HUB INSTRUCTIONS
PART NUMBER 231793
SERVICE MANUAL 2003
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Front hubs- Loose ball
Bontrager Superstock, Superstock Disc, Select ATB, Select ATB Disc, Select Road, and Select Hybrid front wheels;
plus Bontrager Comp II front hub
Recommended tools
ASSEMBLY
Shell shield
13mm cone wrench
1. Place eleven 3/16” balls in
the ball cup on one side of the hub.
17mm cone wrench
Small slot screwdriver
Hammer (soft faced)
2. Place the shell shield, with
its sharp edges facing out (Fig.
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
6A), into the hub. The shell shield
is a press fit, so must be tapped
lightly to fully seat. Lay a cone
wrench over the shell shield and
tap the wrench with a hammer
(Fig. 7A) to protect the shield
and ensure that it is flush with
the shell.
1. Remove external seals
(Fig. 2A) with a screwdriver. Be
careful not to tear or mar the
rubber.
Fig. 1A
External seal
Fig. 5A
Bearings in bearing cup
2. On one side (either) of the
hub place a 13mm cone wrench
on the ball cone. Place a 17mm
cone wrench on the end nut (Fig.
3A). Loosen the end nut.
3. Repeat Assembly steps 1-2
for the other side of the hub.
4. Tighten the end nut
against the ball cone on the axle.
Hold the ball cone with a 13mm
cone wrench on the axle flats
while turning the end nut with a
17mm cone wrench.
3. Remove the end nut,
washer, and ball cone from the
axle (Fig. 4A).
Fig. 6A
Fig. 2A
4. Slide the axle, with the
other end nut, washer, and ball
cone still attached, out of the
hub (Fig. 4A).
5. Insert the axle through the
hub from either side.
6. Thread the ball cone, wash-
er, and end nut onto the axle in
that order. The serrated surface
of the end nut faces out.
5. Gently insert a thin
screwdriver blade under the
shell shield (Fig. 5A) and lift to
remove the shield from the hub.
Pry off the shell shields from
both sides of the hub.
7. Hold the ball cone with a
13mm cone wrench and tighten
the end nut with a 17mm cone
wrench.
Fig. 3A
Fig. 7A
6. If inspection
shows it necessary,
remove the other end
nut and ball cone.
8. Check the bearing adjust-
ment by turning the axle with
your fingers. The axle should
spin smoothly without binding or
feeling gritty. There should be no
lateral play of the axle in the hub.
Readjust the hub as necessary,
and re-lock the end nut.
Axle
End nut
9. Install the external seals,
and apply grease where the seals
contact the hub shell and axle
parts. Make sure the seals prop-
Washer
Seal not seated
Ball cone
Fig. 8A
erly seal against both the end nut and the hub shell. There
should be a smooth transition from seal to sealing surface.
An improperly installed seal (Fig. 8A) will allow rapid con-
Fig. 4A
tamination of the bearings.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It
should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is
eliminated when the wheel is installed with the quick release properly closed.
Clean and inspect the parts
1. Use solvent to completely remove all old grease and
debris from the hub, axle, and axle parts.
2. Inspect the bearing running surfaces of both the
ball cones and the ball cups (inside the hub). Replace any
cones. If the cups are worn, replace the hub shell.
Lubricate bearings and threads
1. Lubricate the threads on the axle with Wrench
Force™ synthetic grease, or a similar product.
2. Place a bead of grease all the way around each ball
cup, sufficient to hold the balls.
2
2003 Bontrager Service Manual
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Exploded view and Parts list
9
1
2
4
3
5
7
6
8
7
6
5
4
3
1
2
Pos Description
Description
Axle set
Locknut set
Model year Model for
99/00/01/02 all
99/00/01/02 all
Parts included (qty)
1(2), 4(2), 3(2), 9
2(2)
TCG Part #
68257
1
2
3
4
5
6
7
8
9
External seal
End nut
Washer
Ball cone
Shell shield
Ball bearings
Ball cup
Hub shell
Axle
68543
1999 Bontrager Comp II
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm
2000/2001/2002/2003 Superstock
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Superstock Disc, Select ATB Disc
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
2002/2003 Select ATB
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Select Road, Hybrid
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
3
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Front hubs- Loose ball, semi-cartridge; Formula FCM
'99, 2000, 2001 Bontrager Race, Race Disk front wheels
Recommended tools
13mm cone wrench
Lubricate bearings and threads
Bearing seal
1. Lubricate the threads on
the axle with Wrench Force™ syn-
thetic grease, or a similar product.
17mm cone wrench
Adjustable wrench
Hammer (soft faced)
Small slot screwdriver
2. Place a bead of grease all
the way around each ball cup,
sufficient to hold the balls.
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
ASSEMBLY
Fig. 1B
Fig. 6B
1. Place eleven 3/16” balls in
the ball cup on one side of the
hub (Fig. 8B).
1. Remove external seals
(Fig. 2B) with a screwdriver. Be
careful not to tear or mar the
rubber.
External seal
2. Place the bearing seal,
with the lettered side facing out,
into the ball cup.
2. On one side of the hub
(usually left), the cone is locked
against a collar on the axle (Fig.
4B). On the other side, place a
13mm cone wrench on the ball
cone. Place a 17mm cone wrench
on the end nut (Fig. 3B). Loosen
the end nut.
3. Place the shell shield, with
its sharp edges facing out, into
the hub. The shell shield is a press
fit, so must be tapped lightly to
fully seat. Lay a cone wrench
over the shell shield and tap the
wrench with a hammer (Fig. 9B)
to protect the shield and ensure
that it is flush with the shell.
Fig. 2B
Fig. 7B
Fig. 8B
Fig. 9B
3. Remove the end nut, wash-
er, and ball cone from the axle
(Fig. 4B).
Bearings in ball cup
4. Repeat Assembly steps 1-3
for the other side of the hub.
4. Slide the axle, with the
other end nut, washer, and ball
cone still attached, out of the hub.
5. Tighten the end nut
against the fixed ball cone
(attached to axle). Hold the axle
with an adjustable wrench on the
axle flats while turning the end
nut with a 17mm cone wrench.
6. Gently insert a thin
screwdriver blade between the
shell shield (Fig. 5B) and bear-
ing seal (Fig. 6B). Pry off the
shell shields from
Fig. 3B
Axle
Collar
both sides of the hub.
Do not attempt to pry
off both shield and
seal at the same time
as you may damage
6. Insert the axle through the
hub from either side.
7. Thread the ball cone, wash-
er, and end nut onto the axle in
that order. The serrated surface
of the end nut faces out.
the bearing seal.
7. Gently pry off
the bearing seals (Fig.
8. Hold the ball cone with a
13mm cone wrench and tighten
the end nut with a 17mm cone
wrench.
End nut
Washer
6B) from both sides of
the hub.
Ball cone
8. If inspection
shows it necessary,
remove the other end nut. Hold
the axle by the wrench flats
(Fig. 7B) while turning the end
nut with a 17mm cone wrench.
9. Check the bearing adjust-
ment by turning the axle with
your fingers. The axle should
spin smoothly without binding or
feeling gritty. There should be no
lateral play of the axle in the hub.
Readjust the hub as necessary,
and re-lock the end nut.
