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Bicycle Repair Manual
Bicycle Repair Manual
LL A D
FU SED TE
V I DA
RE UP
B CYCLE
REPAIR
MANUAL
CHRIS SIDWELLS
CHRIS
SIDWELLS
Intr
trrod
trod
o uc
ction
tiio
on
n
G TT
GE
T ING TO KNO
KNOW
W YOU
UR BIK
BIK
KE 8
The
eb
ba
asic bike
e
10
0
Anatom
An
omy of tthe
he
eb
bik
ke
12
12
Bik
ke forr ge
kes
enera
al use
14
4
Spe
Sp
ecia
alt
ltyy bike
es
16
Settin
in
ng up an ad
a ult
ult
ul
t s bike
e
18
8
Sett
tttin
ing
g up
p a ch
hiilds
ld bike
20
CARI
CA
RIING FOR
OR YOUR
R BIKE
KE
KE
22
T olss
To
24
W rk
Wo
kshop priinc
nciple
es
26
Clea
Cl
eaning you
ea
ourr bike
ke
e
28
8
Lu
Lubr
ub
brric
ric
icat
ating
g yo
your bik
ke
30
Ma
M
aki
king
ng rou
outtiine
ne ssaf
afet
af
ety checks
et
32
M in
Ma
i te
tena
na
anc
nce
e
34
T oublesh
Tr
hootin
hoot
i g
36
Sp
pot
otti
ting
ng
gd
dan
an
nge
ger si
sign
sign
gns
38
38
Prep
Pr
ep
par
arin
in
ng ffo
or w
we
et w
et
we
ea
eat
atthe
her
er
40
40
MAIN
NTAININ
NG
YO
OUR DRIVE
RIIVE
R
V TR
TRA
AIIN
IN
42
42
Ca
abl
be
es
s and
nd shiftters
H w they wor
Ho
ok
44
Drrop handleb
eb
bar gear cabl
ablles
46
46
Stra
St
raight handleb
eb
bar gea
ar ca
ables
48
Fron
Fro
ont and rear deraille
eurs
eu
How
Ho
w th
they
ey work
ey
50
Fron
nt de
d ra
ailille
l ur
52
Discover more at
Rear der
erai
a lllleu
ai
eurr
eu
54
www.dk.com
Hu
H
ub ge
ub
ear
ars
H w th
Ho
they
ey wor
ork
56
Hub
Hu
b ge
gear
ar I
58
8
Hub gear II
60
Chaiin,
n, ca
c ss
s ette
e, and cra
rank
n set
ADJU
AD
ADJ
JUST
STING YOUR BRAKES 10
08
Riim b
R
brrak
a es
How
Ho
w they
th
hey
ey wor
ok
110
Drrop
p han
nd
dllebar
eb
e
ba
arr brake cable
112
How the
Ho
ey wor
ork
k
62
Stra
St
aight
htt han
h
ndl
dle
eb
bar
ar b
bra
r ke cable 114
Chai
aiins
64
4
Caliper br
brak
ak
ke
116
66
66
V-brake
118
Crran
anks
kset
etss
68
C nt
Ca
ntililev
ever brake
ra
ake
k
120
Alternativ
ive
e brake de
essiign
ns
122
Bott
tttom
om brack
cketts
H w th
Ho
hey
y work
70
H bHu
b mo
mounte
te
ed brakes
s
Ca
artridge
rtt
bo
b
bott
ottom
ttom bracket
tt
ett
7
72
Ho
ow th
hey work
k
12
24
4
Hollow-ax
xle
e bo
bottom bra
ra
ack
ket
et
74
74
Replac
ac
cin
i g di
d sc
s bra
rake padss
126
26
B X bo
BM
ott
t om
om brackett
76
D sc bra
Di
ake
k carre
128
28
Hyydr
d aulic d
diissc
c bra
r ke
eI
130
13
Peda
Pe
da
d
als
How
Ho
w th
t ey work
k
78
Hyydrau
Hydr
drra lic diisc brra
ake
ke II
13
32
2
Peda
Pe
dal axle
da
80
80
Ro r--b
Roller
brake ca
ab
ble
13
34
Clip
ple
ess ped
edalls
82
Peda
Pe
dal cl
cleats
ts
8
84
TUN
TU
NING
ING
G YOU
UR SU
SUS
SP
PENSION 1
13
36
STEE
ST
EERI
RIN
NG
G AND WHE
HEEL
ELS
ELS
EL
86
Sus
Su
spen
sp
e siion
n forrk
ks
s
How tth
Ho
hey
y work
k
138
13
He
H
ead
adse
etts
s
Fron
Fr
ontt su
ussp
pen
ensi
s on
14
40
How th
Ho
they
e work
88
Co
oil/o
/o
oil fo
orrk
142
42
Thre
Th
read
dle
ess headset
90
0
Aiir//o
A
oiil fo
ork
rk
144
14
92
Looking
g af
a te
t r su
susp
sp
pe
en
n n forks
nsion
146
14
Thre
Th
re
eaded headset
Rear sus
u pe
p ns
sio
on
Handle
Ha
nd
dle
eba
bars
r
Sttra
r ig
gh
htt han
ndl
d eb
e ar
Drop
op
p han
ndl
dleb
ebarr
94
4
How
w it works
orks
k
148
14
96
6
Rear
Re
ar suspe
ens
nsio
on
150
50
G os
Gl
ossa
ssary
sa
s
ary
ry
152
15
52
In
nde
dex
15
54
4
Ackn
kn
now
owledg
le
edg
dg
gme
ment
ntts
160
Hubs
s
How th
hey w
work
k
Open-be
ea
earing
hu
ub
ub
98
100
Wh
W
heels
Quickk re
ele
easse wh
whee
e ls
ls
10
1
02
Puncture rep
pai
air
104
04
Spok
okes
ess and rims
im
ms
106
106
6
A cl
clea
eaan, wel
e ll-ma
main
ma
inta
in
tain
ta
ined
ed b
bike wi
willll
w rkk eff
wo
ffic
icie
ic
ient
ie
ntly
nt
ly aand
nd
d saf
afely, and add
to you
ur en
e jo
oym
ymen
entt o
en
off cyccling by giving
yo
ou peeac
acee off min
nd.
Safe
Sa
f tyy and
fe
nd eeff
fffic
iciency are closely
linked
e . IIff your
ed
ou
u ge
gears arre no
ot sh
hif
i ti
ting
ng
co
orrectl
t y, for
o iinstancce, they will not
onlyy aff
ffec
e t yo
yourr rid
idiing efficiency, bu
b t
a so
al
o temptt you
o tto
o look down at them
wh
hililee ri
ridi
d ng tto see wh
w at iiss ca
caus
usin
ing
g
t e pr
th
pro
oblem.
m As a resu
sultt, yo
y u mi
m gh
ght
taakee yyou
our ey
e es off what is happening
n
on the rroad
on
d ahead
d and expose yourself
to
o thee posssibi
siib lity
t of a collision. The
ty
Bicy
Bi
cycl
cy
clee Re
cl
Repa
p ir Man
pa
a ual will help you
avoiid su
av
such
h pro
r blems by demonstratting
how
ho
w to
t mai
aint
ntain your bike regularly
and
an
d co
c rrrecctl
tly.
y.
Unders
rstaand
ndin
i g te
tech
chnology
Modeern
Mo
r bik
ikes
es may see
eem complicated,
an
nd the teech
c nolo
logyy tha
h t manufacturers
usse mayy be
b mor
oree so
s ph
his
isti
tica
cate
ted
d th
than
an
everr. Ho
ev
owe
w veer, cycle
l components work
rk,
as they allwa
as
ways
y hav
ave, according to
lo
ogicaal pr
p in
nci
c pl
ples
es, so
s there is no reason
for yo
fo
ou to be daaunted.
Befo
Be
f re
r you
o beg
e in to service a
particcul
ular
ar com
mponent of yo
y ur bike,
f rs
fi
rstt beeco
come
me fam
a iliar with the part
by tur
u niin
ng
g to thee relevant seccti
tion
o .
Know
Kn
ow
win
ing
g ho
how
w a pa
partt w
works makkes it
easi
ea
sier
si
er to ma
main
inta
in
tain
in.
Ab
bov
ovee al
all,l be confident and patient
with
wi
hw
wha
hatt yo
ha
ou are doing. Even if you
do not thi
h nkk of yourself as mech
hanically
ly
minded
d, you
u ma
may come
me tto
o en
enjo
joyy bi
bike
ke
m in
ma
ntenaanc
n e afteer a while and will
cert
ce
rtai
ainl
nlyy en
nl
e jo
j y th
the trouble-free
cyycl
c in
ing
g th
that
at rew
wards your efforts.
Collec
Coll
ecti
ting
ng iinf
nfor
orma
mati
t on
If you buy
u a new bike,
e make sure that
you ke
k ep the accompanyin
i g owners
manuall, so that you can refer to it
alongside this book. Do the same with
anyy new eq
an
equipm
pmentt th
that
at you
ub
buyy.
If your bike is not new, obtain a
manual fro
ma
r m a bike sho
h p or the
m nufacturers Web site. Manuals will
ma
help
he
lp yyou
ou tto
o be aawa
ware
re o
off th
thee pa
part
rtic
icul
ular
ar
main
ma
i tena
nanc
na
n e requirem
men
e ts of all the
components on your bike.
If you want to learn more about
bike mechanics, there are many
magazines available that contain
tips on specific components. However,
the large ma
majority of people who are
simp
si
ply iint
nter
eres
este
ted
d in lleaarn
rnin
ing ho
how
w to
maintain their bike will find
d everything
they need to know in the pages of the
Bicycle Repair Manual.
Using
Usin
g th
t is b
boo
ook
k
Th
he different main
ntenance requirements
of the mosst common
n types of bike
kes are
listed at the beginning of the book.
These requirements are covered in the
step-by-step pages that are specific
to the components fitted to each type
of bikefor example, suspension forks
for mo
moun
untain
in bikes..
You will also find a timettab
a le for
servicing the parts of your bike and
a troubleshooting chart to help you
identify and solve problems. The book
helps yo
ou to spot danger signs and to
carr
ca
rryy ou
ut ro
rout
utin
inee sa
safe
fety
ty cche
heck
cks.
s. TThe
hese
se
features detail what you need to do
and refer you to the relevant step-bystep sequences to explain how
w to do it.
10
Hybrid bike
Advances in technology have
refined the design and improved
the performance of each category
of bike part, producing a machine
that is easy to ride and maintain.
Wheel (see pp.989, 1027)
7
The rims shape and high-tech
aluminum increase the wheels
strength. Wheels with disc brakes,
shown here, can have lighter
rims than bikes with rim brakes.
brake
Frame
me (see pp.1213)
Impr
mproved welding techniques allow
thin-walled aluminum tubes to
provide a relatively cheap, light and
responsive frame. The thickness of
the tube walls varies to cope with
areas of increased stress.
Drivetrain
n (see pp.5677)
pp 5
Stiff materials maximize the
amount of power the drivetrain
transfers to the rear wheel. A
triple crankset increases gear
range and a flexible chain allows
quick, easy gear-shifts.
11
levers that are also mounted on the handlebar, and use brake pads to press against the
wheels rim, or discs attached to the hub, to
stop the bike.
High-tech machine
Many years of design refinement have produced
an adaptable hybrid bike, which combines
technology from road and mountain bikes
for use in an urban environment.
Gear-shift levers
(see pp.449)
9
Ergonomically designed
d
gear-shift levers were
developed from
mountain bikes, and give
vee
easy, precise gear-shifts.
Fork (se
For
see
eee pp
ppp.13
.1384
1384
47)
Forks are designed with varying
thickness in the tube wall. Tubes
are thin in the middle and thick
at both ends. This reduces weight
and absorbs road shock. Some
forks also act as suspension
systems, further reducing shock
and improving control.
Brake (see pp.10835)
5
Disc brakes offer sensitive,
powerful braking that is not
affected by weather conditions.
Other bikes have rim brakes,
O
which are still very good,
w
aalthough they require earlier
braking to slow in the wet.
b
12
Anatomy
of the bike
Understanding how the parts on your bike fit
together will help you perform maintenance
tasks successfully. Although your bike may
differ from the modern mountain bike (right),
t
all bikes fit together in a similar way. For
example, the quick-release levers on the
wheels below perform the same function
as axle nuts on a bike with hub gears.
The main parts and their components,
and where each part is attached to the bike,
are shown on the mountain bike. Take the
time to study the illustration, since it will
act as a useful reference to help you follow
the steps later in the book.
Mountain bike
The mountain bike is a good example of
how parts fit togetherits frame, wheels,
drivetrain, pedals, derailleurs, brakes, and
gear-shift levers are similar to those of
road and hybrid bikes.
Saddle
Saddle cover
Saddle rails
Seat post
Saddle clamp
Rear brake
Cable-guide tube
Braking surface
Brake pad
Brake arm
Frame
Seat tube
Seat stay
Chainstay
Down tube
Rear hub
Rear dropout
Hub
Quick-release
Bottom bracket
Cassette
Rear derailleur
Cassette body
Jockey pulley
Cog
Derailleur plate
Lockring
Barrel adjuster
Bike controls
Gear-shift lever
Grip
Handlebar
Brake lever
Steering
Handlebar stem
Front wheel
Hub
Spoke
Rim
Fork crown
Fork blade
Slider
Quickrelease
Tires
Tire bead
Valve
Tire
Drivetrain
Inner tube
Right-hand crankarm
Pedal
Chainring
Pedal body
Front derailleur
Chain
Pedal axle
13
14
GE
GET
G
ET
E
T TIN
TING TO KN
NOW
NO
O
OW
W YO
YO UR
U R BIK
IK
KE
Bikes for
general use
You
Yo
ou ca
can
a buy a bike for almost any purpose,
butt ev
bu
e en a simple utility, hybrid, or folding
bikke will still increase your fitness, save you
bi
moneyy on train or bus tickets, and have no
nega
gattive impact on your environment.
As long as the bike is of good quality,
you willl o
only need to keep it clean and
checkk it rregularly for signs of wear. Hybrid
bikes, utililitty b
bikes, and folding bikes are all
dependab
blee machines that are suitable for
commuting to work or school, day-to-day
transportation, or simply a relaxing ride on a
b ke trail or country road.
bi
TTh
he hybrid bike
Ligh
igh
ghtw
twei
tw
eigh
ght materials combined with roadbiike
b
ike p
peerform
mance and hardy mountain bike
tech
tech
te
chnolo
nolo
l gyy m
make hybrid bikes perfect for
bumpy urba
bu
b n roads. They are ideal for
comm
co
mmut
mut
u in
ing,
g, familyy ri
ride
d s, fitness riding,
tto
tour
ou
urrrin
i g,
in
g, aan
nd car
arrryin
rying lugg
gage.
Thee ut
Th
util
ilitty bik
bike
ke
Util
Ut
tillit
ity bi
ity
b kees arre ideal fo
for loccal commuting
and sho
an
sh
hortt rid
des.
e They aree equ
uipped with fat
t res th
ti
hat
at ab
bsorb road bum
bs
ump
ps but will drag
on lon
on
ng jou
urneys, making the
hem tiring and
uncomf
mfforta
or able to ride.
TTh
he folding
g bike
Id
deall fo
forr co
com
mm
mmuters,
and for people with
lilittttlee sspa
p ce
c in which
h to sto
tore
re a standard bike,
folding
g bi
bikess ca
ca go anyywhere, esp
can
pecially
on pub
blilicc trransp
sp
por
orta
t ti
tio
on. The fo
old
lded
ed bike can
be easiilyy reas
assem
mbled
mble
ed into a serviceable
machin
ne with
houtt th
thee us
usee of tools.
U an commuting
Urb
W h its head-up, traffic-friendly riding position
Wit
and easy-to-operate gears, the lightweight hybrid
is ideal for urban commuting.
Regularly maintain
and lubricate the
derailleur gears (see
pp.523, 545).
5
blees
Check the gear cab
for signs of wear
(see p.39, pp.489).
9
Check the brake
cables or hoses, and
pads for signs of wear
(see p.39, pp.11415).
5
Check the tires for
signs of wear (see p.39
39).
39
9)
he
Regularly change the
chain (see pp.645).
5
Ti
Tire
Gear cable
Rea
Rear
Re
deraille
dera
illeur
ille
ur
Brake cable
Front
derailleur
C n
Chai
UTILITY BIKE
icat
ate
Regularly lubrric
the hub gears (se
seee
pp.589, 60
1).
t e
Regularlyy checkk th
gear cablees for sign
gns of
gn
wear
we
ar ((ssee
see p.
p.39
39).
