Nukeproof Mega Carbon Bike Owner's Manual (+ PDF)

Contents hide

1 Mega Carbon Bike

2 MEGA MK4 CARBON BIKE

2.1 Contents

2.2 1 – Unboxing your new Mega

2.3 2 – Assembling your Mega

2.4 How to Fit Nukeproof Pedals

2.5 Documents / Resources

2.5.1 References

Mega Carbon Bike

MEGA MK4 CARBON BIKE

Manual 2023

4 TIMES EWS OVERALL WINNING BIKE

Congratulations on your purchase!

Unboxing your new Mega
Assembling your Mega
How to fit Nukeproof pedals

1 – Unboxing your new Mega

Packaging on Arrival:

The bike will arrive in a large cardboard box. The size of the
box will depend on where you bought your bike. Open the end of the
box carefully and remove the parts box. Set it aside.

Carefully pull the bike out of the box. If possible, have
someone hold the box as you lift the bike. If your box has been
stapled, please remove the staples to prevent paint damage.

The bike will be carefully wrapped before shipping to prevent
any damage in transit. If you find any damage, report it directly
to your dealer.

Remove the protective wrapping and dispose of it appropriately,
recycling where possible.

2 – Assembling your Mega

Assembling Steps:

Unscrew faceplate bolts from the stem with a 4mm hex key.
Remove the stem faceplate and bolts, and set them aside safely for
later installation.
Screw the bolts into the stem, starting with the top bolts and
moving to the bottom bolts. Ensure torque is evenly spread around
all four bolts before fully tightening. Refer to the torque details
on the stem.
Adjust the roll of the bars to your personal preference. Ensure
the bars are centered when adjusting.
Once you have adjusted the roll of your bars, you can change
the angles of the brakes, shifter, and dropper lever to suit your
preference. The controls can also be moved laterally along the bars
to suit the position of your hands.

How to Fit Nukeproof Pedals

All Nukeproof pedals are standard 9/16 x 20BSA threading and
compatible with all modern cranks.

How to Determine Left and Right Pedals:

Alloy Pedals:

Alloy pedal axles are marked “L” indicating the left pedal
(non-driveside) and “R” indicating the right pedal
(drive-side).

Plastic Pedals:

Plastic pedal bodies have an “L” molded in the body indicating
the left pedal (non-driveside) and “R” molded indicating the right
pedal (driveside). The axles are also different, with the left axle
having a ring indented around the lip of the axle, whereas the
right does not.

Fitting Steps:

Check the threads on your crankarm are clean and
undamaged.
Take your RIGHT pedal and grease the axle.
Line the pedal up to the driveside crank. Place your 8mm hex
key through the driveside crank and into the back of the pedal
axle. Start turning the hex key in a clockwise direction (as you
look at the crank towards the handlebars). There should be no
resistance as you turn the hex key. If there is resistance, STOP
immediately and check that you are fitting the correct pedal and
the threads are correctly aligned between the axle and crank. Do
not force the pedal into the crank.

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MEGA MK4 CARBON BIKE MANUAL
4 TIMES EWS OVERALL WINNING BIKE

congratulations!
Congratulations on your Mega purchase and welcome to the Nukeproof family! You will soon be swinging your leg over a 4x EWS overall winning machine, ridden by the legendary Sam Hill. This manual will help you get familiar with your Mega and a helpful resource for maintaining and setting up your bike. Please read this manual carefully to help maintain and enjoy your Mega to its fullest. If you have any doubts or queries with the set-up, use, or maintenance of your Mega, please consult with an authorised dealer. To find the full dealer listing, please visit www.nukeproof.com. Please ensure you read the General Bike Manual as well before use of your new Mega. We hope you enjoy the ride!
MEGA MK4 CARBON BIKE MANUAL 2023 | 2

Contents
Section 1 – Unboxing bike Section 2 Assembling Bike Section 3 Suspension Section 4 – Maintenance and Care Section 5 Specifications/Sizing/Geometry/Assembly/Spares Section 6 – Warnings Section 7 Warranty
MEGA MK4 CARBON BIKE MANUAL 2023 | 3

1 – Unboxing your new Mega
For consumer-direct customers: your new Mega is delivered in a specifically-designed bike box and wrapped in protective material. Your new bike will need minor assembly to complete. It will come with a number of Nukeproof tubeless valves and reflectors; additional items will depend on the dealer you have purchased the bike from and the specific components installed to your bike. Some Nukeproof dealers will provide pedals and basic tools with the bike on delivery, typically a pedal wrench and hex key set.
PACKAGING ON ARRIVAL

Bike will arrive in large carboard box, box size Open end of box carefully. Remove parts box will depend on where you bought your bike. and set aside.

Remove cardboard front wheel support from box this will now allow you to remove the bike.

Carefully pull bike out of box. If possible, get someone to hold the box as you lift the bike. If your box has been stapled, please remove staples to prevent paint damage.

MEGA MK4 CARBON BIKE MANUAL 2023 | 4

The bike will be carefully wrapped before shipping to prevent any damage in transit. If any damage is found, report directly to your dealer.

Carefully remove protective wrapping. Please dispose of it appropriately and recycle where possible.

MEGA MK4 CARBON BIKE MANUAL 2023 | 5

BOX CONTENT
Parts content will vary with dealer, but at a minimum you will get tubeless valves, reflectors, bell, component manuals, fork tokens depending on the make and model of fork, and spare cable-ties for cable routing. Basic tools for assembling bike and pedals are supplied at the discretion of the dealer.
MEGA MK4 CARBON BIKE MANUAL 2023 | 6

2 – Assembling your mega
This section details how to get your Mega ready for setting up and riding out of the box. This will be relevant for consumer-direct bikes generally the following will be done already if purchased and collected through a local authorised Nukeproof dealer. FIT BARS
Unscrew face plate bolts from stem with a 4mm Place bars to stem and align faceplate. hex key, remove stem face plate and bolts, set aside safely for installing later.
Screw the bolts to the stem, start with the top Adjust the roll of the bars at this point to your bolts and move to the bottom bolts. Ensure bolt personal preference. Ensure the bars are still torque is evenly spread around all four bolts centered when adjusting. before fully tightening. Reference the torque details on the stem.
MEGA MK4 CARBON BIKE MANUAL 2023 | 7

ADJUST CONTROLS Once you have adjusted the roll of your bars, the controls can be changed to suit rider preference.

