Table Of Content

BIG BLUE BOOK OF BICYCLE REPAIR A Do-It Yourself Bicycle Repair Guide from Park Tool By C. Calvin Jones 3RD EDITION BIG BLUE BOOK OF BICYCLE REPAIR — 3RD EDITION A Do-it-Yourself Bicycle Repair Guide From Park Tool Park Tool Company Copyright © 2013 Park Tool Company ® PARK TOOL and the color BLUE are registered trademarks of Park Tool Co. All other referenced trademarks and trademark registrations are the property of their respective owners. The Big Blue Book of Bicycle Repair is published by Park Tool Company. For more information or to contact us: Park Tool Company 5115 Hadley Ave N St. Paul, MN 55128 T: (651) 777-6868 F: (651) 777-5559 http://www.parktool.com To report errors, please send a note to [email protected] For the latest an all our products and services, please go to http://www.parktool.com Written by: C. Calvin Jones Editor: Bill Gibson Graphic Designer: Joel King Special thanks to the manufacturers of components and bicycles featured within this publication. NOTICE OF RIGHTS No part of this book may be reproduced or transmitted in any form, by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. For information on getting permissions for reprints and excerpts, contact [email protected]. NOTICE OF LIABILITY The information in this book is distributed on an “As Is” basis, without warranty. While every precautions has been taken in the preparation of the book, neither the author nor Park Tool shall have any liability to any person or entity with respect to any loss or damage caused or alleged to be caused directly or indirectly by the instruction contained in this book and products described in it. ISBN 978-0-9765530-4-5 Printed and bound in the United States of America TABLE OF CONTENTS OPENING TFable of contentsoreword.....................................................................................................................................................................xi Introduction...............................................................................................................................................................xii CHAPTER 1 — BASIC MECHANICAL SKILLS Threaded Fastener Tension & Torque................................................................................................................2 Lubrication, ThreadLockers, & Cleaners............................................................................................................4 Bearing Systems....................................................................................................................................................5 Diagnosing & Solving Mechanical Problems.....................................................................................................6 Tools & Tool Selection..........................................................................................................................................6 Repair Stands........................................................................................................................................................6 Home Shop Setup..................................................................................................................................................7 Maintenance Schedule....................................................................................................................................8 CHAPTER 2 — TIRES & TUBES Wheel Removal....................................................................................................................................................12 Removal of Tire & Tube from Rim.....................................................................................................................14 Inner Tube Inspection.........................................................................................................................................15 Cut at Valve Base...........................................................................................................................................15 Leaky Valve Core...........................................................................................................................................15 Large Shredded Hole.....................................................................................................................................15 Hole on the Rim Strip Side of Tube.............................................................................................................15 Long Cut or Rip..............................................................................................................................................16 Single Puncture or Small Hole......................................................................................................................16 Double Slits.....................................................................................................................................................16 Tire Inspection.....................................................................................................................................................16 Rim Strip...............................................................................................................................................................17 Inner Tube Repair................................................................................................................................................17 Pre-Glued Patch Repair.................................................................................................................................17 Inner Tube Repair with Self-Vulcanizing Patches.....................................................................................17 Inner Tube Sealants.............................................................................................................................................18 Tire Liners.............................................................................................................................................................18 Temporary Tire Repair with Tire Boot..............................................................................................................19 Inner Tube Valves................................................................................................................................................19 Tire & Tube Sizing...............................................................................................................................................20 Installation of Tire & Tube on Wheel.................................................................................................................21 Wheel Installation...............................................................................................................................................22 Front Wheels with Disc Brakes....................................................................................................................25 Solid Axle Types............................................................................................................................................25 Thru-Axle Systems........................................................................................................................................25 Tubeless Systems...............................................................................................................................................26 Tubeless Conversion Systems.....................................................................................................................27 Tubular Tires........................................................................................................................................................28 CHAPTER 3 — REAR SPROCKETS Cassette Sprocket Removal & Installation......................................................................................................34 Freewheel Sprocket Removal & Installation...................................................................................................36 Single-Speed Removal.......................................................................................................................................38 Sprocket Inspection & Cleaning........................................................................................................................38 Fixed Gear Sprockets.........................................................................................................................................39 CHAPTER 4 — HUBS Hub Bearing Service: Adjustable Cup-and-Cone Type..................................................................................42 Disassembly...................................................................................................................................................43 Parts Inspection............................................................................................................................................44 Assembly.......................................................................................................................................................44 Hub Adjustment............................................................................................................................................45 Oversized Axle Service: Campagnolo® and Shimano®.............................................................................46 Hub Adjustment: Solid Axle Cup-and-cone..............................................................................................46 www.parktool.com v OPENING TABLE OF CONTENTS Freehub