39
ularl
rlyy ch
rl
cheeck
eck the
the
Regu
brake conttro
ol ca
cabl
bles
bl
e
es
forr si
fo
sign
gn
ns off w
wea
eaar
(pp.1
114
41
15
5).
)
g larlyy ch
heck th
t e
Regu
brakke pa
pads
ds ffor
or ssig
ig
gns
n
of wear (see p.38)
8).
g larly clean
n an
and
d
Regu
grease tthee ccha
hain
in ((se
seee
pp.28
289,
9, 30
0 1).
).
Handlebar basket
Sp ung
Spru
ng sad
addle
Brak
ake
e lever
Hu
Hub
u gears
Chaingua
uard
r
FOLDING BIKE
Rear suspens
pe ion
pens
o
on
Hub
ub and
derailleur
ur gear
gear
syst
stem
st
em
Folded bike
Frame
hinge
Large chainrings
Unfolded
bike
15
16
GET
G
ET
T TIN
T IN G T O K NOW
TING
NO
N
OW
WY
YO U
UR
R BIK
B KE
Specialty bikes
If you
If
u waan
nt to
t ttakke up cycling as a ssport
or ho
ob
bbyy, rather th
han simply as a meeans of
transportaati
tr
t on,, look
look for a more speccialized
bikkee, ssu
bi
uch as a ra
racee-level road bike, a
mou
mo
untain bikke,, or a BMX bike.
un
As bikkes
As
es beeccom
ome more sophisticated, they
ome
neeed
ne
d more caare
r . Fo
or example, lightw
weight
paart
par
rts wearr quickklyy, so they must be kept
scru
sc
rupulo
pu ousslyy cleean. Carbon wheel rim
pu
ms
requirre ssp
re
pecia
eciaal br
brakke pads that do no
ot work
weell
w
elll on me
meta
tal. Hydraulic disc brakes and
sussp
sus
pension
on systtem
tems
te
ms need regular attention.
Do not
ot leett tth
hiss stop you from buyying your
drea
eam bikkee. Justt ass riding it will be a joy,
maintaain
ma
nin
ng it to exacting standardss will
be paarrt
be
rt off th
he who
he
ole cycling experieence.
TThe
he roaad
d biikke
Lig
Li
gh
htweig
ght m
maateri
r als and narrow tires make
ro
oad
ad bik
ikees
es goo
od fo
or fitness riding, dayy touring,
and comp
an
mpet
etittio
ions. Th
T e aerodynamic position
affo
af
ford
rded
db
byy a dr
drop handlebar offers great
drop
spee
sp
eed.
d Road bikes are so light and haave such
a range of gears that almost anyonee, with a
liittle training, can tackle the great m
mountain
passes made famous by the Tour de France.
The mountain bike
The
Fulll-suspension mountain bikes allow
w you
to break new ground and ride acrosss rugged
terrai
ain that was previously unthinkaable and
at spe
peed
e s that were once unattainab
ble.
The BM
BMX bike
Thesee bikes are built for acceleration
n and
agilee bike handling. Like some of thee very
firsst bikes, BMXs are made almost en
ntirely
from
m steel because it transfers poweer in a
way th
hat no other material can.
Road ridiing
R
Ro
TThi
h s road
road
d bi
bike
k represents the ultimate in road-bike
d ign
des
g , and
gn
nd iss the type of bike that proffessionals
use
u
se
s in
in th
the Tour
ou
u d
de FFrance.
Specialty bikes
d
Regularlyy cleaan and
lubr
lu
bric
icate th
thee bi
bike
ke (see
Caliper brake
pp.289, 30
1).
20-speed
d gear Make routine safety
shiftt ssystem
shif
m
c ecks ((seee pp.3
ch
323
3).
Chec
eck th
he braakes
Ch
(see pp.1
116
161
17).
Make suree gears are
working perfectl
wo
tlly (see
pp.52
2 3, 54
5).
me protector
Check fram
paads
d for wea
earr in
n th
hee
locati
lo
tio
onss wh
wher
eree cable
er
oute
ou
ters to
ouch carbo
onfiiber fr
frames (seee p.33
33).
).
Carb
ar on-f
arb
-fiber
be
fram
me
Aluminum
Aluminum
drop
handlebar
Road race
tire
Clipless
Clip
l
less
pedall
peda
ped
Deep secttion
De
carbon fibe
car
ca
ber rim
ms
MOUNTAIN BIKE
up thee susspensi
pe ion
pe
Set up
system
m (see pp.1
140-1
1,
150
1).
)
gu
ula
larrly cleaan and
Regu
lubr
lu
b iccat
a e th
he su
uspension
sp
n
(see pp
pp.1
.1
1423,
42
1445).
14
5
pec
ectt al
alll pivo
vots and
vo
Insp
seals re
reg
gula
gula
larl
rly.
rl
y.
es or
Check brake cables
hoses, and pads regu
ularlly
(see pp.389, pp.114
415
5).).
Replace the casssette
every six months (see
pp.667).
7
rvic
i e the he
ic
heaadseet
Seerv
regu
gu
ula
larly (see pp.90
01,
923).
92
Straight handlebar
Rear
arr sho
h ck
ho
Rear deraill
aill
illeur
eur
Carb
bon-f
on-fiber
iber
e
frame
fram
e
Cross-country
tire
re
Su
Susp
uspensi
ens on fork
Disc
brake
BMX BIKE
cheeckk th
he
Regularly ch
bottom brackket to
o se
seee
that
a it is runni
at
n ng
g ffre
reee,
butt not loosse (se
seee
pp
p.7
.767).
7
Repl
p ace the pe
peda
dals
lss
Re
iff tthe
heir axles are
he
re ben
nt
(se
seee pp.801).
).
djust the
h b
bra
raake
kess fo
or
Ad
mini
nima
m l travel before
ef
the br
b akes
es com
o e on
on,
since th
he sttee
eell ri
rim
ms
ms,
thou
ugh
g vver
e y st
er
stro
rong
ro
ng,
ng
do not make go
good
od
brakkin
i g surf
su facces ((seee
pp.122
223
22
3)).
3
Sing
S
n le geari
ea ng
Gy
Gyro
headset
head
Stunt peg
Opposite
site
t
transmis
smis
m sion
sio
17
18
Setting up an
adults bike
The kn
nee aligns
ns
w h the
wit
h ax
axl
xle
9 and
Undo the brake cable (see pp.11819)
screw in the adjuster on the lever until you can
reach it easily. Then reclamp the brake cables.
19
20
Setting up a
childs bike
Toolbox
Adjust the
e sad
add
dd
d
dle
e
and han
ndlleba
ebarr stil
eb
tiill
further if you
ou nee
nee
eed
d tto
o, so
o,
so
that your
ur ch
hild
i d ccaan ssiit
it in
n
the id
deal
e ri
ridin
ing
in
ng pos
ossitio
osi
ositi
tio
ion
neith
the
herr too
o upr
up
u
prig
pr
ig
igh
gh
ht
ht,
t, no
nor
or
or
too
to
oo
o sttret
rettch
ch
che
heed.
d.
21
24
C ARING
CAR
CA
A
AR
R IN
IING
NG
N
GF
FO
O R YOU
OUR
UR
U
RB
BII KE
KE
Toolss
Iff you are goi
oing to regularly maintaain and
repa
repa
re
pair
air
i you
ur bike, you will need to bu
uy a
t ol
to
o kkit
it or as
it
assemble your own. The to
ools
sh
sho
how
own oppo
osite will enable you to caarry out
aalll th
the es
e se
sent
n ial repairs and to maintaain your
bikkee at pe
bike
p ak
ak performance. Add other tools
aass req
e uired
d when specific parts of you
ur bike
neeed
n
ed maintenance or replacement. Ho
owever,
try to fol
tr
ollo
ow a few general principles w
when
usin
ng th
t e to
tools.
When
e usi
s ng tools on a bike, especiaally
light
gh
htwei
e gh
ghtt bikes, you need a delicate ttouch.
If you
If
ou are use
sed
d to w
working on cars, then use
less
less
le
ss for
orce
ce whe
h n de
dealing with your bike. Nuts
an
nd bo
bollts
t only
ly n
nee
e d to be tight; if you overee
o
tigh
tigh
ghte
teen th
them
m, th
they
eyy w
will shear. If in doub
bt, buy
to
orq
r u
uee gau
uge
g s th
hat
a accurately measure tthe
correc
co
ect le
ec
ect
leve
vel off tig
ve
ig
ghtness on a bikes nuts
ts
and
d bo
b lt
lts.
s.. See
ee thee component manufactu
urers
in
nst
s ru
ucttio
onss ffor rec
eco
ommended torque
s tttin
se
ingss. In
I fac
act,
ct it is essential to keep all
the in
th
nsttru
ructtio
i ns tha
h t come with your bikee,
tto
ool
o s,, and
d anyy ccom
omp
po
ponents
you buy.
Bu
uy th
thee be
b st
st-q
-quaalility, precision-made
-q
tool
to
ols.
s TThe
h y wi
he
w ll last for many years if you
ttaakkee care
are off the
ar
hem.
m. Cheap tools will bend and
a
beecome
b
com
co
mee cchi
h pp
hi
p ed
ed,, ma
maki
king
ng it impossible to
caarrrry out
out so
ou
some
m mai
aint
nten
e ance jobs properly.
They
Th
hey
ey cou
uld
ld even da
dam
magee the components
th
hat
at yyou
ou wor
ou
oko
on
n.
Wor
W
o kin
ing
g witth tools
to
Whe
W
h
hen usin
using your tools to
o
mainta
ma
tain
ta
in or re
rep
ep
pai
air your biike,
give your
giv
oursel
s f plenty
en of roo
room
m
and
aan
nd allwayys wo
ork in a neatt,
weell-l
wel
we
l- it
it env
en iro
ronme
nment.
n
nt.
nt
Tools
Essential tools
Start your toolbox with the two
multi-tools, the wrenches to fit
the cones, needle-nose pliers,
cable cutters, a pump, and a
workstand.
Drivetrain Tools
Wrenches
1318mm
Crankar
m bolt
wrench
Chain
whip
Crank
puller
Cassette remover
Allen keys
210mm
Wrench multi-tool
Frame-mounted
pump
Allen key
multi-tool
Hollow
ow-axle
cup ttool
Mallet
Wrench
Shock pump
Plastic mallet
SPECIA
SPE
CIALTY
LTY TO
TOOLS
OLS
Needlenose
pliers
(narrow)
Some
S
omee maintenan
nce and rep
epla
laceme
m nt tasks
requ
q ire specia
ialtty to
tool
o s that
a you
o w
will not
usee verry oft
ften
e . Oth
her tools, suc
uch
h as the
cab
blee puller
e , arre no
not essentiaal bu
ut wi
w ll
makke
ma
ke som
me jobs easier.
Cable
cutters
Cable
Cabl
ep
puller
Chain
n
measuringg
m
device
Needle
-nose
pliers
(wide)
Ben
nch
h vise
Track
pump
Spok
p e keys
and spoke
rule
er
25
26
Workshop principles
Four key principles govern the work you do
on your bike. The first is neatnessfind a
place for each tool and return it there when
you are finished with it. Second, do not use
too much force to tighten componentsthe
nuts and bolts of lightweight parts can easily
Using pliers
Use needle-nose
pliers to hold cables
and keep them under
tension. Buy a small
pair with pointed jaws
for tight areas. Keep
the jaws clean and
grease-free. Lubricate
the pivot with light oil
occasionally.
Using a wrench
Org
Or
Org
gan
ani
a
n
niizin
zin
zi
ing a bi
bik
ke
e wo
wor
w
orrk
o
ksh
ssh
hop
op
Reg
R
gula
ulllaarly
u
rly m
maaiint
nttai
n
aain
inin
ing
ng yo
yourr b
biik
ike and
nd cca
car
arry
ar
ryyiin
ryi
ng
g
ou
out
o
u
utt es
esssen
seeen
nti
tiaal repa
tia
paairs
rss me
meaan
ans
nss tth
n
hat
at yyo
you
ou
u ccaan
an keeep
eee
yo
yyou
ou
o
ur bike
ike
ik
ke at
at pe
peaakk p
per
errfo
fo
for
orrman
maan
m
ance
cce.
e Iff yyo
ou haave
avve
ve th
thee
sspa
sp
paace
p
ce tth
ce,
he bees
est
sstt p
pllaac
ace
ccee to
to do
do th
this
is is
is in
in a wo
worksho
orrksho
ork
op
tha
that
th
hat is well
ha
weel
ell
ll o
orrrg
gaan
g
gan
aniize
zeed an
nd
d eequ
eq
qu
q
uip
ipp
ipp
pped
ed w
wit
wi
iith all
ll the
he
too
oolss you
oo
yo
ou
o
u ne
neeed
d ffo
for
o
orr yyo
our
ur p
paaarrttic
par
iiccu
ulllaar bikkkeee.. Crea
ula
re te
te a
wor
wo
orksh
k hop
op ttha
h
haat is drryy wit
wi h pllen
leentyy o
off lig
li ht
h and
a
an
fo
fol
o llow
w tth
hee fo
ou
our
u
urr kkey
key work
rkksho
s p princip
rin
ri
rin
i cip
ciplless.
28
Use
se a cas
asse
as
sette
e scrrap
aper to gouge
ape
gee out
g
outt aan
anyy
dirt and
di
nd
d deb
bris th
that
at has ac
accum
cum
mulated
ulaated
betwee
ween the
he cog
gs.
Apply ple
A
pl nty of soapyy water
ter
er
to the restt of
o the bike
bik wit
iha
differentt sponge. Staart at the top
and work down.
Use a har
hard-b
d-b
-bris
-b
bris
ristle
tled brush
tled
rush on th
thee ccasse
ssette
tt
tte
s tha
so
th t the
h deg
egrea
egrea
reasser
se reeach
a es into the
spaces
spa
ces b
betwe
betwe
tween
en
n the
the co
ogs. Allow a few
ew
min
inute
utess forr the de
degre
grease
gre
aserr tto
ase
o workk, and
a d
w h iitt off
wa
was
off with
wit
ith soap
apyy wate
ap
ater.
r.
29
30
Lubricating
your bike
STEP LOCATOR
1
2
Sprea
S
ead an
nti
ti-sei
eizze com
mpound
nd
on the seaat pi
pin
in and
d st
stem to
preven
nt the tw
two
wo co
compo
pon
nents
ts fro
from
m
bin
ndi
ding with tth
the sea
eatt ttu
ube
b or
be
o st
ste
teerer
ere
rer
tube.. Alt
tub
Altho
hough you
hou
you ccaan us
use gre
grease
in
n pla
place
ce off an
a i-s
ant
i-s
-seeize
eize, alw
lways
ays us
ay
usee a
cop
cop
opper
er-b
-ba
-bas
b sed
sed anti
aantiti-sei
se ze ccom
ompo
pound
pou
n
nd
for
fo
orr lu
ubr
bricating
bricat
bri
ting
g co
comp
mpo
onents mad
de
with
wit
h carb
bon
n fib
fiber.
err
31
32
Making routine
safety checks
1 2
1 2
3
5
4
33
Maintenance
LUBRICATE
CHECK
REPLACE
LUBRICATE
Inner cab
bless ffor fray
ayying and
an and outer cab
cablles for weear
(see pp
p.111215)
5
Padss for wear and
nd aliignmen
nt (see pp.116
63, 128
289)
9
Hyd
ydraaulic hose
ses
es forr wear, kinks, or leaks (se
see pp.1301
0 1)
Brake leverss, arms,, discs, and
n ca
calipers ffor cracks
(see pp.11
112223,
2 ppp.1283
33)
Disc and
d ca
caliperr bolts for
or tig
ghtn
h ess (see pp.13011)
Oil expossed cab
bles byy wipin
wip g with wet lu
ube on a rag
R
REPL
ACE
LUBRICATE
CHECK
REPLACE
BRAKES
CHECK
REPLACE
DRIVETRAIN
CHECK
EVERY WEEK
LUBRICATE
MAINTENANCE TIMETABLE
SUSPENSION
34
Teflo
on oil
oi on fork
rkk stanc
nchions and sh
shock
o body,
ock
and on alll seals (see pp
p.1404
47,
7, 150
1 1)
Maintenance
EVERY MONTH
Chaain on
n a heav
avily
ily used
d bike (seee pp
pp.40
.401, 645)
5
Oil th
t e seals on hubs (see pp.1003
3))
Grease op
Gr
pene bea
bearin
r g hubs (see pp.1001)
Greaase headsets (see pp.903)
Gr
Discs for we
w ar and caalipers
ers for
f allignme
nm nt (see pp.13011)
11417)
7
Grease
Gre
ase br
brake
ake bosses (see pp.1201)
Inn
Inner
ne and outer cables (see pp.1121
2155)
For
orkk stee
steerer
rer fo
forr crac
cracks,
ks, b
by removing thee head
headset
set
(se
see pp.903)
35
Troubleshooting
PROBLEM
DRIVETRAIN
The chain rubs on the inner then the outer side of the
front derailleur cage. On a bike with a single chainring,
the chain persistently falls off.
