AC TEAM Model Year 2001 Owners Manual October 2000. · · · · · · · · · ALL CONDITIONS MOUNTAIN BIKE Multi purpose, extreme riding mountain bike (Semi-) downhill, Dual Slalom Frame compatible for chain tension device (included), bash ring, 2.2" tires MPH hydraulic disc brakes Front fork with lock out Coil over rear shock unit (included) Sealed bearings on all pivots 3 rear shock positions Rear wheel travel: 6~5¼~4½ inches, front wheel travel: 125 mm. Contents: 1. 2. 3. Introduction. Sizing. Rear 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. suspension Adjusting travel Coil over shock Rear suspension tuning "SAG" adjustment Damping adjustment Changing the coil spring Removing the rear shock assembly or pivots. 4. Chain tension device 4-1. Assembly. Cleaning and maintenance. 5. - Pag. 1. - 1. Introduction. Giant's products are designed to provide years of recreation and enjoyment. The GIANT AC has been designed primarily as "full time" cross-country bike, with all-conditions features. However, in order to fully understand all the bicycle features, you must read this bicycle manual, the suspension fork and rear shock manuals provided by Giant and parts suppliers. If you do not understand any information in the manuals or if you misplace any of them, please contact your authorised Giant dealer immediately. Please take the time to read and understand this material to help limit the possibility of serious injury. ALWAYS read and follow all instructions in this manual. WARNING: Giant AC frames are designed for single crown front forks. Use of "dual" or "triple" crown forks on any Giant AC bicycle will void the warranty. Giant is not responsible for damages to the bike and rider resulting from the use of dual or triple crown forks. INDEX - Pag. 2. - 2. Sizing. The actual frame measurements and geometries are listed below. Figure 1. Size A. B. C. D. E. F. G. H. I. Top Tube [mm.] (measured horizontally) Seat Tube [mm.] Seat Tube Angle Head Tube Angle B.B. Drop [mm.] Chain stays [mm.] Fork Rake [mm.] Trail [mm.] Wheel Base [mm.] Rear Travel S - 17" 565 430 M - 18" 585 455 72 degrees 68½ degrees -6 430 43 84 1115 6~5¼~4½ " L - 19" 605 480 1100 1135 TOP INDEX - Pag. 3. - 3. Rear suspension. The rear suspension for your Giant AC bicycle is provided by a RockShox Pro Deluxe coil spring shock. For a description of the RockShox Pro Deluxe coil spring shock, refer to section 3-2.: Coil over shock. When tuning suspension, always make one change at a time and write it down. This takes patience, but allows you to understand how each change affects your ride. Use a familiar trail to make these small adjustments. To understand the tuning range it may also help if you ride one extreme to the other (low vs. spring tension or maximum vs. minimum rebound). Keeping a record lets you know what changes you have tried that work and suggests what changes you might try. Ask a shop or local riders what they have found works well. These resources are typically your best bet. WARNING: Improper adjustment of rear suspension shock can result in unstable conditions or loss of control. INDEX 3-1. Adjusting travel. Your Giant AC bicycle gives you the ability to change the travel from 4½" to 5¼" to 6" with minimal effort. This is accomplished by three positions for the upper shock pivot bolt (see figure 2 below). To change the travel: 1. 2. Using a 6 mm. Allen-key, remove the upper shock mounting bolt. Pivot the shock backward or forward to align the eyelet with one of the three holes. The forward most position is for 4½" travel. The middle position is for 5¼" travel. The position closest to the seat tube is for 6" travel. TM The threads of fixing bolt should be cleaned and re-set using Loctite Primer (#7649) and TM Loctite blue Removable Threadlock (#242) or similar material. Install the bolt and tighten to the proper torque of 10-12 Nm. After any adjustment is made to travel, you will need to readjust all spring pre-load settings described in the following sections. 3. 