Page 1
OWNER'S MANUAL
Page 2
© Pinion GmbH 2018
All rights reserved
Printed in Germany 08-2018
Inhalt: www.technische-redaktion.de
www.pinion.eu
Page 3
CONTENTS
INTRODUCTION
SYMBOLS.......................................................4
WARNING INSTRUCTIONS ...............................4
FOREWORD ....................................................5
TECHNICAL DATA
DEVELOPMENT...............................................7
TIGHTENING TORQUES ...................................7
SAFETY
INTENDED USE...............................................8
BASIC SAFETY INSTRUCTIONS … ..................8
ON THE ROAD
RUNNING IN THE GEARBOX ..........................10
BEFORE EVERY RIDE ...................................10
SHIFTING CORRECTLY ..................................11
MAINTENANCE
REGULAR MAINTENANCE WORK ................... 12
ADJUSTING SHIFTING ...................................14
OIL CHANGE.................................................15
OIL CHANGE DATA ........................................35
INSTALLATION WORK
INSTALLING ROTARY SHIFTER ...................... 16
INSTALLING OR REPLACING
SHIFTING CABLES ....................................... 17
INSTALLING PINION CHAIN TENSIONER ........24
ADJUSTING CHAIN TENSION
(PINION CHAIN TENSIONER) ........................25
EXCHANGING PULLEYS
(PINION CHAIN TENSIONER) ........................26
REPLACING CHAIN RING ..............................26
INSTALLING CRANKS ....................................28
CHAIN/TOOTHED BELT
– LENGTH & TENSION ................................. 29
INSTALLING GEARBOX ..................................30
REMOVING GEARBOX ...................................31
SERVICE
SERVICE VIDEOS ..........................................32
OVERVIEW OF DEALERS ............................... 32
TECHNICAL SUPPORT ...................................32
LEGAL INFORMATION
LIABILITY ..................................................... 33
WARRANTY ..................................................33
OIL CHANGE DATA ........................................35
3
Page 4
INTRODUCTION
C1.12
SYMBOLS
This instruction identifies particularly important information and gives
you additional messages or tips.
ÎÎ
The arrow prompts you to carry out an action.
••
The dot indicates results or necessary preconditions.
Instructions with this indication only relate to the corresponding type of your
Pinion gearbox.
The play button draws your attention to a Pinion video on the topic at
www.pinion.eu
https://pinion.eu/en/service-videos/.
For direct access scan the QR code –see SERVICE VIDEOS, page 32.
WARNING INSTRUCTIONS
This instruction warns of a hazardous situation, which if not
avoided can result in death or serious injury.
Ζ
... and shows you how to avoid it.
This instruction warns of a hazardous situation, which if not
avoided can result in minor or moderate injury.
Ζ
... and shows you how to avoid it.
This instruction warns of potential material damage.
Ζ
... and shows you how to avoid it.
This instruction warns of potential environmental
damage.
Ζ
... and shows you how to avoid it.
4
Page 5
C64500
INTRODUCTION
FOREWORD
You are now the owner of a modern Pinion gearbox – made in Germany.
This owner's manual is a part of your Pinion product and contains information on how to operate,
adjust, install and maintain your product safely.
Read this manual carefully before using your Pinion product. Always observe and follow all instruc-
tions in this manual – and also the user instructions from other manufacturers whose products are
used on your bicycle (chain, wheels, quick release skewers etc.).
Remember that the mechanic is responsible for the suitability and compatibility of all components
that interact with your Pinion product.
If the instructions in this manual are not observed, this may result in accidents
with fatal consequences or serious injury.
Keep this manual for other users of your Pinion product. Make sure that every user reads, understands
and observes this manual.
If you ever sell or give away your Pinion product, give this manual to the new owner.
1
The illustrations in this manual may be different from your Pinion product, but the required work steps
are the same for all gearbox types – unless otherwise specified.
(
)
The gearbox type of your Pinion gearbox is stamped on the cable box cover
(
)
number on the rating plate in the area at the back
fig. 2
.
Please note that the transmission will have a different feel compared to a derailleur system.
Familiarize yourself with your new Pinion gearbox and the differences in your transmission during your
initial rides.
See https://pinion.eu for many more tips and more information on your Pinion product.
We wish you all the best with your leisure and competitive riding.
The Pinion Team
fig. 1
– the 6-digit serial
2
5
Page 6
TECHNICAL DATA
A
C
* If the Pinion spider is used, the chain line or beltline is defined by the contact surface
(52 mm) of the spider and the dimension/geometry of the chain ring or the belt
sprocket that is used – e.g.: 52 mm + ½ t = 54 mm chain line
(with symmetrical chain ring with thickness t=4 mm).
** optional
*** Rider + backpack etc.
D
B
E
Gearbox type
(A)
Chain line
Pitch circle Ø
Q-factor
Crank length**
Crank axle standard
Dimension, chain
Gears via rotary shifter
Gear ratio, total
Gear steps, constant
Ratio in 1st gear 1.82 0.95
Ratio in the fastest gear
Oil volume/type
Input torque max.
