Bontrager 231793 Service Manual
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Bontrager 231793 Service Manual

Bontrager hub instructions 231793
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HUB INSTRUCTIONS
PART NUMBER 231793
SERVICE MANUAL 2003

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Summary of Contents for Bontrager 231793

  • Page 1 HUB INSTRUCTIONS PART NUMBER 231793 SERVICE MANUAL 2003...

  • Page 2: Table Of Contents

    Please note: Many sections of this manual must be read in their entirety before performing procedures. In some cases, revised or updated information may be available on the Bontrager wheelworks website at www.bontrager.com. If you cannot find the information you need to service Bontrager wheels, please contact a technical service representative.

  • Page 3: Front Hubs- Loose Ball

    Front hubs- Loose ball Bontrager Superstock, Superstock Disc, Select ATB, Select ATB Disc, Select Road, and Select Hybrid front wheels; plus Bontrager Comp II front hub Recommended tools 13mm cone wrench 17mm cone wrench Small slot screwdriver Hammer (soft faced) DISASSEMBLY Hub parts and names are referenced on next page.

  • Page 4: Superstock, Select Atb/Disc/Road Parts List

    Axle 1999 Bontrager Comp II O.L.D..........100 mm Spoke hole quantity .

  • Page 5: Front Hubs- Semi-Cartridge; Formula Fcm

    Front hubs- Loose ball, semi-cartridge; Formula FCM '99, 2000, 2001 Bontrager Race, Race Disk front wheels Recommended tools 13mm cone wrench 17mm cone wrench Adjustable wrench Hammer (soft faced) Small slot screwdriver DISASSEMBLY Hub parts and names are referenced on next page.

  • Page 6: 1999/2000/2001 Race/Race Disk Parts List

    Rotor BCD ......... . 44.0 mm 2003 Bontrager Service Manual...

  • Page 7: Front Hubs- Cartridge Bearing, Alloy Axle

    Front hubs- Cartridge bearing, alloy axle 2002/2003 Bontrager Race, Race Disc front wheels Recommended tools 17mm cone wrench Special hook spanner Hammer and broad punch Bearing removal tool Bearing press DISASSEMBLY Hub parts and names are referenced on next page.

  • Page 8: Front Hubs 2002 Race/Disk Parts

    Exploded view and Parts list Model year Model for 99/00/01 99/00/01 99/00/01 99/00/01/02 Hayes, RST 99/00 99/00/01/02 2003 Bontrager Service Manual Parts included (qty) TCG Part # 3(2) 4(2) 6, 4(2) 1(2) Not shown Not shown Not shown, see Fig. 4C...

  • Page 9: Cartridge Bearing, Threaded Alloy Axle

    Front hubs- Cartridge bearing, threaded alloy axle 2002/2003 Bontrager Race Lite Road front wheels Recommended tools 17mm cone wrench (2) Hammer and broad punch Bearing press DISASSEMBLY Hub parts and names are referenced on next page. Remove the axle 1. Remove one of the thread- ed axle end caps (Fig.
  • Page 10 Q.R. rod outer diameter ....... . . 5 mm Exploded view and Parts list Model year Model for Parts included (qty) 2(2) 3(2) 1(2), 2(2), 3(2), 5 1(2) 2003 Bontrager Service Manual TCG Part # 221468 73335 221470 221467 221469...

  • Page 11: Freehub Body Running Change

    Freehub body information (non-DT Swiss) FREEHUB BODY RUNNING CHANGE Bontrager rear hubs use an unique freehub body that in some cases has encountered removal issues. In these cases, a high amount of torque is necessary to remove or install the freehub body attachment bolt.

  • Page 12: Loose Ball

    Rear hubs- Loose ball Bontrager Superstock, Superstock Disc, Select ATB, Select Road, Select Hybrid wheels, plus Bontrager Comp II rear hub Recommended tools (2) 15mm cone wrench Adjustable wrench Hammer (soft faced) Small slot screwdriver DISASSEMBLY Hub parts and names are referenced on next page.

  • Page 13: Bontrager Superstock/Atb/Disc/Hybrid Parts

    Cassette body attachment ..... .running change 2002/2003 Bontrager Superstock Disc, Select ATB Disc O.L.D..........135 mm Spoke hole quantity .

