SRAM DualDrive 27 Technical Manual
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SRAM DualDrive 27 Technical Manual

SRAM DualDrive 27 Technical Manual

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2006
TECHNICAL MANUAL
GEAR HUB SYSTEMS
ENGLISH

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Summary of Contents for SRAM DualDrive 27

  • Page 1 2006 TECHNICAL MANUAL GEAR HUB SYSTEMS ENGLISH...
  • Page 2 This Technical Manual is intended for bicycle factories and qualified bicycles dealers only! © Copyright SRAM Corporation 2005 Publ. No. 8053 E Information may be enhanced without prior notice. Released August 2005 SRAM Technical Documentation, Schweinfurt/Germany Campagnolo, EXA-Drive are trademarks of Campagnolo S.R.L., Italia.

  • Page 3: Table Of Contents

    GEAR HUB SYSTEMS G E A R H U B S A N D S H I F T E R S DualDrive SRAM S7 SRAM P5 SRAM P5 Cargo CARGO CARGO SRAM T3 Sparc G E A R H U B S Y S T E M C O M P O N E N T S...
  • Page 4 Technical Manual 2006...

  • Page 5: Dualdrive

    Extra gedichtet Tandem compatib. — — — Disc brake compatib. — — SRAM / Magura / Hayes / Shimano Weight 970 g 1640 g (complete with i-BRAKE) 985 g Hub Shell Aluminum, silver anodized Aluminum, silver anodized Aluminum, silver anodized...
  • Page 6 DUALDRIVE TECHNICAL DATA / ASSEMBLY REQUIREMENTS DualDrive 27 DualDrive 24 Speeds 9 / 8 9 / 8 Shifter Compatibility DualDrive 27 DualDrive 24 Cage Length Short, 75 mm Short, 75 mm Sprocket, max. 34 Teeth 32 Teeth Sprocket, min. 11 Teeth...
  • Page 7 Chainline directions. DualDrive 27 / 24: 45 mm • Note also, that different stem lengths and cable stop positions effects cable housing length. Ask for recommended DualDrive-cranks at: Truvativ http://www.truvativ.com...
  • Page 8 Handlebar grips driver profile. Screw lock nut (3) with provide safety function. cassette tool (Park Tool FR-5 or SRAM For this reason, they should be Part No. 4624 411 010), tightening torque: mounted in such a way as to make sure 40 Nm (350 in.lbs.).
  • Page 9 DUALDRIVE ASSEMBLY D E R A I L L E U R A D J U S T M E N T Index shifting adjustment: Limit screw adjustment: • Check that the chain and the rear • View the rear derailleur and pulleys from derailleur are in the smallest cog position.
  • Page 10 • Mount ball retainer (16), pawl carrier cassette tool (Park Tool FR-5 or (10) and washer (9). SRAM Part No. 4624 411 010). • Press pawls against spring force and • Remove cassette and spoke protector mount gear ring (8) with smaller disc.
  • Page 11 (gear position “8/9“). Lubrication of parts: • Look for cable head entry (3, Fig. 5). Use only SRAM grease (Part No. 0369 135 200/ • Push cable up/out of the shifter and ...201) and standard bicycle oil. discard.
  • Page 12 DUALDRIVE MAINTENANCE T R O U B L E S H O O T I N G Problem Cause Remedy Hub: Shifting difficulties Incorrect gear setting Adjust shifting system, oil control cable, check that cable stop is fastened correctly. Pedals are carried forward Bearings set too tight Re-adjust bearing when freewheeling...
  • Page 13 DUALDRIVE MAINTENANCE Technical Manual 2006...
  • Page 14 Technical Manual 2006...

