Tech.Man. 2002 E

Home , Cogset, Crankset

CONTENTS GEAR HUB SYSTEMS

GEAR HUBS AND SHIFTERS

DualDrive 3

Spectro S7 13

Spectro P5 21

CARGO Spectro P5 Cargo 29

Spectro T3 37

Sparc 45

SPECTRO SYSTEM COMPONENTS

i-brake 53

Two-Axis Brake Lever 62

SmartBar 65

Power Chain 76

SUPPORT

Distributors 78

¥Who to call / SRAM 2 year warranty / Spare Parts 80

Technical Manual 2002 1 2 Technical Manual 2002 DUALDRIVE TECHNICAL DATA /ASSEMBLY REQUIREMENTS

•Expanded gear range •Efficient design •Stand-still shifting (mode selector) •Single chainring design •Sealed system •Easy wheel removal •ESP 1:1 actuation ratio technology 182.6 •Improved material use 135 • Outward facing limit screws 67.5 • Low system weight 44.5 4.6 Chainline

33 18 67

Version for i-brake: see i-brake, page 55.

Cycle frame: The strength must be such that with a maximum braking torque of 250 Nm (2200 in.lbs.) on the rear wheel no residual deformation can occur on the rear structure.

Caution: Not suitable for tandems, trademen’s delivery bicycles and similar.

DualDrive 27/24 · without brake DualDrive 27/24 · i-brake compatible DualDrive 27/24 · disc brake compatible Part No. — R ——R —— R — Brake None Interface for new i-brake Interface for Disc brakes Over Locknut Dim. 135 mm 135 mm 135 mm Length 182.6 mm 182.6 mm 182,6 mm

Axle Ends Diameter FG 10.5 FG 10.5 FG 10.5 Holes 36 R 32 36 R 32 36 R 32 Hole Diameter 2.6 mm 2.6 mm 2.6 mm

Spoke Hole Ref. ø 67 mm 67 mm 67 mm 1 Flange Dist. to /2 OLD 33 mm / 18 mm 33 mm / 18 mm 33 mm / 18 mm H Totally 576% (27spd) / 542% (24spd) Totally hub 186% U Speed 1 73% Ratio B Speed 2 100% S Speed 3 136% Chainline 45 mm 45 mm 45 mm Crankset 33 / 38 Teeth Cogset 8 / 9 Speed, 11-32/34 Teeth Cogset Compatib. DualDrive 27 / DualDrive 24 Shifter Compatib. DualDrive 27 / DualDrive 24 Sealing Extra sealed Tandem compatib. ——— Disc compatib. ——SRAM/Magura / Hayes / Shimano Weight 970 g 970 g 970 g Hub Shell Aluminum Aluminum Aluminum

Finish Shifting device Composite Composite Composite

Technical Manual 2002 3 DUALDRIVE TECHNICAL DATA /ASSEMBLY REQUIREMENTS

DualDrive 27 DualDrive 24 D Part No. —— E Speeds 98 R Shifter Compatibility DualDrive 27 DualDrive 24 Cage Length Short, 75 mm Short, 75 mm A Sprocket, max. 34 Teeth 32 Teeth I Sprocket, min. 11 Teeth 11 Teeth L Pulleys Exchangeable / Bushing Exchangeable / Bushing Direct Mount GG L Weight 260 g 220 g E Knuckles Grilon Composite silver Grilon Composite silver U Outer Link Aluminum Grilon Composite silver R Inner Link Steel / Zinc coat Steel / Zinc coat

Design Outer Cage Forged Aluminum Grilon Composite black S Inner Cage Grilon Composite black Grilon Composite black Hanger Bolt Aluminum Steel

DualDrive 27 DualDrive 24 Part No. —— Largest Cog 34 Teeth 32 Teeth C Speeds 98 A Cogs 11/12/14/16/18/21/24/28/34 11/12/14/16/18/21/26/32 S Spacers Blue Black S Chain compatib. 9spd, HG/IG/PGII comp. 8spd, HG/IG/PGII comp. . Weight 320 g 270 g Cogs SAPH 440 steel Screws Steel / Zinc Coat

Design Finish Matte Nickel Plated Chrome

DualDrive 27 DualDrive 24 Part No. — R — R — R — R —— R — R — R — R — Clickbox Cable 1400mm R 1500mm R 1600mm R 1700mm R 2100mm 1400mm R 1500mm R 1600mm R 1700mm R 2100mm Shifter Type SRS Twistring-Thumbshifter-Combo (2in1) SRS Twistring-Thumbshifter-Combo (2in1) Arrangement Handlebar, right Handlebar, right S Gear Hub DualDrive DualDrive pat. H Com- Derailleur DualDrive 9spd DualDrive 8spd Gear Indication Der. Window Printed I Riding Mode Indic. Printed Printed F Barrel Adj. Gear Hub None None T Barrel Adj. Derailleur Indexing Indexing Clamping Diameter 22.3mm 22.3mm E Handlebar, Straight Area Minimum length = 150mm Minimum length = 150mm R Cable Routing, Gear Hub Continuous housing (preassembled) Continuous housing (preassembled) S Cable Routing, Der. Open or continuous Open or continuous Weight N/A N/A Cables Stainless steel Stainless steel Housing Glass filled PA – Silver painted Glass filled PA – Silver painted Grip Cover Thermoplastic elastomer, Overmolded Thermoplastic elastomer, Overmolded Design Clamping Collar Aluminum Aluminum Clickbox Composite Composite

4 Technical Manual 2002 DUALDRIVE TECHNICAL DATA /ASSEMBLY REQUIREMENTS

Cable routing 1 DualDrive 27 DualDrive 24 Hub cable Along chainstay only Along chainstay only 1 Derailleur cable Along chainstay only Along chainstay or along seatstay 2

3 Cable attachement see Fig. 1 Cable housing Attachement points Cable stops 5 4 Hub Continuous 1 / 2 / 3 / 4 (see Fig. 1) — Derailleur Continuous 1 / 2 / 3 / 4 / 5 (see Fig. 1) — Open — 1/5 (Fig. 1)

2 CABLE HOUSING FOR DERAILLEUR Rear cable stop position Rear housing length (only DualDrive 27)

200

180

160

140

120 X

R2 (mm) L 100 L 90 100 110 120 130 X (mm) R1 90˚ X Length X min. 90 mm. Example: Distance X = 100 mm cable A Cable stop below or beside chainstay. housing length L = 140 – 165 mm.

CABLE HOUSING Recommended cranks: 3 • Use only new high quality cable and Cyclone: 15 com-pressionless cable housing with •DualDrive crank for chainguard, 33 T, Part end caps. No. CPI-104 (chain guide fork necessary). • When choosing cable housing lengths, • DualDrive crank for Trekking, 33 T, 14 be sure to allow enough housing for an Part No. CY-100W.

60 extreme turn of the handlebars in both • DualDrive crank for MTB, 33 T, directions. Part No. CF-100W.

13 45 32 • Note also, that different stem lengths Truvativ: 25 and cable stop positions effects cable •CR-02-XF-SS or CR-02-XF-SSA housing length. DualDrive crank supplier: DROPOUT Cyclone Precision Inc. Only flat and no off-set versions. P.O. Box 3-41 · Nantou 540 · Taiwan Dropout thickness: 7 – 8 mm. Tel.: +886-49-257-829 · Fax: +886-49-257-832 Vertical or horizontal dropout slot. eMail: [email protected] Dropouts must be parallel. http://www.cpi-cw.com or Truvativ · http://www.truvativ.com 4 Dropout dimensions: see Fig. 2 and 3. L X A R1 R2 CHAIN GUIDE FORK 28 6–10 25˚– 30˚ 8.5 max 11.5–13.5 It prevents chain from jumping off front 30 7.5–10 25˚– 30˚ 8.5 max 11.5–13.5 chainring, is bolted inside the chain case (1, Fig. 4).

CRANKSET HANDLEBAR Bicycle without chain case: Diameter: 22.3 mm. Use a chain guard disc (at the outer 1 Minimum length of straight area for shifter: surface of chainring, material no resin) 150 mm. dA max. 220 mm Use only standard chainring version (non- Recommended are handlebars in curved shifting teeth). design. Chainline = 45 mm.

Technical Manual 2002 5 DUALDRIVE ASSEMBLY

ASSEMBLY HUB ASSEMBLY SHIFTER 1 1 2 • Spoke the hub as normal. • Slide the shifter (1, Fig. 6) onto the 3 • Place spoke protector disc (1, Fig. 1) on handlebar. shoulder of hub, fit cassette (2) onto • Rotate the shifter until the barrel 4 driver profile. Screw lock nut (3) with adjuster (4) is beneath (but out of the cassette tool (Park Tool FR-5 or SRAM way of) the brake lever. Part No. 4624 411 010), tightening torque: • Tighten the 3 mm hex clamp bolt (2) to 40 Nm (350 in.lbs.). 1.9 Nm (17 in.lbs.). • Screw shifting rod (4) into the hub axle • Slide the handlebar grip (3) onto the and tighten it with 0.2 Nm (1.8 in.lbs.). handlebar. • Fit wheel in dropouts. 2 • Place retaining washers (Fig. 2) on both Caution: sides of the axle – the serrations must • Check that the shifter and brake lever bear against the dropout. function properly and are unobstructed. – Version for horizontal dropouts (1): • Handlebar grips provide an axial safety the lug must engage in the dropout slot. function. For this reason, they should be – Version for vertical dropouts (2): mounted in such a way as to make sure without lug. they do not slip off handlebar. • Tighten up axle nuts. Tightening • Never use lubricants or solvents to torque 30 – 40 Nm (266 – 350 in.lbs.). install handlebar grips. 2 1 • Never ride without the handlebar grips this can result in severe injury or death. ASSEMBLY DERAILLEUR 3 Advice: Check the rear derailleur hanger INSTALLING CLICKBOX alignment. A bent rear derailleur hanger • Fit the cable and avoid small radius. will result in inaccurate index shifting. • Cable attachment points see Page 5 / Outboard side impacts are the most Fig. 1. 5 mm common causes of this type of damage. Cable housing must be movable inside 8 – 10 Nm attachment. 70 – 85 in.lbs. • Attach the rear derailleur to the frame’s • Place shift lever in uphill riding mode / rear derailleur hanger using a 5 mm hex gear position „1“ (Fig. 7). head wrench (Fig. 3). • Push Clickbox button down (Fig. 7). • Check that the b-adjust washer tab • Push on Clickbox to the stop on the hub (b-adjust screw at DualDrive 24) is clear axle. of the rear derailleur dropout tab (Fig. 4). • Press button up. • Tighten the 5 mm hex hanger bolt to • Place thumb shift lever in standard 8 – 10 Nm (70–85 in.lbs.). riding mode / gear position „2“ (Fig. 8). 4 • Match up the marks in the Clickbox viewing window by twisting the CHAIN LENGTH barrel adjuster. A properly measured chain will prevent accidentally shifting to the largest chain ring and cog combination. This type of DualDrive 24 accidental shifting may cause harmful binding or seizure of the chain and DualDrive 27 potentially cause severe damage.

• Bypassing the rear derailleur, run the chain around the largest cog/large 5 chainring combination (Fig. 5). – For rear suspension frames, position the rear suspension for the greatest chain length required. + • Add 2 LINKS or 1 link + Power Link to this length for proper chain length. (2 Links)

6 1 3

6 Technical Manual 2002 DUALDRIVE ASSEMBLY

DERAILLEUR ADJUSTMENT Index shifting adjustment: 7 Limit screw adjustment: • Check that the chain and the rear • View the rear derailleur and pulleys from derailleur are in the smallest cog position. behind the rear of the bicycle (Fig. 9). • Measure and cut the rear piece of • Using a small screwdriver, turn the limit cable housing. Make sure that it is not screw marked ’H’ on the outer link of the too short or long (DualDrive 27: see derailleur to align the upper guide pulley page 5 for figure and chart). center with the outboard edge of the • Rotate the twist shifter until the largest smallest cog – clockwise moves the number and gear indication tab/dash guide pulley inboard towards the wheel. line up. • While turning the crank, push the rear • Turn the twist shifter barrel adjuster (4, derailleur towards the larger cogs by hand. Fig. 6) clockwise fully into the shifter, • Align the upper guide pulley under the then turn counterclockwise 1 full turn. largest cog, center to center, by turning • Feed the shifter cable through the rear the limit screw marked ’L’ on the outer derailleur cable housing, stops and link – clockwise moves the guide pulley cable guides. outboard away from the spokes. • Feed the rear derailleur cable through the rear derailleur-housing stop and 8 Chain gap adjustment: through the cable guide on the fin. Chain gap is the distance between the upper • Pull the cable tight and position it guide pulley and the cog the chain is riding under the cable anchor washer (Fig. 11). on. Optimal chain gap is small enough to • Tighten the 5 mm hex cable anchor bolt allow quick, efficient shifts to and from any to 4 – 5 Nm (35–45 in.lbs.). cog, but large enough to allow smooth • Rapidly shift the chain and derailleur up shifts to and from the largest cog. and down the cassette several times. If the cable slips repeat the two former steps. • Shift chain to the small chain ring. • Shift the chain to the smallest cog. • While turning the crank, push the rear • While pedaling, move the shifter up one derailleur inboard by hand to the largest detent. cog. – If the chain hesitates or does not shift • Hold the derailleur in this position while to the second cog, increase the cable making the following adjustment. tension by turning the shifter barrel • Use a 3 mm hex wrench, turn the b-adjust adjuster counterclockwise. screw until the chain gap equals – If the chain shifts beyond the second cog, 1 approximately 6 mm ( /4”) from tip of the decrease the cable tension by turning 9 cog to tip of upper guide pulley (Fig. 10). the shifter barrel adjuster clockwise. • Repeat the two former steps until – Turn the b-adjust screw clockwise to shifting and cable tension is accurate. increase the chain gap. • While turning the crank, shift the chain – Turn the b-adjust screw counterclock- up and down the cassette and chain wise to decrease the chain gap. rings several times to ensure that your derailleur is indexing smoothly. Advice: Do not use the b-adjust screw to adjust the rear derailleur to act as a chain- tensioning device or to prevent chain suck. This increases the chain gap causing poor shifting performance.

10 11

6 mm 1 ( /4")

5 mm 3 mm 4 – 5 Nm 35 – 45 in.lbs.

Technical Manual 2002 7 DUALDRIVE MAINTENANCE

11 4 19 3 18 2

1 17 10 9 16 15

8 20 14 7 13 6 5 12

REMOVE WHEEL REASSEMBLY HUB 2 • Rotate the twist shifter to the highest see Fig. 1 gear position (speed “8/9“). Lubrication see “LUBRICATION“. • Place shift lever in uphill riding mode / • Clamp axle with the two axle flats gear position “1“ (Fig. 2). (longer axle thread). • Push Clickbox button down (Fig. 2). • Fit shift sleeve (12), bushing (13) with small • Pull Clickbox off the axle. diameter first, compression spring (15), • Screw out shifting rod (20, Fig. 1). coupling gear clutch (14), and driver (17). • Dismantle wheel. • Mount cone (18) and lock nut (19). Tightening torque 15 – 20 Nm DISMANTLING HUB (133 – 177 in.lbs.). see Figure 1 • Clamp other axle end (driver side facing • Dismantle cassette lock nut with downwards). cassette tool (Park Tool FR-5 or • Mount ball retainer (16), pawl carrier SRAM Part No. 4624 411 010). (10) and washer (9). • Remove cassette and spoke protector • Press pawls against spring force and disc. mount gear ring (8) with smaller • Clamp hub with the two axle flats diameter first. (driverside facing downwards). Rotate gear ring counterclockwise until • Remove cap (1), unscrew lock nut (2), pawls engage inside the gear ring. screwed adjusting cone (3) and hub • Fit planetary gear carrier (7) and 3 shell (4). washer (6). Lubricate the shifting • Dismantle retaining washer (5), remove • Press and rotate planetary gear carrier joints regularly washer (6), planetary gear carrier (7) until axle groove is visible. and gear ring (8). • Mount retaining washer (5). • Squeeze down pawls and remove pawl • Mount hub shell (4) with a slight carrier (10) with washer (9) and ball re- counterclockwise turn. tainer (16). • Mount adjusting cone (3). • Clamp other axle end (longer axle • Screw on counternut (2), adjust bearings thread). to be free of play and tighten with a • Dismantle lock nut (19) and cone (18). torque of 15 – 20 (133 – 177 in.lbs.). • Remove driver (17), compression spring • Mount cap (1). (15), coupling gear clutch (14) and shift • Unclamp hub and mount shifing rod (20) with a torque of 0,2 Nm (1.8 in.lbs.). When disassembled – sleeve (12) with bushing (13). use a waterproof grease Mount spoke protector disc and cassette.

8 Technical Manual 2002 DUALDRIVE MAINTENANCE

LUBRICATION CABLE CHANGE 4 GEAR HUB Advice: 2 Hubs are provided with permanent Use only new high quality cable and lubrication and maintenance-free under compressionless cable housing with normal conditions. end caps.

Cleaning of parts: Twist shifter (rear derailleur): • All parts – except the planetary gear • Detach the cable from the derailleur. carrier and the driver – can be degreased • Cut cable off 15 cm (6") from shifter in a cleaning bath. barrel adjuster. Discard old cable and • Planetary gear carrier and driver only cable housing. 1 need to be cleaned on the outside with • Remove screw (1, Fig. 4) and pull open a brush so as not to degrease the the cable change sleeve (2). bearings. • Rotate the shifter fully in the cable release direction (gear position “8/9“). Lubrication of parts: • Look for cable head entry (3, Fig. 5). Use only SRAM grease (Part No. 0369135 101) • Push cable up/out of the shifter and and standard bicycle oil. discard. 5 • To lubricate the bearing points on • Feed the new cable through the cable the planetary gear sets, position the entry and out the barrel adjuster (4). 3 planetary gear carrier pawls upside and • Pull cable snug. apply 2 – 3 drops of oil to the bearing • Install cable change sleeve (2, Fig. 4). 4 bolts – at the same time turning the • Feed the cable through the new cable planetary gears so that the bearing housing and frame stops. points are completely wet. Oil axle slot, • Attach cable to the derailleur. apply a thin coating of grease to the • Adjust indexing per derailleur instruction. outside. • Grease the teeth of the axle (fill the Thumb shift lever (gear hub): gaps). • Place thumb shift lever (5, Fig. 6) in • Apply grease to gear ring teeth but just uphill riding mode / gear position “1“. oil the pawls and pawl teeth. • Snap open Clickbox-cover (8, Fig. 7) • Oil pawl carrier pawls and pawl (no need to move Clickbox from the 6 bearings. axle end). • Oil cartridge bearing. • Unscrew clamping bolt (9). • Regrease ball retainers, line ball • Remove the shifter escape hatch (6, Fig. 6). bearing running tracks with grease. • Remove and discard the old cable. Caution: • Feed the new cable through the cable For version with mounted i-brake use entry (7, Fig. 6), the new calbe housing only the new highly heat-proof SRAM and pull the cable snug. grease “Typ B“ (Part No.: 35g – 0369 135 • Attach the escape hatch. 200 / 200g – 0369 135 201). • Pull the cable tight and position it under the cable anchor washer (10, Fig. 7). 5 Caution: • Tighten the 4 mm hex cable anchor bolt Do not use high-pressure water when to 4 – 5 Nm (35 – 45 in.lbs.). 7 cleaning the gear hub (e.g. strong water • Cut off cable end to 1 – 3 mm. jets, high-pressure cleaners etc.) – • Snap in Clickbox-cover. if water penetrates it could lead to • Place thumb shift lever in standard 6 functional problems. riding mode / gear position “2“. • Match up the marks in the Clickbox LUBRICATION viewing window (11, Fig. 7) by turning REAR DERAILLEUR the barrel adjuster (12). 7 • Do not use solvants or corrosive materials to clean the components. • Lubricate the shifting joints regularly 11 12 (Fig. 3). 10 • Grease any cable guides (e.g. beneath the bottom bracket).

9 8 4 mm 4 – 5 Nm 35 – 45 in.lbs.

