SRAM DualDrive 24 Technical Manual

2006
TECHNICAL MANUAL
GEAR HUB SYSTEMS
ENGLISH
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.
Grilon is a trademark of EMS-Chemie AG, Switzerland.
MAGURA is a trademark of MAGURA GmbH & Co., Germany.
HAYES is a trademark of der HAYES BRAKE Inc., U.S.A.
Shimano, HG, IG are trademarks of Shimano Inc., Japan.
CONTENTS
GEAR HUB SYSTEMS
GEAR HUBS AND SHIFTERS
CARGO
DualDrive
3
SRAM S7
13
SRAM P5
21
SRAM P5 Cargo
29
SRAM T3
37
Sparc
45
GEAR HUB SYSTEM COMPONENTS
i-BRAKE
53
Front Hubs with Drum Brake
63
i-LIGHT
66
Power Chain
68
SUPPORT
✆
Technical Manual 2006
Who to call / Spare Parts
72
1
2
Technical Manual 2006
DUALDRIVE
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
182.6
135
67.5
4.6/4.6/9.5
Chainline
33
18
67
i-BRAKE for DualDrive:
see page 54.
Caution:
Not suitable for tandems, trademen’s
delivery bicycles and similar.
Cycle frame:
The strength must be such that with a maximum braking torque of 250 Nm (2200 in.lbs.)
on the rear wheel no residual deformation
can occur on the rear structure.
DualDrive · Without brake
Version (Speeds)
Brake
Spoke
Axle
Over Locknut Dim.
DualDrive 27
DualDrive 24
Adaptor for i-BRAKE
DualDrive 27
135 mm
135 mm
182.6 mm
182.6 mm
Ends Diameter
FG 10,5
FG 10,5
FG 10,5
Holes
36 or 28
36
36 or 32
Hole Diameter
Hole Ref. ø
2.6 mm (28 holes also available in 2,8 mm) 2.6 mm
2.6 mm
67 mm
67 mm
67 mm
33 mm / 18 mm
575 % (27spd)
33 mm / 18 mm
541 % (24spd)
575 % (27spd)
136 %
➔
➔
➔
➔
Chainline
45 mm
45 mm
Crankset
33 / 38 Teeth
Totally hub
186 %
Speed 1
73 %
Speed 2
100 %
Speed 3
Cogset
DualDrive 24
Adaptor for Disc brake
182.6 mm
Totally
Ratio
DualDrive 24
Without brake
DualDrive · for Disc brake
135 mm
Length
Flange Dist. to 1/2 OLD
33 mm / 18 mm
541 % (24spd)
➔
575 % (27spd)
➔
➔
➔
➔
42 mm
541 % (24spd)
➔
11-34 Teeth
11-32 Teeth
11-34 Teeth
11-32 Teeth
11-34 Teeth
12-32 Teeth
Cogset Compatib.
DualDrive 27
DualDrive 24
DualDrive 27
DualDrive 24
DualDrive 27
DualDrive 24
Shifter Compatib.
DualDrive 27
DualDrive 24
DualDrive 27
DualDrive 24
DualDrive 27
DualDrive 24
Extra gedichtet
➔
➔
Tandem compatib.
—
—
—
Disc brake compatib.
—
—
SRAM / Magura / Hayes / Shimano
970 g
1640 g (complete with i-BRAKE)
985 g
Aluminum, silver anodized
Aluminum, silver anodized
Aluminum, silver anodized
Composite
Composite
Composite
Sealing
Weight
Finish
H
U
B
S
DualDrive 27
DualDrive · for i-BRAKE
Hub Shell
Shifting device
Technical Manual 2006
3
DUALDRIVE
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
DualDrive 27
9/8
9/8
Shifter Compatibility
Speeds
DualDrive 27
DualDrive 24
Cage Length
Short, 75 mm
Short, 75 mm
Sprocket, max.
34 Teeth
32 Teeth
Sprocket, min.
11 Teeth
11 Teeth
Exchangeable / Bushing
Exchangeable / Bushing
Pulleys
●
●
258 g
265 g
Upper Knuckle
Aluminum, forged
Aluminum, forged
Lower Knuckle
Grilon Composite silver
Grilon Composite silver
Direct Mount
Weight
Design
D
E
R
A
I
L
L
E
U
R
S
Outer Link
Aluminum
Grilon Composite silver
Inner Link
Steel / Zinc coat
Steel / Zinc coat
Outer Cage
Aluminum, forged
Grilon Composite black
Inner Cage
Grilon Composite black
Grilon Composite black
Aluminum
Steel
DualDrive 27
DualDrive 24
34 Teeth
32 Teeth
Hanger Bolt
Largest Cog
Speeds
Cogs
Spacers
Chain compatib.
Weight
Cogs
Design
C
A
S
S
E
T
T
E
S
Screws
Finish
Version
Compat.
8
11/13/15/17/20/23/26/30/34
11/12/14/16/18/21/26/32
Dark Gray
Black
9spd, HG/IG/PC comp.
8spd, HG/IG/PC comp.
410 g
280 g
SAPH 440 Stahl
Steel / Zinc Coat
➔
➔
Chrome, matt
Chrome
DualDrive single sided shifter
Trigger shifter
Twist shifter
DualDrive 27
DualDrive 27
DualDrive 27
DualDrive 24
see Price list
see Price list
DualDrive 24
Trigger shifter
Twist shifter
Rechte Lenkerseite
➔
left and right
left and right
Gear Hub
DualDrive 27
DualDrive 24
DualDrive 27
DualDrive 27
DualDrive 24
Derailleur
Shifter Type
Arrangement
1400 mm / 1500 mm / 1600 mm / 1700 mm / 2100 mm
SRS Twistring-Thumbshifter-Combo (2in1)
DualDrive 27
DualDrive 24
DualDrive 27
DualDrive 27
DualDrive 24
Gear Indication Der.
Window
Printed
Window
Printed
Printed
Riding Mode Indic.
Printed
Printed
Window
Printed
Printed
None
➔
➔
➔
Indexing
Indexing
Indexing
Indexing
➔
➔
➔
➔
Barrel Adj. Gear Hub
Barrel Adj. Derailleur
Clamping Diameter
Indexing
22.3 mm
22.3 mm
Handlebar, Straight Area
Minimum length = 150 mm
N/A
N/A
Cable Routing, Gear Hub
Continuous housing (preassembled)
Open or continuous
Continuous housing (preassembled)
Open or continuous
Open or continuous
Open or continuous
N/A
N/A
Stainless steel
Stainless steel
Cable Routing, Der.
Design
4
9
➔
➔
➔
Clickbox Cable
S
H
I
F
T
E
R
S
DualDrive 24
22.3 mm
Weight
N/A
Cables
Stainless steel
Housing
Grip Cover
➔
➔
Glass filled PA – Silver painted
Aluminum
Glass filled PA
Thermoplastic elastomer
—
Thermoplastic elastomer
Aluminum
Aluminum
Composite
Composite
Clamping Collar
Aluminum
Clickbox
Composite
➔
➔
➔
➔
➔
➔
➔
Technical Manual 2006
DUALDRIVE
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
Cable routing
1
1
DualDrive 27 / DualDrive 24
Hub cable
Along chainstay only
Derailleur cable
Along chainstay only
Cable attachement
see Fig. 1
Hub
Cable housing Attachement points Cable stops
Continuous
1 / 2 / 3 / 4 (see Fig. 1)
Derailleur
Continuous
1 / 2 / 3 / 4 / 5 (see Fig. 1) —
Open
—
2
3
5
4
2
—
1 /5 (Fig. 1)
CABLE HOUSING FOR DERAILLEUR
Rear cable stop position
Rear housing length
200
180
160
L (mm)
140
R2
L
A
90°
X
3
15
45
13
25
32
60
14
100
90
100
X (mm)
X
R1
120
110
120
130
Length X min. 90 mm.
Cable stop below or beside chainstay.
Example: Distance X = 100 mm ➔ cable
housing length L = 140 – 165 mm.
CABLE HOUSING
CRANKSET
• Use only new high quality cable and
com-pressionless cable housing with
end caps.
• When choosing cable housing lengths,
be sure to allow enough housing for an
extreme turn of the handlebars in both
directions.
• Note also, that different stem lengths
and cable stop positions effects cable
housing length.
Bicycle without chain case:
Use a chain guard disc (at the outer
surface of chainring, material no resin)
Use only standard chainring version (nonshifting teeth).
Chainline
DualDrive 27 / 24: 45 mm
Ask for recommended DualDrive-cranks at:
Truvativ
http://www.truvativ.com
DROPOUT
Only flat and no off-set versions.
Dropout thickness: 7 – 8 mm.
Vertical or horizontal dropout slot.
Dropouts must be parallel.
4
CHAIN GUIDE FORK
Dropout dimensions: see Fig. 2 and 3.
1
ø max. 220 mm
Technical Manual 2006
L
X
A
R1
R2
28
30
6–10
7.5 –10
25˚–30˚
25˚–30˚
8.5 max
8.5 max
11.5 –13.5
11.5 –13.5
It prevents chain from jumping off front
chainring, is bolted inside the chain
case (1, Fig. 4).
HANDLEBAR
Diameter: 22.3 mm.
Minimum length of straight area for shifter:
150 mm.
Check the compatibility of intended
handlebars and brake levers.
5
DUALDRIVE
ASSEMBLY
1
1
2
3
2
2
1
0.2 Nm
1.8 in.lbs.
3
A S S E M B LY H U B
A S S E M B LY S H I F T E R
• Lace the wheel as normal.
• Place spoke protector disc (1, Fig. 1) on
shoulder of hub, fit cassette (2) onto
driver profile. Screw lock nut (3) with
cassette tool (Park Tool FR-5 or SRAM
Part No. 4624 411 010), tightening torque:
40 Nm (350 in.lbs.).
• Screw shifting rod (1, Fig. 2) into the hub
axle and tighten it with 0.2 Nm (1.8 in.lbs.).
• Fit wheel in dropouts.
• Place retaining washers (Fig. 2) on both
sides of the axle – the serrations must
bear against the dropout.
– Version for horizontal dropouts (2): the
lug must engage in the dropout slot.
– Version for vertical dropouts (3):
without lug.
• Tighten up axle nuts. Tightening
torque 30 – 40 Nm (266 – 350 in.lbs.).
Caution:
• Never use lubricants or solvents to
install handlebar grips. Handlebar grips
provide safety function.
For this reason, they should be
mounted in such a way as to make sure
they do not slip off handlebar!
• Always check the front and rear brake
levers for proper operation.
If there is interference between shifters
and brake levers, re-adjust lever and
shifter placement.
A S S E M B LY D E R A I L L E U R
3
Advice:
Check the rear derailleur hanger
alignment. A bent rear derailleur hanger
will result in inaccurate index shifting.
• Attach the rear derailleur to the frame’s
rear derailleur hanger using a 5 mm hex
head wrench (Fig. 3).
• Check that the b-adjust washer tab
(b-adjust screw at DualDrive 24) is clear
of the rear derailleur dropout tab (Fig. 4).
• Tighten the 5 mm hex hanger bolt to
8 – 10 Nm (70 – 85 in.lbs.).
5 mm
8 – 10 Nm
70 – 85 in.lbs.
CHAIN LENGTH
4
DualDrive 24
DualDrive 27
5
(4 Links)
6
1
3
• Bypassing the rear derailleur, run the
chain around the largest cog/large
chainring combination (Fig. 5).
– For rear suspension frames, position
the rear suspension for the greatest
chain length required.
• Add 4 LINKS or 3 link + Connecting Link
to this length for proper chain length.
DualDrive single sided shifter:
• Slide the shifter (1, Fig. 6) onto the
handlebar.
• Rotate the shifter until the barrel
adjuster (4) is beneath (but out of the
way of) the brake lever.
• Tighten the 3 mm hex clamp bolt (2) to
1.9 – 2.5 Nm (17 – 22 in.lbs.).
• Slide the handlebar grip (3) onto the
handlebar.
DualDrive Trigger shifter (without picture):
• Slide shifter and brake lever onto handlebar. Either component can be mounted
first, depending on personal preference.
• Slide the handlebar grip onto the
handlebar.
• Tighten the 5 mm hex clamp bolt to 5 Nm
(44 in.lbs.).
DualDrive Twist shifter (without picture):
• Slide the shifter onto the handlebar.
• Tighten the 3 mm hex clamp bolt to
1.9 Nm (17 in.lbs.).
• Slide the plastic washer onto the handlebar.
• Slide the stationary grip onto the handlebar.
INSTALLING CLICKBOX
• Fit the cable and avoid small radius.
• Cable attachment points see Page 5 /
Fig. 1.
Cable housing must be movable inside
attachment.
• Place shift lever in uphill riding mode /
gear position „1“ (Fig. 7).
• Push Clickbox button down (Fig. 7).
• Push on Clickbox to the stop on the hub
axle.
• Press button up.
• Place thumb shift lever in standard
riding mode / gear position „2“ (Fig. 8).
• Match up the marks in the Clickbox
viewing window by twisting the
barrel adjuster (Fig. 8).
2
4
6
Technical Manual 2006
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:
7
Limit screw adjustment:
• View the rear derailleur and pulleys from
behind the rear of the bicycle (Fig. 9).
• Using a small screwdriver, turn the limit
screw marked ’H’ on the outer link of the
derailleur to align the upper guide pulley
center with the outboard edge of the
smallest cog – clockwise moves the
guide pulley inboard towards the wheel.
• While turning the crank, push the rear
derailleur towards the larger cogs by hand.
• Align the upper guide pulley under the
largest cog, center to center, by turning
the limit screw marked ’L’ on the outer
link – clockwise moves the guide pulley
outboard away from the spokes.
8
Chain gap adjustment:
Chain gap is the distance between the upper
guide pulley and the cog the chain is riding
on. Optimal chain gap is small enough to
allow quick, efficient shifts to and from any
cog, but large enough to allow smooth
shifts to and from the largest cog.
• Shift chain to the small chain ring.
• While turning the crank, push the rear
derailleur inboard by hand to the largest
cog.
• Hold the derailleur in this position while
making the following adjustment.
• Use a 3 mm hex wrench, turn the b-adjust
screw until the chain gap equals
approximately 6 mm (1/4”) from tip of the
cog to tip of upper guide pulley (Fig. 10).
9
– Turn the b-adjust screw clockwise to
increase the chain gap.
– Turn the b-adjust screw counterclockwise to decrease the chain gap.
• Check that the chain and the rear
derailleur are in the smallest cog position.
• Measure and cut the rear piece of
cable housing. Make sure that it is not
too short or long (see page 5 for figure
and chart).
• Rotate the twist shifter until the largest
number and gear indication tab/dash
line up.
• Turn the twist shifter barrel adjuster (4,
Fig. 6) clockwise fully into the shifter,
then turn counterclockwise 1 full turn.
