fork. Check b earings for pitting and wear X

Hubs

Pull wh eels off, check hub bearin gs for pit ting an d wear X

Bottom Bracket

Remove crank arms and check B B beari ngs for pitting and wear X

Brakes

Replace brake pads X

Chain

Inspe ct for da mage an d check for stret ching X

General

Complete Tune-Up X

Shock a nd Fork

Overhaul See MFG Recommendations

* THE ABOVE MAINTENANCE SCHEDULE IS ONLY A GUIDELINE. refer to COMPONENT MANUFACTURER FOR SPECIFIC INSTRUCTION ON MAINTAINING THEIR PARTS.

phone: (951)-296-9596

Customer Service: cs@intensecycles.com

General Info: info@intensecycles.com

Media, Marketing, Sponsorship: marketing@intensecycles.com

Intense Cycles USA 42380 rio nedo Temecula, Ca. 92590

www.I NTENSeCYCLES.com

330014

Intense Cycles ACV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual