IA Owner’s Manual 1 Electronic Wiring -1-
Felt IA Owner’s Manual Introduction . . . . . . . . . . . . . . . . . Pg. 3 Fit Chart . . . . . . . . . . . . . . . . . . . Pg. 4 1 Electronic Wiring . . . . . . . . . . . . . . Pg. 5-15 2 Mechanical Cabling . . . . . . . . . . . . . Pg. 16-24 3 Fork Installation . . . . . . . . . . . . . . . Pg. 25-29 4 Stem Installation . . . . . . . . . . . . . . . Pg. 30-32 5 Aerobar Installation . . . . . . . . . . . . . Pg. 33-54 6 Brakes Installation . . . . . . . . . . . . . . Pg.
Introduction Thank you for buying the fastest triathlon bike available, the Felt IA. Jim Felt has been utilizing the wind tunnel since 1991 and is a pioneer in the advancement of aerodynamic frame design. Using Computational Fluid Dynamics (CFD), Jim Felt and Felt engineers have designed the IA to be the fastest bike possible.
The larger footprint (lighter color) indicates the maximum reach and stack for each frame size. Colored, bold numbers show the minimum and maximum rise for each frame size. Fit Chart 740 710 470-545 685 450-520 675 Stack Envelope 450 430-500 640 415-485 430 485 507.5 540 620 410 405-475 395 450 465 Reach Envelope 520 600 505 565 The smaller, darker shaded box indicates the Felt Bicycles recommenced stack and reach envelope.
Section 1: Electronic Wiring 1 Electronic Wiring -5-
Electronic Wiring Road Map Battery to Junction B Front Derailleur Cable to Junction B Rear Derailleur Cable to Junction B Downtube Cable to Junction B Color Code Index The wires in the diagram are colorcoded for your convenience. These wires are all identically black, but for the purpose of clarity, we have colored them periodically thoughout this manual.
Electronic Wiring Parts 1 1 1. BatPac 2. Front Derailleur Wire Grommet (3mm) 3. Rear Derailleur Grommet (3mm) 4. Shimano Di2 Wires (various lengths) Electronic Wiring 2 3 4 5 6 7 5. Shimano Di2 Junction B 6. Shimano Di2 Battery 7.
Step 1 Di2 Routing a. Route a length of Brake Cable through the Cable Entry Point, through the DownTube and out the BatPac opening (located between chainstays). Tape the end of the Di2 Wire to the end of the Brake Cable and pull end of brake cable (exiting BatPac opening) until both ends of the Di2 wire are visible outside of the frame.
Step 2 a. Using the same Tape ‘n Pull Method, route the rear derailleur wire through the right dropout hole, chainstay and out the BatPac Opening. b. Route the Front Derailleur Di2 Wire through the Front Derailleur Frame Hole and out the BatPac Opening. Front Derailleur Cable to Junction B Rear Derailleur Cable to Junction B Downtube Cable to Junction B a. c. Make sure the Downtube Cable is also exiting the BatPac Opening. b. 1 c.
Step 3 a.
Step 4 Mount Battery a. Locate parts: (fig. a) fig. a 1 Electronic Wiring b. Thread Cable Ties through Di2 battery mount as pictured. (fig. b) fig. b c. Tighten Cable Ties around Shimano Di2 Battery, affixing it to the battery mount as shown. Trim excess Cable Tie. (fig. c) fig.
Step 5 a. Plug the Di2 Battery Wire into the Shimano Di2 Battery shown below. Battery to Junction B b. Insert the Di2 BatPac Assembly into the IA frame. (fig. a) fig.
Step 6 a. Continue inserting the Di2 BatPac Assembly into the IA frame as shown below. b. Once BatPac Assembly is in place as shown (fig a), fasten shut with provided M3 x 10mm bolts. fig.
Step 7 Install front and rear derailleurs and plug Shimano Di2 Wires firmly into the respective derailleurs as shown.
Step 8 Wire Grommets a. Press in any remaining grommets. Refer to below images for placement. b. If not already done, connect wires to derailleurs and Junction B.
Section 2: Mechanical Cabling 2 Mechanical Cabling -16-
Mechanical Cabling Road Map Rear Derailleur Cable to Shifter Front Derailleur Cable to Shifter 2 Mechanical Cabling Rear Brake Cable to Brake Lever -17-
Mechanical Cabling Parts 1 2 1. BatPac/ Front Derailleur Housing Stop 2. Front Derailleur Frame Grommet 3. Rear Dropout Cable Grommet (5mm) Mechanical Cabling 2 3 4 5 6 4. Derailleur Cable Housing 5. Derailleur Cables 6.