• Feed the shifter cable through the rear
derailleur cable housing, stops and
cable guides.
• Feed the rear derailleur cable through
the rear derailleur-housing stop and
through the cable guide on the fin.
• Pull the cable tight and position it
under the cable anchor washer (Fig. 11).
• Tighten the 5 mm hex cable anchor bolt
to 4 – 5 Nm (35 – 45 in.lbs.).
• Rapidly shift the chain and derailleur up
and down the cassette several times. If the
cable slips repeat the two former steps.
• Shift the chain to the smallest cog.
• While pedaling, move the shifter up one
detent.
– If the chain hesitates or does not shift
to the second cog, increase the cable
tension by turning the shifter barrel
adjuster counterclockwise.
– If the chain shifts beyond the second cog,
decrease the cable tension by turning
the shifter barrel adjuster clockwise.
• Repeat the two former steps until
shifting and cable tension is accurate.
• While turning the crank, shift the chain
up and down the cassette and chain
rings several times to ensure that your
derailleur is indexing smoothly.
Advice:
Do not use the b-adjust screw to adjust
the rear derailleur to act as a chaintensioning device or to prevent chain
suck. This increases the chain gap
causing poor shifting performance.
10
11
6 mm
( 1/ 4" )
3 mm
Technical Manual 2006
5 mm
4 – 5 Nm
35 – 45 in.lbs.
7
DUALDRIVE
MAINTENANCE
1
11
4
19
3
18
2
1
17
10
9
16
15
8
20
7
5
6
13
14
12
2
REMOVE WHEEL
R E A S S E M B LY H U B
• Rotate the twist shifter to the highest
gear position (speed “8/9“).
• Place shift lever in uphill riding mode /
gear position “1“ (Fig. 2).
• Push Clickbox button down (Fig. 2).
• Pull Clickbox off the axle.
• Screw out shifting rod (20, Fig. 1).
• Dismantle wheel.
see Fig. 1
DISMANTLING HUB
see Figure 1
3
Lubricate the shifting
joints regularly
When disassembled –
use a waterproof grease
8
• Dismantle cassette lock nut with
cassette tool (Park Tool FR-5 or
SRAM Part No. 4624 411 010).
• Remove cassette and spoke protector
disc.
• Clamp hub with the two axle flats
(driverside facing downwards).
• Remove cap (1), unscrew lock nut (2),
screwed adjusting cone (3) and hub
shell (4).
• Dismantle retaining washer (5), remove
washer (6), planetary gear carrier (7)
and gear ring (8).
• Squeeze down pawls and remove pawl
carrier (10) with washer (9) and ball retainer (16).
• Clamp other axle end (longer axle
thread).
• Dismantle lock nut (19) and cone (18).
• Remove driver (17), compression spring
(15), coupling gear clutch (14) and shift
sleeve (12) with bushing (13).
Lubrication see “LUBRICATION GEAR HUB“.
• Clamp axle with the two axle flats
(longer axle thread).
• Fit shift sleeve (12), bushing (13) with small
diameter first, compression spring (15),
coupling gear clutch (14), and driver (17).
• Mount cone (18) and lock nut (19).
Tightening torque 15 – 20 Nm
(133 – 177 in.lbs.).
• Clamp other axle end (driver side facing
downwards).
• Mount ball retainer (16), pawl carrier
(10) and washer (9).
• Press pawls against spring force and
mount gear ring (8) with smaller
diameter first.
Rotate gear ring counterclockwise until
pawls engage inside the gear ring.
• Fit planetary gear carrier (7) and
washer (6).
• Press and rotate planetary gear carrier
until axle groove is visible.
• Mount retaining washer (5).
• Mount hub shell (4), obligatory with a
slight counterclockwise turn.
• Mount adjusting cone (3).
• Screw on counternut (2), adjust bearings
to be nearly free of play and tighten with
a torque of 15 – 20 Nm (133 – 177 in.lbs.).
• Mount cap (1).
• Unclamp hub and mount shifing rod (20)
with a torque of 0,2 Nm (1.8 in.lbs.).
Mount spoke protector disc and
cassette.
Technical Manual 2006
DUALDRIVE
MAINTENANCE
4
LUBRICATION
GEAR HUB
2
Hubs are provided with permanent
lubrication and maintenance-free under
normal conditions.
1
Cleaning of parts:
• All parts – except the planetary gear
carrier and the driver – can be degreased
in a cleaning bath.
• Planetary gear carrier and driver only
need to be cleaned on the outside with
a brush so as not to degrease the
bearings.
Lubrication of parts:
Use only SRAM grease (Part No. 0369 135 200/
...201) and standard bicycle oil.
• To lubricate the bearing points on
the planetary gear sets, position the
planetary gear carrier pawls upside and
apply 2 – 3 drops of oil to the bearing
bolts – at the same time turning the
planetary gears so that the bearing
points are completely wet. Oil axle slot,
apply a thin coating of grease to the
outside.
• Grease the teeth of the axle (fill the
gaps).
• Apply grease to gear ring teeth but just
oil the pawls and pawl teeth.
• Oil pawl carrier pawls and pawl
bearings.
• Oil cartridge bearing.
• Regrease ball retainers, line ball
bearing running tracks with grease.
5
3
4
6
Caution:
Do not use high-pressure water when
cleaning the gear hub (e.g. strong water
jets, high-pressure cleaners etc.) –
if water penetrates it could lead to
functional problems.
5
7
LUBRICATION
REAR DERAILLEUR
6
7
11
12
• Do not use solvants or corrosive
materials to clean the components.
• Lubricate the shifting joints regularly
(Fig. 3).
• Grease any cable guides (e.g. beneath
the bottom bracket).
CABLE CHANGE
Advice:
Use only new high quality cable and
compressionless cable housing with
end caps.
Twist shifter (rear derailleur):
• Detach the cable from the derailleur.
• Cut cable off 15 cm (6") from shifter
barrel adjuster. Discard old cable and
cable housing.
• Remove screw (1, Fig. 4) and pull open
the cable change sleeve (2).
• Rotate the shifter fully in the cable
release direction (gear position “8/9“).
• Look for cable head entry (3, Fig. 5).
• Push cable up/out of the shifter and
discard.
• Feed the new cable through the cable
entry and out the barrel adjuster (4).
• Pull cable snug.
• Install cable change sleeve (2, Fig. 4).
• Feed the cable through the new cable
housing and frame stops.
• Attach cable to the derailleur.
• Adjust indexing per derailleur instruction.
Thumb shift lever (gear hub):
• Place thumb shift lever (5, Fig. 6) in
uphill riding mode / gear position “1“.
• Remove Clickbox from the axle (see
page 8).
• Snap open Clickbox-cover (8, Fig. 7)
as shown.
• Unscrew clamping bolt (9).
• Remove the shifter escape hatch (6, Fig. 6).
• Remove and discard the old cable.
• Feed the new cable through the cable
entry (7, Fig. 6), the new calbe housing
and pull the cable snug.
• Attach the escape hatch.
• Pull the cable tight and position it under
the cable anchor washer (10, Fig. 7).
• Tighten the 4 mm hex cable anchor bolt
to 2.5 – 4 Nm (22 – 35 in.lbs.).
• Cut off cable end to 1 – 2 mm.
• Snap in Clickbox-cover (8).
• Install Clickbox (see page 6).
• Place thumb shift lever in standard
riding mode / gear position “2“.
• Match up the marks in the Clickbox
viewing window (11, Fig. 7) by turning
the barrel adjuster (12).
10
8
9
4 mm
2.5 – 4 Nm
22 – 35 in.lbs.
Technical Manual 2006
9
DUALDRIVE
MAINTENANCE
TROUBLESHOOTING
Problem
Hub:
Shifting difficulties
Cause
Remedy
Incorrect gear setting
Pedals are carried forward
when freewheeling
Bearings set too tight
Loose lock nuts
Adjust shifting system, oil
control cable, check that cable
stop is fastened correctly.
Re-adjust bearing
Tighten lock nuts (15 – 20 Nm,
133 – 177 in.lbs.)
Bend / reorient dropouts
Rear frame dropouts non
parallel
Derailleur:
Chain jumps from smallest
sprocket to frame dropout.
High gear limit screw is not
adjusted properly.
Difficult or impossible to
shift chain onto smallest
sprocket.
High gear limit screw is not
adjusted properly.
Chain jumps over largest
sprocket and falls between
the spokes and largest
sprocket or inner cage
plate scrapes on spokes.
Delayed shifting.
Low gear limit screw is not
adjusted properly.
Rough shifting behavior.
Chain jumps two gears on
small sprocket
Delayed shifting onto
larger sprocket
Delayed shifting onto
smaller sprocket
Rear derailleur or derailleur
hanger is bent.
Clearance between guide
pulley / sprocket is too large.
Clearance between guide
pulley / sprocket is too small.
Shift cable insufficiently
tensioned.
Shift cable insufficiently
tensioned.
Shift cable is too tight.
Excessive cable friction,
pinched or poorly routed
cable.
10
Turn in screw H until the
guide pulley is aligned with
the smallest sprocket.
Unscrew screw H until the
guide pulley is aligned with
the smallest sprocket.
Turn in screw L until the
guide pulley is aligned with
the largest sprocket.
Straighten or replace.
Adjust b-adjust screw by
rotating counterclockwise.
Adjust b-adjust screw by
rotating clockwise.
Turn barrel adjuster on the
shifter counterclockwise.
Turn barrel adjuster on the
shifter counterclockwise.
Turn barrel adjuster on the
shifter clockwise.
Lubricate or replace cable
and housing. Check for
excessive bending of cable
housing.
Technical Manual 2006
DUALDRIVE
MAINTENANCE
Technical Manual 2006
11
12
Technical Manual 2006
SRAM S7
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
L
i-BRAKE for SRAM S7:
see page 54.
Caution:
• SRAM S7 hubs are not suitable for
tandems, trademen’s delivery bicycles
and similar.
• SRAM S7 with coaster brake resp.
i-BRAKE are „DIN Plus City“ certified.
W
W
NNEE
HR
C
D
E
1/2 OLD
DS
min. 13.5
7
3.5
T
Cycle frame:
• Dropouts must be parallel.
• Slot width at rear dropout max. 10,5 mm.
• The strength must be such that with a
maximum braking torque of 250 Nm
(2200 in.lbs.) on the rear wheel no
residual deformation can occur on the
rear structure.
F2
F1
Ø 7.3
A 2 max
R
10
0
A 1 max
SRAM S7 with coaster brake
SRAM S7 for i-BRAKE
SRAM S7 with drum brake
Type
MH 7215
–
MH 7225
Brake
Coaster
i-BRAKE (see page 54)
Drum
Over Locknut Dim., OLD
130 mm
135 mm
135 mm
183.4 mm
188.5 mm
188.5 mm
183.4 mm
FG 10.5
FG 10.5
FG 10.5
FG 10.5
Axle
Length, L
Ends Diameter, T
Dropout Width Dim.
Spoke
Holes
Gear Hub Ratio
Chain
Compatibility
„D“
❘
MH 7205
„NL“
None
130 mm
A1 max.=12.5mm / A2 max.=12mm A1 max.=12.5mm / A2 max.=12.2mm A1 max.=12.5mm / A2 max.=12.2mm A1 max.=12.5mm / A2 max.=10mm
36
36
36
36
3.0 mm
3 mm
2.9 mm
3.0 mm
Hole Ref. ø, HR
75 mm
75 mm
89 mm
75 mm
F1 = 33 mm / F2 = 34 mm
F1 = 35.4 mm / F2 = 32.7 mm
F1 = 34.8 mm / F2 = 35.7 mm
F1 = 33 mm / F2 = 34 mm
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
1
1
Speed 3
81 %
Speed 4
100 %
Speed 5
124 %
Speed 6
148 %
Speed 7
174 %
➔
➔
➔
➔
➔
➔
➔
➔
1
1
Totally
303 %
Speed 1
57 %
Speed 2
68 %
Usable Dimensions
Line, C/D/E
/2" x 1/8" or 1/2" x 3/32"
54 / 51 / 48 mm
/2" x 1/8" or 1/2" x 3/32"
55.5 / 52.5 / 49.5 mm
/2" x 1/8" or 1/2" x 3/32"
/2" x 1/8" or 1/2" x 3/32"
55.5 / 52.5 / 49.5 mm
54 / 51 / 48 mm
➔
➔
➔
Clickbox S7
➔
➔
➔
➔
➔
Hand Brake Lever
—
see page 55
see page 15
—
Tandem
—
—
—
—
Weight
1714 g
2164 g (complete with i-BRAKE) 1737 g
1556 g
Steel
Steel
Aluminum
Steel
Matt Chrome Plated or Black
Matt Chrome Plated
Clear Coat
Matt Chrome Plated or Black
Ratio
Finish
NEW
NEW
SRAM S7 without brake
Hole Diameter, DS
Flange Dist. to 1/2 OLD
H
U
B
S
Version with Coaster Brake
OLD
Shifter
Clickbox
Hub Shell Material
Finish
24", 26", 28"= 1.83 – 1.90 / 20"= 1.83 – 2.00
SRAM Grip 7
Technical Manual 2006
13
SRAM S7
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
SRAM Grip 7
Shifter Type
Twist Shifter
Cable Length
1450 mm
Gear Indication
Window
Clamping Diameter
❘
1550 mm
❘
1650 mm
❘
1750 mm
❘
1850 mm
❘
1950 mm
❘
2050 mm
❘
2150 mm
22.3 mm
Handlebar, Straight Area
Minimum length for shifter = 150 mm
Weight
89g
Housing
Design
S
H
I
F
T
E
R
S
Glass filled PA
Grip
PP
Thermoplastic elastomer, Overmolded
Grip Cover
Clamping Collar
Aluminum
SRAM S7
ASSEMBLY
W
W
NNEE • Fit new retaining washer (3,5 mm thick)
A S S E M B LY H U B
1
1
2
2
4 3
5
6
Mounting Tool
Part No. 0582 104 000
• Lace the wheel as normal. See spoke
length table.
• Place the dust cap (1, Fig. 1) and
sprocket (2) on the driver.
• Push sprocket circlip (3, Fig. 2) onto the
cone of tool sleeve (4). Place tool sleeve
with large diameter on the driver.
• Push the spring end of sliding sleeve (5)
of the tool over the tool sleeve. Thrust
sliding sleeve in direction (6), this forces
circlip into the recess of the driver.
• Remove tool and check that the circlip is
seated correctly.
• Turn dust cap (7, Fig. 3) until the three
lugs (8) are between the three beads (9)
on the sprocket (10).
• Position dust cap and push towards
sprocket until it is felt to lock into place.
• Placing the wheel in the rear frame.
3
8
on left axle end (1, Fig. 4). The serrations
must bear against the dropout and the
lug must engage in the dropout slot.
Advice:
For bicycles with chain tensioner use
previous retaining washers (2 pieces,
2 mm thick) – see Tech. Manual 2005.
