Here’s a table of torque settings:

Bolt/Thread	Torque Setting	Model
* Bearing clamp bolts	14Nm	22X, Patriot, Five
† Axle pinch bolts for 222 only (M5)	4.5Nm	222, 223, 224, 224-evo
* Shock bolts	16Nm	22X, Patriot, Five
* Axle bolts	16Nm	22X

† Copperslip grease must be used.
* Loctite threadlocker (243 or 248 Stick) must be used.

Print version

The threaded spacer sleeve between the Allen bolts comes in three lengths 29mm, 31mm and 33mm. If you need spares measure the outside dimension of the shock mount on your frame or swing-arm. This distance should match the sleeve length. You can buy them as a spare part here.

Print version

We are often asked what size front mech, seat post or bottom bracket fits a particular model and this can be one of the hardest questions to give an answer to. Because we introduced running changes to each bike, knowing the year of manufacture does not help to clearly identify which variation of the model you may have. Some seatposts were shimmed to fit seat tubes, bottom bracket length is determined by the chainset you use (sorry but we don’t check this with every chainset available) and front mech’s could be top pull, bottom pull or even plate style.

We do not have records of frame numbers for older bikes so this cannot be used to accurately identify a model.

What we have tried to do is give an idea of what was produced over the years, please use this guide, measure the component you are replacing and try and get one with identical dimensions. Always check with your dealer that the part you are purchasing will fit, if in doubt let them do it.

Model	Year	Seat-tube	Seat-post	Front Mech	BB Shell	Comment	Max Disc Rotor	Seatpost Clamp
222	00-03	27.2	27.2	n/a	73		200	31.8
223	03-04	27.2	27.2	n/a	73 ISCG		200	31.8
223 DD	03-04	27.2	27.2	31.8	73	1"1/2 steerer	200	31.8
224	05-07	27.2	27.2	31.8	73 ISCG		200	31.8
224-evolution	08>	27.2	27.2	n/a	73 ISCG		200	31.8
AirO	99-01	27.2	27.2	31.8	73		180	31.8
Alpine 160	09-10	27.2	27.2	31.8	73		200	31.8
Big T	06-08	27.2	27.2	31.8	73	1"1/2 steerer	200	31.8
Blood	09>	27.2	27.2	31.8	73 ISCG		200	31.8
C16, C16R	95-97	30	27.2 +shim	31.8	68	Slot faces rear	n/a	31.8
C16, C16R	97-98	29.6	27.2 +shim	31.8	68	Slot faces front	n/a	31.8
Clockwork	93-94	26.8	26.8	28.6	68		n/a	28.6
Clockwork	98-99	29.6	27.2 +shim	31.8	68	Slot faces front	n/a	31.8
Crush	06-10	27.2	27.2	31.8	68		180	31.8
Crush	11>	30.9	30.9	34.9	68	Tapered headtube	180	34.9
E3	95-98	30	27.2 +shim	34.9	68		n/a	34.9
E4	98-99	26.8	26.8	31.8	68		n/a	31.8
E6	00-02	26.8	26.8	31.8	68		160	31.8
E8	02-05	26.8	26.8	31.8	68		160	31.8
Elite	2011	27.2	27.2	31.8	68	Tapered headtube	160	31.8
evo2	99-03	27.2	27.2	31.8	68		180	31.8
evo4	04-05	27.2	27.2	31.8	68		180	31.8
evo6	06	27.2	27.2	31.8	68		180	31.8
evo8	07-09	27.2	27.2	31.8	68		180	31.8
Five	04-10	27.2	27.2	31.8	73		180	31.8
Five	10>	30.9	30.9	34.9	73 ISCG	Tapered headtube	200	34.9
G2, G3, G4	05>	27.2	27.2	31.8	68		160	31.8
Gringo	99-00	27.2	27.2	31.8	68		n/a	31.8
Hitman	04>	29.8	27.2 +shim	n/a	73 ISCG		180	31.8
Mii	06-08	27.2	27.2	n/a	73 ISCG		180	31.8
Miii	10>	27.2	27.2	31.8	73 ISCG		180	31.8
Mr O	99-00	31.6	27.2 +shim	34.9	73		160	34.9
Mr XC	99-01	27.2	27.2	31.8	73		160	31.8
MsIsle	98-99	31.6	27.2 +shim	34.9	73		180	34.9
MsIsle	99-06	27.2	27.2	31.8	73		180	31.8
O2	97-98	31.6	27.2 +shim	34.9	68		n/a	34.9
P7	94-98	30	27.2 +shim	31.8	68	Slot faces rear	n/a	31.8
P7	98-05	29.6	27.2 +shim	31.8	68	Slot faces front	160	31.8
P7	06-09	29.8	27.2 +shim	31.8	68		160	31.8
P7	10-11	27.2	27.2	29.8	68 ISCG 05		180	31.8
Patriot	99-04	27.2	27.2	31.8	73		200	31.8
Patriot	07-08	27.2	27.2	31.8	73		200	31.8
Patriot 66	05-06	27.2	27.2	31.8	73		200	31.8
Patriot 7+	03-05	27.2	27.2	31.8	73		200	31.8
R8	10>	27.2	27.2	31.8	68		180	31.8
ST4	08-10	27.2	27.2	31.8	73		180	31.8
Sub 3	00-03	27.2	27.2	31.8	73		160	31.8
Sub 5	00-03	27.2	27.2	31.8	73		180	31.8
UFO	98-99	31.6	27.2 +shim	34.9	68		n/a	34.9
X1	96-98	30	27.2 +shim	31.8	68		n/a	31.8
X2	97-99	30	27.2 +shim	31.8	68		n/a	31.8
Zero	00-02	27.2	27.2	n/a	73		160	31.8

