HUB INSTRUCTIONS

PART NUMBER 231793

SERVICE MANUAL 2003

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 Freehub body information (non-DT Swiss) Loose ball. Loose ball, double sealed (Formula FCM). Cartridge bearing. 11.12-13.14-15.16-17

DT-SWISS

Comp series hubs Introduction. 19 Comp front.20-21 Comp rear.22-24 Pro series hubs Introduction. 25 Pro front.26-27 Pro rear.28-31
Please note: Many sections of this manual must be read in their entirety before performing procedures. In some cases, revised or updated information may be available on the Bontrager wheelworks website at www.bontrager.com. If you cannot find the information you need to service Bontrager wheels, please contact a technical service representative.
Copyright Trek Bicycle Corporation 2002 All rights reserved 2003 Bontrager Service Manual 1

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
13mm cone wrench 17mm cone wrench Small slot screwdriver Hammer (soft faced) Shell shield

DISASSEMBLY

Hub parts and names are referenced on next page.

Remove the axle

Fig. 1A External seal

Fig. 2A

Fig. 3A
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 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. Remove the end nut, washer, and ball cone from the axle (Fig. 4A). 4. Slide the axle, with the other end nut, washer, and ball cone still attached, out of the hub (Fig. 4A). 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. 6. If inspection shows it necessary, remove the other end nut and ball cone.
End nut Washer Ball cone Fig. 4A
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.
1. Place eleven 3/16 balls in the ball cup on one side of the hub. 2. Place the shell shield, with its sharp edges facing out (Fig. 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 Fig. 5A tap the wrench with a hammer (Fig. 7A) to protect the shield Bearings in bearing cup and ensure that it is flush with the shell. 3. Repeat Assembly steps 1-2 for the other side of the hub. 4. Tighten the end nut 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 Fig. 6A 17mm cone wrench. 5. Insert the axle through the hub from either side. 6. Thread the ball cone, washer, and end nut onto the axle in that order. The serrated surface of the end nut faces out. 7. Hold the ball cone with a 13mm cone wrench and tighten the end nut with a 17mm cone wrench. Fig. 7A 8. 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. 9. Install the external seals, Seal not seated and apply grease where the seals contact the hub shell and axle Fig. 8A parts. 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 improperly installed seal (Fig. 8A) will allow 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.
2003 Bontrager Service Manual
Exploded view and Parts list
Pos Description 1 External seal 2 End nut 3 Washer 4 Ball cone 5 Shell shield 6 Ball bearings 7 Ball cup 8 Hub shell 9 Axle 1999 Bontrager Comp II
Description Axle set Locknut set
Model year 99/00/01/02 99/00/01/02

Model for all all

Parts included (qty) 1(2), 4(2), 3(2), 9 2(2)

TCG Part # 68257 68543

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

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
Front hubs- Loose ball, semi-cartridge; Formula FCM
'99, 2000, 2001 Bontrager Race, Race Disk front wheels Recommended tools
13mm cone wrench 17mm cone wrench Adjustable wrench Hammer (soft faced) Small slot screwdriver
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.