• On the sprocket side fit the protective
bracket (1, Fig. 5) directly below the
axle nut. Tightening torque on axle nuts
30 – 40 Nm (266 – 350 in.lbs.).
• Mount the brake lever using a suitable
frame clamp (2, Fig. 4 resp. Fig. 10).
Caution:
Mount the brake lever between the two
straps of the frame clamp.
The clamp must be seated on the frame
without play.
Use a self-locking nut! Tightening
torque: 2 – 3 Nm (18 – 27 in.lbs.).
7
Spoke length table:
9
10
4
1
Tire Size
47–406
37–490
47–507
37–540
47–559
37–590
47–622
37–622
28–622
32–622
28–630
32–630
20" x 1.75 x 2
22" x 1 3 / 8
24" x 1.75 x 2
24" x 1 3 / 8
26" x 1.75 x 2
26" x 1 3 / 8
28" x 1.75
28" x 1 3 / 8 x 1 5 / 8
28" x 1 1 / 8
28" x 1 5 / 8 x 1 1 / 4
27" x 1 1 / 4 fifty
27" x 1 1 / 4
Cross
3x
3x
3x
3x
3x
3x
3x
3x
3x
3x
3x
3x
Length MH 7215/7205
181 mm
225 mm
232 mm
251 mm
259 mm
275 mm
289 mm
289 mm
289 mm
289 mm
294 mm
294 mm
Length MH 7225
179 mm
222 mm
229 mm
248 mm
256 mm
272 mm
286 mm
286 mm
286 mm
286 mm
291 mm
291 mm
2
Spoke lengths are approximate values. They must be checked through lacing attempts
and adjusted accordingly.
14
Technical Manual 2006
SRAM S7
ASSEMBLY
5
1
2
3
• Push on Clickbox (2, Fig. 5) to the stop on
the hub axle. The guiding rib (4, Fig. 8) of
the locating sleeve thereby engages in
the slot on the housing. In the end position
tighten up the knurled bolt (3, Fig. 5) by
hand (0.3 Nm / 2.7 in.lbs.).
Caution:
Check that all the brake system
components are functioning properly!
ADJUSTMENT
A S S E M B LY S H I F T E R
6
4
5
2
3
7
2
8
1
1
2
4
1
3
5
9
a
25
Advice:
• When choosing cable housing lengths,
be sure to allow enough housing for an
extreme turn of the handlebars in both
directions.
• Note also, that different stem lengths
and handlebar positions effects cable
housing length.
• Slide shifter (1, Fig. 6) onto handlebar.
• Mount fixed grip (2) onto end of handlebar.
• Slide shifter against fixed grip, adjust
shifter on handlebar and tighten with
bolt (3) with a torque of 1.5 Nm (13 in.lbs.).
Caution:
• Never use lubricants or solvents to
install fixed grips.
Fixed grips provide an axial safety
function. For this reason, they should be
mounted in such a way as to make sure
they do not slip off handlebar.
• Check that the shifter and brake lever
function properly and are unobstructed
(realign if necessary).
7
6
• When fitting the cable avoid small radius.
Attach the cable 3 times to the down
tube (1, Fig. 7).
• Last attachment point is on the lower
rear wheel fork (2, Fig. 7) immediately
behind the chain wheel.
Cable housing must be movable inside
attachment.
l
i =—
a
INSTALLING CLICKBOX
l
10
Advice:
• If a different protective bracket (1, Fig. 5)
is used the thickness of the attachment
plate must be max. 3 mm.
• Do not use additional washers.
• At least the beginning of the axle thread
must be visible in front of the axle nut.
2 3 1
4 6
5
7
• Insert shift rod (1, Fig. 8) in shift tube (2)
(oil parts lightly) and then push into axle
bore as far as the stop. Turn slot (6) in
shift tube to a position where it is easily
visible.
• Push locating sleeve (3) with guiding rib
(4) to the front onto the hub axle – making sure that the internal lug (5) is guided
in the slot (6) of the shift tube until it can
be felt – and heard – to engage.
• Turn locating sleeve on the axle until the
guiding rib (4) is facing roughly upwards.
• Place shifter in gear position “1“.
• Be sure to reset rotational shifter from
5th to 4th gear.
• Match up the marks in the Clickbox
viewing window (4, Fig. 6) by turning
the adjusting screw (5).
CONNECTING DRUM BRAKE
Caution:
Only use brake levers with a cable
moving distance of at least 15 mm and a
leverage of “i“ = 3.8 – 4.2 (Fig. 9).
• Fit cable stop (1, Fig. 10) with adjusting
bolt (2) and nut (3) and insert into the slot
on the brake anchor plate.
• Turn adjusting bolt down by approx. 2/3
and route the brake cable from the
brake handle.
• Push lower brake cable end through
adjusting bolt (2) and insert lower cable
housing end into adjusting bolt.
• Thread brake cable end (4) into
fork unit (5).
• Tighten screw (6) slightly.
• Attach fork unit to brake lever (7).
• Pull brake cable end taut with pliers
so that fork unit can still be attached and
removed (important for changing wheel).
• Tighten screw (6).
Caution:
For NL version drum brake hub with
special lever (8), only use original NL
brake cable (fork unit (5) is not suitable).
ADJUSTMENT DRUM BRAKE
• Unscrew adjusting screw (2, Fig. 10)
until the brake pads drag lightly.
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock hex nut (3).
Caution:
Check that all the brake system
components are functioning properly!
8
Technical Manual 2006
15
SRAM S7
MAINTENANCE
1
8
9
33
32
31
7
30
6
29
28
5
4
3
27
21
26
20
19
23
2
18
1
24
25
44
43
42
22
17
16
41
40
14
15
39
13
11
12
38
36
37
10
35
34
REMOVE WHEEL
2
SRAM S7 mounting aid
Part No. 65 0324 103 000
• Place shifter in gear position “1“.
• Loosen the knurled screw (44, Fig. 1) and
pull the Clickbox off the axle.
• Disengage the red location sleeve (43)
and pull it off.
• Remove shift rod (42) and shift tube (41)
out of the axle bore.
• Remove wheel.
X
DISMANTLING HUB
see Fig. 1
3
16
• Remove circlip (38), sprocket (37) and
dust cap (36) as normal.
• Clamp hub by the axle between aluminum jaws with sprocket side facing
downwards.
• Unscrew both locknuts (1).
W
W
NNEE • While turning clockwise, remove lever
cone (2) with friction spring (3) and ball
retainer (4).
• Take out 3 brake segments (5).
• Withdraw hub sleeve (6) upwards.
• Remove brake cone (7).
• Take out retaining washer (8) and thrust
washer (9).
• Remove planetary gear carrier (10),
washer (11) compression spring (12) and
the three sun gears (13, 14, 15).
• Clamp other axle end.
• Unscrew fixed cone (36).
• Remove driver (35), compression spring
(33) with cover (32), large compression
spring (31), ball retainer (34), gear ring (30)
and coupling gear (29).
• Compress spring (26) and remove thrust
block (28).
• Remove cover (27), spring (26) and
cover (25).
• Dismantle retaining washer (24).
• Remove thrust washer (23) and plastic
profile washer (22).
• Unscrew grub screw (17) (Caution: It is
subject to spring pressure) – and dismantle the long compression spring (18)
guide pin (19), thrust block (20) and the
short compression spring (21).
R E A S S E M B LY H U B
see Fig. 1
Lubrication see “MAINTENANCE /
LUBRICATION“.
• Insert into the axle (on the side with the
internal thread):
Short compression spring (21), thrust
block (20) – it is the same both sides, guide
rod (19) – it is the same both sides, long
compression spring (18).
• Compress spring and fit grub screw (17).
Technical Manual 2006
SRAM S7
MAINTENANCE
• Clamp axle, end with groove for Clickbox
facing upwards.
• Fit plastic profile washer (22) with its
large diameter upwards.
• Fit thrust washer (23) and retaining
washer (24).
• Locate cover (25), compression spring (26)
with 7 turns and cover (27, insides to the
spring).
• Compress spring and position thrust
block (28) – it is the same both sides –
centrally in the axle.
• Clamp other axle end (groove is facing
downwards).
• Fit large sun gear (15), with deflector
bevels upwards.
• Position medium sun gear (14), with
deflector bevels upwards.
• Fit small sun gear (13) – with recesses in
front, thrust block engages in the slots.
• Position smallest compression spring (12).
• Fit 1 mm thick washer (11).
• Fit planetary gear carrier (10):
Place the mounting aid(Fig. 2) on the
planetary gear carrier such that the
markings (X) on the 3 small planet gears
and the mounting aid match up.
• Turn planetary gear carrier and at the
same time push it downwards over the
sun gears.
• Fit thrust washer (9) and retaining
washer (8) in the undercut.
Now remove the mounting aid.
4
• Insert ball retainer (4) (balls are facing
upwards) into lever cone (2): the 3 recesses have to engage into the retaining
lugs of the lever cone. Slightly turn ball
retainer to prevent it from falling off.
• Fit lever cone onto hub shell: the retaining lugs of the lever cone have to engage into the openings between the
brake segments. Make sure that lever
cone engages while turning it back and
forth slightly.
• Screw on locknuts (1), adjust bearing
so that there is no play and lock nuts
together with 15 – 20 Nm (133 – 177in.lbs.).
Caution:
Check that all the brake system
components are functioning properly!
Advice:
Dismantling and reassembly of hub types
without coaster brake (MH 7205 / MH 7225)
should be carried out in the same way.
Differences: Instead of brake segments /
cone a click-and-pawl carrier is installed
on the planetary gear carrier.
Advice:
If the gears are not accurately assembled
the hub may feel tight in use. This may
lead to gear wheel damage during travel.
• Clamp other axle end (groove for Clickbox facing upwards).
• Fit coupling gear (29) with carrier plate
downwards
• Push ring gear (30) over the coupling gear.
• Locate large spring (31).
• Fit largest ball retainer (34) with balls
underneath.
• Fit cover (32, inside to the spring).
• Assemble the compression spring (33)
with 12 turns.
• Position driver (35) – push it down – and
screw on fixed cone (36) to the stop,
tightening torque 20 Nm (177 in.lbs.).
• Clamp other axle end (groove for Clickbox is facing downwards).
• Assemble hub shell (6) with a slight
counter-clockwise movement.
In case the hub shell jams, position the
plastic ring (Fig. 3) correctly.
W
W
NNEE • Screw brake cone (7) clockwise onto the
planetary gear carrier (10) until it stops.
• Insert 3 brake segments (5).
• Turn in friction spring (3) counterclockwise into the lever cone (2) (inlying
winding of the spring has to lie against
the lever cone) (Fig. 4).
Technical Manual 2006
17
SRAM S7
MAINTENANCE
CABLE CHANGE
5
2
Dismantling shifter cable:
• Place shifter in gear position “1“.
• Do not remove the Clickbox from the axle
end.
• Unscrew the adjusting screw (1, Fig. 5)
completely. Unscrew the cover screw (2),
brush aside the adjusting screw (1) and
remove the cover (3).
• Withdraw shifter cable and clamping
bolt (1, Fig. 6) upwards, loosen clamp
and pull clamping piece from the cable.
• Slightly lift the grip cover (Fig. 7), push
the cable out and discard.
3
1
6
1
2
7
Assembly shifter cable:
• Route new cable through shifter housing
and pull cable to seat cable head
completely into cable recess.
Feed the cable through the new cable
housing and adjusting screw.
• Position clamping bolt (1, Fig. 8) at a
distance of 90 mm, tighten up with
1.5 Nm (13 in.lbs.) and cut off cable ends
to 2 – 3 mm. For positioning the clamping
bolt use adjust gauge (Fig. 9). (Part. No.
65 0324 107 000)
• Locate clamping bolt (1, Fig. 6) and place
shifter cable around the carrier cylinder
(counter-clockwise winding).
• Position the cover (3, Fig. 5) and tighten
up with the cover screw (2).
Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.).
Screw in the adjusting screw (1)
completely.
Advice:
• If you want to remove the Clickbox from
the axle end for changing the cable, do
as follows:
– Place shifter in gear position “1“.
– Loosen the knurled screw and pull the
Clickbox off the axle.
– Now it’s essential to push the end (1,
Fig. 8) of the adjust gauge completely
into the Clickbox and tighten up the
knurled bolt (so that you maintain the
initial tension of the spring inside the
Clickbox).
– Change cable as per description above.
• If you remove the Clickbox from the
axle and change the cable without
using the end of the adjust gauge, then
you will lose the initial tension of the
spring inside the Clickbox. In this case
you must assemble the cable by placing
it around the carrier cylinder with an
additional winding (Fig. 6).
8
90 ±0,5 mm
2 +1 mm
1
9
1
18
Technical Manual 2006
SRAM S7
MAINTENANCE
DRUM BRAKE
10
2
3
1
4
6
5
11
10
9
8
•
Install brake anchor plate (or exchange it):
• Place thrust washer (8, Fig. 10) over the
•
axle on the adjusting cone and fit
complete brake anchor plate. Position
washer (9) distance sleeve (10) and
•
screw on locknut (11).
• Push brake lever (7) to the stop and hold
W•
it there to center the brake jaws in the NNEEW
brake drum – tighten up locknut with a
•
torque of 15 – 20 Nm (133 – 177 in.lbs.).
7
ADJUSTMENT DRUM BRAKE
• Unscrew adjusting screw (2, Fig. 10)
until the brake pads drag lightly.
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock hex nut (3).
Oil the inside of the sun gears, grease
the outside teeth (fill the gaps in the
teeth).
Oil outside teeth and carrier plate on
the coupling gear and lightly grease the
borehole from right and left.
Do not apply grease to ring gear but just
oil the pawl pockets.
Slightly grease the actuation ramps of
the planetary gear carrier.
Apply grease all around the seat area of
the friction spring. Oil the pawl pockets.
• Spread grease on the complete surfaces
inside and outside of the 3 brake segments.
• Regrease ball retainer and insert into
lever cone, slightly grease cone surface
of the lever cone.
• Line ball bearing running tracks and
brake cylinder in hub shell with grease.
Caution:
Check that all the brake system
components are functioning properly!
MAINTENANCE /
LUBRICATION
Caution:
The SRAM hubs are provided with
permanent lubrication and under normal
conditions is maintenance-free. If the
coaster brake is loaded excessively its
effect can be too strong, the hub may lock.
In such a case the 3 brake segments should
be lubricated with a special grease (Part
No. 0369 135 200/ ...201). Renew brake segments when rhombic pattern is worn out.
Cleaning of parts:
• All parts – except for the planetary gear
carrier – can be degreased in a cleaning
bath.
• The planetary gear carrier only needs to
be cleaned on the outside with a brush
so as not to degrease the planetary gear
bearing.
Caution:
Do not use high-pressure water when
cleaning the gear hub (e.g. strong water
jets, high-pressure cleaners etc.) –
if water penetrates it could lead to
functional problems.
