Intense M16 Carbon bicycle User manual

user manual m16 Carbon

Welcome to the family

AT IN T E N S E , W E H AV E ONE G O A L - TO P R OV ID E T H E R ID E O F YOUR L IF E .

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.

T H E M 1 6 C A R B ON

This is a serious bike… Full DH in Full carbon. Our standard version comes with robust stainless hardware and a bombproof carbon layup creating a strong, race ready sled.

Kick it up a notch to our SL version to get titanium bits, a carbon top link and an extra lite carbon layup. Both use the same DH race geometry, an asymmetrical swing arm for easy shock removal and Intense suspension that will get you to the top of the podium… Fast.

Welcome to Intense, enjoy your experience.

2 / / m 1 6 C u s e r M a n u a l

introduction frame features / component spec

Geometry 5

exploded view and b.o.m. 6

2

4

Assembly 8

torque chart 14

setup 15

maintenance 18

registration

W W W.IN T E N S E CYC L E S .C O M / WA RR A N T Y-C A R D/

contact customer service

[email protected]

951-296-9596

I N T E N S E C Y C L E S / / 3

frame features / spec

Frame features //

• Adjustable travel – 8.5” or 9.5” (215mm or 241mm)

• 27.5" wheel size

• Progressive Shock Curve

• Tapered Head Tube

• ISCG 05 Mounts

• Modern DH Race Geometry

• Integrated 157mm X 12mm dropouts

• Internal Cable Routing System

• Angular Contact Bearing / Collet 15MM Axle System with replaceable Grease Zerks

• FLack GuaRD Chain stay & Down tube Protection

• Integrated fork bumper/cable guide system

• Non-symmetric rear triangle

Component spec

• Fork – accepts 1.125" straight steer or 1.125"/1.5" tapered steer, 200mm Travel,

594mm lower leg length, 42mm offset

• Shock – 9.5” x 3”(241mm x 76mm), 22mm x 8mm and 34mm x 8mm reducers

• Chain Guide Mount - ISCG-05

• Seat post – 31.6mm

• Headset – zero stack 49mm upper / 56mm lower cups

• BOTTOM BRACKET - THREADED 83MM

• Rear Axle – 157mm x 12mm TA

• Brake Mount – international standard for 200mm rotor

4 / / m 1 6 C u s e r M a n u a l

Geometry

GEOMETRY NOTEs

GEOMETRY TAKEN AT TOP OUT WITH 594MM

FORK LENGTH AND 42MM FORK OFFSET.

Component spec NOTE

the m16c is designed around the use of a single chain ring set only. Use of a double or triple ring set will not allow proper clearance with the frame.

G

F

B

D

K

C

A

I

H

J

L

E

J

K

L

I

H

F

G

C

D

A

B

E

Wheel Base

Top Tube Length

Chain Stay Length

Head Tube Length

Head Tube Angle

Reach

Stack

BB Height

Seat Tube Angle (Effective)

Seat Tube Angle (Actual)

Seat Tube Length

Standover Height

SMALL

1194 mm/ 47”

565 mm/ 22.25”

445 mm/ 17.5”

109 mm/ 4.3”

63.5˚

391 mm/ 15.4”

587 mm/ 23.1”

365 mm/ 14.375”

73.3˚

59.5˚

416 mm/ 16.4”

797 mm/ 31.4”

MEDIUM

1219 mm/ 48”

591 mm/ 23.25”

445 mm/ 17.5”

115 mm/ 4.5”

63.5˚

413 mm/ 16.3”

592 mm / 23.3”

365 mm/ 14.375”

73.3˚

59.5˚

440 mm/ 17.3”

803 mm/ 31.6”

LARGE

1245 mm/ 49”

616 mm/ 24.25”

445 mm/ 17.5”

122 mm/ 4.8”

63.5˚

436 mm/ 17.15”

598 mm/ 23.55”

365 mm/ 14.375”

73.3˚

59.5˚

455 mm/ 17.9”

809 mm/ 31.9”

I N T E N S E C Y C L E S / / 5

XLarge

1265 mm/ 49.8”

634 mm/ 25”

445 mm/ 17.5”

132 mm/ 5.2”

63.5˚

452 mm/ 17.8”

607 mm/ 23.9”

365 mm/ 14.375”

73.3˚

59.5˚

457 mm/ 18”

816 mm/ 32.1”

37

25

15

28

16

25

38

32

27

40

19

36

26

21

22 4

6 / / m 1 6 C u s e r M a n u a l

12

5

21

30

3

30

5

14

20

6

31

exploded view

2

31

8

and b.o.m.