  • Page 14: Loose Ball, Double Sealed (Formula Fcm)

    Rear hubs- Loose ball, double sealed (Formula FCM) '99, 2000, 2001 Bontrager Race and Race Disk rear wheels Recommended tools (2) 15mm cone wrench 12mm allen wrench Adjustable wrench Hammer Small slot screwdriver DISASSEMBLY Fig. 1E Hub parts and names are referenced on next page.
  • Page 15 Cassette body type ......Shimano 8/9 speed Cassette body attachment ..... .running change 2003 Bontrager Service Manual Note: Rotor adapter for disc hubs not shown Rotor spacing varies by model year, see details below.

  • Page 16: Cartridge Bearing

    Rear hub- Cartridge bearing 2002/2003 Bontrager Race, Race Disc rear wheels Recommended tools 15mm cone wrench 19mm cone wrench Small slot screwdriver Hammer (soft faced) Cartridge bearing remover Bearing press DISASSEMBLY Hub parts and names are referenced on next page.

  • Page 17: Rear Hub 2002/2003 Race/Race Parts

    Model for Parts included (qty) 01/02 1(2), 2(2), 3(2), 4, 7, 9 01/02 8, 9, removal tool DT Comp/Onyx (not shown) DT Pro/240 (not shown) Not shown 2003 Bontrager Service Manual TCG Part # 211351 73335 211339 211416 211415 211338...

  • Page 18: Comp Front

    If you have further questions about these hubs regarding technical information, sup- port, or warranty, they should be directed to Bontrager Technical Support via phone or on the Bontrager web site at www.bontrager.com. In the event of improper servicing of the hubs, Bontrager has the right to refuse any warranty.
  • Page 19 Comp front hub Bontrager Race Modified, Race Modified Disc front wheel, 2003 Race Lite ATB, Race Lite ATB Disc front wheel Recommended tools Comp bearing press, front hub End cap Short bearing press 17mm cone wrench Multi-purpose grease Bench vise...
  • Page 20 Pos Description Description End cap Axle kit V-seal Bearing Bearing Axle Hub shell Exploded view and Parts list Model year Model for 99/00/01 99/00/01 2003 Bontrager Service Manual Parts included (qty) TCG Part # 1(2), 2(2), 3(2), 4 70361 211349...

  • Page 21: Comp Rear

    Comp rear hub Bontrager Race Modified rear wheel, 2003 Race Lite ATB, 2002/2003 Race Lite Road rear wheel Recommended tools Long bearing press Short bearing press 17mm cone wrench Multi-purpose grease Bench vise Axle vise Hammer, soft faced Thin-bladed slot screwdriver DISASSEMBLY Fig.
  • Page 22 If the pawls do not click into place, the spring may not have been cor- rectly installed, or there could be too much grease in the freewheel. 2003 Bontrager Service Manual Pos Description End nut V-seal, left...
  • Page 23 7(2), 8, 12, 13, 14 5, 6, 10 1, 2, 3, 4, 15, 16, 17 3, 9, 11 10, 11 3 (6000, 12/26 x 8mm) 11 (6900, 10/22 x 6mm) 2003 Bontrager Service Manual 70358 72678 70359 70360 72677 72679...
  • Page 24 If you have further questions about these hubs regarding technical information, sup- port, or warranty, they should be directed to Bontrager Technical Support via phone or on the Bontrager web site at www.bontrager.com. In the event of improper servicing of the hubs, Bontrager has the right to refuse any warranty.

  • Page 25: Pro Front

    Pro front hub 2002 Bontrager Race Lite ATB, Race Lite 29, Race X Lite and Race X Lite Carbon front wheels, 2003 Race X Lite Aero Recommended tools Long bearing press Short bearing press Multi-purpose grease Bench vise Axle vise...
  • Page 26 00/01/02/03 End cap kit 00/01/02/03 Exploded view and Parts list Parts included (qty) TCG Part # 1(2), 2(2), 3(2), 4 3(6802, 15/24 x 5mm) 1(2) 2003 Bontrager Service Manual Pos Description End nut V-seal Bearing Axle Hub shell 70357 211342...

  • Page 27: Pro Rear

    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...
  • Page 28 If the ratchets do not catch, there could be too much grease 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. 2003 Bontrager Service Manual Spacer Spring Fig.
  • Page 29 Parts included (qty) 8, 9(2), 10(2), 11 8, 9(2), 10(2), 11 9(2), 10(2) 1, 2, 3(2), 4, 13 1, 2, 3(2), 4, 13 3 (6902, 15/28 x 7mm) 2003 Bontrager Service Manual Pos Description End cap, left V-seal Bearing Axle Spacer...
  • Page 30 Q.R. rod outer diameter ....... . . 5 mm Exploded view and Parts list- 2000-2001 Parts included (qty) 2003 Bontrager Service Manual Pos Description End cap...

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