Lubrication of parts:
Use only SRAM grease (Part No. 0369 135 200/
...201) and standard bicycle oil.
• To lubricate the bearing points on the
planetary gear sets, position the planetary gear carrier on its crown and apply
2 – 3 drops of oil to the bearing bolts –
at the same time turning the planetary
gears so that the bearing points are
completely wet. Oil axle through the axle
bore and axle slot, apply a thin coating
of grease to the outside.
Technical Manual 2006
TROUBLESHOOTING
Problem
Shifting
difficulties
Pedals are
carried
forward
when freewheeling
Hub locks
when
braking
(coaster
brake)
Coaster
brake
without
function
Remedy
Replace
control cable
Adjust shift.
system
Beginning of
axle thread
must be visible in front of
the axle nut
Re-adjust
bearings
Tighten
lock nuts
(15 – 20 Nm)
Chain is over- Reduce
chain tension
tensioned
Wash out
Brake seghub sleeve,
ments has
repolish and
run dry
relubricate
brake cylinder,
renew brake
segments
Fit friction
Incorrect
mounted fric- spring in
tion spring (3, correct way
Fig.1/Page 16)
Cause
Damaged
control cable
Incorrect
gear setting
To much additional axle
attachments
between hub
and axle nut
Bearings
set too tight
Loose
lock nuts
19
20
Technical Manual 2006
SRAM P5
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
i-BRAKE for SRAM P5:
see page 54.
Version SRAM P5 Cargo:
see page 29.
Version with coaster brake
L
OLD
Caution:
• SRAM P5 hubs are not suitable for
tandems, trademen’s delivery bicycles
and similar.
• SRAM P5 with coaster brake resp.
i-BRAKE are „DIN Plus City“ certified.
HR
C
D
E
1/2 OLD
W
W
NNEE
DS
min. 13.5
7
T
3.5
Cycle frame:
• Dropouts must be parallel.
• Slot width at rear dropout max. 10,5 mm.
• The strength must be such that with a
maximum braking torque of 250 Nm
(2200 in.lbs.) on the rear wheel no
residual deformation can occur on the
rear structure.
F2
MH 5215
Coaster
Over Locknut Dim., OLD
Axle
Type
MH 5225
122 mm
126 mm
126 mm
Length, L
175 mm
179 mm
179 mm
Ends Diameter, T
FG 10.5
FG 10.5 toothed cone FG 10.5
FG 10.5
Spoke
Gear Hub Ratio
Chain
0
„D“
❘
SRAM P5 without brake
MH 5205
„NL“
None
122 mm
175 mm
FG 10.5
❘
A max.=12.5mm / A max.=11.5mm A max.=12.5mm / A max.=12.5mm A max.=12.5mm / A max.=10.5mm A max.=12.5mm / A max.=10.5mm
1
2
1
2
1
2
1
36
36
Hole Diameter, DS
3,0 mm
3,0 mm
2,9 mm
3,0 mm
Hole Ref. ø, HR
75 mm
75 mm
89 mm
75 mm
Flange Dist. to 1/2 OLD
36
2
36
F1 = 28.5 mm / F2 = 29.5 mm
F1 = 31 mm / F2 = 27.7 mm
F1 = 30.5 mm / F2 = 29.5 mm
F1 = 29 mm / F2 = 29 mm
Totally
251 %
Speed 1
63 %
Speed 2
78 %
Speed 3
100 %
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
1
1
Speed 4
128 %
Speed 5
158 %
➔
➔
➔
➔
➔
➔
1
1
Usable Dimensions
Line, C/D/E
/2" x 1/8" or 1/2" x 3/32"
49 / 45.5 / 43 mm
/2" x 1/8" or 1/2" x 3/32"
51.5 / 48.5 / 45.5 mm
/2" x 1/8" or 1/2" x 3/32"
49 / 45.5 / 43 mm
➔
➔
➔
—
Clickbox P5
➔
➔
Hand Brake Lever
—
see page 55
see page 23
Tandem
—
—
—
Shifter
Clickbox
Weight
Hub Shell Material
Finish
24", 26", 28"= 1.8 – 1.9 / 20"= 1.8 – 2.0
SRAM Grip 5
/2" x 1/8" or 1/2" x 3/32"
51.5 / 48.5 / 45.5 mm
➔
➔
➔
Ratio
Compatibility
10
SRAM P5 with drum brake
Drum
Holes
Finish
SRAM P5 für i-BRAKE
—
NEW
NEW
R
A 1 max.
i-BRAKE (see page 54)
Dropout Width Dim.
H
U
B
S
Ø 7.3
A 2 max.
SRAM P5 with coaster brake
Brake
F1
1495 g
1920 g (complete with i-BRAKE) 1536 g
1330 g
Steel
Steel
Aluminum
Steel
Matt Chrome Plated
Matt Chrome Plated
Clear Coat
Technical Manual 2006
❘ Clear o. Black Matt Chrome Plated
21
SRAM P5
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
SRAM Grip 5
Shifter Type
Twist Shifter
Cable Length
1450 mm
Gear Indication
Window
Clamping Diameter
❘
1550 mm
❘
1650 mm
❘
1750 mm
❘
1850 mm
❘
1950 mm
❘
2150 mm
❘
2350 mm
22.3 mm
Handlebar, Straight Area
Minimum length for shifter = 150 mm
Weight
89g
Housing
Design
S
H
I
F
T
E
R
S
Glass filled PA
Grip
PP
Thermoplastic elastomer, Overmolded
Grip Cover
Clamping Collar
Aluminum
SRAM P5
ASSEMBLY
W
W
NNEE • Fit new retaining washer (3,5 mm thick)
A S S E M B LY H U B
1
1
2
2
4 3
5
6
Mounting Tool
Part No. 0582 104 000
• Lace the wheel as normal. See spoke
length table.
• Place the dust cap (1, Fig. 1) and
sprocket (2) on the driver.
• Push sprocket circlip (3, Fig. 2) onto the
cone of tool sleeve (4). Place tool sleeve
with large diameter on the driver.
• Push the spring end of sliding sleeve (5)
of the tool over the tool sleeve. Thrust
sliding sleeve in direction (6), this forces
circlip into the recess of the driver.
• Remove tool and check that the circlip is
seated correctly.
• Turn dust cap (7, Fig. 3) until the three
lugs (8) are between the three beads (9)
on the sprocket (10).
• Position dust cap and push towards
sprocket until it is felt to lock into place.
• Placing the wheel in the rear frame.
3
8
on left axle end (1, Fig. 4). The serrations
must bear against the dropout and the
lug must engage in the dropout slot.
Advice:
For bicycles with chain tensioner use
previous retaining washers (2 pieces,
2 mm thick) – see Tech. Manual 2005.
• On the sprocket side fit the protective
bracket (1, Fig. 5) directly below the
axle nut. Tightening torque on axle nuts
30 – 40 Nm (266 – 350 in.lbs.).
• Mount the brake lever using a suitable
frame clamp (2, Fig. 4 resp. Fig. 10).
Caution:
Mount the brake lever between the two
straps of the frame clamp.
The clamp must be seated on the frame
without play.
Use a self-locking nut! Tightening
torque: 2 – 3 Nm (18 – 27 in.lbs.).
7
Spoke length table:
9
10
4
1
2
22
Tire Size
47–406
37–490
47–507
37–540
47–559
37–590
47–622
37–622
28–622
32–622
28–630
32–630
20" x 1.75 x 2
22" x 1 3 / 8
24" x 1.75 x 2
24" x 1 3 / 8
26" x 1.75 x 2
26" x 1 3 / 8
28" x 1.75
28" x 1 3 / 8 x 1 5 / 8
28" x 1 1 / 8
28" x 1 5 / 8 x 1 1 / 4
27" x 1 1 / 4 fifty
27" x 1 1 / 4
Cross
3x
3x
3x
3x
3x
3x
3x
3x
3x
3x
3x
3x
Length MH 5215/5205
181 mm
225 mm
232 mm
251 mm
259 mm
275 mm
289 mm
289 mm
289 mm
289 mm
294 mm
294 mm
Length MH 5225
179 mm
222 mm
229 mm
248 mm
256 mm
272 mm
286 mm
286 mm
286 mm
286 mm
291 mm
291 mm
Spoke lengths are approximate values. They must be checked through lacing attempts
and adjusted accordingly.
Technical Manual 2006
SRAM P5
ASSEMBLY
Advice:
• If a different protective bracket (1, Fig. 5)
is used the thickness of the attachment
plate must be max. 3 mm.
• Do not use additional washers.
• At least the beginning of the axle thread
must be visible in front of the axle nut.
5
Caution:
Check that all the brake system
components are functioning properly!
1
2
3
ADJUSTMENT
A S S E M B LY S H I F T E R
6
4
5
2
3
7
2
8
1
1
2
4
1
3
5
9
a
25
Advice:
• When choosing cable housing lengths,
be sure to allow enough housing for an
extreme turn of the handlebars in both
directions.
• Note also, that different stem lengths
and handlebar positions effects cable
housing length.
• Slide shifter (1, Fig. 6) onto handlebar.
• Mount fixed grip (2) onto end of handlebar.
• Slide shifter against fixed grip, adjust
shifter on handlebar and tighten with
bolt (3) with a torque of 1.5 Nm (13 in.lbs.).
Caution:
• Never use lubricants or solvents to
install fixed grips.
Fixed grips provide an axial safety
function. For this reason, they should be
mounted in such a way as to make sure
they do not slip off handlebar.
• Check that the shifter and brake lever
function properly and are unobstructed
(realign if necessary).
7
6
• When fitting the cable avoid small radius.
Attach the cable 3 times to the down
tube (1, Fig. 7).
• Last attachment point is on the lower
rear wheel fork (2, Fig. 7) immediately
behind the chain wheel.
Cable housing must be movable inside
attachment.
l
i =—
a
2 3 1
4 6
5
7
8
Technical Manual 2006
• Be sure to reset rotational shifter from
4th to 3rd gear.
• Match up the marks in the Clickbox
viewing window (4, Fig. 6) by turning
the adjusting screw (5).
CONNECTING DRUM BRAKE
Caution:
Only use brake levers with a cable
moving distance of at least 15 mm and a
leverage of “i“ = 3.8 – 4.2 (Fig. 9).
• Fit cable stop (1, Fig. 10) with adjusting
bolt (2) and nut (3) and insert into the slot
on the brake anchor plate.
• Turn adjusting bolt down by approx. 2/3
and route the brake cable from the
brake handle.
• Push lower brake cable end through
adjusting bolt (2) and insert lower cable
housing end into adjusting bolt.
• Thread brake cable end (4) into
fork unit (5).
• Tighten screw (6) slightly.
• Attach fork unit to brake lever (7).
• Pull brake cable end taut with pliers
so that fork unit can still be attached and
removed (important for changing wheel).
• Tighten screw (6).
Caution:
For NL version drum brake hub with
special lever (8), only use original NL
brake cable (fork unit (5) is not suitable).
ADJUSTMENT DRUM BRAKE
INSTALLING CLICKBOX
l
10
• Turn locating sleeve on the axle until the
guiding rib (4) is facing roughly upwards.
• Place shifter in gear position “2“.
• Push on Clickbox (2, Fig. 5) to the stop on
the hub axle. The guiding rib (4, Fig. 8) of
the locating sleeve thereby engages in
the slot on the housing. In the end position
tighten up the knurled bolt (3, Fig. 5) by
hand (0.3 Nm / 2.7 in.lbs.).
• Insert shift rod (1, Fig. 8) in shift tube (2)
(oil parts lightly) and then push into axle
bore as far as the stop. If the shifting rod
is sticking up out of the axle end: apply
slight pressure on the shift rod with its
threaded section and screw inwards in
a clockwise direction until it can again
be moved axially (valid for older hub
versions). Turn slot (6) in shift tube to a
position where it is easily visible.
• Push locating sleeve (3) with guiding rib
(4) to the front onto the hub axle – making
sure that the internal lug (5) is guided in
the slot (6) of the shift tube until it can be
felt – and heard – to engage.
• Unscrew adjusting screw (2, Fig. 10)
until the brake pads drag lightly.
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock hex nut (3).
Caution:
Check that all the brake system
components are functioning properly!
23
SRAM P5
MAINTENANCE
9
1
8
30
7
29
28
27
6
26
5
25
4
3
24
23
2
17
18
16
1
19
20
21
41
22
40
38
15
39
14
37
36
11
12
13
35
33
10
34
32
31
REMOVE WHEEL
2
SRAM P5 mounting aid
Part No. 65 0524 300 000
• Place shifter in gear position “2“.
• Loosen the knurled screw (41, Fig. 1) and
pull the Clickbox off the axle.
• Disengage the red location sleeve (40)
and pull it off.
• Remove shift rod (39) and shift tube (38)
out of the axle bore.
• Remove wheel.
X
DISMANTLING HUB
see Fig. 1
3
24
• Remove circlip (36), sprocket (35) and
dust cap (34).
• Clamp hub with sprocket side facing
downwards with the two axle flats.
• Unscrew both locknuts (1).
W
W
NNEE • While turning clockwise, remove lever
cone (2) with friction spring (3) and ball
retainer (4).
• Take out 3 brake segments (5).
• Withdraw hub sleeve (6) upwards.
• Remove brake cone (7).
• Remove retaining washer (8), thrust
washer (9).
• Remove planetary gear carrier (10) and
thrust washer (11).
• Clamp other axle end.
• Unscrew fixed cone (33).
• Remove driver (32), compression spring
(30), large compression spring (28) and ball
retainer (31).
• Withdraw gear ring (27) and coupling
gear (26) and then remove cover (29)
from the coupling gear.
• Take out thrust block (25), (to do this
compress the spring). Remove spring
(23) and the two covers (24/22).
• Dismantle retaining washer (21), washer
(20), conical compression spring (19),
and the large sun gear (13). Clamp other
axle end (thrust block visible).
• Unscrew grub screw (15) – Dismantle
spring (16), guide bolt (17) and thrust
block (18).
• Remove small sun sun gear (12).
R E A S S E M B LY H U B
see Fig. 1
Lubrication see “MAINTENANCE /
LUBRICATION“.
• Clamp axle with internal thread upwards.
• Position small sun gear (12) with crown
gears to the front.
• Position thrust block (18) in the slotted
hole (is laterally guided when the sun
gear is screwed in).
Technical Manual 2006
SRAM P5
MAINTENANCE
• Locate bolt (17), then spring (16) in the
axle and screw in grub screw (15) until
it is flush with the axle.
• Reclamp axle. Fit large sun gear (13) (it
is the same both sides). Position conical
compression spring (19), with the large
diameter first. Press spring together and
fit washer (20) and retaining washer (21).
• Assemble cover (22), compression
spring with 7 turns (23) and the second
cover (24, insides to the spring).
• Compress spring and position thrust
block (25) (it is the same both sides) in
the center of the slotted hole.
