Manual - Bike - (AMM) (D00 - Bike)

Flatirons Solutions AMM
PRINTED: 10-DEC-2019; 02:47PM.

REV: 1 RELEASE DATE: 14-NOV-2019
Bicycle
Description of how it is made
 
Table of contents
Title
Bicycle - Description of how it is made
1 Physical description of a bicycle
1 Physical description of a bicycle

A bicycle (refer to Figure 1) is a frame and a number of movable components with mechanical parts that are completely open.
There are no covers or sheet metal panels that prevent access to the mechanical parts. Thus, you can disassemble the different
components of a bicycle (refer to Figure 1 item 0) to do:
an inspection
a maintenance task
a repair task
MB: emphasis element right here
a para which should break be on its own line and not inline. It is rather looooooooooooooooooooooong and should be long
in order to test that it lines up properly with the previous para. I am sure that it will.
Another para.
9 10 11 1
2 1 8
2
1
7 6 2 5 4 3
Figure 1. Complete bicycle
The parts that you can immediately identify on a bicycle are given in Table 1.
Table 1. Bicycle parts
Filtering is on: ALL S1000DBIKE-AAA-D00-00-00-00AA-041A-A Page 1

Item Refer to Definition

Frame (Figure 1 item 9) A bicycle frame is made of metal tubes that are
welded together.
Wheels The wheels include these parts:

Hub
Spokes
Metal rim
Rubber tire
Rear wheel (Figure 1 item 7)
Front wheel (Figure 1 item 3)
Seat and seat post (Figure 1 item 8) These install into the seat tube with a mechanism you
can use to change the height.
Handle bars (Figure 1 item 11) A horizontal bar that attaches to the stem with grips at
the ends that attach to the brake levers and the
shifters.
Handle bar stem (Figure 1 item 10) This attaches the handle bar to the steering tube (head
set).
Cranks (Figure 1 item 5) A lever that extends from the bottom of the bracket to
the pedal.
Pedals (Figure 1 item 4) The two platforms for the feet that attach to the crank.
Chain (Figure 1 item 6) A circular set of links that connect the chain ring to the
cogs on the freewheel.
Gears (Figure 1 item 2) The gears include:

Front chain ring
Rear freewheel
Front and the rear derailleur
Shift lever on the handle bars
Cables
Brakes (Figure 1 item 1) The brakes include:

Actuators on the handlebars
Brake cable
Brake callipers
Brake pads
Applicable to: Mountain bicycle and Brook Copyright (C) 2008 by each of the S1000DBIKE-AAA-D00-00-00-00AA-041A-A
trekker and Mk9 following or...
Security: Unclassified 2011-01-31

Bicycle
Description of function
 
Table of contents
Title
Bicycle - Description of function
1 Functional description of a bicycle
References
Reference Title
S1000DBIKE-AAA-DA0-00-00-00AA-041A-A S1000DBIKE-AAA-DA0-00-00-00AA-041A-A
S1000DBIKE-AAA-DA4-10-00-00AA-251B-A S1000DBIKE-AAA-DA4-10-00-00AA-251B-A
1 Functional description of a bicycle

Below is a list of the different bicycle components and a functional description of them.
Frame The frame is the skeleton of the bicycle. Refer to S1000DBIKE-AAA-DA3-00-00-00AA-041A-A for a
functional description of the frame system.
Wheel The wheel is the point of contact between the bicycle and the road for the bicycle to have movement.
Refer to S1000DBIKE-AAA-DA0-00-00-00AA-041A-A for a functional description of the wheel.
Spokes The spokes are thick wires with tension applied that connect the hub to the rim. You can adjust the
tension with the nipple on the rim side.
Hub The hub attaches to the center of the wheel where the axle and the bearings are.
Metal rim The metal rim is a metal ring that has a U-shaped cross section to hold the spokes on the inner side
and the tire on the outer side.
Seat The Seat, which is also known as the 'saddle', is used as the support platform for the person to sit on
the bicycle.
Seat post The Seat post is used as a support post for the seat and to change the height of the seat for the rider.
Handle bar The handle bar is a horizontal bar with handles on each end. The handle bar is a steering mechanism
that the rider uses to change the direction of the bicycle. The brake levers are also on the handle bar.
Refer to S1000DBIKE-AAA-DA2-20-00-00AA-720A-A for information on how to install the handle bar.
Refer to S1000DBIKE-AAA-DA2-20-00-00AA-520A-A for information on removing the handlebar.
Handle bar stem The handle bar stem (the stem) attaches the handle bar to the steering tube. Refer to S1000DBIKE-
AAA-DA2-10-00-00AA-720A-A for information on how to install a stem. Refer to S1000DBIKE-AAA-DA2-
10-00-00AA-520A-A for information on how to remove the stem.
Brake levers When you operate the brake lever, the brake pads move against the wheel to decrease the speed. The
brake lever on the left side operates the front brake. The brake lever on the right side operates the rear
brake.
Brakes When you operate the brakes, the brake pad moves against the wheel to decrease the speed of the

bicycle. Refer to S1000DBIKE-AAA-DA1-00-00-00AA-041A-A for a description of the braking system.
Shifters The shifters are the mechanisms that you use to change the gears on the bicycle. There are 7 different
types of shifters that have been developed over the years, but they all have the same functionality.
When you operate the shifters, they pull the control cable to move the derailleur towards a larger
diameter chain ring. The shifters can also loosen the cable to let the derailleur move towards a smaller
diameter chain ring. Refer to S1000DBIKE-AAA-DA5-30-00-00AA-041A-A for a functional description of
the shifters.
Crank The crank moves the power to the chain rings when the pedals operate.
Pedals The pedals move the force of movement from the feet to the cranks.
Chain The chain moves the power from the chain rings to the cogs on the freewheel. Refer to S1000DBIKE-
AAA-DA4-10-00-00AA-251B-A for the procedure on how to clean the chain.
Gears The gears have different mechanisms that function together to change the speed of the bicycle. These
mechanisms include:
the sprockets
the chain
the derailleur
Refer to S1000DBIKE-AAA-DA5-00-00-00AA-041A-A for a functional description of the gear system.
Chain rings The chain rings (also known as the 'chain wheel') pull on the chain when the cranks turn.
Derailleur A derailleur moves the chain from one sprocket to another to change the gears. There are two different
types of derailleur, the front and the rear. The highest ratio (highest gear) is when the chain is on the
largest sprocket on the front and the smallest at the rear. To get the lowest gear, the smallest sprocket
is at the front and the largest at the rear. Refer to S1000DBIKE-AAA-DA5-10-00-00AA-041A-A for a
functional description of the derailleur system.