Rider weight max.***
– with Pinion chain ring
(B)
, Pinion spider
(C)
(D)
(E)
mm
mm 6.6 – 6.8 (9-speed)
%
ml (oz) 60 (2.0) / Pinion
N·m (lbf·in) 250 (2213)
kg (lb) 110 (243)
C1.12 C1.9
180 / 175 / 170 / 165 / 160 / 155
12 9 6
600 568 295
~ 17.7 ~ 24.3
0.30 0.32
XR
50*
104
166
Pinion Standard
C1.6
3
6
Page 7
1 2 3 4 5 6 7 8 9 10 11 12
1,3 (4.3)
1,5
(4.9)
1,8
(5.9)
2,1 (6.9)
2,5
(8.2)
3,0
(9.8)
3,5
(11.5)
4,1
(13.5)
4,9
(16.1)
5,7
(18.7)
6,7
(22.0)
7,9
(25.9)
1,0 (3.3)
2,0
(6.6)
3,0
(9.8)
4,0
(13.1)
5,0
(16.4)
6,0
(19.7)
7,0
(23.0)
8,0
(26.2)
17,7 %
m (ft)
C1.12
DEVELOPMENT
C1.12
The specified values in m (ft) per crank revolution
correspond to the recommended ratio for sprocket (rear) : chain ring
(front) 26 : 30 = 0.866.
The calculation is based on the tyre size 28×1.4(37-622).
You can find a convenient program for calculating your individual ratio
as well as the development values of other types of Pinion gearbox at
https://pinion.eu.
(
fig. 4
TECHNICAL DATA
4
TIGHTENING TORQUES
Tightening torque in N·m (lbf·in) max.
Gearbox retaining screws
)
Central crank screws
Crank clamp screws
Chain ring lock ring
Cable box retaining screws
Rotary shifter housing clamping screw
Rotary shifter cover housing screw
Shifting cable clamp screws
Oil drain plugs
Pinion chain tensioner retaining screws
Pulley retaining screws
Stainless steel screws will cause corrosion on the gearbox housing.
Ζ
Use original Pinion screws exclusively.
10 (89) with screwlock, medium-strength
10 (89) with screwlock, medium-strength
10 (89) with SCHNORR® lock washer, dry
40 (354) dry
1.5 (13) dry
2 (18) dry
0.4 (4) dry
0.4 (4) dry
3 (27) dry
4 (35) dry
2 (18) dry
7
Page 8
SAFETY
INTENDED USE
Use other than as intended may cause accidents resulting in death
or serious injury.
Pinion gearboxes are designed and intended exclusively
•·
for installation on bicycle frames designed for the purpose with stiff rear triangle
and a corresponding gearbox interface in the area of the bottom bracket.
•·
for installation on bicycle frames designed for the purpose with suspension
rear triangle and a corresponding gearbox interface in the area of the bottom
bracket – and, if necessary, in combination with a suitable chain or belt tensioner
system that compensates for the distance between the chain ring and sprocket or
between the belt sprockets that varies with the movement of the suspension.
•·
for use with a single-gear rear freewheel rear hub without a back pedal brake*.
•·
for use with a rear cassette freewheel rear hub with spacers for setting the correct
chain line.
•·
for use with a rear hub with an electric drive motor.
•·
for use with a suitable chain or belt tensioner system.
•·
for the maximum approved rider weight –see
Pinion gearboxes must never be used in combination with a stiff single gear rear hub!
* A back pedal brake cannot be used with the freewheel integrated in the gearbox!
TECHNICAL DATA, page 6.
BASIC SAFETY INSTRUCTIONS …
Always remember that cycling can be dangerous for the rider and other people and
also for the bicycle and its components. Accidents resulting in death or serious injury
may happen even with the best protective equipment and all required safety devices.
Use your common sense and avoid dangerous actions.
… FOR INSTALLATION & MAINTENANCE
A gearbox damaged as a result of faulty or non-approved installa-
tion may cause an accident.
Ζ
Don't overestimate your technical ability. Have all installation and maintenance
work done by a specialist workshop for bicycles. That is the only way to be sure
that the work is done correctly. For a list of Pinion dealers and specialist workshops, refer to https://pinion.eu/en/dealer-overwiew/. For direct access scan the
QR code –see OVERVIEW OF DEALERS, page 32.
Ζ
Installation work that is not described in this owner's manual (e.g. opening the
gearbox, retightening the housing screws, etc.) must be done exclusively by a
specialist workshop authorized by Pinion or by the Pinion company itself.
Do not attempt work of this type yourself – you will not only endanger your own
health but you may be exposed to liability claims.
Ζ
Never modify your Pinion product in any way (e.g. grinding, drilling, painting, etc.).
Ζ
Always use a torque wrench designed for the required torque at installation steps
that require a specific tightening torque.
Ζ
Keep your bicycle in good technical condition at all times.
Unsuitable accessories and additional components may cause
accidents.
Ζ
Use original Pinion parts and lubricants exclusively.
Ζ
Use a rear wheel quick release system that reaches the required closing pressure
of at least 4000 N exclusively. It is best to use a rear hub that is permanently
fastened with axle nuts in the rear triangle, or which has a through axle.
Ζ
Use exclusively a bicycle chain with a width of 6.6 – 6.8 mm (9-speed) and an
appropriately sized sprocket, or a toothed belt system approved by Pinion.
8
Page 9
SAFETY
Rust-free (e.g. stainless) steel screws and add-ons (protection
plate, etc.) will cause corrosion on the gearbox housing.
Ζ
Use original Pinion screws exclusively.
Ζ
Do not mount any stainless steel add-ons directly on the gearbox housing under
any circumstances.
… WHEN ON THE ROAD
Component failure may cause accidents.
Ζ
Before every ride make sure that the quick release system of your wheels is
correctly installed and that your wheels cannot be accidentally released.
Ζ
Before every ride make sure that your brakes are operating correctly and the brake
pads are not excessively worn.
Ζ
Before every ride make sure your chain or belt is correctly tensioned.
Ζ
Never exceed the maximum approved rider weight –see TECHNICAL DATA, page 6.
Ζ
Avoid jumping from a great height – this exposes your Pinion gearbox to very high
load peaks.