Removal & Installation........................................................................................................................47 Cartridge Bearing Hubs.....................................................................................................................................47 Mavic® Hub (Level 1 Type)...........................................................................................................................48 CHAPTER 5 — WHEEL TRUING Wheel Truing Overview.....................................................................................................................................54 Lateral True....................................................................................................................................................55 Radial True.....................................................................................................................................................55 Rim Centering (Dish)....................................................................................................................................55 Tension...........................................................................................................................................................56 Truing Procedures..............................................................................................................................................56 Lateral Truing..........................................................................................................................................57 Radial Truing............................................................................................................................................58 Wheel Centering (Dishing)....................................................................................................................58 Spoke Tension.........................................................................................................................................60 Broken & Damaged Spoke Replacement..........................................................................................................61 Wheel Wear, Damage, & Repair........................................................................................................................62 CHAPTER 6 — PEDALS Pedal Removal....................................................................................................................................................66 Pedal Installation................................................................................................................................................66 Damage to Crank Pedal Threads......................................................................................................................67 Pedal Bearing Service........................................................................................................................................67 CHAPTER 7 — CRANKSETS Crank Types.........................................................................................................................................................70 Crank Removal & Installation.............................................................................................................................71 Self-Extracting Crank Systems....................................................................................................................71 Three-Piece Cranks: Octalink®, ISIS Drive, Square Spindle, Power Spline™, and Power Drive™.........72 Two-Piece Compression Slotted Cranks: Shimano® and FSA®...............................................................73 Two-Piece Cranks Using Wave Washer: FSA® MegaExo® and SRAM® GXP® PF...................................74 Two-Piece Self-Extracting Cranks: Truvativ®, SRAM® GXP®...................................................................74 Two-Piece Pre-Load Adjuster Nut Cranks: Truvativ®, SRAM® BB30 I-A, and FSA® Afterburner™.....75 Campagnolo® and Fulcrum® Ultra-Torque® Cranks..................................................................................75 Campagnolo® Power Torque™ Cranks........................................................................................................76 Specialized® S-Works® Cranks.....................................................................................................................77 Bottom Bracket System Types.........................................................................................................................78 Threaded Standards.....................................................................................................................................78 Non-Threaded Standards.............................................................................................................................78 BB86 and BB92........................................................................................................................................78 BB90 and BB95........................................................................................................................................78 BB30..........................................................................................................................................................79 PF30..........................................................................................................................................................79 386EVO.....................................................................................................................................................79 BBright®....................................................................................................................................................79 Bottom Bracket Bearing Service for Non-Threaded Shells...........................................................................79 BB30 Bearings...............................................................................................................................................80 PF30 and BBright® Bearings.........................................................................................................................81 BB30 and PF30 Adaptors for non-BB30 Cranks.......................................................................................81 BB86, BB90, BB92, BB95 Bearings (Shimano® PF and GXP® PF)...........................................................82 Campagnolo® Ultra-Torque® and Fulcrum® Bearings...............................................................................83 Campagnolo® Power Torque™ Bearings....................................................................................................84 Campagnolo® BB30 Bearing Adaptors......................................................................................................84 Bottom Bracket Bearing Service for Threaded Shells...................................................................................85 Threaded Bottom Bracket with Two-Piece Cranks..................................................................................87 Threaded Cartridge Bottom Brackets: ISIS Drive, Octalink®, and Square Spindle..............................87 vi TABLE OF CONTENTS OPENING Threaded Adjustable Bottom Bracket Bearings.......................................................................................89 Bottom Bracket Removal.......................................................................................................................89 Bottom Bracket Installation..................................................................................................................90 Bottom Bracket Adjustment.................................................................................................................90 Chainrings.............................................................................................................................................................91 Chainring Replacement................................................................................................................................92 Chainring Wear and Damage......................................................................................................................92 CHAPTER 8 — CHAINS Chain Sizing for Derailleur Bikes......................................................................................................................96 Chain Sizing with Chain Retention System...............................................................................................98 Chain Removal...............................................................................................................................................98 New Chain Installation on Derailleur Bikes.....................................................................................................99 Shimano® and FSA® Chains with Connecting Rivet..................................................................................99 Campagnolo® 10-Speed Chain...................................................................................................................100 Campagnolo® 11-Speed Chain.....................................................................................................................101 Setting or Peening of 11-Speed Coupling Rivet.................................................................................101 Chains with Master Link..............................................................................................................................102 Chain with Reusable