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231793
User Manual
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Bontrager 231793 User Manual

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Page 1
HUB INSTRUCTIONS
PART NUMBER 231793 SERVICE MANUAL 2003
Page 2
HUB INSTRUCTIONS
STANDARD
Front Hubs
Loose ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Loose ball, semi-cartridge; Formula FCM . . . . . . .4-5
Cartridge bearing, alloy axle . . . . . . . . . . . . . . . . .6-7
Cartridge bearing, threaded alloy axle . . . . . . . . . .8-9
Rear hubs
Loose ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
Loose ball, double sealed (Formula FCM) . . . . . .14-15
Cartridge bearing . . . . . . . . . . . . . . . . . . . . . . . . .16-17
DT-SWISS
Comp series hubs
Comp front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21
Comp rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-24
Pro series hubs
Pro front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-27
Pro rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
Page 3
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
13mm cone wrench 17mm cone wrench Small slot screwdriver Hammer (soft faced)
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
Fig. 1A
External seal
Fig. 2A
Fig. 3A
Axle
Ball cone
Fig. 4A
Clean and inspect the parts
1. Use solvent to completely remove all old grease and
debris from the hub, axle, and axle parts.
2. Inspect the bearing running surfaces of both the ball cones and the ball cups (inside the hub). Replace any cones. If the cups are worn, replace the hub shell.
1. Remove external seals (Fig. 2A) with a screwdriver. Be careful not to tear or mar the rubber.
2. On one side (either) of the hub place a 13mm cone wrench on the ball cone. Place a 17mm cone wrench on the end nut (Fig. 3A). Loosen the end nut.
3. Remove the end nut, washer, and ball cone from the axle (Fig. 4A).
4. Slide the axle, with the other end nut, washer, and ball cone still attached, out of the hub (Fig. 4A).
5. Gently insert a thin screwdriver blade under the shell shield (Fig. 5A) and lift to remove the shield from the hub. Pry off the shell shields from both sides of the hub.
6. If inspection shows it necessary, remove the other end nut and ball cone.
End nut
Washer
ASSEMBLY
Shell shield
1. Place eleven 3/16” balls in
the ball cup on one side of the hub.
2. Place the shell shield, with its sharp edges facing out (Fig. 6A), into the hub. The shell shield is a press fit, so must be tapped lightly to fully seat. Lay a cone wrench over the shell shield and tap the wrench with a hammer (Fig. 7A) to protect the shield and ensure that it is flush with
Bearings in bearing cup
the shell.
3. Repeat Assembly steps 1-2 for the other side of the hub.
4. Tighten the end nut against the ball cone on the axle. Hold the ball cone with a 13mm cone wrench on the axle flats while turning the end nut with a 17mm cone wrench.
5. Insert the axle through the hub from either side.
6. Thread the ball cone, wash­er, and end nut onto the axle in that order. The serrated surface of the end nut faces out.
7. Hold the ball cone with a 13mm cone wrench and tighten the end nut with a 17mm cone wrench.
8. Check the bearing adjust­ment by turning the axle with your fingers. The axle should spin smoothly without binding or feeling gritty. There should be no lateral play of the axle in the hub. Readjust the hub as necessary, and re-lock the end nut.
9. Install the external seals, and apply grease where the seals
Seal not seated
contact the hub shell and axle parts. Make sure the seals prop­erly seal against both the end nut and the hub shell. There should be a smooth transition from seal to sealing surface. An improperly installed seal (Fig. 8A) will allow rapid con­tamination of the bearings.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is eliminated when the wheel is installed with the quick release properly closed.
Fig. 5A
Fig. 6A
Fig. 7A
Fig. 8A
Lubricate bearings and threads
1. Lubricate the threads on the axle with Wrench
Force™ synthetic grease, or a similar product.
2. Place a bead of grease all the way around each ball
cup, sufficient to hold the balls.
2
2003 Bontrager Service Manual
Page 4
Exploded view and Parts list
9
1
2
4
3
5
7
6
8
7
6
5
4
3
2
1
Pos Description 1 External seal 2 End nut
Description Model year Model for Parts included (qty) TCG Part # Axle set 99/00/01/02 all 1(2), 4(2), 3(2), 9 68257
Locknut set 99/00/01/02 all 2(2) 68543 3 Washer 4 Ball cone 5 Shell shield 6 Ball bearings 7 Ball cup 8 Hub shell 9 Axle
1999 Bontrager Comp II
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm
2000/2001/2002/2003 Superstock
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Superstock Disc, Select ATB Disc
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
2002/2003 Select ATB
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Select Road, Hybrid
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2003 Bontrager Service Manual
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Page 5
Front hubs- Loose ball, semi-cartridge; Formula FCM
'99, 2000, 2001 Bontrager Race, Race Disk front wheels
Recommended tools
13mm cone wrench 17mm cone wrench Adjustable wrench Hammer (soft faced) Small slot screwdriver
DISASSEMBLY
Hub parts and names are referenced on next page.
Fig. 1B
External seal
Fig. 2B
Fig. 3B
Collar
Fig. 4B
Shell shield
Fig. 5B
Axle
Ball cone
ning surfaces of both the ball cones and the ball cups (inside the hub). Replace any worn parts.
Note: If the ‘fixed’ ball cone is worn, the axle assembly (axle and ball cone) must be replaced.
Remove the axle
1. Remove external seals (Fig. 2B) with a screwdriver. Be careful not to tear or mar the rubber.
2. On one side of the hub (usually left), the cone is locked against a collar on the axle (Fig. 4B). On the other side, place a 13mm cone wrench on the ball cone. Place a 17mm cone wrench on the end nut (Fig. 3B). Loosen the end nut.
3. Remove the end nut, wash­er, and ball cone from the axle (Fig. 4B).
4. Slide the axle, with the other end nut, washer, and ball cone still attached, out of the hub.
6. Gently insert a thin screwdriver blade between the shell shield (Fig. 5B) and bear­ing seal (Fig. 6B). Pry off the
shell shields from both sides of the hub. Do not attempt to pry off both shield and seal at the same time as you may damage the bearing seal.
End nut
Washer
7. Gently pry off the bearing seals (Fig. 6B) from both sides of the hub.
8. If inspection shows it necessary,
remove the other end nut. Hold the axle by the wrench flats (Fig. 7B) while turning the end nut with a 17mm cone wrench.
Clean and inspect the parts
1. Use solvent to completely remove all old grease and debris from the hub, axle, and axle parts.
2. Inspect the bearing run-
Lubricate bearings and threads
Bearing seal
1. Lubricate the threads on the axle with Wrench Force™ syn­thetic grease, or a similar product.
2. Place a bead of grease all the way around each ball cup, sufficient to hold the balls.
ASSEMBLY
1. Place eleven 3/16” balls in the ball cup on one side of the hub (Fig. 8B).
2. Place the bearing seal, with the lettered side facing out, into the ball cup.
3. Place the shell shield, with its sharp edges facing out, into the hub. The shell shield is a press fit, so must be tapped lightly to fully seat. Lay a cone wrench over the shell shield and tap the wrench with a hammer (Fig. 9B)
Bearings in ball cup
to protect the shield and ensure that it is flush with the shell.