Fig. 4B
Shell shield
Clean and inspect the parts
10. Install the external seals.
Make sure the seals properly seal
against both the end nut and
the hub shell. There should be a
smooth transition from seal to sealing surface. An improp-
erly installed seal (Fig. 10B) will allow rapid contamina-
tion of the bearings.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It
should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is
eliminated when the wheel is installed with the quick release properly closed.
1. Use solvent to completely
remove all old grease and debris
from the hub, axle, and axle
parts.
Seal not seated
Fig. 10B
Fig. 5B
2. Inspect the bearing run-
ning surfaces of both the ball cones and the ball cups
(inside the hub). Replace any worn parts.
Note: If the ‘fixed’ ball cone is worn, the axle assembly (axle and ball cone) must be replaced.
4
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Exploded view and Parts list
1
2
10
3
4
5
6
7
8
9
8
7
6
5
12
11
3
2
1
Note:
Rotor adapter for disc hubs not shown
Rotor spacing varies by model year, see details below.
Pos Description
Description
Axle set
Locknut set
Rotor adapter 99/00
w/screws
Disc bolt set 99/00
Model year Model for
Parts included (qty)
10, 4, 2, 5(2), 11, 6(2), 3(2)
2(2)
TCG Part #
68524
68527
991083
1
2
3
4
5
6
7
8
9
External seal
End nut
Washer
Adjust cone
Shell shield
Bearing seal
Ball bearings
Ball cup
99/00/01
99/00/01
all
all
Hayes, RST
Not shown
all
Not shown
991153
Hub shell
10 Axle
11 Spacer
12 Ball cone
1999 Race
2001 Race Disk
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
1999/2000 Race Disk
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.0 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
2000/2001 Race
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
5
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Front hubs- Cartridge bearing, alloy axle
2002/2003 Bontrager Race, Race Disc front wheels
Recommended tools
17mm cone wrench
ASSEMBLY
1. Press a bearing into the
hub with a bearing press.
Note: the black seal faces out (Fig. 9C).
Special hook spanner
Axle
Hammer and broad punch
Bearing removal tool
Bearing press
2. Press the second bearing
with the bearing press.
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
3. Place the bearing seals
into the hub with the lettered
surface facing out.
Axle nut
Fig. 1C
Fig. 2C
Fig. 3C
Fig. 5C
6. Insert the axle through the
hub from either side.
1. Remove axle end caps
(Fig. 2C) by sliding them out of
the axle with your fingers.
7. Thread the axle nut onto
the axle.
End caps
2. Hold the axle with a
17mm cone wrench (Fig. 3C)
while loosening the axle nut
with the special hook spanner
(Fig. 4C).
8. Hold the axle with a 17mm
cone wrench and tighten the axle
nut with the special hook span-
ner until finger tight.
Do not over-tighten the axle nut. The axle should turn freely
with no lateral play in the hub shell.
3. Partially unthread the
axle nut (Fig. 5C) until it
slightly protrudes past the end
of the axle.
9. Press the axle end caps
into both ends of the axle.
After completing assembly of the hub, check its function by
spinning the axle with your fingers. It should rotate freely
without irregular friction. A small amount of lateral play
is acceptable if the play is eliminated when the wheel is
installed with the quick release properly closed.
Fig. 6C
4. Tap the axle nut with a
soft-faced hammer until the axle
slides through the opposite bear-
ing. Once loose, the axle should
come out with your fingers.
5. Remove the axle nut, and
extract the axle (Fig. 6C).
6. Gently insert a thin screw-
driver blade between the bearing
seal (Fig. 7C) and bearing. Pry
off the bearing seals from both
sides of the hub.
Fig. 7C
Bearing
seat
Axle nut
7. Insert a bearing removal
tool into the bearing. Place a
blunt punch through the hub
and against the bearing removal
tool. Tap the punch with the
hammer to drive the bearing out
of the hub (Fig. 8C). Repeat for
the other bearing.
Fig. 8C
Fig. 4C
Clean and inspect the parts
1. Wipe old grease or debris from the hub bearing
seats.
2. Normally, bearings are not re-used. If you are re-
installing an old bearing, wipe off any grease or debris
from both the inner and outer surfaces.
Do not use solvent on the bearing, as the solvent will
contaminate the grease. This may cause bearing failure.
Fig. 9C
Lubricate bearings and threads
1. Lubricate the threads on the axle with Wrench
Force™ synthetic grease, or a similar product.
2. Lightly grease the inner and outer surfaces of
each bearing.
6
2003 Bontrager Service Manual
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Exploded view and Parts list
1
3
2
4
6
5
4
3
1
Note:
Rotor adapter for disc hubs not shown
Rotor spacing varies by model year, see details below.
Description
Seal
Bearing
#6903
Axle set
Adjustable nut99/00/01
Model year Model for
Parts included (qty)
3(2)
4(2)
TCG Part #
68261
Pos Description
99/00/01
99/00/01
all
all
1
2
3
4
5
6
End cap
Adjustable nut
Seal
Bearing
Hub shell
Axle
68262
99/00/01
all
all
6, 4(2)
2
1(2)
68263
68264
211645
End cap,
20.5mm O..D.
99/00/01/02 all
Rotor adapter 99/00
w/screws
Disc bolt set 99/00
Hayes, RST
all
Not shown
991083
991153
68259
Not shown
Special
99/00/01/02 all
Not shown, see Fig. 4C
hook spanner
2002 Race
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002 Race Disk
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
7
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Needs photos and text
Front hubs- Cartridge bearing, threaded alloy axle
2002/2003 Bontrager Race Lite Road front wheels
Recommended tools
17mm cone wrench (2)
ASSEMBLY
1. Press a new bearing onto
the axle with a bearing press.
Note: the black seal faces out (Fig. 4H).
Hammer and broad punch
Bearing press
2. Place the hub seal onto the
axle, and thread on the axle end
cap. Clamp the middle of the axle
and tighten the axle end cap with
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
1. Remove one of the thread-
ed axle end caps (Fig. 2H) by
loosening with the pair of 17mm
cone wrenches.
the 17mm cone wrench.
Fig. 1H
Fig. 4H
3. Press the bearing, with the
axle attached, into the hub.
4. Press the second bearing into the hub.
Note: the black seal faces out (Fig. 4H).
2. With one end cap
removed, drive the axle from
the hub shell with a soft-faced
hammer.
5. Place the hub seal over the bearing, and press into
the hub shell.
6. Thread on the second axle end cap, and tighten with
the 17mm cone wrench.
Do not over-tighten the axle nut. The axle should turn freely with no lateral play in the hub shell.
3. Place a broad punch
through the hub, and tap the
punch with a hammer to drive
the second bearing (Fig. 3H),
with its seal, from the hub.
Fig. 2H
4. If needed, remove the
second bearing from the axle. To do this, clamp the
middle of the axle, loosen the end cap, and remove it.
Support the bearing and tap the axle out with a soft-
faced hammer.
Clean and inspect the parts
1. Wipe old grease or debris from the hub bearing
seats.
2. Normally, bearings are not re-used. If you are re-
installing an old bearing, wipe off any grease or debris
from both the inner and outer surfaces.
Do not use solvent on the bearing, as the solvent will
contaminate the grease. This may cause bearing failure.
Lubricate bearings and threads
1. Lubricate the threads on the axle with Wrench
Force™ synthetic grease, or a similar product.