When you apply the front brake and push the bike
forward, the headset moves forwar
ard
d rela
rela
elativ
tivee to
tiv
to the
head tube.
You hear a sudden snappi
ppi
p ng noi
noise com
no
co e from
m a wheeel
el
while riding and/or the
he whe
h el goes out of tru
ue.
There is side-to-side
de pl
p ay
a off a hub on its
ts axle,
e o
or wh
hen
en
turning the axle in the
thee hub you
you feel eithe
th r a rrough
ghnes
gh
neess
or tight and loose
see sp
spo
ots.
When pedalling
ng
g for
forw
ward, thee casse
ssette spins
inss, but
but theere is no
drive to the biike.
kee Alternatively, th
he cassset
ett
t e spins befo
e ree
the drive is en
ngag
gaged
ed or there iss muc
much side
de-to
-to-side
de playy in
n
the cassette.
The brakes aree haard to apply,, an
nd/or
nd/o
/o sl
slugg
uggish
ish
s to
o relea
relea
eaase
se.
BRAKES
You have to pu
p l thee bra
pul
b kee lev
lever
er a long wa
way befo
e re
r the
he
brakes engag
ge.
e.
SUSPENSION
36
Troubleshooting
CAUSE
SOLUTION
Unc
U
nclam
lamp
lam
p the
the
h cab
able
le at the derailleur, pull through any sla
slack,
ck, and
re igh
ret
g ten
gh
t . Then
h sseet up
up the
the der
derail
aililleu
le r.r. (See
leu
ee pp
pp.52
525)
5
Che
h ck the ch
chain for a stiff link and remove it
it iiff found.
d.. If no stiff link
iss fou
o nd
ou
nd, reeplace the chain. If the problem perssist
istss,
s, rep
e lacee the
he cogs.
Iff the
t ch
th
chain
ai ring is bent, replace it. (See pp.629
ai
9)
The bottom
m brac
brac
acket
ket is wo
worn or itss ax
axle
le may b
be
bent.
Iff tthe
h bottom
b
bo
o
bracket is a cartriidge ty
typ
pe, replace it.
t IIf it is a hol
hollow
l axl
axle
x e bo
otttom bracket, replace thee cup and bea
ott
earing
ing u
unitts. If it iiss a BMX
bottom
bot
to bracket, it may be possiblee to replace
acce th
he bearings if they
th are
worn,
wor
n or to replace the axle if it is bent
nt.. (See
S pp.727
7 7)
The he
h adset
d is loosee or wor
orn
n.
Re ace the
Replac
he spokke and
d tr
true
u the
ue
he wh
wheel
eel
ee
e . (See
S pp.1067)
7
Replac
Rep
acce thee bearing
gs or thee ax
a le. (Seee ppp.10
.1001
01))
0
T freehub body is wo
The
orn
rn.
Re llac
Rep
ace the freehub
b body
body.. (See
(See pp
p .10
.1001
01
1)
Gri
Gr
ritt and
and dir
dirtt is insi
nside
de th
t cablee ho
the
h usi
using or the
lub
bricati
tio
on on the in
on
inner cablees hass dried up.
Strip
i dow
down
n the ca
cables,, flus
flush the housings,
g an
and
d clea
c ean
n the
the inn
nner
er cables
with
h degr
eg eas
aser, lub
bricat
atte both, and reassemble.
e. (See pp.30
301,
30
11, 1111215)
5
Th
The
h pads are
he
re wearing down or the
t e cable has
h slipped
thrrough the cla
cl mp bolt.
If the
he pads aree not to
oo
o worn, tak
t e up the ext
extra
raa tra
ravel
vel by u
un
ncla
l mp
ping
the br
brake
akes, pulliling
g thee cab
able
lee thr
h ough
h the
t cla
clamp,
mp, an
a d tighte
t ing
ten
n . If
the pa
th
pads
ds are
a wo
worn,
n, re
repla
plaace the
th m. (See pp.11
11023, 12635)
5)
Yo r bra
You
rak
a es are not centered
d.
Fol
ollow
low th
he proc
ro edu
dures
res for centering the type
pe off brakes
kes on
your bike. (See
See pp
p.11
.1
1 02
0 3, 128
1 35)
5
Rub the
the pads
dss wi
w th eme
m ryy cloth. Remove fore
me
reign
ign bo
b dies wiitth
h
needle
nee
dle--nose pl
plieers. Fitt new
n pads iff theyy are worn unev
evenl
enly.
y See
y.
eekk
advice from
m a bike
b shop
o reg
op
r arding diiffe
f rent pad compoun
nds.
nds
(See pp.1102
0223, 12635
35)
35
5)
Pump in more
re air. Rep
R lac
lacee springs
ngs wi
w th heavie
vi r-duty sp
vie
prin
ri gs.
gs
(See pp.1
1403
033)
Pump iin
Pump
n air
air, or
o incre
reease
s preload, acccordin
ding to the typ
y e of
of ffork
o
on your bike. (See
(
pp.14
14
403)
Use the
th rele
elevan
antt adjusster to redu
duce
c the speed
ed
d off tthe for
orks rebound.
(See pp
pp.14
.1
1 033)
Set u
up tthe sag
g on the sshock ag
again.. If the pro
p oble
bleem continues, use
the da
dampi
mpi
p ng
g adj
ad ustmen
nt to spee
peed
d up thee act
action
ion of the shock.
io
(See
ee pp.15
.1501
1 01
0 )
37
38
Cables
Rims and tires
Brakes
Cogs
Chainrings
Brakes
Worn teeth
39
Cables
Split or frayed cables
Check all cables and cable housings for signs of
splitting and fraying. Frayed inner cables can snap,
leaving you without gears, which is inconvenient,
or without brakes, which is dangerous. Change the
cable before you ride again (see pp.469, 11215).
5
Worn or split housings reduce the effectiveness of
your brakes and allow dirt to get in and clog the
cables. Change the housing as soon as you can.
Bulging tire
Split tire
Worn tread
40
Mudguard
Headset
Derailleur
Seat post
collar
Pedal
Chain
Fitting mudguards
Fasten a mudguard to the seat pin and you will
block much of the spray from the back wheel.
For the front wheel, fit a guard that clips onto the
frame and is secured in place with tie-wraps. Full
mudguards, which attach to the fork and rear
dropout, give almost full protection for on-road
biking but get clogged up off-road.
41
44
M NTA
MAI
TAINI
A INI
IN NG
N YOUR DRIVETRAIN CABLES AN
AND S HIF
HIFTER
TERS
S
CABLE
ES AND
D SHIFTERS
Cablles
e and shiftter
e s en
enab
able
le tthe
he rrid
ider
er to op
o er
erat
atte th
he geears. Cable
able
ab
les
are under cons
nsta
tant
nt tension
on and neeed to
t be rep
eplla
lace
cedd reg
gular
arlly
ly
and keptt w
wel
elll lubr
briccated.
d. Th
They
e must
stt aals
lsso bee ins
in
nsspeect
cted
d ofte
offteen
and repl
plac
aceed iff th
they
ey sho
h w signss off weear.
ear. SShift
fte
ter
ers reequ
quirre
on
nly oc
occasionall lubrication off their
ir inn
inner woorrking
ng
gs..
How
w they work
An inn
nner cab
a le conneect
ctss th
he g
geear
a -sshift
hiift lev
e er to
th
the
he deraille
l ur, an
le
nd alllo
lows
wss the
he rid
ider
er to ch
chaan
ang
gee
gear
ge
ars.
s Mov
ovin
in
ng the geear-s
ar-sshi
ar
hi t llev
hift
ever
e ccau
er
ause
au
sees th
the
fron
fr
ont dera
dera
de
raililille
l ur to sh
le
s ifft th
t e ch
chai
ain
ai
in fr
from
om
mo
on
ne
ch
hai
ainr
nrrin
ing
g to
to aano
notth
no
her
er,, orr tthe
he reeaar de
he
dera
railililleeur
ur
to
o shift
hiift thee cha
hain
in
n fro
rom
m on
on
nee co
cog to
to ano
notth
noth
herr.
Pu
ullllin
ng th
the ge
gear ccab
able shi
ab
hift
ift
fts th
the ch
chai
ain
from
fr
om
o
m a sm
maallller
ler
er to a la
larg
rger
rg
er chain
hain
ha
inri
nrriing
ng
orr ccog
o
og; re
og
releeas
asin
ing th
ing
the
he g
geeaarr cab
able
le
sh
hifts
ifftss tthe
he ccha
he
haiin
ha
n ffro
rom a la
ro
larg
ger
er
to
o a sma
maller
llller
er cha
chaain
inri
inr
ring
ng or
co
og
g.. The
he leftefftt-ha
hand
nd
shiifftteer co
sh
con
nttrol
rollss the
ro
he front
rro
on
ntt
dera
de
r iillle
l eur
ur;; tthe
hee rig
h
ight
ht-h
-hand
aan
nd
shifte
sh
iffterr co
ont
ntro
rols
ls thee
reear
a der
erai
a lllleu
ai
eur.r.r
eu
C tro
Con
Co
trrolli
lling
lli
ng the
ng
he
e gear
ge
g
ears
arss
Th
The
he ccaables
ble
les and
d sshi
hifte
ftteers
rs
on
n a bike
ikke
ke al
allow
ow th
he riid
ide
deer
d
to
o eff
e fort
ef
ortles
r lles
eesssly
sly cco
ont
ntr
n
ttrrol
ol
thee g
th
the
geear
ar sys
ssyyysstem
tem
te
m.
Cable cla
Cab
cl mp
m
Atttac
aach
hess the ca
c ble
le to tthe
rearr dera
rea
dera
eraill
illleurr
Rea
e r dera
dera
eraill
illeur
ill
eur
Mov
o ess the ch
chain
ain fr
from
om one
one
cog
o to
t an
anoth
other
oth
er
Fr nt derrail
Fro
a leu
leur
leur
Mov
oves
ess th
the
h ch
chain
hain
i
fr m one
fro
onee cha
hainr
ha
inring
in
ng
too ano
othe
t err
th
SHIFTING GEAR
In this Campagnolo
shifter, the rider
pushes the inner
shift lever to pull the
cable and move the
derailleur. When the
rider presses a lever
on the inner side of
the lever hood, the
cable is released
and the derailleur
moves back.
Gear-shift lever
Pulls and releases
the gear cable
Cable
Connects
the lever to
the rear
derailleur
Lever hood
Attaches the levers to the handlebar
Ratchet
mechanism
Holds the
cable
Cable inner
Controls derailleur
Inner shift lever
Releases the cable
Cable housing
Counteracts
the cable pull
Brake lever
Pulls the cable
45
46
Drop handlebar
gear cables
Keeping gear cables clean and lubricated,
and replacing them if they fray, is very
important for smooth shifting. Change
them as a matter of course at least once a
year, or more often if you are a heavy user.
Lubrication reduces the effects of friction
between the inner cable and the cable
housing, and helps to keep out water and
grit. If the gears become difficult to shift to
a different chainring or cog, the cable is
probably dry and needs lubrication.
These steps show how to fit a new gear
cable to a SRAM shifter. Fitting cables to
gear shifters made by other manufacturers,
such as Shimano and Campagnolo, will be
slightly different, but the order of each task
in the overall sequence is generally the same.
STEP LOCATOR
Replacing a
SRAM gear cable
1 3 4
5
2
6
Gear-shift lever
SRAM shifter
Brake lever
47
48
Straight handlebar
gear cables
Replacing a
Rapidfire gear cable
1 2 3
1 1
Gear-shift
levers
Shifter cover
Barrel adjuster
Gear
indicator
Star nut
Ring clamp
Shimano
Rapidfire
Gear-shift levers
Gear-shift
lever
Barrel adjuster
Handlebar clamp
Shimano
Dual Control
Cable port
Toolbox
Replacing a
SRAM gear cable
Replacing a
Dual Control gear cable
49
50
MAINTAINING YOUR
R DRIV
RIVETR
R AIN FRO
FR NT AND
D RE
R AR DER
ERAIL
AILLEU
LEURS
RS
FRONT AND RE
EAR DERAILLEURS
The derailleurss move the cha
ain smoot
othl
hlyy be
betw
ween co
cogs
cogs
gs and
d cha
hain
inrriing
gs,
but only if thee tr
trav
avel
el oof th
the deraille
leur
u s is set
set up corr
corrrec
co
ectly
tly.
tl
y. Deerrail
aaiilllleu
eurr
pivots and jocke
keyy pu
pulllleys must be ch
c ec
ecke
kedd fo
or w
weeaarr and
d lub
ub
ubri
brriica
catteed. The
he
front derailleurr musst be properly al
alig
igne
ig
nedd wiitth
h the
he cha
ain
nri
rin
ring
ng
gs.
s.
How the
ey workk
The front and rearr d
deraailleurs cha
hang
ngee th
thee ge
g ars. To
change up a gear, th
he sh
s ifterr is
i useed to pul
ull on the
he cab
ablee,
which causes the fro
ront
nt d
derailleurr to pus
ush
h th
he ch
chai
haiin fr
from
r m
a smaller to a largeer chainring
g or tthe
hee rreea
ear de
ear
derailleeur
ur tto
push the chain from
m a sm
smal
a ler to
o a llar
arge
gerr co
ge
og.
g TTo
o cch
han
ang
gee
down a gear, the cab
ablle iiss re
releeas
ased
ed, ca
causiing
ing th
the sp
prriing
ngs
gs in
in
both derailleurs to mo
move
ve tthe
he cch
hain to a smal
alle
al
lleer ch
chainriiin
ng
or cog. Each derailleur mo
move
vess aroun
nd a pivvot
ot p
poi
oiint
nt.
Adjusting screws ensure th
hat the derraill
ailleu
ai
eurs
rss do no
not pus
pu
ush
sh
the chain beyond the largest
st chain
hainri
riing
go
orr co
cog
g, o
g,
orr p
pu
ullll it
beyond the smallest. Thiss rang
ng
ge is ccal
allled
leed th
he de
deraaillleeu
urrs
rs
s
travel. Once its travel is set
et up, p
provideed th
he cabl
cabl
ca
blee
tension is sufficient, the derai
rai
a lleu
lllleur wi
will makke a si
sn
ng
gle,
gle
clean gear-shift for eveery ccliickk o
off th
he ssh
hiffte
ter
er.
Reaar
Re
Rea
derrai
de
der
aail
iillle
lleu
eur
ur
Mov
Mo
oovveess ch
cha
haain
in
ffro
room one
ne ccog
co
og
og
to anoth
to
ano
ano
an
nother
tthe
th
h
heer
Caa le
Cab
C
le
Pu
PPus
u h
heeess an
hes
and
pul
ppu
ullls
u
ls rre
rea
eea
ar
der
dde
eerra
rail
aiillleu
leu
le
ur
REAR DERAILLEUR AN
N ATO
ATOMY
Der
erail
aillleur platte
Transf
Tra
nsfers
ers ccable pu
ull to the
t
jockey
joc
k pulllllleeys
Pla spr
Plate
spring
i
Pulls der
dee ailleu
leur back
ac
as cab
able
le is relleas
ea ed
High and low
adjusters
Limit travel of
the derailleur
Cable clamp
Attaches cable to
derailleur plates
Cable
Pulls derailleur plates
Jockey
Joc
key pu
ke
ullleey spri
pring
g
Pr ser
Pre
s ves th
the
tensio
ten
on in
in the
th cha
chain
Jo key
Joc
ey pu
pull
lleyy
lle
PPul
Pu
ulls an
and
d pu
ushe
shess
the ch
chai
ain
JJockey
ey pu
p lleey cage
cagee
Ho dss th
Hol
the
hee jjocke
ckkey
pul
u ley
le s
W kin
Wor
ng w
with
ith
h th
the
he shif
shif
hifter
ter
erss
Thee ffront and
and rear
eaa de
derai
raille
rai
l eurs
ll
lle
urs
wo k in
wor
in harm
armon
ony
ny wi
with
th
h thee
shi
sh
hifte
hi
f rss to
fte
o pr
pro
ovid
vide
de easy
easy
asy,, quic
uick,
k
and
d aacccur
curate
cur
ate
at
te gearr shi
sh ffts
tss
whe
wh
heenev
ever
ev
er the
thee rrider
riderr ne
need
n
ed
eds
d them.
th
hem
em.
m.