Technical Manual 2002 9 DUALDRIVE MAINTENANCE

TROUBLESHOOTING Problem Cause Remedy Hub: Shifting difficulties Incorrect gear setting Adjust shifting system, oil control cable, check that cable stop is fastened correctly. Pedals are carried forward Bearings set too tight Re-adjust bearing when freewheeling Loose lock nuts Tighten lock nuts (15 – 20 Nm, 133 – 177 in.lbs.) Rear frame dropouts non Bend / reorient dropouts parallel Derailleur: Chain jumps from smallest High gear limit screw is not Turn in screw H until the sprocket to frame dropout. adjusted properly. guide pulley is aligned with the smallest sprocket. Difficult or impossible to High gear limit screw is not Unscrew screw H until the shift chain onto smallest adjusted properly. guide pulley is aligned with sprocket. the smallest sprocket. Chain jumps over largest Low gear limit screw is not Turn in screw L until the sprocket and falls between adjusted properly. guide pulley is aligned with the spokes and largest the largest sprocket. sprocket or inner cage Rear derailleur or derailleur Straighten or replace. plate scrapes on spokes. hanger is bent. Delayed shifting. Clearance between guide Adjust b-adjust screw by pulley / sprocket is too large. rotating counterclockwise. Rough shifting behavior. Clearance between guide Adjust b-adjust screw by pulley / sprocket is too small. rotating clockwise. Chain jumps two gears on Shift cable insufficiently Turn barrel adjuster on the small sprocket tensioned. shifter counterclockwise. Delayed shifting onto Shift cable insufficiently Turn barrel adjuster on the larger sprocket tensioned. shifter counterclockwise. Delayed shifting onto Shift cable is too tight. Turn barrel adjuster on the smaller sprocket shifter clockwise. Excessive cable friction, Lubricate or replace cable pinched or poorly routed and housing. Check for cable. excessive bending of cable housing.

10 Technical Manual 2002 DUALDRIVE MAINTENANCE

Technical Manual 2002 11 12 Technical Manual 2002 SPECTRO S7 TECHNICAL DATA /ASSEMBLY REQUIREMENTS

• Comfort Action Shifting • Improved Ergonomics • Short Rotation • Optimal Gear Ratio • Spectro Design • Matte Chrome Finish • Improved Brake Performance • Most Efficient Hub In Its Class

L Version with Coaster Brake

OLD HR C 1/2 OLD D DS E Version for i-brake: see i-brake, page 55.

Caution: Spectro S7 hubs are not suitable for tandems, trademen’s delivery bicycles T and similar.

Cycle frame: The strength must be such that with a maximum braking torque of 250 Nm (2200 in.lbs.) F2 F1 Ø 7.3 on the rear wheel no residual deformation R 100 can occur on the rear structure. A2 max A1 max

MH7215 MH7225 MH7205 Part No. —— R —— Brake Coaster Drum „D“ R „NL“ None Over Locknut Dim., OLD 130mm 135mm 130mm Length, L 183.4mm 188.5mm 183.4mm Ends Diameter, T FG 10.5 FG 10.5 FG 10.5 Axle

Dropout Width Dim. A1 max. = 11.5mm / A2 max. = 12mm A1 max. = 11.5mm / A2 max. = 12.2mm A1 max. = 11.5mm / A2 max. = 10mm Holes 36 36 36 Hole Diameter, DS 3.0mm 2.9mm 3.0mm

Spoke Hole Ref. ø, HR 75mm 89mm 75mm 1 Flange Dist. to /2 OLD F1 = 33mm / F2 = 34mm F1 = 34.8mm / F2 = 35.7mm F1 = 34mm / F2 = 34mm H Totally 303% U Speed 1 57% Speed 2 68% B Speed 3 81% S Speed 4 100% Speed 5 124% Gear Hub Ratio Hub Gear Speed 6 148% Speed 7 174% 1 1 1 3 1 1 1 3 1 1 1 3 Usable Dimensions /2"x /8"or /2"x /32" /2"x /8"or /2"x /32" /2"x /8"or /2"x /32" Line, C/D/E 54/51/48mm 55.5/52.5/49.5mm 54/51/48mm Chain Ratio 24", 26",28"= 1.83–1.90 / 20"= 1.83–2.00 Shifter Compatib. Spectro Grip 7 Clickbox Compatib. Clickbox S7 Tandem Compatib. ——— Weight 1714g 1737g 1556g Hub Shell Material Steel Aluminum Steel

Finish Finish Matt Chrome Plated Clear Coat Matt Chrome Plated

Technical Manual 2002 13 SPECTRO S7 TECHNICAL DATA /ASSEMBLY REQUIREMENTS

S NEWNEW Spectro Grip 7 Part No. — R — R — R — R — R — R — H Shifter Type Twist Shifter I Cable 1400mm R 1500mm R 1600mm R 1700mm R 1800mm R 1900mm R 2100mm Gear Indication Window F Clamping Diameter 22.3mm T Handlebar, Straight Area Minimum length = 150mm E Weight 89g Housing Glass filled PA R Grip PP

S Design Grip Cover Thermoplastic elastomer, Overmolded Clamping Collar Aluminum

SPECTRO S7 ASSEMBLY

ASSEMBLY HUB • Mount the chain. 1 12 • Lace the wheel as normal. See spoke • Fit non-turn washer (1, Fig. 4) to the length table. outside of the dropout (hub side opposite • Place the dust cap (1, Fig. 1) and the sprocket). The serrations must bear sprocket (2) on the driver. against the dropout and the lug must • Push sprocket circlip (3, Fig. 2) onto the engage in the dropout slot. cone of tool sleeve (4). Place tool sleeve • On the sprocket side fit the protective with large diameter on the driver. bracket (1, Fig. 5) directly below the • Push the spring end of sliding sleeve (5) fixing nut. Tightening torque on acorn or of the tool over the tool sleeve. Thrust hex nuts 30 – 40 Nm (266 – 350 in.lbs.). 2 sliding sleeve in direction (6), this forces • Mount the brake lever using a suitable 453 circlip into the recess of the driver. frame clamp (2, Fig. 4). • Remove tool and check that the circlip is Caution: 6 seated correctly. Mount the brake lever between the two • Turn dust cap (7, Fig. 3) until the three straps of the frame clamp. lugs (8) are between the three beads (9) The clamp must be seated on the frame Mounting Tool Part No. 0582 104 000 on the sprocket (10). without play. • Position dust cap and push towards Use a self-locking nut! Tightening sprocket until it is felt to lock into place. torque: 2 – 3 Nm (18–27 in.lbs.). 3 • Placing the wheel in the rear frame.

8 7

9 Spoke length table: Tire Size Cross Length MH 7215/7205 Length MH 7225 47–406 20" x 1.75 x 2 3 x 181 mm 179 mm 3 37–490 22" x 1 /8 3 x 225 mm 222 mm 10 47–507 24" x 1.75 x 2 3 x 232 mm 229 mm 3 37–540 24" x 1 /8 3 x 251 mm 248 mm 47–559 26" x 1.75 x 2 3 x 259 mm 256 mm 3 4 37–590 26" x 1 /8 3 x 275 mm 272 mm 47–622 28" x 1.75 3 x 289 mm 286 mm 3 5 37–622 28"x1 /8 x 1 /8 3 x 289 mm 286 mm 1 28–622 28"x1 /8 3 x 289 mm 286 mm 5 1 32–622 28"x1 /8 x 1 /4 3 x 289 mm 286 mm 1 28–630 27"x1 /4 fifty 3 x 294 mm 291 mm 1 32–630 27" x 1 /4 3 x 294 mm 291 mm 1 Spoke lengths are approximate values. They must be checked through lacing attempts 2 and adjusted accordingly.

14 Technical Manual 2002 SPECTRO S7 ASSEMBLY

Advice: ADJUSTMENT 5 • If a different protective bracket (1, Fig. 5) • Be sure to reset rotational shifter from is used the thickness of the attachment 5th. to 4th gear. plate must be max. 3 mm. • Match up the marks in the Clickbox • Do not use additional washers. viewing window (4, Fig. 6) by turning • A minimum of 1 thread turn must be the adjusting screw (5). visible in front of the axle nut!

CONNECTING DRUM BRAKE ASSEMBLY SHIFTERS Caution: 1 • Slide shifter (1, Fig. 6) onto handlebar. Only use brake levers with a cable 3 2 • Mount fixed grip (2) onto end of handlebar. NEWNEW moving distance of at least 15 mm and a • Slide shifter against fixed grip, adjust minimum leverage of 3.8. shifter on handlebar and tighten with • Fit cable stop (1, Fig. 9) with adjusting bolt (3) with a torque of 1.5 Nm (13 in.lbs.). 6 bolt (2) and nut (3) and insert into the slot 4 on the brake anchor plate. Caution: • Turn adjusting bolt down by approx. 2/ 5 • Check that the shifter and brake lever 3 and route the brake cable from the function properly and are unobstructed brake handle. (realign if necessary). • Push lower brake cable end through • Fixed grips provide an axial safety 3 2 adjusting bolt (2) and insert lower cable function. For this reason, they should be 1 housing end into adjusting bolt. NEW mounted in such a way as to make sure NEW • Thread brake cable end (4) into they do not slip off handlebar. fork unit (5). • Never use lubricants or solvents to • Tighten screw (6) slightly. install fixed grips. 7 • Attach fork unit to brake lever (7). • Never ride without the fixed grips. The 1 • Pull brake cable end taut with pliers 2 turning grip may loosen from housing so that fork unit can still be attached and and slip off handlebar – this can result removed (important for changing wheel). in severe injury or death. • Tighten screw (6). • When fitting the cable avoid small radius. Caution: Attach the cable 3 times to the down For NL version drum brake hub with tube (1, Fig. 7). special lever (8), only use original NL • Last attachment point is on the lower brake cable (fork unit (5) is not suitable). rear wheel fork (2, Fig. 7) immediately behind the chain wheel. 8 Cable housing must be movable inside ADJUSTMENT DRUM BRAKE attachment. 7 • Unscrew adjusting screw (2, Fig. 9) until the brake pads drag lightly. INSTALLING CLICKBOX • Actuate the hand brake lever forcefully 6 • Insert shift rod (1, Fig. 8) in shift tube (2) several times and then, if necessary, 4 (oil parts lightly) and then push into axle turn the adjusting screw further in just bore as far as the stop. Turn slot (6) in until the wheel starts spinning freely. 2 shift tube to a position where it is easily • Lock hex nut (3). 1 visible. 3 5 • Push locating sleeve (3) with guiding rib (4) to the front onto the hub axle – making sure that the internal lug (5) is guided in 9 the slot (6) of the shift tube until it can be felt – and heard – to engage. • Turn locating sleeve on the axle until the 2 guiding rib (4) is facing roughly upwards. 3 1 • Push on Clickbox (2, Fig. 5) to the stop on the hub axle. The guiding rib (4, Fig. 8) of 4 6 the locating sleeve thereby engages in the slot on the housing. In the end position 5 tighten up the knurled bolt (3, Fig. 5) by hand. Assembly can be performed 7 independently of the gear setting but it is best done at shifter position “1”.

Technical Manual 2002 15 SPECTRO S7 MAINTENANCE

8 7 32 1 31 30 SACHS 6 29

28 5 27 4 3 26 20 25 19 18 24 23 2 22 41 42 17 21 1 16 15 40

39 14 13 38 12 11 10 37 35 36 9 34

REMOVE WHEEL • Remove cover (26), spring (25) and 2 • Loosen the knurled screw and pull the cover (24). Clickbox off the axle. • Dismantle retaining washer (23). Spectro S7 mounting aid • Disengage the location sleeve and pull it • Remove thrust washer (22) and plastic Part No. 65 0324 103 000 off. Remove shift rod/tube out of the axle profile washer (21). bore. • Unscrew grub screw (16) (Caution: It is • Remove wheel. subject to spring pressure) – and dismantle the long compression spring (17) DISMANTLING HUB guide pin (18), thrust block (19) and the see Fig. 1 short compression spring (20).

• Remove circlip (38), sprocket (37) and REASSEMBLY HUB dust cap (36) as normal. X see Fig. 1 • Withdraw locating sleeve (42) (latched) • Take out shift rod/tube (40/41). Lubrication see “MAINTENANCE/ • Clamp hub by the axle between aluminum LUBRICATION“. jaws with sprocket side facing downwards. • Insert into the axle (on the side with the • Unscrew both locknuts (1). internal thread): • Remove lever cone (2) ball retainer (3) • Short compression spring (20). and brake shell (4). • Thrust block (19) – it is the same both sides. • Withdraw hub sleeve (5) upwards. • Guide rod (18) – it is the same both sides. • Unscrew brake cone (6) from flat thread. • Long compression spring (17). • Take out retaining washer (7) and thrust • Compress spring and fit grub screw (16). washer (8). • Clamp axle, end for clickbox facing • Remove planetary gear carrier (9), upwards. washer (10) compression spring (11) and • Fit plastic profile washer (21) with its the three sun gears (12, 13, 14). large diameter upwards. • Clamp other axle end. • Fit thrust washer (22) and retaining • Unscrew fixed cone (35). washer (23). • Remove driver (34), compression spring • Locate cover (24), compression spring (25) (32) with cover (31), large compression with 7 turns, cover (26, insides to the spring (30), ball retainer (33), gear ring (29) spring). and coupling gear (28). • Compress spring and position thrust • Compress spring (25) and remove thrust block (27) – it is the same both sides – block (27). centrally in the axle.

16 Technical Manual 2002 SPECTRO S7 MAINTENANCE

• Clamp other axle end. CABLE CHANGE 3 • Fit large sun gear (14), with deflector Dismantling shifter cable: bevels upwards. • Place shifter in gear position "1". 1 4 2 • Position medium sun gear (13), with • Do not remove the Clickbox from the axle 5 deflector bevels upwards. end. • Fit small sun gear (12) – with recesses in • Unscrew the adjusting screw (5, Fig. 3) front, thrust block engages in the slots. completely. Unscrew the cover screw (1), • Position smallest compression spring (11). brush aside the adjusting screw (5) and • Fit 1 mm thick washer (10). remove the cover (2). • Fit planetary gear carrier (9). • Withdraw shifter cable and clamping • Place the mounting aid(Fig. 2) on the bolt (1, Fig. 4) upwards, loosen clamp planetary gear carrier such that the and pull clamping piece from the cable. markings (X) on the 3 small planet gears • Slightly lift the grip cover (Fig. 5), push and the mounting aid match up. the cable out and discard. NEWNEW • Turn planetary gear carrier and at the same time push it downwards over the Assembly shifter cable: sun gears. • Route new cable through shifter housing 4 • Fit thrust washer (8) and retaining and pull cable to seat cable head washer (7) in the undercut. completely into cable recess. Only now remove the mounting aid. • Feed the cable through the new cable 1 housing and adjusting screw. Advice: • Position clamping bolt (1, Fig. 6) at a If the gears are not accurately assembled distance of 92 mm, tighten up with the hub may feel tight in use. This may 1.5 Nm (13 in.lbs.) and cut off cable ends lead to gear wheel damage during travel. to 2 – 3 mm. 2 • Locate clamping bolt (1, Fig. 4) (srew • Reclamp axle (Clickbox end facing head not visible) and place shifter cable upwards) around the carrier cylinder (counter- • Fit coupling gear (28) with carrier plate clockwise winding). downwards • Insert the square nut of the adjusting • Push ring gear (29) over the coupling gear. bolt (2) in the housing and completely NEWNEW • Locate large spring (30). screw in the knurled bolt. • Fit largest ball retainer (33) with balls • Position the cover (2, Fig. 3) and tighten underneath. up with the cover screw (1). 5 • Fit cover (31, inside to the spring). Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.). • Assemble the compression spring (32) Screw in the adjusting screw (5) with 12 turns. completely. • Position driver (34) – push it down – and screw on fixed cone (35) to the stop, tightening torque 20 Nm (177 in.lbs.). ADJUSTMENT • Clamp other axle end. • Be sure to reset rotational shifter from • Screw brake cone (6) onto the flat 5th. to 4th gear. thread. • Match up the marks in the • Assemble hub sleeve – with a slight Clickbox viewing window (4, Fig. 3) by counter-clockwise movement. turning the adjusting screw (5). • Insert brake shell (4) – retaining lugs upwards, thereby the friction spring on the brake cone must engage in the slot on the brake shell. NEWNEW • Locate ball retainer (3) (balls underneath), position lever cone (2), thereby turn it clockwise until the retaining lugs 6 engage. • Screw on locknuts (1), adjust bearing so that there is no play and lock nuts together with 15 – 20 Nm (133 – 177in.lbs.). 2 +1 mm 92 ±0,5 mm Advice: The dismantly and reassembly of the hub types MH 7205 / MH 7225 should be carried out in the same way. Differences: 1 Instead of brake shell/cone a click-and- pawl carrier is installed on the planetary NEWNEW gear carrier here. Without flat thread – fixed with a retaining washer.

Technical Manual 2002 17 SPECTRO S7 MAINTENANCE

DRUM BRAKE • Oil the inside of the sun gears, grease 7 Install brake anchor plate (or exchange it): the outside teeth (fill the gaps in the • Place thrust washer (8, Fig. 7) over the teeth). axle on the adjusting cone and fit • Oil outside teeth and carrier plate on 2 3 complete brake anchor plate. Position the coupling gear and lightly grease the 1 washer (9) distance sleeve (10) and borehole from right and left. 4 6 screw on locknut (11). • Do not apply grease to ring gear but just • Push brake lever (7) to the stop and hold oil the pawl pockets. 5 it there to center the brake jaws in the • Grease the brake cone in the borehole 8 brake drum – tighten up locknut with a and the friction spring. torque of 15 – 20 Nm (133 – 177 in.lbs.). • Spread grease on the inside and outside 9 7 of the brake shell. 10 ADJUSTMENT DRUM BRAKE • Fill lever cone with grease reserves for 11 • Unscrew adjusting screw (2, Fig. 7) until brakes the brake pads drag lightly. • Regrease ball retainer, line ball bearing • Actuate the hand brake lever forcefully running tracks with grease. several times and then, if necessary, Caution: turn the adjusting screw further in just For version with mounted i-brake use until the wheel starts spinning freely. only the new highly heat-proof SRAM • Lock hex nut (3). grease “Typ B“ (Part No.: 35g – 0369 135 200 / 200g – 0369 135 201). Caution: Check that all the brake system components are functioning properly!

MAINTENANCE / LUBRICATION Caution: The Spectro hubs are provided with permanent lubrication and under normal conditions is maintenance-free. If the coaster brake is loaded excessively its effect can be too strong, the hub may lock. In such a case the brake shell should be lubricated with a special grease (Part No. 0369 135 101). Renew brake shell, when rhombic pattern is worn out.

Cleaning of parts: • All parts – except for the planetary gear TROUBLESHOOTING carrier – can be decreased in a cleaning bath. Problem Cause Remedy • The planetary gear carrier only needs to Shifting Damaged Replace be cleaned on the outside with a brush difficulties control cable control cable so as not to degrease the planetary gear Incorrect Adjust shift. bearing. gear setting system To much ad- Axle end must Caution: ditional axle protrude by Do not use high-pressure water when attachments min. 1 thread cleaning the gear hub (e.g. strong water between hub turn jets, high-pressure cleaners etc.) – and axle nut if water penetrates it could lead to Pedals are Bearings Re-adjust functional problems. carried set too tight bearings forward Loose Tighten Lubrication of parts: when free- lock nuts lock nuts • To lubricate the bearing points on wheeling (15 – 20 Nm) the planetary gear sets, position the Chain is over- Reduce planetary gear carrier on its crown and tensioned chain tension apply 2 – 3 drops of oil to the bearing Hub locks Brake shell Wash out bolts – at the same time turning the when has run dry hub sleeve, planetary gears so that the bearing braking repolish and points are completely wet. Oil axle (coaster relubricate through the axle bore and axle slot, brake) brake cylin- apply a thin coating of grease to the der, renew outside. brake shell

18 Technical Manual 2002 SPECTRO S7 MAINTENANCE

Technical Manual 2002 19 20 Technical Manual 2002 SPECTRO P5 TECHNICAL DATA /ASSEMBLY REQUIREMENTS

L Version with Coaster Brake

OLD HR Version for i-brake: C see i-brake, page 55. 1/2 OLD D E DS Version Spectro P5 Cargo: see page 29.

