1. Oil change ...... 87

2. Maintenance and care ...... 89

3. reversing/replacing ...... 90

4. Changing of brake discs ...... 91 5. Changing the gear mech 5.1 Removal of one-piece axle ring ...... 92 5.2 Removal of quick-change axle ring ...... 92 5.3 Mounting the external gear mech ...... 93

86 Service Service

1. Oil change An oil-change must be completed every 5000km or once perAnnum to ensure the 25ml quantity of oil is retained and is free from dirt/moisture contamination. This process ensures that theSPEEDHUB 500/14 will always contain enough oil for lubrication (regardless of oil lost due to sweat oil) and also ensures that any penetrated moisture is 3 4 5 rinsed out.

TheOilChangeKitconsistsof: A A 25mlcleaningoilina50ml POINTER B bottle* E B 25ml RohloffSPEEDHUBOIL * Therewillalreadybeapprox. C Oilfillingtube 25mlfluidinthehub(oldoiland C D Nonreturnablesyringe50ml anypenetratedmoisture). Afterthe E Drainscrewwithnewseal cleaningoilisalsofilledintothe hubthentherewillbeapprox. Theoilfillingtubeshouldbe Removethedrainscrew(3mm Draw25mlSPEEDHUBOIL into Fitanewoildrainscrewand 50mlfluidtodrainout.Forthis placedoverthesyringeand allenkey)andrefitthefillingtube thesyringeandinsertthisintothe tightencorrectly(AllenKeySW3, reasonthecleaningoilcomesina securedwithadropofsuper-glue andsyringe. Turnthewheel,so hub.Drawoutapprox.25mlofair tighteningtorque0.5Nm). Aslong 50mlbottlesothattheoldfluid D beforeuse. thatthefillingpointisunderneath tokeepthepressurecorrectinside asthethreadsealantisnotworn, canbedrainedoutintothisbottle thehub. Waitapprox.15minswith andtherefore,avoidoilseeping thentheoldoildrainscrewmaybe forsafedisposal. thewheelinthisposition,thenuse backout,whenremovingthe usedrepeatedly. thesyringetodrawouttheold fillingtube. fluid.Removethesyringeand

fillingtube,usethistoemptythe 5a fluidintotheempty50mlcleaning oilbottle. Torinsethehubproperly,ride 1 2 approx.1kmorturnthewheelby handusingthecranksforapprox. ATTENTION 3minwhilstsimultaniously The RohloffSPEEDHUB500/14 swichingbetweengears#3and#5. mustbefilled exclusivelywith ATTENTION Inthesegearsallplanetarygear Rohloff oils (gear box/cleaning Theoildrainscrewmustnotbe setsareinuse,makingsurethat oils). Theuseofothertypesof insertedanyfurtherthanflush withthehubshell.Anydeeper thecleaningfluidiswellrinsed lubricantsand/orcleaningfluids throughinordertothinouttheold couldresultinperiodicdriveloss couldleadtothedamageofthe incertaingears. oilforeasierremoval. innermechanism'snylon components. Gefahr Tochangetheoil,the Rohloff Drawthe25mlcleaningoilinto Usedoilshouldbetakentoa Danger SPEEDHUB500/14 shouldbeleft thesyringe,screwthefillingtube specializedoildisposalpoint,soas atroomtemperature(becausethe intothedrainscrewholeandfill tokeeppollutionlevelsdown. oilflowsbetter). Turnthehub,so thecleaningoilintothehub. After TIP H E A LT HH A Z A R D thatthedrainscrewcanbeseenon this,usethesyringetodrawouta RohloffSPEEDHUBOIL and Itisimportanttoprotectthebrake thetop.Removedrainscrew(3mm littleairoutintothesyringe. cleaningoilcanbedisposedof RohloffCleaningOilArt.No.8402-25ml,8407-250ml,8405-1L. disk/pads(ifmounted)withaclean allenkey). Removethefillingtubeandrefit togetherwithothermotoroils. clothtominimizethepossiblity Containsdistillates(petroleum),hydrotreatedlight.Maybefatalif thedrainscrew. thatoilcouldsprayoutontothem. swallowedandentersairways.IF SWALLOWED:Immediatelycalla Donotexposetodirectsunlight. POISONCENTERordoctor/physican.DoNOTincludevomiting. Storelockedup.ContainsPhenol, isopropylated,phosphate(3:1). Keepoutofreachofchildren. Mayproduceanallergicreaction.

87 88 Service Service

2. Maintenance and care 3. Sprocket reversing/replacing

Thecabletensioncanbe The sprocket sizes 15, 16 and 17 of theRohloff SPEEDHUB 500/14 are symmetrical and are therefore reversable, 1 2 alteredbythecableadjusters. When when worn on one side. After reversing the sprocket, fit a new chain. This will now pull on the other, unworn side of windingthecableadjustersout,the the sprocket. Once both sides are worn, the sprocket must be replaced. The 13 tooth sprocket is not reversable, and cabletensionisincreased.Forthe therefore, must always be replaced once worn. lightestpossiblegearchange,the tensionshouldbejustenough,so 1 2 3 thatonthetwistshifterthereis approx.1/2gear(2mm)rotational play,wheninaselectedgear. The dotonthetwistshifterbodycanbe alignedtothecorrectgearnumber withoutalteringthecabletension, Ontheversionswithaninternal Ontheversionswithanexternal bywindingonecableadjusterin gearmechthecableadjusterscan gearmechthecableadjusterscan andtheotherout. befoundonthecableguide. This befoundonthecablebox. This ATTENTION canbefoundonthelefthandchain sitsdirectlyonthelefthandsideof stayorattachedtothelefthand the RohloffSPEEDHUB500/14. Toomuchcabletensionraisesthe brakebossoftheframe. Thesecablesareeitherrouted Checkthattheseatsonthedriver Holdthesprockettoolsteadywith Thesprocketcanberemovedover amountoffrictionwithintheshifter alongtheseatstayorthechainstay arecleansothatthetoolcanbe a24mmwrenchandusingachain thesprockettool. Whenonly cablesandinturn,raisestheforce oftheframe. properlyseated. Placethesprocket whipturnthesprocket reversingthesprocket,cleanthe neededonthetwistshiftertoselect tooloverthecleanseatsofthe anticlockwiseintheopposite sprocketturnitover180°and othergears. driverandwithaquickrelease directiontothe24mmwrench. screwitbackontothecleanedand lever(CC)oranaxlenut(TS) regreasedthreadofthedriverina secureinposition,sothatthe clockwisedirection. Tightenupthe 3 4 5 sprockettoolispreventedfrom sprocketusingthechainwhip.If springingoutoftheseats. thesprocketneedstobereplaced, 2a simplyscrewthenewsprocket tightlyontothedriver. POINTER Makesurethattheareaaroundthe POINTER sprocketandhubshellisfreefrom dirt,sothatthiscannotpenetrate Placingthenew/reversedsprocket intothegear-unitduringthis ontothedriveroverthesprocket toolhelpsthesprockettositevenly onthethread,soastoeliminatethe Whenlubricatingthechain,placea Tolubricatethechaintensioner, RohloffSPEEDHUB500/14 Possibleringofwearordamage ATTENTION onthesealsurface. possibilityofcross-threading. thinthreadoflubricantonthe placeadropofoilontheleftand versionswithexternalgearmech: Makesurethatthesprocket outsideofthechainoverthecentre rightsideoftheupperjockey Tolubricatethecablepulley removertoolisproperlysecured A dropofspecialRohloffcleaning rollers. Thisprocessiscarriedout wheelonthepivotpoint. bearing,removethecableboxand correctlywhenmountingor ATTENTION oil(Art.No.8402)throughthe quickerandeasier,whenrunning placealittlegreaseontheparts dismountingthesprocket. Checkthesprocketforsignsof holesinthenewsprocketfacecan thechainbackwardswhilst arrowedinthepictureabove. Thesprocketshouldnotbe damageorwearcausedbythehub drasticallyhelpreducetheeffectof applyingthelubricant. removedwiththeuseofabench- seal.Ifneeded,reverseorreplaceit thecrankrotationwhilepushing vicemountedsprocketremover forasprocketwithundamagedseal the ATTENTION tool. surfacesimmediately. Thiswillin WhenusingadiscbrakeinconjunctionwiththeRohloffSPEEDHUB500/14 ,thehubcapscrewsshouldbe Failuretocomplycouldresultin turnreducethepossibilitythatoil checkedthattheyarecorrectlytightenedbeforeeveryride. damagetothedriver. couldseepout. Toreducethechanceofaflangebreakingduetounequalspoketension,werecommendthatthisisregularly checkedbyaprofessionalbicyclemechanic. 89 90 Service Service

4. Changing of brake discs 5.Changingthegearmech

If the brake disc is worn or needs to be replaced by a different brake type, the rear wheel along with the axle plate will Thereplacementofthegearmechisnormallyonlyneeded,whenmountingthehubonadifferentbicycleframe. have to be removed before the replacement of the disc can be carried out. Itisnotroutineworkandweadvisethatthisworkiscarriedoutbyaprofessionalbicycleworkshop. 5.1Removalofone-pieceaxlering 1 L 2 3 M 1 2 3

old

Marktheaxleplate,sothatitcan Removethefourmountingbolts M Pulltheoldbrakediscoffthe bereplacedlaterinthesame (M8x 0.75 x 8.5-5mmallenkey). centerdiscmountandremovethis Regardless of which axle plate is Liethewheelonaflatsurfacewith position.Removetheaxleplate overtheexternaltransferbox. TIP mounted, the axle plate must be theaxleringfacingupandthe screws(M4x 25- Torx TX20) . Shouldtheaxleringnotloosenby ATTENTION removed by unscrewing all six of cableguidesfacingtotheright. Removetheaxleplateandsecure hand,useapipewrenchtoholdthe Theexternaltransfer boxmust the axle plate screws (M4x 25 - Rocktheaxleringfromsideto theexternaltransferboxtothehub axleringtight(placecardboard notberemovedasthecogs Torx TX20). sidewhilstpullingitupwardsin withoneofthesescrews L. betweentheaxleringandthepipe withintheboxcouldfalloutof ordertoloosenitfromthehub. synchroni-zation.Seechapter wrench).Rocktheaxleringfrom "Service"paragraph5. sidetosidewiththepipewrench, "Changingthegear mech". whilstpullingitupwardsinorder toloosenitfromthehub.

4 5 6 5.2Removalofquick-changeaxlering M

1 2 3

new

Placethenewbrakediscover Replacethefourmountingbolts M Theremovaloftheaxleplateis theexternaltransfer boxand (M8x 0.75 x 8.5-5mmallenkey, notnecessaryontheOEM downontothecenter discmount tighteningtorque7Nm/61in.lbs.). versions,wheretheaxleplateis (payattentiontotherotational Removetheaxleplatescrew L securedtothehubintheposition Regardlessofwhichaxleplateis Liethewheelonaflatsurfacewith Removetheaxleringscrew directionofthebrakedisc). fromtheexternaltransferbox. shownintheabovediagram. The mounted,theaxleplatemustbe theaxleringfacingupandthe (M4x 20- Torx TX20)androckthe Remounttheaxleplateinthe brakedisccansimplyberemoved removedbyunscrewingallfiveof cableguidesfacingtotheright. axleringfromsidetoside,whilst correctpositionandsecurethisin overtheexternaltransferboxand theaxleplatescrews(M4x 25- Pullthecableguideswiththe pullingitupwardsinorderto placewiththefiveaxleplate theaxleplatetogether. Torx TX20). nyloncylindersandthecable loosenitfromthehub. screws (M4x 25- Torx TX20, pulleyupwardsandoutoftheaxle tighteningtorque:3Nm/25in.lbs.).

