Zipp ZR1 Service Manual
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Zipp ZR1 Service Manual

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ZR1 Hubs
SERVICE MANUAL
GEN.0000000006195 Rev A © 2020 SRAM, LLC

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Summary of Contents for Zipp ZR1

  • Page 1 ZR1 Hubs SERVICE MANUAL GEN.0000000006195 Rev A © 2020 SRAM, LLC...
  • Page 2 (2) years after original purchase of the product. SRAM warrants all Zipp MOTO Wheels and Rims to be free from defects in materials or workmanship for the lifetime of the product. SRAM warrants all non-electronic Zipp branded bicycle components, Model Year 2021 or newer, to be free from defects in materials or workmanship for the lifetime of the product.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS FRONT HUB SERVICE ......................................6 PARTS, TOOLS, AND SUPPLIES ..........................................6 EXPLODED VIEW - FRONT HUB ..........................................7 FRONT HUB END CAPS ..............................................7 FRONT HUB BEARING REMOVAL ..........................................8 FRONT HUB BEARING INSTALLATION ........................................11 REAR HUB SERVICE ......................................14 PARTS, TOOLS, AND SUPPLIES ..........................................
  • Page 4 SAFETY FIRST! We care about YOU. Please, always wear your safety glasses and protective gloves when servicing SRAM® products. Protect yourself! Wear your safety gear!
  • Page 5 Z i p p S e r v i c e We recommend that you have your Zipp compononets serviced by a qualified bicycle mechanic. Servicing Zipp compononets requires the use of specialized tools. Failure to follow the procedures outlined in this service manual may cause damage to your component and void the warranty.

  • Page 6: Front Hub Service

    (not pictured). For additional information about Zipp wheels and hubs, user manuals are available at www.Zipp.com. P a r t s , T o o l s , a n d S u p p l i e s...

  • Page 7: Exploded View - Front Hub

    E x p l o d e d V i e w - F r o n t H u b End Cap Wave Spring Zipp 6903/61903 Hub Bearing Hub Shell Zipp 6903/61903 Hub Bearing Axle End Cap F r o n t H u b E n d C a p s The end cap identification number is laser etched onto the end cap.

  • Page 8: Front Hub Bearing Removal

    F r o n t H u b B e a r i n g R e m o v a l Procedures are the same for rim brake and disc brake rear hubs. Disc brake hub pictured. Insert the Park Tool AV-4 or AV-5 Axle and Spindle Vise Insert tool into a vise.
  • Page 9 Spray isopropyl alcohol onto the axle and clean it with a shop towel. NOTI CE To prevent damage to the hub surfaces, do not use acetone or similar products to clean parts. Isopropyl Alcohol Insert the 17 mm Bearing Puller slotted attachment through the drive side bearing.
  • Page 10 Insert the 17 mm Bearing Puller slotted attachment through the non- drive side bearing. Align the slotted attachment with the bottom of the bearing, and expand it inside the bearing. Do not over tighten the slotted attachment. For more detailed assembly and usage, see the bearing puller manufacturer's instructions.

  • Page 11: Front Hub Bearing Installation

    F r o n t H u b B e a r i n g I n s t a l l a t i o n Install a new Zipp 6903/61903 hub bearing into the drive side of the hub with the black seal facing outward.
  • Page 12 Slide a 6903 30x17 tool onto the Press Tool threaded rod. Insert the threaded rod through the bearing on the non-drive side of the hub shell. Slide a second 6903 30x17 tool onto the threaded rod. Thread the Press Tool handle onto the threaded rod. Turn the handle clockwise to press the bearing into the hub until it is hand-tight.
  • Page 13 Install the wave spring onto the non-drive side of the axle. You may need a tool to press the wave spring against the bearing face. NOTI CE Do not scratch the axle when using a tool to install the wave spring. Apply grease to the following locations on the drive side and non-drive side axle end: •...