Bicycle
Description attributed to crew
 
Table of contents
Title
Bicycle - Description attributed to crew
1 Introduction
2.1 Controls
2.2 Steering
2.3 Shifters
2.4 Brakes
2.5 Pedals
References
Reference Title
Crew
1 Introduction
Data about the bicycle and its control system is given in this document. This data will help you operate the bicycle.
2
2.1 Controls
Data about the controls that follow is given in this document:
Para 2.2
Para 2.3
Para 2.4
Para 2.5
2.2 Steering
The handlebars are used to steer the bike. They are at the front of the bicycle. You hold one of the handlebar grips with each
hand and move the handle bar to change the direction of the bike.
2.3 Shifters
The gears control the ratio of pedal rotation to wheel rotation. You can change this with the shifters S1000DBIKE-AAA-DA5-30-00-
00AA-041A-A . The shifters are on the handlebar.
A description of the two Table 1 follows.
Table 1. shifter correlation
Shifter Location Affected Gears
Left The buttons on the left shifter changes the gears on the front derailleur.
Right The buttons on the right shifter changes the gears on the rear derailleur.
2.4 Brakes

WARNING
IF YOU OPERATE THE FRONT BRAKE WITHOUT THE REAR BRAKE YOU CAN CAUSE A CRASH.
You can decrease the speed of the bike with the brakes. You operate the brakes with the brake levers on the handlebar.
A description of the Table 2 follows.
Table 2. brake lever correlation
Brake Lever Location Affected Brake
Left This lever operates the front brake.
Right This lever operates the rear brake.
2.5 Pedals
The are at the bottom of the seat tube. You operate the to move the bicycle forward.

Bicycle
Pre-operation procedures (crew)
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Table of contents
Title
Bicycle - Pre-operation procedures (crew)
Procedure
References
Reference Title
S1000DBIKE-AAA-DA4-10-00-00AA-251B-A S1000DBIKE-AAA-DA4-10-00-00AA-251B-A
Required person
Person Category Skill Trade Estimated time Number of persons required
Man A Basic user Operator 0,3 h
Support equipment
Name Identification/Reference Quantity Remarks
Tire pressure gauge KZ666 / BSK-TLST-001-01 1 EA
Specialist toolset KZ666 / BSK-TLST-001 1 EA
Consumables
General lubricant KZ222 / LL-001 As required
Procedure
Examine the condition of the brakes.
Open the brake quick release.
Examine the condition and the thickness of the brake pads.
Make sure that there is a large quantity of rubber left.
Make sure that the pad is not too hard.
Clean all the unwanted material.
Do an inspection of the installation of the brakes.
Check the hydraulic brake system function.
Figure 0. Hydraulic brake function
Make sure that there is sufficient clearance between the pad and the inner diameter of the brake surface.

CAUTION
IF THE POSITION OF THE PADS IS TOO LOW ON THE RIM, AS SHOWN IN
(FIGURE 2) , THE PADS CAN MOVE. THIS COULD CAUSE THE SEPARATION OF
THE SPOKES FROM THEIR MOUNTINGS., THEY COULD SLIP OFF CAUSING THE
SPOKES TO BE TORN OUT OF THEIR MOUNTINGS.
A
Figure 1. Brake pad seating
Make sure that the pads are correctly installed in the center of the inner diameter of the brake surface.
Do a check of the tire pressure.
Do a check of the tire pressure with the Tire pressure gauge (BSK-TLST-001-01) .
Compare the value you read with the recommended pressure that is shown into the sidewall of the tire.
Add the necessary air.

Examine the condition of the wheels.

Examine the rims for bulges and dents.
Examine for splits at the seam where an extruded rim is bonded.
Do a check of the headset bearings.
Straddle the bicycle.
Apply the front brakes and push the handle bars forward.
Make sure that the headset bearings are tight.
Do the checks on the chain.
Visually examine the chain.
If the chain is too dirty, clean it as specified in the clean chain task (refer to S1000DBIKE-AAA-DA4-10-00-00AA-251B-A ).
Visually examine the chain for links that are frozen or that do not move easily.
Apply the necessary General lubricant (LL-001) .
Do a check of the chain to make sure that it is tight.
Make sure that the play of the chain is not too much.
Move the chain on the largest chain ring.
Try to pull the chain away from the front of the chain ring.
Make sure that the chain is not loose. Tighten the chain if, when you pull it away from the chain ring, you can see a full tooth.
Tighten the chain with the Allen wrench from the Specialist toolset (BSK-TLST-001).
Requirements after job completion

None
Condition Reference

Bicycle
Normal operation procedures (crew)
 
Table of contents
Title
Bicycle - Normal operation procedures (crew)
Pre-ride inspection
Brakes
1 Pads
2 Callipers
3 Levers
4 Cables
Tires
Wheels
Headset
Chain
Handlebar
Computer
Crew
Pre-ride inspection
Brakes
Pads
1. Pads ................................................................................................
Free of unwanted material
2. Pads ................................................................................................
Acceptable pad width
3. Pads ................................................................................................
Acceptable pad clearance
Callipers
1. Link Wire ................................................................................................

Firmly attached
Levers
1. Levers ................................................................................................
Approximately 1 inch of travel before engagement
2. Levers ................................................................................................
Space between lever and handlebar when fully pulled
Cables
1. Cables ................................................................................................
No cuts or fraying
Tires
1. Pressure ................................................................................................
Table 1. Correlation of tire pressure and terrain
Tire Pressures Min Max
Off Road 35lbs 40lbs
On Road 55lbs 60lbs

2. Tires ................................................................................................
No cracks or splits
Wheels
1. Wheels ................................................................................................
No loose bearings
2. Wheels ................................................................................................
True
3. Spokes ................................................................................................
Not broken
4. If Spokes not broken

1. Spokes ................................................................................................
Tight
5. Axel Nuts ................................................................................................
Tight
Headset
1. Headset bearings ................................................................................................
Tight
Chain
1. Links ................................................................................................
Easy movement of links
Handlebar
WARNING
DO NOT RIDE WITH A CRACKED STEM
1. If Stem cracked
1. Replace stem
2. Else if Stem is loose
1. Tighten stem
3. If Handlebars twist in stem
1. Tighten clamp bolt
Computer
1. Computer Display ................................................................................................
SPEED 0 mph DISTANCE 0 miles
Applicable to: Mountain bicycle and Brook trekker Copyright (C) 2008 by each of the S1000DBIKE-AAA-D00-00-00-00AA-131A-A
and Mk9 following or...

Bicycle
Post-operation procedures (crew)
       
Table of contents
Title
Bicycle - Post-operation procedures (crew)
Procedure
Support equipment
Specialist toolset KZ666 / BSK-TLST-001 1 EA
Consumables
General lubricant KZ222 / LL-001 As required
Procedure
Clean the bicycle.
Clean the bicycle with water.
Use the brush from the Specialist toolset (BSK-TLST-001) to clean the brakes, the shift levers, the sprockets and the tires.
Let the bicycle dry.
Lubricate the bicycle
Spray the General lubricant (LL-001), to these moving parts:
the brake pivots
the derailleur pivots
the derailleur tension guides
the brake lever pivots
the control cables
the gear sprockets
the chain
Remove the lubricant which is more than the necessary.

None
Condition Reference

Bicycle
Other procedures to clean
       
Table of contents
Title
Bicycle - Other procedures to clean
Procedure
6 Wash the Bike
References
Reference Title
Required conditions
Condition Reference
The bicycle is outdoors
Required person
Man A Chemical technician Intermediate Bike cleaner 1,0 h
Support equipment
Water hose KZ666 / BSK-TLST-001-09 1 EA
Stiff bristle brush KZ666 / BSK-TLST-001-02 1 EA
Sponge KZ666 / BSK-TLST-001-11 1 EA
Consumables
Degreasing agent KZ222 / LL-004 1L
Detergent A KZ666 / BSK-TLST-023-14 1L
Detergent B KZ666 / BSK-TLST-001-15 1L
Safety conditions
WARNING
DO NOT GET DETERGENT A (BSK-TLST-023-14) INTO YOUR EYES. IF IT GETS INTO YOUR EYES, WASH
THEM IMMEDIATELY IN CLEAN WARM WATER.