Bearing seal

Hub parts and names are referenced on next page. Fig. 1B

ASSEMBLY

1. Place eleven 3/16 balls in the ball cup on one side of the hub (Fig. 8B). 2. Place the bearing seal, with the lettered side facing out, into the ball cup. 3. Place the shell shield, with its sharp edges facing out, into the hub. The shell shield is a press fit, so must be tapped lightly to fully seat. Lay a cone wrench Fig. 7B over the shell shield and tap the wrench with a hammer (Fig. 9B) Bearings in ball cup to protect the shield and ensure that it is flush with the shell. 4. Repeat Assembly steps 1-3 for the other side 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 Fig. 8B nut with a 17mm cone wrench. 6. Insert the axle through the hub from either side. 7. Thread the ball cone, washer, and end nut onto the axle in that order. The serrated surface of the end nut faces out. 8. Hold the ball cone with a 13mm cone wrench and tighten the end nut with a 17mm cone wrench. Fig. 9B 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. 10. Install the external seals. Seal not seated Make sure the seals properly seal against both the end nut and Fig. 10B the hub shell. There should be a smooth transition from seal to sealing surface. An improperly installed seal (Fig. 10B) will allow 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. Fig. 6B
1. Remove external seals External seal (Fig. 2B) with a screwdriver. Be careful not to tear or mar the rubber. 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 Fig. 2B the end nut. 3. Remove the end nut, washer, and ball cone from the axle (Fig. 4B). 4. Slide the axle, with the other end nut, washer, and ball cone still attached, out of the hub. 6. Gently insert a thin screwdriver blade between the shell shield (Fig. 5B) and bearFig. 3B ing seal (Fig. 6B). Pry off the shell shields from 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 the bearing seal. 7. Gently pry off End nut the bearing seals (Fig. Washer 6B) from both sides of Ball cone the hub. 8. If inspection Fig. 4B shows it necessary, remove the other end nut. Hold Shell shield the axle by the wrench flats (Fig. 7B) while turning the end nut with a 17mm cone wrench. Clean and inspect the parts 1. Use solvent to completely remove all old grease and debris from the hub, axle, and axle parts. Fig. 5B 2. Inspect the bearing running 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.
Note: Rotor adapter for disc hubs not shown Rotor spacing varies by model year, see details below.
Pos Description 1 External seal 2 End nut 3 Washer 4 Adjust cone 5 Shell shield 6 Bearing seal 7 Ball bearings 8 Ball cup 9 Hub shell 10 Axle 11 Spacer 12 Ball cone 1999 Race
Description Axle set Locknut set Rotor adapter w/screws Disc bolt set
Model year 99/00/01 99/00/01 99/00 99/00
Model for all all Hayes, RST all
Parts included (qty) 10, 4, 2, 5(2), 11, 6(2), 3(2) 2(2) Not shown Not shown

TCG Part # 991083 991153

2001 Race Disk
O.L.D. 100 mm Spoke hole quantity. 28 Spoke hole P.C.D., right. 45.0 mm Spoke hole P.C.D., left. 58.0 mm Q.R. rod outer diameter. 6 mm Disc rotor spacing. 10.5 mm Rotor BCD. 44.0 mm
O.L.D. 100 mm Spoke hole quantity. 24 Spoke hole P.C.D. 38.0 mm Q.R. rod outer diameter. 6 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

Front hubs- Cartridge bearing, alloy axle
2002/2003 Bontrager Race, Race Disc front wheels Recommended tools

17mm cone wrench Special hook spanner Hammer and broad punch Bearing removal tool Bearing press
1. Press a bearing into the hub with a bearing press.
Note: the black seal faces out (Fig. 9C). Axle
Hub parts and names are referenced on next page. Fig. 1C
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 cone wrench (Fig. 3C) while loosening the axle nut with the special hook spanner (Fig. 4C). 3. Partially unthread the axle nut (Fig. 5C) until it slightly protrudes past the end of the axle. 4. Tap the axle nut with a soft-faced hammer until the axle slides through the opposite bearing. 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 screwdriver blade between the bearing seal (Fig. 7C) and bearing. Pry off the bearing seals from both sides of the hub. 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.

End caps

2. Press the second bearing with the bearing press. 3. Place the bearing seals into the hub with the lettered surface facing out. 6. Insert the axle through the hub from either side. 7. Thread the axle nut onto the axle. 8. Hold the axle with a 17mm cone wrench and tighten the axle nut with the special hook spanner until finger tight.
Do not over-tighten the axle nut. The axle should turn freely with no lateral play in the hub shell.

Axle nut Fig. 5C

Fig. 2C
9. Press the axle end caps into both ends of the axle.

Fig. 6C

Fig. 3C Axle nut

Fig. 7C Bearing seat

Fig. 4C

Fig. 8C

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 reinstalling 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.
Pos Description 1 End cap 2 Adjustable nut 3 Seal 4 Bearing 5 Hub shell 6 Axle
Description Model year Seal 99/00/01 Bearing 99/00/01 #6903 Axle set 99/00/01 Adjustable nut 99/00/01 End cap, 99/00/01/02 20.5mm O.D. Rotor adapter 99/00 w/screws Disc bolt set 99/00 Special 99/00/01/02 hook spanner