Ζ
Never ride with your Pinion gearbox if damage (to the gearbox housing, cranks,
etc.) is visible, unusual noises can be heard, or if you have any doubts the condition of the gearbox. Have your Pinion gearbox checked by a specialist workshop for
bicycles.
For a list of Pinion dealers and specialist workshops, refer to https://pinion.eu/en/
dealer-overwiew/. For direct access scan the QR code –see OVERVIEW OF DEALERS,
page 32.
Ζ
Do not ride with your Pinion gearbox below -20 °C (-4 °F) or above 40 °C (104 °F)
ambient temperature.
Incorrect riding behaviour or improper equipment may cause
accidents.
Ζ
Always obey the traffic regulations of the country where you are riding your bicycle
(lights, reflector, etc.) and also the regulations governing off-road mountain
biking.
Ζ
Always wear a good-quality, undamaged cycling helmet (e.g. ANSI-certified) and
clothing that is close-fitting but does not hinder movement.
Ζ
Ride your bicycle only when you are in good physical condition and your bicycle
and all its components are in good condition.
9
Page 10
ON THE ROAD
RUNNING IN THE GEARBOX
The surfaces of the gears and transmission components are smoothed down over
the first 1000 km of cycling. Following that, the gearbox will run more smoothly – with slick shifting
operations.
Any roughness present in the drive or when shifting gear is normal when your Pinion gearbox is new,
and is nothing to be concerned about!
BEFORE EVERY RIDE
Component failure may cause accidents.
Ζ
Before every ride make sure that the quick release system of your wheels is correctly installed and
that your wheels cannot be accidentally released.
Ζ
Before every ride make sure that your brakes are operating correctly and the brake pads are not
excessively worn.
Ζ
Before every ride make sure your chain or belt is correctly tensioned.
Ζ
Never ride with your Pinion gearbox if damage (to the gearbox housing, cranks, etc.) is visible,
unusual noises can be heard, or if you have any doubts the condition of the gearbox. Have your
Pinion gearbox checked by a specialist workshop for bicycles.
A chain or belt that continues to rotate when the crank is stationary because
the sprocket or belt sprocket and rear hub do not move easily during freewheel may cause an
accident.
Ζ
Before every ride make sure that the sprocket or belt sprocket and rear hub freewheel smoothly.
* Cracking or creaking noises when pedalling do not come from the inside of your
Pinion gearbox, but usually originate from a loosened bolted connection – in most cases the noise is
eliminated after tightening the pedals, for example. If not, you can find help in a specialist workshop
for bicycles – they will know about other possible problem areas which can often be resolved with
little effort.
10
Page 11
ON THE ROAD
C1.12
C1.6
SHIFTING CORRECTLY
The mark
You can shift through several gears with one movement (e.g. from 06 to 02).
You can shift at a standstill or with the crank rotating backwards and this protects
the gearbox.
Downshifting (12–11–10– … –01) under load is possible to a limited extent.
The shifting operation is not executed if the pressure on the crank or pedal is too high.
1
A mechanism in the gearbox allows upshifts (01–02– … –12) under load. This is
possible during all gear shifts, except when shifting between each of the sub-units. At these points
the pressure on the pedal must be momentarily released.
ÎÎ
Always reduce the pressure on the pedal during downshifts (12–11–10– … –01).
ÎÎ
When shifting up from 04 to 05 and from 08 to 09 always reduce the pressure on the pedal.
ÎÎ
When shifting up from 03 to 04 and from 06 to 07 always reduce the pressure on the pedal.
ÎÎ
5
When shifting up from 03 to 04 always reduce the pressure on the pedal.
Occasionally it can happen that your crank "drops" by about 10° after a shifting operation, you feel a short jolt caused when a gear is not engaged directly until the pawl has engaged in
the next tooth. This phenomenon cannot be eliminated, but it does not lead to damage to the gearbox.
(1)
on the rotary shifter cover indicates the selected gear.
11
Page 12
MAINTENANCE
REGULAR MAINTENANCE WORK
The frequency of use and weather conditions determine the frequency of maintenance
work on your Pinion gearbox.
Carry out the following maintenance operations more frequently if you use your bicycle under extreme
conditions (rain, road grit, dirt, long distances etc.).
Corrosion and material damage by penetration of water.
Ζ
Never use a pressure cleaner or steam cleaner to clean your bicycle – the seals in the bicycle
components cannot withstand this pressure.
Ζ
Be careful even if you use an ordinary hose. Never direct a spray of water directly at the areas of
(
)
fig. 6
a seal.
6
Irreparable damage to the gearbox housing or leakage.
Ζ
Never tighten or loosen gearbox housing screws.
Ζ
Gearbox housing screws are exclusively allowed to be moved in a specialist workshop authorised
by Pinion, or by Pinion itself.
(
fig. 7
)
7
12
Page 13
MAINTENANCE
After every ride
ÎÎ
Clean the gearbox with water, mild detergent and a brush.
ÎÎ
Clean the chain/belt, chain ring and sprocket or belt sprockets as well as, if necessary, the pulleys of the chain tensioner.
ÎÎ
Check the chain or belt tension and correct it if necessary
–see CHAIN/TOOTHED BELT – LENGTH & TENSION, page 29.
ÎÎ
Oil the chain lightly.
ÎÎ
Check that the chain tensioner pulleys move smoothly and inspect for wear (excessive play, loud running noises) – replace pulleys if necessary
–see EXCHANGING PULLEYS (PINION CHAIN TENSIONER), page 26.
ÎÎ
Check for wear on shifting cables, shifting cable outer sleeves, chain/belt, chain
ring and sprocket or belt sprockets, renew if necessary.
ÎÎ
Check shifting cables for tension and freedom of movement, adjust or renew if
necessary –see ADJUSTING SHIFTING, page 14.
