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ROAD BIKE MAINTENANCE Thethe World’S Best-Sellingbest-Selling Bicycle Repairrepair and Maintenance Guide ZINN & THE ART OF ROAD BIKE MAINTENANCE TheThe World’s Best-SellingBest-Selling Bicycle RepairRepair and Maintenance Guide FORFOR ALLALL RROADOAD AANDND CCYCLOCROSSYCLOCROSS LENNARD ZINN BIBICYCLESCYCLES 4TH EDITION PRAISE FOR ZINN & THE ART OF ROAD BIKE MAINTENANCE “Lennard Zinn’s book is packed with in-depth explanations and useful diagrams.” —Velo magazine “Lennard Zinn is a veritable cycling Einstein, and as a naturally gifted teacher he has the unique ability to explain even the most difficult mechanical task. So unless you currently ride on a high-profile pro team with your own mechanic (and maybe even then), Zinn & the Art of Road Bike Maintenance is an absolute ‘must-have’ book.” —Davis Phinney, Olympic medalist, U.S. Pro champion, and Tour de France stage winner “Lennard Zinn is an institution in the bicycle world—a legend. Legions of cyclists have learned to repair bikes from him, ridden bicycles he’s built, or used his advice as guidance on how to better enjoy the world on two wheels.” —Bicycle Times magazine “Zinn is very good at taking you incrementally through the learning process—whether you are a beginner or expert mechanic.” —Out There Monthly magazine “Zinn & the Art of Road Bike Maintenance has instructions on anything an aspiring wrench would want to know. What impresses most is Lennard’s overall approach of simplifying a task and reminding us how rewarding it is to perform our own service.” —PodiumCafe.com “There really is no other bicycle repair manual like this. Zinn & the Art of Road Bike Maintenance is very up-to-date, very clear—thanks to the profuse illustrations—and accurate and comprehensive. And it’s all in a very enjoyable format intended to be encouraging and confidence-building.” —USCyclingReport.com “Simple to read and follow, the illustrated, large-format paperback manual features every- thing from replacing a flat to repairing components. It’s a great addition to any new biker’s library but offers invaluable advice for experts, too.” —Sports Guide magazine “If ever there was a classic text on bike maintenance, this has to be it. Like its predeces- sors, it goes from super simple right through to complete re-builds. All are explained by a combination of Zinn’s unique humour-filled, insightful and clear text, with Todd Telander’s brilliant illustrations.” —220Triathlon.com ZINN & THE ART OF ROAD BIKE MAINTENANCE The World’s Best-Selling Bicycle Repair and Maintenance Guide 4TH EDITION LENNARD ZINN Illustrated by Todd Telander and Mike Reisel BOULDER, COLORADO Zinn & the Art of Road Bike Maintenance, 4th Edition Text copyright © 2013 by Lennard Zinn Illustrations copyright © 2013 by VeloPress All rights reserved. Printed in the United States of America. No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic or photocopy or otherwise, without the prior written permission of the publisher. 3002 Sterling Circle, Suite 100 Boulder, Colorado 80301–2338 USA (303) 440-0601; Fax (303) 444-6788; E-mail [email protected] Distributed in the United States and Canada by Ingram Publisher Services Library of Congress Cataloging-in-Publication Data Zinn, Lennard. Zinn & the art of road bike maintenance / Lennard Zinn; illustrated by Todd Telander and Mike Reisel. —Fourth edition. pages cm Includes bibliographical references and index. ISBN 978-1-934030-98-1 (pbk.: alk. paper) 1. Bicycles—Maintenance and repair. 2. Road bicycles—Maintenance and repair. I. Title. II. Title: Zinn and the art of road bike maintenance. TL430.Z557 20113 629.28’772—dc23 2012047821 For information on purchasing VeloPress books, please call (800) 811-4210 ext. 2138 or visit www.velopress.com. Illustrations by Todd Telander and Mike Reisel Cover and interior design by Erin Farrell/Factor E Creative Cover photo by Brad Kaminski; bike built by Lennard Zinn Title font Ciutadella; body text Deca Serif This paper meets the requirements of ANSI/NISO Z39.48-1992 (Permanence of Paper). 