The angles of the brakes, shifter, dropper lever The controls can be moved laterally along the

can be changed to your preference.

bars as well to suit rider preference and suit the

position of your hands.

MEGA MK4 CARBON BIKE MANUAL 2023 | 8

HOW TO FIT NUKEPROOF PEDALS
All Nukeproof pedals are standard 9/16 x 20BSA threading so are compatible with all modern cranks.
Tools Required · 8mm Hex Key (All pedals) Or 15mm Spanner (Alloy pedals only) · Torque Wrench · Grease
How to determine the difference between the left and right pedal
This step is very important, failure to install the pedals on the correct side of the bike will cause irreparable damage your crank and pedal.
Alloy pedals Alloy pedal axles are marked “L” indicating the left pedal (non-driveside) and “R” indicating the right pedal (drive-side).

Left Pedal

Right Pedal

Plastic Pedals Plastic pedal bodies have an “L” moulded in the body indicating the left pedal (non-driveside) and “R” moulded indicating the right pedal (driveside).

The axles are also different, the left axle has a ring indented around the lip of the axle whereas the right does not.

Left Pedal

Right Pedal

Left Axle

Right Axle
MEGA MK4 CARBON BIKE MANUAL 2023 | 9

Fitting

1. Check the threads on your crankarm are clean and have no damage.

2. Take your RIGHT pedal and grease the axle.

3. Line the pedal up to the driveside crank, place your 8mm hex key through the driveside crank and into the back of the pedal axle. Start to turn the hex key in a clockwise direction (as you look at the crank towards the handlebars). There should be no resistance as you turn the hex key, if there is resistance STOP immediately and check you are fitting the correct pedal and the threads are correctly aligned between the axle and crank. Do not force the pedal into the crank.

4. Take your LEFT pedal and grease the axle.

MEGA MK4 CARBON BIKE MANUAL 2023 | 10

5. Line the pedal up to the non-driveside crank, 6. With both pedals now on the crank arms,

place your 8mm hex key through the non-

tighten to 30Nm with a torque wrench.

driveside crank and into the back of the pedal

axle. Start to turn the hex key in a anticlockwise Your pedals are now fitted and safe to ride.

direction (as you look at the crank towards the

handlebars). There should be no resistance

as you turn the hex key, if there is resistance

STOP immediately and check you are fitting

the correct pedal and the threads are correctly

aligned between the axle and crank. Do not

force the pedal into the crank.

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ADJUST SADDLE HEIGHT, ANGLE, AND POSITION
Once you have installed pedals to your bike, you can accurately adjust your saddle height and angle. If you are experiencing roll in your hips when at full leg stretch, the saddle is too high. The ideal saddle height will put your leg at approximately 30 degrees. This may take some trial and improvement to get exactly right for you. Please ensure when adjusting the saddle height, the dropper cable does not get snagged. If the post is raised and the dropper stops locking into position and free to move without activating the lever, there is tension on the dropper cable. Pull the outer cable through the frame to alleviate this.
ADJUST SADDLE HEIGHT

To adjust the height of the saddle, loosen the seat clamp bolt with a 5mm hex key, adjust to correct height, and then retighten.

To get a starting point for your saddle height, stand beside your bike and adjust the height to your hip bone.

Sit on the bike with assistance from another person or leaning against a secure structure. Pedal to the 6 o’clock position to identify if the saddle height is suitable and you can begin to adjust to suit your preference.

Do not exceed the minimum insertion depth marked on the post.

MEGA MK4 CARBON BIKE MANUAL 2023 | 12

ANGLE

The saddle angle can be adjusted by loosening To lower the nose of the saddle, loosen the

and tightening the saddle rail clamp bolts with rear bolt and tighten the front bolt. To raise the

a 5mm hex key. Saddle angle is personal

nose of the saddle, loosen the front bolt and

preference and subjective to each rider. A good tighten the rear bolt. Please ensure both bolts

starting point is to have the saddle at horizontal are tight once adjustment has been made.

and adjust as you spend more time on your Please ensure the bolts are not loosened

bike.

too much as the clamp parts may become

unseated and fall out.

POSITION
The saddle can be moved forward and backwards to suit the rider preference. To adjust the saddle, position the two clamp bolts need loosened. Start in the middle of the adjustment range and with time on the bike move forward or backwards to suit.

Ensure the saddle stays within the adjustment range of the rails to avoid damage.

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ADJUSTING STEM HEIGHT
The stem height can be made higher or lower to suit rider preference. The headset spacers can be placed below or above the stem. Do not add too many additional spacers under the stem, as both stem bolts must be clamping fork steerer. If you are unsure on this process, please consult with your authorised Nukeproof dealer to complete the work.

Loosen and remove top cap bolt and cover with a 5mm hex key.

Loosen both stem steerer clamp bolts with a 4mm hex key.

Remove stem and place spacers to your preference in this example, the two spacers below the stem raise height. Both spacers can be placed above the stem to lower height if needed.

Install stem to steerer, replace top cap and bolt and tighten with 5mm hex key. If steering becomes stiff, top cap bolt is overtightened.

Straighten stem and retighten stem steerer clamp bolts with a 4mm hex key.

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CONVERT TO TUBELESS
All of our adult complete bike’s are supplied with tubeless tape installed, tubeless valves and tubeless compatible tyres to make tubeless conversation fast and simple. This guide will take you through the steps to make your bike tubeless.
Items Required · Tubeless pump · Tubeless Sealant · Tubeless valves · Tools to remove wheels (Usually 5mm / 6mm hex for thru axles) · Tyre levers (not essential with good tyre fitting technique)

1. Remove your wheel from the bike.

2. Remove valve cap

3. Loosen presta value nut and push to deflate 4. When the tube is deflated, remove the nut

the inner tube.

holding the valve in place.