ÎÎ
Remove cable box. Thoroughly clean cable pulley, sliding surface and cable box seat
on gearbox housing, planetary gears, etc., apply corrosion protection and grease
them liberally –see
ÎÎ
Check that all screw fasteners – except gearbox housing screws – have the required
tightening torque and adjust if necessary
(
fig. 7
–see
ÎÎ
Perform an oil change
–see OIL CHANGE, page 15.
1
In particular in wet conditions or if exposed to road grit. | 2 Alternatively 1× each year. | 3 Or after each ride in wet conditions and if exposed to road grit.
(
)
fig. 14
, page 18.
)
, page 12, –see TIGHTENING TORQUES, page 7.
1
every 250 km every 500 km every 10 000 km
3
3
2
13
Page 14
MAINTENANCE
2
3
ADJUSTING SHIFTING
1
diately (cable tension), all gears can be selected with minimum force (cable tension) and the display
on the rotary shifter matches the selected gear (synchronization).
ADJUSTING CABLE TENSION
are within the stops on the gearbox and rotary shifter housing without play and are not under tension
and it has approx. 2 mm rotary play.
ÎÎ
Unscrew both adjusting screws ¼ revolution counterclockwise (+).
••
Cable tension is increased.
••
Force required is increased.
or:
ÎÎ
Screw in both adjusting screws ¼ revolution clockwise (-).
8
••
Cable tension is reduced.
••
Play on the rotary shifter is increased, the shifting operation is less immediate.
SYNCHRONISING ROTARY SHIFTER POSITION
ÎÎ
Shift rotary shifter clockwise (01–02–03– … ) to the stop towards the last position (12 or 09 or 06).
ÎÎ
Check that the symbol for the last position (12 or 09 or 06) is centrally placed beside the mark
ÎÎ
Screw in adjusting screw
Unscrew adjusting screw
••
The rotary shifter scale moves towards position 11 or 08 or 05.
or:
ÎÎ
Unscrew adjusting screw
Screw in adjusting screw
••
The rotary shifter scale moves towards position 01.
ÎÎ
Check setting and repeat procedure if necessary
Your Pinion gearbox is correctly adjusted if the shifting operation is performed imme-
The cable tension is in the correct range if the ends of the shifting cable outer sleeves
(1)
(2)
¼ revolution clockwise (-).
(3)
¼ revolution counterclockwise (+).
(2)
¼ revolution counterclockwise (+).
(3)
¼ revolution clockwise (-).
.
14
Page 15
CLICK !
3 N·m (27 lbf·in) max.
3 mm
1
MAINTENANCE
OIL CHANGE
Dispose of used lubricants and oils correctly and in accordance
with the applicable regulations – never dispose of waste in the sewage system or in the ground.
Every 10 000 km (6 200 miles) or 1× each year, the oil in your Pinion gearbox must be
changed.
Use original Pinion gearbox oil exclusively. Oil fill volume: 60 ml (2.0 oz).
In the 1st oil change of your Pinion gearbox, the volume of drained oil will be less than
60 ml (2.0 oz) – nevertheless, comply with the fill volume that we specify!
The Pinion oil service-set (P8903) enables you to extract used gearbox oil from the
gearbox quickly and cleanly.
ÎÎ
Remove the cable box cover – do so by prying it off carefully in the area of the lugs using a flatblade screwdriver.
9
ÎÎ
Place the bicycle or secure it in the repair stand so the drain opening is at the lowest point of your
Pinion gearbox.
ÎÎ
Place a drainage tray underneath.
ÎÎ
Unscrew the screw plug
ÎÎ
Unscrew the screw plug
ÎÎ
Drain used oil completely from the drain opening into the drainage tray.
ÎÎ
Screw the screw plug
(27 lbf·in).
ÎÎ
Add fresh oil – oil fill volume: 60 ml (2.0 oz).
ÎÎ
Screw the screw plug
(27 lbf·in).
ÎÎ
Put on cable box cover.
ÎÎ
Enter oil change date –see OIL CHANGE DATA, page 35.
2
••
The oil change is complete.
10
(1)
in the filler opening.
(2)
from the drain opening.
(2)
into the drain opening and tighten with a tightening torque of 3 N·m
(1)
into the filler opening and tighten with a tightening torque of 3 N·m
15
Page 16
INSTALLATION WORK
2 N·m (18 lbf·in) max.
2,5 mm
INSTALLING ROTARY SHIFTER
www.pinion.eu
Incorrect installation can restrict braking and steering and cause accidents.
Ζ
Make sure that the position of the rotary shifter housing does not interfere with the full range of
operation of the brake lever blade.
Ζ
Make sure that the shifting cables do not interfere with the handlebar movement.
3
Ζ
Always follow the manufacturer's directions for carbon handlebars.
2
screws
4
1
In this position you can best see the current gear and the shifting cables do not interfere with the
brake lever blade.
the danger of irreparable damage – including the handlebar. Tighten the clamp screws of the brake
Incorrectly mounted handlebar can fail and cause an accident.
The Pinion rotary shifter housing is generally correctly positioned with the adjusting
(1)
for the shifting cable pointing down and slightly forward – i.e. in the 4–5 o'clock direction.
In the event of a fall it is advantageous if the brake lever blade can twist. This reduces
lever blade just tight enough so it cannot be twisted by hand.
11
You will only need the spacer ring
(2)
if you are using a handlebar grip which has a
tendency for touching the rotary shifter.
ÎÎ
Use carbon assembly paste on the clamp area for carbon handlebars.
ÎÎ
Slide the rotary shifter housing onto the handlebar.