4. Repeat Assembly steps 1-3 for the other side of the hub.
5. Tighten the end nut against the fixed ball cone (attached to axle). Hold the axle with an adjustable wrench on the axle flats while turning the end nut with a 17mm cone wrench.
6. Insert the axle through the hub from either side.
7. Thread the ball cone, wash­er, and end nut onto the axle in that order. The serrated surface of the end nut faces out.
8. Hold the ball cone with a 13mm cone wrench and tighten the end nut with a 17mm cone wrench.
9. Check the bearing adjust­ment by turning the axle with your fingers. The axle should spin smoothly without binding or feeling gritty. There should be no lateral play of the axle in the hub. Readjust the hub as necessary, and re-lock the end nut.
10. Install the external seals. Make sure the seals properly seal
Seal not seated
against both the end nut and the hub shell. There should be a smooth transition from seal to sealing surface. An improp­erly installed seal (Fig. 10B) will allow rapid contamina­tion of the bearings.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is eliminated when the wheel is installed with the quick release properly closed.
Fig. 6B
Fig. 7B
Fig. 8B
Fig. 9B
Fig. 10B
4
2003 Bontrager Service Manual
Page 6
Exploded view and Parts list
1
Note: Rotor adapter for disc hubs not shown Rotor spacing varies by model year, see details below.
2
3
4
5
6
10
7
8
9
8
7
6
5
12
11
3
2
1
Pos Description 1 External seal 2 End nut 3 Washer 4 Adjust cone 5 Shell shield
Description Model year Model for Parts included (qty) TCG Part # Axle set 99/00/01 all 10, 4, 2, 5(2), 11, 6(2), 3(2) 68524 Locknut set 99/00/01 all 2(2) 68527 Rotor adapter 99/00 Hayes, RST Not shown 991083 w/screws
Disc bolt set 99/00 all Not shown 991153 6 Bearing seal 7 Ball bearings 8 Ball cup 9 Hub shell 10 Axle 11 Spacer 12 Ball cone
1999 Race
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm
1999/2000 Race Disk
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.0 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
2001 Race Disk
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
2000/2001 Race
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2003 Bontrager Service Manual
5
Page 7
Front hubs- Cartridge bearing, alloy axle
2002/2003 Bontrager Race, Race Disc front wheels
Fig. 1C
Fig. 2C
Fig. 3C
Fig. 4C
End caps
Axle nut
Recommended tools
17mm cone wrench Special hook spanner Hammer and broad punch Bearing removal tool Bearing press
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
1. Remove axle end caps (Fig. 2C) by sliding them out of the axle with your fingers.
2. Hold the axle with a 17mm cone wrench (Fig. 3C) while loosening the axle nut with the special hook spanner (Fig. 4C).
3. Partially unthread the axle nut (Fig. 5C) until it slightly protrudes past the end of the axle.
4. Tap the axle nut with a soft-faced hammer until the axle slides through the opposite bear­ing. Once loose, the axle should come out with your fingers.
5. Remove the axle nut, and extract the axle (Fig. 6C).
6. Gently insert a thin screw­driver blade between the bearing seal (Fig. 7C) and bearing. Pry off the bearing seals from both sides of the hub.
7. Insert a bearing removal tool into the bearing. Place a blunt punch through the hub and against the bearing removal tool. Tap the punch with the hammer to drive the bearing out of the hub (Fig. 8C). Repeat for the other bearing.
ASSEMBLY
1. Press a bearing into the
hub with a bearing press.
Note: the black seal faces out (Fig. 9C).
2. Press the second bearing
with the bearing press.
3. Place the bearing seals into the hub with the lettered surface facing out.
6. Insert the axle through the hub from either side.
7. Thread the axle nut onto the axle.
8. Hold the axle with a 17mm cone wrench and tighten the axle nut with the special hook span­ner until finger tight.
Do not over-tighten the axle nut. The axle should turn freely with no lateral play in the hub shell.
9. Press the axle end caps into both ends of the axle.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is eliminated when the wheel is installed with the quick release properly closed.
Axle
Axle nut
Fig. 5C
Fig. 6C
Fig. 7C
Bearing seat
Fig. 8C
Clean and inspect the parts
1. Wipe old grease or debris from the hub bearing
seats.
2. Normally, bearings are not re-used. If you are re­installing an old bearing, wipe off any grease or debris from both the inner and outer surfaces.
Do not use solvent on the bearing, as the solvent will
contaminate the grease. This may cause bearing failure.
Lubricate bearings and threads
1. Lubricate the threads on the axle with Wrench Force™ synthetic grease, or a similar product.
2. Lightly grease the inner and outer surfaces of each bearing.
6
2003 Bontrager Service Manual
Fig. 9C
Page 8
Exploded view and Parts list
1
2
Note: Rotor adapter for disc hubs not shown Rotor spacing varies by model year, see details below.
Pos Description 1 End cap 2 Adjustable nut 3 Seal 4 Bearing 5 Hub shell 6 Axle
3
Description Model year Model for Parts included (qty) TCG Part # Seal 99/00/01 all 3(2) 68261 Bearing 99/00/01 all 4(2) 68262 #6903 Axle set 99/00/01 all 6, 4(2) 68263 Adjustable nut 99/00/01 all 2 68264 End cap, 99/00/01/02 all 1(2) 211645
20.5mm O..D. Rotor adapter 99/00 Hayes, RST Not shown 991083 w/screws Disc bolt set 99/00 all Not shown 991153
4
6
5
4
3
1
Special 99/00/01/02 all Not shown, see Fig. 4C 68259 hook spanner
2002 Race
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002 Race Disk
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
2003 Bontrager Service Manual
7
Page 9
2003 Bontrager Service Manual
Needs photos and text
Front hubs- Cartridge bearing, threaded alloy axle
2002/2003 Bontrager Race Lite Road front wheels
Recommended tools
17mm cone wrench (2) Hammer and broad punch Bearing press
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
1. Remove one of the thread-
Fig. 1H
Fig. 2H
second bearing from the axle. To do this, clamp the middle of the axle, loosen the end cap, and remove it. Support the bearing and tap the axle out with a soft­faced hammer.
ed axle end caps (Fig. 2H) by loosening with the pair of 17mm cone wrenches.
2. With one end cap removed, drive the axle from the hub shell with a soft-faced hammer.
3. Place a broad punch through the hub, and tap the punch with a hammer to drive the second bearing (Fig. 3H), with its seal, from the hub.
4. If needed, remove the
ASSEMBLY
1. Press a new bearing onto
the axle with a bearing press.
Note: the black seal faces out (Fig. 4H).
2. Place the hub seal onto the axle, and thread on the axle end cap. Clamp the middle of the axle and tighten the axle end cap with the 17mm cone wrench.
3. Press the bearing, with the axle attached, into the hub.
4. Press the second bearing into the hub.
Note: the black seal faces out (Fig. 4H).
5. Place the hub seal over the bearing, and press into the hub shell.
6. Thread on the second axle end cap, and tighten with the 17mm cone wrench.
Do not over-tighten the axle nut. The axle should turn freely with no lateral play in the hub shell.