35

9

7

29

33

1

34

17

1

29

24

4

11

39

10

23

18

13

130798

140004

140009

140010

140012

140040

140041

346941

401011

410009

PART

NUMBER

130766

130768

130767

130769

130777

130778

130780

130784

130785

130789

130790

130794

130795

20

21

22

16

17

14

15

18

9

10

7

8

11

5

6

3

4

ITEM

NO.

2

1

2

(sl)

ITEM

Bolt Shoulder

Top Link

Top Link

Box Link

Cone Adjuster

Bearing Cap

Axle Upper

Washer

Bolt Shoulder

Spacer

Hanger

12

Rear Axle

Bolt Main

Pivot

13

Hanger Bolt

Plug

Bumper

Bumper

Fender

Cable Guide

19

Grommet

Seat Collar

Zerk Fitting

SHCS

M6 x 22

QTY.

1

1

2

3

4

1

1

1

2

1

1

2

2

1

1

2

1

1

1

2

1

1

2

DESCRIPTION

Top Link Pivot Bolt, Lower Pivot

Forged Top Link

Carbon Top Link

Forged Lower Link

Expander Cone

Box Link Bearing Cap

Top Link Pivot Axle

Top Link Pivot, Lower Washer

Top Link Pivot Bolt, Upper Pivot

Top Link Pivot, Upper Spacer

Forged Derailleur Hanger

157 x 12mm Axle

Bolt Main Pivot 1.5T

Rear Derailleur Hanger Bolt

Box Link Pivot Plug

Fork Bumper Left

Fork Bumper Right

Rear Wheel Fender

Rear derailleur cable exit guide

Rear derailleur cable grommet,

1/2 OD x 3/16 ID

Bolt-on 36.1

M6 x 1.0

Cone Adjuster Bolt, Socket Head,

M6 x 22

TORQUE SPEC.

20 Nm / 175 in-lbs

N/A

N/A

N/A

N/A

N/A

20 Nm / 175 in-lbs

N/A

20 Nm / 175 in-lbs

N/A

N/A

11 Nm / 100 in-lbs

7 Nm / 60 in-lbs

11 Nm / 100 in-lbs

N/A

N/A

N/A

N/A

N/A

N/A

N/A

5 Nm / 40 in-lbs

14 Nm / 125 in-lbs

30

31

38

39

36

37

40

34

35

32

33

ITEM

NO.

23

ITEM

24

BHCS M5 X 12

SHCS

M6 x 25

25

BHCS

M5 X 16

SHCS M8 x 35

26

26 (sl)

SHCS M8 x 35

27

M6 Shoulder

Bolt, Left

27

(sl)

M6 Shoulder

Bolt, Left

28

28 (sl)

M6 Shoulder

Bolt, Right

M6 Shoulder

Bolt, Right

29

Bearing 61901

Bearing 7902

Bearing 6802

Guard Flack DT

Guard Flack CS

Guard Flack SS

Protective Tape

Decal

Head Badge

Front Triangle

Rear Triangle

Rear Shock

PART

NUMBER

410010

410039

410041

410045

410042

410046

410043

410047

410044

430001

430007

430008

500239

500240

500245

500252

500300

500337

DESCRIPTION

Guide Bolt, Button Head, M5 X 12

Cone Adjuster Bolt, Socket Head,

M6 x 25

Fork Bumper Bolt, Button Head,

M5 x 16

Shock Bolt, M8 x 35 Steel

Shock Bolt, M8 x 35 Titanium

Shock Bolt Male,

M6 Thread, Steel

Shock Bolt Male,

M6 Thread, Titanium

Shock Bolt Female, M8 x 45mm,

M6 Internal Thread, Steel

Shock Bolt Female, M8 x 45mm,

M6 Internal Thread, Titanium

12 x 24 x 6 2RS Radial Bearing

15 x 28 x 7 2RS MAX Angular

Contact Bearing

15 x 24 x 5 2RS MAX Radial Bearing

Flack Guard M16C Down Tube

Flack Guard M16C Chainstay

Flack Guard M16C Seatstay

150 mm x 30 mm x 0.6 mm

Decal California Bear

M16 Head Badge

Carbon, 4 Sizes

Carbon, 1 size

240mm x 76mm

QTY.

1

1

1

1

2

1

1

1

1

2

1

1

1

1

2

1

2

4

2

1

1

TORQUE SPEC.

6 Nm / 54 in-lbs

14 Nm / 125 in-lbs

6 Nm / 54 in-lbs

16 Nm / 140 in-lbs

16 Nm / 140 in-lbs

16 Nm / 140 in-lbs

16 Nm / 140 in-lbs

16 Nm / 140 in-lbs

16 Nm / 140 in-lbs

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

I N T E N S E C Y C L E S / / 7

Assembly

P R E FAC 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.

