SRAM DualDrive 24 Technical Manual Download Page 2 | Manualshive

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SRAM DualDrive 24 Technical Manual Download Page 2

© Copyright SRAM Corporation 2005

Publ. No. 8053 E

Information may be enhanced
without prior notice.

Released August 2005

SRAM Technical Documentation,
Schweinfurt/Germany

Campagnolo, EXA-Drive are trademarks of Campagnolo S.R.L., Italia.
Grilon is a trademark of EMS-Chemie AG, Switzerland.
MAGURA is a trademark of MAGURA GmbH & Co., Germany.
HAYES is a trademark of der HAYES BRAKE Inc., U.S.A.
Shimano, HG, IG are trademarks of Shimano Inc., Japan.

This Technical Manual is
intended for bicycle factories
and qualified bicycles dealers
only!

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Summary of Contents for DualDrive 24

Page 1: ...ENGLISH 2006 TECHNICAL MANUAL GEAR HUB SYSTEMS...

Page 2: ...ermany Campagnolo EXA Drive are trademarks of Campagnolo S R L Italia Grilon is a trademark of EMS Chemie AG Switzerland MAGURA is a trademark of MAGURA GmbH Co Germany HAYES is a trademark of der HAY...

Page 3: ...B S A N D S H I F T E R S DualDrive 3 SRAM S7 13 SRAM P5 21 SRAM P5 Cargo 29 SRAM T3 37 Sparc 45 G E A R H U B S Y S T E M C O M P O N E N T S i BRAKE 53 Front Hubs with Drum Brake 63 i LIGHT 66 Power...

Page 4: ...Technical Manual 2006 2...

Page 5: ...FG 10 5 FG 10 5 Holes 36 or 28 36 36 or 32 Hole Diameter 2 6 mm 28 holes also available in 2 8 mm 2 6 mm 2 6mm Hole Ref 67 mm 67 mm 67 mm Flange Dist to 1 2 OLD 33 mm 18 mm 33 mm 18 mm 33 mm 18 mm To...

Page 6: ...fter Twist shifter Version DualDrive 27 DualDrive 24 DualDrive 27 DualDrive 27 DualDrive 24 Clickbox Cable 1400mm 1500mm 1600mm 1700mm 2100mm see Price list see Price list Shifter Type SRS Twistring T...

Page 7: ...ve cranks at Truvativ http www truvativ com C H A I N G U I D E F O R K It prevents chain from jumping off front chainring is bolted inside the chain case 1 Fig 4 H A N D L E B A R Diameter 22 3 mm Mi...

Page 8: ...ents to install handlebar grips Handlebar grips provide safety function For this reason they should be mounted in such a way as to make sure they do not slip off handlebar Always check the front and r...

Page 9: ...w to adjust the rear derailleur to act as a chain tensioning device or to prevent chain suck This increases the chain gap causing poor shifting performance Index shifting adjustment Check that the cha...

Page 10: ...unt cap 1 Unclamp hub and mount shifing rod 20 with a torque of 0 2 Nm 1 8 in lbs Mount spoke protector disc and cassette R E M O V E W H E E L Rotate the twist shifter to the highest gear position sp...

Page 11: ...e g beneath the bottom bracket C A B L E C H A N G E Advice Use only new high quality cable and compressionless cable housing with end caps Twist shifter rear derailleur Detach the cable from the der...

Page 12: ...n guide pulley sprocket is too large Clearance between guide pulley sprocket is too small Shift cable insufficiently tensioned Shift cable insufficiently tensioned Shift cable is too tight Excessive c...

Page 13: ...11 DUALDRIVE MAINTENANCE Technical Manual 2006...

Page 14: ...Technical Manual 2006 12...

Page 15: ...A1max 12 5mm A2max 12 2mm A1 max 12 5mm A2max 12 2mm A1 max 12 5mm A2 max 10mm Holes 36 36 36 36 Hole Diameter DS 3 0mm 3mm 2 9mm 3 0mm Hole Ref HR 75mm 75mm 89mm 75mm Flange Dist to 1 2 OLD F1 33mm F...

Page 16: ...oke length table Place the dust cap 1 Fig 1 and sprocket 2 on the driver Push sprocket circlip 3 Fig 2 onto the cone of tool sleeve 4 Place tool sleeve with large diameter on the driver Push the sprin...