2. Lightly grease the inner and outer surfaces of
each bearing.
Fig. 3H
8
2003 Bontrager Service Manual
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Exploded view and Parts list
1
3
2
5
4
3
2
1
Description
Seal
Model year Model for
Parts included (qty)
2(2)
3(2)
TCG Part #
221468
Pos Description
02
02
all
all
1
2
3
4
5
End nut
Seal
Bearing
Hub shell
Axle
Bearing
#6000
Axle set
End nut
Axle
73335
02
02
02
all
all
all
1(2), 2(2), 3(2), 5
1(2)
5
221470
221467
221469
2002/2003 Race Lite Road
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
9
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Freehub body information (non-DT Swiss)
FREEHUB BODY RUNNING CHANGE
INSTALLATION AND REMOVAL
If the freehub body is worn or damaged, replace it.
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.
Removing the freehub body
1. Follow the Disassembly
instructions for the hub. Remove
the axle, and then the right side
bearings.
To resolve this problem a running change was made
to the 2001 product line. The older, direct contact style
of freehub body has been replaced with a splined freehub
body attachment. This splined attachment requires less
bolt torque. Since it is a running change, the following
information is necessary to identify which freehub body
is on a wheel.
2. Determine the correct size
of allen wrench to engage the
freehub body attachment bolt.
3. Unthread the bolt in a
counter-clockwise direction
(standard threading).
If there is a date code stamped on the freehub body
it probably uses a splined attachment. If there is no date,
it is a threaded attachment. After May 2000, both styles
of freehub bodies (both attachment types) will have this
date mark.
Fig. 4
Installing the freehub body
1. Carefully clean the mating surfaces and threads of
the freehub body, hub shell, and attachment bolt.
These different styles of freehub bodies are not inter-
changeable.
2. Lubricate the threads of the attachment bolt with
Wrench Force™ synthetic grease, or a similar product.
3. Carefully engage the threads of the freehub body
attachment bolt into the hub shell. The bolt is steel, and
the hub is aluminum, so cross-threading the bolt will
result in destruction of the hub shell.
Identification of freehub bodies
Threaded freehub body
With the older, threaded
freehub body, there are two
CNC line
4. With the new splined freehub engagement, make
sure the splines are aligned as you tighten the attachment
bolt.
identifiers. First, there is a
CNC machine line approximately
10mm from the outside end of
the freehub body (Fig. 1).
For the older, threaded style freehub body, tighten the
freehub attachment bolt to 350 lb•in (40Nm).
Second, the thread-attached
freehub body is designed to be
removed with a 12mm allen
For the newer, splined design, tighten the freehub
attachment bolt to 400 lb•in (45.2 Nm).
Fig. 1
wrench.
Splined freehub body
The newer, splined attach-
ment (Fig. 2) freehub body has
no CNC line. Further, it is
designed to use an 11mm allen
wrench for removal. A special
adapter (TCG #211338) is made
which attaches to an 8mm allen
wrench to fit the 11mm allen
head of the freehub attachment
Fig. 2
bolt (Fig. 3).
In addition, as a running
change the new hub bodies will
include a 6-digit part number
embossed on the outside of the
hub shell where it is plainly vis-
ible. All hubs with the part num-
ber visible use the splined free-
hub body.
Fig. 3
Description
Freehub tool,
11mm adapter
TCG Part #
211338
11
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Rear hubs- Loose ball
Bontrager Superstock, Superstock Disc, Select ATB, Select Road, Select Hybrid wheels, plus Bontrager Comp II rear hub
the hub). Replace any worn parts.
ASSEMBLY
Recommended tools
(2) 15mm cone wrench
Adjustable wrench
Lubricate bearings and threads
Hammer (soft faced)
Small slot screwdriver
1. Lubricate the threads on
the axle with Wrench Force™ syn-
thetic grease, or a similar product.
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
2. Place a bead of grease all
the way around each ball cup,
sufficient to hold the balls.
Fig. 1D
1. Remove external seals
with your fingers or a screw-
driver (Fig. 2D). Be careful not
to tear or mar the rubber.
Fig. 6D
Assemble the hub
1. Place nine 1/4” balls in the
ball cup on one side of the hub
(Fig. 6D).
2. On the left side (non-drive)
of the hub place a 15mm cone
wrench on the ball cone. Place a
15mm cone wrench on the end
nut (Fig. 3D). Loosen the end
nut.
2. Place the shell shield,
with its sharp edges facing out,
into the hub. The shell shield is
a press fit, so must be tapped
lightly to fully seat. Lay a cone
wrench over the shell shield and
tap the wrench with a hammer
(Fig. 7D) to protect the shield and
ensure that it is flush with the
shell.
4. Remove the end nut, large
washer, spacer, small washer,
and ball cone from the axle (Fig.
4D).
Fig. 2D
Fig. 7D
5. Slide the axle, with the
other end nut, washer, and ball
cone still attached, out of the hub.
3. Repeat Assembly steps 1-2
for the other side of the hub.
6. Insert a thin screwdriver
blade under the shell shield (Fig.
5D) and pry off the shell shield
from the left side of the hub.
4. Tighten the end nut
against the fixed ball cone
(attached to axle) by holding
the ball cone with a 15mm cone
wrench and turn the end nut with
another 15mm cone wrench.
Seal not seated
8. If inspection shows it
necessary, remove the ball cone,
washers, and end
Fig. 3D
Axle
Fig. 8D
5. Insert the axle through the
hub from the right hand (drive) side.
nut from the right
side of the axle.
7. Thread the ball cone, small washer, spacer, large
washer, and end nut onto the axle in that order. The
serrated surface of the end nut faces out.
9. Remove the
ball bearings (Fig.
6D) from both
End
nut
Small
washer
sides of the hub.
8. From the left side of the hub, hold the ball cone
with a 15mm cone wrench and tighten the end nut with
a 15mm cone wrench.
10. If it is
necessary to
Large
remove the free-
9. Check the bearing adjustment by turning the axle
with your fingers. The axle should spin smoothly without
binding or feeling gritty. There should be no lateral play
of the axle in the hub. Readjust the hub as necessary, and
re-lock the end nut.
washer
Ball cone
Spacer
hub body, refer
to the Freehub
Body section,
pages Freehub 1
and Freehub 2, for
Fig. 4D
10. Install the external seal. Make sure the seal prop-
erly seals against both the end nut and the hub shell.
There should be a smooth transition from seal to sealing
surface. An improperly installed seal (Fig. 8D) will allow
removal and installation instructions.
When overhauling the hub bearings, it is usually not necessary to remove the freehub body.
Clean and inspect the parts
rapid contamination of the bearings.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It
should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is
eliminated when the wheel is installed with the quick release properly closed.
1. Use solvent to completely
remove all old grease and debris
from the hub, axle, and axle
parts. Avoid getting solvent
into the freehub, and be sure to
remove all solvent thoroughly
before proceeding.
2. Inspect the bearing run-
ning surfaces of both the ball
Fig. 5D
cones and the ball cups (inside
12
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Exploded view and Parts list
Note:
1
2
Rotor adapter for disc hubs not shown
Rotor spacing varies by model year, see details below.