• Position coupling gear (26) with carrier
plate facing downwards.
• Fit cover (29, inside to the spring) for
compression spring.
• Position gear ring (27) over the teeth of
the coupling gear.
• Place ball retainer (31), with balls below
on the gear ring.
• Position large compression spring (28)
on gear ring.
• Mount compression spring with 13 turns
(30) on the axle. (Is supported in the
coupling wheel by the cover).
• Locate driver (32), press it down and
screw on fixed cone (33) as far as the
stop. Tightening torque 20 Nm.
• Clamp other axle end.
• Push on thrust washer (11) and fit
planetary gear carrier (10). In doing this:
Position mounting aid (Fig. 2) on the
planetary gear carrier so that the (X)
markings on the three planetary gears
match with the mounting aid.
• Insert planetary gear carrier, place
thrust washer (8) on it and mount
retaining washer (9) in recess.
Now remove the mounting aid.
4
• Fit lever cone onto hub shell: the retaining lugs of the lever cone have to engage into the openings between the
brake segments. Make sure that lever
cone engages while turning back and
forth slightly.
• Screw on locknuts (1), adjust bearing
so that there is no play and lock nuts
together with 15 – 20 Nm (133 – 177in.lbs.).
Caution:
Check that all the brake system
components are functioning properly!
Advice:
Dismantling and reassembly of hub types
without coaster brake (MH 5205 / MH 5225)
should be carried out in the same way.
Differences: Instead of brake segments /
cone a click-and-pawl carrier is installed
on the planetary gear carrier.
Advice:
If the gears are not accurately installed
the hub may be tight to move.
This could lead to damage to the gearwheels in operation.
• Assemble hub shell (6) with a slight
counter-clockwise movement.
In case the hub shell jams, position the
plastic ring (Fig. 3) correctly.
W
W• Screw brake cone (7) clockwise onto the
E
E
NN
planetary gear carrier (10) until it stops.
• Insert 3 brake segments (5).
• Turn in friction spring (3) counterclockwise into the lever cone (2) (inlying
winding of the spring has to lie against
the lever cone) (Fig. 4).
• Insert ball retainer (4) (balls are facing
upwards) into lever cone (2): the 3 recesses have to engage into the retaining
lugs of the lever cone. Slightly turn ball
retainer to prevent it from falling off.
Technical Manual 2006
25
SRAM P5
MAINTENANCE
CABLE CHANGE
5
2
Dismantling shifter cable:
• Place shifter in gear position “1“.
• Do not remove the Clickbox from the axle
end.
• Unscrew the adjusting screw (1, Fig. 5)
completely. Unscrew the cover screw (2),
brush aside the adjusting screw (1) and
remove the cover (3).
• Withdraw shifter cable and clamping
bolt (1, Fig. 6) upwards, loosen clamp
and pull clamping piece from the cable.
• Slightly lift the grip cover (Fig. 7), push
the cable out and discard.
3
1
6
1
2
7
Assembly shifter cable:
• Route new cable through shifter housing
and pull cable to seat cable head
completely into cable recess.
Feed the cable through the new cable
housing and adjusting screw.
• Position clamping bolt (1, Fig. 8) at a
distance of 80 mm, tighten up with
1.5 Nm (13 in.lbs.) and cut off cable ends
to 2 – 3 mm. For positioning the clamping
bolt use adjust gauge (Fig. 9). (Part. No.
65 0324 107 000)
• Locate clamping bolt (1, Fig. 6) and place
shifter cable around the carrier cylinder
(counter-clockwise winding).
• Position the cover (3, Fig. 5) and tighten
up with the cover screw (2).
Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.).
Screw in the adjusting screw (1)
completely.
Advice:
• If you want to remove the Clickbox from
the axle end for changing the cable, do
as follows:
– Place shifter in gear position “1“.
– Loosen the knurled screw and pull the
Clickbox off the axle.
– Now it’s essential to push the end (1,
Fig. 8) of the adjust gauge completely
into the Clickbox and tighten up the
knurled bolt (so that you maintain the
initial tension of the spring inside the
Clickbox).
– Change cable as per description above.
• If you remove the Clickbox from the
axle and change the cable without
using the end of the adjust gauge, then
you will lose the initial tension of the
spring inside the Clickbox. In this case
you must assemble the cable by placing
it around the carrier cylinder with an
additional winding (Fig. 6).
8
80 ±0,5 mm
2 +1 mm
1
9
1
26
Technical Manual 2006
SRAM P5
MAINTENANCE
DRUM BRAKE
10
2
3
1
4
6
5
11
10
9
8
•
Install brake anchor plate (or exchange it):
• Place thrust washer (8, Fig. 10) over
•
the axle on the adjusting cone and fit
complete brake anchor plate. Position
washer (9) distance sleeve (10) and
•
screw on locknut (11).
• Push brake lever (7) to the stop and hold
W•
it there to center the brake jaws in the NNEEW
brake drum – tighten up locknut with a
•
torque of 15 – 20 Nm (133 – 177 in.lbs.).
7
ADJUSTMENT DRUM BRAKE
• Unscrew adjusting screw (2, Fig. 10)
until the brake pads drag lightly.
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock hex nut (3).
Oil the inside of the sun gears, grease
the outside teeth (fill the gaps in the
teeth).
Oil outside teeth and carrier plate on
the coupling gear and lightly grease the
borehole from right and left.
Do not apply grease to ring gear but just
oil the pawl pockets.
Slightly grease the actuation ramps of
the planetary gear carrier.
Apply grease all around the seat area of
the friction spring. Oil the pawl pockets.
• Spread grease on the complete surfaces
inside and outside of the 3 brake segments.
• Regrease ball retainer and insert into
lever cone, slightly grease cone surface
of the lever cone.
• Line ball bearing running tracks and
brake cylinder in hub shell with grease.
Caution:
Check that all the brake system
components are functioning properly!
MAINTENANCE /
LUBRICATION
Caution:
The SRAM hubs are provided with
permanent lubrication and under normal
conditions is maintenance-free. If the
coaster brake is loaded excessively its
effect can be too strong, the hub may lock.
In such a case the 3 brake segments should
be lubricated with a special grease (Part
No. 0369 135 200/ ...201). Renew brake segments when rhombic pattern is worn out.
Cleaning of parts:
• All parts – except for the planetary gear
carrier – can be degreased in a cleaning
bath.
• The planetary gear carrier only needs to
be cleaned on the outside with a brush
so as not to degrease the planetary gear
bearing.
Caution:
Do not use high-pressure water when
cleaning the gear hub (e.g. strong water
jets, high-pressure cleaners etc.) –
if water penetrates it could lead to
functional problems.
Lubrication of parts:
Use only SRAM grease (Part No. 0369 135 200/
...201) and standard bicycle oil.
• To lubricate the bearing points on the
planetary gear sets, position the planetary gear carrier on its crown and apply
2 – 3 drops of oil to the bearing bolts –
at the same time turning the planetary
gears so that the bearing points are
completely wet. Oil axle through the axle
bore and axle slot, apply a thin coating
of grease to the outside.
Technical Manual 2006
TROUBLESHOOTING
Problem
Shifting
difficulties
Pedals are
carried
forward
when freewheeling
Hub locks
when
braking
(coaster
brake)
Coaster
brake
without
function
Remedy
Replace
control cable
Adjust shift.
system
Beginning of
axle thread
must be visible in front of
the axle nut
Re-adjust
bearings
Tighten
lock nuts
(15 – 20 Nm)
Chain is over- Reduce
chain tension
tensioned
Wash out
Brake seghub sleeve,
ments has
repolish and
run dry
relubricate
brake cylinder,
renew brake
segments
Fit friction
Incorrect
mounted fric- spring in
tion spring (3, correct way
Fig.1/Page 24)
Cause
Damaged
control cable
Incorrect
gear setting
To much additional axle
attachments
between hub
and axle nut
Bearings
set too tight
Loose
lock nuts
27
28
Technical Manual 2006
SRAM P5 CARGO
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
Version with coaster brake
L
OLD
W
W
NNEE
Version SRAM P5 for normal bikes:
see page 21.
min. 13.5
T
A 2 max.
Ø 7.3
MH 5215 Cargo
MH 5225 Cargo
NEW
NEW
175 mm
179 mm
FG 10.5 toothed cone
FG 10.5
A1 max. = 12.5 mm / A2 max. = 11.5 mm
A1 max. = 12.5 mm / A2 max. = 12.5 mm
Axle
122 mm
Length, L
Spoke
Hole Diameter, DS
Hole Ref. ø, HR
Gear Hub Ratio
Chain
Compatibility
126 mm
36
36
3.0 mm
2.9 mm
75 mm
89 mm
F1 = 30.5 mm / F2 = 29.5 mm
Totally
224 %
Speed 1
67 %
Speed 2
78 %
Speed 3
100 %
Speed 4
128 %
Speed 5
150 %
➔
➔
➔
➔
➔
➔
1
1
Usable Dimensions
Line, C/D/E
Ratio
Finish
Drum Version „D“
F1 = 28.5 mm / F2 = 29.5 mm
Flange Dist. to 1/2 OLD
Shifter
Clickbox
Hand Brake Lever
/2" x 1/8" or 1/2" x 3/32"
/2" x 1/8" or 1/2" x 3/32"
49 / 45.5 / 43 mm
51.5 / 48.5 / 45.5 mm
24", 26", 28"= 1.8 – 1.9 / 20"= 1.8 – 2.0
Clickbox P5
➔
➔
➔
SRAM Grip 5
—
see page 31
Tandem
Yes
Yes
Weight
1495 g
1536 g
Steel
Aluminum
Matt Chrome Plated
Clear Coat
Hub Shell Material
Finish
Technical Manual 2006
0
SRAM P5 with drum brake
Over Locknut Dim., OLD
Holes
10
Cycle frame:
• Dropouts must be parallel.
• Slot width at rear dropout max. 10,5 mm.
• The strength must be such that with a maximum braking torque of 250 Nm (2200 in.lbs.) on the rear wheel no
residual deformation can occur on the rear structure.
Coaster
Ends Diameter, T
R
A 1 max.
Brake
Dropout Width Dim.
H
U
B
S
F1
F2
SRAM P5 Cargo with coaster brake
Typ
DS
7
3.5
Tolerable stress:
Axle load: max. 120 kilograms
Torque/driver body: max. 85 Nm (750 in.lbs.),
no continuous stress.
Identification SRAM P5 Cargo:
Yellow grub screw inside the axle end.
HR
C
D
E
1/2 OLD
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“ certified.
CARGO
29
SRAM P5 CARGO
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
SRAM Grip 5
Shifter Type
Twist Shifter
Cable Length
1450 mm
Gear Indication
Window
Clamping Diameter
❘
1550 mm
❘
1650 mm
❘
1750 mm
❘
1850 mm
❘
1950 mm
❘
2150 mm
❘
2350 mm
22.3 mm
Handlebar, Straight Area
Minimum length for shifter = 150 mm
Weight
89g
Housing
Design
S
H
I
F
T
E
R
S
Glass filled PA
Grip
PP
Thermoplastic elastomer, Overmolded
Grip Cover
Clamping Collar
Aluminum
SRAM P5 CARGO
ASSEMBLY
W
W
NNEE • Fit new retaining washer (3,5 mm thick)
A S S E M B LY H U B
1
1
2
2
4 3
5
6
Mounting Tool
Part No. 0582 104 000
• Lace the wheel as normal. See spoke
length table.
• Place the dust cap (1, Fig. 1) and
sprocket (2) on the driver.
• Push sprocket circlip (3, Fig. 2) onto the
cone of tool sleeve (4). Place tool sleeve
with large diameter on the driver.
• Push the spring end of sliding sleeve (5)
of the tool over the tool sleeve. Thrust
sliding sleeve in direction (6), this forces
circlip into the recess of the driver.
• Remove tool and check that the circlip is
seated correctly.
• Turn dust cap (7, Fig. 3) until the three
lugs (8) are between the three beads (9)
on the sprocket (10).
• Position dust cap and push towards
sprocket until it is felt to lock into place.
• Placing the wheel in the rear frame.
3
8
on left axle end (1, Fig. 4). The serrations
must bear against the dropout and the
lug must engage in the dropout slot.
Advice:
For bicycles with chain tensioner use
previous retaining washers (2 pieces,
2 mm thick) – see Tech. Manual 2005.
• On the sprocket side fit the protective
bracket (1, Fig. 5) directly below the
axle nut. Tightening torque on axle nuts
30 – 40 Nm (266 – 350 in.lbs.).
• Mount the brake lever using a suitable
frame clamp (2, Fig. 4 resp. Fig. 10).
Caution:
Mount the brake lever between the two
straps of the frame clamp.
The clamp must be seated on the frame
without play.
Use a self-locking nut! Tightening
torque: 2 – 3 Nm (18 – 27 in.lbs.).
7
Spoke length table:
9
10
4
1
2
30
Tire Size
47–406
37–490
47–507
37–540
47–559
37–590
47–622
37–622
28–622
32–622
28–630
32–630
20" x 1.75 x 2
22" x 1 3 / 8
24" x 1.75 x 2
24" x 1 3 / 8
26" x 1.75 x 2
26" x 1 3 / 8
28" x 1.75
28" x 1 3 / 8 x 1 5 / 8
28" x 1 1 / 8
28" x 1 5 / 8 x 1 1 / 4
27" x 1 1 / 4 fifty
27" x 1 1 / 4
Cross
3x
3x
3x
3x
3x
3x
3x
3x
3x
3x
3x
3x
Length MH 5215
181 mm
225 mm
232 mm
251 mm
259 mm
275 mm
289 mm
289 mm
289 mm
289 mm
294 mm
294 mm
Length MH 5225
179 mm
222 mm
229 mm
248 mm
256 mm
272 mm
286 mm
286 mm
286 mm
286 mm
291 mm
291 mm
Spoke lengths are approximate values. They must be checked through lacing attempts
and adjusted accordingly.
Technical Manual 2006
SRAM P5 CARGO
ASSEMBLY
CARGO
Advice:
• If a different protective bracket (1, Fig. 5)
is used the thickness of the attachment
plate must be max. 3 mm.
• Do not use additional washers.
• At least the beginning of the axle thread
must be visible in front of the axle nut.
5
Caution:
Check that all the brake system
components are functioning properly!
1
2
3
A S S E M B LY S H I F T E R
6
4
5
2
3
7
2
8
1
1
Caution:
• Never use lubricants or solvents to
install fixed grips.
Fixed grips provide an axial safety
function. For this reason, they should be
mounted in such a way as to make sure
they do not slip off handlebar.
• Check that the shifter and brake lever
function properly and are unobstructed
(realign if necessary).
• Never ride without the fixed grips. The
turning grip may loosen from housing
and slip off handlebar – this can result
in severe injury or death.