MEGA MK4 CARBON BIKE MANUAL 2023 | 15

5. Unseat tyre by pushing the bead to the centre of the rim. Do this on both sides of the tyre

6. Remove one side of the tyre by taking the bead over the rim.

7. Push the valve through the rim and remove the inner tube.

8. Get your tubeless valve and get it ready to install. At this point also double check that the tubeless tape is still correctly stuck down and not damaged. If it has been damaged the rim will need retaped.

9. Push the valve through the valve hole.

10. Put the o-ring on the valve.

MEGA MK4 CARBON BIKE MANUAL 2023 | 16

11. Fit the tubeless valve nut and tighten.

12. Start to refit the tyre, leave 1/4 open.

13. Add tubeless sealant as per sealant manufacturer recommended amount.

14. Finish fitting tyre. Make sure the bead is pushed to the centre of the rim as this will
make it much easier.

15. Connect your tubeless pump to the valve. 16. Charge the tubeless pump cannister and then release air blast.
MEGA MK4 CARBON BIKE MANUAL 2023 | 17

17. Pump tyre until it is correctly seated. There is a moulded line in most tyres which must be visible and uniform the whole way round. the tyre

18. Reinstall valve cap.

19. Lift your wheel and shake it to get the sealant all round the tyre.

20. Refit your wheel to the bike following the manufacturer’s instructions.
A couple of points to note: It can take a couple of rides for the sealant to get fully around the tyre settle. Don’t be alarmed if you need to top up the air pressure a couple of times between rides. The tyre shouldn’t lose pressure during your ride.
Some tyres will seep sealant from the sidewalls. This should settle after the tyre has been used and generally happens on cheaper sealants so we do recommend using a good quality sealant
If you have an air leak at the rim, it will generally appear to happen at the valve but is most likely to be an issue with the tape. If the air is escaping at the valve then its getting past the tape somewhere and you will need to check your tape is not damaged.
MEGA MK4 CARBON BIKE MANUAL 2023 | 18

INSTALLING WHEELS WITH THROUGH AXLES
*In some cases, if you have mail ordered, your chosen authorised Nukeproof Dealer may have shipped the bike without wheels installed. Please reference the following to install wheels with thru-axles to your bike.
· Nukeproof bikes typically will use thru-axles. · Insert the wheels to the fork and frame dropouts, ensure the rotors are aligned with the
calipers to avoid damage when installing. For the rear wheel please ensure the gears are in the smallest sprocket and pull the derailleur rearwards to give more room for install. Ensure the hub endcaps are seated correctly in the dropouts for a secure fit. · Apply a little grease to the axle and threads and push through the dropouts and hubs until axle cannot be pushed further. · Tighten the thru-axle clockwise to the Nm found on the axle. If no Nm is displayed, please consult with your Nukeproof Dealer. · If the thru-axle is stiff when installing, it may be cross-threading. Stop immediately and check seating of hubs and dropouts. Any further concerns, please consult with your Nukeproof Dealer. · If the forks have pinch bolt dropouts, reference the fork manufacturer guides for correct installation. · If the thru-axles have quick release levers, please reference the axles manufacturer’s instructions for correct install. · Ensure the correct tools are used when fitting and removing thru-axles. If you are unsure, please consult with your Nukeproof Dealers. · Ensure the thru-axles are checked before and after each ride to ensure they are tight. · Riding with loose thru-axles can result in loss of control, injury and death. · If you are unsure on fitting wheels with thru-axles, please consult with your Nukeproof Dealer.
MEGA MK4 CARBON BIKE MANUAL 2023 | 19

FRONT WHEEL

Your bike may be delivered without the front wheel installed.

Insert front wheel and seat hub axle endcaps with fork dropouts, aligning disc with brake caliper and inserting front thru-axle.

Tighten axle fully to fork manufacturers torque specification with a 6mm hex torque wrench.

MEGA MK4 CARBON BIKE MANUAL 2023 | 20

REAR WHEEL

Your bike may be delivered without the rear wheel installed.

Put gears into smallest sprocket position and unlock derailleur clutch mechanism. Insert rear wheel and seat hub axle endcaps with frame dropouts, aligning disc with brake caliper and align chain and cassette.

Insert axle fully to frame and lightly tighten with Tighten rear axle fully to 10NM with 5mm hex

a 5mm hex key

torque wrench and engage derailleur clutch.

MEGA MK4 CARBON BIKE MANUAL 2023 | 21

MEGA CARBON FRAME FEATURES
Now that your bike is assembled, you can familiarise yourself with the following frame features on your Mega Carbon.
Frame Design Details:
1. Full UD Carbon Fibre T700/800 monocoque frame 2. Seat tube designed to allow maximum seat post insertion 3. User friendly cable routing. Tube in Tube – Internally piped cable routing (Carbon frame only) 4. UK PROOF MUD/TYRE CLEARANCE ON SS/CS. 5. MAX TYRE SIZE: 2.75=2.6 / 29=2.5 6. Boost 148mm hub spacing

MEGA MK4 CARBON BIKE MANUAL 2023 | 22

Frame Design Details:
1. Collet Main Pivot for stiffness and security 2. Sram UDH Gear Hanger 3. Sealed bearings used throughout for increased durability 4. Gear accessory mount on underside of TT 5. Threaded 73mm Bottom Bracket 6. 750mm Water bottle now fits inside the front triangle 7. 3D Contoured Rubber frame protection for SS/CS/DT to protect and silence your ride 8. Carbon frames come with clear paint protection kit to protect your paintwork