Step 1 Mechanical Cabling Begin by routing a length of Derailleur Cable Housing through the Cable Routing Insertion Area, into the downtube. 2 Mechanical Cabling Mechanical Cable Tip: to make routing easier, tape the end of the cable to the end of a second brake cable. Once the first cable is visible through the exit hole, pull through and remove tape. Both ends of the second cable should be visible exiting the frame.
Step 2 a. Route a length of Derailleur Cable into the head tube, through the downtube, under the bottom bracket and out the rear brake hole. (fig. a) b. Route the Derailleur Cable through the right dropout hole, right chainstay, and out the rear brake hole. (fig. b) (fig. a) c.
Step 3 a. The Rear Derailleur Cable Housing installation is shown below. (fig. a) b. Route the Front Derailleur Cable Housing through the Routing Insertion Area, down the downtube and out the rear brake hole. (fig. b) c. Then route the end of the Front Derailleur Cable out of the hole between the chainstays as illustrated below. (fig. c) (fig. a) (fig. c (fig.
Step 4 Install Cable Stop a. Feed a ferrule over the Derailleur Cable and press onto the Derailleur Housing. a. Feed the exposed Front Derailleur Cable throught the Front Derailleur Cable Stop as pictured. 2 Be sure the end of the Front Derailleur Cable Housing fits snugly into the hole of the Cable Stop.
Step 5 a. Fit Front Derailleur Cable Housing Stop into the frame as pictued. Fasten securely with provided M3 bolts. Tighten to 2Nm. b. Install Front Derailleur Frame Grommet. (fig. a) c. Install front derailleur and attach Front Derailleur Cable. (fig. b) 2 Mechanical Cabling fig. b fig.
Step 6 a. Fit Rear Dropout Cable Grommet as shown. (5mm conical)Be sure to press securely into frame. (fig. a) b. Install rear derailleur and plug Rear Derailleur Cable Housing into derailleur. (fig. b) fig. b fig.
Section 3: Fork Installation 3 Fork Assembly -25-
Fork Installation Instructions 1 3 1. IA Fork 2. Lower Headset Bearing 3. Upper Headset Bearing Fork Assembly 2 3 4 5 4. Upper Headset Race 5.
Fork & Headset Installation Step 1 a. Install the Carbon Compression Plug into the fork steerer tube and tighten to 5Nm. b. Slide the lower headset bearing over the fork steerer tube and push down onto the fork crown. Note: The fork has an integrated crown race.
Step 2 a. Slide fork steerer tube through frame’s head tube as shown.
Step 3 a. Install upper headset bearing and Headset Race as shown below.
Section 4: Stem Installation 4 Stem -30-
Stem Installation Parts 1 1. Headset Preload Bolt 2. Fit Washer (x4) 3. Stem Top Cap 4 2 4. Handlebar Bolt - 25mm M6 (x4) 5. Stem 3 4 5 6 7 8 6. Handlebar Bolt - 40mm M6 (x4) 7. 15mm Stem Spacer (Used with 40mm Bolt) Stem 9 8. Handlebar Bolt - 55mm M6 (x4) 9.
fig. a Step 1 Stem Installation a. Once Fork is installed, slide the Stem onto steerer tube, then place the Top Cap and tighten the Preload Bolt as needed to eliminate play in the headset. (fig. a & fig. b) fig. c b. Tighten pinch bolts to 6Nm. (fig. c) fig.
Section 5: Aerobar Installation 5 Aero Bar -33-
Section 5 Pt. 1: Basebar Routing Instructions 2 5 2 3 1. Basebar Plate Bolt (M3 x 10mm) 2. Basebar Plate 3.
Step 1 Route Di2 Wire Route Rear Shimano Di2 Shifter Wire through the Aero Basebar as shown. Electronic Wire Tip: to make routing easier, tape the end of the wire to the end of a material that is easier to route than a wire or housing. (we used a blue plastic tubing for this example) Once cable is visible through exit hole, pull through and remove tape. Step 9 Insert end of Shimano Di2 Wire into appropriate hole in Basebar as shown and pull back out through main grip opening.
