Introduction: 3T Exploro Build Up
Building the bike up with shimano dura-ace di2 and hydraulic disc brakes.
Step 1: Install Rear Derailleur
The Exploro uses a dropout that threads onto the rear thru axles.
Step 2: Front Derailleur
If you're running 2x you need to install the front the derailleur hanger that comes in the spare parts kit envelope.
Keep the front derailleur to hanger bolt loose for now. You'll tighten it down once you have the cranks installed and can position it correctly.
Step 3: Route Rear Brake Line
Throw some rubber tubing on the rear hydraulic brake line. You'll thank me later.
Route the hose through the down tube and under the bottom bracket area. It's super difficult to get it through and down the chain stay. Poke a sharpened spoke into the stop, place it in the center of the hose, and guide it the rest of the way through.
Step 4: Battery and Junction Box
I put the battery inside a short piece of pipe insulation to keep it from rolling around the down tube. Tie a piece of string to it so that you can pull it out if you ever need to do any maintenance.
Push the battery into the top tube from the top of the head tube.
Tape the end of the string inside, near the top.
Step 5: String the Rear Derailleur Wire
Route the wire through the the hole on the seat stay, push it down the chain stay, and connect at the Junction block near the bottom bracket.
Step 6: Install Seat Post
Line up the grooves on the seat post clamp by either tightening or loosening the bolt. Loosening the bolt makes the two smaller triangles (top and bottom of assembly) slide towards the longer side of the middle trapezoid piece - effectively make the assembly taller.
Warning: be sure to stop loosening the seat post clamp bolt as soon as you feel the torque drop and you are able to move the seat post. Continuing to loosen the bolt will expand the clamp enough to press on the top and bottom of the top tube - potentially cracking, or even worse, punching a hole through the carbon.
Drop the clamp into the frame.
Step 7: Install Fork
Press the crown race onto the fork.
Install the upper and lower cups into the head tube.
Install fork I to head tube. Hold it I. Place with the stem until you figure out the steer tube length.
Step 8: Install Bottom Bracket
We're using an enduro BBC seen here. Make sure the drive side bearing is square to the non-drive side before starting to torque.
Step 9: Install Junction Box at the Stem
Use the rubber strap to mount the junction block under the stem. Connect the left and right shifter wires as well as the battery wire.
Step 10: Hydraulic Brakes
Push the connector insert I to the hydraulic line for the lever and caliper sides.
Slide the bolt and olive onto the line.
Tighten down the bolt on the shifter and caliper.
Step 11: Seat Clamp
There are two inserts that slide together to make the seat to post attachment.
Push the first one into the seat post, and then the inner insert into the first.
The seat level adjustment is done by rotation of both, or one insert, to get the correct seat pitch. The larger insert has 1 degree of adjustment per tooth, and the smaller insert has 0.5 degrees of rotation per tooth.
Torque to 7 Nm maximum, and follow this strictly so that you don't strip the bolts. Be sure to alternate side as you increase torque. This will ensure that the insert is centered.