WARNING
DO NOT GET DETERGENT B (BSK-TLST-001-15) INTO YOUR EYES. IF IT GETS INTO YOUR EYES, WASH
CAUTION
DO NOT USE A WATER HOSE (BSK-TLST-001-09) THAT HAS HIGH PRESSURE. A WATER HOSE THAT HAS
HIGH PRESSURE CAN CAUSE SOME PARTS TO BECOME LOOSE OR FULL OF WATER.
CAUTION
DO NOT POINT THE HOSE DIRECTLY AT THE HUB OR AT THE BOTTOM BRACKET BEARINGS. THIS CAN
CAUSE DAMAGE TO THE PARTS.
CAUTION
APPLY DETERGENT B (BSK-TLST-001-15) IN ACCORDANCE WITH THE INSTRUCTION ON THE CONTAINER.

THE SUBSTANCE MAY CAUSE DAMAGE TO THE BIKE PAINT IF IT IS NOT APPLIED CORRECTLY.
Procedure
Clean the bicycle with water to remove all dirt. Refer to (Figure 1).

Figure 1. Cleaning the bike
Use a Stiff bristle brush (BSK-TLST-001-02) to get access to areas that are not easy to clean. These are the shift levers, the
knobbly tires, and the brakes.
Clean the caked grime from the chain and the sprockets with a screwdriver that has a small blade.
Remove the grease from the freewheel assembly with the Degreasing agent (LL-004) as shown in (Figure 2) . Use a brush to
remove the grease from these parts:
sprockets
guide and tension wheels of the derailleur
chain ring teeth

A
Figure 2. Degreasing the freehub
Flush the sprockets, the derailleurs, the chain rings and the chain with water.
Note
If necessary, do the flush procedure again.
Applicable to: Mountain bicycle and Brook trekker and Mk9

Wash the Bike
Soak the Sponge (BSK-TLST-001-11) into Detergent B (BSK-TLST-001-15) and water.
Clean the bicycle with the soaked sponge.
Soak the Sponge (BSK-TLST-001-11) into Detergent A (BSK-TLST-023-14) and water.
Fully clean the bicycle with the soaked sponge.
Flush the bicycle to make sure that all detergents are removed.
Move the bicycle up and down on its tires to remove all water.
Lubricate the bicycle (refer to S1000DBIKE-AAA-DA4-10-00-00AA-241A-A).

Condition Reference
Make sure the bicycle is dry

Bicycle
Other procedures to clean
       
Table of contents
Title
Bicycle - Other procedures to clean
Procedure
References
Reference Title
Required conditions
Condition Reference
The bicycle is outdoors
Required person
Man A Chemical technician Intermediate Bike cleaner 1,0 h
Support equipment
Water hose KZ666 / BSK-TLST-001-09 1 EA
Stiff bristle brush KZ666 / BSK-TLST-001-02 1 EA
Sponge KZ666 / BSK-TLST-001-11 1 EA
Consumables
Degreasing agent KZ222 / LL-004 1L
Detergent A KZ666 / BSK-TLST-023-14 1L
Detergent B KZ666 / BSK-TLST-001-15 1L
Safety conditions
WARNING
DO NOT GET DETERGENT A (BSK-TLST-023-14) INTO YOUR EYES. IF IT GETS INTO YOUR EYES, WASH
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WARNING
DO NOT GET DETERGENT B (BSK-TLST-001-15) INTO YOUR EYES. IF IT GETS INTO YOUR EYES, WASH
CAUTION
DO NOT USE A WATER HOSE (BSK-TLST-001-09) THAT HAS HIGH PRESSURE. A WATER HOSE THAT HAS
HIGH PRESSURE CAN CAUSE SOME PARTS TO BECOME LOOSE OR FULL OF WATER.
CAUTION
DO NOT POINT THE HOSE DIRECTLY AT THE HUB OR AT THE BOTTOM BRACKET BEARINGS. THIS CAN
CAUSE DAMAGE TO THE PARTS.
CAUTION
APPLY DETERGENT B (BSK-TLST-001-15) IN ACCORDANCE WITH THE INSTRUCTION ON THE CONTAINER.

THE SUBSTANCE MAY CAUSE DAMAGE TO THE BIKE PAINT IF IT IS NOT APPLIED CORRECTLY.
Procedure
Clean the bicycle with water to remove all dirt. Refer to (Figure 1).

Figure 1. Cleaning the bike
Use a Stiff bristle brush (BSK-TLST-001-02) to get access to areas that are not easy to clean. These are the shift levers, the
knobbly tires, and the brakes.
Clean the caked grime from the chain and the sprockets with a screwdriver that has a small blade.
Remove the grease from the freewheel assembly with the Degreasing agent (LL-004) as shown in (Figure 2) . Use a brush to
remove the grease from these parts:
sprockets
guide and tension wheels of the derailleur
chain ring teeth

A
Figure 2. Degreasing the freehub
Flush the sprockets, the derailleurs, the chain rings and the chain with water.
Note
If necessary, do the flush procedure again.

Wash the Bike
Soak the Sponge (BSK-TLST-001-11) into Detergent B (BSK-TLST-001-15) and water.
Clean the bicycle with the soaked sponge.
Soak the Sponge (BSK-TLST-001-11) into Detergent A (BSK-TLST-023-14) and water.
Fully clean the bicycle with the soaked sponge.
Flush the bicycle to make sure that all detergents are removed.
Move the bicycle up and down on its tires to remove all water.
Lubricate the bicycle (refer to S1000DBIKE-AAA-DA4-10-00-00AA-241A-A).

Condition Reference
Make sure the bicycle is dry
Applicable to: Mountain bicycle and Brook Copyright (C) 2008 by each of the S1000DBIKE-AAA-D00-00-00-00AA-258B-A

Bicycle
Place on test stand
       
Table of contents
Title
Bicycle - Place on test stand
Procedure
Required person
Support equipment
Test stand KZ666 / BSK-TLST-999-01 1 EA
Procedure
Ensure Test stand (BSK-TLST-999-01) is level.
Place bicycle on the test stand.
Tight clamps until bicycle is securely attach to the test stand.

None
Condition Reference

Bicycle
Standard repair procedures
       
Table of contents
Title
Bicycle - Standard repair procedures
Procedure
References
Reference Title
Required person
Man A Operator Basic Bike rider 0,5 h
Support equipment
Tire lever KZ666 / BSK-TLST-001-04 1 EA
Foot pump KZ666 / BSK-TLST-001-05 1 EA
Marker pen KZ666 / BSK-TLST-001-07 1 EA
Tube patch kit KZ666 / BSK-TLST-001-07 1 EA
Spares
Inner-tube KT222 / IT-001 1 EA
Safety conditions
CAUTION
WHEN YOU REMOVE THE REAR WHEEL TO REPAIR A PUNCTURE, DISCONNECT THE BRAKE ARM FROM
THE CHAIN STAY.
Procedure
Remove the rear wheel. (Refer to S1000DBIKE-AAA-DA0-20-00-00AA-520A-A)
Make sure that there is no air in the tube.
Loosen the cap on the valve stem.
Push the valve stem core down to bleed all the air.
Use a Tire lever (BSK-TLST-001-04) to move the tire bead out of its seat. Lift the tire bead above the lip of the rim.

Figure 1. Unseating the tire with a tire lever
Remove the tube.