MEGA MK4 CARBON BIKE MANUAL 2023 | 23

GETTING FAMILIAR WITH YOUR BIKES CONTROLS ONCE ASSEMBLED Nukeproof adult bikes are all equipped with powerful modern disc brake systems. Disc brake systems offer exceptional control and power. Please note, power will improve with some use once the pads and discs have bedded in. Ensure you familiarise which lever operates the front or rear brakes. Your dealer will set the brakes to what is typically used in your country, but please check lever orientation or get the brakes set to your preference by your dealer. Adjust the position of the brake levers so the lever is in a comfortable position and easy to pull. This is shown in the assembly guide. Brake performance will vary with riding terrain and weather conditions, so familiarise yourself with your brake’s performance in different conditions. The gears on the bike are operated by shifter/s on the handlebars, moving through the range of gears by clicking up and down the shifter paddles will help with pedalling in different terrains. Gear shifter position can also be adjusted, as shown in the set-up guide. Ensure the shifter/s are in a position they are easily accessible and use. Ensure when shifting you are pedalling smoothly forward, do not shift and pedal backwards. Pedalling backwards can damage the gears and result in an accident. When initially getting familiar with your brakes and gears, please ride in a familiar location in good conditions while wearing a helmet. If you experience any issues with your brakes and gears, immediately stop riding and consult with an authorised Nukeproof dealer for maintenance or repair.
MEGA MK4 CARBON BIKE MANUAL 2023 | 24

3 – Suspension
This section will help you set up, understand and maintain your Mega’s suspension. If you have any doubts, please consult with an authorised Nukeproof Dealer. The MK4 Mega features a traditional 4-Bar Horst link layout but an all new kinematic compared to previous Mega models. The MK4 has a progression of 17% with a leverage ratio of 2.6. Designed to be more subtle off the top, whilst remaining supportive and progressive though the rest of the range. It has a higher average ratio to improve sensitivity and reduce the forces required for breakaway movement. The MK4 has stronger mid-stroke support for better cornering, pumping and pedalling performance. Another key feature is a reduced overall progression from sag, allowing the MK4 to be much more tuneable for the rider with the use of volume spacers. The new kinematic is designed to have higher levels of anti-squat for climbing gears, but this reduces as you drop down the cassette. The result is a bike that is more confidence-inspiring everywhere on the hill. It behaves itself on the climbs but can still be thrashed through the roughest and most technical terrain on the way back down.
To get the most out of your Mega you will need to set up and maintain your suspension. Suspension maintenance is specialist work we recommend you use official service centres and observe regular service intervals as detailed in the manufacturer’s user guides. Before your first ride, the suspension will need to be adjusted. The recommended sag for the Mega is 30-35%, seated with riding kit on. You will need a shock pump to set your sag. The rebound and compression settings are subjective to terrain, riding style and rider preference. Adjust the settings as you ride to find what works best for you.
· Before setting up your suspension, please read the full manual for your shock and fork. FOX provides a QR code on their 2022 onwards forks and shocks. Scan the code and all specific tuning and service guides will be provided. SRAM includes set-up guides for forks and shocks in one document. Rockshox service documents are model specific and linked below.
· For our limited edition Sprung series frames with EXT, FAST and PUSH shocks, set-up guides are available on Nukeproof Technical Support page.
· Remember when setting your rear shock, the lock-out is in the off position.
MEGA MK4 CARBON BIKE MANUAL 2023 | 25

Always set your sag when the bike is on a level surface and ensure you have something to steady yourself with or a person to hold the handlebars while you sit on the bike.

Always set your sag before rebound and compression is adjusted.

Please make incremental suspension set-up changes to ensure the bike riding characteristics are predictable and controllable. Set the rebound and compression adjusters at mid-point and add and remove clicks to suit.

MANUFACTURER ONLINE SET-UP AND SERVICE GUIDES

FOX

FOX Set-Up & Service Guides

ROCKSHOX

Rockshox Set-Up & Service Guides

MEGA MK4 CARBON BIKE MANUAL 2023 | 26

SHOCK SIZE / TUNE / UPGRADING If you wish to change your shock for an upgrade or a different model to your preference, please consult with your suspension supplier to ensure the shock is the correct size and the tune suits the kinematics of the Mega. The following details will help with fitting a new shock and ensuring the tune is suitable. SIZE 29/297/275 – 230×62.5mm Bearing End (230x65mm shock can be used, but stroke will need a 2.5mm spacer) Note: a standard eyelet shock without a bearing end can be used with the correct hardware size. Please ensure the hardware matches the shock and the required size for the frame. If a bearing end shock can be sourced, this would be preferential to ensure the smoothest suspension action. HARDWARE Front 25x8mm / Rear 30x8mm TUNE When purchasing a new shock, the provider will need a tune to suit the Mega suspension kinematics, the following charts provided will need referenced by your suspension provider.
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LEVERAGE RATIO AND FORCES:

The MK4 kinematics has been updated to work with lower forces before sag and higher forces after sag. This increases sensitivity from zero travel for better small bump absorption and traction and still ensures more mid stroke support for aggressive riding and hard hits. The MK4 has an excellent balance between small bump, traction, stability, and hard hits with predictable feel throughout the full travel range.

(mm/mm)

leverage Ratio

2.93

2.87
mega v4
mega v3
2.81

2.75

2.69

2.63

2.57

2.51

2.45

2.39

2.33

2.27

2.21

2.15 0

120

150

wheel travel

F (N)

Forces

2400

2200

2000

1000

1600

1400

1200

1000

800

2.33

400
mega v4
mega v3
200

120

150

wheel travel

MEGA MK4 CARBON BIKE MANUAL 2023 | 28

ANTI-SQUAT AND ANTI-RISE

The MK4 Mega has been designed for improved anti-squat with good mid-stroke support this is the winning combination for climbing traction. However, anti-squat should never prevent suspension from working well over rough terrain. Therefore, it is designed with higher levels of anti-squat in climbing gears (however still relatively low) that drops off in descending gears to give you a bike that behaves itself on the climbs yet provides ultimate suspension performance on the way back down. Climbing gear 32/50T Anti-Squat is 102%, in descending gear 32/10T Anti-Squat reduces to 65%.