91 92 Service Service

5.3Mountingtheexternalgear mech

correct 1 2 3 7 8 D E 9 C

D incorrect F

F

Shiftthegearboxintogear#14by Holdthealuminiumnutonthe Placethecablepulleyoverthe InsertcogD overthehexagonal Thefiveothermountingpositions ATTENTION turningthehexagonalpegwithan sprocketsidewitha17mmwrench hexagonalpegoftheexternal pegE withthetoothingfacing resultinthescrewholesofthe outward. Thereisonemounting Thewheelmustnotbelaidonthe 8mmwrenchcarefullyinananti- topreventtheaxlefrommoving, transferboxandthenrotateituntil cablepulleybeingsubstantially positionoutofthepossiblesix, axleringsideoncetheaxlering clockwisedirectiontotheendstop. whilstselectingthegear. thetwoscrewholessitonthe wheretheteethofthecogD and moreoutoflinewiththecenter hasbeenremovedbecause: centerlineF ,asshowninthe thesprocketC lineup.Inthis lineF .Inthiscase,removethecog a. Oilcouldleakoutoftheholes. diagramabove.Holdthecable positionthescrewholesofthe D andtrythenextmounting b. Thetwofreewheelspringscould pulleyinthisposition. cablepulleyremainascloseas position. possiblealongthecenterline falloutofthelocatingpegholes. F.Thispositionisthecorrect position.Itmaybeneccessaryto turnthecablepulleylightlytothe leftorrighttoallowforaneasier assembly. Grease 4 5 6 10 11 D E

D

Furtherstepsformountingthe Placeanewpapergasketoverthelocatingpegsoftheexternaltransfer Mounttheexternaltransferbox Placeasmallamountofgrease externalgearmechcanbefoundin box,sothatallholesmeetupwithcorrespondingscrewholesoftheaxle ontothegearbox. betweenthecogDandtheexternal ATTENTION transferbox.Remounttheaxle chapter"Mounting",paragraph7.3 ring. Thesmallersealsitsintherecessontherearsideoftheaxlering. ThesmallersideofcogD must plateandsecureitinthecorrect "Externalgearmech". alwaysbemountedintothe positionwiththefiveaxleplate externaltransferboxfacing screws(M4x 25- Torx TX20, POINTER inwards. WhencogD iswrongly tighteningtorque3Nm/25”lbs.). ThegrubscrewundertheExternal mounted,theaxleplatewillcause GearMechshouldbefittedinthe functionaldifficultieswithinthe correctposition. “Appendix- GrubscrewoftheExternalGear externaltransferbox. Mech”. 93 94 Repairs

1. Changing the hub cable (0.9mm Rohloff special gear cable)...... 97 1.1 One-piece axle ring ...... 98 1.2 Quick-change axle ring ...... 104

2. Changing the chain tensioner spring ...... 108

3. Changing the grip rubber ...... 109 4. Exchanging the gear unit 4.1 Gear unit removal ...... 110 4.2 Gear unit installation ...... 111

5. Hub Seal replacement

6.Appendix Failure Diagnosis ...... 119 Trouble Shooting ...... 120 Tools and Bolts ...... 124 Wheel lacing with a European spoke-hole pattern ...... 125 Wheel lacing with a French spoke-hole pattern ...... 126 Technical Data ...... 127 Reference to Serial Number ...... 128 Threaded Pin under External Gear Mech ...... 129 The correct spoke choice ...... 130 Possible causes for flange breakages on bicycle hubs ...... 132 Twistshifter ‘light’RH -Art. #8206 - Mounting instructions ...... 134-137 Twistshifter ‘light’LH -Art. #8207 - Mounting instructions ...... 138-141 Notes ...... 142-151 Information over the newest version Owners Manual ...... 152 A selectionofandthesprockettool Index ...... 153-154

95 96 Repairs Repairs

1. Changing the hub cable (0.9mm Rohloff special gear cable) 1.1 One-piece axle ring

The method of replacement for a worn or broken hub cable can be carried out differently depending on which axle ring type is mounted. 1 2 3 1. Axleringwithpressed-incableguides(one-pieceaxleringwithspareparts‘Hubcables’Art.#8271) 2. Axleringwithcableguidesseatedwithinnyloncylinders(quick-changeaxleringwithspareparts‘Hubcable EasySet’Art.#8573)

1 6x 2 5x

Removetherearwheel. Withgood Unscrewbothbayonetmale Tochangethehubcables,theaxle wirecutters,cutoffthefourcable connectorsfromthehubcables platemustbefirstremoved. Todo tiesthatholdtheconcertinatubes (M4x 4-2mmallenkey)and thisunscrewthesixaxleplate overthehubcables. removetheconcertinatubes. screws(M4x 25- Torx TX20).

Theone-pieceaxleringwas Thequick-changeaxleringis ATTENTION mountedonallinternalgearmech securedtothegearboxwithfive versionsuntilthebeginningof axleplatescrews. Theaxlering Takenoteofthepositionofthe 2003. Thistypeofaxleringis remainssecuredtothegearbox axleplateagainstthehubcable securedtothegearboxwithsix withonemorescrewandthecable guidesforcorrectrefitmentlater. axleplatescrews. Thecableguides guidesseatedwithinblacknylon oftheone-pieceaxleringremain cylindersrestintheaxlering. This 4 5 6 fixedtotheaxlering. Thiscanbe canbeseenoncetheaxleplatehas seenoncetheaxleplatehasbeen beenremoved. Whenreplacingthe removed. Toreplacethehubcable, hubcable,theaxleringremains theaxleringcompletewiththe attachedtothegearbox. cablepulleymustberemoved.

Replacementprocedure Replacementprocedure seeparagraph1.1. seeparagraph1.2.

POINTER Toholdtheaxlesteady,gripthe Liethewheelonaflatsurfacewith When correctly mounted, the hub cable should last a good 10,000km. Should the cable get damaged and need to be longtorquearmtightlyorholdthe theaxleringfacingupandthe TIP replaced sooner, the reason for this damage should be identified and corrected before mounting a new hub cable. OEMorOEM2axleplatewitha cableguidesfacingtotheright. Shouldtheaxleringnotloosenby Possible reasons: 10mmwrench(seechapter Rocktheaxleringfromsideto hand,useapipewrenchtoholdthe 1. False alignment of the axle plate or the cable guide can result in the cable rubbing against the metal of the cable "Mounting",paragraph4.3). sidewhilstpullingitupwardsin axleringtight(placecardboard adjusters/guides. (see chapter “Mounting”, paragraph 4.1.2). ordertoloosenitfromthehub. betweentheaxleringandthepipe 2. Torque not properly secured. The hub axle rotated and streched the cables to breaking point. wrench).Rocktheaxleringfrom 3. Other physical damage (eg. crashes, accidents). sidetosidewiththepipewrench whilstpullingitupwardsinorder toloosenitfromthehub.

97 98 Repairs Repairs

7 8 9 13 14 15 Rearside withrecess 14.

Groove Frontside

Themountingofthecablepulley Withan8mmwrenchturnthe Nextpushtheotherendofthe Holdthecabelpulleytightand Payattentiontowhichsideofthe ATTENTION mustbecarriedoutingear#14. To hexagonalpeginananticlockwise cableintothetopholeofthecable withtheotherhandgraspthehub cablepulleyisthemountingside. Thewheelmustnotbelaidonthe dothis,theaxlehastobeheld directionuntiltheendstop.Now pulleyuntilbothendsofthecable cablesandpullthemquicklyuntil Theback/mountingsidehasa axleringsideoncetheaxlering steadywitha17mmwrenchonthe thehubisingear#14. stickapprox.thesamelengthout thecablesitsproperlyinthecable recessbeforeitshexagonalhole. hasbeenremovedbecause: aluminumnut(sprocketside). oftheotherside. pulleywithoutgettingkinked. Thefrontsideiswithoutthis a. Oilcouldleakoutoftheholes. b. Thetwofreewheelspringscould falloutofthelocatingpegholes.

16 17 18 Frontside

10 11 12

2¾turns

Putthecablepulleyontoan8mm Holdbothendsofthehubcablein Pressbothendsofthehubcable allenkeywiththefrontsideontop. positionwiththumbandindex togetherwiththethumbandindex Bendthehubcablesinthe finger. fingeroftheotherhand.Remove Removebothpapergasketsfrom Pushthecablepulleyoutofthe Pushthenewhubcableapprox. directionofthecablerunsinthe thecablepulleyfromthe8mm therearsideoftheaxlering axleringfromtherearside. Take halfwayintothecablepulleys cablepulley. Thetopcableshould allenkey. (whereapplicable). Alwaysuse carenottotiltthecablepulleyfor lowerholefromtheinnerside. bewoundapprox.2¾times aroundthecablepulley. newpapergasketswhen aneasierremoval.Removetheold POINTER remountingtheaxlering. hubcableandcleanboththecable pulleyandtheaxlering. Theinwardgrooveofthecable Checkcablepulleyfor burrsand pulleyshouldbesittingfacingin deburr ifnecessary. theoppositedirectiontothegear cable. Therunsofthecablepulley mustbecompletelyfilledbythe gearcable. 99 100 Repairs Repairs

19 20 21 25 26 POINTER Frontside Shouldoneendofthehubcablebe left right pulledcompletelyroundtotheend ¸ stop,thebendinthehubcable (betweenthecableholeofthe cablepulleyandthecablerun)will straightenout. Thisbendingand Front ¾ straighteningofthehubcablewill side considerablyshortenthecablelife. Therefore,thecablepulleymust alwayshaveanendposition Gripthecablepulleywithafree Threadtherightendofthehub Pullthecablepulleyuptotheaxle Holdtheaxleringinthelefthand Pulltheleftendofthehubcableso approx.halfaturnawayfromthe handsothatbothendsofthehub cable(longend)throughtheright ringbypullingbothendsofthe andpulltherightendofthehub thatthegrooverotatesapprox.1/2 cableguides. Thiswaythehub cableareheldinposition.Hold handcableguide. Threadtheleft hubcableequally.Pushthecable cableuntiltheendstop(groove revolution. Thegrooveinthecable cableisguaranteedtorun thissothatfrontsideofthecable endofthehubcable(shortend) pulleyintoaparallelpositionwith rotatestoabout2o'clock). pulleyshouldnowsitbetweenthe smoothlyasitalwayssitsinthe pulleyfacesup. throughthelefthandcableguide. theaxleringusingthethumb 7and8o'clockpositions. Thisis cablerunandthebendremainsin Thisprocedureworksaloteasier (fromoutside)andindexfinger thepositionofgear#14.Holdthe place. whentheaxleringisheldbya (frominside)whilstkeepingthe axleringandthecablepulley thirdhand. tensionappliedtobothhubcable securelyinthispositionandplace ends. Thecablepulleythensprings thisontothegearboxwiththe intotheaxleringhole. locatingpegsinthecorrectholes. Grease Grease 27 28

22 23 24

¾

Makesurethatthehexagonalpeg Checkthefunctionoftheaxlering Thecablepulleymustrotatefreely Placeanewpapergasketoverthe Laythewheelonaflatsurfaceso sitscorrectlywithintheholeofthe bygrippingoneendofthehub withintheaxleringwhenpulling locatingpegsoftheaxleringso thatthetwolocatingpegholes(not cablepulley(groovebetweenthe7 cablewithpliersandpullingthis eachendofthehubcable.Prevent thatallholesmeetupwiththe threaded)layatpositions3and9 and8o'clockpositions).Itmaybe outtotheendstop.Repeatthis thecablepulleyfromspringingout correspondingscrewholesofthe o'clock(arrowed). necessarytoalterthepositionof processwiththeotherendofthe oftheaxleringwiththethumband axlering. Thesmallergasketsitsin thecablepulleybyaminimal hubcable. Attheendstops,both indexfinger. therecessontherearsideofthe amount.Placesomegrease endsofthehubcablesshould axlering. ATTENTION betweenthecablepulleyandthe protudefromthecablesguidesby Makesurethetwofreewheel axlering(arrowed).Replacethe thesameamount. springsremaininthelocatingpeg axleplateandsecureintoposition holes. withthesixaxleplatescrews, tighteningthemincrossformation 101 (Torx TX20,tighteningtorque: 102 3Nm/25”lbs.). Repairs Repairs

1.2 Quick-change axle ring (after Serial Number 25300) A Hub Cable Easy Set (Art. #8573) is available for a quick replacement.A Hub Cable including all needed parts can simply be slotted into the axle ring as a complete unit (See included instruction sheet for mounting instructions).