Step 2 Pull Di2 Wire Through Bar a. As previously mentioned, tape end of Shimano Di2 wire to tube or brake cable. (fig. a) b. Carefully pull through the bar until the taped end exits the basebar. (Remove tape and tube or cable used to route with.) fig.
Step 3 Route Brake Housing In similar fashion to the way we previously routed the Di2 wire, we will use a brake cable to assist in routing the Brake Cable Housing. a. Route the end of a brake cable through the hole where the basebar mounts to the stem and out the right handle. (fig. a) b. Slide Brake Housing over exposed end of brake cable (which just exited the right handle) and advance it through the basebar. (fig. b) fig. b fig.
Step 4 After Brake Cable Housing is routed, remove the cable which was used to route the Brake Cable Housing as pictured. Step 5 a. Plug handlebar end of Brake Cable Housing into Brake Lever and install Brake Lever into handlebar. b. Repeat the previous 4 steps to finish Brake Cable Housing and Di2 Wire for left side of basebar.
Step 6 Basebar Routed Both Di2 Wires and Brake Cable Housing are shown routed through the Basebar properly. To Rear Brake To Front Brake * Note: Front Brake Cable Housing exposed length will vary. Trim after verifying necessary length required to reach front brake when basebar is properly mounted.
Step 7 Barrel Adjuster Installation a. Insert the rear brake housing (which exits the basebar) into the large opening of Barrel Adjuster. b. Insert Stepdown Ferrule into Barrel Adjuster as shown. (fig. a.) c. Insert Rear Brake Housing (rear brake bound into Stepdown Ferrule. fig.
Step 8 Plug Wires Into Junction A a.
Step 9 Basebar Plate Place Aerobar Basebar Plate onto the basebar and tighten bolts as shown to 2Nm.
Section 5 Pt. 2: Aerobar Assembly Parts List QTY.
QTY.
QTY. SIZE - PART NAME 40 Fit Washer 2 Bracket Spacer 2 Armrest Washer 2 Threaded Lower Nut QTY. 1 SIZE - PART NAME PART Basebar Plate QTY.
Adjustability The below reference highlights the five main areas of adjustment that can be manipulated to achieve the desired configuration. 1. Armpad position & angle 2. Armpad fore & aft 3. Armpad width 4. Extension width & angle 5. Extension fore & aft 5 6.
For riders who prefer a narrower position, further adjustment can be achieved by flipping the extension brackets 180 degrees to position the extensions closer together. See the two images below for demonstration. See details below for additional clarity.
Shown below is an example of a high-stack configuration with a narrow armpad and extension position which utilizes a narrow fixed bridge for stability.
If you do not know the dimensions you require, Felt recommends getting fitted by a qualified fit specialist. 5 Aero Bar - c) 25 30 30 35 40 45 50 ad hre n-t X No 25 Fit Wa she rs Top Bo lts (m Bo m) tto m Bo Th lts rea (m m) de dl ow er nu t g.
5mm +10mm Fit Wa she rs Top Bo lts (m Bo m) tto m Bo Th lts rea (m de m) dL ow er Nu t g. nfi Co ad hre n-t X No 36 ed cer pa dS de Sta Th rea Inn er Option A ck He igh t (c - c) Stack Height & Riser Assembly 4 55 X 1 - One extension - Two top bolts (55mm) - One extension bracket - One bracket spacer* - Stack height spacers (5mm + 10mm) - Fit washers (6)** - One threaded lower nut Option A.
- c) 30 ad hre n-t No Fixed Bridge t Fit Wa she rs Top Bo lts (m Bo m) tto m Bo Th lts rea (m de m) dL ow er Nu ed cer Co nfi g. t (c rea de dS pa igh 56 Th Inn er Sta ck He Option B 6 30 30 X - One Extension - Two top bolts (30mm) - One bracket spacer * - One extension bracket - Narrow fixed bridge - Fit washers (6)** - Threaded spacers (30mm) - Bottom bolts Option B.
Important! *BRACKET SPACER Insert the bracket spacer into the slot located on the extension bracket, making sure to align the holes and leave the long, curved edge flush with the edge of the extenion bracket slot as shown in the illustration to the right. **FIT WASHERS Begin with pressing the fit washers into the recessed holes. Sandwich the fit washer between the bolt, spacer/bridge and a threaded spacer. Tighten the bolt until the fit washer is pressed in. Unthread the bolt and assemble.