Fig. 4H
Clean and inspect the parts
1. Wipe old grease or debris from the hub bearing
seats.
2. Normally, bearings are not re-used. If you are re­installing an old bearing, wipe off any grease or debris from both the inner and outer surfaces.
Do not use solvent on the bearing, as the solvent will
contaminate the grease. This may cause bearing failure.
Lubricate bearings and threads
1. Lubricate the threads on the axle with Wrench Force™ synthetic grease, or a similar product.
2. Lightly grease the inner and outer surfaces of each bearing.
8
Fig. 3H
2003 Bontrager Service Manual
Page 10
Exploded view and Parts list
1
Pos Description 1 End nut 2 Seal 3 Bearing 4 Hub shell 5 Axle
2
3
5
4
Description Model year Model for Parts included (qty) TCG Part # Seal 02 all 2(2) 221468 Bearing 02 all 3(2) 73335 #6000 Axle set 02 all 1(2), 2(2), 3(2), 5 221470 End nut 02 all 1(2) 221467 Axle 02 all 5 221469
3
2
1
2002/2003 Race Lite Road
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2003 Bontrager Service Manual
9
Page 11
Freehub body information (non-DT Swiss)
FREEHUB BODY RUNNING CHANGE
Bontrager rear hubs use an unique freehub body that in some cases has encountered removal issues. In these cases, a high amount of torque is necessary to remove or install the freehub body attachment bolt.
To resolve this problem a running change was made to the 2001 product line. The older, direct contact style of freehub body has been replaced with a splined freehub body attachment. This splined attachment requires less bolt torque. Since it is a running change, the following information is necessary to identify which freehub body is on a wheel.
If there is a date code stamped on the freehub body it probably uses a splined attachment. If there is no date, it is a threaded attachment. After May 2000, both styles of freehub bodies (both attachment types) will have this date mark.
These different styles of freehub bodies are not inter­changeable.
Identification of freehub bodies
Threaded freehub body
CNC line
Fig. 1
With the older, threaded freehub body, there are two identifiers. First, there is a CNC machine line approximately 10mm from the outside end of the freehub body (Fig. 1).
Second, the thread-attached freehub body is designed to be removed with a 12mm allen wrench.
INSTALLATION AND REMOVAL
If the freehub body is worn or damaged, replace it.
Removing the freehub body
1. Follow the Disassembly instructions for the hub. Remove the axle, and then the right side bearings.
2. Determine the correct size of allen wrench to engage the freehub body attachment bolt.
3. Unthread the bolt in a counter-clockwise direction (standard threading).
Installing the freehub body
1. Carefully clean the mating surfaces and threads of the freehub body, hub shell, and attachment bolt.
2. Lubricate the threads of the attachment bolt with Wrench Force™ synthetic grease, or a similar product.
3. Carefully engage the threads of the freehub body attachment bolt into the hub shell. The bolt is steel, and the hub is aluminum, so cross-threading the bolt will result in destruction of the hub shell.
4. With the new splined freehub engagement, make sure the splines are aligned as you tighten the attachment bolt.
For the older, threaded style freehub body, tighten the
freehub attachment bolt to 350 lb•in (40Nm).
For the newer, splined design, tighten the freehub
attachment bolt to 400 lb•in (45.2 Nm).
Fig. 4
Splined freehub body
The newer, splined attach­ment (Fig. 2) freehub body has no CNC line. Further, it is designed to use an 11mm allen wrench for removal. A special adapter (TCG #211338) is made which attaches to an 8mm allen wrench to fit the 11mm allen head of the freehub attachment
Fig. 2
bolt (Fig. 3).
In addition, as a running change the new hub bodies will include a 6-digit part number embossed on the outside of the hub shell where it is plainly vis­ible. All hubs with the part num­ber visible use the splined free­hub body.
Fig. 3
Description TCG Part # Freehub tool, 211338 11mm adapter
2003 Bontrager Service Manual
11
Page 12
Rear hubs- Loose ball
Bontrager Superstock, Superstock Disc, Select ATB, Select Road, Select Hybrid wheels, plus Bontrager Comp II rear hub
Recommended tools
(2) 15mm cone wrench Adjustable wrench Hammer (soft faced) Small slot screwdriver
DISASSEMBLY
Fig. 1D
Fig. 2D
Fig. 3D
Axle
End nut
Small washer
Large washer
Fig. 4D
Spacer
removal and installation instructions.
When overhauling the hub bearings, it is usually not necessary to remove the freehub body.
Fig. 5D
12
Hub parts and names are referenced on next page.
Remove the axle
1. Remove external seals with your fingers or a screw­driver (Fig. 2D). Be careful not to tear or mar the rubber.
2. On the left side (non-drive) of the hub place a 15mm cone wrench on the ball cone. Place a 15mm cone wrench on the end nut (Fig. 3D). Loosen the end nut.
4. Remove the end nut, large washer, spacer, small washer, and ball cone from the axle (Fig. 4D).
5. Slide the axle, with the other end nut, washer, and ball cone still attached, out of the hub.
6. Insert a thin screwdriver blade under the shell shield (Fig. 5D) and pry off the shell shield from the left side of the hub.
8. If inspection shows it necessary, remove the ball cone,
washers, and end nut from the right side of the axle.
9. Remove the ball bearings (Fig. 6D) from both sides of the hub.
10. If it is necessary to
Ball cone
remove the free­hub body, refer to the Freehub Body section,
pages Freehub 1 and Freehub 2, for
Clean and inspect the parts
1. Use solvent to completely remove all old grease and debris from the hub, axle, and axle parts. Avoid getting solvent into the freehub, and be sure to remove all solvent thoroughly before proceeding.
2. Inspect the bearing run­ning surfaces of both the ball cones and the ball cups (inside
the hub). Replace any worn parts.
ASSEMBLY
Lubricate bearings and threads
the axle with Wrench Force™ syn­thetic grease, or a similar product.
the way around each ball cup, sufficient to hold the balls.
Assemble the hub
ball cup on one side of the hub (Fig. 6D).
with its sharp edges facing out, into the hub. The shell shield is a press fit, so must be tapped lightly to fully seat. Lay a cone wrench over the shell shield and tap the wrench with a hammer (Fig. 7D) to protect the shield and ensure that it is flush with the shell.
for the other side of the hub.
against the fixed ball cone (attached to axle) by holding the ball cone with a 15mm cone wrench and turn the end nut with another 15mm cone wrench.
hub from the right hand (drive) side.
washer, and end nut onto the axle in that order. The serrated surface of the end nut faces out.
with a 15mm cone wrench and tighten the end nut with a 15mm cone wrench.
with your fingers. The axle should spin smoothly without binding or feeling gritty. There should be no lateral play of the axle in the hub. Readjust the hub as necessary, and re-lock the end nut.
erly seals against both the end nut and the hub shell. There should be a smooth transition from seal to sealing surface. An improperly installed seal (Fig. 8D) will allow rapid contamination of the bearings.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is eliminated when the wheel is installed with the quick release properly closed.