  • Page 15: Sram S7

    SRAM S7: Version with Coaster Brake see page 54. Caution: 1/2 OLD • SRAM S7 hubs are not suitable for min. 13.5 tandems, trademen’s delivery bicycles and similar. • SRAM S7 with coaster brake resp. i-BRAKE are „DIN Plus City“ certified.
  • Page 16 SRAM S7 TECHNICAL DATA / ASSEMBLY REQUIREMENTS SRAM Grip 7 Shifter Type Twist Shifter ❘ ❘ ❘ ❘ ❘ ❘ ❘ Cable Length 1450 mm 1550 mm 1650 mm 1750 mm 1850 mm 1950 mm 2050 mm 2150 mm Gear Indication...
  • Page 17 SRAM S7 ASSEMBLY • Push on Clickbox (2, Fig. 5) to the stop on Advice: the hub axle. The guiding rib (4, Fig. 8) of • If a different protective bracket (1, Fig. 5) the locating sleeve thereby engages in is used the thickness of the attachment the slot on the housing.
  • Page 18 (31), ball retainer (34), gear ring (30) pull the Clickbox off the axle. and coupling gear (29). • Disengage the red location sleeve (43) SRAM S7 mounting aid Part No. 65 0324 103 000 • Compress spring (26) and remove thrust and pull it off.
  • Page 19 SRAM S7 MAINTENANCE • Clamp axle, end with groove for Clickbox • Insert ball retainer (4) (balls are facing facing upwards. upwards) into lever cone (2): the 3 re- • Fit plastic profile washer (22) with its cesses have to engage into the retaining large diameter upwards.
  • Page 20 SRAM S7 MAINTENANCE C A B L E C H A N G E Advice: • If you want to remove the Clickbox from Dismantling shifter cable: the axle end for changing the cable, do • Place shifter in gear position “1“.
  • Page 21 (15 – 20 Nm) Chain is over- Reduce Lubrication of parts: tensioned chain tension Use only SRAM grease (Part No. 0369 135 200/ Hub locks Brake seg- Wash out ...201) and standard bicycle oil. ments has hub sleeve, when •...
  • Page 22 Technical Manual 2006...

  • Page 23: Sram P5

    Version SRAM P5 Cargo: Version with coaster brake see page 29. Caution: 1/2 OLD • SRAM P5 hubs are not suitable for min. 13.5 tandems, trademen’s delivery bicycles and similar. • SRAM P5 with coaster brake resp. i-BRAKE are „DIN Plus City“ certified.
  • Page 24 SRAM P5 TECHNICAL DATA / ASSEMBLY REQUIREMENTS SRAM Grip 5 Shifter Type Twist Shifter ❘ ❘ ❘ ❘ ❘ ❘ ❘ Cable Length 1450 mm 1550 mm 1650 mm 1750 mm 1850 mm 1950 mm 2150 mm 2350 mm Gear Indication...
  • Page 25 SRAM P5 ASSEMBLY Advice: • Turn locating sleeve on the axle until the • If a different protective bracket (1, Fig. 5) guiding rib (4) is facing roughly upwards. is used the thickness of the attachment • Place shifter in gear position “2“.
  • Page 26 • Withdraw gear ring (27) and coupling pull the Clickbox off the axle. gear (26) and then remove cover (29) • Disengage the red location sleeve (40) SRAM P5 mounting aid from the coupling gear. Part No. 65 0524 300 000 and pull it off.
  • Page 27 SRAM P5 MAINTENANCE • Locate bolt (17), then spring (16) in the • Fit lever cone onto hub shell: the retain- axle and screw in grub screw (15) until ing lugs of the lever cone have to en- it is flush with the axle.
  • Page 28 SRAM P5 MAINTENANCE C A B L E C H A N G E Advice: • If you want to remove the Clickbox from Dismantling shifter cable: the axle end for changing the cable, do • Place shifter in gear position “1“.
  • Page 29 (15 – 20 Nm) Chain is over- Reduce Lubrication of parts: tensioned chain tension Use only SRAM grease (Part No. 0369 135 200/ Hub locks Brake seg- Wash out ...201) and standard bicycle oil. when ments has hub sleeve, •...
  • Page 30 Technical Manual 2006...