ÎÎ
Slide handlebar grip
ÎÎ
Push rotary shifter housing onto the handle of the handlebar to the stop and rotate to the correct
(3)
and if applicable bar end onto the handlebar.
position.
ÎÎ
Tighten clamping screw
ÎÎ
Make sure that the rotary shifter can be twisted freely – install a spacer ring
••
The installation of the rotary shifter is complete.
(4)
with a tightening torque of 2 N·m (18 lbf·in).
(2)
if necessary.
16
Page 17
INSTALLATION WORK
0,4 N·m (4 lbf·in) max.
3,5 mm
0,4 N·m (4 lbf·in) max.
1,5 mm
INSTALLING OR REPLACING SHIFTING CABLES
www.pinion.eu
You operate your Pinion gearbox with 2 shifting cables.
The clamps for the shifting cable ends are in the rotary shifter.
3
5
It is essential that you use commercially available shifting cables with dimension Ø1.1–1.25 mm,
nipple 4.4 × 4.4 mm. Genuine Pinion shifting cables guarantee optimum shifting behaviour and can
be ordered from one of the Pinion bicycle dealers.
As a tool for dealing with breakdowns when you are out riding, you will find a bit
(size 1.5 mm/4 mm) inserted inside your rotary shifter
(1)
– this fits the clamping screws of the cable
clamps. You can use the rotary shifter cover as a tool holder if necessary.
During installation of the shifting cables, you will need to move the sun gear of your
Pinion gearbox, so it is a good idea if the right crank and chain ring are fitted. This makes it much
1
2
easier for you to brace the selector shaft.
ÎÎ
Unscrew housing screw
ÎÎ
Unhook rotary shifter cover at top and remove.
12
(2)
of the rotary shifter cover
(3)
.
The clamp screws are easily accessible at rotary shifter positions 01 and 12 or
01and09 or 01and06 depending on the type of your Pinion gearbox.
ÎÎ
Slacken clamp screws
ÎÎ
Pull shifting cables out of the rotary shifter.
ÎÎ
Cut off the spliced-on shifting cable ends with a sharp wire cutter.
ÎÎ
4
First, screw in adjusting screws
••
This ensures an adequate adjustment range for subsequent adjustments of the transmission.
(4)
– 2× per shifting cable end.
(5)
completely – then unscrew 3 revolutions.
13
17
Page 18
INSTALLATION WORK
1,5 N·m (13 lbf·in) max.
2,5 mm
ÎÎ
Remove the cable box cover
8
flat-blade screwdriver.
ÎÎ
Unscrew and remove the retaining screws
(6)
– do so by prying it off carefully in the area of the lugs using a
(7)
of the cable box – mark the holes used (position of
the cable box ring) with a waterproof pen or similar.
ÎÎ
Remove cable box ring with cable pulley.
ÎÎ
7
6
Thoroughly clean the cable box seat on the gearbox housing and apply corrosion protection
(e.g.protective wax).
ÎÎ
Thoroughly clean planetary gears and sun gear and grease them liberally.
ÎÎ
Lightly grease sliding surface
(8)
of the cable pulley.
14
ÎÎ
Remove the cable pulley
ÎÎ
Remove shifting cables from the cable pulley.
ÎÎ
Thoroughly clean the cable pulley.
(9)
with the shifting cables from the cable box ring.
9
15
18
Page 19
INSTALLATION WORK
CLICK – CLICK – … STOPP!
ÎÎ
Hold crank and chain ring in position.
ÎÎ
Rotate sun gear
••
1st gear is engaged.
10
16
ÎÎ
Insert new shifting cables through the holes in the cable pulley.
(10)
clockwise to the stop with a 3 mm Allen wrench.
17
19
Page 20
INSTALLATION WORK
Correctly wound up shifting cables will not cross over one another at any point!
ÎÎ
Wind left shifting cable (output 1.) onto cable pulley – 1 ¼ turns.
ÎÎ
Wind right shifting cable (output 2.) onto cable pulley – ¼ turn.
ÎÎ
Hold the shifting cables with the cable pulley with 1 hand so the shifting cables cannot unwind.
18
ÎÎ
Guide the shifting cables through outputs 1. or 2. of the cable box ring.
ÎÎ
Keep the shifting cables taut.
ÎÎ
Insert cable pulley into cable box ring.
19
20
Page 21
INSTALLATION WORK
≈ 15 cm
1,5 N·m (13 lbf·in) max.
2,5 mm
ÎÎ
Make sure that marks
••
Cable pulley is located in the position for 1st gear.
••
Right shifting cable (output 2.) projects about 15 cm further out of the cable box ring.
ÎÎ
Make sure that both shifting cables are positioned correctly in the cable pulley guides
11
20
ÎÎ
Put on cable box ring with cable pulley in the marked position.
ÎÎ
Tighten retaining screws
(11)
on cable pulley and cable box ring line up.
(7)
with a tightening torque of 1.5 N·m (13 lbf·in).
(
fig. 18
)
.
The shifting cables have a tendency to come unspliced on outer sleeve end caps
made from metal.
Ζ
Use outer sleeve end caps made from plastic (Ø 5.8 mm).
ÎÎ
Insert the left shifting cable (output 1.) through the shifting cable outer sleeve.
ÎÎ
Insert the right shifting cable (output 2.) through the shifting cable outer sleeve.
(
)
ÎÎ
Make sure that both shifting cables are positioned correctly in the cable pulley guides
fig. 18
.
7
21
21
Page 22
INSTALLATION WORK
0,4 N·m (4 lbf·in) max.
1,5 mm
C1.12
0,4 N·m (4 lbf·in) max.
1,5 mm
C1.6
14
13
12
16
17
Damage to the shifting cable liner.
