V3 Dropper Upper Bushing Replacement
Things You Will Need
- V3.1 2-piece upper bushing (polymer bushing & brass ring)
- Light suspension grease (Slickoleum)
- Strap wrench
- Lint-free cloth
- 5mm hex key
Assembly time, approximately 10 minutes. Difficulty: Easy.
This assembly procedure can be completed without removing the dropper post from the bike, using minimal tools that are commonly used for basic bicycle maintenance.
COMPLETE EXPLODED VIEW & PARTS LIST
IDENTIFY YOUR UPPER BUSHING
There are two versions of the V3 dropper upper bushing (10).
The original V3 IGUS upper bushing (10) is a single tan colored bushing.
The Updated V3.1 Bushing is a two piece assembly: 1 shortened black IGUS upper bushing (10) & a lower brass ring (26).
STEP 1: COMPRESS THE DROPPER
Press the remote and compress the dropper to roughly mid-travel.
STEP 2: REMOVE SADDLE CLAMP ASSEMBLY
Unthread the rear seat clamp bolt (5) using a 5mm hex key. Remove the seat clamp nut (4) and upper clamp (3), then remove the saddle and lower clamp (2). Clean the assembly and put it aside.
TIP: Leave the front clamp bolt (5) and do not adjust it. During reinstallation of the clamp assembly and saddle, torque the rear clamp bolt to 8Nm, and the saddle angle will remain correct.
STEP 3: UNTHREAD MID-CAP ASSEMBLY
Unscrew the mid-cap assembly (8,9) by hand or with a strap wrench if necessary. Slide it up towards the seat post head.
STEP 4: UNTHREAD CARTRIDGE FROM UPPER TUBE
With the saddle clamp assembly removed, locate the 5mm hex key fitting at the top of the post and unthread it by rotating the 5mm hex key counterclockwise (following the direction of the lasered arrow).
STEP 5: REMOVE UPPER TUBE
Separate the upper tube (1) from the lower tube (12) by gently pulling upwards until the 2 pieces come apart. Remove slowly, making sure the six guide pins (6,7) do not fall back into the open lower tube.
NOTE: Please keep in mind that the cartridge, without the upper tube, is now fairly loose within the lower tube. Be careful not to knock or apply pressure to it.
STEP 6: REMOVE UPPER BUSHING
Remove the upper bushing (10) from the upper tube (1) and clean the tube below the mid cap assembly (8,9). If the internals are dirty/gritty, take this opportunity to clean & grease the entire internal assembly.
STEP 7: INSTALL V3.1 UPPER BUSHING AND BRASS RING
Snap the upper bushing (10) around the upper tube (1) above the guide pin channels.
From the bottom of the upper tube (1), gently flex the brass ring (26) open and slide it up the upper tube, over top of the lower bushing(s) (11), and guide pins (6,7) until it is above the guide pin channels on the upper tube.
Apply Slickoleum to both the upper bushing (10) and the upper tube (1).
STEP 8: INSTALL UPPER TUBE INTO LOWER TUBE
Align the guide pins (6,7) with the machined grooves in the lower tube (12), ensuring the lasered logos are oriented front to back on the lower tube (12) and centered. The front guide pin (6) should align with the center of the front ONE logo. Slide the tubes together carefully, ensuring the pins enter properly and are not sliding up and out of their channels. This action should feel smooth.
STEP 9: INSTALL CARTRIDGE INTO UPPER TUBE
Continue to slide the upper tube (1) into the lower tube (12) until the upper tube contacts the threads on the top of the cartridge (15). Using the 5mm hex key, thread the cartridge back into the upper tube and torque to 3Nm. Gentle downward pressure on the top of the upper tube can be helpful for getting the threads to properly interface with each other.
STEP 10: INSTALL MID CAP ASSEMBLY
Seat the upper bushing and brass ring into the top of the lower tube, if it is not in the correct position already. Thread the mid cap assembly into the lower tube by hand or with a strap wrench for added security.
STEP 11: INSTALL SADDLE CLAMP ASSEMBLY
Fully extend the post by compressing the remote lever and check the cartridge 5mm hex key fitting is still torqued to 3Nm.
Place the lower saddle clamp (2) into the cradle of the upper tube (1). Make sure the arrow is pointing forward. Place the saddle on the lower clamp (2). Holding the saddle, slide the upper clamp (3), with the arrow forward, under the front clamp nut (4) and place it on top of the saddle rails. Drop the rear clamp nut into its seat at the back of the upper clamp. Thread the rear clamp bolt (5) into the nut and tighten to 8Nm.
Congratulations, you have now successfully completed the V3 upper bushing replacement.
NOW GO RIDE!
If you are having any problems, please first double-check that you have correctly completed each of the above steps.
If you are still having trouble, please follow the link to our contact form for help. Please include a detailed description of your issue. Photos are often helpful.
Thanks,
OneUp
