Whyte 46

Service and Instruction Manual

Edition 1: March 2006
 WHYTE 46 Service Manual

9.0: NOTES

Table of Contents

1.0 Introduction

2.0 Whyte 46 Specifications and Geometry:

2.1 46 Specification
2.2 Geometry

3.0 Preparations for riding:

3.1 Making Adjustments
3.1.1: Getta-Grip Seat Clamp
3.1.2: 46 cockpit adjustments
3.2 Set up of Fork
3.3 Set up of Rear Fox Float RP3 Damper
3.4 Whyte Big Gripper Dropout System

4.0 Safety

5.0 Lubrication:
5.1 Getta-Grip Seat Clamp
5.2 Whyte Big Gripper Dropout System
5.3 General 46 Lubrication

6.0 Servicing the Rear Suspension:

6.1 Removal of Rear Damper
6.2 Rear Suspension Assembly
6.2.1 Removal of Swinging Arm
6.2.2 Removal of Quad-Links
6.3 Stripping and Re-assembling Quad-Links
6.3.1 Extraction of KP5AX Bearings
6.3.2 Installation of KP5AX Bearings
6.3.3 Installation of KP5AX Bearings and Centre Spacer
6.4 Assembly of Quad-Links to Main Frame
6.5 Assembly of Swinging Arm
6.6 Assembly of Rear Damper

7.0 Servicing Whyte Big Gripper Dropout System:

7.1 Disassembly of Rear Big Gripper
7.2 Reassembly of Rear Big Gripper
7.3 Adjustment to Clamping Force of Rear Big Gripper

8.0 Tightening Torque Settings

9.0 Notes

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8.0: TORQUE SETTINGS

Rear Quad-Link Suspension: Nm lbs.ft

SHOCK FRONT MOUNTING BOLTS 5.5 4.0

SWING ARM - TO - LINK THROUGH BOLT M6x85mm 8.0 6.0

LINK - TO - MAIN FRAME THROUGH BOLT M6x70mm 8.0 6.0

Rear Big Gripper Dropout

M5 THROUGH AXLE NUTS 7.0 5.0

M6 HALF NUT ON CATCH STUD 7.0 5.0

1.0: INTRODUCTION Torque explained: If no suitable Torque Wrench is available a Torque of 5 lbf.ft can be obtained by ap-
plying a force of 5lb, with a Spring Balance, to the end of a spanner, 1 Foot in length.
Thanks for choosing the Whyte 46. We hope you will enjoy all the benefits the advanced
IMPORTANT: For all other torque settings, refer to the specific manufacturers information
design and engineering will bring to your riding experience.
bundled with this manual, or alternatively, refer to the specific manufacturers website for
further information.
This manual will guide you through the necessary set-up, safety and maintenance proce-
dures involved in using and servicing your W46 frameset.
9.0: NOTES
Bundled with this manual, are the respective manufacturers instructions and manuals for
the branded parts that go to make up the Whyte 46 build. Please take time to study both
this manual and all the relevant instruction manuals to ensure you have a continually safe
and well set-up bike before every ride, and to help you build up a relationship of knowl-
edge between you and your Whyte Dealer.

Whyte design team. March 2006.

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7.1 DISASSEMBLY OF REAR BIG GRIPPER: 2.0: WHYTE 46 SPECIFICATIONS AND GEOMETRY
Tools Required: 10mm A/F Spanner
8mm A/F socket with ratchet or T-bar drive (2 off)
Flat bladed screwdriver 2.1: W46 Specification
3mm A/F Allen key
Pin punch for removing 5mm Roll pin. Frame: 6061 Aluminum QUAD-Link Twin Monocoque Front Triangle

Remove Rear wheel from bike by rotating both QR levers anticlockwise (1) to the down Fork
Maverick DUC-32, 100mm-150mm Adjustable Travel, Rebound Adjustment, Maverick
position and opening the Dropout Bases (9 & 11). To remove the Big Gripper Bobbins (5) 24mm Axle QR system
from the rear wheel use the 8mm A/F sockets to loosen and remove the M5 Nuts (3) Re- Swinging Arm 6061 Aluminium Monocoque with TARA QR 4”-6” Suspension Adjustment
move Washers (4) and Through Stud (7). The Big Gripper Bobbins (5) can now be pulled
from the axle ends of the wheel. The Detent Spring (2) retains the QR Levers (1) into the Shift Levers Shimano XT
Dropout and so the Detent Spring (2) must be removed first by pulling it vertically down- Brake Levers Hope Hydraulic Disc
wards. The QR Levers (1) can now be removed from the Dropout. To remove Stud-catch
(6) from Dropout Base (9 & 11) remove Lock nut (10) with the 10mm A/F spanner and Crankset Shimano XT, 44/32/22 with Hollowtech II Arms
then turn Stud-catch (6) clockwise using the Flat bladed screwdriver. To remove Dropout
Chain Shimano XT
Base (9 & 11) support the dropout body and use the Pin Punch to drift out Roll Pin (8)
Front Derailleur Shimano XT
7.2 REASSEMBLY OF REAR BIG GRIPPER:
Tools Required: 10mm A/F Spanner Rear Derailleur Shimano XT
8mm A/F socket with ratchet or T-bar drive (2 off)
Cassette Shimano XT, 11-32
Flat bladed screwdriver
3mm A/F Allen key Rear Hub Hope Sport Disc Hub 32 Hole

