User manual BONTRAGER HUB MANU

[. . . ] HUB INSTRUCTIONS PART NUMBER 231793 SERVICE MANUAL 2003 HUB INSTRUCTIONS STANDARD Front Hubs Loose ball . . 28-31 Please note: Many sections of this manual must be read in their entirety before performing procedures. In some cases, revised or updated information may be available on the Bontrager wheelworks website at www. bontrager. com. If you cannot find the information you need to service Bontrager wheels, please contact a technical service representative. Copyright Trek Bicycle Corporation 2002 All rights reserved 2003 Bontrager Service Manual 1 Front hubs- Loose ball Bontrager Superstock, Superstock Disc, Select ATB, Select ATB Disc, Select Road, and Select Hybrid front wheels; plus Bontrager Comp II front hub Recommended tools ASSEMBLY 13mm cone wrench 17mm cone wrench Small slot screwdriver Hammer (soft faced) Shell shield DISASSEMBLY Hub parts and names are referenced on next page. Remove the axle Fig. [. . . ] If inspection Axle shows it necessary, remove the cone, washers, and End nut end nut from the right side of the Small axle. 4E essary to remove the freehub body, refer to the Freehub Body section, pages Freehub 1 and Freehub 2, for removal and installation instructions. When overhauling the hub bearings, it is usually not necessary to remove the freehub body. Fig. Use solvent to completely remove all old grease and debris from the hub, axle, and axle parts. Inspect the bearing running surfaces of both the cones and the ball cups (inside the hub). 5E 14 2003 Bontrager Service Manual Exploded view and Parts list Note: Rotor adapter for disc hubs not shown Rotor spacing varies by model year, see details below. 2 3 4 5 13 6 1 7 8 9 10 11 7 6 12 4 3 2 13 Splined 11a Note: There are two types of freehub body attachments; see below for specifications, and page 9 for more information Threaded Pos Description 1 External seal 2 End nut 3 Washer 4 Spacer 5 Adj. cone 6 Shell shield 7 Bearings 8 Ball cup 9 Hub shell 10 Axle 11 Freehub body 12 Ball cone 13 Cone seal Description Axle set End nut set External seal, yellow External seal, red Freehub body, threaded Freehub body splined Rotor adapter Model year 99/00 99/00 99/00 99/00 99/00 01 99/00 Model for all all all all all all Parts included (qty) 10 2(2) 1, 13 1, 13 11 11a, 6, removal tool TCG Part # 68533 68536 68534 68535 68540 211340 991075 69156 991153 Rotor adapter 99/00 Disc bolt set 99/00 Hayes, RST Not shown rear Magura Gustav, Not shown Louise rear all Not shown 2001 Race 2000 Race O. L. D. . running change 2003 Bontrager Service Manual 15 Rear hub- Cartridge bearing 2002/2003 Bontrager Race, Race Disc rear wheels Recommended tools 15mm cone wrench 19mm cone wrench Small slot screwdriver Hammer (soft faced) Cartridge bearing remover Bearing press ASSEMBLY Lubricate bearings and threads 1. Lubricate the threads on the axle with Wrench ForceTM synthetic grease, or a similar product. Lightly grease the inner and outer surfaces of each bearing where they contact the hub shell and axle. Hold the left side (nondrive) axle spacer with a 19mm Axle spacer End nut cone wrench and loosen the end nut (Fig. Tap the left end of the axle with a hammer to drive the axle out of the hub. If inspection shows it necessary, remove the washers and end nut from the right side of the axle. End To loosen the end nut, reAxle spacer nut install the left side axle spacer Fig. Hold the axle spacer with a cone wrench while you loosen the right side end nut. With a punch on the bearing tool, drive the left bearing out of the hub with a hammer. If it is necessary to remove the freehub body, refer to the Freehub Body section, pages Freehub 1 and Freehub 2, for removal and installation instructions. When overhauling the hub bearings, it is usually not necessary to remove the freehub body. 1. Press the right bearing onto the right side of the axle, denoted by the smooth, non-threaded area with a shoulder. Note: the black seal of the bearing faces out (Fig. Thread the axle spacer onto the axle, and use the bearing press to press the left bearing into the hub. Place the bearing seals into the hub with the lettered surface facing out. Place a 17mm cone wrench on the axle spacer and a 15mm cone wrench on the end nut. Tighten the end nut against the axle spacer. After completing assembly of the hub, check its function by spinning the axle with your fingers. [. . . ] Remove the second star ratchet and second spring from the freehub body. With the splines engaged, turn the wheel firmly in an anti-clockwise direction. The ring nut will be loosened, and the seal between the hub and freehub body will fall over the spline tool onto the vise. Thoroughly clean and inspect all components, including inside the hub, with a dry cloth. [. . . ]