The MK4 is also slightly more active under braking with lower anti-rise figures compared to previous Mega models. This helps to keep good traction when heavy on the brakes in rough
terrain.

a(%)

anti – squad

101%

108%

105%
mega v4
102%
mega v3
99%

96%

93%

90%

87%

84%
anti-squad

81%

(32-50)

78%

75%

72%

69%

66%

63%

60%

57%

54%

51%

48%

45%

42%
anti-squad

39%

(32-10)

36%

33% 0

120

150

wheel travel

ar(%)

anti-rise

112%
mega v4 mega v3
104%

96%

88%

80%

72%

64%

56%

48%

40%

32%

24% 0

120

150

wheel travel

MEGA MK4 CARBON BIKE MANUAL 2023 | 29

MAXIMUM AXLE TO CROWN AND TRAVEL OF FORK The fork length also detailed as axle to crown (A-C) cannot be exceeded. Maximum A-C for the Mega is 596mm. Using a fork that exceeds the A-C may lead to frame failure and injury. Using a longer axle to crown fork will void warranty. The bike is designed with a 170mm in mind, 180mm can be used if the A-C is not exceeded.
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4 – Maintenance and Care, to keep your Mega running proper
Nukeproof bikes and components are designed to be hardwearing and corrosive resistant, but to ensure the bike looks and runs its best, some general maintenance will be required. This will prolong the lifespan of components and ensure your safety. If you have any doubts, please consult with the dealer you purchased the bike from or any authorised Nukeproof Dealer.
BEFORE YOU RIDE
Please inspect your bike before each ride to ensure your bike is in full working order. If there are any issues you cannot resolve yourself, please consult with a local reputable mechanic and escalate to an authorised Nukeproof dealer if needed. Any small concern with your bike could develop into a further issue and ruin your ride or become a safety concern. If you have any doubts, please seek advice from your dealer.
FRAME AND FORK
Please do a visual check of your frame and fork. If you see any cracks or sharp dents, please contact your dealer immediately for inspection and do not ride your bike. If you hear any unusual noises or creaks, please have your bike inspected by a reputable mechanic and escalate to your dealer if needed. Check all pivot points and bearings for signs of play. If any play is detected, please check the pivot bolts for the correct torque this process is detailed within this document. If all torques are correct and play is still present, your frame bearings may have perished. This document details the bearings required for the frame. Please use a reputable mechanic or authorised dealer to replace.
DRIVETRAIN AND BRAKES
Please ensure your drivetrain is cleaned and lubricated often to avoid premature wear. Any unusual noises from your drivetrain would suggest gear indexing needs adjustment If parts have perished, become loose or damaged, please have the bike inspected. Gear cables are perishable parts and will need changed periodically depending on use and riding conditions. The brakes should be inspected often for pad and rotor wear and changed when required. Ensure the brakes are operating correctly before use and ensure there is no play in the calipers and rotors. If play is found, please torque fitting bolts to manufacturers respective guidelines. Brakes will need to be bled occasionally how often is dependent on conditions, riding style, and terrain.
MEGA MK4 CARBON BIKE MANUAL 2023 | 31

WHEELS AND TYRES
Check wheel axles before each ride to ensure they are not loose if loose, tighten to torque specification. Check wheels for bearing wear/play, damage, loose spokes, and trueness. Wheel bearings are a perishable part and will need changed occasionally, this can be identified by rough/ noisy bearings, play, and drag in the freehub. Please consult with a mechanic or authorised Nukeproof dealer to replace bearings and ensure spoke tension. If the rim is damaged/cracked, please refrain from riding your bike and consult with an authorised dealer for a replacement. Tyres will need checked for damage and wear. Cuts in the tread and sidewalls can lead to a tyre failure and will need to be replaced. Ensure tyre pressure is within range to the manufacturer specification found on the sidewall.
HEADSET
If there is play from the headset when the front brake is applied, this is a sign the bearings have perished, or an adjustment is required. To adjust the headset, loosen the two stem steerer bolts, tighten the top cap bolt and then retighten the stem steerer bolts again. This will pull the headset together and remove play. If the play continues, please contact an authorised dealer for replacement bearings or an inspection. Please note if the headset is overtightened, the steering may become stiff.
GENERAL
Pre-ride, check the following: check all bolts are tight and comply with the torque values detailed in this document, check all 3rd party components installed to your bike are installed according to their respective manufacturer’s instructions, check that suspension is correct pressure and within range of manufacturer’s recommendations and tyres are within pressure range of manufacturers detail found on the sidewall. All bearings are perishable parts and wheels/headset/bottom bracket/ frame bearings will need checked and changed periodically. If you think a bearing has perished prematurely, please consult with your dealer for warranty inspection.
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CLEANING Cleaning your bike regularly will help maintain its appearance as well as prolonging the life of wear and tear parts. Allowing dirt to collect on the bike will reduce the lifespan of components, increase chances of unnecessary damage, and make visual inspection difficult. We recommend biodegradable cleaning products and do not use a pressure washer. Using a pressurised washer can cause water ingress, damage components and flush out bearing/pivot grease. Please lubricate your drivetrain after cleaning, wiping off any excess lubricant. Avoid any lubricants contaminating brakes pads and rotors. SERVICE LIFE Your bike is subject to wear and tear, normal for all mechanical components. The service life is subjective to several factors: materials, design, rider weight, how often the bike is used, aggressiveness of the riding, terrain, environment, and maintenance. Regular cleaning, maintenance and periodical inspection by a reputable mechanic will prolong the service life of your bike and its installed components. PAINT REPAIR If you chip or scratch your frame paint, please contact [email protected] for details on paint repair. FRAME NUMBER The frame number is found on the underside of the bottom bracket shell. Please take and note of this number and images to ensure your bike can be identified if lost, stolen and for warranty.
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SPARE PARTS All available Mega frame spares and Nukeproof component spare parts are available through any authorised dealer, first port of call will be your dealer, but any authorised Nukeproof dealer can assist. 3rd party components and spares can be found through respective dealer networks and your Nukeproof dealer.
> Nukeproof Dealers > Shimano Dealers > SRAM/RockShox In the unlikely case you need to make a warranty claim and damage is caused by poor maintenance and care, the warranty claim may be rejected. If you have any doubt on how to maintain and care for your new Mega, please consult with your dealer. In the event of a crash, please inspect your bike and if you have any concerns, please seek advice from your dealer.
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5 – Specifications/Sizing/Geometry/Assembly/Spares