4. WARNING: Improper (dis-)assembly may result in damage to the bicycle or in an accident which can cause serious injury or death. Figure 2. TOP INDEX - Pag. 4. - 3-2. Coil over shock. The drawing below shows a coil over type rear shock (Pro Deluxe made by RockShox). Figure 3. A. B. C. D. E. F. G. H. Upper eyelet Pre-load spring washer Bumper Pre-load spring Spring pre-load collar Lower eyelet External rebound adjuster Compression adjustment knob H The shock has a pre-load spring to set "SAG" and external knobs to control compression and rebound settings. The shock has a knurled pre-load adjustment ring to "pre-load" the spring. Different riders require different performance characteristics from their suspension. A. Heavier riders need a stiffer spring and more compression damping. B. Lighter riders need a softer spring and lighter compression damping. Below is a chart showing the standard spring rates, and the recommended spring rates for different weight riders. Giant frame size 17" - 18" 19" Rider weight range 60-75 kg. 75-90 kg. Spring rate 500 lbs./in. 600 lbs./in. Frame sizes 17" and 18" come with 500 lbs./in. Springs and frame size 19" with 600 lbs./in. Softer and stiffer spring rates (50 lbs./in. increments) are available for these rear suspension shocks either through your authorised Giant dealer or directly from the manufacturer. If you need to change your spring, contact your local authorised Giant dealer or the Giant importer in your country. All Giant AC dual suspension bicycles are equipped with front and rear suspension that offer multiple adjustment and tuneability. Adjustment of your suspension is subjective and cannot be fully prescribed by Giant. If you need help, contact your local authorised Giant dealer. - Pag. 5. - The rear shocks are serviceable and must be returned for maintenance, repair or service, only to an authorised RockShox dealer (or call the RockShox distributor in your country) once a year or more often if the bike is used in extreme conditions. This service is not necessarily free of charge! WARNING: All service and maintenance of the rear shocks should only be performed with proper tools by an authorised RockShox dealer or by the RockShox distributor in your country. TOP INDEX 3-3. Rear suspension tuning. To adjust the pre-load on the coil-spring shock is simple. For a firmer ride while descending or hill climbing on smooth surfaces, turn the spring pre-load collar against to compress or load the spring. For a softer ride while riding cross country, turn the spring pre-load collar away from the spring to relax or unload the spring. WARNING: Turn the spring pre-load collar away from the spring and stop turning just as the spring feels loose on the shock. This is zero pre-load. Do not exceed 2.5 full turns of the threaded spring collar from zero pre-load. Too much spring tension will cause the spring to fail. If the pre-load required exceeds 2.5 full turns of the spring pre-load collar from zero preload, you may require a higher rated spring. Contact your authorised Giant dealer or the manufacturer of the shock for an optional replacement spring. WARNING: Never set the spring pre-load collar so there is no pre-load on the spring. If the required pre-load adjustment ring setting results in no pre-load on the spring or proper adjustment can not be achieved, you may require a lower rated spring. Contact your authorised Giant dealer or the manufacturer of the shock for an optional replacement spring. TOP INDEX 3-4. "SAG" adjustment. SAG is the amount of coil spring pre-compression that is required to compensate for the riders weight and allow the bicycle to perform as it was designed to. To properly set the SAG, you will need a screw driver, measuring-tape and/or calliper. Step 1. Prepare the bicycle. Set the saddle to the correct height for your riding style. Attach all accessories, water bottles etc. that you would normally ride with. Prepare yourself. Dress as you would for a normal ride, including helmet, cycling bag, etc. Push the bumper against the pre-load spring washer with a flat screw driver. Measure the distance (L) between the main cylinder and the bumper of the rear shock. Turn the spring pre-load collar away from the spring and stop turning just as the spring feels loose on the shock. This is zero pre-load. Step 2. Step 3. - Pag. 6. - Step 4. Use a screw driver to slide the bumper of the shock against the main cylinder of the rear suspension. Sit on the bicycle with your feet on the pedals in your normal riding position. Come off from your bike without causing too much movement in the bike. Check the rear shock and you will see that the bumper has been moved along the piston. Measure the distance between the main cylinder and the bumper. This distance should be approx. 