Rivets........................................................................................................................102 Tight Link Repair.........................................................................................................................................103 Chain Sizing and Tension Adjustment: Two-Sprocket Bicycles.................................................................104 Chain Tension: Two-Sprocket Bikes.........................................................................................................104 Chain Tension: Two-Sprocket Bikes with Chain Tension Idler Device.................................................105 Chain Tension: Eccentric Bottom Brackets on Tandem and Single-Speeds.......................................105 Tandem Crank Synchronizing..............................................................................................................105 Chain Wear and Damage..................................................................................................................................106 Chain Cleaning...................................................................................................................................................107 Chain Lubrication..............................................................................................................................................107 CHAPTER 9 — DERAILLEUR SYSTEMS Cable System......................................................................................................................................................110 Cable Housing Length and Routing............................................................................................................111 Cable Lubrication.........................................................................................................................................112 Shift Levers.........................................................................................................................................................112 Flat Bar Trigger Shifters..............................................................................................................................113 Twist Grip Shifters.......................................................................................................................................114 Above-the-Bar Shifters...............................................................................................................................114 Drop Bar Integral Brake/Shift Levers........................................................................................................115 Campagnolo®..........................................................................................................................................116 Down Tube Shifters......................................................................................................................................116 Bar End Shifters............................................................................................................................................116 Front Derailleur..................................................................................................................................................116 Derailleur Cable Attachment......................................................................................................................118 Height Adjustment.......................................................................................................................................118 Rotational Adjustment................................................................................................................................119 Limit Screw Adjustment.............................................................................................................................120 L-Limit Screw.........................................................................................................................................120 H-Limit screw..........................................................................................................................................121 Front Index Adjustment: Three-Chainring Bikes.....................................................................................122 Front Index Adjustment: Two-Chainring Bikes.......................................................................................122 Front Derailleur Performance....................................................................................................................122 Shimano® Front Derailleur FD-9000.........................................................................................................122 Shimano® FD-9000 Front Derailleur Adjustment.............................................................................123 Rear Derailleur...................................................................................................................................................124 Derailleur Capacity and Maximum Sprocket Size...................................................................................124 Derailleur Installation..................................................................................................................................125 www.parktool.com vii OPENING TABLE OF CONTENTS Derailleur Cable Attachment......................................................................................................................125 Limit Screw Adjustment.............................................................................................................................125 H-Limit Screw.........................................................................................................................................126 L-Limit Screw.........................................................................................................................................126 B-Screw Adjustment..............................................................................................................................127 Index Adjustment........................................................................................................................................127 Shimano® Rapid Rise™ Derailleurs.......................................................................................................129 Clutch System Rear Derailleurs.................................................................................................................129 Chainline.............................................................................................................................................................129 Derailleur Hanger Alignment & Repair...........................................................................................................130 Derailleur Wear & Service.................................................................................................................................132 Troubleshooting Derailleur Systems.........................................................................................................133 Electronic Shift Derailleurs...............................................................................................................................133 Shimano® Di2® Intelligent System.............................................................................................................133 Shifters....................................................................................................................................................133 Di2® Battery............................................................................................................................................134 Front Derailleur......................................................................................................................................135 Rear Derailleur.......................................................................................................................................136 Crash Feature.........................................................................................................................................137 Campagnolo® EPS® Derailleurs: Super Record®, Record®, and Athena®...............................................137 EPS® Rear Derailleur Adjustment........................................................................................................138 EPS® Front Derailleur Adjustment.......................................................................................................139 EPS® Derailleur Ride-Setting...............................................................................................................140 Crash Mode and Ride Home Mode.......................................................................................................141 EPS® Battery and Charging Unit...........................................................................................................141 Troubleshooting.....................................................................................................................................141 CHAPTER 10 — INTERNAL GEAR SYSTEMS SRAM® DualDrive™............................................................................................................................................144 SRAM® I-Motion® 9.............................................................................................................................................145 Shimano® Nexus Inter-7®, Nexus Inter-8®, & Alfine® Hubs...........................................................................146 