This procedure is basically the reverse of the dis-assembly procedure. Refer to the Lubrica- Front Hub Maverick 24mm Axle, Double Sealed
tion section for details of maintenance. Bottom Bracket Shimano XT Big Pipe Billet Integrated with Crankset

Hope Mini MONO M4 Hydraulic Disc 180/200mm with Goodridge Stainless Steel
Brakes
7.3 ADJUSTMENT TO THE CLAMPING FORCE ON THE BIG GRIPPER DROPOUT Braided Hoses
Tools Required: 10mm A/F Spanner
Rims Mavic XM 717 Disc, 32 Hole. 26”
Flat bladed screwdriver
Spokes DT Double Butted 1.8-1.6mm, Black Stainless with Brass Nipples
This adjustment is made by loosening the Locknut (10) and rotating Stud-catch (6) until
Tyres Continental Gravity Pro 26 X 2.3" with Kevlar Bead. 26” x 1.5—2.2 Inner Tube
the desired force is obtained. With the unit fully assembled and the wheel in its proper po-
sition the correct setting is when the QR Lever (1) can easily be rotated to the vertically up Headset Cane Creek, S2 Cartridge Sealed Threadless 1 1/8"
position by hand. A slight resistance should only be felt during the last quarter turn as the
cam in the Barrel-catch pulls the Stud-catch up to clamp the wheel in position. Ensure that Seatpost Whyte 2014 Alloy, 31.6mm X 350mm
there is not too much force and that the vertically up position can be achieved. With this Saddle SDG Comp Bel-Air with Ti Rails
system a large clamping force is not required as the wheel is well located. If the force is
too large then turn the Stud-catch (6) clockwise (when viewed from below) and if there is Bar Easton Monkeylite XC Low Rise, 31.8mm OD
not enough force turn the Stud-catch (6) anti-clockwise. When the correct setting has been
Stem Maverick Tuneable Length, 31.8mm Bar Clamp
obtained tighten the Lock nut (10)
Grips Whyte Lock-on's

Fox Float RP3, with Rebound Adjuster and 3 Position ProPedal Lever Adjustment.
Rear Shock
Whyte Designs Cartridge Bearing Kit with Lifetime Guarantee

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2.3: GEOMETRY 7.0: SERVICING WHYTE BIG GRIPPER DROPOUT SYSTEM

Fig.1: 46 Geometry Scheme Fig.12: Exploded view of the Whyte Big Gripper Assembly.

Small Medium Large Small Medium Large

(showroom) (showroom) (showroom) (with sag) (with Sag) (with sag)

Head Angle (D) 69.3° 69.3° 69.3° 67.5° 67.5° 67.5° Item Part No. Description
Seat Angle (C) 72.0° 72.0° 72.0° 70.2° 70.2° 70.2° 1 BARREL-CATCH1P Big Gripper QR Lever
Top Tube (B) 553.6 mm 570.5 mm 593.9 mm 2 SPRING101 Detent Spring
BB Height (F) 364.6 mm 364.6 mm 364.6 mm 322.9 mm 322.9 mm 297.4 mm 3 M5NYLOCKNUT M5 Nylock Nut
Stand Over (E) 728.0 mm 738.0 mm 778.0 mm 4 DROPOUT3108 Washer
Wheel Base (H) 1113.5 mm 1126.5 mm 1148.3 mm 5 DROPOUT3106 Big Gripper Bobbin
Chain Stay (A) 440.7 mm 440.7 mm 440.7 mm 6 DROPOUT3104 Catch Stud
Seat Post (G) 31.6 mm 31.6 mm 31.6 mm 7 DROPOUT3107 Through Stud (Rear 170mm)