1/3 ~ ¼ of the dimension L measured during step 3. Adjust the spring pre-load collar and repeat steps 4 - 6 until you have reached this. Step 5. Step 6. L Figure 4. TOP INDEX 3-5. Damping adjustment. The Pro Deluxe rear shock includes a red rebound damping adjustment knob and a blue compression damping adjustment knob. Rebound adjustment: The rebound controls the extension or return of the shock. The shock's rebound is quickest when the adjustment knob is in the full anti-clockwise position. Rebound is slowest when the adjustment knob is in the full clockwise position. Symptoms of too much rebound damping: Slow shock return, where the shock feels good through the first few bumps and gets harder as you continue, means there is too much rebound damping. In addition, while braking, the rear wheel will tend to skip over the bumps ("pack up"). To adjust it for more consistency and better braking, turn the rebound knob a half turn anti-clockwise and test it again. Symptoms of too little rebound damping: Too little rebound damping is when the shock returns too fast and the bike seems to want to "buck you off" or the rear wheel skips easily over bumps. Turn the rebound knob a half turn clockwise to slow the rebound down for more consistency and better braking through the bumps. Compression adjustment: Compression damping aids in preventing the shock from bottoming out over big hits by absorbing some of the energy of the bump. Increasing the compression damping by turning the adjustment know clockwise will make the shock compress more slowly when you hit a bump and compresses. With increased compression damping the shock will not be as supple over small bumps and is usually reserved for high speed riding where big hits are encountered. Usually the compression damping is kept at a low level for most off road riding conditions. TOP INDEX - Pag. 7. - 3-6. Changing the coil spring. WARNING: Do not try to disassemble or to replace the rear shock coil spring by yourself! Improper (dis)assembly may result in damage to the bicycle or in an accident which can cause serious injury or death. Only an authorised Giant dealer should replace the coil spring. TOP INDEX 3-7. Removing the rear shock assembly or pivots. It is necessary to periodically check the rear shock unit and the suspensions' pivot points for damage or wear. The rear shock unit should be returned to an authorised RockShox dealer or to the RockShox distributor in your country to inspect and repair. (Note: this is not covered under the terms of the warranty). WARNING: Do not try to disassemble or to replace the rear shock or pivot by yourself! Improper (dis-)assembly may result in damage to the bicycle or in an accident which can cause serious injury or death. Only an authorised Giant dealer should disassemble the rear shock or pivots. TOP INDEX - Pag. 8. - 4. Chain tension device. Figure 5. Nr. 1 2 3 4 5 Description Body Roller Shaft Roller bearing 6x19 mm. Washer M8 Qty. 1 2 2 2 2 Nr. 6 7 8 9 10 Description Bolt M6x20 mm. Nut M6 Washer M6 Taper bolt M6x15 mm. Roller bearing 7x22 mm. Qty. 2 3 3 3 2 4-1. Assembly. The AC chain tension device is designed to be easily installed and removed to/from the frame. It can be installed with all 3 chain rings (chain on the largest ring) or a single chain ring on the crank arm. To insure proper chain and (rear) shifting function, keep the chain line at 57mm. Installation: 1. Insert the taper bolt (9) through the bottom bracket shell mount and body (1). The bolt must come in from the non-drive (LH) side. 2. Install washer (5) and nut (10) and tighten firmly. 3. Repeat step 1 and 2 for additional bolt assemblies. 4. With the chain in the largest sprocket on the rear cassette, the upper roller's groove should just rub the top of the chain. 5. The lower roller's groove should have the chain wrap smoothly around it after exiting the chain wheel (about 7 o'clock position). 6. Do not put any tension on the top of the chain, the bottom roller will supply the chain tension. The top roller serves only as a guide. Warning! Rollers need to be tightened on both sides simultaneously befo ...