Arm Rest Assembly To complete the arm rest assembly, you will need the following: - Two 12mm Arm Rest Bolts - One Arm Rest Washer - One Arm Rest - One Arm Rest Bracket - One 15mm Bolt Begin by taking an arm rest bracket and thread a 15mm bolt into the underside and finger-tighten to keep in place. Place the arm rest washer and use two arm rest bolts to fasten in desired position. Finally, slip the arm rest assembly over the extension and tighten the 15mm bolt to 7Nm.
Notice that the diameters of the six holes in the arm rest are each larger than the diameter of the bolt shaft. This allows for fine-tuning to achieve desired arm pad angle. See below for illustrations. Counter-Clockwise Rotation 5 Aero Bar The image below shows the stack assembly and arm rest assembly properly mounted on an extension (actual placement of assemblies in relation to the extension will vary).
Section 6: Felt Aero Brake System 6 Brake Installation -55-
Felt Aero Brake System Parts 1 6 1. Right Brake Arm 2. Return Spring 3. Front Plate Mounting Screw (x2) 4. Carriage Assembly 5. Brake Mounting Bolt 6. Front Plate Brake Installation 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 7. Brake Arm IGUS® Pivot Bushing (x4) 8. 30mm Brake Mounting Screw 9. Backing Plate 10. Brake Pad & Brake Pad Holder (x2) 11. Left Brake Arm 12. Brake Pad Spherical Washer (x2) 13. 1mm Thick Pad Spacer Washer (x2) 14. Brake Shoe Fixing Washer (x2) 15.
Felt Aero Brake System Torque Values No. Part Description Thread 1 2 3a 3b 4a 5 Front Plate Mounting Screw Track Mounting Screw Front Brake Mounting Screw Front Brake Mounting Nut Rear Brake Mounting Screw Cable Clamping Screw M4 x 0.7 M3 x 0.5 M6 x 1.0 M6 x 1.0 M6 x 1.0 M4 x 0.
Felt Aero Brake System Disassembly Step 1: Begin by removing Cable Barrel Adjuster, Noodle, Brake Pad Assemblies and Mounting Screw. 6 Brake Installation Step 2: After Removal of initial parts, the remaining brake should look as the sample above does. Step 3: Remove Front Plate and Mounting Screws.
Step 4: Remove Carriage Assembly. 6 Brake Installation Step 5: Remove Brake Arms, Mounting Bolt and Spring. Step 6: Remove Track from Backing Plate.
Felt Aero Brake System Cleaning and Inspection Cam Surface Step 1: Clean and Inspect Brake Carriage Assembly Rollers and T-Slot 6 Brake Installation Step 2: Clean and Inspect Brake Arm Cam Surfaces and Spring Pocket Step 3: Clean and Inspect Brake Arm Bushings.
Cleaners: The Brake Pivots and Cam Follower Rollers incorporate IGUS® lubrication-free polymer bushings, which DO NOT require any form of lubricant to function properly. It should be noted that if these bushings are exposed to harsh chemical cleaners, aerosol cleaners, solvents, or lubricants, they may experience a chemical reaction causing the bushings to swell up and bind and/or eventually break down. (Notes: WD-40 is particularly harmful to these bushings. Petroleum-based prouducts are okay to use.
Felt Aero Brake System Reassembly Cam Surface Step 1: Remount Track and apply film of light, waterproof grease. Tighten bolts to 1Nm. 6 Brake Installation Step 2: Apply a thin film of light waterproof grease to Brake Arm Cam surfaces. Step 3: Apply thin film of light waterproof grease to spring arms.
Step 4: Preassemble Brake Arms and Spring. 6 Brake Installation Step 5: Add Bushings to Brake Arms. Slip Brake Arm and Spring Preassembly onto Brake Posts. Add Brake Mount Bolt Step 6: Install Carriage Assembly followed by installing the Front Plate and tighten screws to 2Nm.
Section 6 Pt. 1: Felt Aero Brake Front Assembly Step 1 Install Front Brake Fasten the Front Brake to the fork using the Brake Mouting Bolt and the 30mm Brake Mouting Nut and Serrated Nut as shown.
Step 2 Tighten Brake Bolts Using a 4mm and 5mm Hex Wrench, tighten the Brake Mouting Nut and Bolt to 6Nm.
Step 3 Thread the Front Brake Cable through the Front Brake Cable Housing, through the Barrel Adjuster and into the Front Brake as shown.
Step 4 Secure Brake Cable Apply tension on the front brake cable and tighten the Cable Clamping Screw as shown. (fig. a) fig.