8 SPIROL5x18LBT Roll Pin Spirol

9 DROPOUTBASE Dropout Base LH

Note:
10 M6HALFNUT M6 Half Nut
‘Showroom’ Geometry is without rider. ’With Sag’ geometry is with rider after correct sag is set at front and rear. Please
refer to suspension set up for information on how to achieve the correct sag of the fork and rear damper. 11 DROPOUTHANGER Dropout Base RH (Mech Hanger)

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6.4: ASSEMBLY OF QUAD-LINKS TO MAINFRAME: Continued... 3.0: PREPARATIONS FOR RIDING

Tools Required: 10mmA/F socket with ratchet or T-Bar drive
5mm A/F Allen Key 3.1: MAKING ADJUSTMENTS
Torque wrench
3.1.1: WHYTE GETTA-GRIP SEAT CLAMP
The two Quad-Link assemblies used on the Whyte 46 are identical, as are the fitting proce-
dures, which is basically the reverse of the removal procedure. Both Quad-Links are fitted The Getta Grip seat clamp design is a patented design to allow adjustment of the saddle
to the bike with the central crosspiece, part of the Quad Link, on the bottom of the link height by either the use of a QR Lever, or bolt-up method. This manual covers both styles
assembly, as illustrated in Figure 11. Carefully slide the link assembly onto the Main Frame of clamps.
making sure the Shield Washers do not drop out. Insert Bolt (7), (70mm), through the
Quad-Link and Main Frame replace the Nylock Nut (10) and torque tighten using the 5mm
Allen key and torque wrench. Refer to torque settings in section 8.0
Fig.2: Getta-Grip Seat Clamp: Bolt-up
Item Part No. Description
6.5: ASSEMBLY OF SWINGING ARM: Fig 9
Tools Required: 10mmA/F socket with ratchet or T-Bar drive
5mm A/F Allen Key 1 ICAA-SC31.6BAND-V2 W46 Clamp Band
4mm A/F Allen Key – 2 off
Torque wrench
2 SEATCLAMP31.6PADV2 T-Pad
Offer the Swinging arm into position with the Main Frame. Align the boss at the front of the
Swinging Arm with the front Quad-Link assembly making sure the Shield Washers have not
fallen out. Insert the Bolt (8) (85mm), through the M6 Washer (9), Swinging Arm, Main 3 - W46 Main Frame
Frame, Swinging Arm and M6 Washer (9). Replace the Nylock Nut (10) and tighten with
the torque wrench. Next align the rear boss in the swing arm with the rear Quad-Link as-
4 THREADEDBARREL Barrel Nut
sembly making sure the Shield Washers have not fallen out. Insert the Bolt (8) (85mm),
through the washer (9), Swinging Arm, Main Frame, Swinging Arm and M6 Washer (9).
Replace the Nylock Nut (10) and tighten with the torque wrench. The Swinging Arm should 5 M6x30
M6 x 30mm Fas-
now be fixed to the main frame and should move freely with no sideways movement. For tener
torque settings, refer to section 8.0. Remember to re-fit brake and gear assemblies, and
check they are functioning correctly in accordance with the manufacturers instructions be- 6 M6WASHER M6 Washer
fore riding the bike.

6.6: ASSEMBLY OF REAR DAMPER: Fig. 8

Tools required: 4mm A/F Allen key x 2
Basically this is the reverse of the removal procedure. Ensure that the Top Hat Bushes (5)
are installed into the inside of the Main Frame mounting point (1). It is best to loosely as-
semble both the front end and rear QR Assembly of the Damper Unit to ensure correct
alignment before finally tightening M5 Screws (2). Refer to torque settings in section 14.0.
Refit plastic plugs (14)
Bolt-up Type: Fig.2
Tools Required: 5mm Allen Key
(Note, refer to the seat-pin manufacturers instructions in conjunction with these notes).
To adjust the seat height, using the 5mm Allen key, undo the M6 bolt (5) just enough to
allow the seat-pin to slide freely up and down. Set the height to the desired level, and re-
tighten the M6 bolt (5) with the 5mm Allen Key just enough so as to prevent the seat-pin
from slipping down and twisting.

