Bontrager 231793 service manual Pro rear hub

Pro rear hub

Bontrager Race Lite ATB, Race Lite 29, Race X Lite, Race X Lite Carbon rear wheels, Race Lite Aero

A running change to hubs was made in 2001; the newer hub has a part number embossed in the shell. See exploded dioagrams for differences

Recommended tools

ASSEMBLY

Fig. 1I

Spacer

Star ratchet

Fig. 2I

Fig. 3I

Bearing

Fig. 4I

Spacer

Fig. 5I

Long bearing press Short bearing press 17mm cone wrench Multi-purpose grease Bench vise

Axle vise

Hammer, soft faced Thin-bladed slot screwdriver

DISASSEMBLY

Hub parts and names are referenced on next page.

Disassemble the freehub

1.Place the axle vise in the bench vise and clamp the left- hand end of the axle.

2.Pull sharply with your fingers to remove the cassette, with the freehub body attached (Fig. 1I).

3.Remove the star ratchet, spacer and spring (under the star ratchet) from the hub (Fig. 2I).

4.Remove the second star ratchet and second spring from the freehub body.

Disassemble the ring nut

1.Clamp the spline tool into a bench vise (Fig. 3I).

2.Push the right side axle end into the cylinder. With the splines engaged, turn the wheel firmly in an anti-clockwise direc- tion. The ring nut will be loos- ened, and the seal between the hub and freehub body will fall over the spline tool onto the vise.

3.Thoroughly clean and inspect all components, includ- ing inside the hub, with a dry cloth. If necessary, use a tooth- brush. If cracks or any other damage is visible, the parts must be replaced.

Disassemble the bearings

1.From the right side, tap the axle out of the hub with the hammer (Fig. 4I). Remove the axle from the hub.

2.Slide the left end cap, seal and bearing off the axle.

Install the right hand bearing

1.Clamp the spline tool into

a vise.

2.Place the spacer over the splines (Fig. 5I).

3.Place the bearing onto the long end of the axle and push the bearing onto the spline tool (Fig. 6I).

4.Place the wheel over the axle, drive side down. Push the short bearing press over the other end of the axle. Tap the bearing into place with the ham- mer (Fig. 7I).

Install the ring nut

1.Clamp the spline tool into the vise with only the splines above the jaws (Fig. 8I).

2.Inspect the ring nut for cracks or damage. If damaged, replace it.

3.Place the ring nut with the recess uppermost over the splines (Fig. 9I). Place the spacer ring flat inside the ring nut.

4.Place the wheel, drive side down, over the spline tool. Insert the right axle end through the spline tool. Carefully screw the ring nut into the hub by turning the wheel clockwise.

Install the freehub body seal

Important: When installing a new seal, only the right-hand bearing should be in place. The left-hand bearing must not be pressed in until after the seal has been installed.

1. Inspect the seal. If the seal

shows signs of wear or damage,

replace it.

2. Clamp the short bearing

press into a vise (Fig. 10I) and

place the wheel, drive side up,

over the tool.

3. Place the seal over the

freehub body seal installation tool

(Fig. 11I) with the ‘V’ facing the

hub.

4. With the seal on the tool,

push them together over the axle.

Fig. 6I

Fig. 7I

Fig. 8I

Spacer Ring nut

Fig. 9I

Fig. 10I

3. Turn the axle around and

insert it into the left side of the hub until the axle collar butts against the bearing. Tap the second bearing out with the hammer.

4.Thoroughly clean and inspect all components with a dry cloth. If cracks or any other damage is visible, the parts must be replaced.

5. Place the long bearing

press over the axle.

6.Press the seal into the hub by tapping it with the hammer.

Install the left hand bearing

1. Clamp the spline tool into the bench vise (Fig. 3I).

28 2003 Bontrager Service Manual