  • Page 31: Cargo

    Version with coaster brake 1/2 OLD min. 13.5 Caution: • The SRAM P5 Cargo is suitable for tandems, trademen’s delivery bicycles and similar. An additional external rear brake is necessary due to the high load. • SRAM P5 Cargo with coaster brake is „DIN Plus City“...
  • Page 32 SRAM P5 CARGO TECHNICAL DATA / ASSEMBLY REQUIREMENTS SRAM Grip 5 Shifter Type Twist Shifter ❘ ❘ ❘ ❘ ❘ ❘ ❘ Cable Length 1450 mm 1550 mm 1650 mm 1750 mm 1850 mm 1950 mm 2150 mm 2350 mm...
  • Page 33 SRAM P5 CARGO ASSEMBLY CARGO CARGO Advice: • Push locating sleeve (3) with guiding rib • If a different protective bracket (1, Fig. 5) (4) to the front onto the hub axle – making is used the thickness of the attachment sure that the internal lug (5) is guided in plate must be max.
  • Page 34 • Withdraw gear ring (27) and coupling pull the Clickbox off the axle. gear (26) and then remove cover (29) • Disengage the red location sleeve (40) SRAM P5 mounting aid from the coupling gear. Part No. 65 0524 300 000 and pull it off.
  • Page 35 SRAM P5 CARGO MAINTENANCE CARGO CARGO • Locate bolt (17), then spring (16) in the • Fit lever cone onto hub shell: the retain- axle and screw in grub screw (15) until ing lugs of the lever cone have to en- it is flush with the axle.
  • Page 36 SRAM P5 CARGO MAINTENANCE C A B L E C H A N G E Advice: • If you want to remove the Clickbox from Dismantling shifter cable: the axle end for changing the cable, do • Place shifter in gear position “1“.
  • Page 37 (15 – 20 Nm) Chain is over- Reduce Lubrication of parts: tensioned chain tension Use only SRAM grease (Part No. 0369 135 200/ Hub locks Brake seg- Wash out ...201) and standard bicycle oil. when ments has hub sleeve, •...
  • Page 38 Technical Manual 2006...

  • Page 39: Sram T3

    TECHNICAL DATA / ASSEMBLY REQUIREMENTS Version with Coaster Brake i-BRAKE for SRAM T3: see page 54. 1/2 OLD Caution: SRAM T3 hubs are not suitable for tandems, trademen’s delivery bicycles and similar. Cycle frame: • Dropouts must be parallel. Ø 7.3 •...
  • Page 40 SRAM T3 ASSEMBLY A S S E M B L Y H U B Caution: • Only install additional axle attachments • Lace the wheel as normal. See spoke (e.g. struts) between nut and retaining length table. washer. • Place the dust cap (1, Fig. 1) and •...
  • Page 41 SRAM T3 ASSEMBLY A S S E M B L Y S H I F T E R A D J U S T M E N T • Slide shifter (1, Fig. 7) onto handlebar. • Place the shifter in gear position "3".
  • Page 42 SRAM T3 MAINTENANCE R E M O V E W H E E L Coaster brake / MH 3115 • Apply fingertip pressure onto the metal key of locating sleeve to release it from the pull rod. • Remove deflection pulley.
  • Page 43 SRAM T3 MAINTENANCE R E A S S E M B L Y H U B C A B L E C H A N G E see Fig. 1 / 2 / 3 Dismantling shifter cable: • Use only new cable and compression- Lubrication see “...
  • Page 44 – tighten up locknut with a Lubrication of parts: torque of 15 – 20 Nm (133 – 177 in.lbs.). Use only SRAM grease (Part No. 0369 135 200/ ...201) and standard bicycle oil. • To lubricate the bearing points on...
  • Page 45 SRAM T3 MAINTENANCE T R O U B L E S H O O T I N G Problem Cause Remedy Shifting difficulties Incorrect gear setting Adjust shifting system, oil control cable, check that cable stop is fastened correctly. Pedals are carried forward...
  • Page 46 Technical Manual 2006...

