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Summary of Contents for Zipp ZR1
- Page 1 ZR1 and ZR1 SL Hubs SERVICE MANUAL GEN.0000000006195 Rev G* © 2025 SRAM, LLC...
- Page 2 SAFETY FIRST! We care about YOU. Please, always wear your safety glasses and protective gloves when servicing Zipp products. Protect yourself! Wear your safety gear!
- Page 3 W h e e l B u i l d i n g a n d R i m S p e c i f i c a t i o n s For spoke lengths, tension, rim ERD, hub dimensions, and technical specifications, please refer the Zipp Wheel and Hub Specifications document available at www.sram.com/service.
- Page 4 R e c o m m e n d e d S e r v i c e I n t e r v a l s Regular service is required to keep your Zipp product working at peak performance. Follow this maintenance schedule and perform routine maintenence as noted below.
- Page 5 TABLE OF CONTENTS PART PREPARATION ...............................................3 SERVICE PROCEDURES ..............................................3 WHEEL BUILDING AND RIM SPECIFICATIONS ..............................3 REAR HUB SERVICE ......................................6 COMPONENT REMOVAL ...............................................6 PARTS, TOOLS, AND SUPPLIES ..........................................6 EXPLODED VIEW - REAR HUB ............................................. 7 REAR HUB END CAPS ..............................................7 REAR HUB BEARING REMOVAL ..........................................8 DRIVER CLEANING - COIL SPRING DRIVER ......................................
- Page 6 • Wheel Bearing Kit Front/Rear for Zipp ZR1 Hubs, 61903 • Axle and spindle vise inserts - Park Tool AV-4 or AV-5 • Wheel Freehub Kit - XDR Driver Kit - 12x142 / QR - Zipp ZR1 (optional) • Blind hole bearing puller set •...
- Page 7 E x p l o d e d V i e w - R e a r H u b Zipp 6903/61903 (ZR1) or 6803/61803 (ZR1 SL or ZR1 SL SP) Hub Bearing Hub Shell Zipp 6903/61903 (ZR1) Hub Bearing...
- Page 8 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 9 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 10 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 11 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 12 D r i v e r C l e a n i n g - C o i l S p r i n g D r i v e r N OT ICE Service of an 11 speed, Microspline, and N3W driver is identical to the XDR driver service shown below.
- Page 13 Using a grease syringe, apply a small amount of SRAM Butter grease to the pawl slots. SRAM Butter Grease Insert a coil spring into one of the spring slots, then install a pawl into the pawl slot. Note: The springs and pawls are symmetrical and can be installed in any orientation.
- Page 14 D r i v e r C l e a n i n g - L e a f S p r i n g D r i v e r N OT ICE Service of an 11 speed driver is identical to the XDR driver service shown below. Inspect the rubber seal for damage.
- Page 15 Using a grease syringe, apply a small amount of SRAM Butter grease to the pawl slots. SRAM Butter Grease Insert the leaf springs into the spring slots. Orient the long edge of each spring along the inside of the carrier so that it points clockwise. Pick Insert the pawls into the pawl slots.
- Page 16 17 Slotted Attachment Clean the driver bearing bores with a shop towel and cotton swabs. Place the driver on flat surface, outboard side up. Insert a new Zipp 6803/61803 driver bearing into the outboard side of the driver body, with the black seal facing outward.
- Page 17 6803 26x17 Place the driver on a flat surface, inboard side up. Insert a new Zipp 6803/61803 driver bearing into the inboard side of the driver body, with the black seal facing outward.
- Page 18 ZR1: Install a new Zipp 6903/61903 hub bearing into the non-drive side of the hub with the black seal facing outward. ZR1 SL, ZR1 SL SP: Install a new Zipp 6803/61803 hub bearing into the non-drive side of the hub with the black seal facing outward.
- Page 19 Install the non-drive side end of the axle through the hub and into the SRAM 6903 tool. ZR1 SL, ZR1 SL SP: Insert a SRAM 6803 tool into the non-drive side bearing bore. Install the non-drive side end of the axle through the hub and into the SRAM 6803 tool.
- Page 20 Use a rubber mallet to tap the drive side of the axle until the raised step on the axle contacts the bearing Remove the tool from the axle. Plastic Mallet Apply grease to the ratchet ring (a) and the seal surface (b) of the hub shell.
- Page 21 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. The wave spring is crucial to hub performance and must be installed onto the axle.
- Page 22 (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 23 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 (ZR1) or 6803/61803 (ZR1 SL or ZR1 SL SP) Hub Bearing Hub Shell Zipp 6903/61903 (ZR1) or 6803/61803 (ZR1 SL or ZR1 SL SP)
- Page 24 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 25 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 26 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 27 ZR1: Install a new Zipp 6903/61903 hub bearing into the drive side of the hub with the black seal facing outward. ZR1 SL and ZR1 SL SP: Install a new Zipp 6803/61803 hub bearing into the drive side of the hub with the black seal facing outward.
- Page 28 ZR1: Slide a 6903 30x17 onto the Press Tool threaded rod. ZR1 SL, ZR1 SL SP: Slide a 6803 26x17 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 or 6803 26x17 tool onto the threaded rod.
- Page 29 Install the wave spring onto the non-drive side of the axle. You may need a screwdriver or similar 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 30 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 U.S.A. The Netherlands...
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