CHAPTER 11 — CALIPER DISC BRAKE SYSTEMS Caliper Types.....................................................................................................................................................150 Brake Pads..........................................................................................................................................................150 Disc Brake Rotors...............................................................................................................................................151 Hydraulic Brake Systems..................................................................................................................................152 Hydraulic Brake Levers...............................................................................................................................152 Hydraulic Disc Calipers...............................................................................................................................152 Hydraulic Brake Caliper Alignment.....................................................................................................153 Hydraulic Brake Fluid Service.........................................................................................................................154 Shimano® Hydraulic Brakes........................................................................................................................154 Brake Pad Removal and Replacement................................................................................................154 Brake Bleeding.......................................................................................................................................155 Magura® Hydraulic Caliper Brakes............................................................................................................156 Hayes® Hydraulic Caliper Brakes...............................................................................................................157 Avid® Hydraulic Caliper Brakes.................................................................................................................158 Tektro® Hydraulic Caliper Brakes...............................................................................................................161 Mechanical Disc Brake Systems......................................................................................................................162 Brake Lever..................................................................................................................................................163 Caliper Pad Alignment and Clearance......................................................................................................163 Shimano® Mechanical Disc Brakes.............................................................................................................164 Tektro® Mechanical Disc Brakes................................................................................................................164 Hayes® Mechanical Disc Brakes.................................................................................................................164 Avid® Mechanical Disc Brakes....................................................................................................................164 viii TABLE OF CONTENTS OPENING CHAPTER 12 — CALIPER RIM BRAKE SYSTEMS Brake Levers......................................................................................................................................................170 Upright Handlebar Brake Levers...............................................................................................................170 Drop Bar Brake Levers................................................................................................................................170 Cable System......................................................................................................................................................171 Cable Lubrication.........................................................................................................................................172 Cable Housing Length.................................................................................................................................172 Caliper Rim Brakes............................................................................................................................................173 Brake Pads....................................................................................................................................................174 Brake Pad Alignment............................................................................................................................174 Vertical Height Alignment....................................................................................................................175 Tangential Alignment............................................................................................................................175 Vertical Face Alignment.......................................................................................................................175 Pad Toe....................................................................................................................................................175 Linear-Pull Caliper Adjustment.................................................................................................................176 Cantilever Caliper Adjustment..................................................................................................................177 Dual-Pivot Caliper Adjustment..................................................................................................................180 Side-Pull Caliper Adjustment......................................................................................................................181 CHAPTER 13 — HANDLEBARS, STEMS, SADDLES, & SEATPOSTS Upright Handlebars...........................................................................................................................................184 Bar Grips.......................................................................................................................................................184 Drop Style Handlebars (Road Bars)................................................................................................................185 Clip-On and Aero Handlebars....................................................................................................................185 Stems..................................................................................................................................................................186 Quill Stems...................................................................................................................................................186 Threadless Stems.........................................................................................................................................187 Saddles................................................................................................................................................................188 Seatposts............................................................................................................................................................189 CHAPTER 14 — HEADSETS Headset Types...................................................................................................................................................194 Headset Service.................................................................................................................................................195 Threadless Headset Service.......................................................................................................................196 Threadless Headset Adjustment...............................................................................................................198 Threaded Headset Service.........................................................................................................................198 Threaded Headset Adjustment..................................................................................................................199 Headset Replacement & Installation.............................................................................................................200 Headset Stack Height................................................................................................................................200 Pressed Headset Removal.........................................................................................................................200 Pressed Headset Installation.....................................................................................................................201 Fork Crown Race Installation....................................................................................................................202 Fork Steering Column Sizing..........................................................................................................................202 Threadless Steering Columns...................................................................................................................203 Star Nut and Compression Plug Installation.....................................................................................204 Threaded Steering Columns......................................................................................................................205 