3
4
5
6
7
8
9
10
11
Splined
7
6
5
3
11a
12
2
Threaded
Note:
There are two types of freehub body attachments; see below for specifi-
cations, and page 9 from more information
Pos Description
Description
Washer
Freehub body, 99/00
threaded
Freehub body, 01/02
splined
Rotor adapter 99/00
Model year Model for
99/00/01/02 all
Parts included (qty)
3
11, 6
TCG Part #
990008
1
2
3
4
5
6
7
8
9
External seal
End nut
Washer
all
68541
Spacer
all
11a, 6, removal tool
Not shown
211341
991075
69156
Ball cone
Shell shield
Bearings
Ball cup
Hayes, RST
rear
Magura Gustav, Not shown
Louise rear
Rotor adapter 99/00
Hub shell
10 Axle
11 Freehub body
12 Cone seal
Axle set
Axle set
Disc bolt set 99/00
99/00/01
99/00/01
all road, 130mm 2, 3, 4, 5(2), 10
all atb, 135mm 2, 3, 4, 5(2), 10
Not shown
68542
68531
991153
1999 Bontrager Comp II
2002/2003 Bontrager Superstock
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . threaded
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
2002/2003 Bontrager Select ATB
2001/2002 Bontrager Superstock
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . .running change
2002/2003 Bontrager Select Road
2002/2003 Bontrager Superstock Disc, Select ATB Disc
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.25 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
2002/2003 Bontrager Select Hybrid
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
13
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Rear hubs- Loose ball, double sealed (Formula FCM)
'99, 2000, 2001 Bontrager Race and Race Disk rear wheels
Recommended tools
(2) 15mm cone wrench
ASSEMBLY
Lubricate bearings and threads
12mm allen wrench
Adjustable wrench
Hammer
1. Lubricate the threads on
the axle with Wrench Force™
synthetic grease, or a similar
product.
Small slot screwdriver
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
2. Place a bead of grease all
the way around each ball cup,
sufficient to hold the balls.
Fig. 1E
Fig. 6E
1. Remove external seals
(Fig. 2E) with your fingers or
a screwdriver. Be careful not to
tear or mar the rubber.
Assemble the hub
1. Place nine 1/4” balls in the
ball cup on one side of the hub
2. On the left side (non-drive) (Fig. 6E).
of the hub place a 15mm cone
wrench on the bearing cone (Fig.
3E).
2. Place the shell shield, with
its sharp edges facing out (Fig.
6E), into the hub. The shell shield
is a press fit, so must be tapped
3. Place a 15mm cone
wrench on the end nut (Fig. 4E). lightly to fully seat (Fig. 7E).
Loosen the end nut.
Lay a cone wrench over the shell
shield and tap the wrench with a
hammer to protect the shield and
ensure that it is flush with the
shell.
Fig. 2E
Fig. 7E
4. Remove the end nut, large
washer, spacer, small washer,
and cone from the axle (Fig. 4E).
5. Slide the axle (Fig. 4E),
with the other end nut, washer,
and cone still attached, out of the
hub.
3. Repeat steps 1-2 for the
other side of the hub.
4. Tighten the end nut
against the fixed cone (attached
to axle) by holding the cone with
a 15mm cone wrench and turn
the end nut with another 15mm
cone wrench.
6. Insert a thin screwdriver
blade under the shell shield (Fig.
5E) and pry off the shell shields
from both sides of the hub.
Seal not seated
Fig. 3E
Axle
Fig. 8E
8. If inspection
shows it neces-
sary, remove the
cone, washers, and
end nut from the
right side of the
axle.
5. Insert the axle through the
hub from the right hand (drive) side.
7. Thread the cone, small washer, spacer, large washer,
and end nut onto the axle in that order. The serrated
surface of the end nut faces out.
End
nut
Small
washer
8. From the left side of the hub, hold the cone with a
9. Remove the 15mm cone wrench and tighten the end nut with a 15mm
ball bearings (Fig. cone wrench.
Large
washer
6E) from both
9. Check the bearing adjustment by turning the axle
with your fingers. The axle should spin smoothly without
binding or feeling gritty. There should be no lateral play
of the axle in the hub. Readjust the hub as necessary, and
re-lock the end nut.
Ball cone
Spacer
sides of the hub.
7. If it is nec-
essary to remove
the freehub body, refer to the Freehub Body section,
pages Freehub 1 and Freehub 2, for removal and installa-
Fig. 4E
10. Install the external seal. Make sure the seal prop-
erly seals against both the end nut and the hub shell.
There should be a smooth transition from seal to sealing
surface. An improperly installed seal (Fig. 8E) will allow
tion instructions.
When overhauling the hub bearings, it is usually not necessary to remove the freehub body.
rapid contamination of the bearings.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It
should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is
eliminated when the wheel is installed with the quick release properly closed.
Clean and inspect the parts
1. Use solvent to completely
remove all old grease and debris
from the hub, axle, and axle
parts.
2. Inspect the bearing run-
ning surfaces of both the cones
and the ball cups (inside the
hub). Replace any worn parts.
Fig. 5E
14
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Exploded view and Parts list
Note:
Rotor adapter for disc hubs not shown
Rotor spacing varies by model year, see details below.
1
2
3
4
5
13
6
7
8
9
10
11
6
7
12
Splined
4
3
13
2
11a
Threaded
Note:
There are two types of freehub body attachments; see below for specifi-
cations, and page 9 for more information
Description
Axle set
End nut set
External seal, 99/00
yellow
External seal, 99/00
red
Freehub body, 99/00
threaded
Freehub body 01
splined
Model year Model for
Parts included (qty)
10
2(2)
1, 13
TCG Part #
68533
Pos Description
99/00
99/00
all
all
all
1
2
3
4
5
6
7
8
9
External seal
End nut
Washer
68536
68534
Spacer
all
all
all
1, 13
68535
68540
Adj. cone
Shell shield
Bearings
Ball cup
11
11a, 6, removal tool
Not shown
211340
991075
69156
Hub shell
10 Axle
Rotor adapter 99/00
Hayes, RST
rear
Magura Gustav, Not shown
Louise rear
11 Freehub body
12 Ball cone
13 Cone seal
Rotor adapter 99/00
Disc bolt set 99/00
all
Not shown
991153
2000 Race
2001 Race
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . threaded
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . .running change
2000 Race Disk
2001 Race Disk
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . threaded
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.25 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . .running change
15
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Rear hub- Cartridge bearing
2002/2003 Bontrager Race, Race Disc rear wheels
Recommended tools
15mm cone wrench
ASSEMBLY
Inside
Lubricate bearings and threads
19mm cone wrench
Small slot screwdriver
Hammer (soft faced)
Cartridge bearing remover
Bearing press
1. Lubricate the threads on
the axle with Wrench Force™
synthetic grease, or a similar
product.
2. Lightly grease the inner
and outer surfaces of each bear-
ing where they contact the hub
shell and axle.
DISASSEMBLY
Hub parts and names are referenced on next page.
Outside
Fig. 1F
Fig. 5F
1. Hold the left side (non-
drive) axle spacer with a 19mm
Axle spacer
End nut
cone wrench and loosen the end
nut (Fig. 2F) with a 15mm cone
wrench.
Assemble the hub
1. Press the right bearing onto the right side of the
axle, denoted by the smooth, non-threaded area with a
shoulder.