51
REA
RE
R
EA R D ERA
A IL
I L LEU
ILL
L EU
EU
EUR
UR IN
IN U
US
SE
La gee co
Lar
cog The
The cchain
Th
a iss mo
move
ve
ved
to th
the
hee la
h
large
geesstt cog
og by th
t e pullllll
off th
t ca
the
cabl
cable
ble
l .
Sma
S
malll ccog
og The
The
h ch
chain
ain iss re
r tur
turn
urrn
ned
edd
to th
to
the
hee small
h
sm
mall
allest
e co
es
est
c g by the
he
pplla
pla
ate
te spr
spr
p ing
ing.
in
F
FR
FRO
NT
T DER
DERAILL
L EU R A N
LEU
NA
NAT
AT O MY
Pivvott poiint
Actss as a fu
Act
fulcr
crrum
crum
for th
thee arm
m
Fro
Fro
Fr
ront
nt d
der
de
eerrail
aaiil
i leu
e r
eur
eu
Transf
Tr
Tra
Transf
nssffeers
rrs tth
he
chain
cha
in fro
from one
ne
cha
cch
h
ha
ainr
nrring
n
iin
ng to
to
aano
no
othe
tth
heer
Cha
C
hainr
ha
aiin
inr
nrring
n
ing
g
Ca
Car
C
aarrrie
rri
rrie
ies
ie
tthe
th
he ch
h
haain
in
n
Derailleurr
cagee
cag
Moves
Mov
ess the
hee
chain
cha
ain
in
Ch inr
Cha
inring
ing
ing
g
Engage
Eng
ag s
the ch
chaain
n
Cla
l mp bolt
Fixes derailleur
to the framee
52
Front derailleur
Front derailleurs shift the chain from one
chainring to the next. There are two main
kinds: braze-on derailleurs (below)
w are fixed
by an Allen bolt to a lug, or protrusion, on
the bike frame; band-on derailleurs are
attached to a band that goes around the
frame and is part of the derailleur.
There are two important maintenance
jobs for a front derailleur: setting it up after
fitting a new control cable and adjusting it
when it is not shifting properly. You should
also clean the derailleur regularly to prevent
the buildup of dirt, which interferes with the
way it works and will quickly wear it out.
For the derailleur to work perfectly, the
lower edge of the derailleur cages outer side
should be no higher than 2mm above the
largest chainring. The cages outer side must
also be parallel with the chainrings.
Correct shifts depend on the front
derailleurs traveling a certain distance per
shift. High and low adjusting screws on the
derailleur will control this travel.
STEP LOCATOR
1
2
3
4
5
Parts of a braze-on front derailleur
Cable-fixing clamp
High/low
adjusters
Pivots
Front derailleur
cage (outer side)
Frame-fixing
clamp
Front derailleur
cage (inner side)
Front derailleur
Undo the cablefixing clamp until
the cable comes free.
53
54
Rear derailleur
STEP
STE
P LOC
LOCATO
ATOR
R
1 2 3 4 5
Parts of a rear derailleur
Derailleur
pivot
Cable-fixing
clamp
Barrel
adjuster
Jockey cage
Jockey pulley
Toolbox
Rear derailleur
55
56
MAINTAININ
N G YOUR DRIVETRAIN HUB GEARS
HUB GEARS
Hub gearrs located inside the hub casing alter th
he speed att whiich
h
the back wheel revolves. They require little routin
ne maintenan
ance
c
and, sincce they are sealed, most hub-gear system
ms do not nee
eedd to
be lubricated regularly. The control cables must sttill be inspeccte
tedd
regularlyy and replaced if they are worn.
Hub
ub ca
casi
sing
sin
ng
Tur
urns
ns the
hee
wheel
whe
ell
Ca
Cab
ab
ble
e and
and
d satel
tte
e litte
Side
Sid
de viiew
ew
w off tth
he hub
Beaarin
ings
gss
Aidd th
he rot
rot
ota
tation
tion of th
tio
hee hu
hub
h
ub
b cca
asin
si g
si
Carrier unit
Carries the
different--sized cogs
Ring gear
Turns the hub casing
g
Driver
Driver
er un
nit
Transf
Tra
nsf
sfers
ers th
thee cog
cog
oggs driv
rivee and cau
ri
use
se
ses
the ca
carri
rriier uni
unitt to en
eng
ngag
age
ge di
ddif
iffe
feerent
fer
ntt
cog
ogss with
i th
he rring
ing
ngg ge
gear
eaarr
57
Protec
P
e tin
t g the gears
T eh
The
hub gear mecha
ch nis
ni m is
is fully
enclosed to
o pro
p tect it from
dam
mage
a , dirtt, and water.
r.
Hub gear
a unitt
Contai
ains
n the
th
he co
c gs thaat
allow gea
g r ch
hanges
58
Hub gear I
Replacing a
hub-gear cable
STEP
STE
P LOC
LOCATO
ATOR
R
1
3
Lockring
Cable route
Position
i i off red
d dots
d
(underneath)
Gear satellite
G
t llit
Toolbox
Hub gear I
Remove the
R
th rear wheel
h l and
d push
h th
the wheel
h l
forward out of the dropout.
Remove the
R
th cable
bl portt on the plastic part
of the shifter, where the pointer indicates
which gear the system is in.
Pulll on
on the
the cla
clamp
mp bol
boltt and
and mea
measur
suree the
the len
length of
Pul
ns
n ure
re thatt the wheel is straight
EEns
bet
be
b
ettwe
weeen thee chainstays and tighteen
thee axxxle
le nutts. There should be
abo
ab
out
u 14in (6mm) of vertical
pla
layy in
in th
he chain.
59
60
Hub gear II
STEP
STE
P LOC
LOCATO
ATOR
R
1
2
4
Put the satellite back onto the wheel. Line
up its triangles with those on the axle.
Toolbox
Hub gear II
Lift the satellite from
the hub body, noting
the relative positions of the
two yellow triangles that are
marked on it.
61
62
Cha
Ch
C
haain
h
in
Fee
Fee
Fe
eeddss th
tthr
hroug
hr
oou
ugh
ug
joc
jjo
ockey
oc
keeyy ppu
ullllle
lleeeyyyss
Cog
C
og
ogs
gs
Dri
Dr
D
rriiven
n by
by tth
he chai
hai
ha
ain
Reeeaar der
R
Rea
derai
era
er
era
r iill
lllleu
eur
eur
ur
Sh
Shi
hift
hi
ftss th
fts
thee cha
hai
hai
ain
acro
ac
acr
cross
cr
oosss
ss th
the cogs
the
gss
EXPLODED CASSETTE
Cas
asset
sette
te bod
bodyy
Conttai
Con
tains
ins th
thee ffreeew
ewhee
heel
eel
QuickQui
ickck rel
releas
ease
ase leve
everr
Lo ks whe
Loc
wh ell int
into
nto
place
pla
l ce
c
Lockring
Holds cogs on
the body
Spacer
Cog
Slides
Sli
des on
onto
to
casset
cas
sette
tee
boddy
Pro
Profil
Pr
ofil
filee
Sec
ecure
ure
ress cogs
cogs
o too
casset
cas
asset
sette
tee bod
body
Hub
b fl
flang
flan
ge
Spokes
Spo
Sp
Spok
kes
con
connec
on
nnec
ne t hubb
to whe
wheel
el rim
i
H w th
How
they wor
w orkk
CHAIN ANATOM
MY
R ar wh
Rea
Re
heel
hee
Dri
Dri
riven
ven
en
n by
by
the
th
h co
he
cogss
B rel
Ba
Bar
Sitss betw
Sit
ettween
et
eeen teeth of
cha
h inr
nring
i s and
d cog
cogs
J nin
Joi
ning
g pin
pin
Co e tss inn
Connec
nner
aand
d ou
uter links
kss
O er
Out
e lin
nk
Shape to alllooow
Shaped
w
qu ckk ge
qui
gea
gear-s
ar shif
h fts
ftss
Inn
nn
ner
er lin
link
Ro
Rot
o aate
atte
tes around
rou
und
nd th
the
he barre
h
ba
arre
rell
Cranks
Cr
Cra
nkset
kset
ks
et
Powere
Pow
red
ed by
by
peed
pped
edali
alliin
ng
g
Li htw
Lig
tw
we
eig
ig
ght
ht ccom
o pon
ponent
po
ent
nts
T cch
Th
The
hain
in
n, cass
asssett
ette,
ett
ttte,
e, and
nd
d ccrrankkssett arre ligh
ligh
ightwe
htw
tw igh
twe
ight
ht
items
ite
items
ms tha
t t use
use
s the
h lates
laates
test des
e gn
esi
gn and
aan
nd co
c ns
nsttruc
ructio
ru
t n
tio
t ch
tec
hni
niique
n
que
q
qu
u s to maxi
maxi
ximiz
xi
m e sstre
miz
trrengt
tre
n h and
n dur
durrabi
bilit
ilit
lity
ity
while
whi
le mai
le
ma nta
ma
ntaini
ining
in
n ng aan
n aer
aerody
ody
dynam
dy
amic
icc pro
profil
fii e.
fil
Ch
Ch
Cha
hainr
in
nring
n
ing
Caarrrie
C
Car
rriiies
iees the
he
cha
haaiin
n aro
aarround
ro
ound
ndd
th
the
he cr
he
crank
an
an
nkkset
ksse
set
e
et
Cha
Ch
C
hai
ha
aiin
n
Transm
Tra
nssm
mits
iitts
ts
pow
ppo
oweerr fro
ow
fro
r m
the
tth
hee ccrraank
h
an
nksset
nk
seet
et
Ped
P
Pe
eed
dal
dal
al
T ansmit
Transm
Tra
nsm
nsm
mits
iitttss
ene
ene
en
nergy
rgyy too th
rg
the
cra
cranks
raank
nks
n
kkset
et
63
64
Chains
Replacing a
derailleur chain
STEP LOCATOR
1
2
1 2 3 4
Parts of a split-link and a Shimano chain
Split-link pins
Groove
Split-link
chain
Outer platte
Inner
links
Split pin
Shimano
chain
Toolbox
Chains
65
66
Cassette and
freewheel
Removing a cassette
STEP
STE
P LOC
LOCATO
ATOR
R
cassette remover.
2
3
1 2 3
Freewheel mechanism
Cogs
Inner side
ridges of
cassette
Freewheel
Lockring
Cassette
Toolbox
cassette remover.
67
68
Cranksets
Removing a crankset
1
2
3
4
Parts of a crankset
Right-hand
crankarm
Spider
Chainring bolt
Chainrings
Toolbox
Cranksets
69
70
BOTTOM BRACKETS
There are two ma
ain types of bottom bracket: cartridgee-bbearrin
ingg
and hollow-axle. Both use sealed bearings, which can wearr
out over time. If thiss happens on
n th
the ca
cart
r ridge versio
ion,
replace the wh
hol
ole unit, but on a hollow
w-axle type
you only needd to rep
place
ce tth
he bearings.
Providi
iding st
s rength
The axle and bearings off
the bottom bra
racket need to
o
be both stron
ng and reliablee
enough
h to bear the weigh
ht
and power
wer of the rider.
Free cup
Scr
crews
cr
ew into
the bikes
the
fram
fra
ame
Fixed cu
cup
up
Holds the bo
ottoom
bracket in
n placce
Out
uter
ut
e rac
acee
ac
Houses th
Hou
he bear
b ring
ings
ngs
Bal
all-b
al
l- ear
l-b
earing
ing
n
Suppor
Sup
ppor
oorts
t the
the aaxxle
lee
A e
Ax
Axl
Connec
Con
Co
nec
ectss the
hee
cranks
cra
n an
nks
nd
rottate
a s in
the
th
he be
beari
arings
ari
ngs
Crank
Cra
nk
nk
Turns
Tur
Tu
n the
the
h ax
axlee
axle
HOL
OL
L LOW-AXLE BOTTOM BRACKET ANATOMY
Pinch bolts
Hold crank
in place on
the axle
Cup
Holds the
h bearings
in place in the frame
Axle
Connects the cranks
and rotates
in the bearings
Ball-bearing
Lets the axle turn
Crank
Turns the axle
Cup
Holds bearings
in the frame
C nk
Cra
n
Tu nss the
Tur
h aaxle
he
Cartridge-bearing
bottom bracket
Allows the smooth
rotation of the axle
71
72
Cartridge
bottom bracket
Cartridge bottom brackets require no routine
maintenance. Their bearings are sealed from
the elementseven from the water you use
for hosing or pressure-washing your bike,
provided you turn the pedals forward during
the wash.
When the bearings do eventually wear
out, you will have to replace the whole unit.
The remover tools for this job are specific to
each particular bottom bracket, so check
which brand is fitted to your bike before
buying the tools.
If you are planning a replacement, there
are three types of bottom bracket axles to
choose from: square-tapered, Shimano
Octalink, and Isis. The type used in the steps
in this sequence is square-tapered; the type
shown below is Octalink.
Finally, if you are having any problems
installing a bottom bracket on your bike,
ask the experts at a bike shop to help you.
Installing a cartridge
bottom bracket
STEP
STE
P LOC
LOCATO
ATOR
R
1 2 3 4 5
Parts of a cartridge bottom bracket
Drive (fixed-cup) side
Non-drive
(free-cup)
side
Bottom-bracket axle
Toolbox
he
Insert the non-drive (free-cup) side when the
drive side is almost in position. Use the rem
remove
ove
verr
to screw it in a few turns. Fully tight
ghteen
en th
thee dr
drive
ivvee
side, then the non-drive side.
e.
73
74
Hollow-axle
bottom bracket
STEP LOCATOR
1
2
3
5 6
Axle
Combined
drive-side
cup and
sleeve
Left-hand
crank
Spacers
Non-drive
side cup
Pinch bolt
Crank cap bolt
Push the left-hand crank onto the nondrive side of the axle.
Toolbox
75
76
BMX bottom
bracket
Setting up a BMX
bottom bracket
STEP LOCATOR
1 2 3 4 5 6
Parts of a BMX bottom bracket
Chainring
Drive-side cone
Non-drive side cup
Non-drive
side bearings
Non-drive
side cone
Axle threads
Spacing washer
Drive-side cup
Axle
Drive-side
bearings
Locknut
Toolbox
77
78
PEDALS
There are two types of pedals, flat and clipless.. Pedalss w
witth op
open
en
n
bearings require regular inspection and lubrication. Clilippleess peda
dals
da
ls
must be lubricated to ensure easy foot relea
ase. Clea
atss shoul
uld be
correctly fitted to the riders shoes and regularl
rlyy in
i sp
pected
ec d fo
or we
wear
arr.
Converting energy
Pedals
alss aare the invention
tha
h t defi
ha
effines cycling. They
ar th
are
thee first step in the
pro
oce
ces
eesss of converting
hum
uman
an energy into
mec
mec
echa
cha
h ical motion.
han
Crankarm
Transf
Tra
nsfers poower
w to
t
the bo
botto
t m brac
ra ket
et
Pedal bod
body
bo
Rot
otate
atees on
n
the ax
axle
lee
Lockknutt
Holds
ds the
conee in
in plac
lacee
H w th
How
theyy wor
w k
wo
Ped
P
ed
daall
Con
on
nn
nec
ne
eeccts
ts the
t e ri
th
rider
deerrs
s fo
fooot
foo
too th
the
hee dr
h
driv
ive
vetra
ttra
raain
in
79
80
Pedal axle
Removing and
lubricating a pedal axle
STEP LOCATOR
1 2 3 4 5 6
Parts of a pedal
Cleat-release
mechanism
Pedal body
Pedal axle
Retainer
Wrench
flats
Release tension
adjuster
Toolbox
Pedal axle
81
82
Clipless pedals
Clipless pedals were developed in response
to the racing cyclists need to apply power
throughout the entire pedal revolution.
They hold the foot to the pedal by locking
onto a cleat attached to the sole of the
shoe. The mechanism that holds the cleat is
spring-loadedthe foot is released by
turning the heel outward.