Caution: Spectro P5 hubs are not suitable for tandems, trademen’s delivery bicycles T and similar.

MH5215 MH5225 MH5205 Part. No. — R —— R — R — — Brake Coaster Drum „D“ R „NL“ R „NL“ None Over Locknut Dim., OLD 122mm 126mm 122mm Length, L 175mm 179mm 175mm Ends Diameter, T FG 10.5 FG 10.5 toothed cone FG 10.5 FG 10.5

Axle R Dropout Width Dim. A1 max. = 11.5mm / A2 max. = 11.5mm A1 max. = 11.5mm / A2 max. = 12.5mm A1 max. = 11.5mm / A2 max. = 10.5mm Holes 36 36 36 Hole Diameter, DS 3.0mm 2.9mm 3.0mm

Spoke Hole Ref. ø, HR 75mm 89mm 75mm 1 H Flange Dist. to /2 OLD F1 = 28.5mm / F2 = 29.5mm F1 = 30.5mm / F2 = 29.5mm F1 = 29mm / F2 = 29mm Totally 249% U Speed 1 63% B Speed 2 78% S Speed 3 100% Speed 4 128% Gear Hub Ratio Hub Gear Speed 5 158% 1 1 1 3 1 1 1 3 1 1 1 3 Usable Dimensions /2"x /8"or /2"x /32" /2"x /8"or /2"x /32" /2"x /8"or /2"x /32" Line, C/D/E 49/45.5/43mm 51.5/48.5/45.5mm 49/45.5/43mm Chain Ratio 24", 26",28"= 1.8–1.9 / 20"= 1.8–2.0 Shifter Compatib. Spectro Grip 5 Clickbox Compatib. Clickbox P5 Tandem Compatib. ——— Weight 1495g 1536g 1330g Hub Shell Material Steel Aluminum Steel

Finish Finish Matt Chrome Plated Clear Coat R Clear Coat R Black Painted Matt Chrome Plated

Technical Manual 2002 21 SPECTRO P5 TECHNICAL DATA /ASSEMBLY REQUIREMENTS

S NEWNEW Spectro Grip 5 Part No. — R — R — R — R — R — R — R — H Shifter Type Twist Shifter I Cable 1400mm R 1500mm R 1600mm R 1700mm R 1800mm R 1900mm R 2000mm R 2300mm Gear Indication Window F Clamping Diameter 22.3mm T Handlebar, Straight Area Minimum length = 150mm E Weight 89g Housing Glass filled PA R Grip PP

S Design Grip Cover Thermoplastic elastomer, Overmolded Clamping Collar Aluminum

SPECTRO P5 ASSEMBLY

ASSEMBLY HUB • Placing the wheel in the rear frame. 1 12 • Lace the wheel as normal. See spoke • Mount the chain. length table. • Fit non-turn washer (1, Fig. 4) to the • Place the dust cap (1, Fig. 1) and outside of the dropouts. The serrations sprocket (2) on the driver. must bear against the dropout and the • Push sprocket circlip (3, Fig. 2) onto the lug must engage in the dropout slot. cone of tool sleeve (4). Place tool sleeve • On the sprocket side fit the protective with large diameter on the driver. bracket (1, Fig. 5) directly below the • Push the spring end of sliding sleeve (5) fixing nut. Tightening torque on acorn or of the tool over the tool sleeve. Thrust hex nuts 30 – 40 Nm (266 – 350 in.lbs.). 2 sliding sleeve in direction (6), this forces • Mount the brake lever using a suitable 453 circlip into the recess of the driver. frame clamp (2, Fig. 4). • Remove tool and check that the circlip is Caution: 6 seated correctly. Mount the brake lever between the two • Turn dust cap (7, Fig. 3) until the three straps of the frame clamp. lugs (8) are between the three beads (9) The clamp must be seated on the frame Mounting Tool on the sprocket (10). without play. Part No. 0582 104 000 • Position dust cap and push towards Use a self-locking nut! Tightening sprocket until it is felt to lock into place. torque: 2 – 3 Nm (18–27 in.lbs.). 3

8 7

9 Spoke length table: Tire Size Cross Length MH 5215/5205 Length MH 5225 47–406 20" x 1.75 x 2 3 x 181 mm 179 mm 3 37–490 22" x 1 /8 3 x 225 mm 222 mm 10 47–507 24" x 1.75 x 2 3 x 232 mm 229 mm 3 37–540 24" x 1 /8 3 x 251 mm 248 mm 47–559 26" x 1.75 x 2 3 x 259 mm 256 mm 3 4 37–590 26" x 1 /8 3 x 275 mm 272 mm 47–622 28" x 1.75 3 x 289 mm 286 mm 3 5 37–622 28"x1 /8 x 1 /8 3 x 289 mm 286 mm 1 28–622 28"x1 /8 3 x 289 mm 286 mm 5 1 32–622 28"x1 /8 x 1 /4 3 x 289 mm 286 mm 1 28–630 27"x1 /4 fifty 3 x 294 mm 291 mm 1 32–630 27" x 1 /4 3 x 294 mm 291 mm 1 Spoke lengths are approximate values. They must be checked through lacing attempts 2 and adjusted accordingly.

22 Technical Manual 2002 SPECTRO P5 ASSEMBLY

Advice: ADJUSTMENT 5 • If a different protective bracket (1, Fig. 5) • Be sure to reset rotational shifter from is used the thickness of the attachment 4th. to 3th gear. plate must be max. 3 mm. • Match up the marks in the Clickbox • Do not use additional washers. viewing window (4, Fig. 6) by turning • A minimum of 1 thread turn must be the adjusting screw (5). visible in front of the axle nut!

ASSEMBLY SHIFTERS CONNECTING DRUM BRAKE 1 • Slide shifter (1, Fig. 6) onto handlebar. Caution: 3 2 • Mount fixed grip (2) onto end of handlebar. Only use brake levers with a cable NEWNEW • Slide shifter against fixed grip, adjust moving distance of at least 15 mm and a shifter on handlebar and tighten with minimum leverage of 3.8. bolt (3) with a torque of 1.5 Nm (13 in.lbs.). • Fit cable stop (1, Fig. 9) with adjusting 6 bolt (2) and nut (3) and insert into the slot 4 Caution: on the brake anchor plate. 2 5 • Check that the shifter and brake lever • Turn adjusting bolt down by approx. /3 function properly and are unobstructed and route the brake cable from the (realign if necessary). brake handle. • Fixed grips provide an axial safety • Push lower brake cable end through 3 2 function. For this reason, they should be adjusting bolt (2) and insert lower cable 1 NEWNEW mounted in such a way as to make sure housing end into adjusting bolt. they do not slip off handlebar. • Thread brake cable end (4) into fork • Never use lubricants or solvents to unit (5). install fixed grips. • Tighten screw (6) slightly. 7 • Never ride without the fixed grips. The • Attach fork unit to brake lever (7). 2 1 turning grip may loosen from housing • Pull brake cable end taut with pliers and slip off handlebar – this can result so that fork unit can still be attached and in severe injury or death. removed (important for changing wheel). • Tighten screw (6). • When fitting the cable avoid small radius. Attach the cable 3 times to the down Caution: tube (1, Fig. 7). For NL version drum brake hub with • Last attachment point is on the lower special lever (8), only use original NL rear wheel fork (2, Fig. 7) immediately brake cable (fork unit (5) is not suitable). behind the chain wheel. Cable housing must be movable inside 8 attachment. ADJUSTMENT DRUM BRAKE 7 • Unscrew adjusting screw (2, Fig. 9) until INSTALLING CLICKBOX the brake pads drag lightly. • Insert shift rod (1, Fig. 8) in shift tube (2) • Actuate the hand brake lever forcefully 6 (oil parts lightly) and then push into axle several times and then, if necessary, 4 bore as far as the stop. If the shifting rod turn the adjusting screw further in just is sticking up out of the axle end: apply until the wheel starts spinning freely. 2 slight pressure on the shift rod with its • Lock hex nut (3). 1 threaded section and screw inwards in 3 5 a clockwise direction until it can again be moved axially (valid for older hub versions). Turn slot (6) in shift tube to a 9 position where it is easily visible. • Push locating sleeve (3) with guiding rib (4) to the front onto the hub axle – making 2 sure that the internal lug (5) is guided in 3 1 the slot (6) of the shift tube until it can be felt – and heard – to engage. 4 6 • Turn locating sleeve on the axle until the guiding rib (4) is facing roughly upwards. 5 • Push on Clickbox (2, Fig. 5) to the stop on the hub axle. The guiding rib (4, Fig. 8) of 7 the locating sleeve thereby engages in the slot on the housing. In the end position tighten up the knurled bolt (3, Fig. 5) by hand. Assembly can be performed 8 independently of the gear setting but it is best done at shifter position “2”.

Technical Manual 2002 23 SPECTRO P5 MAINTENANCE

1 8 7

5 29 28 4 27 3 2

1 26 25 17 24 16 23 39 15 22 41 21 38 14 20 19 18 40 13 37 36 35 12 11 10 34 32 9 33 31 30

• Remove circlip (35), sprocket (34) and REASSEMBLY HUB dust cap (33). X see Fig. 1 • Clamp hub with sprocket side facing downwards with the two axle flats. Lubrication see “MAINTENANCE/ • Unscrew the two locknuts (1). LUBRICATION“. • Remove lever cone (2), ball retainer (3) • Clamp axle with internal thread up- and brake shell (4). wards. • Withdraw hub sleeve (5) upwards. • Position small sun gear (11) with crown • Unscrew brake cone (6) from flat thread. gears to the front. • Remove retaining washer (7), thrust • Position thrust block (17) in the slotted washer (8). hole (is laterally guided when the sun • Remove planetary gear carrier (9) and gear is screwed in). thrust washer (10). • Locate bolt (16), then spring (15) in the • Clamp other axle end. axle and screw in grub screw (14) until • Unscrew fixed cone (32). it is flush with the axle. • Remove driver (31), compression spring • Reclamp axle. Fit large sun gear (12) (it (29), large compression spring (27) and is the same both sides). Position conical ball retainer (30). – Withdraw gear compression spring (18), with the large ring (26) and coupling gear (25) and then diameter first. Press spring together and remove cover (28) from the coupling fit washer (19) and retaining washer (20). gear.

24 Technical Manual 2002 SPECTRO P5 MAINTENANCE

• Assemble cover (21), compression CABLE CHANGE 3 spring with 7 turns (22) and the second Dismantling shifter cable: cover (23, insides to the spring). • Place shifter in gear position "1". 1 4 2 • Compress spring and position thrust • Do not remove the Clickbox from the axle 5 block (24) (it is the same both sides) in end. the center of the slotted hole. • Unscrew the adjusting screw (5, Fig. 3) • Position coupling gear (25) with carrier completely. Unscrew the cover screw (1), plate facing downwards. brush aside the adjusting screw (5) and • Fit cover (28, inside to the spring) for remove the cover (2). compression spring. • Withdraw shifter cable and clamping • Position gear ring (26) over the teeth of bolt (1, Fig. 4) upwards, loosen clamp the coupling gear. and pull clamping piece from the cable. • Place ball retainer (30), with balls below • Slightly lift the grip cover (Fig. 5), push on the gear ring. the cable out and discard. NEWNEW • Position large compression spring (27) on gear ring. Assembly shifter cable: • Mount compression spring with 13 turns • Route new cable through shifter housing 4 (29) on the axle. (Is supported in the and pull cable to seat cable head coupling wheel by the cover). completely into cable recess. • Locate driver (31), press it down and • Feed the cable through the new cable 1 screw on fixed cone (32) as far as the housing and adjusting screw. stop. Tightening torque 20 Nm. (Then • Position clamping bolt (1, Fig. 6) at a reclamp hub.) distance of 86 mm, tighten up with • Push on thrust washer (10) and fit 1.5 Nm (13 in.lbs.) and cut off cable ends planetary gear carrier (9). In doing this: to 2 – 3 mm. 2 Position mounting aid (Fig. 2) on the • Locate clamping bolt (1, Fig. 4) (srew planetary gear carrier so that the (X) head not visible) and place shifter cable markings on the threeplanetary gears around the carrier cylinder (counter- match with the mounting aid. clockwise winding). • Insert planetary gear carrier, place • Insert the square nut of the adjusting thrust washer (8) on it and mount bolt (2) in the housing and completely NEWNEW retaining washer (7) in recess. screw in the knurled bolt. Only now remove the mounting aid. • Position the cover (2, Fig. 3) and tighten up with the cover screw (1). 5 Advice: Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.). If the gears are not accurately installed Screw in the adjusting screw (5) the hub may be tight to move. completely. This could lead to damage to the gear- wheels in operation. For lubrication of the hub see “MAINTENANCE/LUBRICATION”. ADJUSTMENT • Be sure to reset rotational shifter from • Screw brake cone (6) onto flat threads. 4th. to 3th gear. • Mount hub sleeve (5), with a slight • Match up the marks in the counter-clockwise turn. Clickbox viewing window (4, Fig. 3) by • Locate brake shell (4) – with retaining turning the adjusting screw (5). lugs uppermost –, then the friction spring on the brake cone must engage with the slot on the brake shell. • Insert ball retainer (3) – with balls below. NEWNEW • Position lever cone (2) – in doing this turn it clockwise until the retaining lugs engage. 6 • Screw on counternuts (1), adjust bearings to be free of play and tighten lock nuts. Tightening torque 15 – 20 Nm (133 – 177in.lbs.).

2 +1 mm 86 ±0,5 mm Advice: The dismantly and reassembly of the hub types MH 5205 / MH 5225 should be carried out in the same way. Differences: Instead of brake shell/cone a click-and- 1 pawl carrier is installed on the planetary gear carrier here. Without flat thread – NEWNEW fixed with a retaining washer.

Technical Manual 2002 25 SPECTRO P5 MAINTENANCE

DRUM BRAKE Lubrication of parts: 7 Install brake anchor plate (or exchange it): • To lubricate the bearing points on • Place thrust washer (8, Fig. 7) over the the planetary gear sets, position the axle on the adjusting cone and fit planetary gear carrier on its crown and 2 3 complete brake anchor plate. Position apply 2 – 3 drops of oil to the bearing 1 washer (9) distance sleeve (10) and bolts – at the same time turning the 4 6 screw on locknut (11). planetary gears so that the bearing • Push brake lever (7) to the stop and hold points are completely wet. Oil axle 5 it there to center the brake jaws in the through the axle bore and axle slot, 8 brake drum – tighten up locknut with a apply a thin coating of grease to the torque of 15 – 20 Nm (133 – 177 in.lbs.). outside. 9 7 • Oil the inside of the sun gears, grease 10 the outside teeth (fill the gaps in the 11 ADJUSTMENT DRUM BRAKE teeth). • Unscrew adjusting screw (2, Fig. 7) until • Oil outside teeth and carrier plate on the brake pads drag lightly. the coupling gear and lightly grease the • Actuate the hand brake lever forcefully borehole from right and left. several times and then, if necessary, • Do not apply grease to ring gear but just turn the adjusting screw further in just oil the pawl pockets. until the wheel starts spinning freely. • Grease the brake cone in the borehole • Lock hex nut (3). and the friction spring. • Spread grease on the inside and outside Caution: of the brake shell. Check that all the brake system • Fill lever cone with grease reserves for components are functioning properly! brakes. • Regrease ball retainer, line ball bearing running tracks with grease. MAINTENANCE / Caution: LUBRICATION For version with mounted i-brake use Caution: only the new highly heat-proof SRAM The Spectro hubs are provided with grease “Typ B“ (Part No.: 35g – 0369 135 permanent lubrication and under normal 200 / 200g – 0369 135 201). conditions is maintenance-free. If the coaster brake is loaded excessively its effect can be too strong, the hub may lock. Advice: In such a case the brake shell should be • The Spectro P5 hubs complete with lubricated with a special grease (Part No. shifting component have been modified 0369 135 101). Renew brake shell, when in such a way that the shifting forces rhombic pattern is worn out. are considerably lower than was previously the case. Cleaning of parts: The new shifting component (shifter / • All parts – except for the planetary gear Clickbox) is shown in Fig. 6, page 23. carrier – can be decreased in a cleaning Indentification of the new hubs: red bath. grub screw (14, Fig. 1) in the left axle • The planetary gear carrier only needs to end and new spring (15) in the axle. be cleaned on the outside with a brush In order to achieve the maximum so as not to degrease the planetary gear reduction in shifting forces with a bearing. combination of new shifting component / old hub, the new spring (15) and the red Caution: grub screw (14) should be installed in the Do not use high-pressure water when hub axle (see describtion “REASSEMBLY cleaning the gear hub (e.g. strong water HUB“). jets, high-pressure cleaners etc.) – if water penetrates it could lead to functional problems.

26 Technical Manual 2002 SPECTRO P5 MAINTENANCE

TROUBLESHOOTING Problem Cause Remedy Shifting Damaged Replace difficulties control cable control cable Incorrect Adjust shift. gear setting system To much ad- Axle end must ditional axle protrude by attachments min. 1 thread between hub turn and axle nut Pedals are Bearings Re-adjust carried set too tight bearings forward Loose Tighten when free- lock nuts lock nuts wheeling (15 – 20 Nm) Chain is over- Reduce tensioned chain tension Hub locks Brake shell Wash out when has run dry hub sleeve, braking repolish and (coaster relubricate brake) brake cylinder, renew brake shell

Technical Manual 2002 27 28 Technical Manual 2002 SPECTRO P5 CARGO TECHNICAL DATA /ASSEMBLY REQUIREMENTS CARGO

Caution: The Spectro P5 Cargo is suitable for tandems, trademen’s delivery bicycles and similar. An additional external rear brake is necessary due to the high load.

Tolerable stress: Axle load: max. 120 kilograms Torque/driver body: max. 85 Nm (750 in.lbs.), no continuous stress.

Identification Spectro P5 Cargo: Yellow grub screw inside the axle end. L Version with Coaster Brake

OLD C HR 1/2 OLD D E DS

Version Spectro P5 for normal bikes: T see page 21.

NEWNEW MH5215 Cargo MH5225 Cargo Part. No. — R —— R — R — Brake Coaster Drum „D“ R „NL“ R „NL“ Over Locknut Dim., OLD 122mm 126mm Length, L 175mm 179mm Ends Diameter, T FG 10.5 toothed cone FG 10.5 Axle

Dropout Width Dim. A1 max. = 11.5mm / A2 max. = 11.5mm A1 max. = 11.5mm / A2 max. = 12.5mm Holes 36 36 Hole Diameter, DS 3.0mm 2.9mm

Spoke Hole Ref. ø, HR 75mm 89mm 1 H Flange Dist. to /2 OLD F1 = 28.5mm / F2 = 29.5mm F1 = 30.5mm / F2 = 29.5mm Totally 242% U Speed 1 67% B Speed 2 78% S Speed 3 100% Speed 4 128% Gear Hub Ratio Hub Gear Speed 5 150% 1 1 1 3 1 1 1 3 Usable Dimensions /2"x /8"or /2"x /32" /2"x /8"or /2"x /32" Line, C/D/E 49/45.5/43mm 51.5/48.5/45.5mm Chain Ratio 24", 26",28"= 1.8–1.9 / 20"= 1.8–2.0 Shifter Compatib. Spectro Grip 5 Clickbox Compatib. Clickbox P5 Tandem Compatib. Yes Yes Weight 1495g 1536g Hub Shell Material Steel Aluminum

Finish Finish Matt Chrome Plated Clear Coat

Technical Manual 2002 29 SPECTRO P5 CARGO TECHNICAL DATA /ASSEMBLY REQUIREMENTS

S Design Grip Cover Thermoplastic elastomer, Overmolded Clamping Collar Aluminum

SPECTRO P5 CARGO ASSEMBLY

8 7

30 Technical Manual 2002 SPECTRO P5 CARGO ASSEMBLY CARGO

CONNECTING DRUM BRAKE 1 ASSEMBLY SHIFTERS Caution: 3 2 • Slide shifter (1, Fig. 6) onto handlebar. Only use brake levers with a cable NEWNEW • Mount fixed grip (2) onto end of handlebar. moving distance of at least 15 mm and a • Slide shifter against fixed grip, adjust minimum leverage of 3.8. shifter on handlebar and tighten with • Fit cable stop (1, Fig. 9) with adjusting 6 bolt (3) with a torque of 1.5 Nm (13 in.lbs.). bolt (2) and nut (3) and insert into the slot 4 on the brake anchor plate. 2 5 Caution: • Turn adjusting bolt down by approx. /3 • Check that the shifter and brake lever and route the brake cable from the function properly and are unobstructed brake handle. (realign if necessary). • Push lower brake cable end through 3 2 • Fixed grips provide an axial safety adjusting bolt (2) and insert lower cable 1 NEWNEW function. For this reason, they should be housing end into adjusting bolt. mounted in such a way as to make sure • Thread brake cable end (4) into fork they do not slip off handlebar. unit (5). • Never use lubricants or solvents to • Tighten screw (6) slightly. 7 install fixed grips. • Attach fork unit to brake lever (7). 2 1 • Never ride without the fixed grips. The • Pull brake cable end taut with pliers turning grip may loosen from housing so that fork unit can still be attached and and slip off handlebar – this can result removed (important for changing wheel). in severe injury or death. • Tighten screw (6).