Note: the black seal of the bearing faces out (Fig. 5F).
2. Remove the end nut,
washer, and axle spacer (Fig. 3F)
from the axle.
2. Place the axle through the freehub body.
3. Insert a thin screwdriver
blade under the bearing seal
(Fig. 4F) and pry off the seals
from both sides of the hub.
3. Press the bearing into the hub shell with the bear-
ing press.
Fig. 2F
4. Slide the left bearing onto the axle with the black
seal facing out. Thread the axle spacer onto the axle, and
use the bearing press to press the left bearing into the
hub. The axle should turn freely with no lateral play in
the hub shell.
4. Tap the left end of the
axle with a hammer to drive
the axle out of the hub.
5. If inspection shows it
necessary, remove the washers
and end nut from the right side
of the axle.
5. Place the bearing seals into the hub with the let-
tered surface facing out.
6. Thread the axle spacer onto the axle. Place a 17mm
cone wrench on the axle spacer and a 15mm cone wrench
on the end nut. Tighten the end nut against the axle spacer.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It
should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is
eliminated when the wheel is installed with the quick release properly closed.
End
nut
To loosen the end nut, re-
install the left side axle spacer
and locknut, and lock the end
nut against the axle spacer.
Hold the axle spacer with a cone
wrench while you loosen the
right side end nut. Alternately,
hold the axle with vise grips.
Axle spacer
Fig. 3F
6. Place a bearing removal
tool on the left bearing. With a
punch on the bearing tool, drive
the left bearing out of the hub
with a hammer.
Fig. 4F
7. If it is necessary to remove
the freehub body, refer to the Freehub Body
section, pages Freehub 1 and Freehub 2, for removal and
installation instructions.
When overhauling the hub bearings, it is usually not necessary to remove the freehub body.
Clean and inspect the parts
1. Wipe old grease or debris from the hub bearing
seats.
2. Normally, bearings are not re-used. If you are re-
installing an old bearing, wipe off any grease or debris
from both the inner and out surfaces.
Do not use solvent on the bearing, as the solvent will
contaminate the grease. This may cause bearing failure.
16
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Exploded view and Parts list
1
2
3
4
5
6
7
8
3
5
9
2
1
Pos Description
Description
Axle set
Bearing
Freehub body 01/02
splined
Bearing press 01/02
Model year Model for
Parts included (qty)
1(2), 2(2), 3(2), 4, 7, 9
5
TCG Part #
211351
73335
1
2
3
4
5
6
7
8
9
End nut
Washer
Spacer
Seal
Bearings
Hub shell
Axle
01/02
01/02
all
all
all
8, 9, removal tool
211339
all
DT Comp/Onyx (not shown)
DT Pro/240 (not shown)
Not shown
211416
211415
211338
Removal tool
Freehub body
Freehub seal
2002/2003 Race
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
2002/2003 Race Disc
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm
Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.25 mm
Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Cassette body type . . . . . . . . . . . . . . . . . . . . . . . . . Shimano 8/9 speed
Cassette body attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . splined
17
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DT-Swiss Comp series hubs
Important information before you begin with Comp series hubs
Tool list for DT Swiss front hubs
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.
The following tools may be necessary to perform
maintenance work on DT Swiss
Comp series hubs:
Short
Long bearing press
bearing
Short bearing press
press
This manual details the principle design features of
DT Swiss front hubs and also provides instructions as
to maintenance and repair work. Please take special care
to use only original DT Swiss special tools in order to
undertake the work details in this manual. Use only DT
Swiss replacement parts.
DT 17mm cone wrench
Long
bearing
press
Comp front hub bearing press
Multi-purpose DT grease
These maintenance items are
available as TCG part #211416.
In this manual, the hubs are shown installed in
a complete wheel. Maintenance work should be carried
out on complete wheels where possible. Otherwise, some
steps can not be carried out correctly.
Special screw-
driver
This manual provides technical and spare parts infor-
mation for these hubs. If you have further questions
about these hubs regarding technical information, sup-
port, or warranty, they should be directed to Bontrager
Technical Support via phone or on the Bontrager web site
Front hub bear-
ing press
In the event of improper servicing of the hubs,
Bontrager has the right to refuse any warranty.
Special information before you begin
Bearing resistance: New or newly re-built hubs have
a higher rolling resistance than used hubs because the
grease in the freehub has not yet been evenly distributed
and the seals have not yet bedded in.
Check your work: Before use, always check the hub
for proper functioning.
Regular Maintenance
Maintenance of the front hubs should be performed at
least once a year. This maintenance schedule is based on
normal usage. If you ride your bike more than average,
or in rain, snow, or off road conditions, service your
bicycle more often than the schedule suggests. If any
part appears to be malfunctioning, inspect and service it
immediately.
Things to avoid
Avoid high pressure washing systems, like those at
most car washes. The high pressure can bypass bearing
seals, letting water into the bearings. Do not use any kind
of solvents or tensides- this can damage the hub.
19
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Comp front hub
Bontrager Race Modified, Race Modified Disc front wheel, 2003 Race Lite ATB, Race Lite ATB Disc front
wheel
Recommended tools
ASSEMBLY
Comp bearing press, front hub
Short bearing press
17mm cone wrench
Multi-purpose grease
Bench vise
End cap
1. Place the Comp bearing
press on the workbench or other
solid surface. Push a new bear-
ing onto the axle, and push the
axle into the bearing press (Fig.
4K).
Axle vise
Hammer, soft faced
Thin-bladed slot screwdriver
2. Place the hub over the
axle.
DISASSEMBLY
Hub parts and names are referenced on next page.
Fig. 1K
Fig. 6K
Fig. 7K
Fig. 8K
3. Place the second Comp
bearing press over the axle. Tap
the upper bearing press with the
hammer (Fig. 5K) to press the
bearing into the hub.
Disassemble the hub
1. Tap the axle (either end)
with the hammer until the axle
is flush with the surface of the
end cap.
4. Remove the upper bearing
press.
5. Pull the axle out about
10mm (3/8in). Press the second
bearing over the axle (Fig. 6K).
2. Remove the opposite end
cap (Fig. 1K).
3. Tap the axle end without
the end cap with the hammer
(Fig. 2K) and remove the axle.
6. Place the second bear-
ing press over the axle. Tap the
upper bearing press with the
hammer (Fig. 7K) to press the
second bearing into the hub.
Check the bearing installation be spinning the axle. It
should rotate freely without irregular friction.
Fig. 2K
4. Slide the end cap, seal, and
bearing from the axle (Fig. 3K).
End cap
V-seal
5. Re-insert the axle through
the hub and tap out the second
bearing.
7. Lightly grease the surface
of both bearings.
Clean and inspect the parts
8. Pull the V-seal off the end
cap (Fig. 8K). Clean it thoroughly
with a cloth, lightly grease it,
and reinstall it on the end cap
with the open ‘V’ facing the hub.
Thoroughly clean and
inspect all components with a
dry cloth. If cracks or any other
damage is visible, replace the
part.
Fig. 3K
9. Position the completed end cap over the axle, and
press into place with your fingers.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It
should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is
eliminated when the wheel is installed with the quick release properly closed.