Ζ
Carefully guide shifting cables through the shifting cable liners.
Ζ
Remove shifting cable liners first if necessary and guide back in together with the shifting cable.
ÎÎ
Switch rotary shifter to position 01.
ÎÎ
Insert the left end of the shifting cable (output 1.) through rear adjusting screw
riding direction – shifting cable liner
ÎÎ
Keep the left end of the shifting cable under tension.
ÎÎ
Make sure that the ends of the shifting cable outer sleeve are firmly in the stops on the adjusting
15
screw and cable box.
ÎÎ
Tighten the two clamp screws alternately with a tightening torque of 0.4 N·m (4 lbf·in).
ÎÎ
Cut the left end of the shifting cable as close as possible behind the cable clamp with a small,
(13)
, shifting cable guide
(14)
and shifting cable clamp
(12)
– as seen in
(15)
.
sharp wire cutter.
Pull the cable clamp out of its seat somewhat. Then, it will be easier to cut off the end
of the shifting cable.
Following that, make sure that the cable clamp is once again located in its seat up to the stop.
22
ÎÎ
Rotate rotary shifter clockwise (01–02–03– … –12) to position 12.
or:
ÎÎ
Rotate rotary shifter clockwise (01–02–03– … –09) to position 09.
or:
ÎÎ
Rotate rotary shifter clockwise (01–02–03– … –06) to position 06.
ÎÎ
Insert the right end of the shifting cable (output 2.) through front adjusting screw
seen in riding direction – shifting cable liner
(19)
clamp
19
ÎÎ
Keep the right end of the shifting cable under tension.
ÎÎ
Make sure that the ends of the shifting cable outer sleeve are firmly in the stops on the adjusting
.
(17)
, shifting cable guide
(18)
(16)
– as
and shifting cable
screw and cable box.
ÎÎ
18
Tighten the two clamp screws alternately with a tightening torque of 0.4 N·m (4 lbf·in).
ÎÎ
Cut the right end of the shifting cable as close as possible behind the cable clamp with a small,
sharp wire cutter.
22
23
Page 23
INSTALLATION WORK
0,4 N·m (4 lbf·in) max.
3,5 mm
CLICK !
(1)
ÎÎ
Pull bit
shifter.
ÎÎ
Hook rotary shifter cover
ÎÎ
Tighten housing screw
3
ÎÎ
Test shifting function, if necessary adjust cable tension with the adjusting screws –see ADJUSTING
SHIFTING
1
out of the rotary shifter cover if necessary and insert it into its seat inside the rotary
(3)
in at top and put on.
(2)
with a tightening torque of 0.4 N·m (4 lbf·in).
, page 14.
2
24
ÎÎ
Put on cable box cover
••
The replacement of the shifting cables is complete.
(6)
.
6
25
23
Page 24
INSTALLATION WORK
4 N·m (35 lbf·in) max.
4 mm
INSTALLING PINION CHAIN TENSIONER
www.pinion.eu
If a chain tensioner fails because of improper use, it can cause an accident.
The Pinion chain tensioner is designed and intended exclusively for use with a Pinion gearbox.
Ζ
Only ever install the Pinion chain tensioner on the chain tensioner socket provided for this
purpose on your Pinion gearbox.
Stainless steel screws will cause corrosion on the gearbox housing.
Ζ
Use original Pinion screws exclusively.
The Pinion chain tensioner can be installed in position A, B or C – depending on the
mounting position of your Pinion gearbox.
1
Make sure that your Pinion chain tensioner can transfer the tension effect in full to your bicycle chain
in the position that you select, but also cannot contact the chain stay or tyre of your bicycle at any
position.
ÎÎ
Remove chain.
26
ÎÎ
Remove crank and chain ring –see REPLACING CHAIN RING, page 26.
ÎÎ
Tighten retaining screws
ÎÎ
Install crank and chain ring –see REPLACING CHAIN RING, page 26.
ÎÎ
Position chain and guide it through the tension mechanism.
ÎÎ
Connect chain.
(1)
with a tightening torque of 4 N·m (35 lbf·in).
(
fig. 27
)
Your chain has the correct length if the tension mechanism of the chain tensioner is
pretensioned
(2)
, but can still be moved upwards
(3)
.
In full-suspension bicycles, always check the chain length or the mobility of the
chain tensioner mechanism with the rear triangle suspension fully compressed!
••
The installation of the Pinion chain tensioner is complete.
3
2
24
27
Page 25
INSTALLATION WORK
4 N·m (35 lbf·in) max.
4 N·m (35 lbf·in) max.
ADJUSTING CHAIN TENSION (PINION CHAIN TENSIONER)
If your chain frequently hits the chain stay on your bicycle frame while you are riding,
it may be necessary to increase the chain tension.
If the chain or cranks continue to rotate although the rear wheel freewheel is operating correctly, or if
3
1
2
4
6
5
1
2
the chain tensioner rattles, it may be necessary to reduce the chain tension.
Before proceeding with the following actions, make sure that your chain is the correct
length –see INSTALLING PINION CHAIN TENSIONER, page 24.
ÎÎ
Remove the chain and take it off the chain ring and sprocket.
ÎÎ
Disconnect the spring leg
ÎÎ
Rotate the tension mechanism forward.
ÎÎ
The screw
(3)
of the spring shaft is accessible.
(1)
at the tension mechanism
28
ÎÎ
Unscrew the screw
ÎÎ
Pull the spring shaft out of the baseplate
ÎÎ
Move the spring end pin
••
The chain tension is increased.
(3)
of the spring shaft
(5)
counterclockwise (+).
or:
ÎÎ
Move the spring end pin
••
The chain tension is reduced.