29 30 31 1 2 3

mm 1 6 5m mm 1 6 5m

Checktherear(14) sidecableis Pushthecableupintothemale Placeanewconcertinatubeand Removetherearwheel. Withgood Unscrewthebayonetmale Tochangethehubcablestheaxle pulledouttoitsendstop. bayonetconnectorasfarasitwill malebayonetconnectoroverthe wirecutterscutoffthefourcable connectorsfromthehubcables platemustbefirstlyremoved. To Measure*thisrear(14) cableand goandtightenboth4mmheadless cable. Tightenuptheconnectoras tiesthatholdtheconcertinatubes (M4x 4-2mmallenkey)andthen dothis,unscrewthefiveaxleplate cutitat165mmwithsharpwire screws(2mmallenkey,tightening withtheother.Pulltheshorter overthehubcables. removetheconcertinatubes. screws(M4x 25- Torx TX20). cutters.Placeanewconcertina torque:1.5Nm/12”lbs.).Pullthe cableuntilbothofthehubcables tubecarefullyoverthecableand front(1) sidecablewithpliers areapprox.thesamelength. ATTENTION placethemalebayonetconnector throughthe13clicksofthe Placethetwonewconcertinatubes ontotheendofthecable. gearboxuntiltheendstop(gear#1). overthecableguidesandsecure Takenoteofthepositionofthe Measure*thisfront(1) cableand withcableties.Makesurethatthe axleplateagainstthehubcable cutitat165mmwithsharpwire cabletiesclamptheconcertina guidesforcorrectrefitmentlater. cutters. tubesovertherecessineachofthe cableguides. 4 5 6

32 33 TIP * For easier measurement of the correct cable length the special measuring pipe (Art. #8711) can be ordered. Simply place the measuring pipe as far down as Themountingofthecablepulley possible over the cable. Cut the Theaxleringremainsattachedto mustbecarriedoutingear#14. To cable at the end of this pipe, then theaxlebyonemorecountersunk ATTENTION dothis,theaxlehastobeheld slide the new concertina tube over headboltunderneaththeaxleplate. Donotliethewheelontheaxle steadywitha17mmwrenchonthe the pipe. Remove the measuring Liethewheelonaworktopwith ringside,asitispossiblethatoil lockingnutonthesprocketside. The top ends of the concertina tubes pipe, secure the male connector and theaxleringfacingupwards. couldleakoutoftheboltholes. must be placed over the ends of the the concertina tube in the correct Removethetwocableguideswith male bayonet connectors and positions. thenyloncylindersandthecable secured with cable ties. Make sure pulleybyrockingthecableguides that the cable ties clamp the fromsidetosideuntiltheyare concertina tubes over the recesses. releasedfromtheirseatswithinthe axlering.

103 104 Repairs Repairs

7 8 9 13 14 15

Frontside Nylon

14. Groove ¸ cylinder Groove ¸

Cables Cables Cable guide

Withan8mmwrenchturnthe Removetheoldhubcablefromthe Nextpushtheotherendofthe Thepictureshowsthecablepulley Thecablepulleyshouldbeplaced Placethecableguidesoverthehub hexagonalpeginananticlockwise cablepulley. Cleananddeburr cableintothetopholeofthecable withthecorrectlywoundhub overthehexagonalpegofthe cables,nyloncylinderendfirst! directionuntiltheendstop.Now cablepulleyifnecessary. Insert pulleyuntilbothendsofthecable cables. Thecablerunsare shiftingshaftwiththegroove thehubisingear#14. thenewhubcable(0.9mm)approx. stickapprox.thesamelengthout completelyfilledwiththegear facingtowardsthecountersunk halfwayintothecablepulleys oftheotherside. cableandthegroovefacestoward axlebolt(orasneartoitas lowerholefromtheinnerside. the10o´clockposition. possible approx.9-10o´clock position).Bothendsofthehub cableshouldbeplacedthroughthe seatsofthecableguides. 10 11 Rearside 12 withrecess Groove Groove 2¼turns 16 17 18 incorrect correct

Frontside Frontside ¸1/2turn

Holdthecablepulleytightlyand Payattentiontowhichsideofthe Bendthehubcablesinthe withtheotherhandgraspthe cablepulleyisthemountingside. directionofthecablerunsinthe 0.9mmhubcablesandpullthem Theback/mountingsidehasa cablepulley(thisiseasily quicklyuntilthecablesitsproperly recessbeforeitshexagonalhole. achievedbyplacingthecable Thecableguidesaresitting Pressthenyloncylindersfirmly Placealittlegreasebetweenthe inthecablepulleywithoutgetting Thefrontsideiswithoutthis pulleyontoan8mmallenkey). properlyintheirseatsoftheaxle intotheirseatsoftheaxlering. axleringandthecablepulley. kinked. recess. Thetopcableshouldbewound ringwhentheroundedtopofthe Remounttheaxleplatechecking approx.2¼ timesaroundthe nyloncylinderisfacingupwards thatitisatthesameangleagainst pulley. Thebottomcableapprox. (asshownintheabovepicture). thecablesguidesasitwasbefore. 1/2 ofaturnintheopposite Tightenupthefivecountersunk direction. bolts(Torx TX20-tightening torque:3Nm/25”lbs.).

105 106 Repairs Repairs

1.3 Bajonet connector

19 20 21 ATTENTION The new male bayonet connector (after-2005/Serial Number 43100) differs from the former as discribed below: : - 3mm Drilling (cable mount) - Ring shaped groove (distinction characteristic)

mm 1 6 5m - Cable end sheath

mm 1 6 5m POINTER Do not use the new cable sheaths together with the old bayonet connectors (2mm drilling) to clamp the cables. In this case, the cable sheaths will be squeezed flat and it will no longer be possible to remove them from the 2mm bayonet connectors. Checktherear(14) sidecableis Pushthecableupintothemale Placeanewconcertinatubeand pulledouttoitsendstop. bayonetconnectorasfarasitwill malebayonetconnectoroverthe Measure*thisrear(14) cableand goandtightenthetwo4mm cable. Tightenuptheconnectoras 1 2 3 cutitat165mmwithsharpwire headlessscrewswitha2mmallen withtheother.Pulltheshorter old cutters.Placeanewconcertina key(tighteningtorque cableuntilbothofthehubcables new tubecarefullyoverthecableand 1.5Nm/12”lbs.).Pullthe front(1) areapprox.thesamelength. placethemalebayonetconnector sidecablewithpliersthroughthe Placethetwonewconcertinatubes ontotheendofthecable. 13clicksofthegearboxuntilthe overthecableguidesandsecure endstop(gear#1).Measure*this themwithcableties.Makesure cableandcutitat165mmwith thatthecabletiesclampthe groove sharpwirecutters. concertinatubesovertherecessin groove eachofthecableguides. cablesheath Thebayonetconnectorsshouldbe Insertthehubcableincludingthe Use the 2mm allen key to secure the 22 mountedtogetherwiththecable newcablesheathcompletelyuntil cable inside the bayonet connector TIP sheathsontothe0.9mmhubcable. thebedstopintothebayonet with 0.8Nm. Secure the concertina * For easier measurement of the Thisway,damagetothecableby connector(3mmdrilling).Fixthe tubes with cable ties. correct cable length the special pincingitwiththegrubscrewscan grubscrewswitha2mmallenkey. For further help, refer to beeasilyprevented. “Repairs”1.2. measuring pipe (Art. #8711) can be ordered. Simply place the measuring pipe as far down as possible over the cable. Cut the 1.3.1 New Bajonet version 2014 cable at the end of this pipe, then slide the new concertina tube over the pipe. Remove the measuring 1 2 3 The top ends of the concertina tubes pipe, secure the male connector and must be placed over the ends of the the concertina tube in the correct male bayonet connectors and positions. secured with cable ties. Make sure that the cable ties clamp the concertina tubes over the recesses.

107 108 Repairs Repairs

2. Changing the chain tensioner spring 3. Changing the grip rubber

Since the end of 2002 theRohloff chain tensioner has been equipped with a modified spring. With the conversion kit (Art. #8248) all the olderRohloff chain tensioners can be equipped with the new spring. POINTER 1 2 Circlip Springend 1 2 3 stop Theshiftercableshavetobe Cage removedfromthetwistshifterfirst Shortleg beforeitispossibletoreplacethe Cable rubbergrip.Beforetheshifter run14 Long cablesareremoved,theendsthat Nipple Pivotaxle leg wereclampedinthefemale Torsionspring connectors(internalgearmech)or (oldtype) thecablepulley(externalgear mech)mustbecutsothatthe Cablestop1 frayedendsofthesecablesdonot damagethenylonlinerswhen Removecablestop1androtatethe Withaflatscrewdriver,removethe twistshifteruntilthenippleof Removethesafetyclipfromthe Cleanandgreasethepivotaxle. Pushthecagecompletelyontothe beingremoved. safetyring. Therubbergripcan pivotaxleusingaflatscrewdriver. Mountthenewtorsionspringover pivotaxle.Replacethewasherand shiftercable14canbeseen.Pull nowberemoved.Cleanthetwist Donotreusethisclip.Pullthe thepivotaxleasshown. Turnthe fitthenewsafetyclipintoposition. thecableoutofthetwistshifter. shifterhousing. Repeatthisprocessfortheremoval cageandthewasheroffthepivot torsionspringuntilitsshortleglies ofshiftercable1. axleinthedirectionofthearrow. againstthespringendstop.Hold Removetheoldtorsionspring. thetorsionspringinitspositionon thepivotaxlewhilstswingingthe TIP longlegoverthespringendstop. Shouldonlytherubber grip needtobereplaced. Firstlyshiftintogear#14. DisconnecttheBayonet 4 5 6 ConnectorsortheExternalcable 3 4 box.Screwbothofthecable O-ring Countersunk adjusterscompletelyinand bolt removethetwoscrewsonthe cablestopsoftheshifter.Remove thesafetycirclipandslidethe completerubbergripoutofthe Cone shifterhousingandoffofthe washer handlebars.Hookboththecables outoftheirseatsintherubbergrip, transfertheseandre-hookthem Bringthecageandthelonglegof Pushthelonglegofthespringin Thelonglegofthespringnowsits intothenew,lightlygreasedrubber thespringtogetherintoaposition thedirectionofthearrowoverthe againsttheconewasherandholds Lightlygreasethetwistshifter Thesafetyringcannowbe grip(Art.N°8201). Windthese similartothatshowninthe newboltandletitspringback. thecagebackcreatingthetension. housing. Thearrowed“Oring” remounted.Checkthatthetwist cablesroughly3/4(270°)around diagram.Swaptheoldjockey mustalsobelightlygreasedand shifterrotatessmoothlyandfreely. thenewgripintheirrespective wheelboltforthenewcountersunk POINTER checkedthatitissittinginthe Refitnewshiftercables(see runsandslidethisnewcomplete bolt (M4x 20- Torx TX20, Toreplacethejockeywheels, correctpositionbeforeremounting. chapter"Mounting",paragraph6. unitbackinsidetheshifterhousing tighteningtorque3Nm/25in.lbs.) removethecagefromthepivot "Twistshifter"). andrefitbothofthecablestops. andconewasher. axle(asinstage#1).Removethe Replacethesafetycirclipand lowerjockeywheelboltand lightlytesttheshifterfunctions replacethejockeywheels. correctly.ReconnecttheGear Remountthechaintensioner mechingear#14. 109 (stages#3and#4). 110 Repairs Repairs

4. Exchanging the gear unit 4.2Gear unitinstallation Whenremountingthegearbox,newjointsandanewpapergasketmustbefitted. With theRohloff SPEEDHUB 500/14, the 14 speed gearbox can be removed completely from the hub casing allowing for a quick and easy replacement of the gearbox. 1 A 2 3 4.1 Gear unit removal

1 2 D C

ATTENTION Whenmountingordismounting thesprocket,alwayscheckthatthe B sprockettoolisproperlysecured. Thedrivercouldgetseverely ThebearingseatA andthe Thenewpapergasket(arrowed) ThenewjointsC mustalsobe damaged,whenattemptingthis sprocketthreadB ofthedriver mustbefittedoverthecentering lightlygreasedbeforebeingplaced removal/assemblyprocedurewith mustbelightlygreasedbefore ridgeofthehubcap. Thisisbetter intotheirrespectiveseatsD . These anunsecuredsprockettool. Theremovalproceduremuststart Removethesprocketusingachain remountingthegearbox. accomplishedwhenlightlygreased. jointsarewhattransferethepower withthetherinsinganddrainingof whipandthesprockettool(see Aligntheholesinthepapergasket fromthegearboxtothehubcasing. theoilfromwithinthehub(see chapter"Service",paragraph3. withthoseinthehubcapreadyfor chapter“Oilchange”). Thedrain "Sprocketreversing/replacing"). theboltslater. screwmustnotbereused.