Bearing
Bearing
press
Fig. 4K
Fig. 5K
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Exploded view and Parts list
1
4
2
3
3
2
1
5
Pos Description
Description
Axle kit
Bearing
Model year Model for
Parts included (qty)
1(2), 2(2), 3(2), 4
3
TCG Part #
70361
211349
1
2
3
4
5
End cap
V-seal
Bearing
Axle
99/00/01
99/00/01
All
All
Hub shell
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Comp rear hub
Bontrager Race Modified rear wheel, 2003 Race Lite ATB, 2002/2003 Race Lite Road rear wheel
2. Place the wheel over the
axle with the drive side facing up.
Recommended tools
Long bearing press
Short bearing press
17mm cone wrench
Multi-purpose grease
Bench vise
3. Place a new bearing over
the axle, black side out. Tap the
short bearing press with the ham-
mer to begin pressing the bearing
into the hub (Fig. 7G).
Axle vise
Hammer, soft faced
Thin-bladed slot screwdriver
4. Leave the short bearing
press in place, and lift the wheel
from the long bearing press (in
the vise). Remove the axle from
the hub and replace the wheel
over the long bearing press.
DISASSEMBLY
Hub parts and names are referenced on next page.
Fig. 1G
Fig. 2G
Fig. 3G
Fig. 6G
Fig. 7G
Fig. 8G
Fig. 9G
Spacer
1. Place the axle vise in the
bench vise and clamp the left-
hand end of the axle.
5. Again tap the short bear-
ing press with the hammer to
press the bearing into the hub.
This is an important step, which ensures the bearing is cor-
rectly pressed in.
2. Remove the cassette.
3. Loosen the right end nut
with the 17mm cone wrench and
remove the end nut (Fig. 1G).
6. Turn the wheel over and
place it drive-side down on the
long bearing press. Push the
short 33mm end of the axle
through the hub and bearing.
4. Pull off the freehub body
with your fingers.
The spacer (Fig. 2G) may be stuck to the inside of the free-
hub body with grease.
7. Slide the second hub bear-
ing over the axle, black side on
top.
5. Remove the spacer (Fig. 2G).
6. With the wheel removed
from the vise, tap the right end
of the axle with the hammer
until loose. Pull the axle from
the left side of the hub shell (Fig.
3G).
8. Tap the short bearing
press with the hammer to press
the second bearing into the hub.
9. Turn the wheel over.
Lightly grease the bearing shell.
7. Place the right end of the
axle into the axle vise.
10. Slide the roller bearing
retainer over the hub bearing
and into the housing (Fig. 8G).
Be careful not to dislodge any
roller bearings.
8. Loosen the left end nut
with the 17mm cone wrench,
and remove it from the axle. Also
remove the bearing.
Pawl spring
elbow
Retainer
spring
Pawl
9. Remove the retainer
spring (Fig. 4G) and pawls from
the hub with the screwdriver.
Installing the pawl spring and
pawls
10. Pull the roller bearing
retainer from the hub (Fig. 5G).
1. Place the pawl spring over
the axle and install the spring
into the retainer body with the
elbow pointing up (Fig. 9G).
11. From the left side of the
wheel, place the axle through
the hub and the bearing. Tap
the axle with the hammer to
drive the right hub bearing out.
Remove the bearing from the
axle.
Fig. 4G
2. Push both pawls beneath
the spring with a screwdriver
(Fig. 10G). Make sure they are
placed correctly (Fig. 11G).
3. Lightly grease the roller
bearing retainer, pawls, and hub
bearing.
Clean and inspect the parts
Clean all components and
inspect them thoroughly. If any
cracks or other damage are vis-
ible, the parts must be replaced.
Install the freehub body
Fig. 10G
Fig. 5G
1. Push the spacer (Fig. 2G)
over the axle.
2. Remove the freehub body seal
(Fig. 12G). Clean the seal. If it is faulty or
damaged, replace it.
ASSEMBLY
Pawl
1. Clamp the long bearing press into the bench vise.
Push the axle, long end first, through the hole in the
press. The short, 33mm end of the axle should be on top
(Fig. 6G).
3. Clean the freehub body teeth (a
toothbrush works well).
Spring position
4. Lightly grease the seal and freehub
Fig. 11G
22
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teeth.
5. Install the seal into the
freehub body with the lip toward
the outside of the hub (Fig. 13G).
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).
Freehub body seal
11. Turn the wheel over and
clamp the right end nut in the
vise.
6. Push the pawls in with
a screwdriver as you slide the
complete freehub body onto the
axle (Fig. 14G). Check the align-
ment to avoid excessive force
which could damage the spring.
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 facing the inside.
Fig. 12G
Fig. 14G
7. Grease the freehub end
and axle end.
8. Clean and lightly grease
the right end nut and end seal
(Fig. 15G). Replace the end seal
on the end nut with the lip fac-
ing the inside.
9. Place the complete left
end nut onto the axle and tight-
en it by hand.
10. Tighten the end nut to
150 lb•in (17Nm).
After completely assembling the hub, check for proper
functioning by spinning the freehub body. If the pawls do
not click into place, the spring may not have been cor-
rectly installed, or there could be too much grease in the
freewheel.
9. Place the complete end
nut onto the axle and tighten it
by hand.
Fig. 15G
Fig. 13G
Exploded view and Parts list
Pos Description
1
2
3
4
5
6
7
8
9
End nut
4
V-seal, left
Bearing, left
Axle
Retaining bolt
Driver
Pawl
Pawl spring
Roller retainer
7
1
2
3
5
10 Bearing shell
11 Bearing, right
12 Spacer
13 Freehub seal
14 Freehub body
15 V-seal, right
16 End nut, right
17 Nut cap
18
6
7
8
17
16
9
10
11
12
13
18 Hub shell
14
15
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Description
Freehub kit
(Shimano)
Driver kit
Axle set
Model year Model for
Parts included (qty)
7(2), 8, 12, 13, 14
TCG Part #
70358
2000/01
all
2000/01
2002/03
all
5, 6, 10
72678
70359
Race Lite Road 1, 2, 3, 4, 15, 16, 17
(130 O.L.D.)
Axle
(135 O.L.D.)
2000/01
2003
Race Mod
Race Lite ATB
1, 2, 3, 4, 15, 16, 17
3, 9, 11
70360
72677
Bearing kit
00/01/02/03 all
Bearing shell 2000/01
kit
all
10, 11
72679
Bearing, left 2000/01
Bearing, right 2000/01
all
all
3 (6000, 12/26 x 8mm)
11 (6900, 10/22 x 6mm)
211348
211349
24
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Pro series hubs
letting water into the bearings. Do
Important information before you begin with Pro series hubs
not use any kind of solvents or
tensides- this can damage the hub.
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.
Determining the year of hub
There are two styles of rear
This manual details the principle design features of
DT Swiss hubs and also provides instructions as to main-
tenance and repair work. Please take special care to use
only original DT Swiss special tools in order to undertake
the work details in this manual. Use only DT Swiss
replacement parts.
hub, with some unique parts and
different instructions for assem-
bly and disassembly. To deter-
mine which hub type you will be
working on, it is necessary to
remove the freehub. With the star
ratchet removed, you will be able
to see the right side shell bear-
ing. If the bearing is completely
visible due to its 24mm outer
diameter (Fig. FH5), it’s a year
2000 hub. The 2001 model uses
a larger, 28mm diameter bearing
(Fig. FH6) that is partially cov-
ered by the ring nut (requiring
the removal of the ring nut).