ÎÎ
Insert the spring shaft into the baseplate
ÎÎ
Screw in the screw
(5)
clockwise (–).
(3)
of the spring shaft
(35 lbf·in).
ÎÎ
3
Position the chain on the chain ring and sprocket.
ÎÎ
Attach spring leg
ÎÎ
Check the setting.
(1)
to tension mechanism
(4)
.
(6)
.
(6)
.
(4)
and tighten with a tightening torque of 4 N·m
(2)
.
29
(2)
.
25
Page 26
INSTALLATION WORK
10 N·m (89 lbf·in) max.
10 mm
6 N·m (53 lbf·in) max.
4 mm
2 N·m (18 lbf·in) max.
2
EXCHANGING PULLEYS (PINION CHAIN TENSIONER)
Chain does not run smoothly, inaccurate chain line, accelerated wear.
Ζ
Use genuine Pinion pulleys (P8592).
30
REPLACING CHAIN RING
If you need to replace the chain ring of your Pinion gearbox (because of wear, different
1
2
gear ratio, replacement by chain ring spider), you can order it with the required tools from one of the
Pinion bicycle dealers.
Another method of changing the gear ratio is to replace the sprocket on your rear
wheel.
Chain ring, sprocket and chain always wear on opposite sides during use.
This means that the drive might stop working without problems (chain disengages, more noise) if only
one of these parts is replaced. We recommend always replacing all these parts if one needs replacing.
ÎÎ
Unscrew central crank screw
ÎÎ
Slacken both crank clamp screws
ÎÎ
Pull the crank from the input shaft.
www.pinion.eu
(1)
.
(2)
.
26
31
Page 27
INSTALLATION WORK
30 N·m (266 lbf·in) max.
½"
40 N·m (354 lbf·in) max.
½"
Incorrect removal may damage the chain ring by distorting it.
Ζ
Preferably hold the chain ring by the chain on the rear wheel.
Ζ
3
4
5
6
8
3
If necessary, use chain whip carefully, do not tilt it.
ÎÎ
Hold chain ring tight.
ÎÎ
Unscrew lock ring
ÎÎ
Pull chain ring off the output shaft.
(3)
clockwise (left-hand thread!) with the Pinion lock ring tool
The output shaft can show axial play when the chain ring or spider is disassembled –
this is normal and no cause for concern!
32
ÎÎ
Make sure that the toothing
7
4
(7)
spider
ÎÎ
Lightly grease the toothing
ÎÎ
Put on the chain ring or spider (with chain ring fitted).
ÎÎ
Lightly grease the contact areas of the disc
ÎÎ
Insert the disc
ÎÎ
Lightly grease the contact area and thread of the lock ring
ÎÎ
Screw in lock ring anticlockwise (left-hand thread!) with the Pinion lock ring tool
ÎÎ
Hold chain ring at the left crank.
ÎÎ
Tighten lock ring
ÎÎ
Replace chain if necessary –see CHAIN/TOOTHED BELT – LENGTH & TENSION, page 29.
••
The replacement of the chain ring is complete.
(8)
, disc
and lock ring
(8)
in the chain ring or spider.
(3)
(5)
and contact surfaces on the gearbox side and the chain ring
(3)
are clean and free from old grease.
(5)
.
(8)
.
(3)
with a tightening torque of 40 N·m (354 lbf·in).
(4)
.
(6)
or
.
(4)
.
33
27
Page 28
INSTALLATION WORK
10 N·m (89 lbf·in) max.
10 mm
10 N·m (89 lbf·in) max.
4 mm
INSTALLING CRANKS
www.pinion.eu
To protect the toothing
(3)
on the input shaft and cranks from one-sided loads, it is a
good idea to remove both cranks regularly (1× a year) and to reinstall them offset by 1–2 teeth and
3
3
2
with fresh carbon assembly paste (e.g. DYNAMIC).
ÎÎ
Make sure that the toothing
ÎÎ
Make sure that both crank clamp screws
ÎÎ
Apply a light coating of carbon assembly paste to the toothing.
ÎÎ
Position crank and push it manually on the input shaft to the stop, if necessary carefully spread
(3)
on the input shaft and crank are clean and free from old grease.
(2)
are provided with a SCHNORR® lock washer.
it with a wide screwdriver – do not use any impact tools (hammer etc.).
ÎÎ
Screw in central crank screw
1
2
and no reason for concern!
Ζ
Always pull the crank outward as far as the stop before tightening the crank clamp screws.
34
ÎÎ
Pull the crank outward as far as the stop.
ÎÎ
Tighten the crank clamp screws
The crank can now be moved by another 1–2 mm on the input shaft – this is normal
Incorrectly mounted drive can block and cause an accident.
(1)
and tighten with a tightening torque of 10 N·m (89 lbf·in).
(2)
in stages and alternately until both crank clamp screws have
reached a tightening torque of 10 N·m (89 lbf·in).
28
Page 29
INSTALLATION WORK
~
10–15 mm
CHAIN/TOOTHED BELT – LENGTH & TENSION
The correct length of a bicycle chain or toothed belt depends on various factors:
•·
The number of teeth on the sprocket and chain ring or belt sprockets – after replacement it may
be necessary to determine the correct length of the bicycle chain or toothed belt again.
•·
Suspension travel and type of spring rear hub of your bicycle frame – follow the manufacturer's
instructions.
•·
Type of chain tensioner or tensioning system (horizontal dropouts with adjusting screws) – follow
the manufacturer's instructions.
The basic rule for the length of a bicycle chain or toothed belt is as short as possible and as long as
necessary. The function and adjustment range of your tensioning system and the complete suspension
of the rear triangle must not be impaired under any circumstances.
Accelerated wear of the complete drive because of excessively high tension.