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Item Part No.
1 CAMGRUBSCREW
2 QRCAM
3 ICAA-TARA-QR-4
4 Plastic Shim
5 -
6 ICAA-SC31.6BAND-V2
7 ICAA-SCBOBBIN
Before re-assembling the Shield Washer Components (4) (5) (6), apply large quantities of
Molycoat Grease on top of the KP5AX Bearings (2) seated in the link (1). The grease should
Description Fig.3: Getta-Grip Seat Clamp: QR Lever completely cover each bearing and be applied on both sides of the bearing as it is assem-
QR Lever Cam bled into the Link (1). Next assemble the Shield Washer Components (4) (5) (6). If you
have applied enough Molycoat grease, grease should spread from under the Shield Washer
Grub Screw
component as they are positioned. Wipe excess grease away from around the Shield
QR Lever Cam Washer Components.
Whyte QR Lever
Application of SKF LGAF 3 Compound: Once the Link has been assembled and cor-
rectly greased, SKF LGAF 3 Compound must be applied to all outside faces of the
Shield Washer Components (4) (5) (6) that contact the Main Frame and Swinging
W46 Main Frame Arm. It is additionally suggested to apply SKF LGAF 3 compound to the link con-
tact surfaces on the Main Frame and Swinging Arm.
W46 Clamp Band
6.4: ASSEMBLY OF QUAD-LINKS TO MAINFRAME:
QR Adjuster Bobbin

8 QRSHAFT QR Shaft

9 SEATCLAMP31.6PADV2 T-Pad

Fig. 11: Incorrect Installation of

QR Lever Type: Fig.3
No tools required. Quad-Links onto Main Frame
(Note, refer to the seat-pin manufacturers instructions in conjunction with these notes).
To Adjust the seat height with the QR Lever assembly fitted, simply undo the QR Lever (3)
from the Closed position to the Open position. Next adjust the height of the Seat Pin to the
desired level, and close the QR lever (3) from the Open position to the Closed position. The
QR closing force can be adjusted by turning the QR Adjuster Bobbin (7) clockwise or anti-
clockwise before closing the QR Lever (3).

3.1.2: WHYTE 46 COCKPIT ADJUSTMENTS

Seatpost: Whyte 2014 Alloy, 31.6mm X 350mm Refer to manufacturers instructions

Saddle: SDG Comp Bel-Air with Ti Rails Refer to manufacturers instructions
Bar: Easton Monkeylite XC Low Rise, 31.8mm OD Refer to manufacturers instructions
Stem: Maverick Tuneable Length, 31.8mm Bar Clamp Refer to manufacturers instructions
Shift Levers Shimano XT Refer to manufacturers instructions
Brake Levers Hope Hydraulic Disc Refer to manufacturers instructions

3.2: SET UP OF FORK Fig. 11: Correct Installation of

Tools Required: Good Quality Shock Pump.
Quad-Links onto Main Frame
The Maverick DUC.32 front fork is fitted as original equipment, and will be pre-set with the
standard settings when you buy your 46. Before riding, you will need to adjust the Sag
setting on the fork. This is to ensure the forks are set-up correctly for your own body
weight, so the fork will perform as intended.