Tools needed

• High Grade, waterproof grease

(Maxima Waterproof Grease recommended)

• Blue Loctite #243

• 5mm HEX wrench x2

• 6mm hex wrench

• 8mm HEX wrench

Recommendation

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

8 / / m 1 6 C u s e r M a n u a l

2 5

1 3 4 6

C ONNE C T ING TOP L INK TO F R ON T T R I A NGL E //

A

Hold narrow end of the link

(PART #130767); hold upper spacer

(PART #130789) against inside of bearing race. Match upper linkage to pivot on front triangle, making sure the spacers do not fall out (IMAGE #1). See exploded view for linkage orientation.

B

Using upper pivot axle (PART #130780).

Insert through left (non-drive) side of top link, making sure spacers do not fall out. Thread shoulder bolt

(PART #130785) into upper pivot from opposite side of top link (IMAGE #2).

C

Holding 5MM hex wrench on non-drive side of upper pivot axle, insert torque wrench into shoulder bolt on drive side and tighten to 175 in/lb (IMAGE #3).

C ONNE C T ING B OX L INK TO F R ON T T R I A NGL E //

A

Hold bearing cap (PART #130778) with flat edge against the bearing of the box link (PART #130769) (IMAGE #4).

B

Match box link (PART #130769) to front triangle pivot point and insert main pivot expander bolt (PART #130795) with greased threads through the nondrive side of the box link, holding bearing caps in place (IMAGE #5).

C

Use 8MM hex wrench to thread main pivot expander bolt into box link, and torque to 60 in/lb (IMAGE #6).

I N T E N S E C Y C L E S / / 9

7 10 12

8 9

C ONNE C T ING R E A R T R I A NGL E TO B OX L INK //

A

Follow previous steps to connect rear triangle to box link (IMAGES #7, 8 & 9).

11 13

IN S TA L L ING A D JU S T E R C ONE S //

A

Grease and insert adjuster cone (PART

#130777) into head of main pivot expander bolt (PART #130795) with

M6 x 22 bolt (PART#410009) inserted through adjuster cone (IMAGE #10 & 11).

B

Tighten M6 x 22 bolt (PART #410009) with 5MM hex wrench to 125 in/lb

(IMAGE #12).

C

Insert trim plugs (PART #140004)

(IMAGE #13).

1 0 / / m 1 6 C u s e r M a n u a l

14 16 18

20

15 17 19 21

C ONNE C T ING R E A R T R I A NGL E TO TOP L INK // IN S TA L L ING R E A R S H OC K //

A

Hold washer (PART #130784) against inside of top link mount, then bring the rear triangle forward matching upper pivot to top link (IMAGE #14).

B

Match shoulder bolts (PART#130766) to top linkage, threading bolts into the rear triangle while holding washers in place between bearing and linkage

(IMAGE #15 & 16), and tighten to 175 in/lb (IMAGE #17).

A

Holding rear shock with reservoir up and forward, insert into frame from drive side above box link (IMAGE #18). Move into position, and insert shock end into front triangle (IMAGE #19).

B

Install shock mount shoulder bolt

(PART #410044) through the right side forward shock mount (IMAGE #20) and install shock bolt (PART #410043) through left side forward shock mount

(IMAGE #21) and tighten to 140 in/lb.

I N T E N S E C Y C L E S / / 1 1

22 23

24

25

IN S TA L L ING R E A R S H OC K (C ON' T) // IN S TA L L ING D E R A IL L E UR H A NGE R //

C

Match rear shock to shock mount location on box link and insert M8 x 35 shock mount bolt (PART #410042) through drive side of box link shock mount and shock

(IMAGE #22) and tighten to 54 in/lb (IMAGE #23).

A

Grease outer edges of derailleur hanger (PART #130790) and insert into frame from inside of rear triangle (IMAGE #24) matching derailleur hanger mount bolt (PART #130798) to hanger threads from outside the frame and tighten to 100 in/lb (IMAGE #25).

adjustable travel

the box link shock mount features dual mounting positions which allow you to choose between 215mm and

241mm of rear travel. upper mount: 215mm lower mount: 241mm

1 2 / / m 1 6 C u s e r M a n u a l

26 28

27 29

R E A R A X L E IN S TA L L AT ION //

A

The M16 Carbon uses a rear axle with an expanding system similar to the main pivot bolts on the box link (IMAGE #26). This insures a secure fit between axle and frame.