3 4 5

4 5 6

RemovetheaxlenutsorQ/R Drawthegearboxoutofthehub Liethegearboxonitssideand skewerandthesprockettool.Now casing.Ifthisprovestobedifficult, removeanddisposeoftheexcess removethe8hubcapcountersunk thangentlytapthesprocketsideof oilthatissittinginthehubcasing. bolts(M4x 10- Torx TX20). thegearboxwitharubbermalletto Holdthehubcapandthegearbox Thegearboxonlysitsproperly Oncethehubcasingtouchesthe easetheprocess.CAREFUL! firmlyandfeedthegearboxinto oncethejointssitintheircorrect cap,the8countersunkscrewscan Excessoilcouldstillleakoutof thehubcasinguntilthehubcap positionsagainstthehubcasing. bereplaced. Tightenthesescrews thehubcasing! touchesthehubcasing. Toeasetheprocess,rotatethe inacrossformation,soasto driverinananticlockwisedirection evenlydistributethepressure whilstpushingthetwoparts betweenthetwopartswhilst together. securingthemtogether(M4x 10- Torx TX20,tighteningtorque:

111 112 Repairs Repairs

5.Hubsealreplacementwith Schaftsealreplacementtool(Art.#8503)andremovalhook(Art.#8507) Thehubsealsshouldonlybereplacedbyaprofesionalbicycleworkshopinthecaseofoil leakages. Thenewhubseals(afterSerialNumber25400)withanoutermetalringcanonlybe 7 8 9 replacedbyRohloffdealerswiththehubsealreplacementtools.

Shaftsealpress-intool

Assemblyfor 1x 1x sprocketside Insert (w/oinsert) Centering collar

Refitthesprocketwiththeuseofa Checkthatthesprocketruns Ring chainwhip. smoothlybyspinningthesprocket POINTER backwards.Ifnot,thenhittheaxle Thehubbearingwithinthe Slot Assemblyfor pegfirmlywitharubbermallet. hubshellisafixedbearingandthe axleringside Oncefromthesprocketside(right) hubbearingonthesprocketsideis Insert (w/insert) andoncefromtheaxleplateside amovablebearing.Duringthe (left). Thiswillloosen-upthe replacementofthegearbox,the 8mmhex tensiononthebearings. movablebearingcouldgetstrained (theouterracedoesnotmove parallelwiththeinnerracedueto frictioncreatedagainstthehub min.0.3mm 5.1 Axleringside: 10 11 casing).Byhittingtheaxlepegs 11 Old, witharubbermallet,theinnerand 1 complete outerracesofthebearingwillbe nylon broughtbackintoline. The sprocketshouldspinfreelywhen rotatedbackwardsonceitis New, with correctlyseated. metalring

Freewheelspring Freewheelspring Checkwhichtypeofhubsealismountedwithin yourhub.HubsproducedafterSerialNumber25400 POINTER areequippedwiththenewhubseal. Tobesure: The grubscrew Theremustbeaminimumof Refillthe RohloffSPEEDHUB Furtherdisassemblypastthe newhubsealshaveanoutermetalringandcan Liethewheelonaflatsurfacewiththesprocketside 0.3mmbetweenthesprocketand 500/14with25mlof Rohloff removalofthegearunitfromthe thereforebereplacedwiththetoolsshown. The facingdown.Removetheaxleplateandthe thehubcasing.Ifnot,thenremove SPEEDHUBOIL (seechapter hubshellisnotpermitted.Failure oldertypesarecompletelyformedfromnylon,hubs correspondinggearmech-abrakediscmayhaveto needingthesetypesofsealstobereplaced,mustbe thesprocketandpushthehubseal “Service”,paragraph1.“Oil tocomplywillresultinthelossof beremovedforthisprocedure. warranty/guarantee. sentbacktoRohloffServicedepartmenttobe asfarbackaspossible.Refitthe change”)andrefitanewdrain replaced. sprocketandcheckthatthe screw(3mmallenkey,tightening ATTENTION sprocketrunssmoothly. torque:0.5Nm/4in.lbs.). Makesurethetwofreewheelspringsstayinthe locatingpegholes. ATTENTION Thegrubscrewmountedonhubsproducedafter Theoildrainscrewmustnotbeinsertedanyfurtherthanflushwiththe SerialNumber 47000mustberemovedbefore hubshell.Anydeepercouldresultinperiodicdrivelossincertaingears. replacingthehubsealsandreplacedagain afterwards.See“Appendix”Grubscrew,external 113 114 gear mech. Repairs Repairs

2 3 4 8 9 10

CenteringZentrier- collarbund Groove

Placethenewhubsealaroundthe Usingacottonbud,coverthe Placethepresstoolontothehub ATTENTION Removetheoldhubsealfromthe centeringcollarofthepresstool. outsideedgeofthenewhubseal withthenewhubsealfacing hubshell. Todothisplacethe withathincoatofLoctite641. inwards. Iftherub-ringoftheaxlering insertontothehubandhookthe showssignsofdamage(grooves removaltoolundertheoldhubseal. withintheoutersurface,noticable Levertheremovaltoolintothe POINTER ATTENTION POINTER Removetheoldhubsealby withafingernail),thenpleasepost uprightpositionasshowninthe Theclosedsideofthenewhub Thegrubscrewonhubsafter sharplypullingtheremovaltool MakesurethatnoneoftheLoctite theaxleringtotheRohloffservice picture. sealfacestowardsthetoolitself, upwards.Ifthisdoesn´tremovethe findsitswayintothegrooveofthe SerialNo.47000mustberemoved departmentsothatanewrub-ring theopensideisvisible. sealfromthehubshell,thenfollow newhubseal. inabletoguaranteeaflush canbemounted. themethodshownbelow. mountingoftheHubSeal.

5 6 7 11 12 13

Laya10mmwrenchflatoverthe Useacottonbudtocleanand Threadthetwoincludedwingbolts Windthepresstoolbacktoits insertwiththeopenendhooked degrease(petroleum/brakecleaner) Onethread throughthesquareslotson normalposition.Removethepress underthewoodengripofthe thematingsurfacereadyforthe visible oppositesidesofthepresstool, toolandwingbolts.Cleanaway removaltool.Securetheremoval newhubseal. securetheseintheholesofthehub anyLoctitethathasoverspilled toolbypushingitagainsttheinsert. leftandrightoftheaxle. Turnthepresstoolclockwiseasfar ontothehubshell. Forcethewrenchdownontothe aspossiblewhilstholdingthe Preparethehubsealpresstoolas insertstillwithan8mmallenkey. insertinordertolevertheremoval showninthepicture. toolwiththeoldhubsealupwards Thenewhubsealwillnowbe andoutofthehubshell.Remove pressedfirmlyintothecorrect theinsert. position.

115 116 Repairs Repairs

20 21 22 5.2Sprocketside:

14 15 16

Usingacottonbud,coverthe Groove outsideedgeofthenewhubseal withathincoatofLoctite641. Replacetheaxleplateandthegear Removethesprocketasshownin mechusingnewpapergasketsas theOwnersManual.Liethewheel ATTENTION Cleananddegrease Placethenewhubsealaroundthe shownintheOwnersManual. onaflatsurfacewiththesprocket (petroleum/brakecleaner)the centeringcollarofthepresstool. ATTENTION sidefacingup (Service5.3) Checkthesprocketforsignsof matingsurfacereadyforthenew Theclosedsideofthenewhub MakesurethatnoneoftheLoctite Axleplateposition wear.Ifitiswornthenrotateit hubseal. sealfacestowardsthetoolitself, findsitswayintothegrooveofthe “Mounting4” beforeremounting(seeOwners theopensideisvisible. newhubseal. Internalgearmech ATTENTION Manual). Whenbothsidesare “Repairs1.1+1.2” Oilcouldleakoutoncethe wornthenreplaceitforanunworn Externalgearmech sprocketisremoved. sprocketwithundamagedseal “Service5.3” surfaces.

23 24 25

17 18 19

Removetheoldhubsealfromthe Removetheoldhubsealby Laya10mmwrenchflatoverthe hubshell. Todothisplacethe sharplypullingtheremovaltool sprockettoolwiththeopenend Placethesprockettoolontothe Removetheringandthesprocket Replacethenew/rotatedsprocket sprockettoolontothedriverand upwards.Ifthisdoesn´tremovethe hookedunderthewoodengripof driverandse-cureitinposition tool. (withundamagedsealsurfaces)as hooktheremovaltoolunderthe sealfromthehubshell,then theremovaltool.Securethe withtheQ/Rskeweroranaxlenut. shownintheOwnersManual. oldhubseal.Levertheremoval followthemethodshownbelow. removaltoolbypushingitagainst Settheringoverthesprockettool toolintotheuprightpositionas thesprockettool.Forcethewrench andthreaditclockwiseasfaras showninthepicture. downontothesprockettoolin pos-sibleoverthethreadofthe POINTER ordertolevertheremovaltool driverwhilstholdingthesprocket withtheoldhubsealupwardsand toolstillwithan24mmwrench. Themetalpartofthehubseals outofthehubshell.Removethe Thenewhubsealwillnowbe shouldbeflushwiththeedgeof insert. pressedfirmlyintothecorrect thehubshelland/orhubcap. position.

117 118 Appendix Appendix Troubleshooting Problemsandpossiblereasons Solution Problemsandpossiblereasons Solution 4.2 Shiftercablesworn,dirtyordamaged 1. Toomuchplayinthetwistshifter Readjustthecabletension, see"Service" 2. (morethan2mm) 4.3 Incorrectshiftercablesfitted (notorginal Rohloff) 2. Gear displayisnotalignedcorrectly Alterthecableadjusters,see"Service" 2 . Fitnewshiftercables: 4.4 Cableroutinghastoomanybendsorkinks -Internalgearmech,see"Mounting" 7.2 3. Twist shifter will not turn through all 14 gears -Externalgearmech,see"Service" 2. (14 gears = 13 clicks) 4.5 Innernylonlinershavepenetratedintothe } 3.1 Shifter cables cut at the wrong length Cut cables to the correct length: twistshifterorthecablebox - Internal gear mech, see"Mounting" 7.2.1 (duetoafalsefitment) - External gear mech, see"Mounting" 7.3.1 4.6 Twistshifterrubsagainstthegripitself Leaveasmallgapbetweenthetwistshifterandthe 3.2 Falsely altered cable adjusters Alter the cable adjusters, see"Service" 2. griporinsertateflonwasherbetweenthetwoparts.