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 ATB
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
2002/2003 Bontrager Select Road
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
Rear hubs- Loose ball, double sealed (Formula FCM)
'99, 2000, 2001 Bontrager Race and Race Disk rear wheels Recommended tools
(2) 15mm cone wrench 12mm allen wrench Adjustable wrench Hammer Small slot screwdriver
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. Assemble the hub 1. Place nine 1/4 balls in the ball cup on one side of the hub (Fig. 6E). 2. Place the shell shield, with its sharp edges facing out (Fig. 6E), into the hub. The shell shield is a press fit, so must be tapped lightly to fully seat (Fig. 7E). Lay a cone wrench over the shell Fig. 7E shield and tap the wrench with a hammer to protect the shield and ensure that it is flush with the shell. 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 Seal not seated a 15mm cone wrench and turn the end nut with another 15mm Fig. 8E cone wrench. 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. 8. From the left side of the hub, hold the cone with a 15mm cone wrench and tighten the end nut with a 15mm cone wrench. 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. 10. Install the external seal. Make sure the seal properly 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 rapid contamination of the bearings.
Fig. 1E Hub parts and names are referenced on next page.
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 hub place a 15mm cone wrench on the bearing cone (Fig. 3E). 3. Place a 15mm cone wrench on the end nut (Fig. 4E). Loosen the end nut. Fig. 2E 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. 6. Insert a thin screwdriver blade under the shell shield (Fig. 5E) and pry off the shell shields Fig. 3E from both sides of the hub. 8. If inspection Axle shows it necessary, remove the cone, washers, and End nut end nut from the right side of the Small axle. washer 9. Remove the ball bearings (Fig. Large 6E) from both washer Ball cone Spacer sides of the hub. 7. If it is necFig. 4E essary to remove the freehub body, refer to the Freehub Body section, pages Freehub 1 and Freehub 2, for removal and installation instructions.

Fig. 6E

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 cones and the ball cups (inside the hub). Replace any worn parts.

Fig. 5E 14

Note: Rotor adapter for disc hubs not shown Rotor spacing varies by model year, see details below. 13 6
Note: There are two types of freehub body attachments; see below for specifications, and page 9 for more information
Pos Description 1 External seal 2 End nut 3 Washer 4 Spacer 5 Adj. cone 6 Shell shield 7 Bearings 8 Ball cup 9 Hub shell 10 Axle 11 Freehub body 12 Ball cone 13 Cone seal
Description Axle set End nut set External seal, yellow External seal, red Freehub body, threaded Freehub body splined Rotor adapter
Model year 99/00 99/00 99/00 99/00 99/99/00
Model for all all all all all all
Parts included (qty) 10 2(2) 1, 13 1, 11a, 6, removal tool

TCG Part # 991153

Rotor adapter 99/00 Disc bolt set 99/00
Hayes, RST Not shown rear Magura Gustav, Not shown Louise rear all Not shown 2001 Race

2000 Race

O.L.D. 135 mm Spoke hole quantity. 28 Spoke hole P.C.D., right. 58.0 mm Spoke hole P.C.D., left. 45.0 mm Cassette body type. Shimano 8/9 speed Cassette body attachment. threaded
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

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
Rear hub- Cartridge bearing
2002/2003 Bontrager Race, Race Disc rear wheels Recommended tools

15mm cone wrench 19mm cone wrench Small slot screwdriver Hammer (soft faced) Cartridge bearing remover Bearing press
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 where they contact the hub shell and axle. Assemble the hub

Inside

Fig. 1F Hub parts and names are referenced on next page.

Outside Fig. 5F

1. Hold the left side (nondrive) axle spacer with a 19mm Axle spacer End nut cone wrench and loosen the end nut (Fig. 2F) with a 15mm cone wrench. 2. Remove the end nut, washer, and axle spacer (Fig. 3F) from the axle. 3. Insert a thin screwdriver blade under the bearing seal (Fig. 4F) and pry off the seals Fig. 2F from both sides of the hub. 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. End To loosen the end nut, reAxle spacer nut install the left side axle spacer Fig. 3F 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. 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.
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. Place the axle through the freehub body. 3. Press the bearing into the hub shell with the bearing press. 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. 5. Place the bearing seals into the hub with the lettered 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.
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 reinstalling 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.

Pos Description 1 End nut 2 Washer 3 Spacer 4 Seal 5 Bearings 6 Hub shell 7 Axle 8 Freehub body 9 Freehub seal
Description Axle set Bearing Freehub body splined Bearing press Removal tool
Model year 01/02 01/02 01/02 01/02
Model for all all all all
Parts included (qty) 1(2), 2(2), 3(2), 4, 7, 8, 9, removal tool DT Comp/Onyx (not shown) DT Pro/240 (not shown) Not shown

TCG Part # 211415 211338

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

DT-Swiss Comp series hubs
Important information before you begin with Comp series 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. 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. 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 information for these hubs. If you have further questions about these hubs regarding technical information, support, or warranty, they should be directed to Bontrager Technical Support via phone or on the Bontrager web site at www.bontrager.com. 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. Tool list for DT Swiss front hubs 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 DT 17mm cone wrench Long Comp front hub bearing press bearing Multi-purpose DT grease press These maintenance items are available as TCG part #211416.