2003 Bontrager Service Manual
1. Lubricate the threads on
2. Place a bead of grease all
Fig. 6D
1. Place nine 1/4” balls in the
2. Place the shell shield,
Fig. 7D
3. Repeat Assembly steps 1-2
4. Tighten the end nut
Seal not seated
Fig. 8D
5. Insert the axle through the
7. Thread the ball cone, small washer, spacer, large
8. From the left side of the hub, hold the ball cone
9. Check the bearing adjustment by turning the axle
10. Install the external seal. Make sure the seal prop-
Page 13
Exploded view and Parts list
1
2
3
4
5
6
7
Splined
11a
Note: There are two types of freehub body attachments; see below for specifi-
cations, and page 9 from more information
Pos Description 1 External seal 2 End nut 3 Washer 4 Spacer 5 Ball cone 6 Shell shield 7 Bearings 8 Ball cup 9 Hub shell 10 Axle 11 Freehub body 12 Cone seal
Description Model year Model for Parts included (qty) TCG Part # Washer 99/00/01/02 all 3 990008 Freehub body, 99/00 all 11, 6 68541 threaded Freehub body, 01/02 all 11a, 6, removal tool 211341 splined Rotor adapter 99/00 Hayes, RST Not shown 991075
rear
Rotor adapter 99/00 Magura Gustav, Not shown 69156
Louise rear Axle set 99/00/01 all road, 130mm 2, 3, 4, 5(2), 10 68542 Axle set 99/00/01 all atb, 135mm 2, 3, 4, 5(2), 10 68531 Disc bolt set 99/00 Not shown 991153
Note: Rotor adapter for disc hubs not shown Rotor spacing varies by model year, see details below.
8
9
10
11
7
6
5
3
12
2
Threaded
1999 Bontrager Comp II
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . threaded
2001/2002 Bontrager Superstock
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . running change
2002/2003 Bontrager Superstock Disc, Select ATB Disc
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.25 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
2003 Bontrager Service Manual
2002/2003 Bontrager Superstock
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
2002/2003 Bontrager Select ATB
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
2002/2003 Bontrager Select Road
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
2002/2003 Bontrager Select Hybrid
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
13
Page 14
Rear hubs- Loose ball, double sealed (Formula FCM)
'99, 2000, 2001 Bontrager Race and Race Disk rear wheels
Recommended tools
(2) 15mm cone wrench 12mm allen wrench Adjustable wrench Hammer Small slot screwdriver
DISASSEMBLY
Fig. 1E
Fig. 2E
Fig. 3E
Axle
End nut
Small washer
Large washer
Fig. 4E
Spacer
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. 5E
14
Hub parts and names are referenced on next page.
Remove the axle
1. Remove external seals (Fig. 2E) with your fingers or a screwdriver. Be careful not to tear or mar the rubber.
2. On the left side (non-drive) of the hub place a 15mm cone wrench on the bearing cone (Fig. 3E).
3. Place a 15mm cone wrench on the end nut (Fig. 4E). Loosen the end nut.
4. Remove the end nut, large washer, spacer, small washer, and cone from the axle (Fig. 4E).
5. Slide the axle (Fig. 4E), with the other end nut, washer, and cone still attached, out of the hub.
6. Insert a thin screwdriver blade under the shell shield (Fig. 5E) and pry off the shell shields from both sides of the hub.
8. If inspection shows it neces­sary, remove the cone, washers, and end nut from the right side of the axle.
9. Remove the ball bearings (Fig.
Ball cone
6E) from both sides of the hub.
7. If it is nec­essary to remove
Clean and inspect the parts
1. Use solvent to completely remove all old grease and debris from the hub, axle, and axle parts.
2. Inspect the bearing run­ning surfaces of both the cones and the ball cups (inside the hub). Replace any worn parts.
2003 Bontrager Service Manual
ASSEMBLY
Lubricate bearings and threads
1. Lubricate the threads on the axle with Wrench Force™ synthetic grease, or a similar product.
2. Place a bead of grease all the way around each ball cup, sufficient to hold the balls.
Assemble the hub
1. Place nine 1/4” balls in the ball cup on one side of the hub (Fig. 6E).
2. Place the shell shield, with its sharp edges facing out (Fig. 6E), into the hub. The shell shield is a press fit, so must be tapped lightly to fully seat (Fig. 7E). Lay a cone wrench over the shell shield and tap the wrench with a hammer to protect the shield and ensure that it is flush with the shell.
3. Repeat steps 1-2 for the other side of the hub.
4. Tighten the end nut against the fixed cone (attached to axle) by holding the cone with a 15mm cone wrench and turn
Seal not seated
the end nut with another 15mm cone wrench.
5. Insert the axle through the hub from the right hand (drive) side.
7. Thread the cone, small washer, spacer, large washer, and end nut onto the axle in that order. The serrated surface of the end nut faces out.
8. From the left side of the hub, hold the cone with a 15mm cone wrench and tighten the end nut with a 15mm cone wrench.
9. Check the bearing adjustment by turning the axle with your fingers. The axle should spin smoothly without binding or feeling gritty. There should be no lateral play of the axle in the hub. Readjust the hub as necessary, and re-lock the end nut.
10. Install the external seal. Make sure the seal prop­erly seals against both the end nut and the hub shell. There should be a smooth transition from seal to sealing surface. An improperly installed seal (Fig. 8E) will allow rapid contamination of the bearings.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is eliminated when the wheel is installed with the quick release properly closed.
Fig. 6E
Fig. 7E
Fig. 8E
Page 15
Exploded view and Parts list
Note:
1
2
3
4
5
13
6
7
8
Rotor adapter for disc hubs not shown Rotor spacing varies by model year, see details below.
Splined
11a
Note: There are two types of freehub body attachments; see below for specifi-
cations, and page 9 for more information
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 Model year Model for Parts included (qty) TCG Part # Axle set 99/00 all 10 68533 End nut set 99/00 all 2(2) 68536 External seal, 99/00 all 1, 13 68534 yellow External seal, 99/00 all 1, 13 68535 red Freehub body, 99/00 all 11 68540 threaded Freehub body 01 all 11a, 6, removal tool 211340 splined Rotor adapter 99/00 Hayes, RST Not shown 991075
rear
Rotor adapter 99/00 Magura Gustav, Not shown 69156
Louise rear
Disc bolt set 99/00 all Not shown 991153
9
Threaded
10
11
6
7
12
4
3
13
2
2000 Race
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . threaded
2000 Race Disk
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . threaded
2003 Bontrager Service Manual
2001 Race
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . running change
2001 Race Disk
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.25 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . running change
15
Page 16
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
DISASSEMBLY
Fig. 1F
Axle spacer
Fig. 2F
End nut
Fig. 3F
Fig. 4F
End nut
Axle spacer
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.
Hub parts and names are referenced on next page.
1. Hold the left side (non­drive) axle spacer with a 19mm cone wrench and loosen the end nut (Fig. 2F) with a 15mm cone wrench.
2. Remove the end nut, washer, and axle spacer (Fig. 3F) from the axle.
3. Insert a thin screwdriver blade under the bearing seal (Fig. 4F) and pry off the seals
from both sides of the hub.
4. Tap the left end of the axle with a hammer to drive the axle out of the hub.
5. If inspection shows it necessary, remove the washers and end nut from the right side of the axle.
To loosen the end nut, re­install the left side axle spacer and locknut, and lock the end nut against the axle spacer.
