rs4x service tutorial

8/4/2019 RS4X Service Tutorial

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ROTOR SYSTEMRS4X

SERVICE MANUAL

www.rotorbike.com


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Neccesary tools:

- nylon hammer (mallet)- allen key tools set- calliper- long nose plier

- external snap ring pliers- small or medium flat screwdriver- high strenght threading adhesive

such as Loctite 2701- torx bolt tool- cutter- grease- rotor RS4X tool kit

First step, remove rotor from the frame,Take off the chainrings.In the RD2 version, remove the carterthat cover the spider bearing with theTorx bolt tool so the bearing appears likethis

With the help of a mallet or nylonhammer, take off the axle


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Now you can take off the left bearing61903RS; and disassemble the axle fromthe cartridge.

Take off the inner positioning tube

Take off the orings, be care not to loseanyone.

Take off the links and the last orings.


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Unscrew the right crank bolt 8mm allenkey wrench. You could use the left crankin order to ease this operation, if the boltis too tight.

Take off the right crank using the short-threaded tool from the RS4X tool kit.Tread it into the axle, from the right crankside.

Once the tool is tightened onto the axle,tap with the mallet into the tool, so theaxle be disassembled from the rightcrank.


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Unscrew the tool.

Attach the cartridge tool with a vice.

There are two parallel planes to fit it tothe vice.

Place the cartridge into the tool in thisposition.

Take off the seal from the eccentric withan screwdriver. Look at the seal so youcan install it in the correct direction later.


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Tap on the eccentric with the mallet sothe eccentric gets into the fist step of thetool. (Look at the next step)Be careful. Do not hit the power plate, itcould be damaged.

Take off the snapring from the eccentric

Be careful not to damage this snapringbecause is necessary to fit the newbearing.


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Tap into the eccentric in order to take offthe spider bearing 61810Y

The spider bearing will lay over the toolas you can see and the eccentric goesout to the bottom.

With the long (non threaded) tool we will

be able to take off the right bearing fromthe eccentric. Insert the tool since thetool touches the bearing (RNA6102)


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Place the eccentric over a consistent

surface and tap the tool with a mallet inorder to break the Loctite which securesthe bearing. This bearing could be hardlyattached to the eccentric. In this case itcould be necessary the use of one press.

Then you have to place the eccentricover the arms of the vice so the bearingcould get out between them.

Thats all.

NOTE:

The RD2 model have a carter in the placeof the inner chainring. You have todisassemble this carter with a torx toolbefore initiate the disassembly process


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Assembly process

First of all, remove the high strenghtthreadlock adhesive residue from thepower plate (spider) and the eccentricwith the help of a cutter or sharpscrewdriver.

Installation of the new spiderbearing on the eccentric.

Place the new bearing into the cartridgetool as you can see. Dont care the sideyou place the bearing.

Put some high strenght treadlocker

adhesive around the eccentric as youcan see. Extend it prope.


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With the help of a mallet, place theeccentric into the bearing until the lip ofthe eccentric touch the bearing. Cleanthe adhesive excess.

Place the snapring into his position asyou can see.

With the help of the long nose plier,secure the snapring into his hole at the

eccentric. This step is important becausethe snapring could scratch inside thespider. The snaprng has to be perfectlycircular and without deformations.


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Place a little bit of high strenght

threadlock adhesive into the spider, butonly the sides, not at the bottom, andextend it properly.If you use a high amount of adhesive thebearing could not work properly.

Place the spider (power plate)downwards over the Rotor cartridge tool

and the eccentric over the spider as youcan see.Tap with the mallet over the eccentric sothe bearing fits into his place.


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Right side spindle bearinginstallation.

You could install or uninstall this bearingwithout operating the spider. In thistutorial I assembled the spider bearingthe first and this bearing the second, butyou could do what you prefer.First of all, apply some high strenghtthreadlock adhesive into the eccentric.

Insert the tool into the new bearing andplace them aligned with the cartridge.Tap with a mallet over the tool so thebearing fits into the eccentric.

Installing the right spindle seal in thecartridge.Put a a little bit of adhesive where theseal place and fit it into the eccentric,with the lip pointig outside.


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Installing the right crank into the

spindle.

Place the right crank into a flat surfaceand with the help of a nylon hammer or amallet, insert the spindle into the rightcrank.

Put a pair of drops of high strenghtadhesive into the spindle threading andtighten the right crank bolt.

Insert the inner positioning tube into thespindle. Put some grease on the axle andthe tube.


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Final assembly of the components

Put some grease all over the orings ofthe transfer arm, right crank and powerplate and place the orings around thepivots.

Lubricate the right bearing and the sealwith some grease.

Fit the links into the pivots with the Rlogo up. Sometimes the links could be

difficult to insert into the pivots. In thiscase you could use the mallet in order toinsert them but being careful.


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Insert the spindle into the cartridge andthe right crank & transfer arm into thelinks.

Be careful that the regulation marks andthe eccentric mark are correctlypositioned. This means that if you arelooking the Rotor from the right crank,the triangles are in the right of the crank& over the link.

Fit the left bearing 61903 into the spindlewith the seal pointing outside.


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Fit the left side (outer) positioning tube inthe spindle.

Put the left cup in his position.

You could find on-line support at [email protected]

rs4x service tutorial

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