Print version

The dealer page lists the demo bikes a store holds in stock and the dates of any promotional demo days. If there isn’t a store with the specific bike you need, any Orange dealer has access to a central fleet they may book on your behalf. These bikes must be pre-booked by your dealer, so make sure you plan ahead.

Print version

The world of cycling is full of buzz words and marketing propaganda. At Orange we try not to pigeon-hole bikes, we realise people ride as individuals, not according to the disciplines which are ‘in’ at the time. We created the ‘ride guide’ simply to show the type of riding the bike was designed for, but also its aptitude in related disciplines.

The marked boxes indicate the design brief of each frame, the stars then indicate how we judge its performance within each category. The Alpine 160 was designed for all-mountain and freeride applications, the stars then show its relative strengths within each discipline. The G3 was designed for XC-trail and adventure riding; the stars again show its relative strengths while the stop signs show any restrictions we place upon its use.

We have chosen the categories based on the most commonly used riding terms, a brief explanation of each is provided below:

Downhill: These bikes are designed for one thing: flat out downhill speed. They are built to take the abuse and provide run after run of big-hit excitement. Downhill bikes are purely performance orientated within a very specific discipline.

Freeride: Freeride bikes are designed for tough, technical, nadgery terrain. Freeriding can cover anything from ploughing through an Alpine rock field to negotiating your way through tricky ‘north-shore’ style trails in the local woods. They are built for serious terrain, but slightly higher bottom brackets and steeper head-angles generally make them more nimble at slower speeds than a dedicated downhill bike.

All-Mountain: All-mountain bikes do just that, they take you up and down any part of the mountain. They have the poise of a freeride bike on the downs, but air shocks and a lighter component package make them less of a struggle to get back up again. They’re the bike for those who want to pedal, but still need a bike to take the hits.

XC Trail: This is the kind of riding most of us do in the UK. It includes everything from trail centre bashing to a full day of riding in the wilds. They’re for anyone who rides all day and needs performance on the ups as well as the downs. But don’t be fooled, just because it’s an XC bike doesn’t mean it isn’t going to scream for more on the descents too.

Adventure: Adventure covers the more traditional aspects of XC. Big days out with a map and compass, getting lost on your local bridleways, or even finding a piece of singletrack which makes the commute to work the best part of the day.

Touring: Plan a route, pack your panniers and head out into the hills for a week of downtime. In our ‘ride guide’ this can include touring around country lanes, doing that point to point off-road ride you’ve been planning for years, or simply riding into work. These bikes can handle off-road riding, but they’re designed for efficiency and versatility rather than trail abuse.