Page 17: ...internal lug 5 is guided in the slot 6 of the shift tube until it can be felt and heard to engage Turn locating sleeve on the axle until the guiding rib 4 is facing roughly upwards Place shifter in g...

Page 18: ...18 Compress spring and fit grub screw 17 2 3 SRAM S7 mounting aid Part No 65 0324 103 000 1 1 2 3 4 5 6 7 8 9 16 17 18 21 22 23 24 25 26 15 12 13 14 10 11 31 32 33 42 43 40 41 39 38 37 36 35 34 27 28...

Page 19: ...spring 31 Fit largest ball retainer 34 with balls underneath Fit cover 32 inside to the spring Assemble the compression spring 33 with 12 turns Position driver 35 push it down and screw on fixed cone...

Page 20: ...ig 9 Part No 65 0324 107 000 Locate clamping bolt 1 Fig 6 and place shifter cable around the carrier cylinder counter clockwise winding Position the cover 3 Fig 5 and tighten up with the cover screw 2...

Page 21: ...RAM grease Part No 0369135 200 201 and standard bicycle oil To lubricate the bearing points on the planetary gear sets position the plane tary gear carrier on its crown and apply 2 3 drops of oil to t...

Page 22: ...Technical Manual 2006 20...

Page 23: ...Dropout Width Dim A1 max 12 5mm A2max 11 5mm A1 max 12 5mm A2max 12 5mmA1 max 12 5mm A2max 10 5mm A1 max 12 5mm A2max 10 5mm Holes 36 36 36 36 Hole Diameter DS 3 0mm 3 0mm 2 9mm 3 0mm Hole Ref HR 75mm...

Page 24: ...ve tool and check that the circlip is seated correctly Turn dust cap 7 Fig 3 until the three lugs 8 are between the three beads 9 on the sprocket 10 Position dust cap and push towards sprocket until i...

Page 25: ...it is easily visible Push locating sleeve 3 with guiding rib 4 to the front onto the hub axle making sure that the internal lug 5 is guided in the slot 6 of the shift tube until it can be felt and hea...

Page 26: ...fixed cone 33 Remove driver 32 compression spring 30 large compression spring 28 and ball retainer 31 Withdraw gear ring 27 and coupling gear 26 and then remove cover 29 from the coupling gear Take o...

Page 27: ...nting aid Insert planetary gear carrier place thrust washer 8 on it and mount retaining washer 9 in recess Now remove the mounting aid Advice If the gears are not accurately installed the hub may be t...

Page 28: ...ig 9 Part No 65 0324 107 000 Locate clamping bolt 1 Fig 6 and place shifter cable around the carrier cylinder counter clockwise winding Position the cover 3 Fig 5 and tighten up with the cover screw 2...

Page 29: ...e is loaded excessively its effect can be too strong the hub may lock In such a case the 3 brake segments should be lubricated with a special grease Part No 0369 135 200 201 Renew brake seg ments when...

Page 30: ...Technical Manual 2006 28...

Page 31: ...max 11 5mm A1 max 12 5mm A2 max 12 5mm Holes 36 36 Hole Diameter DS 3 0mm 2 9mm Hole Ref HR 75mm 89mm Flange Dist to 1 2 OLD F1 28 5mm F2 29 5mm F1 30 5mm F2 29 5mm Totally 224 Speed 1 67 Speed 2 78 S...

Page 32: ...emove tool and check that the circlip is seated correctly Turn dust cap 7 Fig 3 until the three lugs 8 are between the three beads 9 on the sprocket 10 Position dust cap and push towards sprocket unti...

Page 33: ...r older hub versions Turn slot 6 in shift tube to a position where it is easily visible Push locating sleeve 3 with guiding rib 4 to the front onto the hub axle making sure that the internal lug 5 is...

Page 34: ...rew fixed cone 33 Remove driver 32 compression spring 30 large compression spring 28 and ball retainer 31 Withdraw gear ring 27 and coupling gear 26 and then remove cover 29 from the coupling gear Tak...

Page 35: ...unting aid Insert planetary gear carrier place thrust washer 8 on it and mount retaining washer 9 in recess Now remove the mounting aid Advice If the gears are not accurately installed the hub may be...