• When fitting the cable avoid small radius. Caution: Attach the cable 3 times to the down For NL version drum brake hub with tube (1, Fig. 7). special lever (8), only use original NL • Last attachment point is on the lower brake cable (fork unit (5) is not suitable). rear wheel fork (2, Fig. 7) immediately behind the chain wheel. 8 Cable housing must be movable inside ADJUSTMENT DRUM BRAKE 7 attachment. • Unscrew adjusting screw (2, Fig. 9) until the brake pads drag lightly. • Actuate the hand brake lever forcefully 6 INSTALLING CLICKBOX several times and then, if necessary, 4 • Insert shift rod (1, Fig. 8) in shift tube (2) turn the adjusting screw further in just (oil parts lightly) and then push into axle until the wheel starts spinning freely. 2 bore as far as the stop. Turn slot (6) in • Lock hex nut (3). 1 shift tube to a position where it is easily 3 5 visible. • Push locating sleeve (3) with guiding rib (4) to the front onto the hub axle – making 9 sure that the internal lug (5) is guided in the slot (6) of the shift tube until it can be felt – and heard – to engage. 2 • Turn locating sleeve on the axle until the 3 1 guiding rib (4) is facing roughly upwards. • Push on Clickbox (2, Fig. 5) to the stop on 4 6 the hub axle. The guiding rib (4, Fig. 8) of the locating sleeve thereby engages in 5 the slot on the housing. In the end position tighten up the knurled bolt (3, Fig. 5) by 7 hand. Assembly can be performed independently of the gear setting but it is best done at shifter position “2”.

Technical Manual 2002 31 SPECTRO P5 CARGO MAINTENANCE

1 8 7

5 29 28 4 27 3 2

1 26 25 17 24 16 23 39 15 22 41 21 38 14 20 19 18 40 13 37 36 35 12 11 10 34 32 9 33 31 30

REMOVE WHEEL • Take out thrust block (24), (to do this 2 • Loosen the knurled screw and pull the compress the spring). Remove spring Clickbox off the axle. (22) and the two covers (23/21). • Disengage the location sleeve and pull it • Dismantle retaining washer (20), washer Spectro P5 mounting aid off. Remove shift rod/tube. (19), conical compression spring (18), Part No. 5024 300 000 • Remove wheel. and the large sun gear (12). Clamp other axle end (thrust block visible). DISMANTLING HUB • Unscrew grub screw (14) – Dismantle see Fig. 1 spring (15), guide bolt (16) and thrust block (17). • Remove circlip (35), sprocket (34) and • Remove small sun sun gear (11). dust cap (33). • Clamp hub with sprocket side facing REASSEMBLY HUB downwards with the two axle flats. X see Fig. 1 • Unscrew the two locknuts (1). • Remove lever cone (2), ball retainer (3) Lubrication see “MAINTENANCE/ and brake shell (4). LUBRICATION“. • Withdraw hub sleeve (5) upwards. • Clamp axle with internal thread up- • Unscrew brake cone (6) from flat thread. wards. • Remove retaining washer (7), thrust • Position small sun gear (11) with crown washer (8). gears to the front. • Remove planetary gear carrier (9) and • Position thrust block (17) in the slotted thrust washer (10). hole (is laterally guided when the sun • Clamp other axle end. gear is screwed in). • Unscrew fixed cone (32). • Locate bolt (16), then spring (15) in the • Remove driver (31), compression spring axle and screw in grub screw (14) until (29), large compression spring (27) and it is flush with the axle. ball retainer (30). – Withdraw gear • Reclamp axle. Fit large sun gear (12) (it ring (26) and coupling gear (25) and then is the same both sides). Position conical remove cover (28) from the coupling compression spring (18), with the large gear. diameter first. Press spring together and fit washer (19) and retaining washer (20).

32 Technical Manual 2002 SPECTRO P5 CARGO MAINTENANCE CARGO

• Assemble cover (21), compression CABLE CHANGE 3 spring with 7 turns (22) and the second Dismantling shifter cable: cover (23, insides to the spring). • Place shifter in gear position "1". 1 4 2 • Compress spring and position thrust • Do not remove the Clickbox from the axle 5 block (24) (it is the same both sides) in end. the center of the slotted hole. • Unscrew the adjusting screw (5, Fig. 3) • Position coupling gear (25) with carrier completely. Unscrew the cover screw (1), plate facing downwards. brush aside the adjusting screw (5) and • Fit cover (28, inside to the spring) for remove the cover (2). compression spring. • Withdraw shifter cable and clamping • Position gear ring (26) over the teeth of bolt (1, Fig. 4) upwards, loosen clamp the coupling gear. and pull clamping piece from the cable. • Place ball retainer (30), with balls below • Slightly lift the grip cover (Fig. 5), push on the gear ring. the cable out and discard. NEWNEW • Position large compression spring (27) on gear ring. Assembly shifter cable: • Mount compression spring with 13 turns • Route new cable through shifter housing 4 (29) on the axle. (Is supported in the and pull cable to seat cable head coupling wheel by the cover). completely into cable recess. • Locate driver (31), press it down and • Feed the cable through the new cable 1 screw on fixed cone (32) as far as the housing and adjusting screw. stop. Tightening torque 20 Nm. (Then • Position clamping bolt (1, Fig. 6) at a reclamp hub.) distance of 86 mm, tighten up with • Push on thrust washer (10) and fit 1.5 Nm (13 in.lbs.) and cut off cable ends planetary gear carrier (9). In doing this: to 2 – 3 mm. 2 Position mounting aid (Fig. 2) on the • Locate clamping bolt (1, Fig. 4) (srew planetary gear carrier so that the (X) head not visible) and place shifter cable markings on the threeplanetary gears around the carrier cylinder (counter- match with the mounting aid. clockwise winding). • Insert planetary gear carrier, place • Insert the square nut of the adjusting thrust washer (8) on it and mount bolt (2) in the housing and completely NEWNEW retaining washer (7) in recess. screw in the knurled bolt. Only now remove the mounting aid. • Position the cover (2, Fig. 3) and tighten up with the cover screw (1). 5 Advice: Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.). If the gears are not accurately installed Screw in the adjusting screw (5) the hub may be tight to move. completely. This could lead to damage to the gear- wheels in operation. For lubrication of the hub see “MAINTENANCE / LUBRICATION”. ADJUSTMENT • Be sure to reset rotational shifter from • Screw brake cone (6) onto flat threads. 4th. to 3th gear. • Mount hub sleeve (5), with a slight • Match up the marks in the counter-clockwise turn. Clickbox viewing window (4, Fig. 3) by • Locate brake shell (4) – with retaining turning the adjusting screw (5). lugs uppermost –, then the friction functional problems. spring on the brake cone must engage with the slot on the brake shell. • Insert ball retainer (3) – with balls below. NEWNEW • Position lever cone (2) – in doing this turn it clockwise until the retaining lugs engage. 6 • Screw on counternuts (1), adjust bearings to be free of play and tighten lock nuts. Tightening torque 15 – 20 Nm (133 – 177in.lbs.).

Technical Manual 2002 33 SPECTRO P5 CARGO MAINTENANCE

Cleaning of parts: • All parts – except for the planetary gear carrier – can be decreased in a cleaning bath. • The planetary gear carrier only needs to be cleaned on the outside with a brush so as not to degrease the planetary gear bearing.

Caution: Do not use high-pressure water when cleaning the gear hub (e.g. strong water jets, high-pressure cleaners etc.) – if water penetrates it could lead to functional problems.

34 Technical Manual 2002 SPECTRO P5 CARGO MAINTENANCE CARGO

Technical Manual 2002 35 36 Technical Manual 2002 SPECTRO T3 TECHNICAL DATA /ASSEMBLY REQUIREMENTS

• Comfort Action Shifting L Version with Coaster Brake HR • Easy Adjust OLD • Superior Quality C DS • Spectro Design 1/2 OLD D E • Matte Chrome Finish • Improved Brake Performance • Most Efficient Hub In Its Class T Ø 7.3 Version for i-brake: see i-brake, page 55.

Caution: F F 100 2 1 R Spectro T3 hubs are not suitable for Cycle frame: tandems, trademen’s delivery bicycles The strength must be such that with a maximum braking torque of 250 Nm (2200 in.lbs.) and similar. on the rear wheel no residual deformation can occur on the rear structure.

MH3115 MH3125 MH3105 Part No. —— R —— R — Brake Coaster Drum „D“ R „NL“ None Over Locknut Dim., OLD 118mm 118mm 117mm Length, L 152/164mm 164mm 152mm R 164mm

Axle Ends Diameter, T FG 10.5 FG 10.5 FG 10.5 Holes 36 R 28 36 36 Hole Diameter, DS 3.0mm 2.8mm 3.0mm

H Spoke Hole Ref. ø, HR 58mm 89mm 58mm 1 U Flange Dist. to /2 OLD F1 = 24.5mm / F2 = 25.5mm F1 = 25.5mm / F2 = 32.5mm F1 = 24.5mm / F2 = 25.5mm Totally 186% B Speed 1 73% S Speed 2 100% Speed 3 136% Gear Hub Ratio Hub Gear Line, C/D/E 44.5/41.5/38.5mm 44.5/41.5/38.5mm 44/41/38mm

Chain Ratio 24", 26",28"= 2.0–2.4 / 20"= 2.0–2.5 Shifter Compatib. Spectro Grip 3/Spectro Bandix 3 Tandem Compatib. ——— Weight 1182g 1270g 911g Hub Shell Material Steel Aluminum Steel

Finish Finish Matt Chrome Plated Silver Painted Matt Chrome Plated

Spectro Grip 3 (for adults) NEWNEW Spectro Bandix 3 (for kids) NEWNEW Part No. — R —— S Shifter Type Twist Shifter Twist Shifter H Cable ø1.2 mm 2000 mm R 2200mm ø1.2 mm I Comp. Cable Housing Capped, Compressionless with Resin Liner inside Gear Indication Printed Printed F Barrel Adjuster Indexing Indexing T Clamping Diameter 22.3mm 22.3mm E Handlebar, Straight Area Minimum length = 145mm Minimum length = 125mm Weight 58g 58g R Housing PA PA S Grip PA PA

Design Grip Cover Thermoplastic elastomer Thermoplastic elastomer Clamping Collar Aluminum Aluminum

Technical Manual 2002 37 SPECTRO T3 ASSEMBLY

12 ASSEMBLY HUB Advice: 1 • Lace the wheel as normal. See spoke The Spectro T3 hubs have been modified length table. for the series launch of the new • Place the dust cap (1, Fig. 1) and deflection pulley. sprocket (2) on the driver. Identification: yellow counter nut on • Push sprocket circlip (3, Fig. 2) onto the the driving end of the axle and modified cone of tool sleeve (4). Place tool sleeve compression spring (22 resp. 14, Fig. 1 / with large diameter on the driver. Page 40) • Push the spring end of sliding sleeve (5) In order to prevent malfunctions, these 2 453 of the tool over the tool sleeve. Thrust modified hubs may no longer be combined sliding sleeve in direction (6), this forces with the chain guide nut. 6 circlip into the recess of the driver. The deflection pulley can also be used for • Remove tool and check that the circlip is the previous hub version (silver-coloured seated correctly. counter nut on the axle). In order to Mounting Tool Part No. 0582 104 000 • Turn dust cap (7, Fig. 3) until the three achieve the maximum reduction in lugs (8) are between the three beads (9) shifting forces with this on the sprocket (10). combination, the new, modified compression spring should be installed (descripti- 3 8 7 • Position dust cap and push towards sprocket until it is felt to lock into place. on see „REASSEMBLY HUB“). 9 • Screw tension chain (2, Fig. 5) into the axle end. Caution: • Placing the wheel in the rear frame. • Only install additional axle attachments • Mount the chain. (e.g. struts) between nut and retaining 10 • After positioning the wheel in the rear washer. fork fit non-turn washer (1, Fig. 4) to the • Cable stop bracket: dimensions outside of the dropout (hub side opposite see Fig. 9. the sprocket). The serrations must bear • Axle end must protrude by min. 1 mm 4 against the dropout and the lug must to max. 4 mm beyond the nut (1, Fig. 5). engage in the dropout slot. • Tighten up special type axle nut (1, Fig. 5) • Mount the brake lever using a suitable and axle nut at other axle end. Tightening frame clamp (2, Fig. 4). torque 30 – 40 Nm (266 – 350 in.lbs.). Caution: • Guide tension chain (2) trough Mount the brake lever between the two deflection pulley (3). Position deflection straps of the frame clamp. 1 pulley at axle nut and push until it is felt The clamp must be seated on the frame 2 to lock into place. In case of stiff without play. assembly, grease housing resp. nut (for Use a self-locking nut! Tightening instance Molykote PG602). torque: 2 – 3 Nm (18–27 in.lbs.). 5 Turn deflection pulley until the yellow area is at the top (4, Fig. 6).

Spoke length table: Tire Size Cross Length MH 3115/3105 Length MH 3125 1 28 / 36 Holes 28 / 36 Holes 36 Holes 2 47–406 20" x 1.75 x 2 2 x / 3 x 182 mm / 184 mm — 3 37–490 22" x 1 /8 — / 3 x — / 228 mm — 3 47–507 24" x 1.75 x 2 2 x / 3 x 234 mm / 235 mm — 3 37–540 24" x 1 /8 — / 3 x — / 254 mm — 47–559 26" x 1.75 x 2 2 x / 3 x 258 mm / 262 mm 253 mm 3 37–590 26" x 1 /8 — / 3 x — / 254 mm 273 mm 6 47–622 28" x 1.75 2 x / 3 x 289 mm / 292 mm 285 mm 1 28–622 28"x1 /8 — / 3 x — / 292 mm 285 mm 5 1 32–622 28"x1 /8 x 1 /4 — / 3 x — / 292 mm 285 mm 3 5 37–622 28"x1 /8 x 1 /8 — / 3 x — / 292 mm 285 mm 1 28–630 27"x1 /4 fifty — / 3 x — / 297 mm 287 mm 1 32–630 27" x 1 /4 — / 3 x — / 297 mm 287 mm 4 Spoke lengths are approximate values. They must be checked through lacing attempts and adjusted accordingly.

38 Technical Manual 2002 SPECTRO T3 ASSEMBLY

ASSEMBLY SHIFTERS ADJUSTMENT 7 • Slide shifter (1, Fig. 7) onto handlebar. • Place the shifter in gear position "3". 1 • Add thrust washer (2). Move the crank to check that the gear • Mount fixed grip (3) onto end is engaged. of handlebar. • To make the adjustment, the cable must • Without applying pressure, slide shifter be taut in third gear to be able to transfer against fixed grip, adjust shifter on a shift movement directly to the hub. 3 handlebar and tighten with bolt (4). Allen • Push locating sleeve (2, Fig. 8) onto the 2 key 2.5 Nm, torque 1,7 Nm (15 in.lbs.) small pull rod (3) until the control cable 4 • Not recommended for use on thin walled is taut. Make sure that you don’t pull the © 2.5 mm aluminum handlebars such as Hyperlite indicator chain out of the deflection 1.7 Nm type handlebars. pulley (4). NEWNEW 15 in.lbs. Caution: Check: • Check that the shifter and brake lever • Place shifter in gear position "1" while 8 function properly and are unobstructed moving the crank. (realign if necessary). • Setting too loose: In gear position "1" the • Fixed grips provide an axial safety tension chain can be pulled out of the function. For this reason, they should be deflection pulley by hand. mounted in such a way as to make sure • Setting too tight: It is difficult to place they do not slip off handlebar. the shift lever in gear position "1". • Never use lubricants or solvents to • If required, readjust the shift mechanism install fixed grips. (in third gear). 5 • Never ride without the fixed grips. The 4 turning grip may loosen from housing and slip off handlebar – this can result CONNECTING DRUM BRAKE 1 in severe injury or death. Caution: 3 2 Only use brake levers with a cable moving distance of at least 15 mm and a INSTALLING CABLE minimum leverage of 3.8. • When fitting the cable avoid small radius. • Fit cable stop (1, Fig. 10) with adjusting 9 Use only compressionless cable housings bolt (2) and nut (3) and insert into the slot with resin liner inside and capped. on the brake anchor plate. • Turn adjusting bolt down by approx. 2/ min. • Screw the cable stop clamp and cable 3 13 mm pully clamp on the down tube or seat tube. and route the brake cable from the max. 30° • Secure the lubricated shift cable at brake handle. equidistant intervals on the frame • Push lower brake cable end through (in case of continuous cable housing). adjusting bolt (2) and insert lower cable • Feed the shifter cable into the locating housing end into adjusting bolt. min. 12 mm sleeve (5, Fig. 8), fix at the appropriate • Thread brake cable end (4) into min. 90 mm length (cable stop bracket: see Fig. 9) fork unit (5). using the clamping bolt (1). • Tighten screw (6) slightly. Allan key 2.5 mm, tightening torque • Attach fork unit to brake lever (7). 1.5 Nm (13 in.lbs.). Shorten any cable • Pull brake cable end taut with pliers which is sticking out. so that fork unit can still be attached and • Connect to the hub: push locating sleeve removed (important for changing wheel). 10 (2, Fig. 8) loosely onto small pull rod (3). • Tighten screw (6).

Caution: 2 For NL version drum brake hub with 3 special lever (8), only use original NL 1 brake cable (fork unit (5) is not suitable). 4 6 ADJUSTMENT DRUM BRAKE 5 • Unscrew adjusting screw (2, Fig. 10) until the brake pads drag lightly. 7 • Actuate the hand brake lever forcefully several times and then, if necessary, turn the adjusting screw further in just until the wheel starts spinning freely. • Lock hex nut (3).

Technical Manual 2002 39 SPECTRO T3 MAINTENANCE

REMOVE WHEEL 1 MH 3115 / Coaster brake • Apply fingertip pressure onto the metal key of locating sleeve to release it from 14 the pull rod. 13 • Remove deflection pulley. 11 5 • Screw off both axle nuts and remove retaining washers. 4 • Remove wheel. 3 12 2 10 DISMANTLING HUB 1 see Fig. 1 9 23 • Unscrew indicator chain (23), remove 8 22 circlip (21), sprocket (20), dust cap (19) 7 21 6 20 and clamp axle (10) on the driver side. 19 • Unlock hexagonal nuts (1) and unscrew. • Remove brake arm (2), ball retainer (3) and brake sleeve (4) and remove hub 17 18 16 shell (5). • Remove safety washer (7), thrust washer (8) and then the planet carrier (9) complete with brake cone (6). Unscrew the brake cone from the planet carrier. • Clamp other axle end. x a • Loosen the lock nut (22) and fixed cone MH 3105 / without brake 2 b (18) and remove. • Remove driver (17), compression springs c (14 and 13) and ball retainer (16). • Push the sliding key (12) through the large bore in the coupling wheel of the ring gear (11) – the bore and thrust block 3 must be aligned. d e • Remove the gear ring (11) from the axle.