Inflate (not fully) the tube with the Foot pump (BSK-TLST-001-05). Examine the tube for leaks.
If you find a leak, identify it with a circle made with a Marker pen (BSK-TLST-001-07).

Figure 2. Circle leak
Release most of the air.

Use a piece of sandpaper from the Tube patch kit (BSK-TLST-001-07) and make the area on and around the hole rough. This will
help the patch bond correctly.

Figure 3. Sanding the application area
Apply a thin layer of glue from the patch kit on and around the hole. Make sure that the area with the glue is larger than the
patch.

Figure 4. Apply glue to application area
Let the glue dry for five minutes until it becomes tacky and dim.
Remove the rear foil from the patch (that is a part of the patch kit) and push the patch in its position.
Push with your thumbs from the center of the patch to the outer part of the applied area.

Figure 5. Apply pressure to tube
Remove the thin cover from the patch.

Put a very thin layer of talcum powder on and around the patch.
Inflate (not fully) the repaired tube with the foot pump.
Start at the valve stem and install the tube again between the tire and the rim.
Push the valve stem through the hole in the rim.
Make sure that the valve stem is straight.
Install the remaining of the tire.

None
Condition Reference


Bicycle
Illustrated Parts Data - IPD
 
Table of contents
Title
Bicycle - Illustrated Parts Data - IPD
003 005
001
004 002
004
005
005
004
004
007 008
000
Figure 01AA. Bicycle
Units *Usable on
per Part No. / code assy ICY
Figure Item NCAGE Nomenclature
assembly NSN .mv/Effect /SMR
01AA
REF KZ999 BICYCLE-001 Bicycle XB
1 1 EA KZ999 BICYCLE-001/1 .Frame assembly PAODD
2 1 EA KZ999 BICYCLE-001/2A . .Seat, assembly PGOOF
2 1 EA KZ999 BICYCLE-001/2B . .Cruiser Seat, assembly PGOOF
3 1 EA KZ999 BICYCLE-001/3 . .Steering system PAFFD
4 1 EA KZ999 BICYCLE-001/4 . .Drive train system PAFFD
5 1 EA KZ999 BICYCLE-001/5 . .Brake sub-system PAFFD
6 1 EA KZ777 LRU1001 . .Light system PAFFD
7 1 EA KZ888 WH-001 . .Wheel, assembly rear PAFFD
8 1 EA KZ888 WH-002 . .Wheel, assembly front PAODD
9 1 EA KZ888 CP-001 . .Computer PAOZZ
Filtering is on: ALL S1000DBIKE-AAA-D00-00-00-01AA-941A-D Page 1

Applicable to: Mountain bicycle and Brook Copyright (C) 2008 by each of the S1000DBIKE-AAA-D00-00-00-01AA-941A-D
Filtering is on: ALL S1000DBIKE-AAA-D00-00-00-01AA-941A-D Page 2

Wiring data
Field description
 
Table of contents
Title
Wiring data - Field description
Wire number The wire number is the unique identifier for all electrical wires installed on the bicycle. Wire type Wire type identifies the
electrical wire in coded form, eg AP. Wire gauge Wire gauge identifies the gauge of the wire in coded form, eg. 010. Wire part number
Wire part number gives the part number of the wire. Harness ident Harness ident identifies the harness in which the wire is pre-
assembled. Wire sequential number Contains the sequential number of the wire, e.g. in the harness. Wire information circuit code
Contains the identifier of the circuit to which the wire belongs. Wire information wire section identification Contains the identifier of the
section to which the wire belongs. Length Length identifies the length of the wire. The given value is approximately 10% higher than
necessary to install the wire on the bicycle. Color Color identifies the color of the wire sheating. Twisting Twistig identifies wires, which are
twisted together with a unique identifier. Electric ident Electric ident shows the electrical identification, to which the wire is connected. It
is available for all electrical equipment, eg L1. Contact Contact identifies the electrical contact to which the wire is connected. Group code
Identifies wires, which are connected to the same terminal lug. Screens Screens identifies all screens that shield the wire. Wires shielded
by the same screen are identified by the same screens value. Responsible partner company The responsible partner company indicates
the company responsible for the integration of the wire to the bicycle. Feed-through Identifies bunges through which the wire is routed.
Next higher assembly Identifies the next higher assenbly, in which the wire is installed. Harness ident Harness ident identifies pre-
assembled wires, which are installed on the bicycle. Harness Part number Harness part number gives the part number of the harness
identified by the harness ident. Harness variant Harness variant identifies the variant of the harness in addition to the harness part
number. Harness issue Harness issue identifies the production variant of the harness in addition to the harness part number. Harness
nomenclature Harness nomenclature identifies the harness by using a specific name. Harness separation code Harness separation code
gives the separation code of the harness. Minimum temperature Minimum temperature gives the minimum environment temperature in
which the harness can be used. Maximum temperature Maximum temperature gives the maximum environment temperature in which the
harness can be used. Harness environment Harness environment indicates that a harness is used in high vibriation or/and hydraulic areas.
Harness sleeve Gives the part number and/or the material of the sleeves used on the harness. Responsible partner company The
responsible partner company indicates the company responsible for the integration of the harness to the bicycle. Electric ident Electric
ident shows the electrical identification, which is available for all electrical equipment, eg L1. Part identification Part identification shows
the part number of the equipment. In most cases the part number is identical to the part desciption. Location Location shows the
installation position of the equipment on the bicycle. Next higher assenmbly Next higher assenmbly identifies the box or panel, in which
the equipment is installed. Position on next higher assenmbly Gives the position on the next higher assenmbly, in which the equipment is
installed. Maximum number of mounting positions Gives the maximum number of mounting positions on the next higher assembly. Sibling
plug identification Sibling plug identification contains the electric ident of the mating connector. Transverse link Transverse link shows
external or internal electrical connections of the equipment. Responsible partner company The responsible partner company indicates the
company responsible for the integration of the equipment to the bicycle. Quantity Gives the quantity of multiple occurence equipment.
Applicable to: All Copyright (C) 2008 by each of the following or... S1000DLIGHTING-AAA-D00-00-00-00AA-029A-A
Filtering is on: ALL S1000DLIGHTING-AAA-D00-00-00-00AA-029A-A Page 1

Electrical system
Description of how it is made and its function
 
Table of contents
Title
Electrical system - Description of how it is made and its function
1 Lighting system
1 Lighting system
The illustration that follows (see Figure 1) shows the lighting system of the bicycle.
S1
Rel
Bat
L1 L2
G
Gen
Figure 1. Lighting system

Wiring
Equipment lists
 
Table of contents
Title
Wiring - Equipment lists
Reference designator Part Location NH Sibling Plug Ident Transverse Connection Responsible
number Assy Link List Class Partner
Company
L1 (exact) Front light
Handle bars 16 UK MoD
L2 (exact) Rear lightSeat post 16 UK MoD
Batt (exact , Mfc: F0001 , Orig: Battery Frame ELO- 16 UK MoD
orig01 , Context ID: PN-AC- Box
12561) (exact)
Gen (exact) Generator Steering 16 UK MoD
tube
Rel (exact) Relay Frame ELO- 10 UK MoD
Box
(exact)
VV1 (exact) Distribution Frame ELO- 07 UK MoD
module Box
(exact)
S1 (exact) Switch Handle bars ELO- 15 UK MoD
Box
(exact)
C_Batt (exact , Mfc: F0001 , Connector Frame ELO- C_Bike (exact) 3 UK MoD
Orig: orig01 , Context ID: PN-AC- Box
12561) (exact)
C_Bike (exact) Receptacle Frame ELO- C_Batt (exact , Mfc: F0001 , 3 UK MoD
Box Orig: orig01 , Context ID: PN-
(exact) AC-12561)
Diode (exact) Diode FrameFrame ELO- 18 UK MoD
Box
(exact)
ELO-
Box
(exact)
Sensor (exact) Speed Steering 16 UK MoD

sensor tube
T01 (exact) Tachometer Handle bars 16 UK MoD
ELO-Box (exact) Electronic Frame 13 UK MoD
Box 01
FT1 (exact) GT-002-WD Frame ELO- 11 UK MoD
Box
(exact)
Box
(exact)
Box
(exact)