The release spring is an essential working
part and must be kept clean and well
lubricated. Use light oils on road pedals
ROAD PEDALS
Ro
oad
ad ped
edal
als
al
ls ar
aree ligh
ght,
ht,
t ssup
u portive,
e and
n ,
beca
be
caaus
use off tthe
use
hee gre
reat
a err sspe
p eds
pe
ed
ds in
invo
volv
vo
lvved
d
in roa
in
oad
d ridiing
n , aero
aero
ody
dyna
naami
n
mic.
c. The
heyy need
ed
to eng
ngagee an
and
d re
rele
leas
le
asse th
thee fe
feeet
et witth eq
equa
ual
ua
Top fa
ace
ce
Time
Tim
e road
road
ad
d pe
pedal
dal
dal
Th se ped
The
pedals
al of
als
offer
fer a
fe
fer
range
ran
ge of movveme
e nt tha
th
hatt
can bee ad
adjus
a jus
justed
ted
d to
o su
s it
the
th
h requ
qui
u rem
ui
ement
ents
ts of
of
ind
ndivi
div
ivi
vidua
du
ual ride
ride
id rs.
s.. Ke
K ep
Keep
the
heem well
el maaint
el
ntain
nt
ain
i ed by
b
scrrubb
ub ing regul
ularl
ul
arlyy with
arl
t
dee reaser, usin
deg
ng a st
stiff
ifff
bru
rush.
sh. Wash this
thi
his off,
fff
the
hen lubr
l brica
icate
ica
te the reelea
l se
sprring
in
ng with
h hea
heavie
vie
ieer oil,
oi
d ibbl
dribbl
dri
bb iing
ng itt fr
from
om a ccan.
an.
Look road
road pedal
pedal
all
These easy-to-maintain
pedals have a small
Allen bolt on top of the
bac
ba
b
a k plate rete
et ntion
mecchan
m
h ism, which adju
ha
adju
justs
u
thee ffo
th
the
oot
oto
t release tens
ension
ion
n.
TThee p
peedal
alls need to be
b
scr
crru
ubb
bb
bed
e cle
clean
an
n regularlyy.
Occ
Occasi
ccasiion
onally
ona
llyy, drib
lly
lly,
bbl
ble
ble
le some
oil betwe
tween
en the
en
th b
back
ck
plate
pla
t and
te
an peeda
dal
al b
al
bo
ody.
dy
Bo
Bot
o to
ttom
om
o fa
face
face
ce
Ped
Peda
daal body
body
Rete
R
e entio
t n
tio
m ch
mech
hanis
anis
nism
ism
Rel
Rele
elease
e
asse
sp ngg
spri
Rele
ele
leasele
easeaase
e-tens
etens
enssion
en
ion
ion
aadju
ad
d ster
ter
e
Top
To
op fa
ace
P dall bo
Peda
ody
d
Release
e
te ion
ten
tens
i
adjuster
adju
ster
e
R ase
Rele
e spri
spring
ng
Bottom
Bot
tom fa
tom
to
f c
ce
e
Back pla
plate
te
Clipless pedals
OFF-ROAD PEDALS
Off-ro
Offoad ped
e als are eq
e uiipp
pped
ed
dw
wit
ith
h
retent
ntio
ion mech
chan
anisms
ms on at lea
eaastt two
w
side
si
dess so thaat th
thee ri
ride
ders feeeett caan
de
n att
ttac
tac
ach
h to
o
Tim
ime
e off
fff ro
road
d peda
e l
ed
The
he fe
few
w movi
movi
viin
ng
g pa
pa ts
par
off thi
this simp
imp
mp
m
plee p
ped
eedall are
ree
pro
p
rrotected
ted
te
eed
d in
n tthe body
body
o o
of
the pe
th
pedal
dal
aall. Keep
e th
thee part
ar s
cleean
an and
an
nd d
n
dribb
ib
bble
b a litt
lit
ittle
itt
llee
hea
he
h
e vy
vy oil
oi iintto
o the point
whe
w
heree thee re
he
relea
lease
se bar
en
ent
nteerss tth
he peda
peda
e l body
ody..
Iff ne
necces
nec
ess
ess
s ary
ary,, repl
rep ace
a th
t e
bea
bea
be
earin
rrin
ngs and aaxles
es (see
ee
pp.
p.80
801).
)
tthe
th
he pe
p dal
dal no
da
n mat
atte
tte
t r wh
hic
ich wa
way up
way
up iitt is
is..
Thee pe
Th
peda
dals
da
ls aals
ls
lsso let
leet mu
mud
d pa
p ss thr
hrou
ough
h to
prev
pr
evven
ent th
ent
them ffro
rom
ro
m be
beco
comi
ming clo
ming
ogg
g ed
d.
Rete
e n
ete
ntio
tion spring
Top
o face
e
Bot
otto
ot
ttom
tom face
c
ce
Release-tension
o
on
aadju
dju
j ster
err
Rete
R
tentio
nttion
n bar
b r
ba
Axle
A
xle
e
t read
thre
ad
d
Shiman
Shi
mano offmano
off-roa
roa
ad peda
peda
edall
TThe
he o
op
pen
n des
design
ign of this
this
ped
eda
dal
al all
allows
o go
ood m
mud
d
cleeara
clear
a nce
nce b
bu
ut expo
xposes
s
ses
th pedal
the
peedalls
s ret
re ent
ention
on
meechan
m
mec
eechan
hanism
ism to
o th
the
elemen
el
ele
en
nts.
ts Cl
Clean
ean aan
nd
deg
de
eeg
grea
r ssee tthe
hee pe
pedal
dal
alss
reg
eg
gula
u rly
l an
and
d lubricate
tee
thee mo
movin
v g part
a s with
it
a heea
ea y lubricant.
eav
nt. Th
Thee
releasse tension ad
adjus
dj terr is
o thee ba
on
back
ck pla
p tee of
o thiss
double-s
-sssided
-si
d d peedal
da .
Top fa
f ce
Rele
ease
asessese
e--tens
tte
ension
on
n
adju
dju
jju
uster
err
Bottom
Bot
ttom
om fa
face
ace
c
Re
R
Rele
elease
sp ng
spri
Rete
entio
on
mechanis
mech
anis
ni m
nis
R ntio
Ret
Rete
nt on spring
spri
ring
Cra
ra
ank Broth
herss ped
he
pedal
a
al
Thiis is aan
n open
n de
d sig
ign
with exc
wit
xce
cceellent mud
cle
cl
l ar
le
aranc
nce and very feew
nc
mov
ovving
in paarts
rttssthe
rettent
enttion
tio
ion meechanism
cha
ch
haa
h
is jus
justt a ssimpl
p e spriing.
g
C an
Cle
a the
h peedal
a s regu
gu
ula
la ly,
lar
aand
an
nd veery
r occ
c aasi
cc
ssio
ona
nally
nally
ly
rre--gre
grease
se th
he bear
bea
ear
aring
ar
ingss
using
usi
ng a grea
grease
see gun an
nd
a special adaptor thaat iiss
sold with
th th
t e peda
pedals
ls.
P n view
Pla
ew
w
Axle th
thread
ad
Proffile view
ew
Rete
Re
e ntion bar
R t ntion bar
Rete
Rete
etentio
n n sp
ntio
pring
Pedal aaxle
Peda
83
84
Pedal cleats
STEP LOCATOR
1 2 3 4 5 6
Parts of a pedal cleat
4
Fixing
bolts
Cleat
Pedal cleats
85
88
HEADSETS
A headset allows the bike to be steered. The headdseet must
ust
us
be properly adjusted to allow smooth, safe stteerin
ng an
and
to prolong its life. The bearings and bearing su
urfaccess
need regular inspection and lubrication, and anyt
y hiing
that is worn must be replaced at once.
Star wash
her
Gr ps the st
Gri
steerer tube
Stem
Links handlebar an
and heeadset
Spacer
Sits on top of the beearin
nggs
ng
Top bearings
Allow the steerer tubbe to
turn in the headset
Steerer tube
Connects the fork
to the headset
Bottom
m
bearings
gs
Allow the
he
fork to tu
urn
ur
Fork crown
n
Turns the forrk
rk
89
THR
HREAD
ADED
AD
E HEA
ED
HEADSE
E T ANAT
A N TOMY
Y
Screwing the
he top cup
cu dow
own the th
hre
r ad of the
th
h st
steeerer
plac
pl
ace
ces a lloa
oad
oa
d on the
he top
p bea
e rings to the
hee p
poi
o nt
oi
nt where
th
he fo
fork
rkks tu
t rn fre
reelyy but wi
w thout play. The cup
p, and
nd
conseq
eque
eq
uent
ntly
ly tthe
he ffro
ontt ffor
ork, iss then loc
ocke
ked in pla
laace
byy a lockrin
ng th
hat
a als
lsso sc
s rews down
n th
the thre
th
hread
aded
de
sttee
eere
rerr. Thee ssteem is
is atttac
ache
hed
d to
o tthe
h hea
eads
dset
et by
tiigh
g teniing the ste
tem
m s exxpand
m
nder
e bolt, whi
hich
ch p
pul
ulls
ls
up a wed
e gee aand
nd
d jjam
amss th
am
the st
s em
ms qui
uillll ins
nsid
ns
id
de th
he
th
hre
read
aded
e ste
teerrer
e.
Stem
Liinks the
handle
dlebar
and
nd heads
dset
e
Quill
Fitts ins
n de the
nsi
thread
eaded
steere
er r
Haaan
Han
H
n
ndle
dlle
dle
d
lebar
baaarr
b
Ste
SSt
tteeeer
ers
rs tth
rs
he
ffro
fr
rroon
ntt w
wh
heee
h
eel
el
TTop cup
Loa
adss tthe
h
beaarin
ri gs
Thr
hrea
ead
ad
ded
e steere
e r
Con
C
onnec
ects
ec
t the
hea
adse
d t to
t fork
the
Hea
He
H
eeaads
dse
d
sseeett
Hool
Hol
H
olddss th
old
th
the
hee
ffor
fo
oorrk in the
he
heea
hea
h
ead ttube
ubbee
ub
ube
Expandeer bo
olt
olt
ol
Draws up
p the
h wedge
dge
ge
LLockring
g
Locks the
th topp
cup
up in pl
place
To
Top
op be
beari
arin
riing
ngs
Alloow the steerer
All
too tur
urn
n in the
headset
hea
Wedgee
Wedge
Jams
ams thee quill
quill in
the st
steerrer
er
Bottom
o beeari
a ngs
Alloow the fork
too turn
Fo
FFor
orrk
Hoollds
Hol
Ho
ds and
aan
ndd tu
turn
rn
rns
nss
the
th
he fr
front
on
on
ntt wh
wheel
whee
eeel
Ste
St
S
tee
eri
rin
ng
ge
efffecti
ectively
vely
A head
e set
seeett aalllow
lo
ow
wss th
the
he rid
rider
er to
o
steeerr th
ste
the
the
he ffrro
ont
nt
nt w
wh
heeel eeffec
ectiv
iveely
ely
and
an
nd cco
confi
onf
nfi
n
fiden
dently
de
t y. The
tly
h handleebar
bar,
wh
whi
wh
hiich
ch iss ccon
o
on
nn
nec
eected
cte
ted
d to the
the
ssttteeeer
ste
eere
rreer
er tu
ub
ube
be by
by the
the sttem
em
m, tu
urn
r s
thee fo
the
forkk aand
nd
n
d th
the fron
frron
ont w
whe
heee
hee
h
eeel
el.
90
Threadless headset
To determine whether your bike is equipped
with a threadless or a threaded headset, look
at the stem. If you can see bolts on the side
of the part that sits on top of the head tube,
it is a threadless headset.
A number of different types of threadless
headsets can be fitted to modern bikes.
These range from the type that has both top
and bottom cups, like the traditional headset,
to others, such as the headset illustrated
here, where the bearing surfaces fit inside
the head tube. All the various types of
headsets work on the same principle and
are taken apart in a similar way.
Occasionally, you need to strip down the
headset in order to check it for wear and to
clean and lubricate the bearings. If you find
any cups or bearing surfaces are worn, you
will need to replace the whole headset. This
job requires special equipment and is best
left to the experts in a good bike shop.
STEP LOCATOR
1 2 3 4 5
Top race
Bottom cup
Threadless headset
Take hold
ld off the ffrontt fork
fo , then lift the
steem and handle
dlebar
b from the steerer. You
can leave
leave these
these to ha
hang
ng out of th
thee w
way,
ay, su
suppo
p rted
by th
by
thee brake
brake an
and
d gear
gear cable
cab s.
s
91
92
Threaded headset
Older bikes and childrens bikes are equipped
with threaded headsets. This type of headset
is designed to make it easy to raise and
lower the stem whenever you want to
change the height of the handlebar and
adjust your riding position.
The headsets top cup and the locknut
that holds it in place are both screwed onto
the steerer. The stem is equipped with a shaft,
or quill, that fits inside the steerer. For safety
reasons, you should never raise a stem above
the limit marked on its quill.
On some even older headsets, the top cup
screws down. Its serrated top edge is held in
place by a clamp bolt on a similarly serrated
lockring assembly. When the clamp bolt is
loosened, the top cup screws off.
Remember to disconnect the brakes
before you start working on the headset
and make sure that you reconnect them
when you are finished. Before the stem
is replaced into the steerer of the headset,
coat the quill with grease (see pp.301).
Servicing a threaded
headset
STEP LOCATOR
1 2 3 4 5 6
Bottom cup
Fork crown race
Threaded headset
93
94
HANDLEBARS
Most modern bikes are equipped with either straight or drop
handlebars. A rider must be able to rely totally on the handlebar, so
for safety reasons, a handlebar must be replaced at once if scratches,
stress marks, or cracks develop on the surface.
Straight handlebar
Owners of road bikes sometimes want to
change the handlebar to a different shape,
often to suit the proportions of their body or
because of their cycling needs. Some cyclists
want to replace a drop handlebar with a
straight, or flat, bar. Others may want to
replace their existing straight bars with riser
bars, or vice versa. Riser bars, which are fitted
to mountain bikes, are straight in the center,
then rise up to become straight where the
grips are. They are installed the same way as
a straight handlebar.
The steps in this sequence apply to all
straight handlebars, whatever the reason for
replacing them. However, when replacing a
drop handlebar with a straight bar, it will be
necessary to swap the brake levers for levers
that work with flat or riser bars. Some of
these steps will also be useful when fitting
new grips, brake levers, gear-shift levers, or
bar-ends to an existing handlebar.
STEP LOCATOR
1 2 3 4 5
Installing a straight
handlebar
Grip
p
Straight
handlebar
Ring
clamp
Bar-end
Shifterr unit
Brake lever
Clamp bolt
Toolbox
Straight handlebar
Push the grips farther on if you are fitting barprevent them from twisting while you are riding.
95
96
Drop handlebar
Road-riding cyclists often fit a drop
handlebar to their bikes so their bodies can
adopt a lower, more aerodynamic posture.
However, the handlebar should never be
positioned so low that breathing is restricted
when holding the bottom of the bar.
Replace a drop handlebar at once if any
cracks develop on its surface. The steps in
this sequence will show how to replace a
drop handlebar and how to fit, and therefore
how to reposition, brake levers. Cyclists with
larger hands and long arms may prefer to
mount the levers lower down the handlebar
than the ideal position shown here.
Regularly replace the handlebar tape as
shown in Steps 5 and 6, and insert a plug in
each end of the handlebar after taping to
help prevent injury in a fall.
Brake levers for flat handlebars will not
work on drop handlebars, and may not work
with all brake types. Check the compatibility
of your components before swapping.
Installing a drop
handlebar
STEP LOCATOR
1 2 3 4 5 6
Cable groove
Handlebar tape
Brake lever
hood
Rubber cover
Toolbox
Brake lever
Drop handlebar
ha f
Wind upward, coverinng half
of the previous turn wi
with each
ch
sub
bsequent turn.
97
98
STE
STEERI
TE ERII NG
N AND
ND
D WH
WHE
W
EE S H
EEL
HUB
BS
BS
HUBS
Th
her
eree ar
aree tw
wo ty
t pe
pess of
o hub
b, op
o en
en-b
-b
bea
e ri
ring
ngg and
nd car
artrid
trid
tr
idge
ge. TTh
he cone
ccoone
nes
aan
nd be
bear
arin
ar
ings
in
gs ooff op
open
pen
n-b
bea
e ri
ring
ng
g hub
ubs mu
must
ustt be
be ad
adju
just
sted
ed to lleet tth
he
hubs
hu
bs sspi
pin
pi
in fr
free
eely
ee
ly,, wi
ly
with
th
h littl
itttle
tlle pl
play
ay.. Th
The bear
beear
arin
in
ngs
gs in
n bo
both
th tyyp
peess of h
hu
ub
ub
need
ne
ed rreg
ed
e ul
eg
ularr che
che
h ck
ckin
in
ing
ng an
andd lu
lubr
bric
br
i at
ic
atin
tin
ing.