Advice: The dismantly and reassembly of the hub types MH 3105 / MH 3125 should be 1 carried out in the same way (Fig. 2 / 3).

Differences • There is no brake sleeve (4) and brake cone (6). • The planet carriers (a) have a cylindrical shaft instead of a flat thread, which hou- ses a pawl carrier (b) held by a safety washer instead of the brake cone. • Further differences: instead of a lever 3 MH 3125 / Drum brake cone (2) for type MH 3115, an adjusting x a cone (d) with dust cap (e) for type b MH 3105 and a small adjusting cone (D) and corresponding ball retainer (f) for c type MH 3125 are fitted.

f D

40 Technical Manual 2002 SPECTRO T3 MAINTENANCE

REASSEMBLY HUB CABLE CHANGE 4 see Fig. 1 / 2 / 3 see Fig. 6:

Lubrication see “MAINTENANCE/ Dismantling shifter cable: LUBRICATION“. • Use only new cable and compression- Ø 1,1 mm • Clamp the hub axle (10) with the slot for less cable housing thrust block upwards), fit ring gear (11) • Detach the cable from the internal hub. and align the large bore in the coupling • Remove the cable housing. Cut the cable wheel with the slot. Position the radius off 15 cm (6") from the shifter barrel of the sliding key (12) facing downwards adjuster. Discard the old cable and cable and turn the coupling wheel slightly. housing. • Fit the compression springs (13 and 14). • Line up the ‘3’ gear number mark with • Place ball retainer with balls in (16) on the indicator mark. ring gear (11), mount driver (17), fit fixed • From the edge, pull open the cable cone and lock with hexagonal nut (22), change hatch (Fig. 6). tightening torque 15 – 20 Nm • Remove and discard the rest of the old (133 – 177 in.lbs). cable. • Turn hub over and slide on planet carrier 5 (9) – thrust washer (X) must first be fitted Assembly shifter cable: for types MH 3105/3125. (For type MH • Feed the new cable through the shifter. 3115, this washer is already integrated in • Feed the cable through the new cable the planet carrier). Mount thrust washer housing and stops. Ø 1,4 mm (8) and place safety washer (7) in the • Feed the shifter cable into the locating recess of the axle. sleeve (5, Fig. 7), fix at the appropriate • Screw brake cone (6, type MH 3111) onto length using the clamping bolt (1). Allan the flat thread – for types MH 3105/3125 key 2.5 mm, tightening torque 1.5 Nm mount pawl carrier (b) and secure in (13 in.lbs.). Shorten any cable which is place using safety washer (c). sticking out. • Fit hub shell (5) – turning it counter- • Connect to the hub: push locating sleeve clockwise slightly to get past the stop (2, Fig. 7) loosely onto small pull rod (3). notches – until the shell runs cleanly onto the ball retainer. ADJUSTMENT • For type MH 3115, insert the brake slee- • Place the shifter in gear position "3". ve (4) so that the spring end of the fric- Move the crank to check that the gear tion spring on the brake cone (6) sits in is engaged. 6 one of the two slots on the brake sleeve. • To make the adjustment, the cable must Insert the ball retainer and fit the lever be taut in third gear to be able to transfer cone – move the lever cone lightly until a shift movement directly to the hub. the lugs on the brake lever catch in the • Push locating sleeve (2, Fig. 7) onto the grooves on the adjusting cone. small pull rod (3) until the control cable • Adjust the hub clearance by screwing on is taut. Make sure that you don’t pull the hexagonal nut (1) until the hub shell runs indicator chain out of the deflection free of play but not under tension. Lock pulley (4). with a second nut to a tightening torque of 15 – 20 Nm (133 – 177 in.lbs.). Check: • For type MH 3105 insert ball retainer (3), • Place shifter in gear position "1" while mount adjusting cone (d) with dust cap moving the crank. NEWNEW (e) and hexagonal nuts (1). Adjust the • Setting too loose: In gear position "1" the hub clearance as for type MH 3115. tension chain can be pulled out of the • For type MH 3125, the ball retainer (f) deflection pulley by hand. 7 and dust cap (pressed in) normally • Setting too tight: It is difficult to place remain in the hub shell. The hub the shift lever in gear position "1". clearance is set with adjusting cone (D) • If required, readjust the shift mechanism as for type MH 3115. For notes on fitting (in third gear). the brake carrier, please refer to mounting drum brake.

1 3 2

Technical Manual 2002 41 SPECTRO T3 MAINTENANCE

DRUM BRAKE Cleaning of parts: 8 Instal brake anchor plate (or exchange it): • All parts – except for the planetary gear • Place thrust washer (8, Fig. 8) over the carrier – can be decreased in a cleaning axle on the adjusting cone and fit bath. 2 3 complete brake anchor plate. Position • The planetary gear carrier only needs to 1 washer (9) distance sleeve (10) and be cleaned on the outside with a brush 4 6 screw on locknut (11). so as not to degrease the planetary gear • Push brake lever (7) to the stop and hold bearing. 5 it there to center the brake jaws in the 8 brake drum – tighten up locknut with a Lubrication of parts: torque of 15 – 20 Nm (133 – 177 in.lbs.). • To lubricate the bearing points on 9 7 the planetary gear sets, position the 10 planetary gear carrier on its crown and 11 ADJUSTMENT DRUM BRAKE apply 2 – 3 drops of oil to the bearing • Unscrew adjusting screw (2, Fig. 8) until bolts – at the same time turning the the brake pads drag lightly. planetary gears so that the bearing • Actuate the hand brake lever forcefully points are completely wet. Oil axle several times and then, if necessary, through the axle bore and axle slot, turn the adjusting screw further in just apply a thin coating of grease to the until the wheel starts spinning freely. outside. • Lock hex nut (3). • Oil the inside of the sun gears, grease the outside teeth (fill the gaps in the Caution: teeth). Check that all the brake system • Oil outside teeth and carrier plate on components are functioning properly! the coupling gear and lightly grease the borehole from right and left. • Do not apply grease to ring gear but just MAINTENANCE / oil the pawl pockets. LUBRICATION • Grease the brake cone in the borehole Coaster Brake: and the friction spring. Improved braking in third gear after • Spread grease on the inside and outside production date CW 38/96 of the brake shell. • In case of repair, older hub models (Fig. 4) • Fill lever cone with grease reserves for can be converted with a repair set (Fig. 5). brakes. It is important that all three parts are • Regrease ball retainer, line ball bearing replaced at the same time – new, running tracks with grease. reinforced compression springs, planet Caution: carrier with 4 lugs and ring gear with For version with mounted i-brake use 4 lugs on the driving plate. only the new highly heat-proof SRAM grease “Typ B“ (Part No.: 35g – 0369 135 A change with of the new or 200 / 200g – 0369 135 201). converted hubs: • When braking in third gear, the tension Caution: chain moves out of the deflection pulley Do not use high-pressure water when by approx. one chain link – after braking, cleaning the gear hub (e.g. strong water the tension chain returns immediately to jets, high-pressure cleaners etc.) – its normal position. if water penetrates it could lead to functional problems. Caution: The Spectro hubs are provided with permanent lubrication and are maintenance- free under normal conditions. For type MH 3111, however, particularly high loading of the coaster brake can cause it to overcompensate. In this case, apply special grease (Part No. 0369 135 101) to the brake sleeve or replace it. Renew brake shell, when rhombic pattern is worn out.

42 Technical Manual 2002 SPECTRO T3 MAINTENANCE

TROUBLESHOOTING Problem Cause Remedy Shifting difficulties Incorrect gear setting Adjust shifting system, oil control cable, check that cable stop is fastened correctly. Pedals are carried forward Bearings set too tight Re-adjust bearing when freewheeling Loose lock nuts Tighten lock nuts (15 – 20 Nm) Chain is overtensioned Reduce chain tension Ccoaster brake: Hub locks when braking Brake shell has run dry Wash out hub sleeve, repolish and relubricate brake cylinder, renew brake shell Pedals yield slowly during Brake cone/brake sleeve Replace brake cone and brake braking (does not impair sleeve safety).

Technical Manual 2002 43 44 Technical Manual 2002 SPARC TECHNICAL DATA /ASSEMBLY REQUIREMENTS

190 205 135 33.5 194 4055 40

16 25

30 2.7

° 185

8.6

Caution: Not suitable for tandems, tradesmen’s 12.5 67.5 49.5 delivery bicycles and similar.

Sparc hub S Sparc Shifter Part No. — H Part. No. — R — R — Engine Type 2 x 12V DC engines I Shifter Type Twist Shifter Power 2 x 100 W max. F Cable 1500mm R 1600mm R 1700mm Assist Type Pedal controlled T Gear Indication Window Electric Drive Electric Assist Ratio Econ / Speed E Clamping Diameter 22.3mm Econ Mode 18 km/h (28") Handlebar, Straight Area Minimum length = 150mm Speed Mode 24 km/h (28") R Weight 70 g V max. V Brake None Over Locknut Dim. 135mm Sparc Remote Control Unit Length 190mm R Part. No. — — — — — Axle Ends Diameter FG 10.5 E R R R R Cable 1500mm 1600mm 1700mm 1800mm 2200mm H Holes 36 M R R R R . Mode Selector Off / Econ / Speed U Hole Diameter 2.7 mm

Spoke Mode Indication Printed B Hole Reference ø 194mm C Clamping Diameter 22.3mm Totally 249% O Cable Connection 3.5 mm stereo jack Speed 1 63% N . Weight 45 g Speed 2 78% Speed 3 100% Speed 4 128%

Gear Hub Ratio Hub Gear Sparc Battery Box Speed 5 158% B Part No. ————— 1 1 1 3 Usable Dimension /2"x /8"or /2"x /32" A Cable 650mm 750mm 850mm 1400mm 1950 mm . Line 49.5 mm (only off-set sprockets) Battery 12V / 7Ah lead battery Chain Ratio 24",26",28"=1.7–1.9 / 20"=2.3–2.6 B Charger 12V / 1.5A 12V / 2.0A Shifter Compatib. Sparc Shifter O Charging time 4 hours 45 minutes 3 hours 30 minutes Frame Compatib. Dropouts max. 7 mm / OLD 135 mm X Luggage carrier comp. Struts: ø 8 mm / dist. 68 mm center to center / parallel Weight 2500g Weight 3000 g

Technical Manual 2002 45 SPARC ASSEMBLY

LACING THE WHEEL ASSEMBLY SHIFTER 1 12 1-cross only. All spoke heads must be posi- • Slide shifter (1, Fig. 6) onto handlebar. tioned at the outside of the spoke flange. • Add 2 thrust washers (2). Spoke tension about 1000 N recommended. • Mount fixed grip (3) onto end of handlebar. • Without applying pressure, slide shifter against fixed grip. ASSEMBLY HUB • Adjust shifter on handlebar and • Place the dust cap (1, Fig. 1) and tighten with bolt (4) with a torque of sprocket (2) on the driver. Toothing close 1.5 Nm (13 in.lbs.). to the hub (only sprocket version off-set). 2 • Push sprocket circlip (3, Fig. 2) onto the Caution: 4 3 5 cone of tool sleeve (4). Place tool sleeve • Check that the shifter and brake lever with large diameter on the driver. function properly and are unobstructed 6 • Push the spring end of sliding sleeve (5) (realign if necessary). of the tool over the tool sleeve. Thrust • Fixed grips provide an axial safety sliding sleeve in direction (6), this forces function. For this reason, they should be Mounting Tool Part No. 0582 104 000 circlip into the recess of the driver. mounted in such a way as to make sure • Remove tool and check that the circlip is they do not slip off handlebar. seated correctly. • Never use lubricants or solvents to • Turn dust cap (7, Fig. 3) until the three install fixed grips. 3 lugs (8) are between the three beads (9) • Never ride without the fixed grips. The 8 7 on the sprocket (10). turning grip may loosen from housing • Position dust cap and push towards and slip off handlebar – this can result 9 sprocket until it is felt to lock into place. in severe injury or death. • Placing the wheel in the rear frame. • Mount the chain. • When fitting the cable (1, Fig. 7) avoid • Fit non-turn washer (1, Fig. 4) to the small radius. 10 outside of the dropouts. The serrations • Last attachment point is on the lower must bear against the dropout and the rear wheel fork (2, Fig. 7) immediately lug must engage in the dropout slot. behind the chain wheel. 4 • On the sprocket side fit the protective Cable housing must be movable inside bracket (1, Fig. 5) directly below the attachment. axle nut. Tightening torque on acorn or hex nuts 30 – 40 Nm (266 – 350 in.lbs.). INSTALLING CLICK BOX Advice: • Insert shift rod (1, Fig. 8) in shift tube (2) • If a different protective bracket is used (oil parts lightly) and then push into axle the thickness of the attachment plate bore as far as the stop. Turn slot (6) in must be max. 3 mm. shift tube to a position where it is easily 1 • Do not use additional washers. visible. • A minimum of 1 thread turn must be • Push locating sleeve (3) with guiding rib visible in front of the axle nut! (4) to the front onto the hub axle – making 5 sure that the internal lug (5) is guided in the slot (6) of the shift tube until it can be felt – and heard – to engage. • Turn locating sleeve on the axle (7) until the guiding rib (4) is facing roughly upwards. • Push on clickbox (2, Fig. 5) to the stop on the axle. The guiding rib (4, Fig. 8) of the locating sleeve thereby engages in the slot on the housing. In the end position 1 tighten up the knurled bolt (3, Fig. 5) by 2 3 hand. Assembly can be performed independently of the gear setting but it is best done at shifter position “2”. 6 1 ADJUSTMENT HUB • Be sure to reset rotational shifter from 5 4th. to 3rd gear. 6 • Match up the arrow marks in the Clickbox viewing window (5, Fig. 6) 2 3 4 by turning the adjusting screw (6).

46 Technical Manual 2002 SPARC ASSEMBLY

ASSEMBLY BATTERY BOX ASSEMBLY REMOTE 7 • Pull both quick releases outward and CONTROL UNIT turn them to the „open“ position (Fig. 9). • Slide remote control unit (1, Fig. 10) onto 1 • Position battery box onto luggage handlebar. 23 carrier struts (3, Fig. 7). • Mount brake lever (2) and fixed grip (3). • Push quick releases inwards and turn • Adjust remote control unit on handlebar them to the „closed“ position. and tighten the bolt (4) with a torque of • Slide plug of battery cable in the slot of 1.5 Nm (13 in.lbs.). the battery box until it snaps in. • Slide plug of remote control cable in the • Attach cable along the frame or luggage slot (5) of the remote control unit until it carrier strut. snaps in. Advice: • Attach cable along the frame. Last attachment point of the cable at the Advice: rear fork: approx. 8 cm away from the Last attachment point of the cable at the axle end. rear fork: approx. 8 cm away from the Do not jam the cable between frame axle end. and rear hub and keep it away from the Do not jam the cable between frame rotating hub shell. and rear hub. 8 • Slide plug in the slot on the hub until it Make a cable loop between plug and snaps in. cable attachment point to avoid tensile load. 7 Advice: • Slide the plug straightly in the slot on the Closed elements such as brazed-on eye hub until it snaps in. 6 bolts are not suitable because plug will Angular installation may damage the 4 not pass through. slot.

Check: 2 Switch remote control to „Speed“ position 1 and rotate the rear wheel. 3 5 At least 2 green and 1 red LED must gleam. If not, assemble plugs again completely. If not, assemble plugs again completely / 9 right.

closed open

1 3 1

5 2 4

Technical Manual 2002 47 SPARC MAINTENANCE

10 7

1 9 8

32 31 30

4 41 6 29 28 5 27

26 39 25 3 24 2 23 38 1 22 21 40 20 36 19 18 17 16 37 15 34 35 14

33 13 12 11

REMOVE WHEEL DISMANTLING GEAR HUB 2 • Pull the remote control cable plug off see Fig. 1 the hub. Sparc mounting aid • Apply fingertip pressure onto the tap and • Remove circlip (35), sprocket (34) and Part No. 3024 001 000 pull battery cable plug off the hub. dust cap (33). • Loosen the knurled screw (40, Fig. 1) and • Clamp hub with the two axle flats pull the Clickbox off the axle. sprocket side facing downwards. • Disengage the locating sleeve and pull it • Remove electric drive (4). off. Remove shift rod/tube (37/36), pull • Unscrew the locknuts (1+2). shift rod out of the axle bore. • Remove plate (6) with washer (5). • Remove wheel. • Remove hub shell (7). • Remove circlip (8) and washer (9). X ELECTRIC DRIVE • Remove planetary gear carrier (10) and Remove: circlip (11). • Unscrew resin nut (3, Fig. 1). • Clamp other axle end. • Remove electric drive (4). • Unscrew fixed cone (32). • Remove driver (31), compression spring Caution: (29), large compression spring (27) and Do not disassemble and do not lubricate ball retainer (30). – Withdraw gear ring the electric drive. (26) and coupling gear (25) and remove cover (28) from the coupling gear. Reassembly: • Take out thrust block (24), (to do this • Position electric drive onto hub. compress the spring). Remove spring (22) • While rotating the electric drive push it and the two covers (23/21). inside until the two small inside pins • Dismantle retaining washer (20), washer engage in corresponding small holes (41). (19), conical compression spring (18), Check: The thread must be visible at and the large sun gear (13). least 8 mm. • Clamp other axle end. • Screw on resin nut (3) with a torque of • Unscrew grey grub screw (14) – dis- 3 – 5 Nm (27 – 44 in.lbs.). mantle spring (15), guide bolt (16) and thrust block (17). • Remove small sun gear (12).

48 Technical Manual 2002 SPARC MAINTENANCE

REASSEMBLY HUB • Mount hub shell (7), with a slight 3 4 see Fig. 1 counterclockwise turn. 3 • Fit plate (6) and washer (5). Lubrication see “LUBRICATION GEAR HUB“, • Screw on counternuts (2+1), tightening 2 next page. torque 15 – 20 Nm (133 – 177 in.lbs.). • Clamp axle with small internal thread • Reassemble electric drive. upwards. 1 • Position small sun gear (12) with crown CABLE CHANGE gears to the front. Dismantling shifter cable: • Position thrust block (17) in the slotted • Place shifter in gear position "1". hole (is laterally guided when the sun • Loosen clamping bolt (1, Fig. 3) on the gear is mounted). shifter and slide the complete shifter • Locate bolt (16), then spring (15) in the inwards towards the middle of handle- axle and screw in grey grub screw (14) bar 20 mm or more. (It may be necessary until it is flush with the axle end. to loosen and move the brake lever.) • Clamp other axle end. Fit large sun gear • Separate housing (2) from turning grip (3). (13). Position conical compression • Unscrew bolt (1, Fig. 4), remove cap (2). 4 spring (18), with the large diameter first. • Withdraw shifter cable and clamping Compress spring and fit washer (19) and bolt (1, Fig. 6) upwards, loosen clamp 2 retaining washer (20). and pull clamping piece from the cable. 4 • Assemble cover (21), compression • Remove the old cable (4, Fig. 3). 1 spring with 7 turns (22) and the second cover (23, insides to the spring). Assembly shifter cable: 5 • Compress spring and position thrust • Route new cable through shifter housing block (24) (it is the same both sides) in and pull cable to seat cable head the center of the slotted hole. completely into cable recess. • Position coupling gear (25) with carrier • Reassemble shifter by aligning four plate facing downwards. tabs on shifter housing with matching • Fit cover (28, inside to the spring) for recesses on turning grip and snap compression spring. together (Fig. 3). • Position gear ring (26) over the teeth of • Feed the cable through the new cable the coupling gear. housing and adjusting screw. • Place ball retainer (30), with balls below • Position clamping bolt (1, Fig. 5) at a on the gear ring. distance of 83 mm, tighten up with • Position large compression spring (27) 1.5 Nm (13 in.lbs.) and cut off cable ends on gear ring. to 2 – 3 mm. 5 • Mount compression spring with 13 turns • Locate clamping bolt (1, Fig. 6) (srew (29) on the axle. (Is supported in the head not visible) and place shifter cable coupling wheel by the cover.) around the carrier cylinder (counter- • Locate driver (31), press it down and clockwise winding). 2 +1 mm 83 ±0,5 mm screw on fixed cone (32). Tightening • Insert the square nut of the adjusting torque 20 Nm. bolt (2) in the housing and completely • Clamp other axle end. screw in the knurled bolt. • Push on thrust washer (11) and fit • Position cap (2, Fig.4) and tighten up 5mm planetary gear carrier (10). In doing this: with bolt. 1 Position mounting aid (Fig. 2) on the planetary gear carrier so that the (X) Advice: markings on the three planetary gears To set the clamping bolt / adjusting match with the mounting aid. screw distance a setting piece can be • Insert planetary gear carrier, place used (Part No. 65 0324 105 001). thrust washer (9) and mount circlip (8) in 6 recess. ADJUSTMENT Remove the mounting aid. • Be sure to reset rotational shifter from 4th. to 3rd gear. Advice: • Match up the arrow marks in the 1 If the gears are not accurately installed Click Box viewing window (4, Fig. 4) the hub may be tight to move. by turning the adjusting screw (5). This could lead to damage to the gear- wheels in operation.