Hold the axle spacer with a cone wrench while you loosen the right side end nut. Alternately, hold the axle with vise grips.
6. Place a bearing removal tool on the left bearing. With a punch on the bearing tool, drive the left bearing out of the hub with a hammer.
7. If it is necessary to remove
ASSEMBLY
Inside
Lubricate bearings and threads
1. Lubricate the threads on the axle with Wrench Force™ synthetic grease, or a similar product.
2. Lightly grease the inner and outer surfaces of each bear­ing where they contact the hub shell and axle.
Outside
Fig. 5F
Assemble the hub
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. 5F).
2. Place the axle through the freehub body.
3. Press the bearing into the hub shell with the bear­ing press.
4. Slide the left bearing onto the axle with the black seal facing out. Thread the axle spacer onto the axle, and use the bearing press to press the left bearing into the hub. The axle should turn freely with no lateral play in the hub shell.
5. Place the bearing seals into the hub with the let­tered surface facing out.
6. Thread the axle spacer onto the axle. 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. It should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is eliminated when the wheel is installed with the quick release properly closed.
Clean and inspect the parts
1. Wipe old grease or debris from the hub bearing
seats.
2. Normally, bearings are not re-used. If you are re­installing an old bearing, wipe off any grease or debris from both the inner and out surfaces.
Do not use solvent on the bearing, as the solvent will
contaminate the grease. This may cause bearing failure.
16
2003 Bontrager Service Manual
Page 17
Exploded view and Parts list
1
2
3
4
5
Pos Description 1 End nut 2 Washer 3 Spacer 4 Seal 5 Bearings 6 Hub shell 7 Axle 8 Freehub body 9 Freehub seal
6
7
8
3
5
9
2
1
Description Model year Model for Parts included (qty) TCG Part # Axle set 01/02 all 1(2), 2(2), 3(2), 4, 7, 9 211351 Bearing 01/02 all 5 73335 Freehub body 01/02 all 8, 9, removal tool 211339 splined Bearing press 01/02 all DT Comp/Onyx (not shown) 211416
DT Pro/240 (not shown) 211415
Removal tool Not shown 211338
2002/2003 Race
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
2002/2003 Race Disc
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.25 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
2003 Bontrager Service Manual
17
Page 18
DT-Swiss Comp series hubs
Important information before you begin with Comp series hubs
Some Bontrager front hubs utilize DT Swiss internal parts. This manual is intended for retailers with the appropriate skills and knowledge to work on these hubs. Please read the entire section before carrying out any kind of maintenance work.
This manual details the principle design features of DT Swiss front hubs and also provides instructions as to maintenance and repair work. Please take special care to use only original DT Swiss special tools in order to undertake the work details in this manual. Use only DT Swiss replacement parts.
In this manual, the hubs are shown installed in a complete wheel. Maintenance work should be carried out on complete wheels where possible. Otherwise, some steps can not be carried out correctly.
This manual provides technical and spare parts infor­mation for these hubs. If you have further questions about these hubs regarding technical information, sup­port, or warranty, they should be directed to Bontrager Technical Support via phone or on the Bontrager web site at www.bontrager.com.
In the event of improper servicing of the hubs, Bontrager has the right to refuse any warranty.
Special information before you begin
Bearing resistance: New or newly re-built hubs have a higher rolling resistance than used hubs because the grease in the freehub has not yet been evenly distributed and the seals have not yet bedded in.
Check your work: Before use, always check the hub for proper functioning.
Tool list for DT Swiss front hubs
The following tools may be necessary to perform maintenance work on DT Swiss Comp series hubs:
Long bearing press
Short bearing press
DT 17mm cone wrench
Comp front hub bearing press
Multi-purpose DT grease
Long bearing press
These maintenance items are available as TCG part #211416.
Short bearing press
Special screw­driver
Front hub bear­ing press
Regular Maintenance
Maintenance of the front hubs should be performed at least once a year. This maintenance schedule is based on normal usage. If you ride your bike more than average, or in rain, snow, or off road conditions, service your bicycle more often than the schedule suggests. If any part appears to be malfunctioning, inspect and service it immediately.
Things to avoid
Avoid high pressure washing systems, like those at most car washes. The high pressure can bypass bearing seals, letting water into the bearings. Do not use any kind of solvents or tensides- this can damage the hub.
2003 Bontrager Service Manual
19
Page 19
Comp front hub
Bontrager Race Modified, Race Modified Disc front wheel, 2003 Race Lite ATB, Race Lite ATB Disc front wheel
End cap
Fig. 1K
Fig. 2K
Fig. 3K
Bearing press
Recommended tools
Comp bearing press, front hub Short bearing press 17mm cone wrench Multi-purpose grease Bench vise Axle vise Hammer, soft faced Thin-bladed slot screwdriver
DISASSEMBLY
Hub parts and names are referenced on next page.
Disassemble the hub
1. Tap the axle (either end) with the hammer until the axle is flush with the surface of the end cap.
2. Remove the opposite end cap (Fig. 1K).
3. Tap the axle end without the end cap with the hammer (Fig. 2K) and remove the axle.
4. Slide the end cap, seal, and bearing from the axle (Fig. 3K).
5. Re-insert the axle through the hub and tap out the second bearing.
Clean and inspect the parts
Thoroughly clean and inspect all components with a dry cloth. If cracks or any other damage is visible, replace the part.
Bearing
ASSEMBLY
1. Place the Comp bearing press on the workbench or other solid surface. Push a new bear­ing onto the axle, and push the axle into the bearing press (Fig. 4K).
2. Place the hub over the axle.
3. Place the second Comp bearing press over the axle. Tap the upper bearing press with the hammer (Fig. 5K) to press the bearing into the hub.
4. Remove the upper bearing press.
5. Pull the axle out about 10mm (3/8in). Press the second bearing over the axle (Fig. 6K).
6. Place the second bear­ing press over the axle. Tap the upper bearing press with the hammer (Fig. 7K) to press the second bearing into the hub.
Check the bearing installation be spinning the axle. It should rotate freely without irregular friction.
7. Lightly grease the surface of both bearings.
8. Pull the V-seal off the end cap (Fig. 8K). Clean it thoroughly with a cloth, lightly grease it, and reinstall it on the end cap with the open ‘V’ facing the hub.
9. Position the completed end cap over the axle, and press into place with your fingers.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is eliminated when the wheel is installed with the quick release properly closed.
End cap
Fig. 6K
Fig. 7K
V-seal
Fig. 8K
20
Fig. 4K
Fig. 5K
2003 Bontrager Service Manual
Page 20
Exploded view and Parts list
1
2
Pos Description 1 End cap 2 V-seal 3 Bearing 4 Axle 5 Hub shell
4
3
5
3
2
1
Description Model year Model for Parts included (qty) TCG Part # Axle kit 99/00/01 All 1(2), 2(2), 3(2), 4 70361 Bearing 99/00/01 All 3 211349
2003 Bontrager Service Manual
21
Page 21
Comp rear hub
Bontrager Race Modified rear wheel, 2003 Race Lite ATB, 2002/2003 Race Lite Road rear wheel
Recommended tools
Long bearing press Short bearing press 17mm cone wrench Multi-purpose grease Bench vise Axle vise Hammer, soft faced Thin-bladed slot screwdriver
Fig. 1G
Spacer
DISASSEMBLY
Hub parts and names are referenced on next page.