The critical reader will notice the overlap between these categories, and this is reflected in the rating system within the ‘ride guide’. A freeride bike, for example, is going to have downhill and all-mountain capabilities. Similarly, an adventure oriented bike is going to have similarities with both an xc-trail bike and touring bike – that’s our point, none of our bikes just do one thing.

When choosing a bike, be realistic about your capabilities. A longer travel bike does not make you a better rider; technique is learnt, not part of the bike package. If you’re riding xc-trails, don’t buy a freeride bike and believe it’s going to make you a better rider. If you’re in any doubt about what is going to suit you best, talk to your local dealer and get their advice. If you are still unsure, arrange a test ride and take the bike on the trails you ride. If you have fun and want to ride it more, it’s definitely the bike for you. Riding is about feel, not the buzz word which forms the catalogue header.

Print version

All our shocks come with a standard spring which is chosen to suit the largest number of riders within the bikes intended application. The 224-evolution comes with a 400lb spring.

Inevitably, some riders will come outside the suitability of the standard spring. If you are frequently bottoming your bike or not using enough of its travel, you can purchase either a standard spring or an upgraded titanium spring through your nearest Orange dealer. To select the correct spring weight use the calculator on the Mojo website.

If you’re upgrading to a Cane Creek Double Barrel we’re offering three spring options depending on rider weight, more info to follow.

Print version

Standard tires have been chosen in accordance with each bikes intended use and the width which best suits the frame and application. The minimum clearance for any part of the frame should be 3mm, this allows sufficient clearance for wheel flex in the event of a heavy side load. Always ensure wheels are trued and dished correctly.

When changing tires, select a width based on the clearance of your current set up. If there is not sufficient clearance, do not use the tire as it may damage paintwork or the frame itself.

Your choice of replacement tires must also consider fork requirements; check the fork manual or website for details on their minimum clearance requirements. Expect a minimum of around 5mm to be necessary for most fork manufacturers. Check clearance on the fork crown by completely compressing the suspension with a correctly fitted and inflated tire.

Remember, tires can provide the most cost effective way of adapting the performance characteristics of your bike. Establish the type and conditions you are riding and select a tire accordingly. If you are unsure of what suits you best, an Orange dealer can advise you on models and widths.

Print version

This is perhaps the most important decision once you have decided which model suits you best. For this reason, we refer you to the expert advice of our premier dealers. Every rider has different needs depending on their height, shape, and what style of riding they intend to do. Our dealers can provide you with the information you need and make sure you get the fit which is perfect for you. If you are still in doubt, arrange a test ride.

Print version

It is important you look after your bike to ensure maximum performance and improved longevity. The programme you adopt will be dependent on you, your riding conditions and your riding style. We will provide a general schedule here, and remember to follow maintenance instructions provided for non-Orange components.

Print version

Yes, we offer a full re-spray service on all Orange mountain bikes. You can either contact us directly or make arrangements through your dealer.

Before sending your frame for re-spray, remove all over-lacquer decals. This minimises the time we have to spend preparing each frame and maximises efficiency. Package carefully and send to the factory (see contact page). Include a clear covering letter with all necessary contact information.

On receipt of your frame, we will strip the existing paint and prepare it for powder-coating. It will then be painted in the earliest allocated window for that particular colour, with standard colours painted more frequently. Fresh out of the oven we'll face and ream any excess paint, reassemble with new bearings, apply new decals and fit a metal headbadge. This is a fairly labour intensive programme, but when it's finished, it'llcome back looking like brand new.

Expect a wait of two to three weeks depending on colour choice and schedule.

Hardtails (including decals and return postage in mainland UK) – £150
Full suspension (including pivot kit, decals and return postage in mainland UK) – £200

Print version

The warranty card supplied with the bike gives you all the details you need to check the eligibility of a warranty claim on the frame. This is also available online here. The bike should have been registered from new and proof of purchase must be sent with any returns. All warranty claims must be sent via your supplying dealer.

Suspension forks, rear shocks and other parts not manufactured by Orange Bikes are covered by the stated warranty of their manufacturer. Claims on components should be sent to their UK representative again through your supplying dealer.

Print version

If left unchecked, normal cable rub can wear away paint, decals and even cause damage to the frame itself.