Fig. FH5
Fig. FH6
Fig. FH7
In this manual, the hubs are shown installed in a
complete wheel. Maintenance work should be carried out
on complete wheels where possible. Otherwise, some steps
can not be carried out correctly.
This manual provides technical and spare parts infor-
mation for these hubs. If you have further questions
about these hubs regarding technical information, sup-
port, or warranty, they should be directed to Bontrager
Technical Support via phone or on the Bontrager web site
In the event of improper servicing of the hubs,
Bontrager has the right to refuse any warranty.
Removing the cassette from the
freehub body
The cassette does not need
Special information before you begin
to be removed from the freehub
body to perform regular main-
tenance. However, if you decide
to remove it, it should only be
removed after the hub has been
completely re-assembled.
Bearing play: A small amount of play between the free-
hub body and the hub shell is automatically eliminated when
the wheel is installed and the quick release is tightened.
Bearing resistance: New or newly re-built hubs have
a higher rolling resistance than used hubs because the
grease in the freehub has not yet been evenly distributed
and the seals have not yet bedded in.
1. Release the lockring using
a lockring tool.
Aluminum freehub bodies: For hubs with an alumi-
num freehub body, we recommend cassettes using a solid,
one piece spider like the Shimano Dura-Ace, Ultegra, XTR,
or Deore XT. Cassettes using loose or bolted sprockets
like Shimano Deore LX can cause notches in the freehub
body. This can cause difficulties when later removing
the cassettes from the freehub body (see “Removing
Cassettes” on this page).
2. Loosen the cassette by lightly
tapping it counter-clockwise with the
hammer.
Freehub seal
installation
tool
3. Remove all the sprockets from
the freehub body.
4. Use a fine file to remove
bad notches from the aluminum free-
hub body (Fig. 14H). The aluminum
freehub body must be cleaned and
inspected. If any cracks or other
damage is visible, the components
must be replaced.
Note: Notches on the freehub body do not have a negative influence
on the functionality of the freewheel.
Short
bearing
press
Check your work: Before use, always check the rear
hub for proper functioning. Check the freehub body and
the ratchet mechanism. If they do not function correctly,
the rear hub should not be used until the fault is cor-
rected. If you are unable to correct the fault, consult
Bontrager Technical Support.
Long
bearing
press
Regular Maintenance
Required tools
Maintenance of the rear and front hubs should be
performed at least once a year. This maintenance schedule
is based on normal usage. If you ride your bike more
than average, or in rain, snow, or off road conditions,
service your bicycle more often than the schedule sug-
gests. If any part appears to be malfunctioning, inspect
and service it immediately.
Maintenance of Pro level hubs
requires special tools, available as TCG
part #211415:
Special screw-
driver
Freehub seal installation tool
Long bearing press
Short bearing press
Special screwdriver
DT Swiss special freehub grease
DT Swiss multi-purpose grease
Spline tool
Things to avoid
Avoid high pressure washing systems, like those at most
car washes. The high pressure can bypass bearing seals,
Spline
tool
25
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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
5. Grease both the outer sur-
face of both bearings.
Recommended tools
Long bearing press
Short bearing press
Multi-purpose grease
Bench vise
End cap
V-seal
6. Pull the V-seal off the both
end caps (Fig. 13I). Clean each
seal thoroughly with a cloth,
lightly grease it, and reinstall it
on the end cap with the open ‘V’
facing the hub.
Axle vise
Hammer, soft faced
DISASSEMBLY
7. Push the completed
1. Loosen both end caps by
rotating them in opposite direc-
tions with your fingers.
adapters into place with your
fingers.
After completing assembly of the hub, check its func-
tion by spinning the axle with your fingers. It should rotate freely without irregular friction. A small
amount of lateral play is acceptable if the play is eliminated when the wheel is installed with the
quick release properly closed.
Fig. 1J
Fig. 2J
Fig. 3J
Fig. 4J
Fig. 5J
Fig. 6J
2. Clamp the axle end cap
(either side) in the axle vise
(avoid over tightening).
3. Pull the wheel upward
(Fig. 1J) to remove the end cap
held by the vise.
2002 Race Lite, ATB, Race Lite 29, 2003 Race X Lite ATB
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.5 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
4. Tap the axle out of the
hub with the hammer (Fig. 2J).
5. Slide the bearing off the
axle (Fig. 3J).
2002/2003 Race X Lite
6. Re-insert the axle into
the hub from the side opposite
the remaining bearing. With the
axle end resting on the inside of
the bearing, tap the bearing out
of the shell with the hammer.
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Race X Lite Carbon, Race X Lite Aero
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16°
Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Clean and inspect all com-
ponents. If any cracks or other
damage are visible, replace the
part.
ASSEMBLY
1. Clamp the long bearing
press into the vise.
2. Push the new bearing over
the front axle. Insert the axle
into the bearing press (Fig. 4J).
2. Place the wheel over the
axle and pull the axle out by
about 10 mm (1/2 inch). Push
the second bearing over the axle
and into the hub.
3. Center the axle using the
short bearing press.
4. Tap both bearings into
place with the hammer (Fig. 5J)
at the same time.
Turn the axle to check the bearings. You should not be
able to feel any irregular friction. Make sure that there is
no play in the axle.
26
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Exploded view and Parts list
Pos Description
1
2
3
4
5
End nut
V-seal
Bearing
Axle
4
Hub shell
1
2
3
2
1
5
3
Description
Axle kit
V-seal
Bearing
End cap kit
Model year Model for
00/01/02/03 all
00/01/02/03 all
00/01/02/03 all
00/01/02/03 all
Parts included (qty)
1(2), 2(2), 3(2), 4
2
3(6802, 15/24 x 5mm)
1(2)
TCG Part #
70357
211342
211344
221803
27
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Pro rear hub
Bontrager Race Lite ATB, Race Lite 29, Race X Lite, Race X Lite Carbon rear wheels, Race Lite Aero
A running change to hubs was made in 2001; the newer hub has a part number embossed in the shell. See exploded dioagrams for differences
Recommended tools
Long bearing press
ASSEMBLY
Install the right hand bearing
Short bearing press
1. Clamp the spline tool into
a vise.
17mm cone wrench
Multi-purpose grease
Bench vise
2. Place the spacer over the
splines (Fig. 5I).
Axle vise
Hammer, soft faced
3. Place the bearing onto the
Thin-bladed slot screwdriver
long end of the axle and push
the bearing onto the spline tool
(Fig. 6I).
DISASSEMBLY
Hub parts and names are referenced on next page.
Fig. 1I
Fig. 6I
Fig. 7I
Fig. 8I
Fig. 9I
4. Place the wheel over the
axle, drive side down. Push the
short bearing press over the
other end of the axle. Tap the
bearing into place with the ham-
mer (Fig. 7I).
Disassemble the freehub
Spacer
1. Place the axle vise in the
bench vise and clamp the left-
hand end of the axle.
Star
ratchet
2. Pull sharply with your
fingers to remove the cassette,
with the freehub body attached
(Fig. 1I).
Install the ring nut
1. Clamp the spline tool into
the vise with only the splines
above the jaws (Fig. 8I).