Minimi
M
Min
in
nimi
imizin
im
zin
in
ng friccttio
tion
Free-s
Fre
ree-s
e pin
ep nin
ing
in
ng hub
ubss aare an essse
ubs
ssse
senti
ntial
nt
aall
parrt of an
p
an eeffi
f ccie
ff
ffi
iieentt bik
bikke.
ke.
e. Th
TThe
heeir
h
ir
bea
b
eaarin
rin
ri
ng
gss mus
mus
mu
ust crea
reeate
te as
as lit
iittttle
ittle
lee
fricct
fri
cttiion
cti
on
n ass p
po
pos
osssib
o
siib
blle,
lee,
e, sso
o as
as n
no
ot to
slo
lo
ow th
hee rid
id
deer
errrs forw
orw
war
ard
rd p
rd
prrog
ogr
o
g ess
ess
ss.
s.
EXPLOD
LODED
E CAR
ED
CA TRIDGE HU
UB
Th axlee o
The
of a cart
rtridge hub
b is nott thr
h eaded, so th
he bearings are
pushed ont
n o each end of the axle and coverred by a seal. Wh
W en
t e hub is assembl
th
bled, the bearings sit in the hu
h b body, just to
t e outs
th
tside of the flaanges, witth the axle running through
h them.
L ckring
Lo
gs en
e su
s re that everything is held in place.
Flangee
Anc
n hors the
spokes to
the hubb
Axl
xle
Rottatees the
wheel
Seal
Seal
Cov
o ers th
he
be rings
bea
Hub bo
b dy
d
Co taiins thee
Con
axl
xe
Cartri
tridge
dg
b rings
bea
gs
Suppor
Sup
port the
he
hub bo
b dyy
Open-bearing
front hub
Allows the wheel to
revolve smoothly
Hub body
Rotates
around
the axle
Ball
bearings
Support the
hub body
Quick-release
skewer
Locks the axle
in place
99
100
Open-bearing hub
Hubs are available in two typesopenbearing or cartridge. The open-bearing hubs
require much more maintenance than the
cartridge type, since their bearings need
regular inspection, cleaning, and regreasing.
As a result, the ability to strip down and
service an open-bearing hub is a skill that
can be used repeatedly.
The following steps will help you to
remove an axle and a freehub, as well as
regrease and retighten the bearings. They
can be applied to a Shimano front or rear
hub and a Campagnolo front hub. However,
leave servicing a Campagnolo rear hub to
the experts at a bike shop because it
requires special tools.
If you are working on a rear hub, you
need to remove the cassette by following
the steps on pp.667 before tackling the
steps in this sequence.
Overhauling an
open-bearing hub
STEP LOCATOR
STE
1 2 3 4 5
Parts of an open-bearing hub
Locknut
Flange
Cone
Flange
Freehub body
Hub
body
Locknut
Spacers
Non-drive side
Axle
Drive side
Toolbox
Open-bearing hub
101
102
WHEELS
Quick-release mechanisms help to remove and replace a wheel more
quickly than ever before. The tires are the component that make
contact with the ground. Match the tires on your bike to the prevailing
riding conditions and always be ready to replace worn-out tires.
Quick-release wheels
Removing and replacing a wheel is a very
straightforward task, but if any of the
following steps are overlooked, the wheel
may come loose and compromise the riders
safety. The steps are for wheels that use
quick-release levers to secure them in the
dropout (the frame recess into which the axle
fits). For bikes with axle nuts, loosening and
tightening with a wrench corresponds to
unlocking and locking the quick-release lever.
Levers are labeled locked or closed on
the side facing the cyclist when the wheel is
secure, and unlocked or open when it is
not. Check levers are locked before each ride,
and during a ride if disc brakes are fitted.
The rim brake needs to be released on the
wheel being removed. For V-brakes, unhook
the cable from its cradle; for cantilevers,
unhook the straddle wire from the left brake
arm; for calipers, use the quick-release lever.
STEP LOCATOR
1 2 3
1 2
Quick-releasse
bod
dy
Quick-release
Qu
leve
ver
Wheel dropout
Toolbox
Quick-release wheels
103
104
Puncture repair
When you are out on a ride, it is much easier
to replace a punctured inner tube with an
intact tube rather than painstakingly mend
the puncture. At home, you can repair the
punctured tube with adhesive and a patch.
It is still a good idea to carry a repair kit on
every ride, because you might be unlucky
enough to get a second puncture and be
forced to repair the tube outdoors.
The main point to remember about
mending a puncture is not to rush any of
the stages. If you patiently give the glue
time to dry, closely examine the inside of
the tire, and carefully refit the tube, then
you will be rewarded with a successful repair.
If you miss anything or pinch the inner tube,
you may get another puncture.
Mending a punctured
inner tube
STEP LOCATOR
1 2 3 4 5
Parts of a wheel
Tire
Inner tube
Valve
Rim
Toolbox
Puncture repair
ve the tu
ube for
or a few
w minut
nutes
tes to
to mak
makee sure
sure
Leave
105
106
STEP
STE
P LOC
LOCATO
ATOR
R
1 3 4 5 6
Parts of a spoke
Spoke head
Spoke
Bend
Nipple
Toolb
lbox
Threads
Spoke
Note how out of line the rim is, then give the
nipple a one-quarter tightening turn and check
again between the jaws. Repeat and check each
quarter-turn until the rim is straight.
107
ADJUSTING YOUR
a bikes most important
component. The braking
system needs to be
adjusted and serviced
carefully and precisely to
guarantee a riders safety
in all conditions.
BRAKES
110
RIM BRAKES
Rim brakes stop a bike by contactiing
g the rim of th
thee wh
heels
ls.
s
Pads must be checked to ensure that they con
ntact
tact tthee rim
im
fully and at the same time, and replaced wheen th
hey are
re woorrn.
n.
Brake cables must be checked and lubricate
tedd regula
arllyy..
Bra
akin
king ssafe
a elyy
afe
Ri br
Rim
b aakees must
usst b
bee se
set
et up
pro
roper
p ly and
pe
per
nd ma
main
in
int
nttain
i ed
in
ed to
o
vverry
ry hiigh
gh st
stan
tand
nd
dard
r s if they
rd
heeeyy
ar to
are
to wo
ork eff
effect
ef
ec ive
ivel
iv
ely
ly an
and
and
nd
saaafely o
saf
on
n aan
ny surffac
ace
cce an
and in
a co
all
ond
n tio
ndi
tions.
ns.
V-BRAKE ANATOMY
Cable-guide tub
be
Pushes the brake
arm
Brake arm
Pivots inward on
a brake boss
othe
ot
herr arrm in
he
inwa
ward
wa
r . Th
rd
Thee tw
wo arrms
m p
piv
iivvo
ott aro
roun
ro
un
nd
thee brak
th
brak
br
akee bo
boss
sses
ss
es,, pu
es
push
shin
sh
i g th
in
thee br
brak
a e pa
ak
p d
dss
agai
ag
ains
ai
nstt the
ns
th
he br
b ak
akin
ing
in
g su
surf
rfac
rf
acce on
n the rim
m. On
Once
ce
t e ca
th
cabl
b e
bl
e s pull
pulll iss reeleeas
ased
e , sp
ed
pri
ring
ng
gs arou
und
d th
hee
pivvot
pi
vot bo
bolt
ltss pu
lt
p sh the
h bra
rake aarms apar
arrtt..
Inn
nn
ner cab
c lee
ca
Pulls
Pul
ls th
the
he
brake
brake
bra
k arm
m
Cab
ble
le--cla
clamp
m bol
mp
bo t
At ach
Att
acc ess thee cable
b to
to th
t e bbra
rakke arm
m
Bra
raake
k bo
boss
Alloows
All
ow
ow
ws th
t e bra
rake arm
rak
m to piv
p ot
ot
Brrrakee pad
Bra
B
ad
Contacctss the
h riim and
d sto
st ps
p
tthe
th
he w
whe
wh
heel
el
Spr
prrin
i s
ing
Pus
ush
h bbrak
rakee arms apart
rak
apart
ar
Pi ot
Piv
o bol
oltt
Anchor
Anc
ho s the
hor
he
br ke
bra
ke arm to
t br
the
b ake boss
bo
osss
H ow
How
Ho
o w th
the
eyy w
wor
or
o k
B ke
Br
Bra
k lev
lever
err
PPullls the
h ca
c ble
blle
Bra
Br
rake
ra
ke arm
ar
ar
Mov
Mo
M
ov
oves
es the
he
h
brake
br
bra
ke pad
padss
pa
tow
to
oward
ow
ard th
the
the rim
rim
m
Bra
Bra
Br
r ke
rake
ke pad
paad
SSllo
Slo
lows
ws do
ddow
ow
own
th
the
th
he wh
wheel
e l
BR KE LEV
BRA
LEVER
ER ANA
AN TOMY
When
Wh
e the rid
en
der
e app
p lies
es tthe
he b
braake lever, it pulls the
niipp
pple
le of th
thee in
nne
n r caabl
b e. A
As it leaves the lever, the
brak
br
akke ca
cabl
b e ru
bl
runs
n iins
ns
nssiid
n
de a ca
cable hous
u ing, which sits in
a ba
barr
r el adj
rr
djus
uste
us
ter.r. Thiss baarr
te
rrel
el adj
djussteer allows the brake
ttrrav
avel
el tto
o be
b fin
finee-tu
etune
tu
n d.
ne
N plee
Nip
Fixxess inn
Fi
nner
er cab
able
lee to braake lev
le er
Inner cable
Lin
nks the
th br
brake
akk ar
ake
arm
m to
the
h br
brake
rake
ak le
lever
verr
B rel ad
Bar
adjus
j ter
jus
Adj
dju
usts brak
ust
brak
rakee
t avel
tra
el
Cabblee hou
housin
ousin
ng
Re istts the
Res
h
pulll on
pul
on tthe
he
cab
ble
Bra
rake
ke lever
Pullss the
nipple
nip
ple
111
112
Drop handlebar
brake cable
STEP
STE
P LOC
LOCATO
ATOR
ATO
R
3
4
Brake cable
Pear
nipple
Brake
cable
Campagnolo Ergoshift
Toolb
lbox
Brake lever
113
114
Straight handlebar
brake cable
Replacing brake cable inners and housings
is a job that should be done fairly often on
a mountain bikeabout once every six to
12 months. They also need replacing if they
start fraying and become worn. The hybrid
bike in this sequence has V-brakes, but some
mountain bikes are equipped with cantilever
brakes. Fitting cables is similar for both.
Brake cables also require regular cleaning
and lubricating, especially if the bike has
been ridden consistently in wet weather. All
brake levers that fit onto a straight or riser
handlebar require a cable with a barrel nipple.
Regardless of the manufacturer, the barrel
nipple fits into the brake lever in the same
way. Remember to use ferrules on both ends
of every length of new cable housing. Put a
cable crimp on the end of the cable once
everything is secure and working as it should.
In these steps, the tire is removed from
the wheel to show clearly what is happening.
STEP
STE
P LOC
LOCATO
ATOR
R
1
4
6
Parts of a brake lever and a brake cable
Brake lever
Ring clamp
Brake cable
Nipple
Reach
adjuster
Brake
cable
Brake lever
Barrel adjuster
Toolb
lbox
cable-clamp bolt.
115
116
Caliper brake
1 2 3 4
1
1
Caliper arm
Center-fixing bolt
Centering
adjusting
screw
Brake shoe
bolt
Brake pad
Brake shoe
Toolb
lbox
Caliper brake
Using quick-release
mechanisms
been set too low will develop a lip and will need
to be replaced.
117
118
V-brake
Adjusting a V-brake
STEP
STE
P LOC
LOCATO
ATOR
ATO
R
notice that the brake boss was dry with the arm
removed, smear a little grease on it.
1 2 3 4 5
6
Parts of a V-brake
Cradle
Cablefixing
bolt
V-brake arm
Spacers
Spring
clip
Pivot
bolt
Brake pad
Toolb
lbox
V-brake
119
120
Cantilever brake
Cantilever brakes work with the brake
levers that fit dropped handlebars, whereas
V-brakes do not. This is why touring and
cyclo-cross bikes are fitted with cantilevers.
Cantilevers were the predecessors of
V-brakes, so they may also be fitted to
older mountain and hybrid bikes.
Keep cantilever brakes running smoothly
by regularly checking the pads for wear and
adjusting the pad alignment and brake travel.
The cable of the cantilever brake shown
in these steps is clamped to one brake arm
and the straddle wire running off it attaches
to the other arm. On some older cantilever
brakes, the brake cable is attached to a
straddle. This hooks the straddle wire that
transfers the cables pull to both brake arms
and needs regular adjustment (see Step 1
Adjusting a BMX U-brake, pp.12223).
Adjusting a
cantilever brake
1 2 3 4 5
1m
mm
m
Brake pad
Cantilever arm
Cable-clamp bolt
Spring
clip
2 mm
mm
Angle the pads so that the front of each
pad hits the rim before the rear when the
brakes are appliedthis is called toe in.
Spacers
Toolb
lbox
Cantilever brake
121
122
Alternative
brake designs
Adjusting a side-pull
caliper brake
STEP
STE
P LOC
LOCATO
ATOR
R
Barrel adjuster
Pivot nut
Brake
arms
Brake
pad
Cable-clamp
bolt
Brake-pad bolt
Brake
arms
Straddlewire seat
Straddleclamp
bolt
Pivot bolts
BMX U-brake
Brakepad bolt
Brake
pads
Toolb
lbox
Centering
screw
Undo the
straddle clamp
bolt and pull the brake
cable through the
straddle with needlenose pliers to take
up the pad wear.
Then tighten the nut.
123
124
ADJUST
ADJ
USTING YOUR BRAKES
E HUB-MO
O UNT
NTED
T ED BRA
B KES
HU
UB-M
MOUNTED BR
RAKES
Hub-moun
untedd br
b akess stop a bike by sl
slow
owin
ow
ingg do
in
dow
wn the spe
p ed
d of the
th
he hub.
hub.
Regu
Re
g la
gu
larl
rlyy ch
heck disc
sc bra
rake
ke ppad
a s fo
forr we
wear
ar aand
nd alil gn
g meent
nt,, re
repl
placcing
in
ng th
them
em
m
when
wh
en the
heyy ar
aree wo
w rn
rn. Reegu
gula
la
arl
rlyy ch
checkk an
andd re
repl
plac
pl
aacccee th
t e ca
cabl
bles
bl
ess on ca
cabl
blee
bl
discss and
an
nd hu
ub br
brak
akkess. Exam
Examin
i e thee ho
h se
sess of hyd
dra
raul
ulic
ic bra
r ke
kes fo
kes
f r le
leak
akss.
ak
s.
How th
hey work
Hub-mo
H
ountted brakes are activated by th
t e pu
pullll of a le
pull
l ver on a
cabl
ca
ble,
e, w
whi
hich
ch ccauses pa
p ds to co
ont
ntac
a t a braking
n surfacce.
e Sprin
ings
in
gs
push
pu
sh tthe
he pad
ads
ds away wheen th
thee le
leve
ver is rel
elea
e se
ea
sed. In disc bra
r ke
kes,
s,
tth
he pa
pads act
ct on discs at
attaach
ched to th
he hub
b.
In rollller and coaster brakes, the pads act on a brak
In
akin
ing
surfac
facce in
nsi
s de the
h hub. The action of the pads on the surfacce
then
th
en sslo
lows
ws d
dow
own th
t e hub
hu
ub an
and therefore th
the wh
whee
eel. In hydraaulic
brak
br
akes
es, th
thee le
leve
veer
r s ac
actiion p
pus
ushe
hess fl
f uid through a ho
ose
se;; this
is flu
uid
d
push
pu
shess tthe
he bra
rake
k pad
a s in the cal
ad
a ipeer int
n o ac
acti
tion
on.. Of aalll the
hub-mounted br
brak
akes
ak
es,, hyydr
drau
aulilic disc b
brake
kes offfe
fer a ride
fer
riide
derr th
thee
b stt control ove
be
verr th
t e br
brak
akin
ing
g fo
f rc
rces tha
hatt can
n be app
pplilied
ed.
