user manual carbine 275
Welcome to
the family
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 talented people work in a Temecula, CA factory, Intense has been
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, we hope it’s the ride of your life.
THE CARBINE 275
For the trail, all mountain or endure riders, the Carbine 275 has the perfect blend of
stability and travel options for any type of terrain. The oversized 1.5 lower headset
contact point keeps you pointing exactly where you want to go and the ACB, 15mm
collet axle system holds it all together with precision. The Carbine 275 has been
at the forefront of the 27.5” wheel revolution and holds all the key attributes and
advantages of this wheel size.
2 // carbine 275 user Manual
frame features 4
Geometry 5
exploded view and b.o.m. 6
Assembly 8
torque chart 12
setup 13
maintenance 16
registration 19
INTENSE CYCLES // 3
4 // carbine 275 user Manual
frame
features /
spec
frame Features //
• Adjustable Travel – 5.5” or 6” (135mm or 150mm)
• Patented VPP Suspension Technology
• 27.5 Wheel Size
• Available in 26” configuration
• G1 Replaceable Drop Out System
• 5.5lbs Frame weight (Medium Naked)
• integrated Internal Brake and Derailleur Cable Routing System
• Angular Contact/Collet Bearing System with replaceable Grease Zirks
• Internal Cable Routing for dropper posts
• Tapered Head Tube
• ISCG 05 Mounts
• FLack GuaRD Chain stay & Down tube Protection
• H20 Bottle Fitment
component spec //
• Fork – accepts 1.125" straight steer or 1.125"/1.5" tapered steer,
150mm Travel, 544mm lower leg length, 44mm offset
• Shock – 200mm x 57mm (7.875” x 2.25”), 22mm x 6mm and 30mm x 6mm reducers
• Front derailleur – Direct Mount, top pull
• Seat post – 31.6mm
• Headset – zero stack 44 upper / external cup 49 lower
• Rear Axle – 135mm qr or 142mm x 12mm ta
• Brake Mount – international standard for 160mm rotor
INTENSE CYCLES // 5
Geometry
C
B
A
F
I
K
E
D
G
H
L
J
GEOMETRY NOTEs
GEOME TRY TA KEN AT TOP OUT WITH 54 4MM
FORK LENGTH, 44MM FORK OFFSET and
27.5" wheel configuration .
SMALL MEDIUM LARGE
A Wheel Base 1097 mm / 43.2” 1123 mm / 44.2” 1148 mm / 45.2”
B Top Tube Length 559 mm / 22” 584 mm / 23” 610 mm / 24”
C Chain Stay Length 432 mm / 17” 432 mm / 17” 432 mm / 17”
D Head Tube Length 107 mm / 4.2” 114 mm / 4.5” 122 mm / 4.8”
E Head Tube Angle 67˚ 67˚ 67˚
F Reach 387 mm / 15.25” 413 mm / 16.25” 438 mm / 17.25”
G Stack 572 mm / 22.5” 584 mm / 23” 597 mm / 23.5”
H BB Height 348 mm / 13.7” 348 mm / 13.7” 348 mm / 13.7”
I Seat Tube Angle (Effective) 72.5˚ 72.5˚ 72.5˚
J Seat Tube Angle (Actual) 70.5˚ 70.5˚ 70.5˚
K S eat Tube Length 394 m m / 15.5” 445 mm / 17.5” 495 mm / 19.5”
L Standover Height 783 mm / 30.8” 799 mm / 31.4” 808 mm / 31.8”
6 // carbine 275 user Manual
exploded view
and b.o.m.
36
10
28
5
4
1
24
27
11
21
24
37
30
13
25
2
7
6
31
3
9
12
29
22
10
10
34
8
20
18
15
18
35
26
26
19
19
26
18
18
14
16
18
18
33
18
18
18
26
19
18
18
32
18
1726
18
23
23
INTENSE CYCLES // 7
ITEM
NO.