3. Remove the star ratchet,
spacer and spring (under the star
ratchet) from the hub (Fig. 2I).
Fig. 2I
2. Inspect the ring nut for
cracks or damage. If damaged,
replace it.
4. Remove the second star
ratchet and second spring from
the freehub body.
3. Place the ring nut with the
recess uppermost over the splines
(Fig. 9I). Place the spacer ring flat
inside the ring nut.
Disassemble the ring nut
1. Clamp the spline tool into
a bench vise (Fig. 3I).
4. Place the wheel, drive side
down, over the spline tool. Insert
the right axle end through the
spline tool. Carefully screw the
ring nut into the hub by turning
the wheel clockwise.
2. Push the right side axle
end into the cylinder. With the
splines engaged, turn the wheel
firmly in an anti-clockwise direc-
tion. The ring nut will be loos-
ened, and the seal between the
hub and freehub body will fall
over the spline tool onto the vise.
Fig. 3I
Ring nut
Spacer
Bearing
Install the freehub body seal
Important: When installing a new seal, only the right-hand
bearing should be in place. The left-hand bearing must not
be pressed in until after the seal has been installed.
3. Thoroughly clean and
inspect all components, includ-
ing inside the hub, with a dry
cloth. If necessary, use a tooth-
brush. If cracks or any other
damage is visible, the parts must
be replaced.
1. Inspect the seal. If the seal
shows signs of wear or damage,
replace it.
Fig. 4I
2. Clamp the short bearing
press into a vise (Fig. 10I) and
place the wheel, drive side up,
over the tool.
Spacer
Disassemble the bearings
3. Place the seal over the
freehub body seal installation tool
(Fig. 11I) with the ‘V’ facing the
hub.
1. From the right side, tap
the axle out of the hub with the
hammer (Fig. 4I). Remove the
axle from the hub.
4. With the seal on the tool,
push them together over the axle.
2. Slide the left end cap, seal
and bearing off the axle.
Fig. 10I
Fig. 5I
5. Place the long bearing
press over the axle.
3. Turn the axle around and
insert it into the left side of the hub until the axle collar
butts against the bearing. Tap the second bearing out
with the hammer.
6. Press the seal into the hub by tapping it with the
hammer.
4. Thoroughly clean and inspect all components with
a dry cloth. If cracks or any other damage is visible, the
parts must be replaced.
Install the left hand bearing
1. Clamp the spline tool into the bench vise (Fig. 3I).
28
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2. Push the wheel over the
tool, drive side down.
5. Carefully clean the star
ratchets with a dry cloth. Inspect
both star ratchets for damage.
If any damage is visible, replace
the ratchet.
Spacer
Freehub body seal
Spring
3. Place the bearing care-
fully into the hub (Fig. 12I).
4. Place the short bearing
press over the axle (Fig. 7I). Tap
the bearing into place with the
hammer.
Turn the axle and check that you do not feel any irregular
friction.
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 the spacer ring
(Fig. 15I).
Fig. 11I
Fig. 14I
5. Lightly grease the surface
of the bearing.
6. Pull the V-seal off the
end cap (Fig. 13I). Clean it
thoroughly with a cloth, lightly
grease it, and reinstall it on the
end cap with the open ‘V’ facing
the hub.
7. Place both greased star
ratchets into the freehub body
(Fig. 16I).
8. Push the freehub body,
7. Replace the completed
together with the cassette, over
end cap onto the left axle end.
the axle.
Caution: Ensure the freehub body is not tilted !
Fig. 15I
Fig. 12I
9. Pull the V-seal off the right
end cap (Fig. 13I). Clean it thor-
oughly with a cloth, lightly grease
it, and reinstall it on the end cap
with the open ‘V’ facing the hub.
Install the freehub
End cap
V-seal
1. Grease the splines inside
the hub shell with DT Swiss spe-
cial grease (only).
2. Push the spacer over
the axle (Fig. 14I) until it butts
against the bearing.
10. Place the end cap over
the right end of the axle and
manually press into place.
Ensure the end cap is not tilted
and that it audibly clicks into
3. Insert the spring, with
the large diameter in contact
with the bearing (Fig. 14I).
place.
Fig. 16I
Fig. 13I
After completing assembly of the hub, check its function
4. Clean the outside end of the
freehub body with a clean cloth.
Before positioning the spacer and the ratchet in the freehub body, check that the freehub body bear-
ings spin freely without binding. If any binding or scratching is detected, replace the freehub body with
a new or reconditioned one.
by giving the cassette a sharp, quick spin. If the ratchets do not catch, there could be too much grease
inside the freehub body, or the wrong type of grease was used. In this case, remove some of the grease
or replace it using the correct grease.
Part list on following page
29
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Exploded view and Parts list- 2001-2003
Pos Description
1
2
3
4
5
6
7
8
9
End cap, left
V-seal
Bearing
Axle
Spacer
Ring nut
Washer
Spacer
Spring
4
1
2
3
13
10 Star ratchet
11 Freehub body
12 End cap, right
13 Hub shell
3
5
6
8
7
9
10
10
9
11
A running change to hubs was made in 2001; the newer hub (shown here)
12
has a part number embossed in the shell. See the following page for the
earlier model hub.
Description
Freehub kit
(Shimano)
Model year Model for
Parts included (qty)
8, 9(2), 10(2), 11
TCG Part #
70354
02/03
all
Freehub kit
(Campagnolo)
Star ratchet 02/03
and spring kit
02/03
all
8, 9(2), 10(2), 11
9(2), 10(2)
211579
211343
70355
all
Axle kit
02/03
all road
1, 2, 3(2), 4, 13
130mm O.L.D.
(Shimano)
Axle kit
130mm O.L.D.
(Campagnolo)
Axle kit
135mm O.L.D.
V-seal
Freehub seal 02/03
Bearing 02/03
02/03
all road
1, 2, 3(2), 4, 13
211580
70356
02/03
02/03
Race Lite ATB 1, 2, 3(2), 4, 13
all
all
all
2
7
211342
211591
211345
3 (6902, 15/28 x 7mm)
2001, 2002 Race Lite, 2003 Race X Lite ATB
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Race X Lite
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
2002/2003 Race X Lite Carbon, Race X Lite Aero
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
30
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Exploded view and Parts list- 2000-2001
Pos Description
1
2
3
4
6
7
8
9
End cap
V-seal
Bearing
Axle
Freehub seal
Bearing
Spacer
4
10
1
10
Spring
11
12
10 Star ratchet
11 Washer
2
3
13
12 Freehub body
13 End nut, right
14 Hub shell
14
7
6
8
9
Description
Freehub kit
(Shimano)
Model year Model for
Parts included (qty)
TCG Part #
70354
2000
Race, Race Lite 8, 9(2), 10(2), 12
Star ratchet 2000
and spring kit
Race, Race Lite 9(2), 10(2)
211343
Axle
2000
Race, Race Lite 1, 2, 3(2), 13 (135mm O.L.D.)
Race, Race Lite 6
70356
Freehub seal 2000
Bearing, left 2000
Bearing, right 2000
211591
Race, Race Lite 3 (6902, 15/28 x 7mm)
Race, Race Lite 7 (3802, 15/24 x 7mm)
211345
211346
2000 Race Lite
O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 mm
Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28°
Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.0 mm
Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm
Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
31
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