1. Place the axle vise in the bench vise and clamp the left­hand end of the axle.
2. Remove the cassette.
3. Loosen the right end nut with the 17mm cone wrench and remove the end nut (Fig. 1G).
4. Pull off the freehub body
Fig. 2G
with your fingers.
The spacer (Fig. 2G) may be stuck to the inside of the free­hub body with grease.
5. Remove the spacer (Fig. 2G).
6. With the wheel removed from the vise, tap the right end of the axle with the hammer until loose. Pull the axle from the left side of the hub shell (Fig. 3G).
7. Place the right end of the
Fig. 3G
Retainer spring
axle into the axle vise.
8. Loosen the left end nut with the 17mm cone wrench,
Pawl
and remove it from the axle. Also remove the bearing.
9. Remove the retainer spring (Fig. 4G) and pawls from the hub with the screwdriver.
10. Pull the roller bearing retainer from the hub (Fig. 5G).
Fig. 4G
11. From the left side of the
wheel, place the axle through the hub and the bearing. Tap the axle with the hammer to drive the right hub bearing out. Remove the bearing from the axle.
Clean and inspect the parts
Clean all components and
inspect them thoroughly. If any
Fig. 5G
cracks or other damage are vis­ible, the parts must be replaced.
ASSEMBLY
1. Clamp the long bearing press into the bench vise. Push the axle, long end first, through the hole in the press. The short, 33mm end of the axle should be on top (Fig. 6G).
22
2003 Bontrager Service Manual
2. Place the wheel over the
axle with the drive side facing up.
3. Place a new bearing over the axle, black side out. Tap the short bearing press with the ham­mer to begin pressing the bearing into the hub (Fig. 7G).
4. Leave the short bearing press in place, and lift the wheel from the long bearing press (in the vise). Remove the axle from the hub and replace the wheel over the long bearing press.
5. Again tap the short bear­ing press with the hammer to press the bearing into the hub.
This is an important step, which ensures the bearing is cor­rectly pressed in.
6. Turn the wheel over and place it drive-side down on the long bearing press. Push the short 33mm end of the axle through the hub and bearing.
7. Slide the second hub bear­ing over the axle, black side on top.
8. Tap the short bearing press with the hammer to press the second bearing into the hub.
9. Turn the wheel over. Lightly grease the bearing shell.
10. Slide the roller bearing retainer over the hub bearing and into the housing (Fig. 8G).
Pawl spring elbow
Be careful not to dislodge any roller bearings.
Installing the pawl spring and pawls
1. Place the pawl spring over the axle and install the spring into the retainer body with the elbow pointing up (Fig. 9G).
2. Push both pawls beneath the spring with a screwdriver (Fig. 10G). Make sure they are placed correctly (Fig. 11G).
3. Lightly grease the roller bearing retainer, pawls, and hub bearing.
Install the freehub body
1. Push the spacer (Fig. 2G) over the axle.
2. Remove the freehub body seal (Fig. 12G). Clean the seal. If it is faulty or damaged, replace it.
3. Clean the freehub body teeth (a toothbrush works well).
4. Lightly grease the seal and freehub
Fig. 6G
Fig. 7G
Fig. 8G
Fig. 9G
Fig. 10G
Pawl
Spring position
Fig. 11G
Page 22
Freehub body seal
teeth.
5. Install the seal into the freehub body with the lip toward the outside of the hub (Fig. 13G).
6. Push the pawls in with a screwdriver as you slide the complete freehub body onto the axle (Fig. 14G). Check the align­ment to avoid excessive force
Fig. 12G
which could damage the spring.
7. Grease the freehub end and axle end.
8. Clean and lightly grease the right end nut and end seal (Fig. 15G). Replace the end seal on the end nut with the lip fac­ing the inside.
9. Place the complete end nut onto the axle and tighten it by hand.
Fig. 13G
Exploded view and Parts list
1
2
3
5
18
6
7
8
7
9
10
11
12
10. Place the wheel with the left end of the axle in the axle vise and tighten the right end nut to 150 lb•in (17Nm).
11. Turn the wheel over and clamp the right end nut in the vise.
12. Grease the bearing.
13. Clean and lightly grease the left end nut and end seal. Replace the end seal on the end nut with the lip facing the inside.
9. Place the complete left end nut onto the axle and tight­en it by hand.
10. Tighten the end nut to 150 lb•in (17Nm).
After completely assembling the hub, check for proper functioning by spinning the freehub body. If the pawls do not click into place, the spring may not have been cor­rectly installed, or there could be too much grease in the freewheel.
4
16
13
14
15
Fig. 14G
Fig. 15G
Pos Description 1 End nut 2 V-seal, left 3 Bearing, left 4 Axle 5 Retaining bolt 6 Driver 7 Pawl 8 Pawl spring 9 Roller retainer 10 Bearing shell 11 Bearing, right 12 Spacer
17
13 Freehub seal 14 Freehub body 15 V-seal, right 16 End nut, right 17 Nut cap 18 Hub shell
2003 Bontrager Service Manual
23
Page 23
Description Model year Model for Parts included (qty) TCG Part # Freehub kit 2000/01 all 7(2), 8, 12, 13, 14 70358 (Shimano) Driver kit 2000/01 all 5, 6, 10 72678 Axle set 2002/03 Race Lite Road 1, 2, 3, 4, 15, 16, 17 70359 (130 O.L.D.) Axle 2000/01 Race Mod 1, 2, 3, 4, 15, 16, 17 70360 (135 O.L.D.) 2003 Race Lite ATB
Bearing kit 00/01/02/03 all 3, 9, 11 72677
Bearing shell 2000/01 all 10, 11 72679 kit Bearing, left 2000/01 all 3 (6000, 12/26 x 8mm) 211348 Bearing, right 2000/01 all 11 (6900, 10/22 x 6mm) 211349
24
2003 Bontrager Service Manual
Page 24
Pro series hubs
Important information before you begin with Pro series hubs
Some Bontrager hubs utilize DT Swiss internal parts. This manual is intended for retailers with the appropriate skills and knowledge to work on these hubs. Please read the entire section before carrying out any kind of mainte­nance work.
This manual details the principle design features of DT Swiss hubs and also provides instructions as to main­tenance and repair work. Please take special care to use only original DT Swiss special tools in order to undertake the work details in this manual. Use only DT Swiss replacement parts.
In this manual, the hubs are shown installed in a complete wheel. Maintenance work should be carried out on complete wheels where possible. Otherwise, some steps can not be carried out correctly.
This manual provides technical and spare parts infor­mation for these hubs. If you have further questions about these hubs regarding technical information, sup­port, or warranty, they should be directed to Bontrager Technical Support via phone or on the Bontrager web site at www.bontrager.com.
In the event of improper servicing of the hubs, Bontrager has the right to refuse any warranty.