3.3 For external gear mech: Correctly align the hexagonal peg 4.6.1 Twistshifterdegreasedbyweather Removethetwistshiftergriprubber,cleanit,and Hexagonal peg of the gear transfer box in regreaseit.See“Repairs”3 . an incorrect position see"Riding with the SPEEDHUB 500/14" 3.2 4.7 Hubcablebrokenandfrayed Checktheshiftercables: 4. Twistshifter doesnotturnfreely Loosentheconcertinatubesatthehubandpull themuptowardsthebayonetconnectors.Checkthe 4.1 Cabletensionistoohigh Reducetheshiftercabletension, see"Service" 2. conditionofthesecablesingearpositions1and14. Ifthehubcableisdamaged,itwillneedreplacing: Checktheinternalgearmech: -One-pieceaxlering,see"Repairs" 1.1 Openthebayonetconnectorsand(holdingacable - Quick-change axle ring, see"Repairs" 1.2 ineachhand)pullthecablesinturn. Theyrun smoothly,seepoints4.2-4.6. Theydonotrun 4.8 Gear transfer box (external gear mech) is bent Replace the gear transfer box smoothly,seepoint4.7. Mounting, see"Service" 5.3 Checktheexternalgearmech: Selectgear#14.Removethecableboxjustenough 4.8.1 Changing between gears 8 and 14 is not Grub screw (after hub Nr 47000 with an external sothatthetwistshiftercanbeturnedwithoutforce possible or only possible with extreme force gear mech) is threaded too far into the axle. This must andthecableskeeptheirnormalroutingbends. be unscrewed approx. 2mm. See“Appendix” . Turnthetwistshifterbackandforth.Itdoesnot turnsmoothly,seepoints4.2-4.6.Itturns 4.9 Hexagonal peg of the external gear mech does Checking: smoothly,seepoint4.8. notturnfreely(duetocorrosion) Placean8mmwrenchover thehexagonalpegoftheexternaltransferbox. Whenusingthewrenchtoswitchgears,the changingofgearsmusthavealightandpositive feel.Ifnot,removetheexternaltransferbox. Regreasethehexagonalpegandthesprocket ("Service"5.3).

4.9.1 The cable pulley of the external gear mech Check: doesn´t turn freely (after the conversion from The correct position of the cogD over the hexagonal an internal to an external gear mech) pegE . See “Service” 5.3

119 120 Appendix Appendix

Problemsandpossiblereasons Solution Problemsandpossiblereasons Solution

10. Freespinning(after agear change) 5. Twist shifter fails to turn in 0° temperatures.

5.1 Waterhaspenetratedintothetwistshifterand Removetherubbergrip.Clean,regreasethisand 10.1 Axlenuts(CC/TSaxle)toofirmlytightened Tightenaxlenutstothecorrecttightening hasfrozen whennecessaryreplacetheseal, see"Repairs" 3. torque(CC7Nm/60inlbs/ TS35Nm/310in.lbs.)

5.2 Waterhaspenetratedintotheshiftercables Replacetheshiftercablesandthenylonliners: 10.2 Shiftercabletensionistoohigh.Nopositive Adjustshiftercabletension,see"Service" 2. andhasfrozen -Internalgearmech,see"Mounting" 7.2 feeltothegearchange -Externalgearmech,see"Mounting" 7.3 10.3 Gearboxoiltoothick Test: AddRohloff specialoilchangeassistentfluid 5.3 Waterhaspenetratedintothecableboxand Openthecablebox,cleanthisandreplacethecable totheoilwithinthehubandgoforatestride hasfrozen pulleywithalittlelightgrease. Nomorefreespinning?Carryoutanoilchange, Fitment, see"Mounting" 7.3.1 see"Service" 1. 6. Shifter cableisloosefromthecableclamp Cutoffthefrayedendsoftheshiftercableand (Bayonetconnectorsoninternalgearmech trimthecablehousing/nylonlinerbythesame 10.4 AxlefixationwithaPITLOCK Tightentheaxleto7Nm/60in.lbs.max.torque orcablepulleyonexternalgearmech) amount. Alternative:fitnewcables: orallenkeysystem (payattentiontothemanufacturersadvice) -Internalgearmech,see"Mounting" 7.2 -Externalgearmech,see"Mounting" 7.3 10.5 Noneoftheabove:Contactthe Rohloff Serviceteam 7. Malebayonetconnector isloosefromthehub Replacehubcable: cable -One-pieceaxlering,see"Repairs" 1.1 11. Freespinning(after agear change) -Quick-changeaxlering,see"Repairs" 1.2 below0°C 11.1 Gearboxoiltoothick Carryoutanoilchangewithanintensiverinsing, 8. Chainspringsover theteethofthesprocket see"Service" 1.

8.1 Chaindefect(stiffchainlink) Loosenupthestifflinkorreplacethechain 11.2 Ridingthebikebelow-15°C Rinsethegear-unitandrefillthehubwitha50:50 mixtureof AllSeasonOilandCleaningOil 8.2 Wornsprocketorchain Rotateorreplacethesprocket,replacethechain, (totalfillquantity-25ml) see"Service" 3. 12. Freespinningofgears#1to#7after removing Checkthatthetwofreewheelingspringsarethere 8.3 Notenoughtensioninthechain Correctthechainlength/tension, theaxleringor theexternaltransfer box andsittinginthecorrectholes,see"Repairs" 1.1 see"Mounting" 5.3 and"Service" 5.3 9. Onbikeswithachaintensioner,thechain 13. Freewheeldoesnotrotatesmoothly Test: Thesprocketmustrotatebackwardsfreely springsoffthesprockets withoutrestriction 9.1 Chaintensionerrunsdryandturnswith Greasethechaintensionerorreplacethejockey difficulty wheels,see"Service" 2.or "Repairs" 2. 13.1 Hubsealrubsagainstthesprocket Pushthehubsealback(untilSerial.No.25299 possible)see"Repairs" 4.2 9.2 Chaintensionerspringisdefect Replacethechaintensionerspring,see"Repairs" 2. Checkthemin.chainlengthonfullsuspension 13.2 Strainedhubbearings Destrainthehubbearings,see"Repairs" 4.2 bikes,see"Mounting" 5.3.1 (crashoraccidents) 9.3 Nochainguideinuse Mountachainguide,see"Mounting" 5.4 Allbikesfittedwithachaintensionerneedtobe 13.3 Chain Tensiontoohigh Reducethechaintensiontoabout5mmof fittedwithachainguide(egRohloff chainguide verticalslack,replaceorreverseuntruechainrings. CC Art.#8290). Thispreventsthechainfrom springingoffthechainring.

121 122 Appendix Appendix

Problemsandpossiblereasons Solution Toolsand bolts Below is a list of all tools and bolts (along with their corresponding tightening torques) for the mounting of the 14. Oilleaks Rohloff SPEEDHUB 500/14 and ist accessories. 14.1 Oiltraces(nodroplets) Thisisnotanoilleak. Thisissweatoil,which Torx TX20wrench(Art.#8504)* 7mmwrench formsaroundthehubbearing,thepapergasketand RohloffSPEEDHUB500/14: RohloffchainguideCC: 8or9Hubcapscrews:M4x 10(3Nm/25”lbs.) M4Nut,reardistancebush theoildrainscrewduetovariationsinair 5or6 Axleplatescrews:M4x 25(3Nm/25”lbs. ) temperatureandpressure. 8mmwrench 2Cableboxcoverbolts:M4x 10(3Nm/25in-lbs. ) Shiftingshaft Externalgearmech: 14.2 Oilleaksfollowinghorizontaltransportation See "RidingwiththeSPEEDHUB500/14" 2Guidepinbolts:M4(3Nm/25in-lbs.) 10mmwrench Twistshifter: TSversions: 14.3 Oiltracesonthequickreleaseskewer Theventilationfunctionsthroughtheaxleholefor 2Cableguidebolts:M4x 16(3Nm/25in-lbs.) Torquearmclampnut thequickreleaseskewer.Oiltracesonthequick Rohloffchaintensioner/DHchaintensioner: Cableguide0° releaseskewerare,therefore,normal 2Endstopbolts(DH:justone):M4x 10(3Nm/25in-lbs.) Frameclampnut 14.4 Oildropsoutofthehollowquickreleaseaxle PleasecontacttheRohloff Serviceteam Jockeywheelaxlebolt:M4(3Nm/25in-lbs.) 13mmwrench RohloffchainguideCC: Internalgearmech: 14.5 Oildropletsontheaxlering,theaxleplateor Checktheaxleplatescrewsareallinplaceand Bolt(reardistancebush):M4x 20 (3Nm/25in-lbs.) Cableguide Bolt(rearthreadedbush):M4x 20(3Nm/25in-lbs.) theconcertinatubes tightenedtothecorrecttighteningtorque.(see 15mmwrench "Mounting" 4.3)Renewthepapergasketsbetween Bolt(rearthreadedbush) :M4x 35 (3Nm/25in-lbs.) TSversions: theaxleringandtheaxle(see"Service" 5.3or 2Clampbolts:M4x 35 (3Nm/25in-lbs.) 2 TSaxlenuts:M10(35Nm/310in.lbs.) "Repairs"1.1)Onlyuse Rohloff axleplatescrews 2mmallenkey Screwdriver withthreadsealant Internalgearmech: CCversions: 8Bayonetconnectorbolts:M4x 4 2clamps(5Nm/43in.lbs.) 14.6 Oildropletsbetweenthehubcasingandthe Checkthehubcapscrewsareallinplaceand Externalgearmech: hubcap tightenedtothecorrecttighteningtorque, 2Cablepulleybolts:M4x 4 17mmwrench see"Repairs" 4.2 RohloffDHchainguide: Lockingnut(holdingtheaxlesteady) 3Mountingbolts:M4x 8 24mmwrench 14.7 Oiltracesaroundtheoildrainscrew Usenewthreadsealantontheoildrain 2.5mmallenkey forsprockettool screw(Loctitethreadsealant511)oranewoil RohloffSPEEDHUB500/14: Sprockettool(Art.#8501) drainscrewwithRohloff threadsealant, TwistShifter(oldversion) Art.#8200(0,5Nm/4in-lbs.) Sprocketremoval see"Service" 1. 3mmallenkey Chainwhip 14.8 Oildropletsonthehubbearings PleasecontacttheRohloff Serviceteam RohloffSPEEDHUB500/14: Sprocketremoval Oildrainscrew(0,5Nm/4in-lbs. ) (Bothendsofthehubsmearedwithoil) Brasstube165mm(Art.#8711) 4mmallenkey Cuttinghubcables(internalgearmech) 15. Completeblockageofthegear systemafter Thegrubscrew (mountedinhubsafterSerial RohloffSPEEDHUB500/14: Brasstube200mm(Art.#8712) Cableguidemountingbolt:M6(6Nm/51in-lbs. ) Number47000 Cuttingshiftercables(externalgearmech) workingontheexternalgear mech withanexternalgearmech)isscrewedtoofarinto TSversions: Shifter cablemeasurementtool(Art.#8506) theaxle. Thismustbeunscrewedapprox.2mm. Torquearmclampbolt:M6x 12(6Nm/51in-lbs.) Cuttingshiftercables(internalgearmech) See“Appendix” ,Grubscrew externalgearmech. RohloffSPEEDBONE/MonkeyBone : 2Mountingbolts:M6x 25 5mmallenkey POINTER RohloffSPEEDHUB500/14: 4or5Chainringbolts:M88x 0.75 (7Nm /61in-lbs. ) * Theuseof Torxscrews/boltsasopposedtothe commonallenkeyboltsallowsamoresafeand DBversions: ATTENTION nondestructivemountinganddismountingwith- 4brakediscmountingbolts:M8x 0.75(7Nm/61in-lbs.) Too much oil within the gearbox increases the risk of oil leaks. Therefore, when an oil leak is discovered, new outtheheadsroundingoutafter severaltimes Retrofitversions(notOEMorOEM2): usage. Toavoiddamagingtheheadsofthe replacement oil must not be added (risk of overfilling). Reduced oil level by leakage through the seals will not 2 Torquearmmountingbolts:M8(7Nm/61in-lbs.) screws/bolts,the Torxkeymustbesecurely cause problems and riding further until the next oil change (annually or every 5000km) is possible (see Rohloffchaintensioner/DHchaintensioner: pressedintothehead. Wesuggesttheuseofa T- "Service" 1.). Mountingbolt(8Nm/70in-lbs.) gripkeytokeepthepressurecentralover the Pivotaxle(8Nm/70in-lbs.) bolt(theuseofother toolscouldresultin 123 (Attention: Turningclockwiseunscrews) 124 damagetothebolts). Appendix Appendix