Technical Manual 2002 49 SPARC MAINTENANCE

LUBRICATION GEAR HUB BATTERY CHANGE 7 Cleaning of parts: Disassembly: • All parts – except for the planetary gear • Apply fingertip pressure onto the tap and carrier – can be decreased in a cleaning pull battery cable plug off the battery bath. box. • The planetary gear carrier only needs to • Turn quick releases to the „open“ be cleaned on the outside with a brush position (Fig. 7) and pull them outward. so as not to degrease the planetary gear • Take off battery box from luggage bearing. carrier. • Unscrew the 4 bottom screws (slotted Lubrication of parts: screwdriver / Torx T10) and take off Use only SRAM grease (Ref. No. 0369 135 101) battery box cover. closed open and standard bicycle oil. • Hang out stirrup (3, Fig. 8). • To lubricate the bearing points on • Take out battery and pull off plugs (1+2). the planetary gear sets, position the Advice: planetary gear carrier on its crown and Do not pull off any plug from card modul. apply 2 – 3 drops of oil to the bearing bolts – at the same time turning the Reassembly: 8 planetary gears so that the bearing • Connect plugs to new battery: points are completely wet. – black cable: Negative Pole (1, Fig. 8) • Oil axle through the axle bore and axle – red cable: Positive Pole (2) slot, apply a thin coating of grease to the and put battery inside. 2 outside. • Assemble stirrup (3) (bulge downward). 1 • Oil the inside of the sun gears, grease • Mount battery box cover by the 4 screws. the outside teeth (fill the gaps in the • Pull both Quick Releases outward and teeth). turn them to the „open“ position (Fig. 7). • Oil outside teeth and carrier plate on • Position battery box onto luggage the coupling gear and lightly grease the carrier struts. borehole from right and left. • Push Quick Releases inwards and turn • Do not apply grease to ring gear but just them to the „closed“ position. 3 oil the pawl pockets. • Slide plug of battery cable in the slot of • Regrease ball retainer, line ball bearing the battery box until it snaps in. 4 running tracks with grease. Advice: Advice: •Use only batteries as specified. •Do not use high-pressure water when •Battery charging: see Sparc Instruction cleaning (e.g. strong water jets, Manual Publ. No. 5200. high-pressure cleaners etc.) – if water penetrates it could lead to functional REMOTE CONTROL UNIT problems. Do not disassemble the remote control •If the cycle is not used for a lengthy unit. period, set shifting lever to gear position “2” so that the system is not strained.

50 Technical Manual 2002 SPARC MAINTENANCE

TROUBLESHOOTING Problem Cause Remedy Gear hub: Shifting difficulties Damaged control cable Replace control cable Incorrect gear setting Adjust shifting system To much additional axle Axle end must protrude by attachments between hub min. 1 thread turn and axle nut Pedals are carried forward Bearings set too tight Readjust bearings when freewheeling Loose lock nuts Tighten lock nuts (15 – 20 Nm) Chain is overtensioned Reduce chain tension Electric system: Electric drive does not work Remote control in position OFF Switch to ECON or SPEED Remote control defect Replace remote control Plugs not engaged Slide all plugs completely in slots Cable defect Replace defect cables Battery discharged Charch battery Battery inside not connected Connect battery inside Battery defect Replace battery Fuse blasted Replace fuse (4, Fig. 8) in battery box (25 A) Electric drive defect Replace electric drive Electric drive emits Foreign body in electric Take out foreign body unusual noise drive Electric drive defect Replace electric drive

Technical Manual 2002 51 52 Technical Manual 2002 i-BRAKE AND COMPATIBLE HUBS TECHNICAL DATA /ASSEMBLY REQUIREMENTS

• Simple and efficient design 9.5 • Modular configuration 15 • Stainless steel drum • Sealed system • Linear pull compatible

Caution: • There is a risk of accident if unsuitable forks or frames are used (see Page 55)! 16 • The total weight of the bicycle with rider and baggage may not exceed 125 kilograms. • Not suitable for tandems, tradesmen’s delivery bicycles and similar. 165 • The i-brakes must go on the left side

viewed from behind the rear of the 142 bicycle.

8 48

33.6 17.4 16.6 51

95 100 140 110

NEWNEW i-brake System for Front Hubs Brake Model i-brake CD (large cooling disc) i-brake CD (large cooling disc) i-brake (small cooling disc) Brake ——— F No. Part Hub —— ———— Over Locknut Dim. 100 mm 100 mm 100 mm R Length 110 mm 110 mm 110 mm O Type Hollow Hollow Solid N Axle Material Steel Steel Steel Ends Diameter 9 mm 9 mm M9x1 T Holes 36 32 36 32 36 32 Diameter 2 mm 2 mm 2 mm H Spoke Hole Reference ø 39 mm 39 mm 39 mm Bearing Cartridge Cone Cone U Sealing Lip Seal / Labyrinth / Dust Cap Dust Cap Dust Cap B Tandem Compatib. —— ——— S Compat. brake lever Linear Pull compatible, Two-Axis Linear Pull compatible, Two-Axis Linear Pull compatible, Two-Axis Brake anchor plate Version D Version D Version D Total Weight 750 g 750 g 750 g Hub Shell Aluminum, painted Aluminum, painted Aluminum, painted

Finish Brake Drum Stainless steel Stainless steel Stainless steel

Technical Manual 2002 53 i-BRAKE AND COMPATIBLE HUBS TECHNICAL DATA /ASSEMBLY REQUIREMENTS 18

21 30

51 110

135 144

Caution: 45 • There is a risk of accident if unsuitable forks or frames are used (see Page 55)! ° 4 5 4 • The total weight of the bicycle with rider and baggage may not exceed 125 kilograms. • Not suitable for tandems, tradesmen’s delivery bicycles and similar. • The i-brakes must go on the left side viewed from 95.5 behind the rear of the bicycle.

NEWNEW i-Brake System for Cassette Hubs Brake Model i-brake CD (large cooling disc) i-brake CD (large cooling disc) Brake ——

Part No. Part Hub —— —— Speeds 9/8 9/8 C Driver Type Cassette Cassette A Over Locknut Dim. 135 mm 135 mm Length 177 mm 177 mm S Type Hollow Solid

S Axle Material Steel Steel . Ends Diameter M10x1 M10x1 Holes 36 32 36 32 H Diameter 2 mm 2 mm U Spoke Hole Reference ø 39 mm 39 mm B Bearing Cartridge Cone Sealing Lip Seal / Labyrinth / Dust Cap Dust Cap S Tandem Compatib. —— —— Compat. brake lever Linear Pull compatible, Two-Axis Linear Pull compatible, Two-Axis Brake anchor plate Version D Version D Total Weight 1000g 1000gg Hub Shell Aluminum, painted Aluminum, painted

Finish Brake Drum Stainless steel Stainless steel

54 Technical Manual 2002 i-BRAKE AND COMPATIBLE HUBS TECHNICAL DATA /ASSEMBLY REQUIREMENTS

NEWNEW DualDrive Spectro S7 Spectro P5 Spectro T3 Brake Model i-brake CD (for DualDrive) i-brake CD i-brake i-brake i-brake G Brake ————— Part No. Part Hub —— — —— E Over Locknut Dim. 135 mm 135 mm 126 mm 118 mm A Length 177 mm 188.5 mm 179 mm 164 mm

R Axle Ends Diameter FG 10.5 FG 10.5 FG 10.5 FG 10.5 Holes 36 32 36 36 36 Hole Diameter 2.6 mm 2.9 mm 2.9 mm 2.8 mm H Spoke Hole Reference ø 75 mm 75 mm 89 mm 89 mm U Tandem Compatib. —— ———— B Compat. brake lever Linear Pull compatible, Two-Axis Linear Pull compatible, Two-Axis Lin.P. comp.,Two-Axis Lin.P. comp.,Two-Axis S Brake anchor plate Version D Version D Version D Version D Total Weight N/A N/A N/A N/A Hub Shell Aluminum Steel Steel Steel

Finish Brake Drum Stainless steel Stainless steel Stainless steel Stainless steel

FRONT FORK HAND BRAKE LEVER 1 REQUIREMENTS COMPATIBILITY 1 Strength: • Use only Linear Pull compatible hand The strength must be such that with a maxi- brake levers. For example SRAM 2-Axis / mum braking torque of 300 Nm (2700 in.lbs.) 9.0SL / 9.0 / 7.0 / 5.0. on the wheel no residual deformation can • Leverage must be 1.9 – 2.1. occur on the front fork. • Cable pull of at least 25 mm. • Hand brake lever with adjustable lever- Dimensions: age: Important dimensions for front forks are Adjust the leverage to get above described R 145 R shown in Fig. 1. values of leverage and cable pull. Fork dropouts must be parallel. (SRAM 9.0SL / 9.0 / 7.0 – adjust to R 48 R smallest leverage, that means max. min. 5 max. 7 Brake arm anchor boss (1, Fig. 1): cable pull.) 16 Brazed-on or screwed (suspension forks) 100 Warning: Warning: Don’t use brake arm clamps (Fig. 2). There is a risk of accident if unsuitable brake levers are used. Mudguard and luggage carrier attachment: Mounting screws should not collide with BRAKE CABLES 2 i-Brake (Fig. 3). • Use only new high quality cable and cable housing. • When choosing cable housing lengths, REAR FRAME be sure to allow enough housing for an REQUIREMENTS extreme turn of the handlebars in both Strength: directions. The strength must be such that with a maxi- • Note also that different stem lengths mum braking torque of 250 Nm (2200 in.lbs.) effect cable housing length. on the rear wheel no residual deformation can occur on the rear structure. 3 Dimensions: Important dimensions for rear frames see previous page. Rear fork dropouts must be parallel.

Mudguard and luggage carrier attachment: Mounting screws should not collide with i-Brake (Fig. 3).

Technical Manual 2002 55 i-BRAKE AND COMPATIBLE HUBS ASSEMBLY

ASSEMBLY Fastening wheel / solid axle: 1 Caution: • Fit washers resp. retaining washers to Internal area of the brake drum and brake the axle ends. lining material must be free of dirt and oil • Tighten up axle nuts, torque 30 – 40 Nm or other substances containing grease. (270 – 350 in.lbs.). Danger of accident! Fastening wheel / quick release (Fig. 3): • Lace the wheel as normal. 3-cross only. • Only use quick release devices with the correct length. Caution: 2 Plane faces of brake drum and hub must • Position quick release opposite to the be clean and free from oily and greasy brake. 3 substances. • Turn release lever (8) outwards until it is at least at a right angle to the bike • Slide brake drum (1, Fig. 1) onto centering (position “open“). 1 seat (2) and fasten crosswise with appropriate four screws (3), • Tighten adjusting nut (9) as much as torque 5,5 – 6 Nm (49 – 53 in.lbs.). possible by hand. 2 • Slide brake anchor plate (4, Fig. 2) onto • Turn release lever (8) to the “closed“ centering seat (5) without tilting it. position (10) (the word “close” is visible from the outside). Front hubs and rear cassette hubs: After closure, the release lever should • Apply steel washer (6) and lock nut (7), be parallel to the fork. If the release minted side outwards. Wrench 15 mm, lever can be closed relatively easily, torque 15 – 20 Nm (133 – 177 in.lbs.). the tension force is inadequate. Gear Hubs: In this case, open release lever again, • Apply steel/resin washer (6). Lock nut (7) tighten adjusting nut (9) slightly and must not be used. close release lever again. If considerable force is required to Advice: close the lever, open the lever again, The wheel must turn freely. undo the adjusting nut slightly and close lever again. • Placing the wheel in fork ends. Guide the top end of brake anchor plate Warning: 6 7 into the brazing part of the front fork • Do not tighten wheel by turning the 5 resp. fit frame clamp to fasten the brake quick release lever clockwise (Fig. 4)! 4 anchor plate at rear fork. • Only use hand force with the skewer. Caution: • By incorrectly mounting the skewer or Mount the brake anchor plate between the wheel in the dropout, or by wrongly the two straps of the frame clamp. adjusting the closing force, the wheel The clamp must be seated on the rear may come loose and fall off during the fork with no play. ride. This may lead to severe rider 3 Use a self-locking nut! Hex screw, injury or death. property class 8.8. Tightening torque: 7– 8 Nm (62–70 in.lbs.).

closed 10 9

open

56 Technical Manual 2002 i-BRAKE AND COMPATIBLE HUBS ASSEMBLY

CONNECTING i-BRAKE ADJUSTMENT i-BRAKE 4 • Screw nut (1, Fig. 5) completely onto • Unscrew adjusting screw (2, Fig. 5) until adjusting screw (2) and insert into the the brake pads drag lightly. hole of the brake anchor plate. • Actuate the hand brake lever forcefully • Route the brake cable. several times and then, if necessary, turn the adjusting screw further in just • Push brake cable end through adjusting until the wheel starts spinning freely. screw. • Insert cable housing end into adjusting Caution: screw. • Check that all the brake system components are functioning properly. • Thread brake cable end (4, Fig. 5) into • The i-Brake requires a braking-in link (5) and tighten screw (6) slightly period to achieve maximum braking (hex wrench 5 mm). power. Caution: Ensure that the brake cable lies in the notch of the link. • Attach link to brake lever (3). • Pull brake cable end tight with pliers so that link can still be attached and removed (important for changing wheel). • Tighten screw (6), torque 7 – 8 Nm (62 – 70 in.lbs.). Counter the screw with 5 a 10 mm wrench.

7 3

6 4

Technical Manual 2002 57 i-BRAKE AND COMPATIBLE HUBS MAINTENANCE

ADJUSTING THE BRAKE DISMANTLING i-BRAKE 1 Readjust the brake if the hand brake lever Caution: can be pulled close to the handlebar (for • Internal area of the brake drum and example, after the run-in time or after long brake lining material must be free of 1 use). dirt and oil or other substances containing grease. • Unscrew adjusting screw (1, Fig. 1) until Danger of accident! the brake pads drag lightly. • Plane faces of brake drum and hub must be clean and free from oily and greasy • Actuate the hand brake lever forcefully substances. several times and then, if necessary, turn the adjusting screw further in just Front hubs and rear cassette hubs: until the wheel starts spinning freely. – Unscrew lock nut (1, Fig. 2) and Caution: remove steel washer (2). Before riding your bicycle, always check Gear Hubs: if the brakes function without problems. – Remove steel/resin washer (2, Fig. 2). • Remove brake anchor plate (3). • Unscrew four screws (4) and remove 2 3 WEAR INSPECTION brake drum. If the brake lining is worn, the complete brake anchor plate must be replaced. Caution: Do not disassemble the brake anchor plate. Inspection: With your finger, press brake lever (2, Fig. 1) forcefully against the spring resistance. If REASSEMBLY i-BRAKE the upper edge of the brake lever reaches 2 see “ASSEMBLY“ the "LIMIT" mark of the wear display (3), complete brake anchor plate must be replaced. REMOVING THE WHEEL • Detach the link (1, Fig. 3) on the brake lever (if necessary, screw the adjustment screw (2) in somewhat until the link can be detached). • Grab the adjustment screw (2) and remove the entire brake cable unit from the brake. 2 4 1 • Rear wheel only: Remove the screw (4, 3 Fig. 4) on the frame clamp. • Attachment using axle nuts: To remove the wheel, remove both axle nuts (3). • Attachment using quick-release: 3 4 To remove the wheel, open the quick- release lever.

2 3

1 4

58 Technical Manual 2002 i-BRAKE AND COMPATIBLE HUBS MAINTENANCE

MOUNTING THE WHEEL Attaching a wheel with quick-release: 5 • Insert the wheel in the dropouts. • Only use quick-release devices with the correct length. Front wheel (Fig. 5): 2 Insert the upper end of the brake anchor • Turn release lever (5, Fig. 7) outwards plate (1) into the brake boss of the front until it is at a right angle to the bike. 1 wheel fork (2). • Tighten adjusting nut (6) as much as Rear wheel (Fig. 6): possible by hand. Attach the brake anchor plate to the frame using a suitable frame clamp. • Turn release lever to the closed Caution: position (7) (the word “close” is Mount the brake anchor plate between visible from the outside). the two straps of the frame clamp. After closure, the release lever should The clamp must be seated on the rear be parallel to the fork. If the release fork with no play. lever can be closed relatively easily, Use a self-locking nut! Hex screw, the tension force is inadequate. property class 8.8. In this case, open release lever again, Tightening torque: 7– 8 Nm (62–70 in.lbs.). tighten adjusting nut (6) slightly and close release lever again. Attaching a wheel with axle nuts: If considerable force is required to close • Slide the washers (3, Fig. 6) onto the the lever, open the lever again, undo the ends of the axles. adjusting nut slightly and close lever again. 6 • Mount the axle nuts (4) and tighten them with a torque of 30 – 40 Nm Warning: (270 – 350 in.lbs.). • Do not tighten the wheel by turning the release lever clockwise (Fig. 8)! • Close the quick release lever by hand only. • If the quick release or the wheel is mounted incorrectly in the dropouts or if the locking force is incorrectly set, the wheel could become loose and fall off while in motion. This could result in serious injuries.

7 8

closed 7 6

5 open

Technical Manual 2002 59 i-BRAKE AND COMPATIBLE HUBS MAINTENANCE

CONNECTING THE BRAKE Assembling the brake cable: 9 • Attach the entire brake cable unit to the • Mount the brake cable brake anchor plate (9, Fig. 9) using the and cable housing. adjustment screw (8). • Insert the adjustment screw (4, Fig. 12) • Attach the link (10) to the brake lever (11). on the brake anchor plate (5) and screw this completely in. 9 • Attach the bellows to the adjustment screw. • Push the end of the brake cable 8 through the adjustment screw. • Check the brake adjusting. See “ ADJUSTING THE BRAKE“ . • Place the end of the cable housing in the adjustment screw. Caution: • Push the brake cable Check whether the brake through the bellows. functions correctly. • Thread the end of the brake cable into the link under the clamping washer (6) BRAKE CABLE CHANGE and tighten the nut somewhat (7). Disassembling the brake cable: Caution: 11 10 • Detach the link (1, Fig. 11) on the brake Ensure that the brake cable lies in the lever (if necessary, screw the adjust- notch of the link. ment screw (2) in somewhat until the link can be detached). • Attach the link (8, Fig. 13) to the brake lever (9). 10 • Remove the nut (3) on the link and remove the entire old brake cable. • Use pliers to pull the end of the cables so that the link can still be attached and Advice: detached (important for wheel removal). • Only use new, high-quality brake cables • Tighten the nut with a torque of 7 – 8 Nm and compression-free cable housings. (62 – 70 in.lbs.). Counter the screw with a • Ensure that the length of the cable 10 mm wrench. 11 housings allow a maximum turn of the handlebar. • Slide the bellows onto the adjustment screw (Fig. 14). 2 • Check the brake adjusting. See “ADJUSTING THE BRAKE“.

Caution: Check whether the brake functions correctly.

4 5

7 6

60 Technical Manual 2002 i-BRAKE AND COMPATIBLE HUBS MAINTENANCE

MAINTENANCE 13 Caution: While lubricating the bearings from i-brake hubs use only the new highly heat-proof SRAM grease “Typ B“ (Part No.: 35g – 0369 135 200 / 200g – 0369 135 201).