To install rear axle (PART #130794), insert threaded end of axle through non-drive side of dropout until it reaches the female threads of the derailleur hanger. Insert a 5MM hex wrench into the drive side of the axle through the derailleur hanger (IMAGE #27) and thread counterclockwise into the derailleur hanger, hand tighten to approximately

100 in/lb (IMAGE #28). Grease the expander cone (Part #130777), insert M6 x 25 bolt

(PART #410039) and tighten expander bolt to 125 in/lb (IMAGE #29).

I N T E N S E C Y C L E S / / 1 3

torque

Achieving proper torque is vital to ensuring the safe performance and function of the m16 Carbon 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.

M8 HEX 7 Nm / 60 in-lbs

M6 HEX 14 Nm / 125 in-lbs

16 Nm / 140 in-lbs

1 4 / / m 1 6 C u s e r M a n u a l

torque chart

20 Nm / 175 in-lbs

16 Nm / 140 in-lbs

20 Nm / 175 in-lbs

6 Nm / 54 in-lbs

Rear Axle 11 Nm / 100 in-lbs

M6 HEX 14 Nm / 125 in-lbs

M8 HEX 7 Nm / 60 in-lbs

M6 HEX 14 Nm / 125 in-lbs

set up

seatpost

make sure to insert seat post at least

4” into the main frame. Anything less than this amount could cause damage to the frame or even failure.

4”

adjustable travel

upper mount: 215mm lower mount: 241mm

I N T E N S E C Y C L E S / / 1 5

shock setup

cane creek db coil 241 x 76mm (9.5" x 3.0")

set up and tune

proper set up and tuning can vary from shock to shock. Please consult the cane creek manual included with your bike for complete information about set up, tuning and general maintenance or visit www.canecreek.com/products/ suspension

note

coil springs stocked in 50 lb. increments from 350 to 500

Shock Sag

35% when sitting on the bike

shock stroke

76 mm (3.0")

Fork Sag

25-30% when sitting on the bike

travel

216 mm (8.5")

RIDER WEIGHT

(LBS/KGS)

140 lbs / 64 kgs

150 lbs / 68 kgs

160 lbs / 73 kgs

170 lbs / 77 kgs

180 lbs / 82 kgs

190 lbs / 86 kgs

200 lbs / 91 kgs

210 lbs / 95 kgs

220 lbs / 100 kgs

230 lbs / 104 kgs

240 lbs / 109 kgs

250 lbs / 113 kgs

260 lbs / 118 kgs

270 lbs / 122 kgs

SPRING WEIGHT

(LBS)

350

400

450

500

travel

241 mm (9.5")

RIDER WEIGHT

(LBS/KGS)

140 lbs / 64 kgs

150 lbs / 68 kgs

160 lbs / 73 kgs

170 lbs / 77 kgs

180 lbs / 82 kgs

190 lbs / 86 kgs

200 lbs / 91 kgs

210 lbs / 95 kgs

220 lbs / 100 kgs

230 lbs / 104 kgs

240 lbs / 109 kgs

250 lbs / 113 kgs

260 lbs / 118 kgs

270 lbs / 122 kgs

I N T E N S E C Y C L E S / / 1 7

maintenance

GE NE R A L S E RV IC E A ND C A R E //

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.

1 8 / / m 1 6 C u s e r M a n u a l

maintenance Schedule*

500 Miles or

1 Month

2000 Miles or 6

Months

Action Every Ride

Tires

Check air pressure, inspect tread and sidewalls for tears and punctures

Chain

Brakes

General

Headset

Brush off and lubricate

Squeeze brakes and confirm function

Clean complete bike of mud and debris

Check adjustment

Box Link

Add grease thru zerk fittings

Frame Pivots

Check torques

Spokes

Inspect for damage, check tension

Shock and Fork

Check air pressure, inspect for leaks

Deraileur Cables

Inspect and lube

Seatpost

Clean and regrease interface with frame

Frame Pivots

Remove pivot bolts, check bearings for pitting and wear

Headset

Disassemble stem, headset and fork. Check bearings for pitting and wear

Hubs

Bottom Bracket

Pull wheels off, check hub bearings for pitting and wear

Remove crank arms and check BB bearings for pitting and wear

Replace brake pads

Brakes

Chain

General

Shock and Fork

Inspect for damage and check for stretching

Complete Tune-Up

Overhaul

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

See MFG Recommendations

4000 Miles or

1 Year

X

*

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

I N T E N S E C Y C L E S / / 1 9

w w w . I N T E N S e C Y C L E S . c o m

p hone: (951)-296-9596

Customer Service: cs @ intensecycles.com

General Info: info @ intensecycles.com

Media , Marke ting, Sp onsorship : marke ting @ intensecycles.com

Intense Cycles USA 4 2380 rio nedo Temecul a , Ca . 92590

330014