Hubcap Wheellacingfor rims 1 2 Wheellacingfor rims 1 2 screw witha European spoke- 1 2 witha French spoke-hole 3 1 holepattern 4 pattern 2 3 Thefollowingwrittenwheellacing Valvehole Thefollowingwrittenwheellacing Valvehole methodalwaysconcentratesitself methodalwaysconcentratesitself aroundthedirectionalrotationof aroundthedirectionalrotationof Front thewheel,themethodalsoonly thewheel,themethodalsoonly Trailing Front appliestowheelswithatwocross appliestowheelswithatwocross spoke lacingpattern.Forsimpleone Hubcap Leadingspoke lacingpattern.Forsimpleone (outward crosslacingpatterns,payattention screw (inwardhead) crosslacingpatterns,payattention head) tothenumbersinbrackets. tothenumbersinbrackets. Starttolaceupthewheelfromthe Theendofthisspokeshouldbe Starttolaceupthewheelfromthe Theendofthisspokeshouldbe hubcapsideofthehub. Thefirst insertedintothenippleholeofthe sprocketsideofthehub. Thefirst insertedintothenippleholeofthe POINTER leadingspokeshouldbeinserted rimthatis4holesawayfromthe POINTER trailingspokeshouldbeinserted rimthatis3holesawayfromthe Trailingspokescrossinfrontof fromtheinsideofthehubflange valvehole. Trailingspokescrossinfrontof fromtheoutsideofthehubflange valvehole. Leadingspokes. behindahubcapscrew(spoke Leadingspokes. oppositeahubcapscrew(spoke Leadingspokescrossbehindthe headfacinginwards). Leadingspokescrossbehindthe headfacingoutwards). Trailingspokes. Trailingspokes.

ATTENTION ATTENTION Further information on correct spoke lengths and tension (mind. 1000N with inflated tire) can be found in the Further information on correct spoke lengths and tension (mind. 1000N with inflated tire) can be found in the section ‘The Wheel’ and also in the Appendix . section ‘The Wheel’ and also in the Appendix .

3 4 5 3 4 5 1 Front 1 1 2 1 3 2 1 2 2 2 1 4 Leading 3 3 spoke 4 Leading Trailing Trailing (inward spoke spoke spoke Front (inward head) (outward First (outward head) head) head) sprocket First sidespoke 2 hubcap 1 sidespoke 1 2 Front 1 2 Front 3 Front 2 3 Front 1

Threeholes(onehole)behindthis Thenexttrailingandleading Thevalveholeistobefound Threeholes(onehole)behindthis Thenexttrailingandleading Thevalveholeistobefound firstspokeiswherethetrailing spokesarelacedintotherimin oppositefromahubcapscrew. The firstspokeiswheretheleading spokesarelacedintotherimin oppositefromahubcapscrew. The spokeshouldbeinserted,this exactlythesameway. Theonly spokeholeoftheflangeopposite spokeshouldbeinserted,this exactlythesameway. Theonly spokeholeoftheflangethatistwo spokeistobeinsertedfromthe differencebeingthattheyenterthe fromthisiswherethefirstspoke spokeistobeinsertedfromthe differencebeingthattheyenterthe holesbehindthis,iswherethefirst outsideofthehubflange(spoke hubflangetwoholesawayfrom onthesprocketsideistoinserted insideofthehubflange(spoke hubflangetwoholesawayfrom spokeonthehubcapsideistobe headfacingoutwards). Thisspoke thelastrespectiveleadingor fromtheinside(spokeheadfacing headfacinginwards). Thisspokeis thelastrespectivepullorcross insertedfromtheoutside(spoke istobecrossedoverthefirstspoke trailingspoke,andthattheyenter inwards). Thisspokeistobe tobecrossedoverthefirstspoke spoke,andthattheyentertherim headfacingoutwards). Thisspoke andinsertedintothenippleholeof therimfourholesawayfromthe insertedintothenippleholeofthe andinsertedintothenippleholeof fourholesawayfromthelast istobeinsertedintothefirst therimthatistwoholesbefore lastrespectivespokes.Continue rimthatis3holesbehindthevalve therimthatistwoholesbehind respectivespokes.Continuethis nippleholeoftherimthatlies thatofthefirstspoke. thisprocessinpairsofleadingand hole.Lacealltheremainingspokes thatofthefirstspoke. processinpairsofleadingand behindthevalvehole.Laceallthe trailingspokesuntilallthespokes inthesamepatternaswiththe trailingspokesuntilallthespokes remainingspokesinthesame havebeenlacedintothehubcap othersideofthewheel(Fig.3and havebeenlacedintothesprocket patternaswiththeothersideofthe sideofthewheel. Turnthewheel sideofthewheel. Turnthewheel wheel(Fig.3and4).

125 126 Appendix Appendix

Technicaldata ReferencetoSerialNumber ofthe RohloffSPEEDHUB500/14 Number of gears: ................................ 14 Gear increases: ................................. even 13.6% Range of gears: ................................. 526% ATTENTION S e r i a lN u m b e r Frame spacing: ................................. 135mm (XLVersion = 170mm) EachRohloff SPEEDHUB 500/14 is provided with a Number of spoke holes: ........................... 32/36 (XLVersion = 32 hole only) consecutive Serial Number which is found on the sticker Spoke flange distance: ............................ 58mm, symmetrical (XLVersion= 93mm) band around the hub shell. Spoke hole circle diameter: ........................ Ø100mm SPEEDHUBs built after Serial Number 75000, have the Spoke hole diameter: ............................. Ø2.7mm Serial Number engraved directly into the hub shell. Spoke flange width: .............................. 3.2mm Axle diameter at dropout:.......................... 9.8mm Axle overall width CC: ........................... 147mm (XLVersion = 182mm) Hollow axle inner diameter:........................ Ø5.5mm, for quick release lever Total axle width TS: .............................. 171mm / TS long 179mm TIP S t i c k e r Total axle width TS (XLVersion): ................... 206mm / TS long 214mm Axle thread TS: ................................. M10x1 If the tape around the hub shell should be removed at any time, we recommend to separate first the Serial Number Center disc mounting diameter: ..................... Ø52mm with a sharp carpet knife from the tape and then to leave just this SerialNumber on the hub. If the tape should be Mounting bolt hole circle diameter: .................. Ø65mm removed completely, theSerial Number should be saved and/or stuck onto the warranty card. Alternatively, the Brake disc mounting bolts:......................... 4 x M8x0.75 Serial Number can be engraved on the hub cap! Distance between dropout and center disc mount: ....... 16.3mm (IS1999) Weight: ....................................... 1700g (CC), 1800g (CC EX), 1825g (CC DB) Weight (XLVersion) ............................. 1980g (CC DB) Oil volume: .................................... 25ml max. Sprocket thread:................................. M34x6 P1, tolerance 6H POINTER Wa r r a n t yC a r d Sprocket type: .................................. for bicycle chain 1/2" x 3/32” (ISO Nr. 082) EachSPEEDHUB 500/14 and each complete bicycle Number of sprocket teeth: ......................... 16 (optional: 13, 15 and 17) equipped with theSPEEDHUB 500/14 comes complete Chainline: ..................................... 54mm (58mm with 13tooth sprocket) with an orangeRohloff warranty card attached. Chainline (XLVersion):........................... 71.5mm (75mm with 13tooth sprocket) Smallest permissible gear ratios (26”):................32/17, 30/16, 28/15, 26/13 ( factor ~ 1.90) ThisorangeRohloff warrantycard mustbe: (Riders over 100kg/tandem): .......................42/17,40/16,38/15,34/13 (transmission factor ~ 2.50) 003005 Gates Carbondrive beltline: ....................... 54.75mm (XLVersion= 72.25) -completedinfull(withSerialNumber!) Smallest permissible belt sprocket ratios (26”): .........39/19, 39/20, 42/22, 46/24 (transmission factor ~ 1.90) -stampedbythedealer (Riders over 100kg/tandem): ....................... 46/19,50/20,55/22,60/24 (transmission factor ~ 2.50) -returnedtoRohloff AG ,Germany Maximum input torque: ........................... 100Nm Gear control: ................................... by twist shifter (version right or left) Twist shifter angle per gear change: .................. 21°/273° ThisRohloffwarrantycardisvitaltoensuringwecanprovideyourhubwiththebestpossibleservice. Gear control transfer:............................. via two shifter cables (pull-pull system) Shifter cable movement per gear change:. .............7.4mm/96,2mm ConsecutiveSerialNumber -Production Year ATTENTION Wa r r a n t y 000000-0004001998 Inner gear ratios (hub rotation per sprocket rotation): 000401-0027001999 This Serial Number informs us about the production year and is 002701-0065002000 Gear #1: .....................................0.279 important for guarantee or warranty claims, as well as a acting 006501-0120002001 as proof of ownership. 012001-0188002002 Gear #2: .....................................0.316 018801-0277002003 Gear #3: .....................................0.360 027001-0385002004 Gear #4: .....................................0.409 Only with knowledge of the appropriate Serial Number can an 038501-0500492005 optimal service can be completed by Rohloff. 050050-0650002006 Gear #5: .....................................0.464 065001-0816002007 Gear #6: .....................................0.528 080601-1000002008 100001-1159002009 Gear #7: .....................................0.600 115901-1358002010 Gear #8: .....................................0.682 135801-1528002011 Gear #9: .....................................0.774 152801-1724992012 Gear #10: ....................................0.881 172500-1913982013 191399-2069992014 Gear #11: ....................................1.000 207000-______2015 Gear #12: ....................................1.135 Gear #13: ....................................1.292 We expressively point out that theRohloff AG doesnot accept any warranty claims for Rohloff Gear #14: ....................................1.467 SPEEDHUB 500/14 gearhubs without a Serial Number. Service, repairs, and the spare parts service will also only be carried out on hubs when the hub is presented with the corresponding Serial Number (either on the sticker, The RohloffAG reserves the right to change the engraved into the hub shell, or on the warranty card). technical specifications without prior warning. 127 128 RohloffAG Appendix Appendix

Grub screw of the External Gear Mech Thecorrectspokechoice Version12_2013

All gear hubs built after Serial Number 47000 and equipped with an external gear mech have an M4x8 grub screw Thereareaconfusingamountofdifferentspokescurrentlyavailableonthemarket. Thesediffernotonlybytheir mounted into the sixth threaded hole of the axle (it helps to prevent potential oil leaks). Therefore, the external gear lengthanddiameter,butalsomoreimportantlybythedifferencesinthespokebendatthehead. Toaccomplish mech can only be properly fitted in one position (PFig. 2) over the axle. theoptimallongevityofboththehubflange,thespokeitselfandtheentirewheel,thespokebenddimensions mustbeharmonizedwithboththehubflangeandthespokeholes. Itisnotsufficientenoughtosimplychooseaspokeaccordingtoitslengthanddiameter(eg.2.0-256mm),the spokebenditselfmustadditionallybeharmonizedwiththespokeholesothatthespokecanfinditsoptimalsit A 3 Grubscrew withinthespokeholesofthehubflange.

blind hole B P o i n t e r C Becauseretrofitspokesfor theRohloffSPEEDHUB500/14 withtherequiredheadlengthareonly Grub availablein2.0mmdiameter,wegenerallyrecommendtheuseofDD2.0/1.8/2.0mmspokesfor lacing screw A SPEEDHUBwheels.

