STEP BY STEP INSTRUCTIONS TO CHANGE VARIOTEC FLIPCHIP POSTIONS ON UNPLUGGED MODELS

TOOLS

Bike Stand

Grease. 8mm torque Allen Key. Threadlock. Rag

remove the rear wheel

1.DISENGAGE REAR DERAILLEUR CLUTCH
Follow manufacturers instructions

 

2.REMOVE REAR AXEL
All UNPLUGGED models have a threaded DT Swiss Axel.  When removing, support the wheel to ensure it does not fall

 

3.REMOVE WHEEL
Take care of chain placement and brake disc when removing

remove frame bolts

4.REMOVE FRAME BOLTS
This requires an 8mm Allen Key

 

5.SEPARATE FRAME TUBES
Move the seatstays upwards from the chainstays.

 

6.REMOVE FLIPCHIP BUSHINGS
Unscrew by hand. you may need to cover them with a rag if they are slippy with grease

 

 

changing flipchip settings

7.REMOVE FLIPCHIPS
Pull each flipchip out of the housing by hand.

 

8. RECONFIGURE FLIPCHIP SETTING
Flip 180 degrees, or replace the FlipChip to achieve your desired number setting. Refer to the images below for the setting index

 

9.INSERT FLIPCHIPS
Apply fresh grease to each FlipChip, and push into the frame by hand

flipchip settings

FLIPCHIP SETTING 1
This has the longest chainstay and highest BB offset. Refer to geometry table for measurments according to bike model, wheel size, fork length and headset variances.
FLIPCHIP SETTING 2
This setting is 2.5mm shorter in chainstay and 5mm lower BB offest than setting 1
FLIPCHIP SETTING 3
This setting is 7.5mm shorter in chainstay and 10mm lower BB offest than setting 1
FLIPCHIP SETTING 4
This setting is the shortest and lowest – 11mm shorter in chainstay and 20mm lower BB offest than setting 1

REASSEMBLE FRAME

10.INSERT FLIPCHIP BUSHINGS
Apply fresh grease to outer bushing and inner thread. Hand tighten. Use a rag to ensure that bushings are screwed completely hand tight. IMPORTANT – BUSHINGS MUST BE FULLY HAND TIGHT. IF THEY ARE TOO LOOSE, THIS WILL CAUSE PLAY IN THE REAR TRIANGLE

 

11.RE ALIGN FRAME
Slide seat stay into the chain stay slots

 

12.INSERT FRAME BOLTS
Apply fresh grease to the smooth surfaces and fresh threadlock the threaded surface. Tighten to 15Nm

INSERT REAR WHEEL

13. INSERT WHEEL
Ensure chain in and brake disc are properly aligned

 

14.INSERT AXEL
Apply fresh grease. Ensure that is it fully tight

 

15.CHECK DRIVETRAIN AND BRAKE
Check the bike is running properly and no play is in the rear triangle

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