4: Main Pivot
5: Shock Removal and Installaton
1 x 4mm Allen Key
1 x 5mm Allen Key
1 x 6mm Allen Key
22mm spanner (or adjustable spanner)
17mm socket and rachet
Torque Wrench (with 14 Nm in range)
Orange Switch 7 Bearing Tool Kit
Orange Switch 7 Bearing Kit
You will also need:
Rag or paper towel
Bearing lock (EG: Loctite 641)
Threadlock (EG: Loctite 243)
Anti-Seize Grease
Notes:
Bearings should be installed using Orange Bearing Installation Tools (22mm and 26mm)
Bearing should not be re fitted once removed
Bearings should only be installed using correct tools which push on bearing outer race
All bearings should have a tight push fit. If any bearings are loose these should be fitted using bearing lock. Loctite 641 Bearing Fit
Grease should only be used when fit is tight.
Any excess grease should be removed as this can contaminate the thread lock on the bearing retention bolts.
Swingarm bearing: 6000 2RSL
Dog bone, Linkage, Trunnion bearing: 6900 2RSL
Bearings can be purchased on Orange website link at the bottom of document
1.1 To remove the trunnion bearings first remove the shock see: 5: Shock Removal & Installation
1.2 Fit the M8 inner bearing removal nut on the inside of the shock mount, fit the hollow removal tube on the outside. Install the M8 bolt with washer.
1.3 Hold the inner nut with 17mm open ended spanner, tighten the M8 bolt so it pulls the bearing out into the removal tube.
22mm bearing removal set-up:
22mm bearing removal cross section:
1.4 Discard and replace the bearing once it has been removed as removal will damage the bearing.
1.5 The same process is used for all 6900 (22mm) bearings.
1.6 To install new bearings apply a small amount of bearing grease to the bearings, remove excess once fitted to avoid contamination.
1.7 Put the larger m8 nut that centres on the back face of the bearing mount, the 22mm bearing push tool on the outside.
1.8 hold the large M8 nut with adjustable spanner and tighten the M8 bolt until the bearing is seated.
22mm bearing install set up:
22mm bearing install set up cross section:
1.9 The process is the same for 22mm and 26mm bearings the only difference is the tools.
26mm bearing removal set up:
26mm bearing removal cross section:
26mm bearing installation set up:
26mm bearing removal cross section:
Aluminium bolts should be torqued using a torque wrench to 14NM.
Bolts should not be re used - fit fresh bolts on a fresh frame assembly.
Bolt must not be contaminated with grease.
Bolts have pre applied Loctite on, no additional Loctite is required.
Bolts should always be replaced when bearings are replaced.
2 x 17mm bolts for trunnion shock mount
6 x 19mm bolts for linkage
Spacers should be used between all bearings and hardware
Excessive grease should be removed from any spacers as this can contaminate the Loctite on the threads.
All bolts should be marked with a pen to indicate they have been torqued up correctly.
3.1 The lower shock bolt can be re used. It should have Loctite 243 reapplied (New bolts come with pre-applied Loctite).
3.2 Lower shock bolt torque 14Nm.
3.3 Bearing Grease should only be used under the head of the bolt and between the lower shock spacer and the linkage not on the thread. Excess grease should be removed to avoid contamination.
5.1 Support the bike in a bike stand that lifts the weight off the rear wheel.
5.2 Remove the rear wheel.
5.3 Remove both trunnion bolts (Item 9 Figure 1) note the inner spacers (item 10) sit between the shock and the bearings; these should be removed and cleaned. The bearings are a push fit and should be left in the frame unless they are to be replaced. Check bearings for play, or roughness and replace if necessary. See 1: Linkage Bearings:
Figure 1:
5.4 Inspect the trunnion bolts. If the pre applied Loctite is no longer present these should be discarded and new bolts should be fitted. See: 2: Aluminium bolts for details. Bolts should be replaced when new bearings are fitted. Bolts should not be re used more than three times.
5.5 Support the rear shock to avoid it contacting the frame lift the rear swingarm slightly (about 40mm) to expose the lower shock bolt (item 7 Figure 2), remove the lower shock bolt and remove the shock from the frame.
Figure 2:
5.6 Installation is the reverse of removal.
5.7 The lower shock bolt can be re used. It should have Loctite reapplied (the new bolts come with pre applied Loctite).
5.8 Lower shock bolt torque: 14Nm.
5.9 Trunnion bolts: 14Nm - do not put grease on thread of Loctite bolts as it will stop the Loctite from functioning correctly.
6.1 First remove the rear shock see: 5:Shock Removal & Installation
6.2 Gently lift the rear swingarm to the maximum point of travel, then simultaneously lift the linkage at the front edge. The linkage should cam over centre slightly, allowing the swingarm to lower will reveal the inner dog bone bolts. Note: the rear wheel and shock must be removed to perform this operation. It should look like the below once completed:
Figure 3:
6.3 loosen by half a turn both of the swing arm bolts, figure 1 item 4 and the dog bone bolts figure 4 item 6.
Figure 1:
6.4 When all the bolts are slackened off, remove the dog bone bolts and swing arm bolts taking note of the spacer locations between the bearing and linkages. It may be necessary to resist the swingarm from moving to undo the bolts on the drive side.
6.5 Lift the swingarm to its fullest extent to expose the linkage pivot bolts figure 1 item 5.
6.6 remove the linkage pivot bolts.
6.7 Installation is the reverse of removal.
6.8 aluminium linkage bolts should be replaced if Loctite is no longer present.
Pivot bolts and dog bone bolts torque: 14NM - do not put grease on thread of Loctite bolts as it will stop the Loctite from functioning correctly.
Additional information on general bike maintenance for example main pivot removal instructions can be found here on the Orange Bikes website:
www.orangebikes.com/support/faqs/
Bike service equipment can be purchased for here:
www.orangebikes.com/shop/components/tools
Bike service parts can be purchased for here:
US Website
UK Website