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 WHYTE 46 Service Manual
It is vital the Link Spacer Tool (8) is placed here to prevent bending of the One
Piece Link during installation of the Bearings. Apply Loctite 641 on the outside of the
KP5AX bearing (2) and on the inside bearing surface of the Link (1). Using the Bearing
insertion Tool (9), assemble as shown in figure 5 using an engineers vice with ‘soft jaws’ to
prevent any damage to the Link. Align the components and press the bearing into the link.
Ensure the bearing presses in squarely, and is correctly seated in the bottom of it’s hous-
ing. Repeat until three KP5AX bearing are installed. The final bearing will require the Cen-
ter Spacer to be fitted at the same time as pressing the bearing in.
6.3.3: INSTALLATION OF KP5AX BEARING AND CENTRE SPACER
Fig.10f
The final bearing will require the Centre Spacer (3) to be fitted at the same time as press-
ing the bearing in. Place the Link Spacer Tool (8) in between the One Piece Link (1) as
shown in Figure 6. It is vital the Link Spacer Tool (8) is placed here to prevent
bending of the One Piece Link during installation of the Bearing. Ensure the KP5AX
Bearing (2) and Link (1) surfaces are clean and apply Loctite 641 on the outside of the
KP5AX Bearing (2) and the inside bearing surface of the Link (1). Before sliding the Centre
Spacer (3) into position, it is essential that each end of the Centre Spacer (3) has a large
amount of MOLYCOAT grease on both ends to create a donut of the grease. This will then
spread and fill the Labyrinth on assembly. Pass the Centre Spacer (3) though the Link (1),
taking care not to contaminate any bearing surfaces, and locate against the bearing al-
ready pressed in. Using an engineers vice with ‘soft jaws’ to prevent any damage to the
Link, align the Bearing Insertion Tool (9) and Bearing (2) to be pressed into the Link (1)
correctly. Press the Bearing (2) into the Link (1), ensuring that the Centre Spacer (3) is
located in both it’s Labyrinth gaps. Remove any excess Molycoat grease from around the
area. Once all the KP5AX bearings (2) and Link Centre Spacer (3) have been assembled,
the final application of lubricants can be applied before assembly into the Bicycle.
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WHYTE 46 Service Manual
To set Sag on a front fork, you need to measure the amount the fork compresses when
you sit on the bike in the normal riding position. We recommend for the best synergy be-
tween front and rear suspension systems to run approximately 20mm (16%) Sag on the
front fork.
Sag on the DUC.32 fork is controlled by adjusting the Air Spring pressure in the Left hand
fork leg. Unscrew the Maverick Star cover on the top of the left hand fork leg, which covers
the standard Schrader valve. Using a shock pump, either add or remove air until Sag is
correctly set.
Please note that for the detailed instructions for servicing and all matters relating to the
Maverick DUC.32 Forks, please refer to the manufacturers instructions.
Rebound Damping adjustment:
This adjustment fine-tunes the speed at which the wheel returns to its normal ride height
after hitting a bump. The dial is coloured grey and is found inside of the green lock down
dial on top of the right hand fork leg. To demonstrate the effect of this function, turn the
adjuster to its slowest setting. Press down on the handlebars to compress the forks, then
release the load. The suspension recovers very slowly to its original position.
Repeat the above with the adjuster turned to the fastest setting and the difference will be
seen immediately the load is released. We recommend the optimum setting is to adjust the
re-bound damping to be as slow as possible, but not so slow that the normal ride height is
not recovered. On very rough terrain, if the rear of the bike becomes progressively lower
as more bumps are hit then the re-bound damping is set too slow. On the other hand if the
bike feels choppy and not plush then the re-bound damping is too fast. A bit of trial and
error is needed to get the exact setting. Riders may choose to change their settings, while
stationary, depending on the terrain they are riding.
3.3: SET UP OF REAR FOX FLOAR RP3 DAMPER
Tools Required: Good Quality Shock Pump.
The Whyte 46 is equipped with the Fox Float RP3 rear damper. The air pressure in the
shock determines the spring rate. The correct ‘sag’ can be found using the sliding ‘o’ ring
fitted to the shaft of the shock piston. Slide the ‘o’ ring against the shock body. Then gen-
tly sit on the bike in your normal riding position. Carefully dismount and measure the dis-
tance the ‘o’ ring has moved away from the shock body.
The optimum distance for the 46 QUAD system is 17mm displacement from the ‘o’ ring
back up to the shock body. If there is less than 17mm fit a shock pump and release air
pressure. Conversely if there is greater than 17mm of travel, fit the shock pump and in-
crease air pressure. Repeat the ‘sag’ test until the 17mm displacement is achieved.
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WHYTE 46 Service Manual
6.3.1: EXTRACTION OF KP5AX BEARINGS
See the table below for a rough guide to initial shock pressures, based on an ‘all-up’ rider weight.
Remove all the outer shield washers (4,5,6) and wipe off old grease and dirt from the
Rider Weight Pressure * Rider Weight Pressure * Rider Weight Pressure *
Labyrinth areas. Assemble the link as shown in Fig 10a on top of the jaws of an engineer’s
vice, supporting the link whilst allowing the KP5AX bearing to be drifted out between the
8.5st / 53.9kg 123 12.0st / 76.2kg 175 15.5st / 98.4kg 217 vice jaws. Slide the M8x65mm bolt (7) through the top KP5AX bearing, and drift out the
Centre Spacer (3) and KP5AX bearing (2) together as shown in figure 4b. Once the Centre
9.0st / 57.1kg 129 12.5st / 79.4kg 184 16.0st / 101.6kg 224
Spacer (3) has been removed from the assembly, the remaining KP5AX bearings can be
9.5st / 60.3kg 136 13.0st / 82.5kg 194 16.5st / 104.8kg 231 removed.
To remove the remaining 3 KP5AX bearings (2) from the one piece link body (1) assemble
10.0st / 63.5kg 143 13.5st / 85.7kg 204 17.0st / 108.0kg 238 the components as illustrated in Figure 10c. Using an inner top hat washer (4) seated in
the bearing, slide the M8x65mm bolt (7) through the top KP5AX bearing, and repeat the
10.5st / 66.7kg 150 14.0st / 88.9kg 215 17.5st / 111.1kg 245
procedure to drift out the lower KP5AX bearing. Once these bearings have been removed,
11.0st / 69.9kg 158 14.5st / 92.1kg 203 18.0st / 114.3kg 252 it should be possible to remove the remaining two KP5AX bearings with a normal size drift
tool.
11.5st / 73.0kg 166 15.0st / 95.3kg 210

* Pounds per Square Inch (psi) 6.3.2: INSTALLATION OF KP5AX BEARINGS

Rear Suspension Set-up - Rebound Damping:

Fig. 10e

When the damper unit is being compressed, this is known as the compression stroke. As
the suspension unit recovers from compression back towards its full length, this is called
the re-bound stroke. All the shocks fitted as standard to the Whyte E-5 XT and WORKS
bikes have factory set compression damping, and manually adjustable rebound damping.