Work
Wor
king in
kin
in any
any wea
weath
the
th
h r
her
he
An adv
advant
antag
age
ge of h
hu
u
ub
b
brakkes over rim
m bra
b
braake
kees iiss
that their perf
tha
erffo
orm
or
man
a e
anc
is lar
largel
gel
e y unaf
unaf
naaffec
fe te
ted
ed by
by
adv
ad
dvers
ersee rid
rid
idiing ccon
ondittion
ion
ns..
HYD
YDRAU
R
LIC
C DI
D SC BRA
BR
R AKE
KE A NATOM
MY
When the
W
h rid
der
e p
pul
ulls
ls the
the b
bra
rake
ke llev
ever,
thee hy
th
hydraulicc fl
flui
u d in tth
he hose
push
pu
shes
es on th
thee pi
p st
ston
on
ns in tthe
he
calilipe
per.r. TThe
hese
se pis
isto
tons in turn
cau
ca
use th
thee br
braake pa
pad
d on eacch
sidee o
off th
the disc to co
ont
n acct
the di
dissc and sslo
low
w the
rota
ro
tation
ta
tati
o of the whee
e l.
When
n the rider
reele
leaas
ases the
ases
h bra
r kee
leve
le
ver,r, the preessur
ssur
ss
uree
off tthe
he fluid
id in
n th
he
ho
ose
s d
dec
eccre
r asses
e,
allo
al
lowi
wing
ng
g the spr
p in
ngs
g
(not
(n
ott vissible
ib
ble
le)) in tthe
he
caalil per to
t push the
brake paads apaartt.
Disc
Slows dow
down the hub of the
wheel under pressure from
the brakee pads
Ho
ose
ose
Contains
Co
fluid
flui
id
Calipe
iper
ip
Con
Con
Contai
o tains
ainss
pis
isto
tons and
two br
b ake
ke
pads
pad
Brak
Bra
rake
ke pad
p
Con
C
on
ntac
tacts
thee di
disc
sc
un er
und
e
preessu
pr
uree
fro
from
rom thee
f id
flu
Ho th
How
h ey
e y w orr k
Bra
B
rak
rake le
lev
eever
Com
Co
mppr
pre
r sse
re
ssess
th
the
hee br
h
brake
ak
flu
fl
flu
uid
id
Hosee
Hos
Car
arrrie
riess th
the
he braake
ke
fluid
flu
i fro
id
from
m tthe
he le
lev
e er
too the
th
hee cca
alip
perr
Cal
C
Ca
aallip
ipe
ipe
per
Hoou
Ho
Hou
usses
sees
es tth
he
bra
bbr
rraakkin
kiin
ing
meecchan
mec
mech
me
haan
ha
nism
issm
is
m
Dissc
Sloows
Slo
ws ddow
doow
wn
n
tthe
th
h
hee wh
whee
ee
eel
HYD
YDR
R AULIC BR
BRAKE
AKE LE
E VER
VE
Brake hose
sess ar
aree co
conn
nnec
ecte
ted
d to a reserrvo
voir
ir o
of
brake fluid on eacch br
brak
a e lever. The fluid
fills the hosess alll thee way to the caliper on
the wheel. P
Pulliing tthe brake lever operates
a pi
p st
sto
on iin the re
reserv
rvoi
oir,r, which pushes
the fl
flui
u d down
wn
n tth
he hose an
and, as a result,
accti
tivates th
thee caliper pi
p st
stons.
125
126
Replacing disc
brake pads
When brake pads wear down, the brakes
will not stop the wheel as quickly. Eventually,
the pads become so worn that they have to
be replaced. Unevenly worn pads should
also be replaced immediately and the caliper
may need to be realigned (see p.129).
9
Although replacing pads is broadly the
same for all makes and models of disc brake,
there are some differences, mostly in the
way the pads are retained within the brake
caliper. Some brake pads are kept in position
within the caliper by retaining bolts, while
others rely on the spring that keeps the two
pads apart to fix them in place.
Only use replacement pads recommended
by the manufacturer of your brakes, and be
very careful how you handle the pads.
STEP
STE
P LOC
LOCATO
ATOR
R
Brake
hose
Caliper
Rotor
Brake pads
(not visible)
Toolb
lbox
127
128
Disc-brake care
STEP LOCATOR
Hub
Brake
cable
Brake
caliper
Rotor-mounting
bolts
Toolb
lbox
Brake disc
129
Clean the rotor with a special rotorcleaning fluid after removing the wheel.
130
Hydraulic
disc brake I
Installing a hydraulic
disc-brake system
Toolb
lbox
131
132
Hydraulic disc
brake II
Draining and
replacing brake fluid
1
3
2
133
134
Roller-brake cable
All brake cables wear out, no matter how
much time is spent maintaining them. Cables
for roller brakessometimes called drum
brakesare no different. If the bike is
equipped with roller brakes, the steps in this
sequence show how to replace a cable when
it is frayed or worn out. However, lubricating
the brakes and replacing the internal parts
are occasional jobs that are best left to the
experts at a good bike shop.
If the rear inner tube is punctured, or it is
necessary to take off the back tire to replace
it, you need to know how to disconnect the
rear brake in order to remove the back wheel.
At the same time, you should know how to
reconnect and adjust the brake after replacing
the wheel. Once this is a familiar routine, it
will also be possible to adjust the roller
brakes for brake pad wear from time to time.
Replacing a
roller-brake cable
STEP
STE
P LOC
LOCATO
ATOR
ATO
R
1 2 3 4 6
Parts of a roller brake
Brake
body
Wheel
axle nut
Brake
arm
Cableclamp
bolt
Barrell
adjuster
Cable
C
bl
guide
Toolb
lbox
Wrenches
Needle-nose pliers
C bl
Cable
Roller-brake cable
Pull the cable backward with the needlenose pliers while you push the brake-arm
cradle forward and hook the clamp bolt into it.
Keep about
135
Suspension technology
has revolutionized
off-road riding. Accurate
adjustment of the front
fork and rear shock
allows uneven terrain to
be tackled safely and
confidently.
138
SUSPENSION FORKS
A suspension foork softens the blow of a bump on the road
d or trai
ail.
The fork must be checked for wear and lubricated reg
gularly
lyy. The
oil and springs should be changed either when they wea
earr oorr to
alter the characcteristics of the fork.
Reacct
Rea
cti
tn
ng
g to
to bu
bum
b
um
u
mpss
Dam
mpin
pi g sho
hould
hou
lld
d
pre
reven
ven
nt th
the
he ffo
forrk from
ro
ro
om
m
reach
rea
ching
chi
ch
ng thee li
lim
mits of
mit
of
its trrav
it
aave
vel,
el,, b
butt the
the fo
ork
or
rk
rk
sh uld
sho
d sttilll b
bee re
react
act
cctive
ve
ve
enough
en
eno
gh
h to co
cope
pe w
wit
wi
ith
ith
ev ry bum
eve
bump.
p.
FRONT FORK CO
O MPRESSION
Compr
Co
mpress
ession
Landin
ng on the gro
ound
nd
d ret
etturn
rns the
rns
thee
riderss weig
ei ht
h to the
he bi
bikke
bike
kees frame
ram
ra
ame and
d
com
mpre
resse
ss s the fro
front
ront
n for
fo
ork.
ork.
k
How
w tth
h ey
e wor
o k
A R /OI
AIR
/O L FORK
W en
Wh
en a b
bum
u p pushes up the sliders on this fork, a piston
mo
ove
vess up the left stanchion, compressing the air. Once the
bump has
as b
beeen absorbed, the air pu
ush
shes
e thee p
pis
i ton back and
the fork reb
bou
ound
n s. The dam
mpi
p ng mec
echa
haniism iin
n th
t e ri
righ
ghtt
stanchion, which
ch iiss fu
full of oil,l aalso move
ves up and down with
th
t e bump, conttro
th
rolling the speed of com
ompression and
d rreb
ebound
nd.
F k crown
For
Tur
urns
ur
r the fork
Brake arch
Coon
onnects the
two sliders
Seal
Keeeps
p dirt out
of forks
interior
Rig
ght
stanch
hio
on
on
Contains
n th
thee
dampin
pin
ingg
in
mec
echanis
issm
sm
Oil ch
O
chamb
ber
er
Con
C
ontains oil
oili
Dampin
Dampin
Da
Dam
p g
mee hanism
mec
sm
m
M es up
Mov
p
and
n doown
wn
with
wit
h slilid
lider
Slliderr
S
Sli
Mov
M
Mo
Moves
ooves up
p and
down on the
dow
the
he
sta
tanch
ta
nchion
nch
ion
io
ion
Leftt
Lef
staanc
nch
chio
ch
ion
on
Con
ontai
a ns
the sprin
ring
me hanism
mec
and
d pi
p ston
Air
cha
hambe
mbe
b r
Co tai
Con
ains
air
ai
Pisston
t
Mov
o es
e up
and do
d wn
w
in respon
po se
to
o bum
bu ppss
Shaftt bol
Sha
Sh
b t
Fasten
Fas
tens
sha
haaft to
sliide
der
er
139
140
Front suspension
A suspension fork works best if it has been
set up to accommodate the riders weight.
When you sit on your bike, the amount the
fork depresses, as the slider moves down the
stanchion, is called the sag. As you ride, sag
allows the fork to extend into the hollows in
the ground, giving a smooth ride. To set the
amount of sag, you can increase or decrease
the amount of preload in the fork.
Damping controls the speed at which a
fork works. To find out if a fork is working
too fast, lean on the handlebar, then quickly
lift up the front of the bike. If the suspension
fork bangs back to its limit, its action is too
quick and its rebound damping needs to be
increased. Adjust the damping still further
after a few rides. The best setup will let
the fork absorb a hit and rebound quickly
enough to be ready for the next.
Setting sag
STEP LOCATOR
1 3 4
1
1
Brake boss
Slider
Dropout
Toolbox
Front suspension
141
142
Coil/oil fork
1 2 3 4 5
Parts of a coil/oil fork
Steerer
Fork crown
Top cap
Fork crown bolts
Stanchion
Fork brace
Brake boss
Slider
Dropout
Toolbox
Coil/oil fork
143
144
Changing oil
Air/oil fork
Air/oil suspension forks usually have short
travel and are popular with cross-country
riders. Their spring medium is air, which
makes them very light, and their mechanism
is damped by oil.
Sometimes they have a negative spring
working in the opposite direction of the
main air spring. This helps to overcome the
stiction (the sticky friction between two
adjacent but motionless objects) which is
inherent in air/oil suspension forks and is
caused by their very tight seals.
Changing oil is necessary from time to
time, as dirt in the system starts to cause
excessive wear. If you have increased the
damping on your fork and its action is still
too fast, replacing the oil with a heavier
one will slow it down. In the same way,
lighter oil can help to speed it up.
STEP LOCATOR
1 2 3 4 5
Air valve
Fork brace
Brake boss
3
Slider
Dropout
Toolbox
Wrench
Shock pump
Air/oil fork
Pour the old oil out
of the stanchion and
into a plastic cup. This
air/oil fork has an openbath damping system, in
which the damping rod
moves up and down an
open oil bath. The oil also
lubricates the rest of the
suspension system.
145
146
Looking after
suspension forks
Suspension forks soak up a lot of abuse
because that is what they are designed to
do. Although manufacturers do whatever
they can to protect the inner workings, there
are still some things you need to do to look
after your forks.
Chief among them is cleaning. If you
do not clean your forks regularly, dirt will
wear down the seals at the top of the
sliders and allow water to get into the inner
workings and damage them. Worn seals will
also allow oil to leak out, which affects the
forks performance.
Cleaning also gives you the opportunity
to examine the forks for cracks and defects.
You can also look for tell-tale signs of seal
wear, such as the absence of a dirt ring on
the stanchions after a rideyou should see
this ring after every ride.
Another one of your regular jobs is to
check the forks settings. You can set the
speed at which some forks work, along with
other features. You need to check these
settings have not been reset after a tough
ride or after cleaning.
Do not use pressure hoses to clean
suspension forks, since they can force water
into the inner workings. You need to use
a much gentler method of cleaning this
part of your bike.
Remove mud and dirt with a dry, stiffbristled brush. Remove the front wheel if
there is a lot of mud on the fork, since it will
make the job easier.
STEP LOCATOR
1 2 3 4 5 6
spray
raying
ing de
degre
grease
aserr from
f
the top of
Again, start sp
thee fo
fork
rk and
an work
w
workk dow
downwa
nw rd
nwa
rd.
the lower
147
148
REAR SUSPENSION
The rear suspension absorbs the shock caused by a bump in
the ground or rough terrain. A shock absorber must be kept
clean and lubricated, and the bushings and frame mounts
checked regularly for damage and wear.
Rear shock
Absorbs the
force of a
bump
Bushing
Attaches shock to frame
Air valve
Controls air
pressure in the
sleeve
Rebound
adjuster
Changes speed
of rebound
Shaft
Runs into
shock body
Air sleeve
Contains
compressed air
Shock body
Contains the
damping device
Rear triangle
Transmits the
force of a
bump to the
rear shock
Rear wheel
Moves up
and down in
response to
bumps
149
150
Rear suspension
STEP
STE
P LOC
LOCATO
ATOR
R
1 2 3 4 5
Shock body
Air sleeve
Air valve
Toolbox
Rebound
adjuster
Rear suspension
Sit on the bike
and ask someone to
measure this distance again.
Cross-country racers
tend to want stiffer shocks,
so they sometimes go for a
quarter or less.
151
152
GLOSSARY
Glo
ossary
Terms in italic within an entry
are deffined under their own
he din
hea
ngs
g within the glossary.
ALL
AL
L EN
N BOLT A threaded bolt
w h a hexagonal depression
wit
in the center of its head.
ALLEN KEY
AL
K
Hexagonal
a tool
th t fits
tha
ts Allen bolts.
BEA
ARIN
NG A mechanism that
usu
uallyy consists of a number
of ball bearings and circular
channe
nnels, or races. It allows
t metal
two
me surfaces to move
freely
ly while in contact.
B CK
BLO
K Cogs fitted to a
freewheeel.
fre
BOSS Thrread
e ed metal fixture
on
n a bicy
cycle frame to which
an
n ite
item such as a bottle cage
or a pannier rack is attached.
BO
OTTTOM BRACKET Rotating
unitt that connects the
uni
cran
nkarms.
BO
OTTO
TOM OUT A term that
desccribes the point when
a su
uspension fork or shock
ab
bso
orber reaches the limit
off its
ts travel.
BRAKEKE-LEV
L ER HOOD The
body in
n which the brake
lever
lev
e sit
sitss, con
connec
nectin
i g it
in
i to
the handl
handl
nd eba
b r.
BRA
RA
AKE TRAVEL The
T dista
distance
nce
a brak
rakee leve
everr move
o s befo
befo
f re
r
the brake
ke pads
pads engage the
braking surface on the rim
or hub off a wheel.
CABLE CRI
RIMP
MP A small metal
cylinder tha
t t iss closed at one
end an
nd fitss ov
over
er the
h cut ends
of a cabl
b e to prevvent ffrayi
aying.
g.
CASSETTE A collectio
ion of
cog
gs that fit on the rear
wheeelss freehub.
f
Glossary
GEA
EAR-S
R HIFT LEVER The
con
ntro
tr l mechanism,
m usu
usuall
allyy
on th
he handlebar, used to
initiaate gear-shifts.
QUICK-RELEASE MECHANISM
QUICK
A lever connected to a skew
skewer
er
that locks or releases a
component from the frame.
GR
RUB SCREW A headless,
threa
thr
eaded bolt that has a
singl
sin
gle dia
diamete
ter throughout
ut
its leength.
TOP
OP TUBE The frame tube
tha
th
h t joins the seat tube to
the head tube.
HEA
EADSE
D T The bearing unit
that attaches the forks to a
frame and allows them to
turn. There are two varieties:
threaded and threadless.
HEAD TUBE The frame tube
through which the
he steerer
tube runs.
HEXAGONAL BOLT OR NUT
A threaded bolt with a
hexagonal head, or a
hexagonal nut that fits
onto a threaded bolt.
HYDRAULIC A type off
me han
mec
nica
ic l system tha
hatt uses
co pressed flui
com
luid
d to
t move
ov
an
n ob
object.
LOCKRING/LOCKNUT A ring
LO
or nut used to tighten onto
a threaded object and lock
it in place.
