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Contents Acknowledgments 8 Crankarm Adjustment 114 Introduction 9 Bottom Bracket Overhaul 116 Anatomy of a Road Bike 10 Removal and Installation of a 122 Anatomy of a Mountain Bike 12 Shimano Octalink Crankset Chainring Maintenance 124 CHAPTER 1 Sealed-Bearing Cartridge-Style 126 Home Bicycle Repair 1 5 Bottom Bracket Installation Boxing a bike 24 Removal and Installation of 128 CHAPTER 2 Two-Piece Cranksets Frames 27 CHAPTER 7 Freewheels and Cassettes 1 31 CHAPTER 3 138 Suspension 39 Basic Cassette and Freewheel Maintenance Basic Suspension Adjustment 46 Cassette Removal and 140 Cassette Cog Disassembly CHAPTER 4 Freewheel Removal and Replacement 142 Wheels and Tyres 49 Freewheel Cog Removal 143 Wheel Removal and Remounting 66 and Replacement Clincher Removal, Repair 68 and Remounting CHAPTER 8 UST Tubeless Tyre Removal, 72 Chains 1 45 Repair and Remounting Chain Maintenance and Repair 152 Tubular Removal, Repair 76 and Remounting CHAPTER 9 Rim Maintenance and Repair 80 Shift Levers 1 55 Spoke Maintenance and Replacement 82 Braze-On Shifter Installation 161 Truing Wheels 84 Bar-End Shifter Installation 1 64 Brake-Lever Shift Lever Installation 1 66 CHAPTER 5 Twist-Grip Mountain Bike Shifter 1 68 Hubs 87 Removal, Installation and Service Adjusting Cone-and-Locknut 92 Mountain Bike Thumb Shifter Removal 1 70 Type Hubs and Installation Cone-and-Locknut Type 94 Three-Speed-Type Shifter Removal 1 71 Hub Overhaul and Installation Overhauling and Adjusting a 98 Campagnolo Hub Equipped CHAPTER 10 with an Oversize Axle Front Derailleurs 1 73 Lubricating Sealed Cartridge Bearings 1 01 Front Derailleur Basic Maintenance 1 77 CHAPTER 6 Front Derailleur Installation 179 Cranksets 1 03 Front Derailleur Adjustment 182 CHAPTER 11 Direct-Pull Cantilever 252 Rear Derailleurs 185 (V-Brake) Adjustment Rear Derailleur Removal 1 92 Brake Pad Maintenance 254 and Installation CHAPTER 14 Rear Derailleur Cleaning and 1 94 Lubrication Handlebars and Stems 257 Rear Derailleur Adjustment 1 96 Handlebar and Stem Adjustment 265 Removing and Installing 268 CHAPTER 12 Road Stem and Bar for Headsets 199 Threadless Headset Threaded Headset Adjustment 208 Taping a Handlebar 270 Threaded Headset Overhaul 210 Installing Mountain Bike Stem 272 and Grips Threadless Headset Adjustment 214 and Overhaul CHAPTER 15 CHAPTER 13 Saddles and Seatposts 275 Brakes 217 Saddle Installation and Adjustment 281 Brake Lever Adjustment and Removal 232 Brake Cable Installation 233 CHAPTER 16 Mountain Bike Lever 237 Pedals 287 and Cable Installation Mountain Bike Clipless 294 Aero Lever and Cable Installation 238 Pedal Maintenance Sidepull Installation 240 Shimano SPD Pedal Bearing Overhaul 296 Basics of Disc Brake Maintenance 242 Conventional Pedal 298 Repair and Maintenance Mechanical (Cable-Actuated) 244 Disc Brake Installation and Look Pedal Bearing Overhaul 300 Setup (Avid and similar) Hydraulic Disc Brake Installation 246 CHAPTER 17 and Setup (Hayes and similar) Gears 303 Hydraulic Disc Brake Installation 248 and Setup (Shimano, Hope, Glossary 310 Magura and similar) Resources 315 Cantilever Installation 250 and Adjustment Index 316 Acknowledgments This, the fifth edition of Bicycling Magazine's Illustrated Bicycle Maintenance, would never have been possible without the help of dozens of people and organizations. This book has been a collaborative effort between the author and many talented and knowledgeable mechanics and product designers, as well as photographers, artists and editors. There is hardly time or space to personally thank everyone who has been involved, but here appear a handful of key people whove gone to great lengths to ensure that this is the most comprehensive and up-to-date resource of bicycle maintenance available. Heidi Rodale Park Tool Alan Daniels Pedros Aaron Murray Phil Wood Dan Lipow Quality Bicycle Products David Jones RaceFace Drew Frantzen RockShox Jim Langley Seven Cycles Kathy LeSage Shimano Mark Bowman South Mountain Cycles, Emmaus, Pennsylvania Matt Reigner Specialized Bicycles Mitch Mandel SRAM Nancy N. Bailey Tarrytown Cycles, Tarrytown, NY Nic Cheetham Trek Bicycle Corp. Rita Baker Titec Sarah S. Dunn Tri-Flow Ultimate Support Systems Thank you to all the companies that loaned their United Bicycle Institute time, knowledge and products: United Bicycle (Tool) Supply Ace and Belmont Wheelworks, Somerville and Belmont, MA And finally, Id like to thank some of the people Answer-Manitou whove been influential and supportive, both in the Avid making of this book and throughout my years as a Bacchetta writer and professional bicycle mechanic. Bianchi USA The Bicycle Museum of America John and Jill Downs Bike Sport, Tracce, Pennsylvania Marjorie Howsen Bontrager Danielle Ciraulo Burley Design Cooperative John Allis Campagnolo USA Butch Balzano Cane Creek Components Michael Browne Cannondale Chipps Chippendale Chris King Components Ralph Cronin Crank Brothers Matt Eames