Special screwdriver

Front hub bearing press

Comp front hub

Bontrager Race Modified, Race Modified Disc front wheel, 2003 Race Lite ATB, Race Lite ATB Disc front wheel Recommended tools
End cap 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
1. Place the Comp bearing press on the workbench or other solid surface. Push a new bearing onto the axle, and push the axle into the bearing press (Fig. 4K). 2. Place the hub over the axle. 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. 4. Remove the upper bearing press. 5. Pull the axle out about 10mm (3/8in). Press the second bearing over the axle (Fig. 6K). 6. Place the second bearing 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. 1K

Fig. 6K
Disassemble the hub 1. Tap the axle (either end) with the hammer until the axle is flush with the surface of the end cap. 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. 4. Slide the end cap, seal, and bearing from the axle (Fig. 3K). 5. Re-insert the axle through the hub and tap out the second bearing. Clean and inspect the parts

Fig. 3K

Fig. 2K

Fig. 7K End cap V-seal

Thoroughly clean and inspect all components with a dry cloth. If cracks or any other damage is visible, replace the part.

Bearing

Bearing press
7. Lightly grease the surface of both bearings. 8. Pull the V-seal off the end cap (Fig. 8K). Clean it thoroughly with a cloth, lightly grease it, Fig. 8K and reinstall it on the end cap with the open V facing the hub. 9. Position the completed end cap over the axle, and press into place with your fingers.

Fig. 4K

Fig. 5K
Pos Description 1 End cap 2 V-seal 3 Bearing 4 Axle 5 Hub shell
Description Axle kit Bearing
Model year 99/00/01 99/00/01

Model for All All

Parts included (qty) 1(2), 2(2), 3(2), 4 3

TCG Part # 70361 211349

Comp rear hub
Bontrager Race Modified rear wheel, 2003 Race Lite ATB, 2002/2003 Race Lite Road rear wheel 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

Fig. 1G Spacer

Fig. 2G
1. Place the axle vise in the bench vise and clamp the lefthand end of the axle. 2. Remove the cassette. 3. Loosen the right end nut with the 17mm cone wrench and remove the end nut (Fig. 1G). 4. Pull off the freehub body with your fingers.
The spacer (Fig. 2G) may be stuck to the inside of the freehub body with grease.
2. Place the wheel over the axle with the drive side facing up. 3. Place a new bearing over the axle, black side out. Tap the short bearing press with the hammer to begin pressing the bearing into the hub (Fig. 7G). 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. 5. Again tap the short bearing press with the hammer to press the bearing into the hub.
This is an important step, which ensures the bearing is correctly pressed in.

Fig. 6G

Fig. 3G Retainer spring

Fig. 4G

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). 7. Place the right end of the axle into the axle vise. 8. Loosen the left end nut with the 17mm cone wrench, and remove it from the axle. Also remove the bearing. 9. Remove the retainer spring (Fig. 4G) and pawls from the hub with the screwdriver. 10. Pull the roller bearing retainer from the hub (Fig. 5G). 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. Clean and inspect the parts Clean all components and inspect them thoroughly. If any cracks or other damage are visible, the parts must be replaced.
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. 7. Slide the second hub bearing over the axle, black side on top. 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. 10. Slide the roller bearing retainer over the hub bearing and into the housing (Fig. 8G). Be careful not to dislodge any roller bearings. Installing the pawl spring and pawls 1. Place the pawl spring over the axle and install the spring into the retainer body with the elbow pointing up (Fig. 9G). 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. Install the freehub body

Fig. 7G

Fig. 8G Pawl spring elbow

Fig. 9G

Fig. 5G
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).
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. 3. Clean the freehub body teeth (a toothbrush works well). 4. Lightly grease the seal and freehub

Fig. 10G

Spring position Fig. 11G

Freehub body seal

Fig. 12G
teeth. 5. Install the seal into the freehub body with the lip toward the outside of the hub (Fig. 13G). 6. Push the pawls in with a screwdriver as you slide the complete freehub body onto the axle (Fig. 14G). Check the alignment to avoid excessive force which could damage the spring. 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 facing the inside. 9. Place the complete end nut onto the axle and tighten it by hand.
10. Place the wheel with the left end of the axle in the axle vise and tighten the right end nut to 150 lbin (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 facing the inside. 9. Place the complete left end nut onto the axle and tighten it by hand. 10. Tighten the end nut to 150 lbin (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 correctly installed, or there could be too much grease in the freewheel.

