Bontrager 231793 service manual Install the freehub, Part list on following

Freehub body seal

Fig. 11I

Fig. 12I

End cap V-seal

Fig. 13I

2.Push the wheel over the tool, drive side down.

3.Place the bearing care- fully into the hub (Fig. 12I).

4.Place the short bearing press over the axle (Fig. 7I). Tap the bearing into place with the hammer.

Turn the axle and check that you do not feel any irregular friction.

5.Lightly grease the surface of the bearing.

6.Pull the V-seal off the end cap (Fig. 13I). Clean it thoroughly with a cloth, lightly grease it, and reinstall it on the end cap with the open ‘V’ facing the hub.

7.Replace the completed end cap onto the left axle end.

Install the freehub

1.Grease the splines inside the hub shell with DT Swiss spe- cial grease (only).

2.Push the spacer over

the axle (Fig. 14I) until it butts against the bearing.

3. Insert the spring, with

the large diameter in contact

with the bearing (Fig. 14I).

5.Carefully clean the star ratchets with a dry cloth. Inspect both star ratchets for damage.

If any damage is visible, replace the ratchet.

5.Lightly grease both star ratchets with DT Swiss special grease (only).

6.Place the spacer ring into the freehub body. Place the spring into the freehub body with the large diameter end in contact with the spacer ring (Fig. 15I).

7.Place both greased star ratchets into the freehub body (Fig. 16I).

8.Push the freehub body, together with the cassette, over the axle.

Caution: Ensure the freehub body is not tilted !

9.Pull the V-seal off the right end cap (Fig. 13I). Clean it thor- oughly with a cloth, lightly grease it, and reinstall it on the end cap with the open ‘V’ facing the hub.

10.Place the end cap over the right end of the axle and manually press into place. Ensure the end cap is not tilted and that it audibly clicks into place.

Spacer

Spring

Fig. 14I

Fig. 15I

Fig. 16I

4. Clean the outside end of the

freehub body with a clean cloth.

After completing assembly of the hub, check its function

by giving the cassette a sharp, quick spin. If the ratchets do not catch, there could be too much grease

Before positioning the spacer and the ratchet in the freehub body, check that the freehub body bear- ings spin freely without binding. If any binding or scratching is detected, replace the freehub body with a new or reconditioned one.

inside the freehub body, or the wrong type of grease was used. In this case, remove some of the grease or replace it using the correct grease.

Part list on following page

2003 Bontrager Service Manual 29