Ζ
For direct tension (horizontal dropouts with adjusting screws) make sure that the chain or toothed
belt has approx. 10–15 mm play
35
Ζ
Make sure that the gaps between your rear hub and the chain line or beltline of your Pinion
gearbox match –see
Accelerated wear of the complete drive because of skewed running.
TECHNICAL DATA, page 6.
(
)
fig. 35
. Follow the manufacturer's precise information.
29
Page 30
INSTALLATION WORK
INSTALLING GEARBOX
www.pinion.eu
Irreparable damage to the gearbox housing or leakage.
(
)
Ζ
Never tighten or loosen gearbox housing screws.
Ζ
Gearbox housing screws are exclusively allowed to be moved in a specialist workshop authorised
fig. 36
by Pinion, or by Pinion itself.
36
Incorrect installation may distort and damage the gearbox.
Ζ
Make sure that all 4 key sleeves
housing – if necessary, press in with a parallel pressing tool (e.g. screw clamp, suitable clamp,
(
)
fig. 37
etc.)
Ζ
Follow the sequence and tightening torque.
.
1
(1) (
fig. 37/38
)
are installed flat in their seats in the gearbox
(
)
fig. 38
37
30
Page 31
INSTALLATION WORK
1.
2.
3.
4.
6.
10 N·m (89 lbf·in) max.
T30
5.
3.
6.
5.
4.
T30
2.
1.
Stainless steel screws will cause corrosion on the gearbox housing.
Ζ
Use original Pinion screws exclusively.
The gearbox retaining screws are allowed to be reused – providing they have been
cleaned and have fresh screwlock (medium-strength) applied to them.
ÎÎ
1
Make sure that all contact points between the gearbox and gearbox interface of the bicycle frame
are clean and coated with carbon assembly paste (e.g. DYNAMIC).
ÎÎ
Position gearbox in the gearbox interface of the bicycle frame.
ÎÎ
Install all 6 retaining screws.
ÎÎ
Tighten retaining screws in the specified sequence with a tightening torque of 10 N·m (89 lbf·in).
(
)
fig. 38
••
The installation of the gearbox is complete.
38
REMOVING GEARBOX
ÎÎ
Remove the cable box –see
Ζ
Get a helper to secure the gearbox during removal.
ÎÎ
Initially only loosen the 2 middle retaining screws.
ÎÎ
Unscrew the 4 upper and lower retaining screws.
ÎÎ
Get a helper to secure the gearbox.
ÎÎ
Unscrew the 2 middle retaining screws.
ÎÎ
If necessary, tap the right and left sides of the input shaft alternately with a rubber mallet and
remove the gearbox downwards from the gearbox interface of the bicycle frame.
cleaned and have fresh screwlock (medium-strength) applied to them.
www.pinion.eu
(
)
fig. 14
, page 18 – do not remove shifting cables.
Danger of injury if the gearbox drops down – approx. 2.1 kg (5 lb) weight.
The gearbox retaining screws are allowed to be reused – providing they have been
39
31
Page 32
SERVICE
SERVICE VIDEOS
You can view the following helpful Pinion videos at https://pinion.eu/service-videos/ or
by scanning the QR code:
•·
Installing gearbox.
www.pinion.eu
•·
Removing gearbox.
www.pinion.eu
•·
Installing rotary shifter.
www.pinion.eu
•·
Removing rotary shifter.
www.pinion.eu
•·
Replacing grip/rotary shifter scale.
www.pinion.eu
•·
Installing shifting cables, C-line.
www.pinion.eu
•·
Installing cranks, chain ring/spider.
www.pinion.eu
•·
Removing cranks, chain ring/spider.
www.pinion.eu
OVERVIEW OF DEALERS
You can view all Pinion dealers at https://pinion.eu/en/dealer-overwiew/ or by scanning
the QR code:
TECHNICAL SUPPORT
If you have any questions about the technology, function, maintenance or a malfunction
of your Pinion gearbox, you will find many answers and solutions at https://pinion.eu/
en/service/ in our extensive and constantly updated FAQs and troubleshooting lists.
•·
Installing Pinion chain tensioner.
www.pinion.eu
•·
Removing Pinion chain tensioner.
www.pinion.eu
32
Page 33
LEGAL INFORMATION
LIABILITY
The legal liability requirements apply for damage to material and workmanship. The
liability period starts on the date of initial purchase.
This does not include components that are subject to normal wear (e.g. shifting cable
with outer sleeve).
Damage caused by improper use, unintended use or improper installation or maintenance (e.g. opening the gearbox, modifications, etc.) is not included.
We also do not accept liability for immediate or consequential damages arising from
negligence.
In case of damage, first contact the dealer from which you purchased your Pinion
product.
The dealer will contact the bicycle manufacturer, distributor or us directly to discuss
the procedure on your behalf.
Do not return a defective Pinion product directly to us without prior consultation.
WARRANTY
You can find out all information about the Pinion warranty provisions at https://pinion.eu/
en/service/ or by scanning the QR code:
33
Page 34
Page 35
OIL CHANGE DATA
The adjacent table is used for documenting oil changes on your Pinion
gearbox.
It is not essential to have oil changes performed by a specialist workshop, but they must be done proficiently so as to avoid the possibility of
claims on the grounds of liability for material defects.
ÖLWECHSELDATENOIL CHANGE DATA
Gearbox serial no.: Purchase date:
Oil change Date / dealer stamp Oil change Date / dealer stamp
1 7
2 8
3 9
4 10
5 11
6 12
35
Page 36
M AD E I N G ERM AN Y
Pinion GmbH I Heerweg 15 A I 73770 Denkendorf I info@pinion.eu
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