The following section has exploded diagrams and specifications for 275/297/290 Mega MK4 Carbon. It is essential you reference diagrams and specifications for parts compatibility, maintenance, and sizing of bike. If there is any doubt, please consult with an authorised Nukeproof Dealer.
EXPLODED DIAGRAM

Shok Bolt Kit Bearing Kit Horst Link Kit Main Pivot Kit Upper Swing Link Lower Swing Link Cable Guide Kit Rubber Frame Protection Kit Hanger Kit Disc Brake Mount Kit Water Bottle Bolt Kit

11 8

9 7

10 25 24 c 23 20 19
22 21 11 9

13 14 15

13 14 15 16

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Mega 275 Carbon Material Fork Travel Axle to Crown Fork Offset Shock Travel Wheels Size Max Tyre Size Shock Size Shock Hardware F Shock Hardware R Sizing Headtube Headset Bearings Required Seatpost Seat Clamp BB Rear Hub Rear Axle Chain Guide Brake Mount Protection
Mega 290 Carbon Material Fork Travel Axle to Crown Fork Offset Shock Travel Wheels Size Max Tyre Size Shock Size Shock Hardware F Shock Hardware R Sizing Headtube Headset Bearings Required Seatpost Seat Clamp BB Rear Hub Rear Axle Chain Guide Brake Mount Protection

Ultra Strong T700/800 Monocoque Carbon Fibre 170mm (RS 180mm) 562mm (RS 572mm) 46mm 165mm 27.5″ 2.5″ 230x65mm 25x8mm 30x8mm S/M/ML/L/XL 44-56mm Tapered Semi-Integrated ZS44-28.6 – T2 / ZS56/40 – B8 2x NP-5 (6902 2RS), 4x NP-7 (6800 2RS), 4x NP-9 (61802-2RS1 EXTENDED) 31.6mm (Internal Routing for Dropper Seatpost) 36.4mm Threaded 73mm BSA Boost 148x12mm Sram Maxle Stealth M12x1.75 180mm ISCG05 160mm Direct Post 3D Contoured Rubber Frame Protection for DT/SS/CS
Ultra Strong T700/800 Monocoque Carbon Fibre 170mm (RS 180mm) 582mm (RS 591mm) 44mm 160mm 29″ 2.5″ 230×62.5mm 25x8mm 30x8mm M/L/XL 44-56mm Tapered Semi-Integrated ZS44-28.6 – T2 / ZS56/40 – B8 2x NP-5 (6902 2RS), 4x NP-7 (6800 2RS), 4x NP-9 (61802-2RS1 EXTENDED) 31.6mm (Internal Routing for Dropper Seatpost) 36.4mm Threaded 73mm BSA Boost 148x12mm Sram Maxle Stealth M12x1.75 180mm ISCG05 160mm Direct Post 3D Contoured Rubber Frame Protection for DT/SS/CS
MEGA MK4 CARBON BIKE MANUAL 2023 | 36

GEOMETRY AND SIZING 275 Frame Only

Reach

Stack

Effective Top Tube Length

Seattube Length

Effective Seattube Angle

Seattube Angle (Actual)

Saddle Height at Saddle Offset

Saddle Offset at Saddle Height

Headtube Length

Headtube Angle

Chainstay Length

Front Centre

Wheelbase

Bottom Bracket Drop

Bottom Bracket Height

Stand Over Height Alloy/ Stand Over Height Carbon

Fork Travel

Trail

Fork Offset

Axle to Crown

Maximum Seatpost Insert (alloy/carbon)

Small 435 591.48 566.13 380 77.5° 71° 650 154.84 100 64° 435 759.77 1194.66 10 350 725.49/728.77 170 134.42 37 562 216/250

Medium 460 600.47 593.12 410 77.5° 71° 700 170.16 110 64° 435 789.16 1224.04 10 350 724.6/728.28 170 134.42 37 562 245/250

Large 480 618.44 611.45 440 78° 71.5° 750 178.28 130 64° 435 817.92 1252.81 10 350 726.15/726.9 170 134.42 37 562 270/255

X-Large 500 627.43 633.36 470 78° 71.5° 800 193.18 140 64° 435 842.31 1277.19 10 350 728.82/728.13 170 134.42 37 562 301/274

XX-Large 520 636.42 655.27 500 78° 71.5° 850 208.08 150 64° 435 866.69 1301.58 10 350 733.51/735.61 170 134.42 37 562 330/293

MEGA MK4 CARBON BIKE MANUAL 2023 | 37

GEOMETRY AND SIZING 297 Frame Only

(A) REACH (B) STACK (C) EFFECTIVE TOP TUBE LENGTH (D) SEATTUBE LENGTH (E) EFFECTIVE SEATTUBE ANGLE (F) SEATTUBE ANGLE (ACTUAL) (G) SADDLE HEIGHT AT SADDLE OFFSET (H) SADDLE OFFSET AT SADDLE HEIGHT (I) HEADTUBE LENGTH (J) HEADTUBE ANGLE (K) CHAINSTAY LENGTH (L) FRONT CENTRE (M) WHEELBASE (N) BOTTOM BRACKET DROP (O) BOTTOM BRACKET HEIGHT (P) STAND OVER HEIGHT (Q) FORK TRAVEL (R) TRAIL (S) FORK OFFSET (T) AXLE TO CROWN (U) MAXIMUM SEATPOST INSERT

SMALL 430 621.16 567.71 380 77.5° 71° 650 142.22 100 64° 435 758.5 1192.48 30/10 345 721.75/725.16 170 132.33 42 584 250mm

MEDIUM 455 621.16 592.71 410 77.5° 71° 700 158.59 100 64° 435 783.5 1217.48 30/10 345 720.28/724.41 170 132.33 42 584 250mm

