SBC 2022-2023 Front Rack and Adventure Plate Installation Guide

ASSEMBLY GUIDE
Front Rack & Adventure Plate

INTRODUCTION

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION. PLEASE READ IT CAREFULLY AND STORE IT IN A CONVENIENT PLACE.
This assembly guide takes you through the installation of the Front Rack & Adventure Plate for the 2022/2023 Turbo Vado, Turbo Como, Turbo Tero EQ, and Turbo Tero X bicycles. This guide was drafted in the English language (original instructions) and has been translated into other languages as applicable (translation of original instructions). If there is a difference between the instructions in this guide and the information provided by a component manufacturer, please refer to your Authorized Specialized Retailer.
This document is available for download in additional languages at www.specialized.com.
We may occasionally issue updates and addenda to this document. Please periodically check www.specialized.com or contact Rider Care to make sure you have the latest version.

SYMBOLS

When reading this assembly guide, note the various important symbols and warnings explained below:

| WARNING! The combination of this symbol and word indicates a potentially hazardous situation that, if not avoided, could result
in serious injury or death. Many of the warnings say “you may lose control and fall.” Because any fall can result in serious injury or even death, we do not always repeat the warning of possible injury or death.
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| CAUTION: The combination of the safety alert symbol and the word CAUTION indicates a potentially hazardous situation that,
if not avoided, may result in minor or moderate injury, or is an alert against unsafe practices.
| The word CAUTION used without the safety alert symbol indicates a situation that, if not avoided, could result in serious damage to the bicycle or the voiding of your warranty.
| This symbol alerts the reader to information that is particularly important.
| This symbol means high-quality grease should be applied as illustrated.
| This symbol means high-quality carbon assembly paste should be applied as illustrated.
| Tech tips are useful tips and tricks regarding installation and use.

GENERAL NOTES ABOUT ASSEMBLY

This guide is not intended as a comprehensive assembly, use, service, repair, or maintenance guide. Please see an Authorized Specialized Retailer for all service, repairs, or maintenance.

| The Front Rack & Adventure Plate will ship partially assembled with the Adventure Plate assembled to the front rack. You do not have to disassemble the Adventure Plate from the Front Rack as shown in this manual.
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| WARNING! Due to the high degree of complexity of the Front Rack & Adventure Plate, proper assembly requires a high degree of mechanical expertise, skill, training, and specialty tools.
Therefore, it is essential that the assembly be performed by an Authorized Specialized Retailer.
| WARNING! The maximum load capacity of the Front Rack & Adventure Plate is 10kg/13lbs. When using accessories on the rack, the weight limit of the accessory may be lower. Always adhere to the lower weight limits of either the rack or the accessory.
| WARNING! Always secure items on the Adventure Plate using the supplied Adventure Plate cargo net. After installation and before your ride, ensure that the net and cargo are secured on your rack by gently tugging on the cargo net and item.
| WARNING! Racks and baskets, especially when loaded, affect the handling of your bicycle by altering the center of gravity, weight,
and balance. Before your first ride, you should practice riding in a controlled environment.

3.1.Components

| COMPONENT| QTY| TOOL| TORQUE
---|---|---|---|---
Nm| inlbf
A| Front Rack| 1| N/A| N/A| N/A
B| Adventure Plate| 1| N/A| N/A| N/A
C| Adventure Plate cargo net| 1| N/A| N/A| N/A
D| Head plate| 1| N/A| N/A| N/A
E| Head plate bolts and washers| 4| 4 mm hex| 4.5| 40
F| Front Rack bolts and orientation
washers| 2| 4 mm hex| 9| 80
G| Front Rack lower bolt and washer| 1| 4 mm hex| 9| 80
H| Adventure Plate bolts and nylon lock
nuts| 6| 3 mm hex| 4.5| 40
I| Cable guide bolts and washers| 4| 3 mm hex| N/A| N/A

3.2. Pre-installation requirements
Front light cable
The front light cable needs to extend at least 550 mm / 21⅝ in from the drive side ICR port to mount the front light on the front of the rack. Before installation, follow the steps to disassemble the front light and extend the cable. If you don’t have sufficient cable available, please halt the installation and have the Front Rack installed at your nearest Authorized Specialized retailer. Certain 2022/2023 Turbo Vado, Turbo Como, Turbo Tero EQ, and Turbo Tero X models do not feature a long enough front light cable to mount the light on this rack. An Authorized Specialized retailer will need to install this component.
Front light mount
Specific Turbo Vado, Turbo Como, Turbo Tero EQ, and Turbo Tero X models are equipped with a wire mount attached to the fork bridge. The wire mount is incompatible with the Front Rack which is only compatible with the Lezyne E-bike Suntour Mobie Fork Crown Mount (SKU 06223-2001) and is available from www.specialized.com. 3.3. Tools and components required for assembly

• Stable repair stand
• 2.5 mm hex key
• 3 mm hex key
• 4 mm hex key
• Torque wrench covering 4-10 Nm / 35 in-lbf to 80 in-lbf
• Required on bicycles with wire front light mount:
  • Lezyne Ebike Suntour Mobie Fork Crown Mount. (SKU: 06223-2001)

To access video content relating to the assembly process of the Front Rack & Adventure Plate, click on the link next to the video icon in the manual to go directly to the assembly video. You can also manually enter the web address.
https://vimeo.com/770994746/ac2be50284

ASSEMBLY INSTRUCTIONS

Following the order of assembly outlined in this manual is essential to assemble the Front Rack & Adventure Plate. Modifying the order of assembly will result in a longer build process.
The Front Rack & Adventure Plate ships partially assembled with the Adventure Plate assembled to the front rack. You do not have to disassemble the Adventure Plate from the front rack, as shown in this assembly guide.
Preparation

• Power off the bicycle using the MasterMind TCD and remove the battery.