CHAPTER 15 — FRAME & FORK Frame Components..........................................................................................................................................208 Fork...............................................................................................................................................................208 Head Tube....................................................................................................................................................208 Top Tube......................................................................................................................................................208 Down Tube...................................................................................................................................................208 Seat Tube.....................................................................................................................................................208 Chain Stay....................................................................................................................................................208 Seat Stay......................................................................................................................................................209 www.parktool.com ix OPENING TABLE OF CONTENTS Dropouts......................................................................................................................................................209 Bottom Bracket Shell.................................................................................................................................209 Swing Arm...................................................................................................................................................209 Frame Construction & Service........................................................................................................................209 Steel..............................................................................................................................................................209 Aluminium....................................................................................................................................................210 Titanium........................................................................................................................................................210 Carbon Fiber................................................................................................................................................210 CHAPTER 16 — SUSPENSION Spring Systems..................................................................................................................................................214 Helical Compression Springs.....................................................................................................................214 Elastomer and Rubber Springs..................................................................................................................214 Air (Gas) Springs.........................................................................................................................................214 Shocks (Dampers).............................................................................................................................................215 Suspension Linkages.........................................................................................................................................215 Service & Tuning................................................................................................................................................216 Spring Preload.............................................................................................................................................216 Fluid Viscosity..............................................................................................................................................216 Valving..........................................................................................................................................................216 Linkage..........................................................................................................................................................216 Cyclist Posture.............................................................................................................................................216 Tire Contact..................................................................................................................................................216 CHAPTER 17 — ON-RIDE REPAIR Tool Choices......................................................................................................................................................220 Repair Procedures............................................................................................................................................220 Flat Tire........................................................................................................................................................220 Cut or Ripped Tire......................................................................................................................................220 Broken Spoke..............................................................................................................................................220 Dented Rim..................................................................................................................................................220 Broken Chains.............................................................................................................................................220 Chain Suck...................................................................................................................................................220 Twisted Chain...............................................................................................................................................221 Squeaky and Noisy Chain...........................................................................................................................221 Rear Derailleur Shifting into the Spokes or Frame.................................................................................221 Derailleur Not Indexing Properly...............................................................................................................221 Broken Derailleur Body, Cage, or Hanger.................................................................................................221 Missing Derailleur Pulleys...........................................................................................................................221 Front Derailleur Cage Bent or Twisted.....................................................................................................221 Crank Falling Off..........................................................................................................................................221 Pedals Falling Off........................................................................................................................................222 Bent Crank...................................................................................................................................................222 Bottom Bracket Loose or Falling Apart...................................................................................................222 Broken Derailleur Cable.............................................................................................................................222 Broken Brake Cable....................................................................................................................................222 Twisted or Bent Handlebars or Stem.......................................................................................................222 Bent Frame or Fork.....................................................................................................................................222 Bent Saddle or Seat Post...........................................................................................................................222 APPENDICES A–E — REFERENCE MATERIALS A: Tool List.........................................................................................................................................................226 B: Glossary.........................................................................................................................................................228 C: Torque Recommendations..........................................................................................................................233 Torque Conversion Scale...........................................................................................................................237 D: Headset Standards.......................................................................................................................................238 E: Bike Map........................................................................................................................................................240 x

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Big Blue Book of Bicycle Repair PDF

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Author:C. Calvin Jones, Bill Gibson (editor)
Publication Year:2013
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