2mm

Thegrubscrewonhubswitha Theblindhole(B) mustbelocated Tocontrolthatthemountingis SerialNumberbetween47000and directlyoverthegrubscrew(A) . correct,thescrew(C )mustbe SpokediameterD 48500liesflush(externalgear Whenusinganexternalgearmech screwedsmoothlyapprox.4 atthebend/head DBL mechwithoutablindhole).On withoutablindhole(B ),thegrub completeturnsintothehub 2.0 2.9 +/-0.1 hubswiththeSerialNumber screwmustbescrewedflushinto withoutforce. Afterwards,the 48501andover,thisgrubscrew theaxle. installationoftheaxleplate pertrudesbyapprox.2mm Thepaper gasketsshouldthen includingallthescrewscanbe (externalgearmechwithablind befittedsothatalltheholes completed(3Nm). SpokebendlengthBL hole). meetupwiththecorresponding screwholesoftheaxle. Problem1 Ifthespokebendistoolongand/orthediameterofthespokeatthisbendbetoosmall,thenthiswillresultinthe POINTER spokehavinganamountofaxialplayafterthewheelhasbeentrued. Thespokebendcannowbebentopen, resultinginapossiblespokefailure. Ifanaxleplatescrewcannotoronlywithforcebescrewedintohole(C),thenitmustbecheckedthatthegrub screw(A)isnotsittingdirectlybehindthishole.Ifthisisthecase,thentheexternalgearmechmustbe Problem2 disassembledturnedaround180°andmountedagaininthisposition. Thegrubscrewstaysinitsoriginalposition Ifthespokebendistooshortand/orthediameterofthespokeatthebendbetoolarge,thenthehubflangecould (2mmpertruding). becomeslightlydeformedasthespokesarethreadedintothehubshellorasthespokesaretensioned. The damagecausedherecouldpossiblyleadtoaflangebreakage.

Checkingthecorrectsitfor theRohloffSPEEDHUB ThehubflangeandthespokeholediameterontheSPEEDHUB500/14aredesignedsothatanoptimalsitcanbe ATTENTION achievedwiththefollowingspokedimensions: Iftheexternalgearmechshouldbefalselymounted,thenthefittingofanaxleplatescrewintohole(C )would causethegrubscrew(A )tobeforcedintotheaxle. Thisinturnwillleadtoacompleteblockageofthegearbox.

Theremovalofthegrubscrewisonlynecessarywhenconvertingtheexternaltoaninternalgear mech,or whenworkingwiththehubsealreplacementtools. Theexternalgear mechshouldnever beremovedfrom ATTENTION thegearboxwithoutgoodreason! Astherequiredspokeheadlengthiscurrentlyonlyavailableon2.0/1.8/2.0mmspokes,wegenerallyadvise theuseofDDspokesofthissize.Bicyclemanufacturerswhoutilisethickspokeswithanoversizedhead diameter whenlacingSPEEDHUBwheels,mustguaranteethecorrectlengthofeachspokehead(3.7mm).

Thespokesshouldthenbetensionedtoaminimumof1000Nmeasuredwithaninflatedtireor 1300N withouttire.

129 130 Appendix Appendix

Thecorrectspokegeometrycanbeeasilyidentifiedasfollows: Possiblecausesforflangebreakagesonbicyclehubs Cause: Spokebendlengthistooshortand/or Threadaspokefromoutsidethroughthehubflangeofthehubcapsidesothatthespokeheadfindsitsseat thespokediameter atthebendistoolarge. withinthecountersinkofthespokehole. Thisshouldbepossiblewithoutrequiringanynoticeableforce.Holdthe Effect: Thespokeslightlydeformstheflangeastheyarethreadedandalignedintothehubshellorasthe hubsothattheflangesarehorizontalandthesprocketsidefacesupwards. Thespokeshouldbefacingradially spokesaretensioned. Thiscouldleadtoaflangebreakageifthisdamageoccursatapproximately90° outwards. Thethreadedendofthespokeshouldnowfinditselfwithintheshadedareashownonthediagram tothedirectionofthespoketension. Thesourceofthecrackisthedamage. below.Fig.b.

Countersunk a spokehole

Hubflange, Spokebendside b

+/-5° Notchcausedby Directionofspoketension stampingburronspoke head. c Crackbegin ca.90° Crackin Hubflange a)Spokebendistooshortand/orthespokebenddiameteristoolarge. b)Spokebendandspokebenddiameterarecorrect. c)Spokebendistoolongand/orthespokebenddiameteristoosmall.

Repeatthisprocess. Thistimethreadthespokefromtheinside,outwardsthroughthespokeflangeonthe sprocketsideofthehub. Again,thespokeheadshouldbeseatedwithinthecountersinkofthespokeholeandthis withoutrequiringanoticeableamountofforce.Holdthehubsothattheflangesarehorizontalwiththespoke Cause: Stampingburr onthespokehead. facingradiallyoutwards. Thethreadedendofthespokeshouldnowfinditselfwithintheshadedareashownon thediagrambelow.Fig.e. Effect: Theburronthespokeheadstampsitselfintothehubflangeleavinganotchatthecountersunkspoke hole.Ifthisnotchistobefoundatanangleofapproximately90°tothedirectionofthespoketension, thentheflangecouldcrack. Thesourceofthecrackistheburronthespokehead. d

e

+/-5° Countersunk spokehole Hubflange, f Spokebendside

Notchcausedby Directionofspoketension stampingburronspoke d)Spokebendistooshortand/orthespokebenddiameteristoolarge. Spokehead head. e)Spokebendandspokebenddiameterarecorrect. Crackbegin c)Spokebendistoolongand/orthespokebenddiameteristoosmall. ca.90° Crackin Hubflange

Stampingburr

131 132 Appendix

Possiblecausesforflangebreakagesonbicyclehubs Twist Shifter ‘light’- Right-Hand (Art. #8206) Cause: Loosespokesduetotoolongspokebendlengthand/or toosmalldiameter of thespokeatthebend.Spoketensiontolow. Mounting the Twist Shifter Effect: Thespokeheadoftheunloadedspokecanmovefreelywithinthespokeholeofthehubflange,thisin 1 2 turndamagestheinnersurfaceofthespokeholeandleavesnotches. Thedamagethatcanbefoundat 3 CableStopper1 approximately90°tothedirectionofthespoketensioncouldleadtothehubflangecrackingatthis Point.

Cable Stopper14 Countersunk 1 Hubflange, spokehole Spokeheador 14 CableStoppers1+14 spokebendside The TwistShifterworkswithtwo TheCableStoppersforboth Slidethe TwistShifteroverthe Damages/Notchesaround shiftercables. Whenthe Twist shiftercablesareidenticalandare right-handhandlebarend thespokeholecaused Directionofspoketension Shifterisrotatedforward byaloosespoke, simplyinsertedintotheshifter (handlebardiameter22-22.3mm/ Crackbegin (directionofgear#14),thenthen housingfacinginopposing 7/8”).Rotatethe TwistShifterso therearshiftercable#14is directions. TheCableStopperscan thattheCableStoppersareevenly pulled.Whenthe TwistShifteris Crackin ca.90° onlybefullyinsertediffitted distancedaboveandbelowthe Hubflange rotatedbackwards(directionof correctly. Anincorrectmountingis brakelever. gear#1),thenthentherearshifter thereforeimpossible. cable#1ispulled.

4 5

Cause: Re-lacingwithalternativespokealignment(secondlacingofthehub). 1 Effect: Theoldembedmentactsjustlikeanotchorpreviousdamagetothespokehole. Asthisprevious notchliesatanangleofapproximately90°tothenewdirectionofthespoketension,thiscouldlead Tothehubflangecrackingatthispoint.

Countersunk BothClampScrews(M3x12- Torx spokehole TX20)shouldbelightlyfittedso Newembedment Hubflange, afterspoke thatthegapbetweenbothclamp 2 3 4 5 6 7 Spokebendside tensioning elementsisidentical.

Insertthescrewsusingthe 1=ClampScrews(Art.#8192) pressureofjusttwofingersonthe 2=ClampwithClampScrews(Art.#8193) Oldembedment Directionofspoketension throughprevious TX20tool.Finallytighteneach 3=CableStoppers(Art.#8191) spoketensioning screwbymax.1/2rotation. 4=ShifterHousing(Art.#SA 01) The TwistShiftershouldnowbe 5=CablePulleywithO-Ring/RubberSeal(Art.#8194) ca.90° tightlysecuredtothehandlebars. 6=RubberGripwithO-Ring/RubberSeal(Art.#8190) 7=Circlip(Art.#SA 18-N) Crackin Hubflange ATTENTION Over tighteningoftheClamp Screwscancausedamageto both TwistShifter and/or 133 handlebars. 134 V1-2015-02 Rubber Grip replacement - Right-hand (Art. # 8190)

6 7 8 1213 1314 1415

Left-hand CableRun

Right-hand CableRun

FitmentofShifter Cable14: RotatetheGripRubbersothatthe InsertShifter Cable1 intothe Replacement: BeforefittingthereplacementGripRubber,checkthattheO-ringisseated RemovebothCableStoppersfrom gearindicatorarrowfalls between CablePulleyasillustratedabove, WhenreplacingtheGripRubber,it correctlyontheCablePulley. theShifterHousing. gears#8and#9.HoldtheShifter untilthecableendexitstheShifter isnotnecessarytoremoveor InsertShifter Cable14 intothe inthisposition. Housing. replacetheshiftercables. CablePulleyasillustratedabove, PullShifter Cable14 completely ATTENTION TIP untilthecableendexitstheShifter intoptheShifterHousinguntilthe Usingasmall,flatscrewdriver Housing. Nippleisseatedcorrectlyinthe prisetheCirclipoutofposition RemoveShifter fromCarbon Lightlygreasetheinsideofthe CablePulley. andremovefromtheShifter Fiber Handlebarstoavoid CablePulleytoensureeasy Housing. potentialdamagewhen operation. removingtheCirclip.