13 14 15 / 10 9 8 7 6 5 4 3 2 1 v CONTENTS A Tip of the Helmet to . vii Introduction xi MAINTENANCE AND REPAIR 1 Tools 1 2 Basic Stuff 19 3 Emergency Repairs 39 4 The Chain 53 5 The Shifting System 77 6 Wheels and Tires 151 7 Brakes 205 8 Cranks and Bottom Brackets 257 9 Pedals 301 10 Saddles and Seatposts 321 11 Stems, Handlebars, and Headsets 337 12 Wheel Building 379 13 Forks 403 14 Frames 413 APPENDIXES A Troubleshooting Index 427 B Gear Chart 433 C Road Bike Fitting 437 D Glossary 451 E Torque Table 461 Bibliography 475 Index 477 Illustration Index 487 About the Author and Illustrators 491 INTRODUCTION First things first, but not necessarily in that order. —Doctor Who ABOUT THIS BOOK firmly believe—and my experience with the repair classes I have taught confirms this—that anyone o, you want to maintain your road bike? can perform the repairs illustrated on these S Congratulations. You will be glad you took pages. It takes only a willingness to learn and the this step. Although it is nice to learn about your appropriate tools. bike from friends or shop employees who know This book is intended for everyone from more about bicycles than you do, you don’t want shop mechanics to those who only want to know to depend on them for routine maintenance or about the most minimal maintenance their bike fixing basic mechanical problems. And the exhila- requires. Chapter 2 is for those whose interest ration of riding with the wind in your hair will be is limited to the latter; the rest of the book is enhanced by understanding the structure of the for those who choose to go to greater lengths to mechanical system on which you are sitting and make everything work optimally and look clean to which you are trusting your life. and beautiful. Even for those who wish to focus Even the purest romantic can follow the on Chapter 2, the information in Appendix C simple step-by-step procedures and exploded on fitting your bike to y ou instead of the other diagrams in this book and discover a passion for way around will increase your riding pleasure spreading new grease on old parts. And, I hope, and safety. everyone will develop an appreciation for how infusing love into the work will guarantee suc- WHY DO IT YOURSELF? cess at bike maintenance. If not, frustration will take over, you will use less care, and your riding There are a number of reasons for learning to enjoyment will be compromised. maintain your bike. Obviously it is a lot cheaper Zinn & the Art of Road Bike Maintenance to fix a bike yourself than to pay someone else to allows you to pick maintenance tasks appropriate do it. Once you have some skill and experience, it for your level of skill and confidence. However, I is also faster. And home-based maintenance is a xi xii necessity for most racers and others who live to and last a long time. With the proper attention, ride and have no visible means of support. they can shine in appearance and performance As your income increases, economic neces- for many years. Satisfaction can be found in dis- sity ceases to be a significant issue. However, you mantling and cleaning a filthy, barely functional may find that you enjoy working on your bike for part, lubricating it with fresh grease, and reas- reasons other than just saving money. Unless you sembling it so that it works like new. Knowing have a trusted mechanic who services your bike that you made those parts work so smoothly— regularly, you are not likely to find anyone who and that you can do it again when they next need cares as much about your bicycle’s smooth oper- it—is rewarding. You will be eager to ride hard and ation and cleanliness as you, or who will make long to see how your work holds up, rather than your bike a priority when you need to have it the being reluctant to get far from home for fear of next day or in the next few hours. Furthermore, breaking down. if you love to ride, you need to be able to fix It is liberating to go on a long ride confident mechanical breakdowns that occur on the road, that you can fix just about anything that may go especially if you ride alone. wrong. Armed with this confidence and the tools If time is your biggest issue, having some- to put it into action, you will have the freedom to one else work on your bike might seem like a no- explore new roads and go farther than you may brainer. But in reality, even finding the time to otherwise have gone. You may also find yourself drop off your bike and pick it up from the shop, more willing to share your love of the sport with while coordinating with the shop’s schedule, can riders who are less experienced. You will enjoy be hard. You may be able to perform a simple riding with them more if you know that you can repair faster or more conveniently than you can fix their questionably maintained bikes, and you make a trip to the bike shop during working can bask in their appreciation after you have hours. And you won’t like missing a ride during eliminated an annoying squeak or skipping chain. beautiful weather while your bike sits in a shop that is backed up with repairs. Finding out that HOW TO USE THIS BOOK you can’t just drop off your ailing bike during high season and expect anything faster than a three- Skim through the entire book.
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