NEGATIVE SPRING A device
that works against the main
n
spring in a suspension
syystem. In compression, forr
example, a negative spring
ex
works to extend the fork,
helping to overcome the
effects of stiction.
NIP
PPLE
P
PL
The piece of metal
attac
ached to the end of a
cablle that secures the cab
ble
in the
th control lever.
PLA
AY A term describing an
any
looseness in mechanical
al parts.
SEA
EATT POST
ST A hollow tub
u e
tha
haat holds the saddle
dle and
d iis
inserted in
nto
o the
he sea
seat tube.
SE
SEA
E T STAY The
Th frame
frame tube
joining
g the
th bot
bottom
om bracket
shell and
an reear dro
r pou
poutt.
SEA
EAT TUBE
UBE The frrame
me tube
tha
hatt holds
h
the sea
seatt post
post.
t
SID
SIDEWALL
L Part of thee tire
betwee
een the tread an
nd rrim.
S ERER TUBE
STE
UBE The
Th
he tu
tube
be tha
that
connectss the fork to the ste
tem
and haandl
nd eba
eb r.r
STE
TEM The compo
mponen
nentt that
nen
that
connec
ne ts thee ha
handl
nd eba
barr to
to
the
he ste
steerer tube.
STICTION A term
m that
combines
es the wo
ords stat
atic
at
and friction. Itt describ
bes the
he
tension between
n movin
ng and
and
st tic
sta
i parts at rest,
ree such
ch
h as
t seals and
the
d staanchions
ns in
a sus
uspen
pe sion fo
ork.
STOPPER
R PIN Th
he end of a
cantilever or V-br
-brake return
spring that fitss into a
locating hole on the
h bik
bikes
es
brake-mountiing bosses.
SUS
S
U PENSION An air//o
/oil or
c l/oil system
coi
m that abs
a orbs
the
h bumps frrom a trail or
road. The sys
ystem
s
is either
integrated into thee fork or
connected to thee rear
r
wheel
via a linkag
ge.
TRAVEL
TRA
VEL A term that refers
to the
th ttotal distance a
com
mponent moves in carrying
out its purpose. For example,
ou
traavel in a suspension fork is
the total distance the fork
has available to move in
order to absorb a shock.
Brake
Bra
ke tra
travel
vel is the distance
ab
brake leveer must be pulled
beffore
or the brak
rakes
es fully
contac
actt the
h braking
g surf
surface
ace.
TREAD Th
he centrral par
pa t off a
tire that makes conta
tact witth
the groun
nd.
VIS
V
SCOS
OSITY A rating system fo
or
oils, which also refers to the
weight
wei
ght. A lig
ght oil has low
viscosity and
d moves more
q ckl
qui
ck y than a heavy oil
thr
h oug
ough
hag
giiven
en dam
dampin
pingg
mechan
mec
hanism
han
ism.. This
ism
hi re
results in a
faster
fas
ter-ac
ter
actin
ac
ti g susspen
pensio
s n
system
sys
tem or
o reduc
duced
duc
e dampin
p ng.
WH EL
WHE
EL JIG A stan
stan
and
d that h
holds
a whee
eeel so that
at it
itss rim
rim run
runs
betwee
be
bet
w n two
t o jaw
jaws. Use
ja
Used in
truing a w
whe
h el aft
af er
e replaccing
g
a broken spo
oke.
e
153
154
INDEX
Index
A
adult's bike, setting up 1819
air sleeve 149, 150
air valve 13, 104, 144, 149, 150
air-damping 141
air/oil fork 139, 1445, 146
Allen bolt/wrench 13, 256, 152
antiseize compound 13
axle
cartridge-bearing bottom
bracket 703
hollow-axle bottom bracket
701, 745
hub quick-release mechanism
98, 99
nut 102, 134
open-bearing hub 989,
1001
pedal 13, 17, 18, 78, 801
B
band-on derailleur 52
bar end 94
barrel, chain 63
barrel adjuster
brake 111, 114, 119, 122, 129,
1345
gear-shifter 48, 60
rear derailleur 12, 54
basic bike 1011, 1415
bearing 152
BMX bottom bracket 17, 70,
767
cartridge-bearing bottom
703
gear hub 6
headset 889, 93
hollow-axle bottom 701,
745
hub 98100
lubrication 30
pedal 78, 80
Index
45, 467
hood 45, 96, 112, 152
hub-mounted brake 125
hydraulic 125, 127
nipple 111, 112, 114, 122
piston 1245
position/reach adjustment 18,
19, 114
rim brake 11011
side-pull caliper brake 122
straight handlebar 94, 114
brake pad 12, 15, 16, 17
cable disc brake 124, 1267
caliper brake 11617, 1223
cantilever brake 120
coaster brake 124
hub-mounted brake 124
hydraulic disc brake 124
maintenance 32, 34, 1267
rim brake 11011
roller brake 124
side-pull caliper brake 1223
troubleshooting 367
V-brake 11819
braze-on derailleur 52
bunnyhopping 138
bushing 149, 150
C
cable, see brake cable; gear
cable
cable disc brake 124, 1267,
128
cable-clamp 44, 50, 53, 54
bolt 110, 120, 122, 128, 134
cable-guide tube 12, 110
caliper brake 17, 102, 114
adjusting 11617
brake lever 116
cable 110
cable disc brake 126
hydraulic disc brake 124, 125,
128
quick-release mechanism 117
side-pull 1223
Campagnolo
caliper brake 117
gear-shifter 45, 96
wheel hub 100
cantilever brake 102, 110, 1223
adjusting 1201
cable 110, 114, 1201
carbon fibre, and lubrication 31,
131
carrier unit 56
cartridge-bearing bottom
bracket 703
cassette 152
cleaning 28, 289
lockring 62
maintenance 17
profile 62
removal 667
replacement 17
tools 25, 29, 66
working of 623, 66
chain
barrel 63
cleaning 289
derailleur 645
gear-shifter and 44, 501
joining pin 63, 64
links 63, 64
lubrication 15, 29, 30, 41
measuring device 25, 64
replacement 15, 645
safety checks 33
servicing 345
Shimano 645
split-link 645
troubleshooting 367
wear estimation 64
weatherproofing 41
whip 25
working of 44, 623
chainring 13, 15, 51, 62, 63, 68,
76, 152
cleaning 28
danger signs 38
removal 69
servicing 345
D
damping
disc brake 152
fork 138, 139, 140, 1445
danger signs 26, 389
see also safety checks
155
156
INDEX
degreasing 289, 30
derailleur 40, 153
adjustment 50, 51, 525
band-on 52
barrel adjuster 12
braze-on 52
cage 51, 52
cleaning 289, 52, 54
front, see front derailleur
jockey wheel 12, 30, 345,
44, 501, 545, 62
lubrication 29, 30, 41, 501,
54, 78
maintenance 52
plate 12, 50, 51
rear, see rear derailleur
safety checks 33
servicing 345
troubleshooting 367
weatherproofing 41
working of 10, 12, 445, 501
derailleur gear 62, 645, 98, 152
maintenance 15, 17
disc brake 10, 11, 34
cable 124, 1267, 128
damping 152
hydraulic, see hydraulic disc
brake
lubrication 128
maintenance 1289
rotor 126, 1289
driver unit, hub gear 56
drivetrain 10, 13, 152
see also chain; chainring;
crankset; pedal; sprocket
drop handlebar 16, 17, 967
brake cable 11213, 1201
brake lever 96, 112
gear cable 467
drop-out 12, 102, 140, 142, 144,
152
drum brake, see roller brake
Dual Control gear-shifter,
Shimano 49
F
flange, hub 62, 98, 100
flat pedal 11, 78
folding bike 1415, 15
foot retention mechanism 13,
78, 823
see also pedal cleat
fork
air/oil 139, 1445, 146
brace 139, 140, 142, 144
cleaning 1467
coil/oil 141, 1423
compression 138, 139, 152
crown 13, 88, 139, 140,
1423, 144
damping 1389, 140, 1445
drop-out 140, 142, 144, 152
headsets 88, 89
leg 13, 142
lockout 141
lubrication 345, 1445, 146
maintenance 1467
pistons 139
sag setting 1403, 145
seal 139
servicing 345
Shrader air valve 1445
slider 13, 139, 140, 142, 144
spring 138, 142, 144
stanchions 139, 140, 142, 144
troubleshooting 367
working of 11, 138
frame 10
aluminum 33
anatomy 12
carbon-fiber 31, 33
chainstay 12
metal fatigue 323
protector pads 17
safety checks 323, 150
seat stay and tube 12
steel 16
freehub 100, 152
freewheel 152
removal 667
working of 66, 98
front derailleur 41, 44, 501
adjustment 523
outer arm 51
front suspension, see fork
front wheel
hub 98, 99, 100
removal 103
G
gear 152
adjustment 601
control 445
danger signs 39
derailleur 15, 62, 64
hub 5661
lubrication 15, 34
ring 56
safety checks 33
satellite 56, 58
servicing 345
Shimano Nexus hub 56, 589
SRAM 58
Sturmey Archer 58, 60
working of 56, 58
gear cable 445, 50, 589
cutting outer 26
danger signs 39
drop handlebar 467
lubrication 301, 467, 48
maintenance 15, 34
split or frayed 34, 39
straight handlebar 489
gear-shifter 11, 13
barrel adjuster 48, 60
Campagnolo 45, 96
combined brake lever 45
drop handlebar 467
maintenance 445, 60
Shimano 469
SRAM 469
working of 445, 501
grease
applying 301
removing 289, 30
Index
HIJ
hairspray on grips 95
handlebar 13, 94, 96
adjustment 201, 923
drop, see drop handlebar
maintenance 345
replacement 947
riser bars 94, 114
safety checks 32
stem 13, 88, 89, 92, 153
straight, see straight
handlebar
tape 967
headset 17, 347, 153
adjustment 901
bearing 889, 93
cleaning 901
fork connection 88, 89
lubrication 30, 90, 923
sealing 40
threaded 89, 923
threadless 88, 901
working of 889, 90, 92
high and low adjuster, derailleur
50, 51, 523, 55
hollow-axle crank cap and cup
tools 25
hose, brake 1245, 130
hub
axle quick-release 98, 99
flange 62, 98, 100
lockring 99, 100
open-bearing 989, 1001
rear 12, 98, 100
hub-mounted brake
cable 1245, 126, 128, 130
see also cable disc brake;
coaster brake; hydraulic disc
brake; roller brake
KLM
knurled retainer 78, 80, 81
lever, see brake lever;
gear-shifter
lockring/locknut 12, 153
bottom bracket 70, 76
cartridge hub 100
cassette 62
flat pedal 78
headset 92
hub 99, 100
Look road pedal 82
low and high adjuster, derailleur
50, 51, 523, 55
lubrication 17
applying 301
bearing 30
brake cable 301, 345,
11215
cable 301, 345, 467, 48,
59, 11215
and carbon fiber 31
chain 15, 29, 30, 41
derailleur 29, 30, 41, 501,
54, 78
dry lube 30
fork 345, 1445, 146
gear cable 301, 467, 48
headset 30, 90, 923
NOP
negative spring 144, 153
Nexus hub gear, Shimano 589
nipple 153
brake lever 111, 112, 114, 122
pear 112, 122
spoke 106Octalink bottom
bracket axle 72
off-road pedal 83, 845
oil, see lubrication
outer arm, front derailleur 51
pear nipple 112, 122
pedal 10, 40
axle 13, 17, 18, 78, 801
bearing 78, 80
cleaning 41, 823
cleat 78, 82, 83, 845, 152
cleat-release mechanism 80,
82, 83
clipless 11, 41, 78, 823,
845, 152
crank 701, 78, 80
Crank Brothers 83
flat 11, 78
foot retention mechanism 13
157
158
INDEX
QR
quick-release mechanism 153
caliper brake 117
hub axle 98, 99
wheel 12, 1023
quill 89, 92
race 70, 90, 92
race level road bike 1617, 17
Rapidfire gear-shifter 49
reach adjustment 18, 19, 114
rear hub 12, 98, 100
rear derailleur 12, 15, 501, 62
adjusting 545
barrel adjuster 12, 54
cable 445
lubrication 30, 41
rear suspension 17
compression 1489
pro-pedal adjuster 150
sag adjustment 1501
rear wheel removal 1023
rebound 138, 139, 148, 153
adjuster 149, 150
see also suspension
release mechanism
pedal 80, 82, 83
quick-release, see quickrelease mechanism
retainer, knurled 78, 80, 81
retention mechanism
pedal 13, 78, 823
riding position
adult 1819
child 201
rim 13, 39, 104
straightening 1067
see also tire; wheel
rim brake 11, 39, 102
drop handlebar 11213
straight handlebar 11415
working of 11011
see also caliper brake;
cantilever brake; U-brake;
V-brake
ring clamp 48
ring gear 56
riser bars 94, 114
road bike 16, 17
drop handlebar gear cable
11213
road pedal 82
roller bearing, see bearing
roller brake 124
brake arm 134
cable replacement 1345
rotor cleaner 129
S
saddle 12
adjustment, adult 1819
adjustment, child 201
Index
spring
brake 110, 124
fork 138, 142, 144
negative 144, 153
plate 50, 51
shock absorber 148, 149
see also suspension
sprocket 12, 38, 51, 56, 62, 66,
153
square-tapered bottom bracket
723
SRAM gear-shifter 469
stanchions, fork 139, 140, 142,
144
star washer 88
steering
headset, see headset
safety checks 32
servicing 345
steerer 13, 89, 140, 142, 144
steerer tube 13, 88, 153
troubleshooting 367
see also handlebar
stem, handlebar 13, 88, 89, 92,
153
stiction 144, 153
straddle clamp 122
straddle and straddle wire 1201
straight handlebar
brake cable 11415
fitting 945
gear cable 489
Sturmey Archer, 3-speed gear
58, 60
suspension 11, 16, 17, 153
compression 1389, 148, 152
damping, see damping
fork, see fork
lubrication 17, 34
mountain bike 16, 17
negative spring 144, 153
rear 14851
rear, see rear suspension
rebound, see rebound
sag 1401, 1501
servicing 345
T
tape, handlebar 967
3-piece crankset 10, 767
Time pedals 82, 83
timetable, servicing 345
toe-in brake 120
tools and workshop 247
torque gauge 24
transmission, see cable; chain;
derailleur; shifters
travel 153
tread 153
wear 15, 39
troubleshooting 367
danger signs 389
troubleshooting chart 367
truing, wheel 1067
tire 10, 11, 17
bead 13
bulge 33, 39
danger signs 389
inner tube 13, 1045
pressure 33
puncture repair 1045
puncture resistance 11
replacing 105
safety checks 33, 102
sidewall 153
split 39
tread, see tread
wear signs 15, 102
UV
U-brake 1223
utility bike 1415
V-brake 102, 110, 120
adjusting 11819
cable 102, 110, 11415, 118
cable replacement 11415
valve
fork, air/oil 1445
tire 13, 104
vice, bench 25
viscosity, lubrication 153
W
washing and degreasing 289,
30
wedge 88, 89
wet weather 401, 114
best brakes for 1245
wheel 10, 13
carbon rims 16
cassette, see cassette
child's bike sizes 20
cleaning 289
danger signs 389
derailleur, see derailleur
jig 106, 153
levers, quick-release 33, 34
lubrication 30
mudguard 40, 41
quick-release 12, 1023
removal 1023
rim straightening 1067
safety checks 323
servicing 345
size 20
spoke, see spoke
troubleshooting 367
truing 1067
wheel hub 12, 13, 128
Campagnolo 100
cartridge 98
freewheel, see freewheel
front 98, 99, 100
lubrication 101
maintenance 1001
open-bearing 989, 1001
rear 12, 98, 100
Shimano 1001
working of 989, 100
workshop principles 267
workstand 25
159
160
ACKNOWLEDGMENTS
Acknowledgments
Authors
acknowledgments
Publishers
acknowledgments
Picture credits
The publisher would like to
thank the following for their
kind permission to reproduce
their photographs:
567: Stockfile/Steve Behr;
150: Fox Racing Shox.
All other images DK Images.
For further information see
www.dkimages.com
PLEASE NOTE
Bicycle maintenance is potentially hazardous. While the information in
this book has been prepared with the readers personal safety in mind, the reader may help to
reduce the inherent risks involved by following these instructions precisely. The scope of this
book allows for some, but not all, the potential hazards and risks to be explained to the reader.
Therefore, the reader is advised to adopt a careful and cautious approach when following the
instructions, and if in any doubt, to refer to a good bike shop or specialist.