  • Page 47: Sparc

    SPARC TECHNICAL DATA / ASSEMBLY REQUIREMENTS 33.5 Caution: Not suitable for tandems, trades- men’s delivery bicycles and similar. Cycle frame: • Dropouts must be parallel. 12.5 67.5 49.5 • Slot width at rear dropout max. 10,5 mm. Sparc hub 16,8V Sparc Shifter Shifter Type Twist Shifter...
  • Page 48 Use only rim „Rigida 20x406 59 (L 01 12 E)“ Fixed grips provide an axial safety (or contact SRAM). function. For this reason, they should be All spoke heads must be positioned at the mounted in such a way as to make sure outside of the spoke flange.
  • Page 49 All batteries are shipped with an additional completely / right. documentation about the last charging date within our SRAM facility. This documentation of battery charging also allows you to fill in the dates of additional charge actions that you would need to perform if the batteries stay in your warehouse over a longer period of time.
  • Page 50 SPARC MAINTENANCE R E M O V E W H E E L D I S M A N T L I N G G E A R H U B • Pull the remote control cable plug off see Fig. 1 the hub.
  • Page 51 SPARC MAINTENANCE R E A S S E M B L Y H U B C A B L E C H A N G E see Fig. 1 Dismantling shifter cable: • Place shifter in gear position “1“. Lubrication see “ LUBRICATION GEAR HUB “, •...
  • Page 52 Pay attention of correct cable routing (Fig. 9). Lubrication of parts: • Mount battery box cover by the 4 screws. Use only SRAM grease (Part No. 0369 135 200/ • Pull both Quick Releases outward and open closed ...201) and standard bicycle oil.
  • Page 53 All batteries are shipped with an additional documentation about the last charging The LED will glow red during charging, date within our SRAM facility. This changing to green when the battery is fully documentation of battery charging also recharged.
  • Page 54 Technical Manual 2006...

  • Page 55: I-Brake

    • The i-BRAKE is not useable for tandems, transport bicycles, and similar loads. • The i-BRAKEs must go on the left side viewed from behind the rear of the bicycle. • SRAM i-BRAKEs are „DIN Plus City“ certified. 33.6 17.4 16.6 i-BRAKE System for Front Hubs...
  • Page 56 ➔ ➔ ➔ Performance Level Comfort / City / Trekking DD 27 / 24 i-BRAKE comp. SRAM S7 i-BRAKE comp. SRAM P5 i-BRAKE comp. SRAM T3 i-BRAKE compatible Over Locknut Dim., OLD 135 mm 135 mm 126 mm 118 mm Length, L 182.6 mm...
  • Page 57 i-BRAKE AND COMPATIBLE HUBS TECHNICAL DATA / ASSEMBLY REQUIREMENTS F R O N T F O R K H A N D B R A K E L E V E R R E Q U I R E M E N T S C O M P A T I B I L I T Y Strength: •...
  • Page 58 i-BRAKE AND COMPATIBLE HUBS ASSEMBLY Fastening wheel / solid axle: A S S E M B L Y • Fit washers resp. retaining washers (3, • Lace the wheel as normal. 3-cross only. Fig. 4) to the axle ends. Caution: •...
  • Page 59 i-BRAKE AND COMPATIBLE HUBS ASSEMBLY C O N N E C T I N G i - B R A K E A D J U S T M E N T i - B R A K E • Screw adjusting screw (2, Fig 7) with •...
  • Page 60 i-BRAKE AND COMPATIBLE HUBS MAINTENANCE R E M O V I N G T H E W H E E L M O U N T I N G T H E W H E E L Caution: • Placing the wheel in fork ends. After cycling, the brake and hub should Front wheel: not be touched.
  • Page 61 i-BRAKE AND COMPATIBLE HUBS MAINTENANCE Attaching a wheel with quick release: C O N N E C T I N G T H E B R A K E • Only use quick release devices with the • Fit cable stop (1, Fig. 7) with adjusting correct length.
  • Page 62 i-BRAKE AND COMPATIBLE HUBS MAINTENANCE B R A K E C A B L E C H A N G E • Attach link (10, Fig. 11) to brake lever (11). Caution: Disassembling the brake cable : Curved side of the link should be out- •...
  • Page 63 i-BRAKE AND COMPATIBLE HUBS MAINTENANCE A D J U S T M E N T i - B R A K E M A I N T E N A N C E Readjust the brake if the hand brake lever Under normal circumstances, your i-BRAKE can be pulled close to the handlebar (for is maintenance-free and well-protected...
  • Page 64 Technical Manual 2006...