Wiring
Wire list
 
Table of contents
Title
Wiring - Wire list
State ID Connection Information

active FL1AA
FROM TO Wirecode : AP
(Gauge:
Reference : L1 (exact) Reference : VV1 (exact)
proj=010)
designator designator
Contact Info : Contact Info :
Contact Contact P/N : W2201-K
Ident : + Ident : 1+ Harness : Lamp1
P/N : P2201-P ID
Connection Code Wire Seq : 1
El. : CO Val. Connection Code No.
Potential 1 El. : TMG Circuit ID : 234
Potential Val. 1 Section : 567
Network Analysis ID
BG Val.
Code Twists : Lamp1, 1
1
01
SG Val. Length : 1000
1 Color : red
RPC : UK MoD
CO Val. Routing : Hole ID: 1
1
Func:
Network Analysis FT3
Code (exact)
03
active FL2AA
(Gauge:
proj=010)
Contact Contact P/N : 23-4567
Ident : - Ident : 1- Harness : Lamp1
ID
Connection Code Connection Code Wire Seq : 2
El. : CO Val. El. : TMG No.
Potential 2 Potential Val. 1 Twists : Lamp1, 1
BG Val. Length : 1000
Network Analysis
1 Color : blue
Code
01 SG Val. RPC : UK MoD
2 Routing : Hole ID: 2
CO Val. Func:
5 FT3
(exact)
Network Analysis
Code
03
notactiv NC1VI
FROM
Reference : VV1 (exact)

designator
Contact Info :
Contact
Ident : 4+
Connection Code
El. : TMG
Potential Val. 1
BG Val.
1
SG Val.
1
CO Val.
4
Network Analysis
Code
03
active RL1AA
(Gauge:
proj=010)
Contact Contact Harness : Lamp2
Ident : + Ident : 2+ ID
P/N : P2201-P Wire Seq : 1
Connection Code No.
El. : CO Val. Connection Code Circuit ID : 134
Potential 1 El. : TMG Section : 467
Potential Val. 1 ID
Network Analysis Twists : Lamp2, 1
BG Val.
Code
1 Length : 1500
01
SG Val. Color : red
1 RPC : UK MoD
Routing : Hole ID: 3
CO Val.
2 Func:
FT3
Network Analysis (exact)
Code
03
active RL2AA
(Gauge:
proj=010)
Contact Contact Harness : Lamp2
Ident : - Ident : 2 - ID
P/N : P2201-M Wire Seq : 2
Connection Code No.
El. : CO Val. Connection Code Twists : Lamp2, 1
Potential 2 El. : TMG
Potential Val. 1 Length : 1500
Network Analysis Color : blue
BG Val. RPC : UK MoD
Code
1 Routing : Hole ID: 4
01
SG Val. Func:
2 FT3
CO Val. (exact)
6
Network Analysis
Code
03
active GE2AA
(Gauge:
Reference : Gen (exact) Reference : VV1 (exact)

designator designator proj=010)

Contact Info : Contact Info : Wire Seq : 2
Contact Contact
No.
Ident : GND Ident : 3 -
Length : 500
P/N : P2201-M
Connection Code RPC : UK MoD
El. Potential : CO Connection Code Routing : Hole ID: 2
Val. 2 El. : TMG
Func:
Potential Val. 1
Pot. Conn. : 1 FT2
Order BG Val. (exact)
1
Network Analysis
Code SG Val.
01 2
Group Code CO Val.

G1- 7
Network Analysis
Code
03
active BT2AA
(Gauge:
Reference : Batt (exact , Mfc: F0001 , Reference : C_Batt (exact , Mfc: F0001 ,
proj=010)
designator Orig: orig01 , Context ID: PN- designator Orig: orig01 , Context ID: PN-
AC-12561) AC-12561)
Harness : Batt_01
Contact : Contact :
Contact Contact ID
Info Info
Ident : - Ident : - Wire Seq : 2
Wire Install Direction : A Wire Install Direction : B No.
Twists : Batt, 1
Connection Code Connection Code
El. Potential : CO Val. 2 El. Potential : CO Val. 2 Length : 400,
critical
Network Analysis Code Network Analysis Code Color : black
01 02 RPC : UK MoD
NHA : ELO-Box
(exact)
active GE1AA
(Gauge:
Reference : Gen (exact) Reference : Rel (exact)
proj=010)
Connection Code Contact Wire Seq : 1
El. Potential : CO Ident : 2 No.
Val. 1 Function : Generator Length : 500
mode RPC : UK MoD
Pot. Conn. : 1 Routing : Hole ID: 1
Order Connection Code
El. : BG Val. 2 Func:
Network Analysis FT2
Potential
Code SG Val. 2 (exact)
01
CO Val.
Group Code 102
G1+
Network Analysis
Code
04
active GE3AA
(Gauge:
Reference : Gen (exact) Reference : Diode (exact)
proj=010)
El. Potential : CO Ident : A No.
Val. 1 Length : 500
Pot. Conn. : 2 El. : BG Val. Routing : Hole ID: 3
Order Potential 1
Network Analysis SG Val. Func:

Code 1 FT2
01 (exact)
CO Val.
Group Code 1
G2+
Network Analysis
Code
04
active GE3AB
(Gauge:
Reference : Gen (exact) Reference : Diode (exact)
proj=010)
El. Potential : CO Ident : A No.
Val. 1 Length : 500
Pot. Conn. : 3 El. : BG Val. Routing : Hole ID: 4
Order Potential 1
Func:
Network Analysis SG Val. FT2
Code 1 (exact)
01
CO Val.
Group Code 1
G2+
Network Analysis
Code
04
active BT1AA
(Gauge:
Reference : Batt (exact , Mfc: F0001 , Reference : C_Batt (exact , Mfc: F0001 ,
proj=010)
designator Orig: orig01 , Context ID: PN- designator Orig: orig01 , Context ID: PN-
AC-12561) AC-12561)
Harness : Batt_01
Contact : Contact :
Contact Contact ID
Info Info
Ident : + Ident : + Wire Seq : 1
Wire Install Direction : A Wire Install Direction : B No.
Twists : Batt, 1
El. Potential : CO Val. 1 El. Potential : CO Val. 1 Length : 400,
critical
Network Analysis Code Network Analysis Code Color : red
01 02 RPC : UK MoD
NHA : ELO-Box
(exact)
active BA1AA
(Gauge:
Reference : C_Bike (exact) Reference : S1 (exact)
proj=010)
Contact Contact Wire Seq : 1
Ident : + Ident : Batt No.
Length : 1200
Connection Code Connection Code RPC : UK MoD
El. : CO Val. El. : BG Val. Routing : Hole ID: 1
Potential 1 Potential 1
Func:
SG Val. FT1
Network Analysis
1 (exact)
Code
02 CO Val. NHA : ELO-Box
1 (exact)
Network Analysis
Code
04
active BA1AB
Reference : S1 (exact) Reference : Rel (exact) (Gauge:

Contact Contact
Ident : ON Ident : 3 Wire Seq : 1
Function : Battery No.
Connection Code Length : 1000
mode
El. : BG Val. 1 RPC : UK MoD
Potential Connection Code Routing : Hole ID: 2
SG Val. 1
El. : BG Val. 2
CO Val. Potential Func:
SG Val. 1 FT1
102
CO Val. (exact)
Network Analysis 103 NHA : ELO-Box
Code (exact)
04 Network Analysis
Code
04
active BA2AA
(Gauge:
Reference : C_Bike (exact) Reference : VV1 (exact)
proj=010)
Ident : - Ident : 4 - No.
P/N : P2201-M Length : 200
El. : CO Val. Connection Code NHA : ELO-Box
Potential 2 El. : TMG (exact)
Potential Val. 1
Network Analysis
BG Val.
Code
1
02
SG Val.
2
CO Val.
8
Network Analysis
Code
03
active LL1AA
(Gauge:
Reference : Rel (exact) Reference : VV1 (exact)
proj=010)
Ident : 1 Ident : 3+ No.
P/N : P2201-P Length : 500
El. : BG Val. Connection Code NHA : ELO-Box
Potential 2 El. : TMG (exact)
Potential Val. 1
SG Val.
1 BG Val.
1
CO Val.
1 SG Val.
1
Network Analysis
CO Val.
Code
3
04
Network Analysis
Code
03
active GE4AA

Reference : Gen (exact) Reference : Rel (exact) (Gauge:

Contact Connection Code
Wire Seq : 4
Ident : GND El. : BG Val.
No.
Potential 1
Connection Code Length : 500
El. Potential : CO SG Val. RPC : UK MoD
Val. 2 1 Routing : Hole ID: 4
Pot. Conn. : 2 CO Val. Func:

Order 1 FT2
(exact)
Network Analysis
Network Analysis
Code
Code
01
04
Group Code
G1-
logconn GE5AA
FROM TO
Reference : Diode (exact) Reference : Rel (exact)

Ident : K El. Potential : BG
Val. 1
Connection Code
El. : BG Val. SG
Potential 1 Val. 1
SG Val. CO
1 Val. 2
CO Val. Pot. Conn. : 1

2 Order
Network Analysis
Network Analysis
Code
Code
04
04
Group Code
R1
logconn GE5AB
FROM TO
Reference : Diode (exact) Reference : Rel (exact)

Ident : K El. Potential : BG
Val. 1
Connection Code
El. : BG Val. SG
Potential 1 Val. 1
SG Val. CO
1 Val. 2
CO Val. Pot. Conn. : 2

2 Order
Network Analysis
Network Analysis
Code
Code
04
04
Group Code
R1
active T001
FROM TO Wirecode : XY
(Gauge:
Reference : T01 (exact) Reference : Sensor (exact)
proj=010)
Contact Contact Harness : Tacho

Ident : 1 Ident : A ID
Wire Seq : 001

No.
Screen : 2 Screen : 2
Screens : SCT1
Order Order
El. : CO Val. El. : CO Val. Twists : Tacho, 1
Length : 1200
Color : yellow
Network Analysis Network Analysis
RPC : UK MoD
Code Code
01 01
Screens : lvl: 00 type: 01 style: Screens : lvl: 00 type: 01 style:
00 00
active T002
FROM TO Wirecode : XY
(Gauge:
Reference : T01 (exact) Reference : Sensor (exact)
proj=010)
Contact Contact Harness : Tacho
Ident : 2 Ident : B ID
Wire Seq : 002
Connection Code Connection Code No.
Screen : 3 Screen : 3 Screens : SCT1
Order Order
El. : CO Val. El. : CO Val. Twists : Tacho, 1
Length : 1200
Color : green
Network Analysis Network Analysis RPC : UK MoD
Code Code
01 01
Screens : lvl: 00 type: 01 style: Screens : lvl: 00 type: 01 style:
00 00
logconn ND1
FROM TO
Reference : T01 (exact) Reference : T01 (exact)

Order Order
Special : 100 El. Potential : CO Val.
Conn. 0
El. : CO
Potential Val. 0 Network Analysis
Code
Network Analysis 01
Code Screens : SCT1, lvl: 01 type: 03
01 style: 01
Screens : lvl: 01 type: 03 style:
01
logconn ND2
FROM TO
Reference : Sensor (exact) Reference : Sensor (exact)

Order Order
Special : 100 El. Potential : CO Val.
Conn. 0
El. : CO
Potential Val. 0 Network Analysis
Code
Network Analysis 01
Code Screens : SCT1, lvl: 01 type: 03
01 style: 01
Screens : lvl: 01 type: 03 style:
01

Wiring
Loom list
 
Table of contents
Title
Wiring - Loom list
Identification Information RPC

UK MoD
Harness ID: Batt_01 P/N : Battery_123
Context PN-AC-12561 Harness Variant : 123
MFC F0001 Harness Issue : A
ORIG orig01 Harness Name : Battery harness
EMC Code : LS1
Temperature(s) : max. 500 degF
Environment : VIBR
HYDR
Sleeve : Material: Teflon
P/N: SPN1234
UK MoD
Harness ID: Tacho P/N : Tachometer_101
Harness Variant : 101
Harness Issue : A
Harness Name : Tachometer harness
EMC Code : LS2
Temperature(s) : min. -10 degC
max. 60 degC
Environment : VIBR
Sleeve : Material: Silicon
UK MoD
Harness ID: Lamp1 P/N : Front light_501
Harness Issue : A
Harness Name : Front light harness
EMC Code : LS3
Temperature(s) : min. -10 degC
Sleeve : P/N: SPN1234
P/N: SPN4321
UK MoD
Harness ID: Lamp2 P/N : Rear light_503
Harness Issue : A
Harness Name : Rear light harness
EMC Code : LS3
Environment : HYDR

Lights
Manual test
       
Table of contents
Title
Lights - Manual test
Procedure
Required person
Procedure
Set the lights to on.
Make sure that all the lights operate correctly.

None
Condition Reference

Lights
Observed fault
       
Table of contents
Title
Lights - Observed fault
References
Reference Title
S1000DLIGHTING-AAA-D00-00-00-00AA-341A-A S1000DLIGHTING-AAA-D00-00-00-00AA-341A-A
Fault Fault description Context information

code Remarks Remarks
Remarks
NYCJD02 The lights are set to the dim During use or maintenance Bulb
position. Manufacturer: KZ111
Part No.: LiRUs-L1-11
Test
References
Type Code Test description Data
Operation O-001 Test the bulbs 1 Days
Reference Title
S1000DLIGHTING-AAA-D00-00-00-00AA-341A- S1000DLIGHTING-AAA-D00-00-00-00AA-341A-
A A
References
Reference Title
Remarks
This is the data module you would visit when you notice that the lights do not operate correctly.
Applicable to: All Copyright (C) 2008by each of the following org... S1000DLIGHTING-AAA-D00-00-00-00AA-413A-A

Lighting
Assemble, install and connect procedures
       
Table of contents
Title
Lighting - Assemble, install and connect procedures
Procedure
References
Reference Title
S1000DLIGHTING-AAA-D00-00-00-01AA-941A-D S1000DLIGHTING-AAA-D00-00-00-01AA-941A-D
Required conditions
Condition Reference
Bike is stationary
Production maintenance data

Work Area
Type Number Name
Zone 200
Zone 300
Support equipment
BSK-TLST-001 1 EA
Procedure
Impacted zones: and
Remove the lighting system from the packaging.