• Do not use high-pressure water when cleaning the hub (e.g. strong water jets, high-pressure cleaners etc.) – if water penetrates it could lead to functional problems. • Do not rinse hub with benzine, petroleum etc. as this could produce impurities in the brake linings. 9 8 Caution: The brake anchor plate must be replaced if oil or other substances containing grease get into the brake linings. Oily 14 brake linings reduce braking effect and cause the brake to fail completely. This may result in accidents with extremely serious injuries.

Technical Manual 2002 61 TWO-AXIS BRAKE LEVER TECHNICAL DATA / ASSEMBLY REQUIREMENTS

Caution: Two-Axis SRAM Brake Levers are designed for use Part No. —— with i-Brakes and linear-pull brakes. Do Brake Lever Left Right not use SRAM Brake Levers with conven- T tional cantilever brakes (those with arms Lever Size 4 Finger W measuring less than 76 mm and utilizing a Brake Compatibility i-Brake/Linear Pull non-linear straddle cable). Use of SRAM O Leverage Adjust Single Position Brake Levers with conventional canti- - Cable Pull 28 mm lever brakesets, drum brakes or roller brakes will result in faulty braking A Pivot Bushing I-Glide performance. X Reach Adjust Yes Yes I Barrel Adjuster Ergonomic Indexing Ergonomic Indexing S Clamping Diameter 22.3mm 22.3mm Weight 155 g 155 g 108 mm 108

Housing Grilon Composite – 76

Design Lever Forged Aluminum

Designed for use with Do not use conventional linear-pull brakes. cantilever brakes.

CABLE HOUSING • Use only new brake cable and cable housing. • When choosing cable housing lengths, be sure to allow enough housing for an extreme turn of the handlebars in both directions. • Note also, that different stem lengths and cable stop positions effects cable housing length.

62 Technical Manual 2002 TWO-AXIS BRAKE LEVER ASSEMBLY / MAINTENANCE

BRAKE LEVER ANATOMY INSTALLATION REACH ADJUSTMENT • When sliding the brake lever onto the Using a 2 mm hex wrench (Fig. 3): clamp bolt handlebar, allow enough room for the • Turn the reach adjustment screw clock- clamp shifter, the handlebar grip, and the bar end. wise to bring the lever closer to the • Using a 3 mm hex wrench, tighten the handlebars. clamp bolt to 3.4 Nm (30 in.lbs.) (Fig. 1). • Turn the screw counterclockwise to lever Be careful not to over tighten! move the lever further away. • Line up the barrel adjuster and the brake lever housing cable slots. Caution: • Pull on the lever and push the brake After any adjustment to the reach always cable head through the opening in the check the brake cable tension to ensure reach adjustment brake lever housing (Fig. 2). proper brake system performance. screw barrel adjuster • Install the brake cable head into the Readjust the cable tension if necessary. cable socket in the lever. • Set up the brakes and brake pads per brake instructions. • Actuate each brake lever 5 – 10 times.

Caution: 1 Check that all the brake system 3mm components are functioning properly! 3.4 Nm 30 in.lbs.

2mm

Technical Manual 2002 63 64 Technical Manual 2002 SMARTBAR TECHNICAL DATA / ASSEMBLY REQUIREMENTS

• New Style • ErgoFit – allows for height, reach, and rise adjustment • ErgoFunction – improved control, enhanced ergonomics and safety • Upgradeable – full suite of integrated accessories

SmartBar Quill Stem Q Part No. ———————— U Stem diameter 1“ GGGG 1 GGGG I Stem diameter 1 /8“ L Rear, 9spd GG GG GG GG L Rear, 8spd

Shifter Front, Micro Adjust GGGG Front, Index GGGG

SmartBar Clamp-On Stem C Part No. ———————— L Stem diameter 1“ GGGG 1 GGGG A Stem diameter 1 /8“ M Rear, 9spd GG GG GG GG P Rear, 8spd

Shifter Front, Micro Adjust GGGG Front, Index GGGG

Technical Manual 2002 65 SMARTBAR ASSEMBLY ERGOFIT STEM (QUILL STEM)

Caution: • Rotate the elastomer quill cover upward 1 The SmartBar requires a knowledgeable to allow access to the 6 mm hex wedge and trained bicycle mechanic for proper bolt (Fig. 3). installation and adjustment. • Tighten the 6 mm hex wedge bolt to To ensure rider safety, all stem adjust- 20 – 30 Nm (177 – 270 in.lbs). ments should be made by a trained mechanic using a calibrated torque Caution: wrench to verify required tightening • Always check that the stem cannot slip torque. up/down or rotate in/on the steerer tube when the handlebars are turned. • Lightly grease the outside of the stem • If the handlebars can be turned quill tube below the MINIMUM so that the stem does not line up with INSERTION mark before assembly. the front wheel, check and re-tighten the hex wedge bolt. • Slide the stem into the steerer tube of the • Re-tighten and check again for proper front fork making sure that it is inserted attachment and operation! past the ”MINIMUM INSERTION” mark on the stem quill (Fig. 1).

• Align the SmartBar assembly so that the stem centerline is in line with the centerline of the front wheel (Fig. 2). 2

6 mm 20 – 30 Nm 177 – 270 in.lbs.

66 Technical Manual 2002 SMARTBAR ASSEMBLY ERGOFIT STEM (CLAMP-ON STEM)

Caution: • Rotate the elastomer quill cover upward 4 The SmartBar requires a knowledgeable to allow installation of the headset top and trained bicycle mechanic for proper cap and access to the two 5 mm hex installation and adjustment. clamp bolts (Fig. 6). To ensure rider safety, all stem adjustments should be made by a trained Advice: mechanic using a calibrated torque Adjust the headset bearings and top cap wrench to verify required tightening tension following the headset manufactu- torque. rers’ recommendations.

• Make sure that there is at least 37 mm of • Tighten the two 5 mm hex clamp bolts to threadless steerer tube above the head- 15 – 20 Nm (133 – 177 in.lbs) (Fig. 6). set (and spacers) for clamping the stem. Caution: Advice: • Always check that the stem cannot slip Use several headset spacers between the up/down or rotate in/on the steerer tube headset and stem to allow for more height when the handlebars are turned. adjustment. • If the handlebars can be turned so that the stem does not line up with the front • Slide the stem over the steerer tube of wheel, check and re-tighten the hex the front fork (Fig. 4). clamp bolts. • Re-tighten and check again for proper • Make sure that the top of the stem clamp attachment and operation! is no more than 5 mm above the top of the 5 steerer tube (Fig. 6).

• Align the SmartBar assembly so that the stem centerline is in line with the centerline of the front wheel (Fig. 5).

6 max. mm 5

5 mm 15 – 20 Nm 133 – 177 in.lbs.

Technical Manual 2002 67 SMARTBAR ADJUSTMENT ERGOFIT STEM (REACH ADJUSTMENT)

The ErgoFit stem has two rotating adjust- • Tighten the 6 mm hex front 7 ment bolts and a ”Flip-Flop” design that adjustment bolt to 35 – 40 Nm (310 – 350 allow for a very wide range of adjust- in.lbs) (Fig. 7). ments. • Tighten the 6 mm hex rear adjustment bolt to 35 – 40 Nm FORE-AFT POSITION (310 – 350 in.lbs). • To fine-tune the fore-aft position of the handgrips adjust the Ergo- Caution: Fit rotation adjustments (Fig. 7). • Always check that the stem rotation • Loosen the two 6 mm hex adjustment adjustments cannot be rotated up or bolts just enough that the links can be down after tightening. rotated freely. • If the handlebars can be moved up or down or rotated forward or backward • Rotate the main structure and links after tightening the adjustment bolts, forward and down or backward and up check and re-tighten both the adjust- until the desired fore-aft position is ment bolts making sure that they are in achieved. Choose any one of the locking one of the locking positions. positions that are evenly spaced in 6 mm • Re-tighten and check again for proper 15-degree increments (Fig. 8). 6 mm 35 – 40 Nm attachment and operation! 35 – 40 Nm 310 – 350 in.lbs. • Tighten the 6 mm hex rear adjustment 310 – 350 in.lbs. bolt just enough to hold the desired position. • Rotate the main structure and grips so that lower flat section of the main structure is nearly level with the ground 8 and the gear indicators are clearly visible from the riding position. Locking positions are evenly spaced in 15-degree increments (Fig. 9).

68 Technical Manual 2002 SMARTBAR ADJUSTMENT ERGOFIT STEM (REACH ADJUSTMENT)

FLIP-FLOP POSITION • Tighten the 6 mm hex rear adjustment 10 • To make a large change to the fore-aft bolt to 35 – 40 Nm (310 – 350 in.lbs). position adjust the ”Flip-Flop” position • Align the SmartBar assembly so that to long or short adjustment (Fig. 10): the stem centerline is in line with the • Loosen the 6 mm hex wedge bolt or the centerline of the front wheel (Fig. 2 / two 5 mm hex clamp bolts to allow the Fig. 5). stem to rotate freely on the steerer tube • Quill stem: Tighten the 6 mm hex wedge (Fig. 3 / Fig. 6). bolt to 20 – 30 Nm (177 – 270 in.lbs) (Fig. 3). • Loosen the two 6 mm hex • Clamp-On stem: Tighten the two 5 mm adjustment bolts just enough that the hex clamp bolts to 15 – 20 Nm (133 – 177 long links can be rotated freely (Fig. 11). in.lbs) (Fig. 6). • Loosen the 6 mm hex rear adjustment bolt and remove the bolt completely. Caution: • Always check that the stem rotation Advice: adjustments cannot be rotated up or You will have to support the main down after tightening. structure while you make this change. • If the handlebars can be moved up or • Change the Flip-Flop stem quill or stem down or rotated forward or backward clamp 180 degrees to the desired short after tightening the or long position. adjustment bolts, check and re-tighten both the adjustment bolts making sure • Re-insert the 6 mm hex rear adjustment that they are in one of the locking bolt and tighten just enough to hold the positions. desired position. • Re-tighten and check again for proper • Follow the prior instructions to fine-tune attachment and operation! the fore-aft position. short • Tighten the 6 mm hex front adjustment bolt to 35 – 40 Nm (310 – 350 in.lbs).

6 mm 6 mm 35 – 40 Nm 35 – 40 Nm 310 – 350 in.lbs. 310 – 350 in.lbs.

Technical Manual 2002 69 SMARTBAR ADJUSTMENT ERGOFIT STEM (HEIGHT ADJUSTMENT)

To fine tune the up-down position of the Caution: 12 handgrips of a quillstem SmartBar adjust • Always check that the stem cannot slip the stem up or down on the steerer tube. up/ down or rotate in/on the steerer tube when the handlebars are turned. • Loosen the 6 mm hex wedge bolt (Fig. 12). • If the handlebars can be turned so that • Move the stem to the desired position up the stem does not line up with the front 6 mm or down making sure that it is inserted wheel, check and re-tighten the hex 20 – 30 Nm past the ”MINIMUM INSERTION” mark wedge bolt or hex clamp bolts. 177 – 270 in.lbs. on the stem quill (Fig. 13). • Re-tighten and check again for proper attachment and operation! • Align the SmartBar assembly so that the stem centerline is in line with the centerline of the front wheel (Fig. 14). • Tighten the 6 mm hex wedge bolt to 20 – 30 Nm (177 – 270 in.lbs) (Fig. 12).

70 Technical Manual 2002 SMARTBAR ADJUSTMENT CONTROL POD

Verify that the rotational position of the Caution: 15 brake levers is desired as assembled. • Do NOT rotate the control pod assembly outside of the allowed adjustment range If no position change is required: of 20 – 60 degrees down from horizontal • Insert a 5 mm hex wrench into the hole (Fig. 17)! in the end of the handgrip. Tighten the • Rotating the pods beyond their allowed 5 mm hex bolt to 6 Nm (53 in.lbs) (Fig. 15). adjustment range will damage the gear indication cables and function. If a different position is desired: • Insert a 5 mm hex wrench into the hole • The pods can be adjusted in increments in the end of the handgrip (Fig. 15). of 10 degrees within the range of Loosen the bolt five complete turns. This 20 – 60 degrees down from horizontal. is enough to allow the control pod to be 5 mm pulled a few millimeters away from the • Once desired position is determined 6 Nm main structure without disassembly of the tighten the 5 mm hex bolt to 6 Nm 53 in.lbs. control pod unit. (53 in.lbs) (Fig. 15). Caution: Do NOT disassemble the control pod! The gear indication cables are set at the factory, and improper disassembly will 16 damage the gear indication cables and function.

max. 3 – 5 mm • Pull the control pod slightly away (3 – 5 mm) from the main structure and rotate to the desired position (Fig. 16).

20°

20–60°

Technical Manual 2002 71 SMARTBAR ASSEMBLY BRAKE CABLE

• Line up the barrel adjuster with the slot 18 in the underside of the control pod housing. • Pull on the brake lever and push the cable head through the opening in the brake lever housing (Fig. 18). Use only new cable and housing. • Install the cable head into the cable socket in the brake lever (Fig. 19). • Set up the brakes and brake pads per brake instructions. • Actuate each brake lever 5 – 10 times and ensure proper operation.

SMARTBAR BRAKE LEVER REACH ADJUSTMENT

Using a 2 mm hex wrench. 20 • Turn the reach adjustment screw clockwise to bring the lever closer to the handgrip (Fig. 20). • Turn the screw counterclockwise to move the lever further away. • Actuate each brake lever 5 – 10 times and ensure proper operation.

Caution: • Do NOT force the screw past its normal stop! • After any adjustment to the reach always check the brake cable tension to ensure proper brake system performance. • Readjust the cable tension if necessary.

72 Technical Manual 2002 SMARTBAR ASSEMBLY SHIFTER CABLE INSTALLATION

24spd and 27spd ESP systems 7 Speed Spectro Gearhubsystems 21 • Feed the cable through the cable • The cable, housing and Clickbox are housing and stops. pre-assembled at the factory. 2 1 • Attach the cable to the derailleur. Advice: Use only new cable and housing. When fitting the cable avoid small radius. • Adjust indexing per derailleur instructions. • See figure for cable attachment points (1, Fig. 21).

• Last attachment point is on the lower rear wheel fork (2, Fig. 21) immediately behind the chain wheel.

Advice: Cable housing must be movable inside attachment.

• CLICKBOX INSTALLATION AND ADJUSTMENT per Technical Manual / Spectro S7.

SMARTBAR ADJUSTMENT GEAR INDICATION

Caution: • While holding the lockring stationary 22 Do NOT disassemble the gear indication turn the clear gear indication dome until display! the middle gear number is exactly lined up with the gear indicator needle. The gear indicators and cables are set at the factory and improper disassembly will • Use the three protruding tabs on the damage the gear indication and its clear gear indication dome to turn the function. In the event of external damage dome and the gear display beneath it or adjustment problems not solved by the while holding the lockring stationary following procedures, please call technical (Fig. 22). service for detailed repair instructions.

• Check all gears are shifting well, shift the derailleur or internal gear hub into Protruding the middle gear: tabs Lockring Gear 4 = middle gear for 7spd internal hub Gear 4 = 4th largest sprocket on 8spd cassette Gear 5 = 5th largest sprocket on 9spd cassette Gear 2 = middle chainring for front derailleurs with triple chainrings (left side gear indication).

Technical Manual 2002 73 SMARTBAR GRIP REPLACEMENT

STATIONARY GRIP: TWIST GRIP: 23 Removal Removal • Rotate the shifter fully in the cable • Remove stationary grip, see left. release direction. (Gear “1” on the front shifter, gear “1” on the Spectro 7spd • Pull the spacer tube straight off the shifter, gear “8” on the 8spd shifter, and SmartBar (Fig. 24). gear “9” on the 9spd shifter). • Next, while pressing the control pod Caution: housing toward the center of the Do NOT disassemble the control pod! handlebar, slowly pull the twist grip straight off, taking care to keep the coil • The gear indication cables are set at the spring from falling out. 5 mm factory, and improper disassembly will 6 Nm damage the gear indication cables and Replacement 53 in.lbs. function. • Slide new twist grip over SmartBar.

• Insert a 5 mm hex wrench into the hole • Slide the spacer tube back onto the in the end of the handgrip (Fig. 23). SmartBar and part way through the new grip, making sure that the flange is on 24 • While pressing the twist grip toward the the outboard side toward the stationary center of the handlebar, unscrew the grip (Fig. 24). bolt completely until the stationary grip can be pulled straight off (Fig. 24). • Replace rear end of coil spring onto spring tab of new grip (Fig. 25). Replacement Stationary • Align the flat keyed feature on the new • While sliding the grip towards the grip stationary grip assembly with the flat housing, align the free end of the spring Twist keyed feature on the end of the Smart- into the spring cavity in the spool grip Bar and push the grip assembly onto the (already in the housing). SmartBar until it makes contact with the Flat Spacer keyed tube spacer tube (Fig. 24). • Push the spacer tube all the way into the feature grip assembly. • Tighten the 5 mm hex bolt to 6 Nm (53 in.lbs) (Fig. 23). • Rotate grip forward slightly compressing the coil spring and push the grip towards the housing until there is no gap 25 between the housing and grip.

• Align the flat keyed feature on the stationary grip assembly with the flat keyed feature on the end of the Smart- Bar and push the grip assembly onto the SmartBar until it makes contact with the spacer tube (Fig. 24).

• Tighten the 5 mm hex bolt to 6 Nm (53 in.lbs) (Fig. 23).

74 Technical Manual 2002 SMARTBAR CABLE CHANGE / CLEANING

24SPD & 27SPD ESP SYSTEMS Replacement 26 • Feed the new cable through the cable Removal entry and out the barrel adjuster. 1 • Detach the cable from the derailleur. • Pull the cable snug to seat cable head in • Cut cable off 15 cm (6”) from shifter the shifter. arrel adjuster. Discard old cable and housing. • Replace the cable change hatch.

• From the top edge pull open the cable • Feed the cable through the new cable change hatch (1, Fig. 26). housing and adjusting barrel.

• Rotate the shifter fully in the cable • Position clamping bolt at a distance of release direction. (Gear “1” on the front 92 mm, tighten to 1.5 Nm (13 in.lbs.) and shifter, gear “8” on the 8spd shifter, and cut off cable end to 2 – 3 mm (Fig. 29). gear “9” on the 9spd shifter.) • Locate clamping bolt (5, Fig. 28) (screw 27 • Look for cable head and push cable up / head not visible) and place shifter cable out of the shifter and discard (Fig. 26). around carrier cylinder (counter-clockwise winding). 3 Replacement 4 • Feed the new cable through the cable 2 • Position cap (4, Fig. 27) and tighten entry and out the barrel adjuster. Be with bolt (3), torque 0.35 – 0.45 Nm sure to thread the cable through the (3.1– 4.0 in.lbs.). small hole in the spool. • Screw the barrel adjuster (2) completely • Pull the cable snug to seat the cable onto the clickbox. head in the shifter. • CLICKBOX INSTALLATION AND • Replace the cable change hatch. ADJUSTMENT per Technical Manual Gear Hub Systems / Spectro S7. • Feed the cable through the new cable housing and frame stops.

28 • Attach the cable to the derailleur. • Adjust indexing per derailleur 5 instructions.

7 SPEED SPECTRO GEARHUBSYSTEMS Removal • Rotate the shifter fully in the cable release direction. Gear position “1”.

• Do not remove the Clickbox from the axle end.

• Unscrew the barrel adjuster (2, Fig. 27) 29 completely.

• Unscrew bolt (3, Fig. 27), remove cap (4).

• Withdraw shifter cable and clamping 2 +1 mm 92 ±0,5 mm CLEANING bolt (5, Fig. 28) upwards, loosen clamp • Clean all parts with soapy water only. and pull clamping piece from the cable. • It is recommended that you clean the bike in a upright position, this allows the • From the top edge pull open the cable water to drain out correctly. change hatch (1, Fig. 26) • After cleaning, if moisture does impair the clarity of the gear indication lens • Look for cable head and push cable up / cap it is not recommended to remove the out of the shifter and discard. lens, instead leave your bike in a warm dry room, until the moisture disappears from the lens.