LARGE 475 639.22 610.87 440 78° 71.5° 750 166.66 120 64° 435 812.11 1246.09 30/10 345 721.3/722.92 170 132.33 42 584 255mm

MEGA MK4 CARBON BIKE MANUAL 2023 | 38

GEOMETRY AND SIZING 290 Frame Only

Reach

Stack

Effective Top Tube Length

Seattube Length

Effective Seattube Angle

Seattube Angle (Actual)

Saddle Height at Saddle Offset

Saddle Offset at Saddle Height

Headtube Length

Headtube Angle

Chainstay Length

Front Centre

Wheelbase

Bottom Bracket Drop

Bottom Bracket Height

Stand Over Height Alloy/ Stand Over Height Carbon

Fork Travel

Trail

Fork Offset

Axle to Crown

Maximum Seatpost Insert (alloy/carbon)

Small 430 621.16 647.71 380 77.5° 71° 650 142.22 100 64° 440 758.5 1197.48 30 345 721.75/725.16 170 132.33 42 582 `216/250

Medium 455 621.16 592.71 410 77.5° 71° 700 158.59 100 64° 440 783.5 1222.48 30 345 720.28/724.41 170 132.33 42 582 245/250

Large 475 639.22 610.87 440 78° 71.5° 750 166.66 120 64° 440 812.11 1251.09 30 345 721.3/722.92 170 132.33 42 582 270/255

X-Large 495 648.24 632.79 470 78° 71.5° 800 181.58 130 64° 440 836.42 1275.39 30 345 720.73/730.78 170 132.33 42 582 301/274

XX-Large 515 657.27 654.71 500 78° 71.5° 850 196.49 140 64° 440 860.72 1299.7 30 345 726.77/736.07 170 132.33 42 582 330/293

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AVAILABLE SPARE PARTS
The following is the available spares for the Mega, all are available through authorised Nukeproof Dealers. Anything you need that is not listed, please consult with a dealer.

Part – Mega Carbon Protection Kit Horst Link Kit
Down Tube Protector Shock Bolt Kit Chain Stay Protector 290 Cable Guide Kit
Chain Stay Protector 297/275 Main Pivot Kit
Seat Stay Protector Brake Mount Kit UDH Stop Bolt Lower Swing Link Kit
Swing Link Upper Swing Link Kit Bearing Kit

Diagram #
13 16 14 C 3 28 A 1 2 23 24 A 22 21 11 12 B 20 19 18 6 10 7 8 27 5 26 4 9 15

Part Code
2x FB-SUP-BD23 2x FB-SUP-B72 4x FB-SUP-B73 VLF-C-1124 2x FB-SUP-LK116 1x FB-SUP-LK115 VLF-C-1122 1x FB-DAO-138 2x FB-DAO-139 2x FB-SUP-LK182 2x FB-GAN-063 VLF-C-1121 1x FB-SUP-LK122 1x FB-SUP-LK112 2x FB-SUP-LK113 1x FB-SUP-LK111 VLF-C-1123 2x FB-GAN-114 1x FB-GUO-197 1x FB-GAN-127 2x FB-SUP-LK117 2x FB-SUP-LK118 2x FB-SUP-LK119 2x FB-SUP-B29 1x FB-SUP-LK114 2x FB-SUP-LK120 1x FB-LUO-072 F6902 LLU MAX-EA BB 6902 LLU MAX BB F6802 LLU MAX

Link Protection Kit Horst Link Kit
Down Tube Protector Shock Bolt Kit Chain Stay Protector 290 Cable Guide Kit
Chain Stay Protector 297/275 Main Pivot Kit
Seat Stay Protector Brake Mount Kit Available through authorised Dealers Lower Swing Link Kit
Swing Link Upper Swing Link Kit Available through authorised Dealers

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6 Warnings
MINIMUM SEAT POST INSERTION
The seatpost installed to your bike will have a minimum insert line do not exceed this line. Exceeding the minimum insert can lead to post and frame damage. If you find you need the saddle higher than the insert level allows, please consult with your dealer regarding frame sizing or a longer post. Damage to a seat post or frame caused by not adhering to the minimum insert line is not covered by warranty.
MAXIMUM TYRE WIDTH
Do not exceed the fork and frame maximum tyre widths. The frame is designed to accept a tyre up to 2.6 and the fork’s maximum tyre widths are detailed below. Please note some manufacturer tyre and rim combinations can be wider when fitted together, always check for clearance when tyres are changed to a different model. Tyre rub can damage frame and will not be covered by warranty if incorrect tyre size has been used.
· Fox 36 29 max tyre clearance 2.6 · Rockshox ZEB max tyre clearance 2.8 · Rockshox Domain max tyre clearance 2.8
MAXIMUM AXLE TO CROWN AND TRAVEL OF FORK
The fork length also detailed as axle to crown (A-C) cannot be exceeded. Maximum A-C for the Mega is 596mm. Using a fork that exceeds the A-C may lead to frame failure and injury. Using a longer A-C fork will void warranty. The bike is designed with a 170mm in mind, 180mm can be used if the A-C is not exceeded.
TOP TUBE
Under no circumstances should a workstand clamp be used with the top tube of the Mega frame. Due to the layup of the carbon, using a workstand clamp can crush the top tube and cause irreparable damage.
TRANSPORT
Care is required when transporting your Mega. If using a car rack, ensure clamping is to wheels or fork and not the frame. Do not stack items on top of bike when loaded in a vehicle. Ensure the bike cannot move when transporting to avoid sudden movements and damage. Ensure rear wheel is always installed when transporting to avoid lateral loads on rear dropouts.
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DIRECT SUNLIGHT AND HEAT
Try to avoid exposing your bike to direct sunlight and excessive heat. This can damage the paint and fatigue plastic components.