Make sure that the components in the package are the same as those on the S1000DLIGHTING-AAA-D00-00-00-01AA-941A-D
Install the light bulb to the front and rear lights (refer to S1000DLIGHTING-AAA-D00-00-00-00AA-921A-A).
Attach the front light fitting on the top of the handlebar.
Apply the protective strip around the handlebar.
Pull the clamp open and put it around the protective strip with the light connector at the top.
Install the washer on the screw.
Use the correct screwdriver from the 1 and tighten the screw into the hole at the bottom of the clamp. This safeties the clamp to
the handlebar.
Attach the rear light fitting to the rear triangle of the bike frame.
Apply the protective strip around one of the two rear triangle up-tubes.
Pull the clamp open and put it around the protective strip. Make sure the light connector points rearwards.
Install the washer on the screw.
Use the correct screwdriver from the 1 and tighten the screw into the hole at the bottom of the clamp. This safeties the clamp to
the tube.
Attach the light with the white glass to the front connector.
Attach the light with the red glass to the rear connector.

None
Condition Reference

Light system
Illustrated Parts Data - IPD
 
Table of contents
Title
Light system - Illustrated Parts Data - IPD
9
10 2
8
11
18
7 19
1 17
16
6
5
13
12
4
14
3
15
000
Figure 01AA. Light system
Units *Usable on
per Part No. / code assy ICY
Figure Item NCAGE Nomenclature
assembly NSN .mv/Effect /SMR
01AA
REF KZ777 LRU1001 Light system PAFFD
1 1 EA KZ777 LRU1010 .Light, sub-assembly front PAODF
2 1 EA KZ777 LRU1011 . .Light, main body PAFFD
3 1 EA KZ777 LRU1012 . . .Light, base PAFFD
4 1 EA KZ777 LRU1013 . . . . Seal PAFFD
5 2 EA KZ777 LIRUS-L1-10 . . .Battery PAFFD
6 1 EA KZ777 LRU1018 . .Lens, assembly PAFFD
7 1 EA KZ777 LRU1019 . . .Lens sub-assembly PAFFD
8 1 EA KZ777 LRU1022 . . . . Seal PAFFD
9 1 EA KZ777 LRU1020 . . .Reflector PAFFD
10 2 EA KZ777 LIRUS-L1-11 . . . . Bulb PAFFD
11 1 EA KZ777 LRU1026 . .Ledningsløkke PAFFD
12 1 EA KZ777 LRU-B001 .Bracket, light mounting PAFFD
13 1 EA KZ777 LRU-B003 . .Clip PAFFD
14 1 EA KZ777 LRU-B124 * *Screw,special PAFFD
15 1 EA KZ777 LRU-B556 * *Washer,flat PAFFD
16 1 EA KZ777 LRU-B789 . . .Grip,strip PAFFD
17 1 KZ777 LRU2010 .Light, sub assembly rear PAFFD
Filtering is on: ALL S1000DLIGHTING-AAA-D00-00-00-01AA-941A-D Page 1

18 1 EA KZ777 LRU1011 . .Light, main body PAFFD
19 1 KZ777 LRU2018 . .Lens, assembly rear PAFFD

20 1 KZ777 LIRUS-B1-12F . . .Front Bulb PAFFD
21 1 KZ777 LIRUS-B1-12R . . .Rear Bulb PAFFD
22 2 KZ777 LIRUS-G1-10 . . .Glass PAFFD
23 1 KZ777 LIRUS-G1-10H . . .Glass with hole PAFFD
Applicable to: All Copyright (C) 2008 by each of the following or... S1000DLIGHTING-AAA-D00-00-00-01AA-941A-D
Filtering is on: ALL S1000DLIGHTING-AAA-D00-00-00-01AA-941A-D Page 2

Fork
Manual test
       
Table of contents
Title
Fork - Manual test
Procedure
Required person
Procedure
Climb on the bicycle.
Turn right and left several times.
Ride forward the bicycle.
Make sure that the wheels are stable.
Push in the fork.
Make sure that no oil or air is leaking out the fork.

None
Condition Reference

Fork
Remove procedures
       
Table of contents
Title
Fork - Remove procedures
Procedure
References
Reference Title
Procedure
Remove the stem, refer to: S1000DBIKE-AAA-DA2-10-00-00AA-520A-A
Remove the headset, refer to: S1000DBIKE-AAA-DA2-30-00-00AA-520A-A
Push the fork downwards to remove it from the frame
Put the frame on the floor

None
Condition Reference

Bicycle
Service Bulletin - Replacement of standard forward fork by telescopic fork
 
Table of contents
Title
Bicycle - Service Bulletin - Replacement of standard forward fork by telescopic fork
1 Compliance
References
Reference Title
BRAKE-AAA-DA1-00-00-00AA-341A-A BRAKE-AAA-DA1-00-00-00AA-341A-A
S1000DBIKE-AAA-D00-00-00-01AA-941A-D S1000DBIKE-AAA-D00-00-00-01AA-941A-D
S1000DBIKE-AAA-D00-00-01-00AA-341A-A S1000DBIKE-AAA-D00-00-01-00AA-341A-A
S1000DBIKE-AAA-D00-00-01-00AA-933A-A Headset - Removal/Installation
S1000DBIKE-AAA-D00-00-01-00AA-93AA-A S1000DBIKE-AAA-D00-00-01-00AA-93AA-A
S1000DBIKE-AAA-D00-00-01-00AB-720A-A S1000DBIKE-AAA-D00-00-01-00AB-720A-A
SB Management Information
Compliance
Optional
Task type
Modification
Product modification list

1. Installation of telescopic fork with 100mm clearance (A2002) (major)
Product impact list

1. (Weight) +0.5 kg / +1.1 lbm
Concurrent SB list
No information
Accomplishment limit
1. Basic limit
At customer convenience
2. Grace period
Not Applicable
Time assessment
1. Conditions:
References

Reference Title
S1000DBIKE-AAA-D00-00-01-00AA-933A-A Headset - Removal/Installation
2. Duration
1h
3. Estimated time
1h
Original issue date

