ROTOR SYSTEM RS4X

SERVICE MANUAL

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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 carter that cover the spider bearing with the Torx bolt tool so the bearing appears like this

With the help of a mallet or nylon hammer, take off the axle

Now you can take off the left bearing 61903RS; and disassemble the axle from the cartridge.

Take off the inner positioning tube

Take off the orings, be care not to lose anyone.

Take off the links and the last orings.

Unscrew the right crank bolt 8mm allen key wrench. You could use the left crank in order to ease this operation, if the bolt is too tight.

Take off the right crank using the shortthreaded tool from the RS4X tool kit. Tread it into the axle, from the right crank side.

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

Unscrew the tool.

Attach the cartridge tool with a vice. There are two parallel planes to fit it to the vice.

Place the cartridge into the tool in this position.

Take off the seal from the eccentric with an screwdriver. Look at the seal so you can install it in the correct direction later.

Tap on the eccentric with the mallet so the eccentric gets into the fist step of the tool. (Look at the next step) Be careful. Do not hit the power plate, it could be damaged.

Take off the snapring from the eccentric

Be careful not to damage this snapring because is necessary to fit the new bearing.

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

The spider bearing will lay over the tool as you can see and the eccentric goes out to the bottom.

With the long (non threaded) tool we will be able to take off the right bearing from the eccentric. Insert the tool since the tool touches the bearing (RNA6102)

Place the eccentric over a consistent surface and tap the tool with a mallet in order to break the Loctite which secures the bearing. This bearing could be hardly attached to the eccentric. In this case it could be necessary the use of one press.

Then you have to place the eccentric over the arms of the vice so the bearing could get out between them.

Thats all. NOTE: The RD2 model have a carter in the place of the inner chainring. You have to disassemble this carter with a torx tool before initiate the disassembly process

Assembly process
First of all, remove the high strenght threadlock adhesive residue from the power plate (spider) and the eccentric with the help of a cutter or sharp screwdriver.

Installation of the new spider bearing on the eccentric.

Place the new bearing into the cartridge tool as you can see. Dont care the side you place the bearing.

Put some high strenght treadlocker adhesive around the eccentric as you can see. Extend it prope.

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

Place the snapring into his position as you can see.

With the help of the long nose plier, secure the snapring into his hole at the eccentric. This step is important because the snapring could scratch inside the spider. The snaprng has to be perfectly circular and without deformations.

Place a little bit of high strenght threadlock adhesive into the spider, but only the sides, not at the bottom, and extend it properly. If you use a high amount of adhesive the bearing could not work properly.

Place the spider (power plate) downwards over the Rotor cartridge tool and the eccentric over the spider as you can see. Tap with the mallet over the eccentric so the bearing fits into his place.

Right side spindle bearing installation.

You could install or uninstall this bearing without operating the spider. In this tutorial I assembled the spider bearing the first and this bearing the second, but you could do what you prefer. First of all, apply some high strenght threadlock adhesive into the eccentric.

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

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

Installing the right crank into the spindle.

Place the right crank into a flat surface and with the help of a nylon hammer or a mallet, insert the spindle into the right crank.

Put a pair of drops of high strenght adhesive into the spindle threading and tighten the right crank bolt.

Insert the inner positioning tube into the spindle. Put some grease on the axle and the tube.

Final assembly of the components

Put some grease all over the orings of the transfer arm, right crank and power plate and place the orings around the pivots.

Lubricate the right bearing and the seal with some grease.

Fit the links into the pivots with the R logo up. Sometimes the links could be difficult to insert into the pivots. In this case you could use the mallet in order to insert them but being careful.

Insert the spindle into the cartridge and the right crank & transfer arm into the links.

Be careful that the regulation marks and the eccentric mark are correctly positioned. This means that if you are looking 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 spindle with the seal pointing outside.

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

Put the left cup in his position.

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