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2003 Bontrager Service Manual
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
DISASSEMBLY
Hub parts and names are referenced on next page.
1. Place the axle vise in the
bench vise and clamp the left-
hand 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
with your fingers.
The spacer (Fig. 2G) may be stuck to the inside of the free-
hub 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
axle into the axle vise.
8. Loosen the left end nut
with the 17mm cone wrench,
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).
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
cracks or other damage are vis-
ible, 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).
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 ham-
mer 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 bear-
ing press with the hammer to
press the bearing into the hub.
This is an important step, which ensures the bearing is cor-
rectly 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 bear-
ing 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).
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
Comp rear hub
Bontrager Race Modified rear wheel, 2003 Race Lite ATB, 2002/2003 Race Lite Road rear wheel
Fig. 1G
Fig. 3G
Fig. 2G
Spacer
Fig. 6G
Fig. 4G
Retainer
spring
Pawl
Fig. 5G
Fig. 7G
Fig. 8G
Fig. 10G
Fig. 9G
Pawl spring
elbow
Fig. 11G
Pawl
Spring position