Rebound Damping Adjustment:

This adjustment fine-tunes the speed at which the rear wheel returns to its normal ride
height after hitting a bump. The adjuster is coloured red and is found on the rear damper
unit. An arrow marked slower indicates the direction to turn the dial to slow down the re-
bound speed of the suspension. To demonstrate the effect of this, turn the adjuster to its
slowest setting. Press down on the saddle to compress the suspension, then release the
load. The suspension recovers very slowly to its original position.

Repeat the above with the adjuster turned to the fastest setting and the difference will be
seen immediately the load is released. We recommend the optimum setting is to adjust the
re-bound damping to be as slow as possible, but not so slow that the normal ride height is
not recovered. On very rough terrain, if the rear of the bike becomes progressively lower
as more bumps are hit then the re-bound damping is set too slow. On the other hand if the
bike feels choppy and not plush then the re-bound damping is too fast. A bit of trial and Item Part No. Description Quantity
error is needed to get the exact setting. IMPORTANT SAFETY NOTE: Always stop riding
1 1 Piece Link body Quad-Link Body -
when making adjustments of any kind to the bicycle!
2 KP5AX KP5AX bearing 4
Fox Float RP3 Adjustment
8 - Link Spacer Tool -

The Fox Float RP3 damper gives you three Pro Pedal options to help you tune the damper
even further for the type of trail you are about to ride. Refer to the Fox Float RP3 Instruc-
tion Manual to learn more about these advanced features.
9 - Bearing Insertion Tool -
To install the KP5AX (2) bearings into the links, first ensure all bearing surfaces and faces
are free from grease old retaining compound and all other contamination. Slide the Link
spacer tool (8) in between the inner faces of the One Piece Link (1), as shown in Figure 5.

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WHYTE 46 Service Manual

3.4: WHYTE BIG GRIPPER DROPOUT SYSTEM

Fig. 4a

TO REMOVE WHEEL: Fig. 4a

Rotate QR lever anti-clockwise to down position.

Open dropout base.
Remove wheel by lowering vertically down.

LH RH

Fig. 4b
Fig. 10c

TO REFIT WHEEL: Fig. 4b

Place Axle Adapters on wheel into dropout.

Close Dropout Base.
Rotate QR lever clockwise to up position.
Check wheel is secure by pushing down on top of
wheel.

LH RH

Fig. 4c

OK TO RIDE: Fig. 4c

QR Lever is in up position.
Dropout Base is closed.

Fig. 10d To check if secure, lift bike and push down on top
of the wheel.

LH RH

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3.4: WHYTE BIG GRIPPER DROPOUT SYSTEM CONTINUED...

Fig 10a
Fig. 4d

DO NOT RIDE: Fig. 4d

Dropout Base NOT closed. QR Lever Open

LH RH

Fig. 4e

DO NOT RIDE: Fig. 4e Fig. 10b

QR Lever NOT in up position and Closed

LH RH

IMPORTANT SAFETY NOTE:

If at any stage you are uncertain about the safety or safe operation of the Whyte Big Grip-
per Dropout System as a whole, or any specific component, please consult your Whyte
Dealer for advice.

