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Bontrager 231793 manual

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Table of contents for the manual

  • Page 1

    HUB INSTRUCTIONS PART NUMBER 231793 SERVICE MANUAL 2003[...]

  • Page 2

    1 2003 Bontrager Service Manual HUB INSTRUCTIONS STANDARD Front Hubs Loose ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Loose ball, semi-cartridge; Formula FCM . . . . . . .4-5 Cartridge bearing, alloy axle . . . . . . . . . . . . . . . . .6-7 Cartridge bearing, threaded alloy axle . . . . . . . . . . 8-9 Rear hubs Free[...]

  • Page 3

    2 2003 Bontrager Service Manual Recommended tools 13mm cone wrench 17mm cone wrench Small slot screwdriver Hammer (soft faced) DISASSEMBLY Hu b p ar ts an d n am es ar e re fe re nc ed on ne xt pa ge . Remove the axle 1. Remove external seals (Fig. 2A) with a screwdriver. Be careful not to tear or mar the rubber. 2. On one side (either) of the hub [...]

  • Page 4

    3 2003 Bontrager Service Manual 1 2 3 Exploded view and Parts list 4 5 6 7 8 9 1 2 3 4 5 6 7 Pos Description 1 Ext e r n al s e al 2 End nut 3 Washer 4 Ball cone 5 Shell shield 6 Bal l b ea r i n gs 7 Ball cup 8 Hub shell 9 Axle Description Model year Model for Parts included (qty) TCG Part # Axle set 99/00/01/02 all 1(2), 4(2), 3(2), 9 68257 Lockn[...]

  • Page 5

    Recommended tools 13mm cone wrench 17mm cone wrench Adjustable wrench Hammer (soft faced) Small slot screwdriver DISASSEMBLY Hu b p ar ts an d n am es ar e re fe re nc ed on ne xt pa ge . Remove the axle 1. Remove external seals (Fig. 2B) with a screwdriver. Be careful not to tear or mar the rubber. 2. On one side of the hub (usually left), the con[...]

  • Page 6

    5 2003 Bontrager Service Manual 1 2 3 Exploded view and Parts list 4 5 6 7 8 9 1 2 3 11 5 6 7 10 8 12 1999 Race O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24° Spoke hole P.C.D. . . . . . .[...]

  • Page 7

    6 2003 Bontrager Service Manual Recommended tools 17mm cone wrench Special hook spanner Hammer and broad punch Bearing removal tool Bearing press DISASSEMBLY Hu b p ar ts an d n am es ar e re fe re nc ed on ne xt pa ge . Remove the axle 1. Remove axle end caps (Fig. 2C) by sliding them out of the axle with your fingers. 2. Hold the axle with a 17mm[...]

  • Page 8

    7 2003 Bontrager Service Manual Exploded view and Parts list 2002 Race O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24° Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 9

    2003 Bontrager Service Manual 2003 Bontrager Service Manual Recommended tools 17mm cone wrench (2) Hammer and broad punch Bearing press DISASSEMBLY Hu b p ar ts an d n am es ar e re fer en ce d o n ne xt p ag e. Remove the axle 1. Remove one of the thread- ed axle end caps (Fig. 2H) by loosening with the pair of 17mm cone wrenches. 2. With one end [...]

  • Page 10

    2003 Bontrager Service Manual 2003 Bontrager Service Manual Exploded view and Parts list 2002/2003 Race Lite Road O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20° Spoke hole P.C.D. . . . . .[...]

  • Page 11

    11 2003 Bontrager Service Manual FREEHUB BODY RUNNING CHANGE Bontrager rear hubs use an unique freehub body that in some cases has encountered removal issues. In these cases, a high amount of torque is necessary to remove or install the freehub body attachment bolt. To resolve this problem a running change was made to the 2001 product line. The old[...]

  • Page 12

    12 2003 Bontrager Service Manual Recommended tools (2) 15mm cone wrench Adjustable wrench Hammer (soft faced) Small slot screwdriver DISASSEMBLY Hu b p ar ts an d n am es ar e re fer en ce d o n ne xt p ag e. Remove the axle 1. Remove external seals with your fingers or a screw- driver (Fig. 2D). Be careful not to tear or mar the rubber. 2. On the [...]

  • Page 13

    13 2003 Bontrager Service Manual Exploded view and Parts list 1999 Bontrager Comp II O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32° Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . [...]

  • Page 14

    Recommended tools (2) 15mm cone wrench 12mm allen wrench Adjustable wrench Hammer Small slot screwdriver DISASSEMBLY Hu b p ar ts an d n am es ar e re fer en ce d o n ne xt p ag e. Remove the axle 1. Remove external seals (Fig. 2E) with your fingers or a screwdriver. Be careful not to tear or mar the rubber. 2. On the left side (non-drive) of the h[...]

  • Page 15

    15 2003 Bontrager Service Manual Exploded view and Parts list 2000 Race O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28° Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 16

    16 2003 Bontrager Service Manual Recommended tools 15mm cone wrench 19mm cone wrench Small slot screwdriver Hammer (soft faced) Cartridge bearing remover Bearing press DISASSEMBLY Hu b p ar ts an d n am es ar e re fer en ce d o n ne xt p ag e. 1. Hold the left side (non- drive) axle spacer with a 19mm cone wrench and loosen the end nut (Fig. 2F) wi[...]