9 10 11 1516 1617 1718

RotatetheGripRubbersothatthe CheckthattheShifterCablesrun MountingofCableHousings TheGripRubberandtheCable Whenconnectingbothcomponents, ReplacetheCirclipbackontothe gearindicatorarrowfalls between smoothlybypullingoneachcable withintegratedliners: Pulleywillonlymarryinone slidetheGripRubberfullyover ShifterHousing.Checkthatthe gears#6and#7. HoldtheShifter endalternatively. TheGripRubber ThreadtheCableStoppersback position. TheCablePulleyhas5 theShifterHousingandlightly Shifterrotatesfreely. inthisposition. shouldrotatefreelybetweenboth overeachShifterCableandpush blindholeswhichcorrelatewith rotateuntilitfallsintopositionin PullShifter Cable1 completely bed-stops slightlybeyondgears#1 thesefirmlyintotheShifter the5pinsfoundontheGrip theCablePulley. intoptheShifterHousinguntilthe and#14. Housingfacinginthecorrect Rubber.Itisthereforeimpossible Nippleisseatedcorrectlyinthe position.MakesuretofitFerrules tore-mounttheGripRubber CablePulley. betweenCableHousingandCable incorrectly. Stoppers. Lightlygreasetheinsideofthe TIP GripRubberpriortomounting ATTENTION PushtheRubber Griplightly backovertheShifterHousing. PushingtheCables withoutthe intothefinalpositionover theO- CableStoppersfitted could ringuntilitreachesthebedstop. resultintheNipplebecoming clampedononeoftheShifter Cableexitsor withintheShifter 135 Housingitself. 136 Twist Shifter ‘light’- Left-hand (Art. #8207) Removing Shifter Cables for Replacement (Repair) Right-Hand Twist-Shifter Left-hand Twist Shifter Mounting

Cable 18 19 20 1 2 3 Stopper1

Cable Stopper14 Left-hand 14 1 CableStoppers CableRun 1+14

RemovebothShifterCables RotatetheShifter(withfitted RemovebothCableStoppers. The TwistShifterworkswithtwo TheCableStoppersforboth Slidethe TwistShifteroverthe housingsandcorresponding CableStoppers)untilthegear PushShifter Cable14 outofthe shiftercables. Whenthe Twist shiftercablesareidenticalandare left-handhandlebarend(handlebar FerrulesfromtheShifterHousing. indicatorontheShifterHousingis ShifterHousinguntiltheNippleis Shifterisrotatedforward simplyinsertedintotheshifter diameter22-22.3mm/7/8”). positioned betweennumbers8 free.PulltheCableNippleto (directionofgear#14),thenthen housingfacinginopposing Rotatethe TwistShiftersothatthe and9. HoldtheShifterinthis completelyremovetheShifter therearshiftercable#14is directions. TheCableStopperscan CableStoppersareevenly Position. Cable. pulled.Whenthe TwistShifteris onlybefullyinsertediffitted distancedaboveandbelowthe rotatedbackwards(directionof correctly. Anincorrectmountingis gear#1),thenthentherearshifter thereforeimpossible. cable#1ispulled. Mounting Shifter cables:

21 22 23 4 5 1

Right-hand CableRun

2

RotatetheShifter(withfitted RemovebothCableStoppers. RefittheShifterCablesintothe BothClampScrews(M3x12- Torx CableStoppers)untilthegear PushShifter Cable1 outofthe TwistShifterasdescribedinthe TX20)shouldbelightlyfittedso thatthegapbetweenbothclamp indicatorontheShifterHousingis ShifterHousinguntiltheNippleis mountinginstructions-Fig.6-11. 7 6 5 4 3 nowpositioned betweennumbers free.PulltheCableNippleto elementsisidentical. 6and7. HoldtheShifterinthis completelyremovetheShifter 1=ClampScrews(Art.#8192) Position. Cable. Insertthescrewsusingthe pressureofjusttwofingersonthe 2=ClampwithClampScrews(Art.#8193) TX20tool.Finallytighteneach 3=CableStoppers(Art.#8191) ATTENTION screwbymax.1/2rotation. 4=ShifterHousing(Art.#SA 01) The TwistShiftershouldnowbe 5=CablePulleywithO-Ring/RubberSeal(Art.#8194) PushingtheCables withoutthe tightlysecuredtothehandlebars. 6=RubberGripwithO-Ring/RubberSeal(Art.#8195) CableStoppersfitted could 7=Circlip(Art.#SA 18-N) resultintheNipplebecoming clampedononeoftheShifter ATTENTION Cableexitsor withintheShifter Housingitself. Over tighteningoftheClamp Screwscancausedamageto 137 both TwistShifter and/or 1138 handlebars. Fitment of Shifter Cables Rubber Grip replacement - Left-hand (Art. #8195)

6 7 8 12 13 14 Grease

FitmentofShifter Cable14: RotatetheGripRubbersothatthe InsertShifter Cable1 intothe Replacement: BeforefittingthereplacementGripRubber,checkthattheO-ringisseated RemovebothCableStoppersfrom gearindicatorarrowfalls between CablePulleyasillustratedabove, WhenreplacingtheGripRubber,it correctlyontheCablePulley. theShifterHousing. gears#8and#9.HoldtheShifter untilthecableendexitstheShifter isnotnecessarytoremoveor InsertShifter Cable14 intothe inthisposition. Housing. replacetheshiftercables. CablePulleyasillustratedabove, PullShifter Cable14 completely TIP untilthecableendexitstheShifter intoptheShifterHousinguntilthe Usingasmall,flatscrewdriver Housing. Nippleisseatedcorrectlyinthe prisetheCirclipoutofposition Lightlygreasetheinsideofthe CablePulley. andremovefromtheShifter CablePulleytoensureeasy Housing. operation.

9 10 11 15 16 17 Grease

RotatetheGripRubbersothatthe CheckthattheShifterCablesrun MountingofCableHousings TheGripRubberandtheCable Whenconnectingbothcomponents, ReplacetheCirclipbackontothe gearindicatorarrowfalls between smoothlybypullingoneachcable withintegratedliners: Pulleywillonlymarryinone slidetheGripRubberfullyover ShifterHousing.Checkthatthe gears#6and#7. HoldtheShifter endalternatively. TheGripRubber ThreadtheCableStoppersback position. TheCablePulleyhas5 theShifterHousingandlightly Shifterrotatesfreely. inthisposition. shouldrotatefreelybetweenboth overeachShifterCableandpush blindholeswhichcorrelatewith rotateuntilitfallsintopositionin PullShifter Cable1 completely bed-stops slightlybeyondgears#1 thesefirmlyintotheShifter the5pinsfoundontheGrip theCablePulley. intoptheShifterHousinguntilthe and#14. Housingfacinginthecorrect Rubber.Itisthereforeimpossible Nippleisseatedcorrectlyinthe position.MakesuretofitFerrules tore-mounttheGripRubber CablePulley. betweenCableHousingandCable incorrectly. Stoppers. TIP ATTENTION PushtheRubber Griplightly PushingtheCables withoutthe intothefinalpositionover the CableStoppersfitted could O-ringuntilitreachesthe resultintheNipplebecoming bedstop. clampedononeoftheShifter Cableexitsor withintheShifter 2139 Housingitself. 140 Notes

Removing Shifter Cables for Replacement (Repair) - Left-Hand Twist Shifter

18 19 20

RemovebothShifterCables RotatetheShifter(withfitted RemovebothCableStoppers. housingsandcorresponding CableStoppers)untilthegear PushShifter Cable14 outofthe FerrulesfromtheShifterHousing. indicatorontheShifterHousingis ShifterHousinguntiltheNippleis positioned betweennumbers8 free.PulltheCableNippleto and9. HoldtheShifterinthis completelyremovetheShifter Position. Cable.

Mounting Shifter Cables:

21 22 23

RotatetheShifter(withfitted RemovebothCableStoppers. RefittheShifterCablesintothe CableStoppers)untilthegear PushShifter Cable1 outofthe TwistShifterasdescribedinthe indicatorontheShifterHousingis ShifterHousinguntiltheNippleis mountinginstructions-Fig6to11. nowpositioned betweennumbers free.PulltheCableNippleto 6and7. HoldtheShifterinthis completelyremovetheShifter Position. Cable.

ATTENTION PushingtheCables withoutthe CableStoppersfitted could resultintheNipplegetting clampedononeoftheShifter Cableexitsor withintheShifter Housingitself.

141 142 143 144 145 146 147 148 149 150 Notes

ThisOwnersManualisalsoavailableinavarietyofother languages.Shouldyourequireadifferentversion,youcan downloaditfromourhomepageunder:

www.rohloff.de>download>description>ownersmanual

Thefollowinglanguagesareavailable:

-English -German -French -Dutch

TIP -OwnersManual- Newestversion -Films -TechnologyPresentationCD ThenewestversionofthisManualisavailableonthewebunder: www.rohloff.de>download>description>ownersmanual

Further tothemanual,themostimportantwork,serviceandrepairsonthe Rohloff SPEEDHUB500/14areshowninshortfilmsontheweb. www.rohloff.de>videos>workshop...

ThetechnologyPresentationCD(Art.#8296) explainsthefunctionandbuildofthe Rohloff SPEEDHUB500/14withtheuseofvariousanimationsandfurther in-depth technicaldetails

151 152 Index Index

Keyword Page Keyword Page A Advantagesoftheoptions 38 N Noises 6 Axle plate alignment 64 Notes 134-135 Axle plates 46 O OEMaxleplate 67 Axle ring - One-piece / Quick-change 98, 104 OEM2-mountingwithasupportbolt/SPEEDBONE 59 Axle types 24 OEM2 axle plate 67 B Beltdrive System (Gates Carbon Drive) 3, 48 Oil change 7, 87 Bolt/tool info 124 One-piece axle ring - removal 92 Brake disc - replacement 60, 91 Options 38 Brake discs / rotors 37 P Packagecontents-checking 51 Break-in period 6 Particular components 45, 46, 47 C Cableroutingviathebrakeboss-Internalgearmech 76 Pushing the bike 6 Cable routing via the chainstay - External gear mech 80 Q Quick-change axle ring -removal 92 Cable routing via the chainstay - Internal gear mech 79 R Racing bike/drop handlebars 46 Cable routing via the top tube - External gear mech 83 Reference to Serial No. 128 Carbon handlebars 48 Removal of the wheel from the frame 13 Chainguide-DH(accessoryfordownhill) 45,58 Chain guide - CC 71 Replacing the gear unit 92 Chaintensioner-DH(accessoryfordownhill) 45,68,69 Reversing / Replacing of the sprocket 90 Chain tensioner - mounting 70 Riding noises 6 Chain tensioner spring - changing 109 Rims 46 Chainguard enclosed 48 Rubber grip - replacement 110 Chainring - two chainrings 45, 47 S Safetyinformation 3 Cleaning the Rohloff SPEEDHUB 500/14 7 Schlumpf Speed-drive, High Speed-drive 47 Colors 33 Securing to the frame 23-30 Comparison -Derailleurgearsand RohloffSPEEDHUB 500/14 21 Serial No. - Pointers 128 Comparison to derailleur gears 22 Service procedures 96 Components that we recommend 45 Shifter - mounting 73 Cranks, 45, 57 Shifter cables 75 D Distance travelled per crank revolution (20", 26" and 28") 20 Shifting gears 5 E EccentricBB 48 Small parts bag - checking the contents 53 Effective Rim Diameter - calculating 44 Small wheels 47 Emergency repairs 10 Smallest permitted sprocket ratios 19 External gear mech - grub screw 129 Special applications 47, 48 External gear mech - mounting 32, 93 SPEEDBONE 46 Externalgearmech-OEM/OEM2/longtorquearm 63 Spoke length - calculating 42, 43 F Flangebreakagesonbicyclehubs-possiblecauses 132 Spokes 46, 130 Failure Diagnosis 119 Sprocket ratios - smallest 19 Filling with oil 84 Sprocket reversing/replacement 90 Frame mounted gear box 47 Sprockets 45 Frametypes-OEM/OEM2/longtorquearm 27-29 Stand - axle mounted 47 G GatesCarbonDrive 3, 48 T Tandem use 47 Gear display 83 Technical data 17, 127 Gear mech - replacement 92 Tools and Bolts / Tools for the tour 124 , 9 Gear unit - installation - removal 111, 112 Torque securing 25 Grub screw of the External gear mech 129 Tour info 9 Guarantee information 1, 128 Trailer use 47 H Hubcable-replacement 97 Hub seal - replacement 114 Transport - Info for the tour 9 I Internalgearmech 31 Trouble shooting 119 Internalgearmech-viabrakeboss/viachainstay 61,62 Twist shifter - mounting 73 L Longtorquearm 56 W Warrantyinformation 1, 128 M Maintenanceandcare 7, 8, 89 Wearable parts 6 Mechanical efficiency - comparsion 18 Weight comparison 18 Model codes - explanation 33 Wheel installation 14 Model variations 39 WheellacingforrimswithaEuropeanspokeholepattern 125 Modular system 23 WheellacingforrimswithaFrenchspokeholepattern 126 Mounting(CC/TSversions)withalongtorquearm 65,66 Wheelremoval(internal,externalgearmech) 11 Mounting necessities OEM2 30 Wheel stability 41 Mounting processes 49 Wheel lacing 55, 130

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