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6.3: STRIPPING AND REASSEMBLING QUAD-LINKS
Fig.10: Front and Rear Quad-Link Assemblies
Item Part No.
1 1 Piece Link body
2 KP5AX
3 Spacer4B
4 Washin4B
5 Washpl4B
6 Washout4B
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WHYTE 46 Service Manual
4.0: SAFETY
IMPORTANT: The following are intended to be advisory notes on the safe use of your
Whyte 46. If at any stage you are uncertain about the safety or safe operation of the bike
as a whole, or any specific component, then DO NOT RIDE YOUR WHYTE 46 and instead
please consult the specific component manufacturers instruction manual or your Whyte
Dealer for advice.
Maximum Rider Weight Limit for Whyte 46: 18 Stone/114.3kg
WARNING: As is the case with all mechanical components, the bicycle is subjected to
wear and high stresses. Different materials and components may react to wear and stress
fatigue in different ways. If the design life of a component has been exceeded, it may fail
suddenly causing possible injury to the rider. Any cracks, scratches and decolourisation in
highly stressed areas are showing that the component has exhausted its life time and has
to be replaced. If you are in any doubt about one or more components on your Whyte 46
DO NOT RIDE YOUR BIKE. Consult the specific component manufacturers literature, or
take your bike to your local Whyte Dealer.
Before your first ride:
• Brake levers: Familiarise yourself with which brake lever operates which brake. As
standard the Whyte 46 is set-up so as the right-hand brake lever operates the front
brake, and the left hand brake lever operates the rear brake.
• Gear Shifters: Familiarise yourself with the function and operation of the gear shift
levers in accordance with
• Whyte Lock On Grips: Make sure the grips are securely fastened to the handle-
bars and cannot rotate or become loose at any time during riding.
• Tyre pressures: They should be set by your dealer before you collect the bike.
However, ensure that the tyre pressures are in between the upper and lower limits
as shown on the sidewalls of the tyres.
• Maverick Fork Dropout System: Ensure that you have consulted the Maverick
DUC.32 Fork Instruction Manual and are fully aware of how to remove and replace
the front wheel from the Maverick DUC.32 Forks. This is different system to the
Whyte Big Gripper Dropout System explained elsewhere in this manual.
• Suspension Settings: Ensure that you have followed the recommended proce-
Description Quantity dures for setting up the Whyte 46 suspension systems outlined in Sections 3.2 and
3.3 of this manual
Quad-Link Body -
• IMPORTANT: please note that you must ensure that your Whyte 46 complies with
KP5AX bearing 4 your countries National Legal Requirements when the bicycle is used on public
roads.
Centre Spacer 1
Shield washer 2
Shield washer 2
Shield washer 2
2006 Edition 1 Page 11 2006 Edition 1
 WHYTE 46 Service Manual
WHYTE 46 Service Manual
Point Description Part No.
After Every Ride:
1 M5x16 Socket Head Cap Screw 97-0000
• Post-Ride cleaning: We strongly recommend cleaning your bike after every ride.
This provides you with the best opportunity of a close and systematic inspection of 2 Collar 97-3035
almost every component, for damage and wear on a ride by ride basis. 3 Shaft 97-3036
• Lubrication: Directly after cleaning your bike after a ride, is the best time to carry
4 Top Hat Bushes TOPHAT2012
out the lubrication regime for the various components as outlined in this manual,
and in the respective component manufactures technical information. 5 Whyte QR Lever Assembly -

6 QR Lever Assembly Adjuster Nut -

Before every ride: Pre-ride safety check
• Frameset Components: We recommend that before every ride you visually in- 7 M6 Cap Head Bolt BOLTM6x70-4B
spect the mainframe swinging arm and associated components for signs of damage 8 M6 Cap Head Bolt BOLTM6x85-4B
or excessive wear due to hard use.
• Brakes: Check the Disc and Brake pads for wear and performance degradation, and 9 Washer M6 Washer

the hydraulic hoses for damage, in accordance with the specific recommendations in 10 Nyloc nut M6 Nyloc
the relevant component makers instruction manual bundled with this manual.
11 Plastic Plug 97-3032
• Wheels: Check that both wheels are securely attached to the bike, and the respec-
tive dropout systems are correctly adjusted. Check the condition of both wheels,
6.2.1REMOVAL OF SWINGING ARM: Fig 9
and look for cracks or large dents in the aluminium Rim, and check for loose or bro- Tools required: 5mm A/F Allen keys
ken spokes and/or spoke nipples, and wheels out of alignment in line with the spe- 10mmA/F socket with ratchet or T-Bar drive
cific recommendations in the relevant instruction manual bundled with this manual.
• Lubrication: Check all parts have been lubricated in accordance with the specific To remove the Swinging Arm from the bike, follow the procedure to remove the Damper
component makers instruction manual. Unit (Section 6.1). Next remove the Rear Disc Brake Calliper from the drop-out, and de-
• Gear Shifting: Check for and replace any frayed or degraded cable inner wire and tach hose from the stops. Do not allow calliper to dangle unsupported by it’s hose. Remove
outer casing and check all relevant parts are in correct adjustment for use in accor- the rear derailleur mechanism from the swing arm. Next remove the two Plastic Plugs (11).
dance with the specific instruction manual Now using the 5mm Allen key to hold the Bolt (8) at the front of the Swinging Arm and
using the 10mm A/F socket loosen and remove the Nylock Nut (10) and M6 Washer (9),
• Steering and Headset: Check for loose headset bearings or tight spots when turn-
now remove the Bolt (8) and M6 Washer (9). The Swinging Arm should now be released
ing the handlebars in both directions, and service, adjust or replace in accordance
form the Front Quad-Link. Next use the 5mm Allen key to hold the Bolt (8), in the Swing-
with the manufacturers specific instruction manual.
ing Arm just behind the seat tube, use the 10mm A/F socket loosen and remove the Nylcok
• Tyres: Check for excessively worn, or cut tyres. Check the inflation pressure is Nut (10) and M6 Washer (9), now remove the Bolt (8) and M6 Washer (9). It should now
within the recommended range. Refer to the specific manufacturers recommenda- be possible to remove the Swinging arm by lifting it vertically upwards then forwards away
tions. from the Main Frame.
• Helmet: We recommend that for off-Road riding, a helmet meeting a reputable
international standard is used and be worn on every ride. Check the helmet is not 6.2.3: REMOVAL OF QUAD-LINKS: Fig. 9
damaged in any way before riding. Do not ride if your helmet has sustained dam- Tools Required: 5mm A/F Allen Key
age. 10mmA/F socket with ratchet or T-Bar drive