Fig. 14G

Fig. 13G

Fig. 15G

Pos Description 1 End nut 2 V-seal, left 3 Bearing, left 4 Axle 5 Retaining bolt 6 Driver 7 Pawl 8 Pawl spring 9 Roller retainer 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 Hub shell
Description Freehub kit (Shimano) Driver kit Axle set (130 O.L.D.) Axle (135 O.L.D.) Bearing kit
Model year 2000/01 2000/01 2002/03 2000/00/01/02/03

Model for all

Parts included (qty) 7(2), 8, 12, 13, 14

TCG Part # 72677

all 5, 6, 10 Race Lite Road 1, 2, 3, 4, 15, 16, 17 Race Mod Race Lite ATB all 1, 2, 3, 4, 15, 16, 17 3, 9, 11
Bearing shell 2000/01 kit Bearing, left 2000/01 Bearing, right 2000/01

all all all

10, (6000, 12/26 x 8mm) 11 (6900, 10/22 x 6mm)

211349

Pro series hubs
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 maintenance work. This manual details the principle design features of DT Swiss 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. 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 information for these hubs. If you have further questions about these hubs regarding technical information, support, or warranty, they should be directed to Bontrager Technical Support via phone or on the Bontrager web site at www.bontrager.com. In the event of improper servicing of the hubs, Bontrager has the right to refuse any warranty. Special information before you begin Bearing play: A small amount of play between the freehub 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. Aluminum freehub bodies: For hubs with an aluminum 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). 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 corrected. If you are unable to correct the fault, consult Bontrager Technical Support. Regular Maintenance Maintenance of the rear and front hubs should be performed at least once a 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. Determining the year of hub There are two styles of rear hub, with some unique parts and different instructions for assembly and disassembly. To determine 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 bearing. If the bearing is completely visible due to its 24mm outer diameter (Fig. FH5), its a year 2000 hub. The 2001 model uses a larger, 28mm diameter bearing (Fig. FH6) that is partially covered by the ring nut (requiring the removal of the ring nut). Removing the cassette from the freehub body The cassette does not need to be removed from the freehub body to perform regular maintenance. However, if you decide to remove it, it should only be removed after the hub has been completely re-assembled. 1. Release the lockring using a lockring tool. 2. Loosen the cassette by lightly tapping it counter-clockwise with the hammer. 3. Remove all the sprockets from the freehub body. 4. Use a fine file to remove bad notches from the aluminum freehub 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.

Fig. 4J

Fig. 5J
Pos Description 1 End nut 2 V-seal 3 Bearing 4 Axle 5 Hub shell
Description Axle kit V-seal Bearing End cap kit
Model year 00/01/02/03 00/01/02/03 00/01/02/03 00/01/02/03
Parts included (qty) 1(2), 2(2), 3(2), 3(6802, 15/24 x 5mm) 1(2)

TCG Part # 211344 221803

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

Install the right hand bearing 1. Clamp the spline tool into a vise. 2. Place the spacer over the splines (Fig. 5I). 3. Place the bearing onto the long end of the axle and push the bearing onto the spline tool (Fig. 6I). 4. Place the wheel over the axle, drive side down. Push the short bearing press over the other end of the axle. Tap the bearing into place with the hammer (Fig. 7I). Install the ring nut 1. Clamp the spline tool into the vise with only the splines above the jaws (Fig. 8I). 2. Inspect the ring nut for cracks or damage. If damaged, replace it. 3. Place the ring nut with the recess uppermost over the splines (Fig. 9I). Place the spacer ring flat inside the ring nut. 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. 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. Fig. 7I

Fig. 1I

Fig. 6I

Disassemble the freehub

Spacer

Star ratchet

Fig. 2I
1. Place the axle vise in the bench vise and clamp the lefthand end of the axle. 2. Pull sharply with your fingers to remove the cassette, with the freehub body attached (Fig. 1I). 3. Remove the star ratchet, spacer and spring (under the star ratchet) from the hub (Fig. 2I). 4. Remove the second star ratchet and second spring from the freehub body. Disassemble the ring nut 1. Clamp the spline tool into a bench vise (Fig. 3I). 2. Push the right side axle end into the cylinder. With the splines engaged, turn the wheel firmly in an anti-clockwise direction. The ring nut will be loosened, and the seal between the hub and freehub body will fall over the spline tool onto the vise. 3. Thoroughly clean and inspect all components, including inside the hub, with a dry cloth. If necessary, use a toothbrush. If cracks or any other damage is visible, the parts must be replaced. Disassemble the bearings