Section 6 Pt. 2: Front Brake Cover Installation 1 6 2 3 1. Lower Front Brake Cover 2. Brake Cover Bolt 3.
fig. a Step 1 Add Lower Cover a. In order to make Di2 Wires easier to manage, it is recommended that a cable tie be used to affix wires to Junction A as pictured. (fig. a) fig. b b. Place Lower Front Brake Cover. (fig.
Step 2 Add Upper Cover a. Place the Upper Front Brake Cover as shown. b. Secure both Lower and Upper Brake Cover with M3 bolts tightened to 2Nm.
Section 6 Pt. 3: Felt Aero Brake Rear Assembly Step 1 Rear Brake Installation a. Locate the Rear Brake Cable Housing currently exiting the hole under the bottom bracket. (fig. a) b. Insert a flexible guide noodle onto Rear Brake Cable Housing and install Rear Brake Cable. fig. a 6 Brake Installation fig.
Step 2 Install Brake a. Thread the Rear Brake Cable Into the Rear Brake as shown. (fig. a) b. Mount the rear brake by tightening M 6 bolt to 6Nm. (fig. b) fig. b fig.
Step 3 a. Trim Excess brake cable and install a cable crimp as shown.
Step 4 Install Brake Cover a. Orient the brake cover as shown and tighten included M3 bolts to 2Nm.
Section 7: Seatpost Installation 7 Seatpost Assembly -75-
VR Seatpost Parts 1 7 1. VR Seatpost 2. 3T Difflock End-Cap 3. 3T DiffLock M5 Bolts/star washers (x2) 4. 3T Difflock Inner Spline Suppport Seatpost Assembly 2 3 4 5 6 5. 3T Difflock Outer Spline 6. InternaLoc Seatpost Wedge 7. Compression Spring 8. Seatpost Seals 7 8 9 9.
Step 1 Internaloc Seatpost Wedge Assembly a. Place Compression Spring between Internaloc Seatpost Wedges. (fig. a) fig. a 7 Seatpost Assembly b. Place Internaloc Seatpost Wedge on top of other wedge, sandwiching the Compression Spring. (fig. b) fig. b c. Make sure spring is alined with seatpost wedges. (fig. c) fig.
Step 2 d. After the Compression Spring is installed in the two halves of the InternaLoc Seatpost Wedge, orient the seatpost so the bottom edge will slant downward toward the ground at the front of the bike. (fig. d) e. Apply a thin coat of carbon friction paste on the surface of aluminum InternaLoc Seatpost Wedge that will contact the carbon fiber surface of seatpost to prevent slipping or noise. (fig.e) f.
Step 2 fig. a a. Insert the 3T Difflock Outer Spline into VR seatpost seat clamp area. (fig. a) b. Insert the 3T Difflock Inner Spline Support into the 3T Difflock Outer Spline. (fig. b) c. Insert 3T Difflock End-Cap and M5 Bolt. (fig. c) d. Partially tighten with 4mm Allen Wrench. (fig. d) fig. b fig. c 7 fig.
fig. a fig. b Step 2 a. If not done yet, press-fit the Seatpost Seals into the VR Seatpost Slot. (fig. a) 7 c. Insert seatpost into frame, thread seatpost binder bolts, but do not tighten completly. (fig. b) d. After determining appropriate seatpost insertion, trim silicone slot cover so exposed seatpost slot is entirely covered by slot cover. (fig. b) b. Apply a thin coat of carbon friction paste on the surface of Seatpost to insertion point and inside seat tube to prevent slipping or noise. (fig.
Section 8: CalPac / AeroPac Installation 8 Calpac -81-
Step 1 Install CalPac Cover Once the protrusions of the Calpac are aligned with the cavities located on the underside of the AeroPac, press the AeroPac firmly into place.
Step 2 AeroPac Properly Installed Be sure the CalPac is properly installed. There should be no significant gap between the CalPac and AeroPac cover. Once installed, it should appear as pictured. (fig. a) fig.
Complete The IA is shown with CalPac, Fork, Headset, Stem, Aerobars, Brakes, Brake Covers Installed and all Brake Cables and Shimano Di2 Wires Routed. Should you ever need further clarification, or do not feel entirely confident performing manintenance on your IA, please contact your local Felt Dealer for help.
Felt Racing, LLC 12 Chrysler Irvine, CA 92618 Industriestr. 39 26188 Edewecht Germany www.feltbicycles.