ITEM
PART
NUMBER
DESCRIPTION QT Y. TORQUE SPEC.
1
Derailler Moun t
Cover
130209 For Single Chain Ring Setup 1 N /A
2
Box Link 130770 Forged Top Link 1 N/A
3
Top Link 130771C Main Pivot Expander Cone 1 N /A
4
Left Dropout 130774
Dropout Forged G1 Left,
Syntace X-12, 142mm Blk
1 N /A
5
Right Dropout 130775
Dropout Forged G1 Rig ht,
Syntace X-12, 142mm Blk
1 N /A
6
Cone Adjuster 130777 Main Pivot Expander Cone 2 N /A
7
Bearing Cap 130778 Main Pivo t Bearing Cap 4 N/A
8
Axle Upper 130780 Top Link Pivot Axle 1
20 Nm /
175 in-lbs
9
Washer 130784 Top Link Pivot Lower Wash er 2 N/A
10
Bolt Shoulder 130785 Top Link Pivot B olt 3
20 Nm /
175 in-lbs
11
Rear Axle 130786 142 x 12mm Wheel Axle Kit 1
11 Nm /
100 in-lbs
12
Spacer 130789 Top Lin k Pivot Upper Spacer 2 N /A
13
Bolt Main Pivot 130791
Main Pivo t 1.5t
Expander Bolt Blk
2
7 Nm /
60 in-lbs
14
Plug 140004 Box Link Pivot Plu g 2 N/A
15
Ring 140005 Ring Cock 1.5265 Blk 1 N /A
16
Bumper 140006 Box Link Bumper 1 N /A
17
Plastic Plug 140007 Plug Hole .3125 1 N/A
18
Clip Plastic 310001 Snap-on Cable Guide Single 15 N/A
19
Guide Plastic 310004 B olt-on Cable Guide Single 3 N/A
20
Seat Collar 346939 QR 34.9 Blk 1 N/A
21
Shock 350332 Rear Sh ock 7.875 x 2.25 1 N/A
ITEM
NO.
ITEM
PART
NUMBER
DESCRIPTION QT Y. TORQUE SPEC.
22
Nut 400012
Dropout Nut Steel
9.9 x 10.5L Blk UCP
4 N/A
23
Zerk Fitting 401011 M6 x 1.0 2
5 Nm /
40 in-lbs
24
SHCS M6 x 40 410002
Shock Bolt,
Socket Head, M6 x 40
2
7 Nm /
60 in-lbs
25
SHCS M6 x 22 410009
Cone Adjuster Bolt,
Socket Head, M6 x 22
2
14 Nm /
125 in-lbs
26
BHCS M5 X 12 410010
Guide Bo lt, Button Head,
M5 X 12
5
6 Nm /
54 in-lbs
27
Bolt 410030
Dropout Bolt Steel
M8-0.75 x 10L Black UCP
4
8 Nm /
70 in-lbs
28
FHCS M6 x 12 410037
Derailleur Mou nt Cover Bolt,
Flat Head , M6 x 12
1
7 Nm /
60 in-lbs
29
Bearing 6901 430001
12 x 24 x 6 2RS
Radial Bearing
2 N/A
30
Bearing 7902 430007
15 x 28 x 7 2RS MAX
Angular Contact Bearing
4 N/A
31
Bearing 6802 430008
15 x 24 x 5 2RS
MAX Radia l Bearing
2 N/A
32
Guard Fla ck DT 500180
Flack Guard
Carbine 275C Down Tube
1 N /A
33
Guard Fla ck CS 500181
Flack Guard
Carbine 275C Chain Stay
1 N /A
34
Decal California
Bear
500300 Decal California Bear 1 N/A
35
Head Badge 500335 Head Badge Flame Logo 1 N /A
36
Front Triangle Carbon, 3 Sizes 1 N/A
37
Rear Triangle Carbon, 1 Size 1 N /A
8 // carbine 275 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.