  • Page 65: Front Hubs With Drum Brake

    SRAM VT 5000 / VT 3000 TECHNICAL DATA / ASSEMBLY REQUIREMENTS Typ VT 5000 21,5 Version D Front fork: The strength must be such that with a maximum torque of 300 Nm (2700 in.lbs.) on the wheel no residual deformation can occur on the front fork.
  • Page 66 SRAM VT 5000 / VT 3000 ASSEMBLY F I T T I N G W H E E L I N A D J U S T M E N T D R U M B R A K E F R O N T F O R K •...
  • Page 67 SRAM VT 5000 / VT 3000 MAINTENANCE M A I N T E N A N C E Advice: Caution: • Do not use high-pressure water when The brake anchor plate must be replaced • Bearings is sufficiently lubricated and cleaning the hub (e.g.

  • Page 68: I-Light

    i-LIGHT TECHNICAL DATA / ASSEMBLY REQUIREMENTS i-LIGHT Hub Dynamo Model D324s D330s D330b D730s D730s-ib and D724s-ib ➔ ➔ ➔ Version Standard i-BRAKE compatible Output 2.4 Watt 3.0 Watt 3.0 Watt 3.0 Watt 3,0 W (D724s-ib 2.4 Watt) Voltage ➔ ➔...
  • Page 69 i-LIGHT ASSEMBLY / MAINTENANCE C O N N E C T I N G C A B L E S M A I N T E N A N C E • Do not disassemble the internal hub me- • Recommended wire specifications: chanism.

  • Page 70: Power Chain

    POWER CHAINS TECHNICAL DATA / ASSEMBLY REQUIREMENTS PC 991 PC991 Hollow Pin PC991 Cross Step PC 971 PC 951 Application MTB / Road MTB / Road MTB / Road MTB / Road MTB / Road Max. No. of sprockets 9 only 9 only 9 only 9 only...
  • Page 71 Power Link connecting links: Caution: Closing chain with 3pcs Connection Link: • Use only for SRAM chains, use as specified, • Fit the shortened chain, bring the two to avoid material damage or the rider to ends together and connect with the fall off his bicycle resulting in injury.
  • Page 72 NOTICES Technical Manual 2006...
  • Page 73 NOTICES Technical Manual 2006...

  • Page 74: Support

    SRAM ORIGINAL PARTS You can find an extensive spare parts Caution: program in SRAM’s Spare Parts List Installation of parts and accessories not originally intended Model Year 2006 · Publ. Number 8506. could result in less than optimal performance and/or injury.
  • Page 76 WORLD HEADQUARTERS SRAM Corporation 1333 North Kingsbury, 4th floor Chicago, Illinois 60622 U.S.A. phone: +1-312-664-8800 fax: +1-312-664-8826 EUROPEAN HEADQUARTERS SRAM Europe Basicweg 12-D 3821 BR Amersfoort The Netherlands phone: +31-33-450-6060 fax: +31-33-457-0200 ASIAN HEADQUARTERS SRAM Taiwan No. 1598-8 Chung Shan Road...

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