7
6
2
4
1
3
5
9
a
25
l
10
2 3 1
4 6
5
7
8
Technical Manual 2006
Advice:
• When choosing cable housing lengths,
be sure to allow enough housing for an
extreme turn of the handlebars in both
directions.
• Note also, that different stem lengths
and handlebar positions effects cable
housing length.
• Slide shifter (1, Fig. 6) onto handlebar.
• Mount fixed grip (2) onto end of handlebar.
• Slide shifter against fixed grip, adjust
shifter on handlebar and tighten with
bolt (3) with a torque of 1.5 Nm (13 in.lbs.).
l
i =—
a
• When fitting the cable avoid small radius.
Attach the cable 3 times to the down
tube (1, Fig. 7).
• Last attachment point is on the lower
rear wheel fork (2, Fig. 7) immediately
behind the chain wheel.
Cable housing must be movable inside
attachment.
• Push locating sleeve (3) with guiding rib
(4) to the front onto the hub axle – making
sure that the internal lug (5) is guided in
the slot (6) of the shift tube until it can be
felt – and heard – to engage.
• Turn locating sleeve on the axle until the
guiding rib (4) is facing roughly upwards.
• Place shifter in gear position “2“.
• Push on Clickbox (2, Fig. 5) to the stop on
the hub axle. The guiding rib (4, Fig. 8) of
the locating sleeve thereby engages in
the slot on the housing. In the end position
tighten up the knurled bolt (3, Fig. 5) by
hand (0.3 Nm / 2.7 in.lbs.).
ADJUSTMENT
• Be sure to reset rotational shifter from
4th to 3rd gear.
• Match up the marks in the Clickbox
viewing window (4, Fig. 6) by turning
the adjusting screw (5).
CONNECTING DRUM BRAKE
Caution:
Only use brake levers with a cable
moving distance of at least 15 mm and a
leverage of “i“ = 3.8 – 4.2 (Fig. 9).
• Fit cable stop (1, Fig. 10) with adjusting
bolt (2) and nut (3) and insert into the slot
on the brake anchor plate.
• Turn adjusting bolt down by approx. 2/3
and route the brake cable from the
brake handle.
• Push lower brake cable end through
adjusting bolt (2) and insert lower cable
housing end into adjusting bolt.
• Thread brake cable end (4) into
fork unit (5).
• Tighten screw (6) slightly.
• Attach fork unit to brake lever (7).
• Pull brake cable end taut with pliers
so that fork unit can still be attached and
removed (important for changing wheel).
• Tighten screw (6).
Caution:
For NL version drum brake hub with
special lever (8), only use original NL
brake cable (fork unit (5) is not suitable).
INSTALLING CLICKBOX
ADJUSTMENT DRUM BRAKE
• Insert shift rod (1, Fig. 8) in shift tube (2)
(oil parts lightly) and then push into axle
bore as far as the stop. If the shifting rod
is sticking up out of the axle end: apply
slight pressure on the shift rod with its
threaded section and screw inwards in
a clockwise direction until it can again
be moved axially (valid for older hub
versions). Turn slot (6) in shift tube to a
position where it is easily visible.
• Unscrew adjusting screw (2, Fig. 10)
until the brake pads drag lightly.
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock hex nut (3).
Caution:
Check that all the brake system
components are functioning properly!
31
SRAM P5 CARGO
MAINTENANCE
9
1
8
30
7
29
28
27
6
26
5
25
4
3
24
23
2
17
18
16
1
19
20
21
41
22
40
38
15
39
14
37
36
11
12
13
35
33
10
34
32
31
REMOVE WHEEL
2
SRAM P5 mounting aid
Part No. 65 0524 300 000
• Place shifter in gear position “2“.
• Loosen the knurled screw (41, Fig. 1) and
pull the Clickbox off the axle.
• Disengage the red location sleeve (40)
and pull it off.
• Remove shift rod (39) and shift tube (38)
out of the axle bore.
• Remove wheel.
X
DISMANTLING HUB
see Fig. 1
3
32
• Remove circlip (36), sprocket (35) and
dust cap (34).
• Clamp hub with sprocket side facing
downwards with the two axle flats.
• Unscrew both locknuts (1).
W
W
NNEE • While turning clockwise, remove lever
cone (2) with friction spring (3) and ball
retainer (4).
• Take out 3 brake segments (5).
• Withdraw hub sleeve (6) upwards.
• Remove brake cone (7).
• Remove retaining washer (8), thrust
washer (9).
• Remove planetary gear carrier (10) and
thrust washer (11).
• Clamp other axle end.
• Unscrew fixed cone (33).
• Remove driver (32), compression spring
(30), large compression spring (28) and ball
retainer (31).
• Withdraw gear ring (27) and coupling
gear (26) and then remove cover (29)
from the coupling gear.
• Take out thrust block (25), (to do this
compress the spring). Remove spring
(23) and the two covers (24/22).
• Dismantle retaining washer (21), washer
(20), conical compression spring (19),
and the large sun gear (13). Clamp other
axle end (thrust block visible).
• Unscrew grub screw (15) – Dismantle
spring (16), guide bolt (17) and thrust
block (18).
• Remove small sun sun gear (12).
R E A S S E M B LY H U B
see Fig. 1
Lubrication see “MAINTENANCE /
LUBRICATION“.
• Clamp axle with internal thread upwards.
• Position small sun gear (12) with crown
gears to the front.
• Position thrust block (18) in the slotted
hole (is laterally guided when the sun
gear is screwed in).
Technical Manual 2006
SRAM P5 CARGO
MAINTENANCE
CARGO
• Locate bolt (17), then spring (16) in the
axle and screw in grub screw (15) until
it is flush with the axle.
• Reclamp axle. Fit large sun gear (13) (it
is the same both sides). Position conical
compression spring (19), with the large
diameter first. Press spring together and
fit washer (20) and retaining washer (21).
• Assemble cover (22), compression
spring with 7 turns (23) and the second
cover (24, insides to the spring).
• Compress spring and position thrust
block (25) (it is the same both sides) in
the center of the slotted hole.
• Position coupling gear (26) with carrier
plate facing downwards.
• Fit cover (29, inside to the spring) for
compression spring.
• Position gear ring (27) over the teeth of
the coupling gear.
• Place ball retainer (31), with balls below
on the gear ring.
• Position large compression spring (28)
on gear ring.
• Mount compression spring with 13 turns
(30) on the axle. (Is supported in the
coupling wheel by the cover).
• Locate driver (32), press it down and
screw on fixed cone (33) as far as the
stop. Tightening torque 20 Nm.
• Clamp other axle end.
• Push on thrust washer (11) and fit
planetary gear carrier (10). In doing this:
Position mounting aid (Fig. 2) on the
planetary gear carrier so that the (X)
markings on the three planetary gears
match with the mounting aid.
• Insert planetary gear carrier, place
thrust washer (8) on it and mount
retaining washer (9) in recess.
Now remove the mounting aid.
4
• Fit lever cone onto hub shell: the retaining lugs of the lever cone have to engage into the openings between the
brake segments. Make sure that lever
cone engages while turning back and
forth slightly.
• Screw on locknuts (1), adjust bearing
so that there is no play and lock nuts
together with 15 – 20 Nm (133 – 177in.lbs.).
Caution:
Check that all the brake system
components are functioning properly!
Advice:
Dismantling and reassembly of hub types
with drum brake (MH 5225 Cargo) should
be carried out in the same way.
Differences: Instead of brake segments /
cone a click-and-pawl carrier is installed
on the planetary gear carrier.
Advice:
If the gears are not accurately installed
the hub may be tight to move.
This could lead to damage to the gearwheels in operation.
• Assemble hub shell (6) with a slight
counter-clockwise movement.
In case the hub shell jams, position the
plastic ring (Fig. 3) correctly.
W
W• Screw brake cone (7) clockwise onto the
E
E
NN
planetary gear carrier (10) until it stops.
• Insert 3 brake segments (5).
• Turn in friction spring (3) counterclockwise into the lever cone (2) (inlying
winding of the spring has to lie against
the lever cone) (Fig. 4).
• Insert ball retainer (4) (balls are facing
upwards) into lever cone (2): the 3 recesses have to engage into the retaining
lugs of the lever cone. Slightly turn ball
retainer to prevent it from falling off.
Technical Manual 2006
33
SRAM P5 CARGO
MAINTENANCE
CABLE CHANGE
5
2
Dismantling shifter cable:
• Place shifter in gear position “1“.
• Do not remove the Clickbox from the axle
end.
• Unscrew the adjusting screw (1, Fig. 5)
completely. Unscrew the cover screw (2),
brush aside the adjusting screw (1) and
remove the cover (3).
• Withdraw shifter cable and clamping
bolt (1, Fig. 6) upwards, loosen clamp
and pull clamping piece from the cable.
• Slightly lift the grip cover (Fig. 7), push
the cable out and discard.
3
1
6
1
2
7
Assembly shifter cable:
• Route new cable through shifter housing
and pull cable to seat cable head
completely into cable recess.
Feed the cable through the new cable
housing and adjusting screw.
• Position clamping bolt (1, Fig. 8) at a
distance of 80 mm, tighten up with
1.5 Nm (13 in.lbs.) and cut off cable ends
to 2 – 3 mm. For positioning the clamping
bolt use adjust gauge (Fig. 9). (Part. No.
65 0324 107 000)
• Locate clamping bolt (1, Fig. 6) and place
shifter cable around the carrier cylinder
(counter-clockwise winding).
• Position the cover (3, Fig. 5) and tighten
up with the cover screw (2).
Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.).
Screw in the adjusting screw (1)
completely.
Advice:
• If you want to remove the Clickbox from
the axle end for changing the cable, do
as follows:
– Place shifter in gear position “1“.
– Loosen the knurled screw and pull the
Clickbox off the axle.
– Now it’s essential to push the end (1,
Fig. 8) of the adjust gauge completely
into the Clickbox and tighten up the
knurled bolt (so that you maintain the
initial tension of the spring inside the
Clickbox).
– Change cable as per description above.
• If you remove the Clickbox from the
axle and change the cable without
using the end of the adjust gauge, then
you will lose the initial tension of the
spring inside the Clickbox. In this case
you must assemble the cable by placing
it around the carrier cylinder with an
additional winding (Fig. 6).
8
80 ±0,5 mm
2 +1 mm
1
9
1
34
Technical Manual 2006
SRAM P5 CARGO
MAINTENANCE
CARGO
DRUM BRAKE
10
2
3
1
4
6
5
11
10
9
8
•
Install brake anchor plate (or exchange it):
• Place thrust washer (8, Fig. 10) over the
•
axle on the adjusting cone and fit
complete brake anchor plate. Position
washer (9) distance sleeve (10) and
•
screw on locknut (11).
• Push brake lever (7) to the stop and hold
W•
it there to center the brake jaws in the NNEEW
brake drum – tighten up locknut with a
•
torque of 15 – 20 Nm (133 – 177 in.lbs.).
7
ADJUSTMENT DRUM BRAKE
• Unscrew adjusting screw (2, Fig. 10)
until the brake pads drag lightly.
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock hex nut (3).
Oil the inside of the sun gears, grease
the outside teeth (fill the gaps in the
teeth).
Oil outside teeth and carrier plate on
the coupling gear and lightly grease the
borehole from right and left.
Do not apply grease to ring gear but just
oil the pawl pockets.
Slightly grease the actuation ramps of
the planetary gear carrier.
Apply grease all around the seat area of
the friction spring. Oil the pawl pockets.
• Spread grease on the complete surfaces
inside and outside of the 3 brake segments.
• Regrease ball retainer and insert into
lever cone, slightly grease cone surface
of the lever cone.
• Line ball bearing running tracks and
brake cylinder in hub shell with grease.
Caution:
Check that all the brake system
components are functioning properly!
MAINTENANCE /
LUBRICATION
Caution:
The SRAM hubs are provided with
permanent lubrication and under normal
conditions is maintenance-free. If the
coaster brake is loaded excessively its
effect can be too strong, the hub may lock.
In such a case the 3 brake segments should
be lubricated with a special grease (Part
No. 0369 135 200/ ...201). Renew brake segments when rhombic pattern is worn out.
Cleaning of parts:
• All parts – except for the planetary gear
carrier – can be degreased in a cleaning
bath.
• The planetary gear carrier only needs to
be cleaned on the outside with a brush
so as not to degrease the planetary gear
bearing.
Caution:
Do not use high-pressure water when
cleaning the gear hub (e.g. strong water
jets, high-pressure cleaners etc.) –
if water penetrates it could lead to
functional problems.
Lubrication of parts:
Use only SRAM grease (Part No. 0369 135 200/
...201) and standard bicycle oil.
• To lubricate the bearing points on the
planetary gear sets, position the planetary gear carrier on its crown and apply
2 – 3 drops of oil to the bearing bolts –
at the same time turning the planetary
gears so that the bearing points are
completely wet. Oil axle through the axle
bore and axle slot, apply a thin coating
of grease to the outside.
Technical Manual 2006
TROUBLESHOOTING
Problem
Shifting
difficulties
Pedals are
carried
forward
when freewheeling
Hub locks
when
braking
(coaster
brake)
Coaster
brake
without
function
Remedy
Replace
control cable
Adjust shift.
system
Beginning of
axle thread
must be visible in front of
the axle nut
Re-adjust
bearings
Tighten
lock nuts
(15 – 20 Nm)
Chain is over- Reduce
chain tension
tensioned
Wash out
Brake seghub sleeve,
ments has
repolish and
run dry
relubricate
brake cylinder,
renew brake
segments
Fit friction
Incorrect
mounted fric- spring in
tion spring (3, correct way
Fig.1/Page 24)
Cause
Damaged
control cable
Incorrect
gear setting
To much additional axle
attachments
between hub
and axle nut
Bearings
set too tight
Loose
lock nuts
35
36
Technical Manual 2006
SRAM T3
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
L
OLD
i-BRAKE for SRAM T3:
see page 54.
Version with Coaster Brake
C
D
E
1/2 OLD
Caution:
SRAM T3 hubs are not suitable for
tandems, trademen’s delivery bicycles
and similar.
