Bontrager 231793 Service Manual Download Page 1 | Manualshive

Page: 1 / 30

background image

HUB INSTRUCTIONS

PART NUMBER 231793

SERVICE MANUAL 2003

1
2
3
...
»

Summary of Contents for 231793

Page 1: ...HUB INSTRUCTIONS PART NUMBER 231793 SERVICE MANUAL 2003...

Page 2: ...SWISS Comp series hubs Introduction 19 Comp front 20 21 Comp rear 22 24 Pro series hubs Introduction 25 Pro front 26 27 Pro rear 28 31 Copyright Trek Bicycle Corporation 2002 All rights reserved Plea...

Page 3: ...shell shield and tap the wrench with a hammer Fig 7A to protect the shield and ensure that it is flush with the shell 3 Repeat Assembly steps 1 2 for the other side of the hub 4 Tighten the end nut ag...

Page 4: ...poke 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...

Page 5: ...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...

Page 6: ...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 Pos Descript...

Page 7: ...aring 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 bearing...

Page 8: ...p 2 Adjustable nut 3 Seal 4 Bearing 5 Hub shell 6 Axle 1 2 3 4 5 6 1 3 4 Note Rotor adapter for disc hubs not shown Rotor spacing varies by model year see details below Description Model year Model fo...

Page 9: ...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...

Page 10: ...hole P C D 38 0 mm Q R rod outer diameter 5 mm Pos Description 1 End nut 2 Seal 3 Bearing 4 Hub shell 5 Axle 1 2 3 4 5 1 2 3 Description Model year Model for Parts included qty TCG Part Seal 02 all 2...

Page 11: ...ial adapter TCG 211338 is made which attaches to an 8mm allen wrench to fit the 11mm allen head of the freehub attachment bolt Fig 3 In addition as a running change the new hub bodies will include a 6...

Page 12: ...b 1 Place nine 1 4 balls in the ball cup on one side of the hub Fig 6D 2 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 t...

Page 13: ...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...

Page 14: ...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 s...

Page 15: ...Shimano 8 9 speed Cassette body attachment running change 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 bo...

Page 16: ...nstalling 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...

Page 17: ...0 mm Disc rotor spacing 15 25 mm Rotor BCD 44 0 mm Cassette body type Shimano 8 9 speed Cassette body attachment splined 1 3 2 1 4 5 3 5 6 7 8 9 2 Pos Description 1 End nut 2 Washer 3 Spacer 4 Seal 5...

Page 18: ...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 be...

Page 19: ...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...

Page 20: ...oded view and Parts list 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 Pos Description 1 End cap 2 V seal 3 Beari...

Page 21: ...p 3 Place a new bearing over the axle black side out Tap the short bearing press with the ham mer to begin pressing the bearing into the hub Fig 7G 4 Leave the short bearing press in place and lift th...

Page 22: ...l 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...

Page 23: ...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...

Page 24: ...until the fault is cor rected If you are unable to correct the fault consult Bontrager Technical Support Regular Maintenance Maintenance of the rear and front hubs should be performed at least once a...

Page 25: ...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 bear...

Page 26: ...nut 2 V seal 3 Bearing 4 Axle 5 Hub shell 1 2 3 5 3 1 4 2 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 Bear...

Page 27: ...l 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 d...

Page 28: ...se remove some of the grease or replace it using the correct grease 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 o...

Page 29: ...tity 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...

Page 30: ...ts 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 703...

Reviews:

No comments

Related manuals for 231793

Brand: echoflex Pages: 8

SANbox 5000 Series

Brand: Qlogic Pages: 8

Brand: CalDigit Pages: 13

Sierra Video 1208V3S

Brand: Kramer Pages: 2

Brand: Pakedge Pages: 12

Brand: ADS Technologies Pages: 2

SmartSwitch SBU128

Brand: Cabletron Systems Pages: 76

Brand: Wyrestorm Pages: 4

Brand: Black Box Pages: 3

Brand: NETGEAR Pages: 8

Brand: Black Box Pages: 76

Brand: Lantech Pages: 24

Brand: Kramer Pages: 8

Brand: CityGrow Systems Pages: 21

Brand: Gefen Pages: 136

Brand: UHPPOTE Pages: 10

Emulation Pod M306V2T-RPD-E

Brand: Renesas Pages: 74

Brand: Omron Pages: 8

Brands by name

0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Popular brands

Load more brands