2011-03-31
SB Approval
S1000D-020AA
SB Approval references
References
Reference Title
S1000DBIKE-AAA-D00-00-01-00AA-933A-A Applicable to: Mountain bicycle and Brook trekker and Mk9
S1000DBIKE-AAA-DA0-30-00-00AA-520A-A Applicable to: Mountain bicycle and Brook trekker and Mk9
S1000DBIKE-AAA-D00-00-01-00AA-93AA-A Applicable to: Mountain bicycle and Brook trekker and Mk9
S1000DBIKE-AAA-D00-00-01-00AB-720A-A Applicable to: Mountain bicycle and Brook trekker and Mk9
Generic information
1. Passenger comfort affected (YES)
2. Structural life extension (YES)
3. Product operation affected (YES)
SB Revision Information
1. Revision history
Revision history
This document is the first issue of the Service Bulletin
2. Revision sequence
Revision sequence
Original Issue date
Revision history
This document is the first issue of the Service Bulletin
Revision sequence
Original Issue date
SB Summary
1. Reason
Reason
A lot of customers asked for the improvement of the front hanging in order to use the bike in more severe conditions.
2. Description
Description
Replacement of the fork
3. Compliance
Compliance
4. Applicability
Applicability
This Service Bulletin is applicable to bikes manufactured between 01/05/2001 and 30/09/2009
Configuration no. 2 covers mountain bicycle Brook trekker version Mk9
5. Concurrent requirements
Concurrent Requirements
No information
6. Manpower
Manpower
S1000DBIKE-AAA-D00-00-01-00AA-933A-A
Total workload
Estimated time
7. Industry support information
Industry Support Information
For any issue with the fork assembly, please contact your local retailer.
The UK MoD Company only provides assistance via its network of retailers.
8. General evaluation
General evaluation
EVALUATION TABLE
Passenger comfort
affected
Structural life
extended
Bike operation
affected
SB Planning Information
1. Applicability
Applicability
This Service Bulletin is applicable to bikes manufactured between 01/05/2001 and 30/09/2009
The S/N of the impacted bikes are: U8025 P/N : U8025 P/N :
Configuration no. 2 covers mountain bicycle Brook trekker version Mk9
2. Concurrent requirements
Concurrent Requirements
No information
3. Reason
Reason
Objective :
Improvement of the bike's front hanging.
Problem and effect :
A lot of customers would like to use the bike in more severe conditions.
Solution :
Replacement of the fork.
4. Description
Description
Replacement of the original fork

by telescopic fork with a 100 mm clearance
5. Compliance
Compliance
1 Compliance

The modification should be made in accordance with the customer's availability, but within the following limits (before
marked wear of the frame)
Table 1. Accomplishment time scale
Limit Grace period
6. Approval
Approval
This modification has been approved and certified in conformity with the requirements of the S1000D community.
Approval No. .
7. Manpower
Manpower
S1000DBIKE-AAA-D00-00-01-00AA-933A-A
Job Set-up 5 min
Removal 20 min
Install 30 min
Testing 5 min
Total workload
Estimated time
8. Weight and balance
Weight and Balance
Effect on weight
9. Electrical load data
Electrical Load Data
No information
10. Software accomplishment summary
Software Accomplishment Summary
No information
11. Referenced documentation
Referenced Documentation
Removal of the headset S1000DBIKE-AAA-DA2-30-00-00AA-520A-A
Install of the headset S1000DBIKE-AAA-DA2-30-00-00AA-720A-A
Removal of the stem S1000DBIKE-AAA-DA2-10-00-00AA-520A-A
Install of the stem S1000DBIKE-AAA-DA2-10-00-00AA-720A-A
Testing of the brakes BRAKE-AAA-DA1-00-00-00AA-341A-A
12. Documentation affected
Documentation Affected
IPD S1000DBIKE-AAA-D00-00-00-01AA-941A-D
13. Industry support information
Industry Support Information
For any issue with the fork assembly, please contact your local retailer.
The UK MoD Company only provides assistance via its network of retailers.
SB Material Information
Material type:
Ident: Issue: Procurable: Supplier:
Name QTY Remarks
Saw tool set 1
General grease
Fork 1
Removed spare set
Wheel axis
Tool type: Set of material or individual material specific to the Service Bulletin
Ident: BSK-TLST-200 Name: Saw tool set Issue: 001 Procurable: 1 Supplier: manufacturer
Name PN / MFC Remarks

Saw tool BSK-TW-100 / KZ666

Threading tool BSK-THR-3001 / KZ666
Supply type: Set of material or individual material not specially built for the Service Bulletin
Ident: Name: Issue: Procurable: 1 Supplier: any
General grease LL-005 / KZ222
Spare type: Set of material or individual material specific to the Service Bulletin
Ident: FK-TEL1002 Name: Issue: 001 Procurable: 1 Supplier: manufacturer
Fork FK-TEL1002 / KZ666
Spare type removed:

Ident: Name: Removed spare set Issue: Procurable: Supplier:
Name PN / MFC Replacement P/N Remarks
Fork FK-1000 / KZ666 Interchange P/N: FK-TEL1002 / KZ666
Conical expansion washer St-001-05 / KZ555
Spare type removed: Set of re-identified material

Ident: Name: Issue: Procurable: Supplier:
Name PN / MFC Replacement P/N Remarks
Wheel axis BSK-AXS-2000 / KZ666 Altered to P/N: BSK-AXS-2001 / KZ666
SB Accomplishment Instructions
References
Reference Title
SB Additional Information
No information

Bicycle axis
Modification procedures
       
Table of contents
Title
Bicycle axis - Modification procedures
Procedure
References
Reference Title
Support equipment
Saw tool set BSK-TLST-200_001 1 EA
Spares
Wheel axis KZ666 / BSK-AXS-2001 1 EA
Procedure
Use the ( Saw tool (BSK-TW-100)) to saw the ( Wheel axis (BSK-AXS-2000)).
Use the ( Threading tool (BSK-THR-3001)) when the saw is unbent.
Put the frame on the floor.

None
Condition Reference
Applicable to: Mountain bicycle and Brook Copyright (C) 2008 by each of the S1000DBIKE-AAA-D00-00-01-00AA-93AA-A
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Manual - Bike - (AMM) (D00 - Bike)

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Manual - Bike - (AMM) (D00 - Bike)

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Flatirons Solutions AMM

PRINTED: 10-DEC-2019; 02:47PM.

Description of how it is made

1 Physical description of a bicycle

Figure 1. Complete bicycle

Table 1. Bicycle parts

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Item Refer to Definition

Wheels The wheels include these parts:

Rear wheel (Figure 1 item 7)

Front wheel (Figure 1 item 3)

Gears (Figure 1 item 2) The gears include:

Brakes (Figure 1 item 1) The brakes include:

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1 Functional description of a bicycle

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bicycle. Refer to S1000DBIKE-AAA-DA1-00-00-00AA-041A-A for a description of the braking system.

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Description attributed to crew

Table 1. shifter correlation

Shifter Location Affected Gears

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Table 2. brake lever correlation

Brake Lever Location Affected Brake

Left This lever operates the front brake.

Right This lever operates the rear brake.

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Pre-operation procedures (crew)

Figure 0. Hydraulic brake function

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IF THE POSITION OF THE PADS IS TOO LOW ON THE RIM, AS SHOWN IN

SPOKES TO BE TORN OUT OF THEIR MOUNTINGS.

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Examine the condition of the wheels.

Requirements after job completion

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Normal operation procedures (crew)

1. Link Wire ................................................................................................

Tire Pressures Min Max

Off Road 35lbs 40lbs

On Road 55lbs 60lbs

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DO NOT RIDE WITH A CRACKED STEM

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Post-operation procedures (crew)

Remove the lubricant which is more than the necessary.

Requirements after job completion

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Other procedures to clean

THEM IMMEDIATELY IN CLEAN WARM WATER.

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THEM IMMEDIATELY IN CLEAN WARM WATER.

CAUSE DAMAGE TO THE PARTS.

APPLY DETERGENT B (BSK-TLST-001-15) IN ACCORDANCE WITH THE INSTRUCTION ON THE CONTAINER.

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Figure 1. Cleaning the bike

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Applicable to: Mountain bicycle and Brook trekker and Mk9

Requirements after job completion

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Other procedures to clean

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THEM IMMEDIATELY IN CLEAN WARM WATER.