Technical Manual 2002 75 POWER CHAINS TECHNICAL DATA /ASSEMBLY REQUIREMENTS

PC99 PC89R PC69 PC59 PC49 NEWNEW P Part No. ————— O Application MTB Road MTB MTB MTB Compatibility Front HG/EXA-Drive HG/EXA-Drive HG/EXA-Drive HG/EXA-Drive HG/EXA-Drive W Compatibility Rear HG/EXA-Drive HG/EXA-Drive HG/EXA-Drive HG/EXA-Drive HG/EXA-Drive E Max. No. of sprockets 9 only 9 only 9 only 9 only 9 only 1 11 1 11 1 11 1 11 1 11 R Dimension /2"x /128" /2"x /128" /2"x /128" /2"x /128" /2"x /128" Length 6.7mm 6.7mm 6.7mm 6.7mm 6.7mm C Riveting Cross Step Step Step Step Step Pin Chrome Hardened Yes Yes Yes Yes Yes H Push Power 2000N / 450 in.lbs. 1500N / 340 in.lbs. 1500N / 340 in.lbs. 1500N / 340 in.lbs. 1500N / 340 in.lbs. A Tensile Strength 9800N / 2200 in.lbs. 9800N / 2200 in.lbs. 9800N / 2200 in.lbs. 9800N / 2200 in.lbs. 9800N / 2200 in.lbs. I Weight (116 links) 300g 295g 300g 300g 300g External Pin Plate Silver/Nickel Plated Silver/Nickel Plated Silver/Nickel Plated Silver/Nickel Plated Grey /Polished N Internal Pin Plate Silver/Nickel Plated Silver/Nickel Plated Silver/Nickel Plated Grey /Polished Grey /Polished

S Design Weight Reduced Yes Connecting Method Power Link 9SPD Power Link 9SPD or Pin Power Link 9SPD or Pin Power Link 9SPD or Pin Power Link 9SPD or Pin

PC68 PC58 PC 48 PC38 Saltshaker PC38 P Part No. ————— O Application MTB MTB MTB MTB MTB W Compatibility Front HG/IG/PG/EXA-Drive HG/IG/PG/EXA-Drive HG/IG/PG/EXA-Drive HG/IG/EXA-Drive HG/IG/EXA-Drive E Compatibility Rear HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive Max. No. of sprockets max. 8 max. 8 max. 8 max. 8 max. 8 1 3 1 3 1 3 1 3 1 3 R Dimension /2"x /32" /2"x /32" /2"x /32" /2"x /32" /2"x /32" C Length 7.1mm 7.1mm 6.8mm 6.9mm 6.9mm Riveting Cross Step Step Step Step Step H Chrome Hardened Yes Yes Yes A Push Power 2000N / 450 in.lbs. 1500N / 340 in.lbs. 1500N / 340 in.lbs. 1100N / 350 in.lbs. 1100N / 350 in.lbs. I Tensile Strength 9800N / 2200 in.lbs. 9800N / 2200 in.lbs. 9800N / 2200 in.lbs. 9800N / 2200 in.lbs. 9800N / 2200 in.lbs. Weight (116 links) 315g 315g 305g 305g 305g N External Pin Plate Silver/Nickel Plated Silver/Nickel Plated Grey /Polished Grey /Dacromet Grey /Polished S Internal Pin Plate Silver/Nickel Plated Grey /Polished Black/Burnished Grey /Dacromet Brown/Annealed Design Pin Connecting Method Power Link S or Pin Power Link S or Pin Power Link S or Pin Power Link G or Pin Power Link G or Pin

P PC10 Saltshaker PC10 PC7X1 PC1 Saltshaker PC1 Ni PC1 O Part No. —— ———— Application MTB MTB BMX / Track Gear Hubs Gear Hubs W Compatibility Front HG HG Single Single Single E Compatibility Rear HG HG Single Single Single R Max. No. of sprockets max. 7 max. 7 1 1 1 1 3 1 3 1 1 1 1 1 1 Dimension /2"x /32" /2"x /32" /2"x /8" /2"x /8" /2"x /8" C Length 6.9mm 6.9mm 8.2mm 7.8mm 7.8mm H Riveting Step Step Step Step Step Pin Push Power 1000N / 225 in.lbs. 1000N / 225 in.lbs. 1500N / 340 in.lbs. 800N / 180 in.lbs. 800N / 180 in.lbs. A Tensile Strength 9800N / 2200 in.lbs. 9800N / 2200 in.lbs. 11000N / 2500 in.lbs. 8000N / 1800 in.lbs. 8000N / 1800 in.lbs. I Weight (116 links) 305g 305g 345g (114 links) 350g 350g N External Pin Plate Grey /Dacromet Brown/Annealed Gold/Gold Plated Grey /Dacromet Silver/ Brown/ Internal Pin Plate Grey /Dacromet Brown/Annealed Black/Burnished Grey /Dacromet Nickel Plated Annealed

S Design Connecting Method Power Link G or Pin Power Link G or Pin 3 pcs. Connecting Link Snap Lock or Pin Snap Lock or Pin 1 PC 7X 114 links only 76 Technical Manual 2002 POWER CHAINS ASSEMBLY / MAINTENANCE

1 " 3 " 1 " 11 " 1 1 /2 x / 32 AND /2 x / 128 PC 1 /2 " x /8 " 1 (DERAILLEURS / SINGLE (SINGLE AND MULTI- AND MULTI-SPEED HUBS) SPEED HUBS) + Chain length: Closing chain with Snap Lock: • Shorten chain to the length specified by • Fit the shortened chain, bring the ends (2 Links) the derailleur manufacturer. together and connect with the Snap Lock. SRAM derailleurs: Place the outer plate on one pin (Fig. 6). • Place chain over largest front chain- • Gently flex the chain until the outside 2 wheel and largest rear sprocket and add connector plate snaps into position over 2 links or 1 link + Power Link (Fig. 1). the second pin (Fig. 7). • For rear suspension frame, position the rear suspension for the greatest chain Caution: length required. •Make sure plate is fully seated in the pin channel and plates are parallel to each other. Closing standard version with clamping pin: •If movement of the connector plate is • Fit chain, bring the two ends together noticed a new Snap Lock must be used. and press pin (Fig. 2) through with •Always use a new Snap Lock when 3 assembly tool. The pin must extend by fitting a new chain. Failure to shorten the same amount at both outer plates. It the chain properly or to lock it exactly must be possible to move the connecting into place may cause damage to the link slightly. chain and eventually total chain failure, • The use of the SRAM assembly plier material damage or the rider to fall off (Part No. 00 2799 980 001) is recommen- his bicycle resulting in injury. ded for PC 68, PC 58 and PC 48.

1 1 4 PC 7X /2 " x /8 " Power Link connecting links: (BMX / TRACK) Caution: Use only as specified, to avoid material Closing chain: damage or the rider to fall off his bicycle • Fit the shortened chain, bring the two resulting in injury. ends together and connect with the chain lock. The chain lock consists of an 5 Power Link G grey coloured outer plate with pins (1, Fig. 8), an outer for PC 38, PC 10 plate (2) and a retaining spring (3). Power Link S silver coloured • Insert outer plate with pins (1) into the for PC 68, PC 58, PC 48 chain ends, attach outer plate (2) and Power Link 9SPD gold coloured press chain lock together (1+2). for PC 99, PC 89R, • Attach retaining spring (3) with the 6 PC 69, PC 59, PC 49 closed end of the retaining ring pointing in the direction of chain travel (Fig. 9). Closing: • Slide retaining spring in the direction • Fit chain, bring the ends together and of arrow (4, Fig. 9) to engage it in the insert both halves of the Power Link into grooves in the pins. the chain ends. (Fig. 3) 7 • Press both halves of the Power Link together (Fig. 4) and lock in place by MAINTENANCE pulling the chain apart. (Fig. 5) • Regular lubrication will extend the chain's service life. Opening: • Apply oil to the chain rollers and allow • Press both plates of the Power Link to work in. together (Fig. 4) while sliding the chain • Clean dirty chains before oiling. Do not 8 1 ends together (unlock). Remove the two use any grease-dissolving or acidic halves of the link from the chain ends. agents. Cleaning agent must be rinsed off after a few minutes with water. Caution: Apply oil after chain is completely dried. 2 3 Always use a new Power Link when fitting a new chain. Failure to shorten the chain properly or to lock it exactly into 9 place may cause damage to the chain and eventually total chain failure, material 4 damage or the rider to fall off his bicycle resulting in injury.

Technical Manual 2002 77 SUPPORT DISTRIBUTORS

FRANCE UNITED STATES Savoye, S.A. Rue de l’industrie Action Bicycle USA The Merry Sales Company Wilson Bicycle Sales 1470 Serrières de briord 217 Washington Avenue -A 1415 San Mateo Avenue 31157 Wiegman Road Ph: +33 4 74 36 13 77 Carlstadt, NJ, 07072 San Francisco, CA, 94080 Hayward, CA, 94544 Fx: +33 4 74 36 15 14 Ph: +1 800.284.2453 Ph: +1 800.245.9959 Ph: +1 800.877.0077 Bicycle Tech International Olympic Cycle Supply World Wide Cycle Supply Lapierre Cycles S.A. 3201 B Richards Lane 5711 West Douglass Avenue 100 D Executive Drive Eurostar Sante Fe, NM, 87505 Milwaukee, WI, 53218 Edgewood, NY, 11717 SUNN Ph: +1 800.558.8324 Ph: +1 800.236.8380 Ph: +1 800.330.2550 GERMANY DiamondBack, Distributor Performance Cycle Products Hartje KG 300 Camarillo Ranch Rd. 22 South 6th Avenue Deichstraße 120-122 Camarillo, CA, 93012 Mount Vernon, NY, 10550 27318 Hoya Ph: +1 800.776.7641 Ph: +1 888.269.1846 Ph: +49 42 51 81 11 15 Downeast Bicycle Specialists Quality Bicycle Products Fx: +49 42 51 81 12 49 Porter Road, P.O. Box 226 6400 West 105th Street Epple Zweirad GmbH Fryeburg, ME, 04037 Bloomington, MN, 55438 Mittereschweg 1 Ph: +1 800.242.1043 Ph: +1 800.346.0004 87700 Memmingen Ph: +49 83 31 7 51 41 Euro-Asia Imports Quantum Fx: +49 83 31 7 51 97 3935 FootHill 400 Venture Court, Suite 101 La Crescenta, CA, 91214 Verona, WI, 53593-1821 EUROPE Bico Ph: +1 818.248.1814 Ph: +1 800.545.1229 E. Wiener Bike parts GZR AUSTRIA Giant Bicycle, Inc. Quentin Rabeneick/Schlote 737 W. Artesia Boulevard 454 Scott Drive KTM Fahrrad GmbH Veloring Rancho Dominguez, CA, 90220 Bloomingdale, IL, 60108 Harlochnerstrasse 13 ZEG Ph: +1 800.874.4268 Ph: +1 800.323.1741 5230 Mattighofen Ph: +43 7742 409 132 GREECE Great Northwest Raleigh Bicycle Co., USA Fx: +43 7742 409 126 2335 North West Savier 22710 72nd Avenue South Gatsoulis Imports Portland, OR, 97210 Kent, WA, 98032 8, Thessalonikis Street BELGIUM Ph: +1 800.927.9242 Ph: +1 800.222.5527 14342 New Filadelfia-Athens Transmission S.A. Ph: +30 1 25 12 779 Hans Johnsen Company Riteway Products Boulevard du Centenaire 4 Fx: +30 1 25 33 960 8901 Chancellor Row 2001 East Dyer 1325 Dion-Valmont Dallas, TX, 75248-5326 Santa Ana, CA, 92705-5709 Ph: +32 10 24 46 46 HUNGARY Ph: +1 800.879.1515 Ph: +1 800.869.9866 Fx: +32 10 24 47 77 Biker Kft. The Hawley Company Schwinn Cycling and Fitness Gyepsor u. 1 One Hawley Drive 1690 38th Street CZECH REPUBLIC 1211 Budapest Lexington, SC, 29074-7812 Boulder, CO, 80301 Vokolek Import Ph: +36 1278 1021 Ph: +1 800.822.1980 Ph: +1 800.SCHWINN Rezlerova 308 Fx: +36 1278 1023 10900 Praha-Petrovice Island Cycle Supply Seattle Bike Supply Ph: +420 2692 3399 ICELAND 425 Washington Avenue North 7620 South 192nd Fx: +420 2692 3399 Oerninn Hjol LTD. Minneapolis, MN, 55401 Kent, WA, 98032 P.O. Box 8036, Skeifan 11 Ph: +1 800.627.2453 Ph: +1 800.955.2453 Zitny Ceskobratske Nam. 133 Reykjavik J&B Importers, Inc. Security Bicycle 29301 Mlada Boleslav Ph: +354 1 88 98 92 P. O . B o x 1 6 1 8 5 9 32 Intersection Street Ph: +420 326 72 22 14 Fx: +354 5 88 98 96 Miami, FL, 33116-1859 Hempstead, NY, 11550-1332 Fx: +420 326 72 22 14 Ph: +1 800.666.5000 Ph: +1 800.645.2990 ITALY J&B Importers West, Inc. Sinclair Imports DENMARK A.M.G. S.r.l. P. O . B o x 1 2 4 8 2755 Highway 40 Dan Agentur Via Piave 10 Englewood, CO, 80150 Verdi, NV, 89439 Stationsvej 77 23871 Lomagna (Como) Ph: +1 800.999.9228 Ph: +1 800.654.8052 5792 Arslev Ph: +39 039 5 30 11 67 Ph: +45 65 99 24 11 Fx: +39 039 9 22 02 70 J&B Importers Pacific, Inc. Trek Bicycle Corporation Fx: +45 65 99 28 42 P. O . B o x 8 8 8 0 8 801 West Madison St. NETHERLANDS Seattle, WA, 98138-2808 Waterloo, WI, 53594-0183 FINLAND Koch Kleeberg B.V. Ph: +1 800.627.2453 Ph: +1 800.369.8735 J. Syväranta Oy Postbus 1069, Dukdalfweg 25 KHS Inc., Distributor United Bicycle Parts Nervanderinkatu 5E 47/PL 64 1300 BB Almere 1264 East Walnut Street 691 Washington Street F-00101 Helsinki Ph: +31 36 532 05 04 Carson, CA, 90746 Ashland, OR, 97520 Ph: +358 9 490 137 Fx: +31 36 532 25 48 Ph: +1 800.347.7854 Ph: +1 800.482.1984 Fx: +358 9 493 890 Vertex Cycle Systems

78 Technical Manual 2002 SUPPORT DISTRIBUTORS ¥

NORWAY U.K. JAPAN Stians Sport A.S. Raleigh P&A Vollveien 13, Bygg D, POB 107 Triumph Road Kawashima Cycle Supply Corp. 1324 Lysaker NG 72 DD Nottingham No. 4-2-4 Kushiya-Cho Higashi Ph: +47 67 11 00 20 Ph: +44 115 9420202 Sakai, Osaka 590 Fx: +47 67 11 00 42 Fx: +44 115 9282044 Ph: +81-722 381 557 Fisher Outdoor Leisure PLC POLAND Nichinao Shokai Co., Ltd. Unit 2, Haslemore Business Centre 6-16-8 Sotokanda Chiyoda-ku Harfa-Harryson Lincolnway off Lincoln Road Tokyo 101 Ul. Ks. Witolda 48 EN 11 TE Enfield, Middx Ph: +81-3 3382 6251 50203 wroclaw Ph: +44 181 8053088 Ph: +48 7 13 72 15 70 Fx: +44 181 8058821 Fx: +48 7 13 27 80 92 Chickens & Sons Bisley Works/Landpark Lane PORTUGAL LU 62 PP Kensworth, Beds Ciclo Coimbrões Ph: +44 1582 873329 Praça Manuel da Silva Reis, 122 Fx: +44 1582 873583 NEW ZEALAND 4400-211 Vila Nova de Gaia Ph: +351 22 379 44 61 Cycle Supplies Fx: +351 22 375 61 63 PO Box 33051 Christchurch RUSSIA AUSTRALIA Ph: +64.3.338.6803 Sportclub Triatlon H.S. White & Sons Groupe Sportif Pty. Ltd. 7C Anwen Place, East Tamacki SLOVAKIA 20 Harker Street PO Box 58331 Greemouni Burwood, Victoria 3125 Excelia s.r.o. Auckland Ph: +61.3.9888.9882 Ph: +64.9273.7690 SLOVENIA & CROATIA Velo-Vita Pty. Ltd. Unit A, 602-612 Botany Road Proloco Trade d.o.o. NSW 2015 Alexandria Partizanska 4 Ph: +61.2.9700.8177 64000 Kranj Ph: +386 64 38 02 00 Fx: +386 64 38 02 022 SOUTH AFRICA

SPAIN Cape Cycle Systems (PTY) LTD. Casa Masferrer CANADA 10/12 Argo Road, Wetton Pol. Ind. Congost-Avda. 7780 Cape Town San Julian, S/N Apdo Correos 89 Bell Sports Canada Ph: +27.21.761.3528 E-08400 Granollers 700 Chemin Bernard Ph: +34 9 38 46 60 51 Granby, PQ, J2G 9H7 Fx: +34 9 38 46 53 56 Ph: +1 800.661.1662 Kempter Marketing SWEDEN 1271 St Louis St Lazare, PQ, J7T 1Z9 Vartex Ph: +1 514.424.4600 Batterivägen 14 43232 Varberg Norco Products Limited Ph: +46 340 850 80 1465 Kebet Way Fx: +46 340 61 11 90 Port Coquitlam, BC, V3C 6L3 Ph: +1 800.663.8916 SWITZERLAND Intercycle Industriegebiet, Haldemattstr. 3 6210 Sursee Ph: +41 41 92 66 511 Fx: +41 41 92 66 352 ISRAEL Amsler & CO AG Hobby’s LTD. Lindenstraße 16 POB 1231 8245 Feuerthalen 53111 Givataim Ph: +41 5 26 47 36 36 Ph: +972 5 24 299 05 Fx: +41 5 26 47 36 37 Fx: +972 35 75 45 29

Technical Manual 2002 79 SUPPORT WHO TO CALL / SRAM WARRANTY / SPARE PARTS ¥

WHO TO CALL NORTH AMERICA

For fast SRAM dealer warranty and Dealer Helpdesk Number: technical support help, please contact us at the appropriate locations. (800)-346-2928

EUROPE

Please contact your local distributor.

SRAM 2 YEAR WARRANTY

In addition to standard legal warranty nent of higher value from the current caused by disregard for our assembly entitlements, SRAM components include a SRAM product line. Defective and operating instructions, shall not be two year full warranty beginning on the components which have been replaced covered by this warranty. Furthermore, date of purchase. This warranty is subject become the sole property of SRAM. this warranty shall not cover damages to the following conditions: 2. Any other warranty claims not included caused by the use of parts of different in this statement are void. This manufacturers or otherwise which are 1. During the warranty period, SRAM especially includes any disassembly or not compatible or suitable for use with components with material or production assembly costs (for instance by the SRAM components. defects which as a result adversely affect dealer), which shall not be covered by 5. The servicing of a valid warranty claim the proper functioning of such compo- SRAM. shall neither extend this warranty nor nents, shall either be repaired or replaced 3. Warranty claims are only valid upon establish a warranty period. with a functioning SRAM component free presentation of a proper proof of 6. If a defect is discovered, please contact of charge, whereby we are free to deter- purchase. the dealer where the bicycle or the mine whether repair or replacement 4. Parts subject to normal wear and tear SRAM component in question was should take place. If a component cannot (for example brake sleeves, brake pads, purchased. be replaced or repaired, the purchaser chains etc.) and damage which is shall receive, free of charge, a compo- caused by improper use, specifically

SPARE PARTS SRAM ORIGINAL PARTS

You can find an extensive spare parts Installation of parts and accessories not program in SRAM’s Spare Parts List originally intended could result in less Model Year 2002 · Publ. Number 8502. than optimal performance and/or injury.

80 Technical Manual 2002