Page 36: ...e Fig 9 Part No 65 0324 107 000 Locate clamping bolt 1 Fig 6 and place shifter cable around the carrier cylinder counter clockwise winding Position the cover 3 Fig 5 and tighten up with the cover scre...

Page 37: ...AM grease Part No 0369135 200 201 and standard bicycle oil To lubricate the bearing points on the planetary gear sets position the plane tary gear carrier on its crown and apply 2 3 drops of oil to th...

Page 38: ...Technical Manual 2006 36...

Page 39: ...89mm 58mm Flange Dist to 1 2 OLD F1 24 5mm F2 25 5mm F1 23 7mm F2 26 3mm F1 25 5mm F2 32 5mm F1 24 5mm F2 25 5mm Totally 186 Speed 1 73 Speed 2 100 Speed 3 136 Line C D E 44 5 41 5 38 5mm 44 5 41 5 3...

Page 40: ...1 4 3 x 297 mm 287 mm Spoke length table A S S E M B L Y H U B Lace the wheel as normal See spoke length table Place the dust cap 1 Fig 1 and sprocket 2 on the driver Push sprocket circlip 3 Fig 2 on...

Page 41: ...gaged To make the adjustment the cable must be taut in third gear to be able to transfer a shift movement directly to the hub Push locating sleeve 2 Fig 8 onto the small pull rod 3 until the control c...

Page 42: ...Remove driver 17 compression springs 14 and 13 and ball retainer 16 Push the sliding key 12 through the large bore in the coupling wheel of the ring gear 11 the bore and thrust block must be aligned R...

Page 43: ...H 3105 insert ball retainer 3 mount adjusting cone d with dust cap e and hexagonal nuts 1 Adjust the hub clearance as for type MH 3115 For type MH 3125 the ball retainer f and dust cap pressed in norm...

Page 44: ...maintenance free under normal conditions For type MH 3115 however particularly high loading of the coaster brake can cause to overcompensate In this case apply special grease Part No 0369135 200 201...

Page 45: ...ct gear setting Bearings set too tight Loose lock nuts Chain is overtensioned Brake shell has run dry Brake cone brake sleeve Remedy Adjust shifting system oil control cable check that cable stop is f...

Page 46: ...Technical Manual 2006 44...

Page 47: ...g H U B Sparc hub 16 8V Wheel 28 26 20 26 USA Econ Mode 20 km h 16 km h 26 km h Speed Mode 25 km h 23 km h 32 km h with 15 km h about 15 km Speed Mode with 20 km h about 25 km Speed Mode with 24 km h...

Page 48: ...the attachment plate must be max 3 mm Do not use additional washers At least the beginning of the axle thread must be visible in front of the axle nut A S S E M B L Y S H I F T E R Slide shifter 1 Fi...

Page 49: ...cumentation of battery charging also allows you to fill in the dates of additional charge actions that you would need to perform if the batteries stay in your warehouse over a longer period of time Yo...

Page 50: ...E A R H U B see Fig 1 Remove circlip 35 sprocket 34 and dust cap 33 Clamp hub with the two axle flats sprocket side facing downwards Remove electric drive 4 see left column Unscrew the locknuts 1 2 R...

Page 51: ...ening torque 15 20 Nm 133 177 in lbs Reassemble electric drive C A B L E C H A N G E Dismantling shifter cable Place shifter in gear position 1 Do not remove the Clickbox from the axle end Unscrew the...

Page 52: ...battery and pull off plug 1 and cable shoe 2 from card modul Reassembly Connect plug and cable shoe of new battery to card modul white plug with red and black cable 1 Fig 9 cable shoe with yellow cabl...

Page 53: ...nd the battery box do not pull on the cables Regularly check the cable and protect it from sharp edges If it is damaged have it renewed immediately by a specialist workshop Protect the unit from oil g...

Page 54: ...52 Technical Manual 2006...

Page 55: ...lid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Material Steel Steel Steel Steel Steel Steel Ends Diameter 9 mm M 9x1 9 mm M 9x1 9 mm M 9x1 9 mm M 9x1 9 mm M 9x1 9 mm M 9x1 Holes 36 36 36 36 3...