Designed for the following
The Whyte 46 has been designed, tested and Din Plus certified for XC riding.
The two Quad-Link assembly’s used on the Whyte 46 are identical, as are the removal pro-
cedures. Having followed the procedures above to remove the Damper unit and Swinging
arm, use the 5mm Allen key to hold the Bolt (7) then use the 10mm A/F socket to loosen
and remove the Nylock Nut (10), next remove the Bolt (7), now remove the Quad-Link
assembly from the Main Frame, taking care not to drop any parts if the assembly.

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 WHYTE 46 Service Manual
WHYTE 46 Service Manual
6.1 continued...
Tools required: 4mmA/F Allen Key - 2 off 5.0: LUBRICATION

Support the bike by clamping the seat post in a work stand. Remove the rear wheel. Open 5.1: GETTA-GRIP SEAT CLAMP
the Whyte QR Lever (7) and undo the QR Adjuster nut (8) completely. Pull out the QR
Shaft (7) from the bike. The Damper Unit should now be disconnected from the Swinging 5.1.1: BOLT-UP
Arm. Next, in order to remove the Damper Unit from the Main Frame (1) use the two 4mm
Allen keys to loosen the Screws (2). Whichever Screw (2) loosens first, remove the Shaft Point Description Lubricant
Lubrication Fig.6a: Bolt-up Style Lubrication
Interval
(4) from the opposite side. The Damper Unit may now be removed from the bike. Ensure
you collect the Top Hat Bushes (5) from the Shock Mount (1) as you remove the Damper Castrol LM
Unit. M6 x 30mm
1 or Once a Month
Fastener
equivalent
6.2: REAR SUSPENSION ASSEMBLY

Fig.9: Whyte 46 Assembly

5.1.2: QR STYLE

Lubrication Fig.6b: QR Style Lubrication

Point Description Lubricant
Interval

Whyte QR Castrol LM
After Every
1 Lever Cam or
Ride
Surface equivalent

Castrol LM
2 M6 QR Shaft or Once a Month
equivalent

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 WHYTE 46 Service Manual WHYTE 46 Service Manual

5.2: WHYTE BIG GRIPPER DROPOUT SYSTEM 6.0: SERVICING THE REAR SUSPENSION

6.1: REMOVAL OF REAR DAMPER

Fig.7: Rear Big Gripper lubrication

Fig.8: Whyte 46 Damper Assembly

Point Description Part No.

Point Description Lubricant Lubrication Interval
1 Main Frame Shock Mount N/A
1 QR Lever (Shaft Only) Castrol LM or equivalent Once a Month
2 M5x16 Socket Head Cap Screw 97-0000
2 Catch Stud (Head Only) Castrol LM or equivalent Once a Month
3 Collar 97-3035
3 Bobbin Outer Contact Surface SKF Anti Fret Paste Once a Month

4 Bobbin Inner Contact Surface SKF Anti Fret Paste Once a Month 4 Shaft 97-3036

5 Dropout Inner bore Castrol LM or equivalent Once a Month 5 Top Hat Bushes TOPHAT2012

6 FOX Bushes (22mm) FOXBUSH5

5.3: GENERAL W-46 LUBRICATION
For the correct lubrication regime and maintenance of all parts on both the Whyte 46, 7 QR Lever Assembly -
please refer to the specific component manufacturers detailed instructions bundled with 8 QR Adjuster Nut -
this manual or for further information visit the specific manufacturers website.
9 Rear Swinging Arm N/A

10 Whyte Bearing Up-Grade Kit (42mm) -

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