PR E F A CE //
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
CONNECTING TOP LINK TO FRONT TRIANGLE //
A Holding top link (#130771) with shock
mount pointed forward; hold upper
spacer (#130789) against inside of
bearing race.
B Match upper linkage to pivot point on
top tube, making sure that spacers do
not fall out (IMAGE #1).
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. Then, apply loctite #243 to bolt
(#130785) as well as upper axle threads,
and thread bolt into axle from drive side
using 5mm HEX wrench (IMAGE #2).
D Holding 5mm HEX wrench on non-
drive side upper axle, insert torque
wrench into bolt on drive side and
tighten to 20 Nm / 175 in-lbs
(IMAGE #3).
CONNECTING BOX LINK TO FRONT TRIANGLE //
A Hold bearing cap (#130778) with
rounded edge facing outwards against
bearings on linkage piece (IMAGE #4).
See exploded view on page 6 for linkage
orientation.
B Match link to front triangle pivot point
and insert main pivot expander bolt with
greased threads (#130791) through nondrive side of box link, holding bearing
caps in place (IMAGE #5). Use 8mm
HEX to install and torque bolt to 7 Nm
/ 60 in-lbs.
1 4 5
2
3
10 // carbine 275 user Manual
CONNECTING REAR TRIANGLE TO
BOX LINK //
A Follow previous steps to connect rear
triangle to box link (IMAGE #6 & 7).
CONNECTING REAR TRIANGLE TO
TOP LINK //
A Insert shoulder bolts (#130779)
through seat stay bearings. Hold lower
top link washer (#130784) against
inside race of seat stay bearing on top
of shoulder bolt threads (IMAGE #8).
B Apply loctite #243 to female threads of
top link (#130771). Match shoulder bolts
to top link threads and tighten shoulder
bolts to 20 Nm / 175 in-lbs making sure
that each washer is in place between
bearing and linkage (IMAGE #9).
INSTALLING REAR SHOCK //
A Using rear shock, match forward end to forward shock mount and install M6x40mm
bolt (#410002) through drive side of frame (IMAGE #10). Do not tighten.
B Match rear end of shock to desired travel setting (see below) on upper linkage and
install M6x40mm bolt (#410002) through non-drive side of linkage.
C Tighten both M6x40mm (#410002) shock bolts in small increments until you reach
approximately 7 Nm / 60 in-lbs.
adjustable travel
the upper linkage features dual
mounting positions which allow you
to choose between 150mm and 135mm
rear travel. for more information see
the set up guide on page 13.
10
6 8
7 9
INTENSE CYCLES // 1 1
INSTALLING ADJUSTER CONES //
A Grease and insert cone adjuster
(#130777) into head of main
pivot expander bolt (#130791)
with M6x22mm bolt (#410009)
inserted through cone adjuster
(IMAGE #11 & 12).
B Tighten M6x22mm bolt (#410009) with
5mm HEX and torque to 14 Nm / 125 in-lbs
(IMAGE #13).
1413
15
16
11
12
INSTALLING DERAILLEUR HANGER //
A Locate the right and left G1 dropouts.
The right dropout has the derailleur
hanger built into it.
B Apply grease to the face of the dropout
(I MAGE 14).
C Position dropout into the recessed area
on the right side of the rear triangle.
Insert the mounting bolt from the front
and tighten into the nut (IMAGE 15).
D Using a chainring tool hold the dropout
nut from behind while tightening the
dropout bolt to 10NM (88 inch/lbs) using
a 5mm hex (IMAGE 16).
E Repeat attachment steps for left side
dropout.
torque
Achieving proper torque is vital to
ensuring the safe performance and
function of the carbine 275 frame.
Failure to do so could result in suboptimal performance of your frame
as well as premature wear and tear
of individual parts.
additional reference
In addition to this chart, all torque
values are laser etched onto
corresponding hardware for your
reference.