Page 56: ...or SRAM S7 i BRAKE for SRAM P5 i BRAKE for SRAM T3 Performance Level Comfort City Trekking Hub DD 27 24 i BRAKE comp SRAM S7 i BRAKE comp SRAM P5 i BRAKE comp SRAM T3 i BRAKE compatible Over Locknut D...

Page 57: ...the rear wheel no residual deformation can occur on the rear structure Dimensions Important dimensions for rear frames see previous page Rear fork dropouts must be parallel Mudguard and luggage carri...

Page 58: ...he clamp must be seated on the rear fork with no play Use a self locking nut Hex screw property class 8 8 Tightening torque 7 8 Nm 62 70 in lbs Fastening wheel solid axle Fit washers resp retaining wa...

Page 59: ...otal weight of the bicycle with cyclist and baggage Positioning of link can be changed to personal preferences but we advise to use according to weight Make sure you use the same position after changi...

Page 60: ...ent using quick release To remove the wheel open the quick release lever M O U N T I N G T H E W H E E L Placing the wheel in fork ends Front wheel Guide the top end of the brake anchor plate 1 Fig 3...

Page 61: ...e lever again Caution Do not tighten the wheel by turning the release lever clockwise Fig 6 Only use hand force By incorrectly mounting the skewer or the wheel in the dropout or by wrongly adjusting t...

Page 62: ...Attach the bellows to the adjustment screw Thread brake cable end into link and under the washer 8 and tighten nut 9 slightly hex wrench 5 mm Caution Ensure that the brake cable lies in the notch of t...

Page 63: ...rake drum and hub must be clean and free from oily and greasy substances Front hubs Unscrew lock nut 4 Fig 13 and remove steel washer 5 Gear Hubs Remove steel resin washer 5 Fig 13 Remove brake anchor...

Page 64: ...Technical Manual 2006 62...

Page 65: ...3 3 3mm Hole Reference 89mm 89mm 86mm 86mm Hand Brake Lev Comp see page 64 Cable moving distance 15 mm and leverage 3 8 4 2 Bearing Cartridge Cartridge Cartridge Cartridge Sealing Lip Seal Lip Seal L...

Page 66: ...ver 1 Fig 1 goes on the left side viewed from behind the rear of the bicycle Guide the top end of brake anchor plate 2 into the brazing part of the fork if fitted If there is no brazing part use VT pi...

Page 67: ...petroleum etc as this could produce impurities in the brake pads M A I N T E N A N C E Bearings is sufficiently lubricated and essentially maintenance free Cable housing without inner tube lubricate r...

Page 68: ...the tension force is inadequate In this case open release lever again tighten adjusting nut slightly and close release lever again If considerable force is required to close the lever open the lever a...

Page 69: ...front wheel and check the lamp illumination Advice Hubs equipped with i BRAKE Please read the i BRAKE documentation M A I N T E N A N C E Do not disassemble the internal hub me chanism Do not apply an...

Page 70: ...ngth 9000N 2023 lbs 9000N 2023 lbs 9000N 2023 lbs 9000N 2023 lbs 9000N 2023 lbs Weight 114 links 307 g 307 g 307 g 307 g 307g External Pin Plate Silver Nickel Plated Silver Nickel Plated Grey Polished...

Page 71: ...t use any grease dissolving or acidic agents Cleaning agent must be rinsed off after a few minutes with water Apply oil after chain is completely dried P C 9 9 1 P C 9 7 1 P C 9 5 1 PC 68 PC 58 PC 48...

Page 72: ...70 NOTICES Technical Manual 2006...

Page 73: ...71 NOTICES Technical Manual 2006...

Page 74: ...H AMERICA Dealer Helpdesk Number 8 0 0 3 4 6 2 9 2 8 EUROPE Please contact your local distributor SPARE PARTS SRAM ORIGINAL PARTS You can find an extensive spare parts program in SRAM s Spare Parts Li...

Page 75: ......

Page 76: ...fax 1 312 664 8826 EUROPEAN HEADQUARTERS SRAM Europe Basicweg 12 D 3821 BR Amersfoort The Netherlands phone 31 33 450 6060 fax 31 33 457 0200 ASIAN HEADQUARTERS SRAM Taiwan No 1598 8 Chung Shan Road...

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