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15

2003 Bontrager Service Manual

Exploded view and Parts list

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

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

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

1

3

13

2

2

3

4

5

6

6

7

7

9

10

11

12

13

8

4

Note:
Rotor adapter for disc hubs not shown
Rotor spacing varies by model year, see details below.

Note:
There are two types of freehub body attachments; see below for specifi-
cations, and page 9 for more information

Splined

Threaded

11a

«
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13
14
15
16
17
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»

Содержание 231793

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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