RIDER WEIGHT
Nukeproof bikes are designed and tested to ISO 4210 / EN 15194 standards; our bikes conform to the load tolerance of 120kg the standards require. If the user is over this weight when kitted, we would recommend regular inspection and maintenance to avoid issues. Please expect wear and tear parts to be replaced more often. 3rd party components may have different load and weight standards if you have any concerns with components weight limits, please consult with your Nukeproof Dealer. We cannot guarantee the integrity of the bike and its components if the user is over 120kg.

LOOK AFTER YOURSELF
Always wear a helmet that meets legal safety standards when riding your Mega and additional protective equipment when required. Ensure you are riding your bike in accordance with local laws, with protective equipment, reflectors and lights installed when and where required.

ON-ROAD RIDING
· Ensure all local traffic laws are obeyed when using your bike on-road. · Respect all other road users’ journeys. · Ride safely and be prepared for actions of other road users or road conditions that may
jeopardize your safety or safety of other road users. · Do not allow yourself to be distracted while cycling on-road. · Carry maintenance tools and spares to ensure you can complete your ride if a mechanical
was to occur.

OFF-ROAD RIDING

· Off-road riding can be dangerous with a variety of terrain, conditions and hazards. Please ensure you have developed the adequate skill levels for the terrain you are riding and you are confident in your off-road abilities. Please get familiar with your bike, its handling and capabilities before riding off-road.

· Ensure the location you are riding is legal, you have a right to ride there, and no laws are being broken.

· Ensure you are wearing the appropriate safety equipment.

· Ride in groups to ensure your safety and make someone aware of your route and location.

· Carry maintenance tools and spares to ensure you can complete your ride if a mechanical was to occur.

· Be respectful and courteous to other off-road users, respect their journey.

· Be courteous to wildlife and the natural environment.

· Stay on designated trails to avoid unnecessary erosion.

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RIDING AT NIGHT Be cautious when riding at night riding at night can be more hazardous than daytime. At night, a rider is harder to see by drivers and pedestrians. Ensure you are wearing brighter clothing with reflective features. Please ensure you use reflectors and lights on your bike, and these comply with local laws. Reflectors are not a suitable alternative to lights; lights must be used along with reflectors at night. Ensure reflectors and light mounts are of sound condition and secure. Ensure lights are charged and are powered adequately. Ensure there is enough power for the duration of your journey. WET WEATHER RIDING In wet weather conditions please ensure you are riding within your skill level and experience. Wet weather can reduce surface grip, reduce tyre traction, reduce visibility, and reduce braking performance. Contacts points on the bike may be slippery when wet these include handlebar grips, brake levers, pedals, saddle, and shifters. Please consider these factors when riding in the wet to avoid loss of control and potential injury. Please ensure adequate wet weather clothing is used. Gloves and shoes suitable for wet weather riding will help with using the bike’s controls and maintaining grip on the pedals.
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7 Warranty
NUKEPROOF WARRANTY TERMS
Nukeproof warranties against manufacturing defects for the periods specified below. We will repair or replace any item verified as a legitimate warranty claim.
You can download the Nukeproof warranty claim form here.
WHAT IS COVERED?
This warranty covers the original purchaser from defects in materials, paint, and workmanship from the original purchase date for a period as listed below:
· Nukeproof Frames = 5 Years (2016-CURRENT, excluding Downhill products) · Nukeproof Components = 2 Years (lifetime on Carbon Handlebars) · Fox Suspension = 2 years · RockShox Suspension = 2 years · Shimano Components = 2 years · Sram Components = 2 years
Transfer of the item from the original purchaser to another person terminates this limited warranty and proof of purchase is required to validate the warranty period.
Where we repair or replace items under Warranty, they are covered for the remainder of the original warranty period and subject to the conditions outlined in the original warranty.
This limited warranty does not cover items used in rental operations or any defect caused by wear and tear, accident, neglect, improper handling, abuse, misuse, improper assembly, incorrectly performed maintenance or repairs, non-compliance with recommended maintenance and care procedures, racing or competition use.
NB: Bearings that fail due to contamination, misuse, improper, or lack of maintenance are not covered under warranty even if failure occurs within an unexpected time from date of purchase. Water ingress from power washing will invalidate this warranty. Stripped pedal threads on cranks are also not covered under warranty.
CONSEQUENTIAL LOSS
Nukeproof is not responsible for direct, incidental or consequential damages resulting from any breach of warranty or condition or under any other legal theory, including but not limited to loss of use, loss of revenue, loss of actual or anticipated profits (including contracts) loss of the use of money, loss of anticipated savings, loss of business, opportunity, goodwill, reputation, any indirect or consequential loss.
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CRASH REPLACEMENT
Nukeproof understand that accidents do happen and endeavour to produce some of the most reliable products available. However, in the event of a crash, Nukeproof offer a crash replacement service on all frames within the term of their warranty period. A discounted replacement will be offered through the registered dealer where the product was purchased. In circumstances where the dealer is unable to fulfil the service, a crash replacement will be dealt with through the International Distributor directly www.hotlines-uk.com
HOW TO MAKE YOUR WARRANTY CLAIM
Complete the online form with as much information as possible and include images if you can. (Be sure they are in focus) A copy of this form must then be supplied to the retailer where the item was purchased for it to be logged and for a resolution to be offered through Nukeproof or one of its affiliated distribution partners. If you are unable to provide an official Nukeproof warranty claim form, a letter or suitable document must be provided containing the following information:
Customer details: · Full name · Order reference or copy of shop receipt (with store name) · Telephone number · Address and Post Code · Email address
Product details: · Model, Stock ID, Serial number · Photograph of the problem if possible · Description of the issue and how it happened
Preferred Action to resolve: (detail the resolution you want from your dealer) Registering your bike – You do not need to register your bike for warranty, your dealer will have a record of the sale and keep any invoice/receipts supplied with the bike as proof of purchase.
3RD PARTY WARRANTY
Please familiarise yourself with the respective manufacturer’s warranty policies. We endeavour to select and install the most reliable components for our bikes, any unlikely issues with the following 3rd party components please consult with your Nukeproof dealer and they will resolve with Nukeproof and the manufacturer on your behalf.
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