  • Page 14: Rear Hub Service

    • Blind hole bearing puller set (optional) • 17 mm slotted attachment • Wheel Freehub Kit - 11 Speed Driver Body Kit - 12x142 / QR - Zipp ZR1 • Wheels Manufacturing Press-1 Sealed Bearing Press Kit or similar (optional) •...

  • Page 15: Exploded View - Rear Hub

    E x p l o d e d V i e w - R e a r H u b Zipp 6903/61903 Hub Bearing Hub Shell Zipp 6903/61903 Hub Bearing End Cap Wave Spring Axle Ratchet Ring End Cap Driver Body...

  • Page 16: Rear Hub Bearing Removal

    R e a r H u b B e a r i n g R e m o v a l Procedures are the same for rim brake and disc brake rear hubs. Disc brake hub pictured. Insert the Park Tool AV-4 or AV-5 Axle and Spindle Vise Insert tool into a vise.
  • Page 17 Place the axle in between flat aluminum vise soft jaws, drive side down, with the bearing resting on top of the soft jaws. Make sure the axle bearing step does not contact the soft jaws. Use a plastic mallet to gently tap on the top of the non-drive end of the axle until it is dislodged from the bearing.
  • Page 18 Insert the 17 mm Bearing Puller slotted attachment through the drive side bearing. Align the slotted attachment with the bottom of the bearing, and expand it inside the bearing. Do not over tighten the slotted attachment. For more detailed assembly and usage, see the bearing puller manufacturer's instructions.
  • Page 19 Clean the bearing bores with a shop towel. Isopropyl Alcohol Shop Towel Clean the ratchet ring and hub internals with isopropyl alcohol, a shop towel, and cotton swabs. Do not remove the ratchet ring. Rear Hub Bearing Removal...

  • Page 20: Rear Hub Bearing Installation

    Install a new bearing onto the longer, non-drive side of the axle, with the blue bearing seal facing away from the raised step on the axle. Insert the non-drive side of the axle into a Zipp 61903 tool, with the flat, non-stepped end of the tool against the bearing.
  • Page 21 Install the non-drive side end of the axle through the hub and into the SRAM 6903 tool. SRAM 6903 Install a Zipp 61903 tool onto the drive side end of the axle with the stepped end of the tool contacting the bearing. Zipp 61903 Stepped End...
  • Page 22 If a brush is used to apply grease, confirm there are no loose bristles in the grease or on the part. Zipp Cognition or SRAM Butter Grease Apply grease to the last 10-15mm of the axle. Installation of the driver body will distribute the grease on the entire hub axle.
  • Page 23 Install the wave spring onto the non-drive side of the axle. You may need a tool to press the wave spring against the bearing face. NOTI CE Do not scratch the axle when using a tool to install the wave spring. Apply grease to the following locations on the drive side and non-drive side axle ends: •...
  • Page 24 PowerTap®, Qollector®, Quarq®, RacerMate®, Reba®, Rock Shox®, Ruktion®, Service Course®, ShockWiz®, SID®, Single Digit®, Speed Dial®, Speed Weaponry®, Spinscan®, SRAM®, SRAM APEX®, SRAM EAGLE®, SRAM FORCE®, SRAM RED®, SRAM RIVAL®, SRAM VIA®, Stylo®, Torpedo®, Truvativ®, TyreWiz®, Varicrank®, Velotron®, X0®, X01®, X-SYNC®, XX1®, Zed tech®, ZIPP® These are registered logos of SRAM, LLC: These are trademarks of SRAM, LLC: 10K™, 1X™, 202™, 30™, 35™, 302™, 303™, 404™, 454™, 808™, 858™, 3ZERO MOTO™...
  • Page 25 ASIAN HEADQUARTERS WORLD HEADQUARTERS EUROPEAN HEADQUARTERS SRAM Taiwan SRAM LLC SRAM Europe No. 1598-8 Chung Shan Road 1000 W. Fulton Market, 4th Floor Paasbosweg 14-16 Shen Kang Hsiang, Taichung City Chicago, Illinois 60607 3862ZS Nijkerk Taiwan R.O.C. U.S.A. Niederlande...

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