F2
F1
R
SRAM T3 for i-BRAKE
SRAM T3 with drum brake
MH 3115
—
MH 3125
Brake
Coaster
i-BRAKE (see page 54)
Drum
Over Locknut Dim., OLD
118 mm
127 mm
118 mm
118 mm
155 oder 166 mm 166 mm
166 mm
166 mm
Spoke
Axle
SRAM T3 with coaster brake
Length, L
Ends Diameter, T
FG 10.5
Holes
36 or 28
Hole Diameter, DS
Hole Ref. ø, HR
Compatibil. Chain Gear Hub Ratio
❘
❘
❘
3.0 mm
36
„D“
❘
10
0
SRAM T3 without brake
MH 3105
„NL“
None
117 mm
155 mm oder 166 mm
FG 10.5
FG 10.5
FG 10.5
36
36
36
3.0 mm
2.8 mm
3.0 mm
58 mm
58 mm
58 mm
89 mm
F1 = 24.5 mm / F2 = 25.5 mm
F1 = 23.7 mm / F2 = 26.3 mm
F1 = 25.5 mm / F2 = 32.5 mm
F1 = 24.5 mm / F2 = 25.5 mm
Totally
186 %
Speed 1
73 %
Speed 2
100 %
136 %
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
44.5 / 41.5 / 38.5 mm
44.5 / 41.5 / 38.5 mm
Flange Dist. to 1/2 OLD
Speed 3
Line, C/D/E
44.5 / 41.5 / 38.5 mm
44 / 41 / 38 mm
➔
➔
SRAM T3 / SRAM Bandix 3
➔
➔
➔
Hand Brake Lever
—
see page 55
see page 39
—
Tandem
—
—
—
—
Weight
1182 g
1554 g (complete with i-BRAKE) 1270 g
911 g
Steel
Steel
Aluminum
Steel
Matt Chrome Plated
Matt Chrome Plated
Silver Painted
Matt Chrome Plated
Ratio
Shifter
Hub Shell Material
Finish
Shifter Type
Cable
Comp. Cable Housing
24", 26", 28"= 2.0 – 2.4 / 20"= 2.0 – 2.5
SRAM T3 ( for adults)
SRAM Bandix 3 ( for kids)
Twist Shifter
Twist Shifter
ø 1.2 mm
ø 1.2 mm
2174 mm / 2500 mm
2174 mm
Capped, Compressionless with Resin Liner inside
Gear Indication
Printed
Clamping Diameter
22.3 mm
22.3 mm
Minimum length for shifter = 155 mm
Minimum length for shifter = 155 mm
Handlebar, Straight Area
Design
S
H
I
F
T
E
R
S
Ø 7.3
Type
Finish
H
U
B
S
DS
T
Cycle frame:
• Dropouts must be parallel.
• Slot width at rear dropout max. 10,5 mm.
• The strength must be such that with a maximum braking torque of 250 Nm (2200 in.lbs.)
on the rear wheel no residual deformation
can occur on the rear structure.
HR
Printed
Weight
65 g
65 g
Housing
PA
PA
Grip
PP
PP
Grip Cover
Clamping Collar
Thermoplastic elastomer
Thermoplastic elastomer
Aluminum
Aluminum
Technical Manual 2006
37
SRAM T3
ASSEMBLY
1
1
2
A S S E M B LY H U B
2
4 3
5
6
Mounting Tool
Part No. 0582 104 000
3
8
7
9
10
4
1
2
5
1
• Lace the wheel as normal. See spoke
length table.
• Place the dust cap (1, Fig. 1) and
sprocket (2) on the driver.
• Push sprocket circlip (3, Fig. 2) onto the
cone of tool sleeve (4). Place tool sleeve
with large diameter on the driver.
• Push the spring end of sliding sleeve (5)
of the tool over the tool sleeve. Thrust
sliding sleeve in direction (6), this forces
circlip into the recess of the driver.
• Remove tool and check that the circlip is
seated correctly.
• Turn dust cap (7, Fig. 3) until the three
lugs (8) are between the three beads (9)
on the sprocket (10).
• Position dust cap and push towards
sprocket until it is felt to lock into place.
• Screw tension chain (2, Fig. 5) into the
axle end.
• Placing the wheel in the rear frame.
• Mount the chain.
W
W• Fit new retaining washer (3,5 mm thick)
E
E
NN
on left axle end (1, Fig. 4). The serrations
must bear against the dropout and the
lug must engage in the dropout slot.
Advice:
For bicycles with chain tensioner use
previous retaining washers (2 pieces,
2 mm thick) – see Tech. Manual 2005.
• Tighten up special type axle nut (1, Fig. 5)
and axle nut at other axle end. Tightening
torque 30 – 40 Nm (266 – 350 in.lbs.).
• Guide tension chain (2) trough
deflection pulley (3).
• Position deflection pulley at axle nut and
push until it is felt to lock into place.
Turn deflection pulley until the circular
area is at the top (4, Fig. 6).
Tire Size
4
6
5
38
• Mount the brake lever using a suitable
frame clamp (2, Fig. 4 resp. Fig 11).
Caution:
Mount the brake lever between the two
straps of the frame clamp.
The clamp must be seated on the frame
without play.
Use a self-locking nut! Tightening
torque: 2 – 3 Nm (18 – 27 in.lbs.).
Caution:
Check that all the brake system
components are functioning properly!
Spoke length table:
2
3
Caution:
• Only install additional axle attachments
(e.g. struts) between nut and retaining
washer.
• Cable stop bracket: dimensions
see Fig. 9.
• Axle end must protrude by min. 1 mm
to max. 4 mm beyond the nut (1, Fig. 5).
47–406
37–490
47–507
37–540
47–559
37–590
47–622
28–622
32–622
37–622
28–630
32–630
20" x 1.75 x 2
22" x 1 3 / 8
24" x 1.75 x 2
24" x 1 3 / 8
26" x 1.75 x 2
26" x 1 3 / 8
28" x 1.75
28" x 1 1 / 8
28" x 1 5 / 8 x 1 1 / 4
28" x 1 3 / 8 x 1 5 / 8
27" x 1 1 / 4 fifty
27" x 1 1 / 4
Cross
28 / 36 Holes
2x/3x
— /3x
2x/3x
— /3x
2x/3x
— /3x
2x/3x
— /3x
— /3x
— /3x
— /3x
— /3x
Length MH 3115/3105
28
/ 36 Holes
182 mm / 184 mm
—
/ 228 mm
234 mm / 235 mm
—
/ 254 mm
258 mm / 262 mm
—
/ 254 mm
289 mm / 292 mm
—
/ 292 mm
—
/ 292 mm
—
/ 292 mm
—
/ 297 mm
—
/ 297 mm
Length MH 3125
36 Holes
—
—
—
—
253 mm
273 mm
285 mm
285 mm
285 mm
285 mm
287 mm
287 mm
Spoke lengths are approximate values. They must be checked through lacing attempts
and adjusted accordingly.
Technical Manual 2006
SRAM T3
ASSEMBLY
7
1
2
3
2.5 mm
1.7 Nm
15 in.lbs.
8
5
4
2
3
9
1
A S S E M B LY S H I F T E R
ADJUSTMENT
• Slide shifter (1, Fig. 7) onto handlebar.
• Mount fixed grip (2) onto end
of handlebar.
• Without applying pressure, slide shifter
against fixed grip, adjust shifter on
handlebar and tighten with bolt (3). Allen
key 2.5 mm, torque 1,7 Nm (15 in.lbs.)
• Not recommended for use on thin walled
aluminum handlebars such as Hyperlite©
type handlebars.
• Place the shifter in gear position "3".
Move the crank to check that the gear
is engaged.
• To make the adjustment, the cable must
be taut in third gear to be able to transfer
a shift movement directly to the hub.
• Push locating sleeve (2, Fig. 8) onto the
small pull rod (3) until the control cable
is taut. Make sure that you don’t pull the
indicator chain out of the deflection
pulley (4).
Caution:
• Never use lubricants or solvents to
install fixed grips.
Fixed grips provide an axial safety
function. For this reason, they should be
mounted in such a way as to make sure
they do not slip off handlebar.
• Check that the shifter and brake lever
function properly and are unobstructed
(realign if necessary).
• Never ride without the fixed grips. The
turning grip may loosen from housing
and slip off handlebar – this can result
in severe injury or death.
INSTALLING CABLE
min.
13 mm
max. 30°
min. 12 mm
min. 90 mm
10
a
25
l
11
2 3 1
4 6
l
i =—
a
• When fitting the cable avoid small radius.
Use only compressionless cable housings
with resin liner inside and capped.
• Screw the cable stop clamp and cable
pully clamp on the down tube or seat tube.
• Secure the lubricated shift cable at
equidistant intervals on the frame
(in case of continuous cable housing).
Advice:
To avoid malfunction the cable frictional
force must not exceed 6 N (1.4 lbs.).
• Feed the shifter cable into the locating
sleeve (5, Fig. 8), fix at the appropriate
length (cable stop bracket: see Fig. 9)
using the clamping bolt (1).
Allan key 2.5 mm, tightening torque
1.5 Nm (13 in.lbs.). Shorten any cable
which is sticking out.
• Connect to the hub: push locating sleeve
(2, Fig. 8) loosely onto small pull rod (3).
Check:
• Place shifter in gear position "1" while
moving the crank.
• Setting too loose: In gear position "1" the
tension chain can be pulled out of the
deflection pulley by hand.
• Setting too tight: It is difficult to place
the shift lever in gear position "1".
• If required, readjust the shift mechanism
(in third gear).
CONNECTING DRUM BRAKE
Caution:
Only use brake levers with a cable
moving distance of at least 15 mm and a
leverage of “i“ = 3.8 – 4.2 (Fig. 10).
• Fit cable stop (1, Fig. 11) with adjusting
bolt (2) and nut (3) and insert into the slot
on the brake anchor plate.
• Turn adjusting bolt down by approx. 2/3
and route the brake cable from the
brake handle.
• Push lower brake cable end through
adjusting bolt (2) and insert lower cable
housing end into adjusting bolt.
• Thread brake cable end (4) into
fork unit (5).
• Tighten screw (6) slightly.
• Attach fork unit to brake lever (7).
• Pull brake cable end taut with pliers
so that fork unit can still be attached and
removed (important for changing wheel).
• Tighten screw (6).
Caution:
For NL version drum brake hub with
special lever (8), only use original NL
brake cable (fork unit (5) is not suitable).
ADJUSTMENT DRUM BRAKE
• Unscrew adjusting screw (2, Fig. 11)
until the brake pads drag lightly.
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock hex nut (3).
5
7
8
Technical Manual 2006
Caution:
Check that all the brake system
components are functioning properly!
39
SRAM T3
MAINTENANCE
1
REMOVE WHEEL
Coaster brake / MH 3115
• Apply fingertip pressure onto the metal
key of locating sleeve to release it from
the pull rod.
• Remove deflection pulley.
• Screw off both axle nuts and remove
retaining washers.
• Remove wheel.
14
13
11
5
4
3
12
2
DISMANTLING HUB
10
see Fig. 1
1
9
7
6
23
8
22
21
20
19
18
17
16
2
x
a
Without brake / MH 3105
b
c
3
d
e
Advice:
The dismantly and reassembly of the hubs
with drum brake and without brake
should be carried out in the same way
(Fig. 2 / 3).
1
3
• Unscrew indicator chain (23), remove
circlip (21), sprocket (20), dust cap (19)
and clamp axle (10) on the driver side.
• Unlock hexagonal nuts (1) and unscrew.
• Remove brake arm (2), ball retainer (3)
and brake sleeve (4) and remove hub
shell (5).
• Remove safety washer (7), thrust washer
(8) and then the planet carrier (9)
complete with brake cone (6). Unscrew
the brake cone from the planet carrier.
• Clamp other axle end.
• Loosen the lock nut (22) and fixed cone
(18) and remove.
• Remove driver (17), compression springs
(14 and 13) and ball retainer (16).
• Push the sliding key (12) through the
large bore in the coupling wheel of the
ring gear (11) – the bore and thrust block
must be aligned.
• Remove the gear ring (11) from the axle.
Drum brake / MH 3125
a
b
c
x
Differences
• There is no brake sleeve (4) and brake
cone (6).
• The planet carriers (a) have a cylindrical
shaft instead of a flat thread, which houses a pawl carrier (b) held by a safety
washer instead of the brake cone.
• Further differences: instead of a lever
cone (2) for type MH 3115, an adjusting
cone (d) with dust cap (e) for type
MH 3105 and a small adjusting cone (D)
and corresponding ball retainer (f) for
type MH 3125 are fitted.
f
D
40
Technical Manual 2006
SRAM T3
MAINTENANCE
4
R E A S S E M B LY H U B
CABLE CHANGE
see Fig. 1 / 2 / 3
Dismantling shifter cable:
• Use only new cable and compressionless cable housing
• Detach the cable from the internal hub.
• Remove the cable housing. Cut the cable
off 15 cm (6") from the shifter barrel
adjuster. Discard the old cable and cable
housing.
• Line up the ‘3’ gear number mark with
the indicator mark.
• Remove and discard the rest of the old
cable (Fig. 6).
Lubrication see “MAINTENANCE /
LUBRICATION“.
• Clamp the hub axle (10) with the slot for
thrust block upwards), fit ring gear (11)
and align the large bore in the coupling
wheel with the slot. Position the radius
of the sliding key (12) facing downwards
and turn the coupling wheel slightly.
• Fit the compression springs (13 and 14).
• Place ball retainer with balls in (16) on
ring gear (11), mount driver (17), fit fixed
cone and lock with hexagonal nut (22),
tightening torque 15 – 20 Nm
(133 – 177 in.lbs).
• Turn hub over and slide on planet carrier
(9) – thrust washer (X) must first be fitted
for types MH 3105/3125. (For type MH
3115, this washer is already integrated in
the planet carrier). Mount thrust washer
(8) and place safety washer (7) in the
recess of the axle.
• Screw brake cone (6, type MH 3111) onto
the flat thread – for types MH 3105/3125
mount pawl carrier (b) and secure in
place using safety washer (c).
• Fit hub shell (5) – turning it counterclockwise slightly to get past the stop
notches – until the shell runs cleanly
onto the ball retainer.
• For type MH 3115, insert the brake sleeve (4) so that the spring end of the friction spring on the brake cone (6) sits in
one of the two slots on the brake sleeve.
Insert the ball retainer and fit the lever
cone – move the lever cone lightly until
the lugs on the brake lever catch in the
grooves on the adjusting cone.
• Adjust the hub clearance by screwing on
hexagonal nut (1) until the hub shell runs
free of play but not under tension. Lock
with a second nut to a tightening torque
of 15 – 20 Nm (133 – 177 in.lbs.).
• For type MH 3105 insert ball retainer (3),
mount adjusting cone (d) with dust cap
(e) and hexagonal nuts (1). Adjust the
hub clearance as for type MH 3115.
• For type MH 3125, the ball retainer (f)
and dust cap (pressed in) normally
remain in the hub shell. The hub
clearance is set with adjusting cone (D)
as for type MH 3115.
Ø 1,1 mm
5
Ø 1,4 mm
6
7
Assembly shifter cable:
• Feed the new cable through the shifter.
• Feed the cable through the new cable
housing and stops.
• Feed the shifter cable into the locating
sleeve (5, Fig. 7), fix at the appropriate
length using the clamping bolt (1). Allan
key 2.5 mm, tightening torque 1.5 Nm
(13 in.lbs.). Shorten any cable which is
sticking out.
• Connect to the hub: push locating sleeve
(2, Fig. 7) loosely onto small pull rod (3).
ADJUSTMENT
• Place the shifter in gear position "3".