Special information before you begin
Bearing play: A small amount of play between the free­hub body and the hub shell is automatically eliminated when the wheel is installed and the quick release is tightened.
Bearing resistance: New or newly re-built hubs have a higher rolling resistance than used hubs because the grease in the freehub has not yet been evenly distributed and the seals have not yet bedded in.
Aluminum freehub bodies: For hubs with an alumi­num freehub body, we recommend cassettes using a solid, one piece spider like the Shimano Dura-Ace, Ultegra, XTR, or Deore XT. Cassettes using loose or bolted sprockets like Shimano Deore LX can cause notches in the freehub body. This can cause difficulties when later removing the cassettes from the freehub body (see “Removing Cassettes” on this page).
Check your work: Before use, always check the rear hub for proper functioning. Check the freehub body and the ratchet mechanism. If they do not function correctly, the rear hub should not be used until the fault is cor­rected. If you are unable to correct the fault, consult Bontrager Technical Support.
letting water into the bearings. Do not use any kind of solvents or tensides- this can damage the hub.
Determining the year of hub
There are two styles of rear hub, with some unique parts and different instructions for assem­bly and disassembly. To deter­mine which hub type you will be working on, it is necessary to remove the freehub. With the star ratchet removed, you will be able to see the right side shell bear­ing. If the bearing is completely visible due to its 24mm outer diameter (Fig. FH5), it’s a year 2000 hub. The 2001 model uses a larger, 28mm diameter bearing (Fig. FH6) that is partially cov­ered by the ring nut (requiring the removal of the ring nut).
Removing the cassette from the freehub body
The cassette does not need to be removed from the freehub body to perform regular main­tenance. However, if you decide to remove it, it should only be removed after the hub has been completely re-assembled.
1. Release the lockring using a lockring tool.
2. Loosen the cassette by lightly tapping it counter-clockwise with the hammer.
3. Remove all the sprockets from the freehub body.
4. Use a fine file to remove bad notches from the aluminum free­hub body (Fig. 14H). The aluminum freehub body must be cleaned and inspected. If any cracks or other damage is visible, the components must be replaced.
Note: Notches on the freehub body do not have a negative influence on the functionality of the freewheel.
Fig. FH5
Fig. FH6
Fig. FH7
Freehub seal installation tool
Short bearing press
Long bearing press
Regular Maintenance
Maintenance of the rear and front hubs should be performed at least once a year. This maintenance schedule is based on normal usage. If you ride your bike more than average, or in rain, snow, or off road conditions, service your bicycle more often than the schedule sug­gests. If any part appears to be malfunctioning, inspect and service it immediately.
Things to avoid
Avoid high pressure washing systems, like those at most car washes. The high pressure can bypass bearing seals,
2003 Bontrager Service Manual
Required tools
Maintenance of Pro level hubs requires special tools, available as TCG part #211415:
Freehub seal installation tool
Long bearing press
Short bearing press
Special screwdriver
DT Swiss special freehub grease
DT Swiss multi-purpose grease
Spline tool
Special screw­driver
Spline tool
25
Page 25
Pro front hub
2002 Bontrager Race Lite ATB, Race Lite 29, Race X Lite and Race X Lite Carbon front wheels, 2003 Race X Lite Aero
Fig. 1J
Fig. 2J
Fig. 3J
Recommended tools
Long bearing press Short bearing press Multi-purpose grease Bench vise Axle vise Hammer, soft faced
DISASSEMBLY
1. Loosen both end caps by rotating them in opposite direc­tions with your fingers.
2. Clamp the axle end cap (either side) in the axle vise (avoid over tightening).
3. Pull the wheel upward (Fig. 1J) to remove the end cap held by the vise.
4. Tap the axle out of the hub with the hammer (Fig. 2J).
5. Slide the bearing off the axle (Fig. 3J).
6. Re-insert the axle into the hub from the side opposite the remaining bearing. With the axle end resting on the inside of the bearing, tap the bearing out of the shell with the hammer.
Clean and inspect all com­ponents. If any cracks or other damage are visible, replace the part.
5. Grease both the outer sur-
face of both bearings.
End cap
V-seal
6. Pull the V-seal off the both end caps (Fig. 13I). Clean each seal thoroughly with a cloth, lightly grease it, and reinstall it on the end cap with the open ‘V’ facing the hub.
7. Push the completed adapters into place with your fingers.
After completing assembly of the hub, check its func­tion by spinning the axle with your fingers. It should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is eliminated when the wheel is installed with the quick release properly closed.
Fig. 6J
2002 Race Lite, ATB, Race Lite 29, 2003 Race X Lite ATB
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.5 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Race X Lite
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Race X Lite Carbon, Race X Lite Aero
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Fig. 4J
Fig. 5J
ASSEMBLY
1. Clamp the long bearing
press into the vise.
2. Push the new bearing over the front axle. Insert the axle into the bearing press (Fig. 4J).
2. Place the wheel over the axle and pull the axle out by about 10 mm (1/2 inch). Push the second bearing over the axle and into the hub.
3. Center the axle using the short bearing press.
4. Tap both bearings into place with the hammer (Fig. 5J) at the same time.
Turn the axle to check the bearings. You should not be able to feel any irregular friction. Make sure that there is no play in the axle.
26
2003 Bontrager Service Manual
Page 26
Exploded view and Parts list
Pos Description 1 End nut 2 V-seal
4
1
2
3
5
3
2
1
3 Bearing 4 Axle 5 Hub shell
Description Model year Model for Parts included (qty) TCG Part # Axle kit 00/01/02/03 all 1(2), 2(2), 3(2), 4 70357 V-seal 00/01/02/03 all 2 211342 Bearing 00/01/02/03 all 3(6802, 15/24 x 5mm) 211344 End cap kit 00/01/02/03 all 1(2) 221803
2003 Bontrager Service Manual
27
Page 27
Pro rear hub
Bontrager Race Lite ATB, Race Lite 29, Race X Lite, Race X Lite Carbon rear wheels, Race Lite Aero
A running change to hubs was made in 2001; the newer hub has a part number embossed in the shell. See exploded dioagrams for differences
Recommended tools
Long bearing press Short bearing press 17mm cone wrench Multi-purpose grease Bench vise Axle vise Hammer, soft faced Thin-bladed slot screwdriver
Fig. 1I
DISASSEMBLY
Hub parts and names are referenced on next page.
Disassemble the freehub
Spacer
1. Place the axle vise in the bench vise and clamp the left­hand end of the axle.
Star ratchet
2. Pull sharply with your fingers to remove the cassette, with the freehub body attached (Fig. 1I).
Fig. 2I
3. Remove the star ratchet, spacer and spring (under the star ratchet) from the hub (Fig. 2I).
4. Remove the second star ratchet and second spring from the freehub body.
Disassemble the ring nut
1. Clamp the spline tool into a bench vise (Fig. 3I).
2. Push the right side axle
Fig. 3I
end into the cylinder. With the splines engaged, turn the wheel
Bearing
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.
3. Thoroughly clean and inspect all components, includ­ing inside the hub, with a dry
Fig. 4I
cloth. If necessary, use a tooth-
brush. If cracks or any other damage is visible, the parts must
Spacer
be replaced.