During the initial setup and after the inaugural ride it is important you identify any potential areas which may cause issue. Once found, apply necessary protection and/or alter your cable routing to avoid damage.

Figure 1: Typical positions can easily be protected with clear adhesive patches (available at all good bike shops).
Figure 2: The cables can often be lifted away from the frame using cleverly positioned zip-ties; here are a couple of examples as a guide.

NOTE: If damage does occur due to excessive cable rub, this is not a condition covered under your frame warranty. Adhesive patches are not a quick fix for incorrectly installed cables; if you find the patches are wearing quickly, and the tips provided above haven’t helped, consult your Orange Bikes dealer for more information about routing on your bike.

Print version

After a serious accident the frame should be checked for any indication of stress or potential failure. This may include cracks, deformation, corrosion, paint peeling, dents or any other marks consistent with the trauma of a severe impact.

If a problem is identified and you feel that it may be repairable, e-mail a picture to us. We will then contact you with our recommendation and an estimate for any work which we could potentially carry out. Due to the process of heat treatment, any frame repaired which is over three years old may not retain its original strength, so in most cases we recommend the frame be replaced.

In the event that the damage is irreparable, or that the cost would be too dramatic to justify, we refer you to the accidental damage section of your warranty card. To the original owner, and with proof of purchase supplied, we offer a discount for replacement frames damaged in a crash. This discount is a gesture of goodwill and dependant on the conditions set out on the warranty card. If a replacement is provided, be more careful where you’re riding!!

Print version

No. While we stock most standard sticker kits, we do not provide custom options - this includes standard decals in different colours.

Print version

We offer replacement stickers for most models. We may not be able to match your original decals exactly, but suitable alternatives will be offered. All kits include a full set of decals and a metal head-badge.

To order sticker-sets give us a call and be prepared with your frame number and colour so we can find a suitable match. Standard kits cost £19.99 including postage.

Print version

We get a lot of speculative correspondence requesting placements under various study/work experience schemes. Unfortunately we cannot provide a structured experience which would provide the rewards traditional engineering firms may offer. Because of the way we operate, the design, manufacture, marketing and distribution is quite a unique setup which would not give you sufficient exposure and would be difficult for us to implement with the small number of staff at the factory. If we do ever have opportunities these will be advertised with application details on the website.

Print version

Your bearings are maintenance free. They come greased from new. Avoid using a high pressure washer to clean your bike as this will remove the grease. Check the wear of the bearings every 6 months. Remove your rear wheel and rear shock and lift the swing arm up and down. If they feel rough then get a new pair!

Print version

The LT used a Fox Vanilla RC coil shock with a 57mm stroke, if it’s got a 5th element, Fox R or RS unit then its a 5 inch travel version, The Fox RC was the only shock ever specc’ed that was available with a 57mm stroke, there were no changes to LT frames other than removing canti bosses to stop V brakes contacting the seattube under full compression. if you can find a 190/57 Fox RC its an easy upgrade to make provided you run discs.

Print version

This answer applies to the Horiz-Hold pivot models only (Five, Patriot etc), for more detailed instructions and other bearing systems check the tech documents section.

Firstly, you’ll need 3mm and 5mm allen keys, a rubber mallet and a liberal dose of grease.

1. Remove the two dust caps with the 3mm allen key so the bearings are exposed.

2. Loosen the 2 bearing clamp bolts that clamp up the bearings with the 5mm allen key.

3. Using the rubber mallet, tap the drive side of the swingarm away from you. (Make sure you tap the weld so you don’t dent the frame).

4. Clamp up the pinch bolt on the drive side. Now go round to the non-drive side. With some force, using the rubber mallet again, tap the swingarm away from you.

5. This will move the bearing off the pivot pin. Now slacken the pinch bolt and repeat the process until the bearing is drawn completely off. Do the same for the opposite side.

6. To fit the new bearings, apply copperslip grease to the internal bearing surface. Centre the bearing with the pivot pin and tap it on.

7. Centre the swingarm on the pivot pin and torque up the bearing clamp bolts (16NM) and the dust caps (5NM).

8. Done

For more detailed instructions and pictures see the tech docs.

Print version