Z & ZW Owner’s Manual
Felt Z & ZW Internal Routing Manual Part I Part II Part III Z & ZW Mechanical Cable Instruction . . . . Pg. 1-7 Z & ZW Brake Routing Instruction . . . . . . Pg. 8-11 Z & ZW Electronic Wiring Instruction . . . . . Pg. 13-19 Note: This manual is not intended as a comprehensive use, service, repair or maintenance manual. Please see your dealer for all service, repairs or maintenance. Your dealer may also be able to refer you to classes, clinics or books on bicycle use, service, repair or maintenance.
Z & ZW Small Parts Mechanical Cable & Brake Instruction 1 1. Mousetail Ferrule 2. Cable Bottom Bracket Cable Guide 3. Brake Cable Housing 4. Front Derailleur Grommet 2 3 4 5 6 7 8 5. Cable Housing Stop (x4) 6. Hydrolic Brake Grommet 7. Shifter Cable (x2) 8.
Z & ZW Mechanical Cable Internal Routing Road Map Rear Derailleur Cable to Shifter Front Derailleur Cable to Shifter Rear Brake Cable to Brake Lever -2-
Step 1 Thread Front Derailleur Shifter Cable through the shifter and into cable housing until the head of the shifter cable is seated correctly in shifter. (depending on your shifter, may look different than the one pictured) Step 2 a. Feed Front Derailleur Cable into Mousetail Ferrule and downtube via Cable Stop as pictured. Pull cable taut as it exits the bottom bracket hole. b. b. The grommet on the end of the cable housing should fit snugly into the Cable Stop.
Step 3 Front Derailleur Cable is shown exiting the bottom bracket hole. Step 4 Repeat steps 1 and 2, routing the Rear Derailleur Cable through the right shifter, cable housing, though the Cable Stop and out the bottom bracket hole.
Step 5 Slide the mousetail over the Front Derailleur Cable until at least 2” of cable is exposed. Pull both cables to ensure tautness and confirm they cross over each other in the downtube, but do not touch each other, or shifting will be compromised. b. Route Front Derailleur Cable through small bottom bracket hole and out Front Derailleur Grommet Hole as pictured below. c. Insert Bottom Bracket Cable Guide as pictured below. Align with frame and press until it snaps into place.
Step 6 a. Take cable housing and apply a ferrule to each end. Fit one end into the chainstay cable housing mount and route Rear Derailleur Cable through as pictured. b. Locate the eyelet on the rear derailleur and route Rear Derailleur Cable though and fit Ferruled cable housing into the eyelet as pictured. c. Tension and tighten Rear Derailleur Cable in the tension bolt assembly as shown.
Step 6 a. If necessary, slide mousetail into place; about 1” should extend through the Front Derailleur Grommet Hole as shown. If Mousetail is too long, trim Mousetail. b. Slide the Front Derailleur Grommet over the Front Derailleur Cable and press into Front Derailleur Grommet Hole as shown. c. Mount the Front Derailleur if needed. While under tension, reattach the Front Derailleur Shifter Cable to the Front Derailleur.
Step 7 Rear Brake Routing Prior to routing the rear brake, you’ll want to remove the Top Tube Cable Stop near the seat tube. Place the Top Tube Cable Stop and 2mm bolt aside to be in stalled after routing the rear brake cable.
Step 8 a. Route the Rear Brake Cable into the Top Tube Cable Stop nearest to the frame’s head tube as pictured. * If using hydraulic brakes, be sure to replace the Cable Housing Stop with a press-fit silicone Hydraulic Brake Housing Stop before routing Hydraulic Brake Housing.
Step 9 b. Feed cable through the top tube until cable exits rear top tube grommet nearest to the seat tube. c. Replace the top tube grommet and tighten the 2mm screw to secure in place as shown. d. Slide the piece of Rear Brake Cable housing (ferrule side) into the top tube grommet as shown. e. Route the Rear Brake Cable into the rear brake tension bolt as shown and attach cable to brake.
Step 10 Front Brake Cable Installation a. Insert brake cable into brake lever and route through cable housing. Pull taught until cable head is firmly seated in the shifter lever. b. Thread brake cable into Front Brake Tension Bolt. Exposed brake cable housing should fit into Front Brake Tension Bolt. c. Pull cable to tension and attach to front brake as shown.
-12-
Z & ZW Small Parts Electronic Wiring Instruction 1 1. Bottom Bracket Grommet 2. *Junction B 3. Di2 Wire Grommet 4. Frame Grommet Plug *not included with frame 2 3 4 5 6 7 8 5. Brake Cable Housing Stop 6. Brake Cable Housing Stop Screw 7. Small Di2 Grommet 8.
Z & ZW Electronic Wire Routing Road Map Battery Cable to Junction Front Derailleur Cable to Junction External Battery (if applicable) * Di2 Junction Box B Rear Derailleur Cable to Junction Downtube Cable Brain to Junction -14-
Shifter Junction Wire Step 1 Brake Cable Electronic Wire a. Route the wire down thruogh the top tube wire-endtry point, through the downtube and out the bottom bracket as pictured. Tip: to make routing easier, tape the end of the wire to the end of a piece of brake cable (as a steel cable is easier to route than a wire or housing). Once cable is visible through exit hole, pull through and remove tape.
Front Derailleur Wire Step 2 (A) Route the wire, entering the small hole located under the front derailleur mount and out the hole under the bottom bracket as pictured. Press-fit the Front Derailleur Grommet (A) into the hole to prevent Di2 wire from falling into the frame. b. If needed, attach front derailleur and plug in Rear Derailleur Wire.
Rear Derailleur Wire Step 3 a. Route the rear derailleur wire through the hole in the drive-side dropout, through the chainstay and out the wire-exit hole under the bottom bracket as pictured. b. If needed, attach rear derailleur and plug in Rear Derailleur Wire.
b. After, fit the connected Di2 Junction B into the hole in the bottom bracket and plug with supplied bottom bracket plug as pictured. Plug Di2 wire into battery mount. 1 2 Rear 3 4 Front Junction B Step 5 a. Plug front and rear derailleur wires (1&2) into junction box (Rear). Plug battery wire (3) and shifter wire (4) into junction box (Front).
Wire Grommets Step 8 C a. Press in any remaining grommets. Refer to below images for placement. A b. If not already done, connect wires to derailleurs and Junction B.
Felt Racing, LLC 12 Chrysler Irvine, CA 92618 Industriestr. 39 26188 Edewecht Germany www.feltbicycles.