Disassemble the bearings
1. From the right side, tap the axle out of the hub with the hammer (Fig. 4I). Remove the axle from the hub.
2. Slide the left end cap, seal
Fig. 5I
and bearing off the axle.
3. Turn the axle around and
insert it into the left side of the hub until the axle collar butts against the bearing. Tap the second bearing out with the hammer.
4. Thoroughly clean and inspect all components with a dry cloth. If cracks or any other damage is visible, the parts must be replaced.
ASSEMBLY
Install the right hand bearing
1. Clamp the spline tool into
a vise.
2. Place the spacer over the
splines (Fig. 5I).
3. Place the bearing onto the long end of the axle and push the bearing onto the spline tool (Fig. 6I).
4. Place the wheel over the axle, drive side down. Push the short bearing press over the other end of the axle. Tap the bearing into place with the ham­mer (Fig. 7I).
Install the ring nut
1. Clamp the spline tool into the vise with only the splines above the jaws (Fig. 8I).
2. Inspect the ring nut for cracks or damage. If damaged, replace it.
3. Place the ring nut with the recess uppermost over the splines (Fig. 9I). Place the spacer ring flat inside the ring nut.
4. Place the wheel, drive side down, over the spline tool. Insert the right axle end through the spline tool. Carefully screw the ring nut into the hub by turning the wheel clockwise.
Install the freehub body seal
Important: When installing a new seal, only the right-hand bearing should be in place. The left-hand bearing must not be pressed in until after the seal has been installed.
1. Inspect the seal. If the seal shows signs of wear or damage, replace it.
2. Clamp the short bearing press into a vise (Fig. 10I) and place the wheel, drive side up, over the tool.
3. Place the seal over the freehub body seal installation tool (Fig. 11I) with the ‘V’ facing the hub.
4. With the seal on the tool, push them together over the axle.
5. Place the long bearing press over the axle.
6. Press the seal into the hub by tapping it with the hammer.
Install the left hand bearing
1. Clamp the spline tool into the bench vise (Fig. 3I).
Spacer
Fig. 6I
Fig. 7I
Fig. 8I
Ring nut
Fig. 9I
Fig. 10I
28
2003 Bontrager Service Manual
Page 28
Freehub body seal
2. Push the wheel over the
tool, drive side down.
3. Place the bearing care-
fully into the hub (Fig. 12I).
4. Place the short bearing press over the axle (Fig. 7I). Tap the bearing into place with the hammer.
Turn the axle and check that you do not feel any irregular
Fig. 11I
friction.
5. Lightly grease the surface of the bearing.
6. Pull the V-seal off the end cap (Fig. 13I). Clean it thoroughly with a cloth, lightly grease it, and reinstall it on the end cap with the open ‘V’ facing the hub.
7. Replace the completed end cap onto the left axle end.
Fig. 12I
Install the freehub
End cap
V-seal
1. Grease the splines inside the hub shell with DT Swiss spe­cial grease (only).
2. Push the spacer over the axle (Fig. 14I) until it butts against the bearing.
3. Insert the spring, with the large diameter in contact
Fig. 13I
with the bearing (Fig. 14I).
4. Clean the outside end of the freehub body with a clean cloth.
Before positioning the spacer and the ratchet in the freehub body, check that the freehub body bear­ings spin freely without binding. If any binding or scratching is detected, replace the freehub body with a new or reconditioned one.
5. Carefully clean the star ratchets with a dry cloth. Inspect both star ratchets for damage.
Spring
Spacer
If any damage is visible, replace the ratchet.
5. Lightly grease both star ratchets with DT Swiss special grease (only).
6. Place the spacer ring into the freehub body. Place the spring into the freehub body
Fig. 14I
with the large diameter end in contact with the spacer ring (Fig. 15I).
7. Place both greased star ratchets into the freehub body (Fig. 16I).
8. Push the freehub body, together with the cassette, over the axle.
Caution: Ensure the freehub body is not tilted !
Fig. 15I
9. Pull the V-seal off the right end cap (Fig. 13I). Clean it thor­oughly with a cloth, lightly grease it, and reinstall it on the end cap with the open ‘V’ facing the hub.
10. Place the end cap over the right end of the axle and manually press into place. Ensure the end cap is not tilted and that it audibly clicks into place.
After completing assembly of the hub, check its function by giving the cassette a sharp, quick spin. If the ratchets do not catch, there could be too much grease inside the freehub body, or the wrong type of grease was used. In this case, remove some of the grease or replace it using the correct grease.
Fig. 16I
2003 Bontrager Service Manual
Part list on following page
29
Page 29
2003 Bontrager Service Manual
Exploded view and Parts list- 2001-2003
4
1
2
3
13
3
5
6
A running change to hubs was made in 2001; the newer hub (shown here) has a part number embossed in the shell. See the following page for the earlier model hub.
8
7
9
10
10
9
11
Pos Description 1 End cap, left 2 V-seal 3 Bearing 4 Axle 5 Spacer 6 Ring nut 7 Washer 8 Spacer 9 Spring 10 Star ratchet 11 Freehub body 12 End cap, right 13 Hub shell
12
Description Model year Model for Parts included (qty) TCG Part # Freehub kit 02/03 all 8, 9(2), 10(2), 11 70354 (Shimano) Freehub kit 02/03 all 8, 9(2), 10(2), 11 211579 (Campagnolo) Star ratchet 02/03 all 9(2), 10(2) 211343 and spring kit Axle kit 02/03 all road 1, 2, 3(2), 4, 13 70355 130mm O.L.D. (Shimano) Axle kit 02/03 all road 1, 2, 3(2), 4, 13 211580 130mm O.L.D. (Campagnolo) Axle kit 02/03 Race Lite ATB 1, 2, 3(2), 4, 13 70356 135mm O.L.D. V-seal 02/03 all 2 211342 Freehub seal 02/03 all 7 211591 Bearing 02/03 all 3 (6902, 15/28 x 7mm) 211345
2001, 2002 Race Lite, 2003 Race X Lite ATB
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Race X Lite
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Race X Lite Carbon, Race X Lite Aero
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
30
2003 Bontrager Service Manual
Page 30
Exploded view and Parts list- 2000-2001
Pos Description
4
1
2
3
14
7
6
8
9
10
10
11
12
13
1 End cap 2 V-seal 3 Bearing 4 Axle 6 Freehub seal 7 Bearing 8 Spacer 9 Spring 10 Star ratchet 11 Washer 12 Freehub body 13 End nut, right 14 Hub shell
Description Model year Model for Parts included (qty) TCG Part # Freehub kit 2000 Race, Race Lite 8, 9(2), 10(2), 12 70354 (Shimano)
Star ratchet 2000 Race, Race Lite 9(2), 10(2) 211343 and spring kit
Axle 2000 Race, Race Lite 1, 2, 3(2), 13 (135mm O.L.D.) 70356
Freehub seal 2000 Race, Race Lite 6 211591
Bearing, left 2000 Race, Race Lite 3 (6902, 15/28 x 7mm) 211345
Bearing, right 2000 Race, Race Lite 7 (3802, 15/24 x 7mm) 211346
2000 Race Lite
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2003 Bontrager Service Manual
31
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