Euro-Asia Imports Leif Erickson Finish Line Chris Fallon FSA Adrian Fletcher Giant Bicycles Clint Paige Hayes Disc Brake JuliRae Mitchell Hope Technology Jack Mowatt Hutchinson Ed Nasjleti Independent Fabrication Rob Reed Iron Horse Matt Roy LeMond Bicycles Merlyn Townley Magura Dave Weagle Marzocchi Karl Wiedermann Maverick American Tripp Wyckoff Michelin Introduction Almost two decades ago, the first edition of this advancements in the way bicycles function, but book was published. Much has changed in those more subtle improvements in frame construction, years. But edition after edition, the goal of bearing design and component manufacture Bicycling Magazine's Illustrated Bicycle Maintenance have made the past few years an exciting and has been to keep up with and anticipate the pace challenging time for bicycle mechanics. of that change, and to be the definitive source of Still, there are a good many tried-and-tested bicycle maintenance and repair techniques for designs that have withstood the test of time and cycling enthusiasts of every stripe. that remain as functional today as they did The craft of bicycle mechanics, though well decades ago and these are highlighted and developed and documented for over a century, is explained in the same detail as the most current still largely passed on from master to apprentice technology. So, in this guide, you will find topics through guidance and shared experience, in much of maintenance and repair covered for bicycles the same way as any other traditional craft is ranging from the trusty 1970s ten-speed through taught. Through this text, you will benefit in the to the latest in dual-suspension mountain bikes. same spirit from the knowledge and experience Even if you don't intend to perform your own of not just one, but several bicycle mechanics repairs, knowing your bike, its component parts and who have helped to shape this guide over the how they work together can dramatically improve years. With, no doubt, hundreds of years' experi- your cycling experiences. By learning to recognize ence between them, you could not hope to find when something is out of kilter before it leads to a yourself in better company. more serious – and expensive – problem, you will Within the pages of this book, you will be save time, money and possibly prevent injuries, too. introduced to and get to know all the parts of This book may be all the reference you need. your bike.You will learn which components Then, there are those of you who want to save perform what functions, and you will learn how even more by performing basic maintenance tasks they all come together to make your bicycle at home.You will likely be pleasantly surprised at work.Tools and supplies will be explained, just how easy many of these procedures can be. lending you insight as to which ones you will You will quickly learn that most components of a need and what, though perhaps less necessary, bicycle are much more simple than they appear; can improve the speed, accuracy and ease of each and that, with every new technique you learn and repair. Then, you will take all of this together and apply, your savings will grow greater and greater. discover how all those bits and pieces are kept in Of course, there are those who want to go top working order by cleaning, inspecting, lubri- even deeper. If you want to begin performing all cating and adjusting. of your own routine bicycle maintenance, and A great deal of new information has been to explore the possibilities of taking on more added to this, the fifth edition, but not at the major repairs, this is the ideal first volume of an expense of the old. Changes in technology occur entire library of guides, manuals and catalogues every year, but perhaps there has never been a that you can build, covering every minute detail period where those changes have come as of bicycle maintenance. quickly and as frequently as they have in the last Remember: the key to success lies not in decade. The advent and evolutions of suspension knowing the answers to everything, but in and disc brakes are clearly the most obvious knowing where to find them... Anatomy of a Road Bike Anatomy of a ■ SADDLE RAIL Mountain Bike GRIP SHIFT LEVER ■ STEM a BRAKE LEVER HEAD TUBE FORK CROWN ■ FORK STANCHION TYRE FORK ARCH •---11GiltIL ■ DOWN TUBE FRONT DERAILLEUR a PEDAL CHAPTER 1 Home Bicycle Repair Whether you ride a bicycle for fun, fitness, transport or an `So what does it really take?' you ask. 'And have I got it?' adrenalin fix — or maybe all of these — you need this book. Every cyclist needs a pump, a patch kit, a folding tool or mini Even if you think you never want to perform your own tool kit, and just a little bit of know-how to keep a favourite repairs, knowing your bike intimately is an invaluable tool for bike — or any bike, for that matter — rolling along smoothly. any cyclist. Just by taking this book from the shelf, you've That's it.
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