• Clamp the bicycle in a stable bicycle stand.
  Bicycles equipped with Lezyne front light mount

• Swivel the front light (B) upward to access the mounting bolt (A).

• Use a 4mm hex key to remove the mounting bolt.

• Gently pull the front light from the ICR port to release the additional cable stored in the frame.

• For successful relocation of the front light to the front of the rack, you need at least 550 mm / 21⅝ in of cable.

Certain 2022/2023 Turbo Vado, Turbo Como, Turbo Tero EQ, and Turbo Tero X models do not feature a long enough front light cable to mount the light on this rack. An Authorized Specialized retailer will need to fit this component.
Bicycles equipped with wire light mount

• Use a 4mm hex key to remove the mounting bolt (A) and the lower light mounting bolt (B). Store the wire mount if you need it in the future.
• Use the spacer (C) supplied in the Lezyne E-bike Suntour Mobie Fork Crown Mount (SKU 06223-2001) and replace the bolt and washer into the back of the fork bridge.
• Gently pull the front light from the ICR port to release the additional cable stored in the frame.
• For successful relocation of the front light to the front of the rack, you need at least 550 mm / 21⅝ in of cable.

Certain 2022/2023 Turbo Vado, Turbo Como, Turbo Tero EQ, and Turbo Tero X models do not feature a long enough front light cable to mount the light on this rack. An Authorized Specialized retailer will need to fit this component.
Once the front light wire mount is removed from the back of the fork bridge, insert the spacer included in the kit Lezyne E-bike Suntour Mobie Fork Crown Mount (SKU 06223-2001) between the bridge and the bolt before replacing it to prevent it from bottoming out.
Front plate removal

• Use a 2.5 mm hex key to remove the bolt (A) on the front plate (B) and remove the plate from the head tube of the frame.
• Clean the head tube mounting points of any debris or lubricant if required.

1. The three mounting bolts for the Front Rack will ship pre-assembled into the head plate and must be removed before assembly. Note the position of each bolt and the washers on each bolt. These must be reassembled back in the same position and orientation.
   Head plate assembly

• Insert the bolts (B) through the head plate (A) into the head tube mounting holes, then using a 4mm hex bit and torque wrench, torque the bolts to 4.5 Nm / 40 in-lbf.Front Rack assembly
• Remove the Front Rack bolt warning sticker to reveal the lower Front Rack mounting hole.
• Align the holes of the Front Rack (C) with the head plate.
• Use a 4mm hex key to tighten the Front Rack lower bolt (D) and washer and secure the Front Rack to the head plate.
• Align the curved surfaces of the orientation washers (E) onto the Front
  Rack bolts (F) and insert the bolts.

WARNING! The correct use of the orientation washers is critical to the secure mounting of the front rack. Assembling the Front Rack without the correct orientation washers will cause the bolts to protrude past the head plate and could damage the steerer tube or prevent it from rotating freely. Front Rack alignment

• Align the Front Rack with the centerline of the frame.
• Use a torque wrench and 4 mm hex bit to torque the bolts to 9 Nm / 80 in-lbf.
• Inspect the front brake hose and control cables to make sure the Front Rack does not prevented them from moving freely.
• Turn the handlebar right and left to ensure that the range of motion is not affected.

WARNING! Make sure the Front Rack does not interfere with the front brake hose or control cables preventing the handlebar from rotating from right to left. Adventure Plate assembly

• Align and insert the six Adventure Plate nuts (B) into the cavities underneath the front rack.
• Place the Adventure Plate (A) on the Front Rack and align the six holes in the Adventure Plate with the holes in the front rack.
• Use a torque wrench and 3 mm hex bit to torque the bolts (C) to 4.5 Nm / 40 in-lbf. Front light mounting
• Align the front light mount with the front of the rack.
• Insert the bolt (A) through the light mount into the Front Rack mounting hole, then use a 4mm hex key to tighten. Front light cable routing
• Use a 3 mm hex key to remove the four cable guide bolts (A) and washers (B).
• Guide the light cable from behind the light into the cable guide tube.
• Allow enough cable behind the light for adjustability.
• Align the cable guide washer (B) and bolt (A), then use a 3 mm hex key to tighten the four cable guide bolts to secure the front light cable.
• Feed any additional cable back into the ICR port.Adjustment of front light
• Replace the battery and power on the bicycle using the button on the MasterMind TCD.
• Use a 3 mm hex key on both sides of the bolt (A) to loosen the bolt at the base of the front light.
• Adjust the light so the beam points slightly downward.
• Use the 3 mm hex keys to tighten the bolts (A).

CAUTION: An incorrectly adjusted beam will not provide proper visibility of the road ahead and may obstruct the vision of oncoming traffic.

SPECIALIZED BICYCLE COMPONENTS
15130 Concord Circle, Morgan Hill, CA 95037 408-779-6229
0000193818_AG_R1, 11/22

References

• Made for riders, by riders. | Specialized.com

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