12 // carbine 275 user Manual
torque chart
7 Nm / 60 in-lbs
7 Nm / 60 in-lbs
20 Nm / 175 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
11 Nm / 100 in-lbs
20 Nm / 175 in-lbs
8 Nm / 70 in-lbs
seatpost
make sure to insert seat post at le ast
4” into the main frame. Anything less
than this amount could cause damage
to the frame or even failure.
INTENSE CYCLES // 1 3
set up
adjustable travel
upper mount: 150mm
lower mount: 135mm
seat post should be
inserted at least 4”
into main frame
14 // carbine 275 user Manual
shock setup
x-fusion, 02 rl, 200x57mm
set up and tune
prope r set up and tun ing can vary from
shock to shock. Please consult the
X-Fusion manual included with your
bike for complete information about
set up, tuning a nd general ma intenance
or visit www.xfusionshox.com
Trav el 135 mm 150 mm
Shock Stoke
57 mm
Shock Sag
20% when sitting on t he bike
Fork Sag
25-30% when sitting on th e bike
SHOCK
X-Fusion, 02 RL, 200x57 m m
RIDER WEIGHT(LBS/KGS) SPRING (PSI) REBOUND (clicks out) SPRING (PSI) REBOUND (clicks out)
100 lbs / 45 kgs 63
1 to 2
82
1 to 2
110 lbs / 50 kgs 71 89
120 lbs / 54 kgs 79 97
130 lbs / 59 kgs 87 105
140 lbs / 63.5 kgs 95 112
150 lbs / 68 kgs 104
3 to 4
120
3 to 4
160 lbs / 72.57 kgs 112 127
170 lbs / 77.11 kgs 120 135
180 lbs / 81.65 kgs 128 143
190 lbs / 86.18 kgs 136 150
200 lbs / 90.72 kgs 14 4 158
210 lbs / 95.25 kgs 152 166
220 lbs / 99.79 kgs 161 173
230 lbs / 140.33 kgs 169
5 to 6
181
5 to 6
240 lbs / 108.86 kgs 177 188
250 lbs / 113.40 kgs 185 196
260 lbs / 117.93 kgs 193 204
270 lbs / 122.50 kgs 201 211
280 lbs / 127.00 kgs 210 219
290 lbs / 131.54 kgs 218 227
300 lbs / 136.08 kgs 226 234
INTENSE CYCLES // 1 5
16 // carbine 275 user Manual
maintenance
GENERAL SERVICE AND CARE //
You have purchased a high performance bicycle which requires a certain level of service
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 the carbon care information as well as follow the maintenance schedule
and inspect your bicycle before each ride. 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 performance 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 7
maintenance Schedule*
Action Every Ride
500 Mil es or
1 Month
2000 Mi les or 6
Months
4000 Miles or
1 Year
Tires
Check air pressure, inspect tread an d sidewalls for tears and punctures X
Chain
Brush off and lubricate X
Brakes
Squeeze brakes and confirm function X
General
Clean co mplete bike of mud and de bris X
Headset
Check adjustment X
Box Lin k
Add grea se thru zerk fittings X
Frame Pivots
Check torques X
Spokes
Inspect for damage, check tension X
Shock a nd Fork
Check air pressure, inspect for leaks X
Deraileur Cables
Inspect and lube X
Seat post
Clean and regrease interface with frame X
Frame Pivots
Remove pivot bolts, check bearings for pitting an d wear X
Headset
Disass emble stem, headset and fork. Check b earings for pitting and wear X
Hubs
Pull whe els off, check hub bearings for pittin g and wear X
Bottom Bracket
Remove crank arms and check BB b earings for pitting and wear X
Brakes
Replace brake pads X
Chain
Inspe ct for damage and check for stretching 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.
18 // carbine 275 user Manual
INTENSE CYCLES // 1 9
registration
WWW.INTENSECYCLES.COM/WARRANTY-CARD/
contact customer service
cs@intensecycles.com
951-296-9596
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
330005
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