  • Page 17

    17 2003 Bontrager Service Manual Exploded view and Parts list 2002/2003 Race O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28° Cassette body type . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 18

    Im po rt an t i nfo rm at io n b efo re you be gin wi th C om p se ri es h ub s Some Bontrager front hubs utilize DT Swiss internal parts. This manual is intended for retailers with the appropriate skills and knowledge to work on these hubs. Please read the entire section before carrying out any kind of maintenance work. This manual details the pri[...]

  • Page 19

    20 2003 Bontrager Service Manual Recommended tools Comp bearing press, front hub Short bearing press 17mm cone wrench Multi-purpose grease Bench vise Axle vise Hammer, soft faced Thin-bladed slot screwdriver DISASSEMBLY Hu b p ar ts an d n am es ar e re fer en ce d o n ne xt p ag e. Disassemble the hub 1. Tap the axle (either end) with the hammer u[...]

  • Page 20

    21 2003 Bontrager Service Manual Exploded view and Parts list Description Model year Model for Parts included (qty) T CG Pa rt # Axle kit 99/00/01 All 1(2), 2(2), 3(2), 4 70361 Bearing 99/00/01 All 3 211349 Pos Description 1 End cap 2 V-seal 3 Bearing 4 Axle 5 Hub shell 1 1 2 2 3 3 4 5[...]

  • Page 21

    22 2003 Bontrager Service Manual Recommended tools Long bearing press Short bearing press 17mm cone wrench Multi-purpose grease Bench vise Axle vise Hammer, soft faced Thin-bladed slot screwdriver DISASSEMBLY Hu b p ar ts an d n am es ar e re fer en ce d o n ne xt p ag e. 1. Place the axle vise in the bench vise and clamp the left- hand end of the [...]

  • Page 22

    23 2003 Bontrager Service Manual 10. Place the wheel with the left end of the axle in the axle vise and tighten the right end nut to 150 lb•in (17Nm). 11. Turn the wheel over and clamp the right end nut in the vise. 12. Grease the bearing. 13. Clean and lightly grease the left end nut and end seal. Replace the end seal on the end nut with the lip[...]

  • Page 23

    24 2003 Bontrager Service Manual Description Model year Model for Parts included (qty) T CG Pa rt # Freehub kit 2000/01 all 7(2), 8, 12, 13, 14 70358 (Shimano) Driver kit 2000/01 all 5, 6, 10 72678 Axle set 2002/03 Race Lite Road 1, 2, 3, 4, 15 , 1 6, 17 70359 (130 O.L.D.) Axle 2000/01 Race Mod 1, 2, 3, 4, 15 , 1 6, 17 70360 ( 1 3 5 O .L .D .) 2 00[...]

  • Page 24

    25 2003 Bontrager Service Manual Important information before you begin with Pro series hubs Some Bontrager hubs utilize DT Swiss internal parts. This manual is intended for retailers with the appropriate skills and knowledge to work on these hubs. Please read the entire section before carrying out any kind of mainte- nance work. This manual detail[...]

  • Page 25

    26 2003 Bontrager Service Manual Pro front hub 2002 Bontrager Race Lite ATB, Race Lite 29, Race X Lite and Race X Lite Carbon front wheels, 2003 Race X Lite Aero Recommended tools Long bearing press Short bearing press Multi-purpose grease Bench vise Axle vise Hammer, soft faced DISASSEMBLY 1. Loosen both end caps by rotating them in opposite direc[...]

  • Page 26

    27 2003 Bontrager Service Manual Exploded view and Parts list Pos Description 1 End nut 2 V-seal 3 Bearing 4 Axle 5 Hub shell 1 2 3 5 3 1 4 2 Description Model year Model for Parts included (qty) T CG Pa rt # Axle kit 00/01/02/03 all 1(2), 2(2), 3(2), 4 70357 V-seal 00/01/02/03 all 2 211342 Bearing 00/01/02/03 all 3(6802, 15/24 x 5mm) 211344 End ca[...]

  • Page 27

    28 2003 Bontrager Service Manual Recommended tools Long bearing press Short bearing press 17mm cone wrench Multi-purpose grease Bench vise Axle vise Hammer, soft faced Thin-bladed slot screwdriver DISASSEMBLY Hu b p ar ts an d n am es ar e re fer en ce d o n ne xt p ag e. Disassemble the freehub 1. Place the axle vise in the bench vise and clamp th[...]

  • Page 28

    29 5. Carefully clean the star ratchets with a dry cloth. Inspect both star ratchets for damage. If any damage is visible, replace the ratchet. 5. Lightly grease both star ratchets with DT Swiss special grease (only). 6. Place the spacer ring into the freehub body. Place the spring into the freehub body with the large diameter end in contact with t[...]

  • Page 29

    2003 Bontrager Service Manual 30 2003 Bontrager Service Manual Description Model year Model for Parts included (qty) T CG Pa rt # Freehub kit 02/03 all 8, 9(2), 10(2), 11 70354 (Shimano) Freehub kit 02/03 all 8, 9(2), 10(2), 11 211579 (Campagnolo) Star ratchet 02/03 all 9(2), 10(2) 211343 and spring kit Axle kit 02/03 all road 1, 2, 3(2), 4, 13 703[...]

  • Page 30

    2003 Bontrager Service Manual Exploded view and Parts list- 2000-2001 Pos Description 1 End cap 2 V-seal 3 Bearing 4 Axle 6 Freehub seal 7 Bearing 8 Spacer 9 Sp r in g 10 Star ratchet 11 Washer 12 Fre eh ub bo dy 13 E n d n u t , r i gh t 14 Hub shell 1 2 3 14 6 7 8 9 4 10 10 11 12 13 Description Model year Model for Parts included (qty) T CG Pa rt[...]