Move the crank to check that the gear
is engaged.
• To make the adjustment, the cable must
be taut in third gear to be able to transfer
a shift movement directly to the hub.
• Push locating sleeve (2, Fig. 7) onto the
small pull rod (3) until the control cable
is taut. Make sure that you don’t pull the
indicator chain out of the deflection
pulley (4).
Check:
• Place shifter in gear position "1" while
moving the crank.
• Setting too loose: In gear position "1" the
tension chain can be pulled out of the
deflection pulley by hand.
• Setting too tight: It is difficult to place
the shift lever in gear position "1".
• If required, readjust the shift mechanism
(in third gear).
5
4
3
Technical Manual 2006
2
1
41
SRAM T3
MAINTENANCE
DRUM BRAKE
8
2
3
1
4
6
5
11
10
9
8
Install brake anchor plate (or exchange it):
• Place thrust washer (8, Fig. 8) over the
axle on the adjusting cone and fit
complete brake anchor plate. Position
washer (9) distance sleeve (10) and
screw on locknut (11).
• Push brake lever (7) to the stop and hold
it there to center the brake jaws in the
brake drum – tighten up locknut with a
torque of 15 – 20 Nm (133 – 177 in.lbs.).
7
ADJUSTMENT DRUM BRAKE
• Unscrew adjusting screw (2, Fig. 8) until
the brake pads drag lightly.
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock hex nut (3).
Caution:
Check that all the brake system
components are functioning properly!
MAINTENANCE /
LUBRICATION
Coaster Brake:
Improved braking in third gear after
production date CW 38/96
• In case of repair, older hub models (Fig. 4)
can be converted with a repair set (Fig. 5).
It is important that all three parts are
replaced at the same time – new,
reinforced compression springs, planet
carrier with 4 lugs and ring gear with
4 lugs on the driving plate.
• Feature of the new or converted hubs:
When braking in third gear, the indicator
chain moves out of the deflection pulley
by approx. one chain link – after braking,
the tension chain returns immediately to
its normal position.
Cleaning of parts:
• All parts – except for the planetary gear
carrier – can be degreased in a cleaning
bath.
• The planetary gear carrier only needs to
be cleaned on the outside with a brush
so as not to degrease the planetary gear
bearing.
Lubrication of parts:
Use only SRAM grease (Part No. 0369 135 200/
...201) and standard bicycle oil.
• To lubricate the bearing points on
the planetary gear sets, position the
planetary gear carrier on its crown and
apply 2 – 3 drops of oil to the bearing
bolts – at the same time turning the
planetary gears so that the bearing
points are completely wet. Oil axle
through the axle bore and axle slot,
apply a thin coating of grease to the
outside.
• Oil the inside of the sun gears, grease
the outside teeth (fill the gaps in the
teeth).
• Oil outside teeth and carrier plate on
the coupling gear and lightly grease the
borehole from right and left.
• Do not apply grease to ring gear but just
oil the pawl pockets.
• Grease the brake cone in the borehole
and the friction spring.
• Spread grease on the inside and outside
of the brake shell.
• Fill lever cone with grease reserves for
brakes.
• Regrease ball retainer, line ball bearing
running tracks with grease.
Caution:
Do not use high-pressure water when
cleaning the gear hub (e.g. strong water
jets, high-pressure cleaners etc.) –
if water penetrates it could lead to
functional problems.
Caution:
The SARM hubs are provided with
permanent lubrication and are maintenancefree under normal conditions. For type
MH 3115, however, particularly high
loading of the coaster brake can cause
to overcompensate. In this case, apply
special grease (Part No. 0369 135 200/...201).
to the brake sleeve or replace it.
Renew brake shell, when rhombic pattern
is worn out.
42
Technical Manual 2006
SRAM T3
MAINTENANCE
TROUBLESHOOTING
Problem
Shifting difficulties
Cause
Incorrect gear setting
Pedals are carried forward
when freewheeling
Bearings set too tight
Loose lock nuts
Chain is overtensioned
Ccoaster brake:
Hub locks when braking
Pedals yield slowly during
braking (does not impair
safety).
Brake shell has run dry
Brake cone / brake sleeve
Technical Manual 2006
Remedy
Adjust shifting system, oil
control cable, check that cable
stop is fastened correctly.
Re-adjust bearing
Tighten lock nuts (15 – 20 Nm)
Reduce chain tension
Wash out hub sleeve, repolish and relubricate brake
cylinder, renew brake shell
Replace brake cone and brake
sleeve
43
44
Technical Manual 2006
SPARC
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
190
135
55
40
205
194
33.5
40
25
185
30°
2.7
16
8.6
Caution:
Not suitable for tandems, tradesmen’s delivery bicycles and similar.
12.5
67.5
Cycle frame:
• Dropouts must be parallel.
• Slot width at rear dropout max. 10,5 mm.
49.5
Electric Drive
Range
V max.
Sparc hub 16,8V
28" / 26"
20"
26" USA
Econ Mode
20 km/h
16 km/h
26 km/h
Speed Mode
25 km/h
23 km/h
32 km/h
with 15 km/h ø
about 15 km (Speed Mode)
with 20 km/h ø
about 25 km (Speed Mode)
with 24 km/h ø
about 35 km (Speed Mode)
Engine Type
Power
Axle
Spoke
Ratio
2 x 16,8V DC engines
Assist Type
Pedal controlled
Econ / Speed
None
Over Locknut Dim.
135 mm
Length
190 mm
Ends Diameter
FG 10.5
Holes
36
Hole Diameter
2.9 mm
Hole Reference ø
194 mm
Totally
Speed 1/2/3/4/5
Usable Dimension
Line
Ratio
Sparc Shifter
Shifter Type
Cable Length
Twist Shifter
❘
❘
Window
❘
❘
1950 mm 2150 mm 2350 mm
Gear Indication
Clamping Diameter
Handlebar, Straight Area
Weight
❘
❘
1450 mm 1550 mm 1650 mm 1750 mm 1850 mm
22.3 mm
Minimum length = 150 mm
89 g
R
E
M
.
C
O
N
.
Sparc Remote Control Unit
Part. No.
Cable Length (mm)
Mode Selector
❘ —1600 ❘ —1700 ❘ —1800 ❘ —2000 ❘ —2200
❘ ❘ ❘ ❘ ❘
Off / Econ / Speed
—
1500
Mode Indication
Printed
Clamping Diameter
22.3 mm
Cable Connection
Weight
3.5 mm stereo jack
45 g
251%
63 % / 78 % / 100 % / 128 % / 158 %
1
/2" x 1/8" or 1/2" x 3/32"
49.5 mm (only off-set sprockets)
1.7 – 2.6
Shifter Compatib.
Sparc Shifter
Frame Compatib.
Dropouts max. 7 mm
Over Locknut Dim. (OLD) 135 mm
Weight
S
H
I
F
T
E
R
2 x 100 W max.
Assist Ratio
Brake
Chain
H
U
B
Wheel ø
2450 g
Technical Manual 2006
B
A
.
B
O
X
Sparc Battery Box 16,8V
Battery
❘ —750 ❘ —850 ❘ —1400 ❘ —1650 ❘ —1950
❘ ❘ ❘ ❘ ❘
16,8V / 8Ah NiMH battery
Charger
16,8V / 2A
Part. No.
Cable Length (mm)
Charging time
Luggage carrier comp.
Weight
—
650
4 hours 30 minutes
Struts: ø 8 mm / dist. 68 mm center to center / parallel
2400 g
45
SPARC
ASSEMBLY
1
1
2
2
4 3
5
Mounting Tool
Part No. 0582 104 000
3
• Slide shifter (1, Fig. 6) onto handlebar.
• Mount fixed grip (2) onto end of handlebar.
• Slide shifter against fixed grip, adjust
shifter on handlebar and tighten with
bolt (3) with a torque of 1.5 Nm (13 in.lbs.).
A S S E M B LY H U B
8
• Place the dust cap (1, Fig. 1) and
sprocket (2) on the driver. Toothing close
to the hub (only sprocket version off-set).
• Push sprocket circlip (3, Fig. 2) onto the
cone of tool sleeve (4). Place tool sleeve
with large diameter on the driver.
• Push the spring end of sliding sleeve (5)
of the tool over the tool sleeve. Thrust
sliding sleeve in direction (6), this forces
circlip into the recess of the driver.
• Remove tool and check that the circlip is
seated correctly.
• Turn dust cap (7, Fig. 3) until the three
lugs (8) are between the three beads (9)
on the sprocket (10).
• Position dust cap and push towards
sprocket until it is felt to lock into place.
• Placing the wheel in the rear frame.
Advice:
Dropouts must be parallel.
W
W
NNEE • Fit new retaining washer (3,5 mm thick)
on left axle ends (1, Fig. 4). The serrations
must bear against the dropout and the
lug must engage in the dropout slot.
Advice:
For bicycles with chain tensioner use
previous retaining washers (2 pieces,
2 mm thick) – see Tech. Manual 2005,
Page 46.
• On the sprocket side fit the protective
bracket (1, Fig. 5) directly below the
axle nut. Tightening torque on axle nuts
30 – 40 Nm (266 – 350 in.lbs.).
7
9
10
4
1
5
1
2
3
4
5
3
46
A S S E M B LY S H I F T E R
Version 28" / 26":
1-cross only.
All spoke heads must be positioned either
at the outside or the inside of the respective spoke flange.
Spoke tension about 1000 N recommended.
Version 20":
• 1-cross:
Use only rim „Rigida 20x406 59 (L 01 12 E)“
(or contact SRAM).
All spoke heads must be positioned at the
outside of the spoke flange.
Spoke tension about 1000 N recommended.
• Radial lacing:
No restrictions.
Spoke tension about 1000 N recommended.
6
6
LACING THE WHEEL
2
Advice:
• If a different protective bracket is used
the thickness of the attachment plate
must be max. 3 mm.
• Do not use additional washers.
• At least the beginning of the axle thread
must be visible in front of the axle nut.
Caution:
• Never use lubricants or solvents to
install fixed grips.
Fixed grips provide an axial safety
function. For this reason, they should be
mounted in such a way as to make sure
they do not slip off handlebar.
• Check that the shifter and brake lever
function properly and are unobstructed
(realign if necessary).
• When fitting the cable (1, Fig. 7) avoid
small radius.
• Last attachment point is on the lower
rear wheel fork (2, Fig. 7) immediately
behind the chain wheel.
Cable housing must be movable inside
attachment.
INSTALLING CLICK BOX
• Insert shift rod (1, Fig. 8) in shift tube (2)
(oil parts lightly) and then push into axle
bore as far as the stop. Turn slot (6) in
shift tube to a position where it is easily
visible.
• Push locating sleeve (3) with guiding rib
(4) to the front onto the hub axle –
making sure that the internal lug (5) is
guided in the slot (6) of the shift tube
until it can be felt – and heard – to engage.
• Turn locating sleeve on the axle (7) until the
guiding rib (4) is facing roughly upwards.
• Place shifter in gear position “2“.
• Push on clickbox (2, Fig. 5) to the stop on
the axle. The guiding rib (4, Fig. 8) of the
locating sleeve thereby engages in the
slot on the housing. In the end position
tighten up the knurled bolt (3, Fig. 5) by
hand (0.3 Nm / 2.7 in.lbs.).
ADJUSTMENT HUB
• Be sure to reset rotational shifter from
4th. to 3rd gear.
• Match up the arrow marks in the
Clickbox viewing window (4, Fig. 6)
by turning the adjusting screw (5).
1
Technical Manual 2006
SPARC
ASSEMBLY
A S S E M B LY B AT T E R Y B O X
7
• Pull both quick releases outward and
turn them to the „open“ position (Fig. 9).
• Position battery box onto luggage
carrier struts (3, Fig. 7).
• Push quick releases inwards and turn
them to the „closed“ position (Fig. 9).
• Slide plug of battery cable in the slot of
the battery box until it snaps in.
• Attach cable along the frame or luggage
carrier strut.
Advice:
Last attachment point of the cable at the
rear fork: approx. 8 cm away from the
axle end.
Do not jam the cable between frame
and rear hub and keep it away from the
rotating hub shell.
• Slide plug in the slot on the hub until it
snaps in.
1
2
3
8
7
6
Advice:
Closed elements such as brazed-on eye
bolts are not suitable because plug will
not pass through.
4
S T O R I N G B AT T E RY B O X
2
1
3
The battery box should be stored fully
charged in a dry and cool place. Remove
the plug of the battery cable from the box.
5
All batteries are shipped with an additional
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.
You can identify the next necessary charge
date at a glance (at least 3 months after
last charge).
9
A S S E M B LY R E M O T E
CONTROL UNIT
• Slide remote control unit (1, Fig. 10) onto
handlebar.
• Mount brake lever (2) and fixed grip (3).
• Adjust remote control unit on handlebar
and tighten the bolt (4) with a torque of
1.5 Nm (13 in.lbs.).
• Slide plug of remote control cable in the
slot (5) of the remote control unit until it
snaps in.
• Attach cable along the frame.
Advice:
Last attachment point of the cable at the
rear fork: approx. 8 cm away from the
axle end.
Do not jam the cable between frame
and rear hub.
Make a cable loop between plug and
cable attachment point to avoid tensile
load.
• Slide the plug straightly in the slot on the
hub until it snaps in.
Angular installation may damage the
slot.
Check:
Switch remote control to „Speed“ position
and rotate the rear wheel (Battery has to be
fully charged).
At least 1 green and the red LED must
gleam. If not, assemble plugs again
completely / right.
open
closed
10
2
3
1
5
1
Technical Manual 2006
4
47
SPARC
MAINTENANCE
10
7
1
9
8
31
32
30
41
4
6
29
5
27
28
26
39
25
3
2
23
1
24
38
22
19
17
20
40
21
36
18
16
37
15
34
35
14
33
13
12
11
2
Sparc mounting aid
Part No. 65 3024 001 000
X
REMOVE WHEEL
DISMANTLING GEAR HUB
• Pull the remote control cable plug off
the hub.
• Apply fingertip pressure onto the tap and
pull battery cable plug off the hub.
• Loosen the knurled screw (40, Fig. 1) and
pull the Clickbox off the axle.
• Disengage the red locating sleeve (38)
and pull it off. Remove shift rod (37) and
shift tube (36) out of the axle bore.
• Remove wheel.
see Fig. 1
ELECTRIC DRIVE
Remove:
• Unscrew resin nut (3, Fig. 1).
• Remove electric drive (4).
Caution:
Do not disassemble and do not lubricate
the electric drive.
Reassembly:
• Position electric drive onto hub.
• While rotating the electric drive push it
inside until the two small inside pins
engage in corresponding small holes (41).
Check: The thread (6) must be visible at
least 8 mm.
• Screw on resin nut (3) with a torque of
3 – 5 Nm (27 – 44 in.lbs.).
48
• Remove circlip (35), sprocket (34) and
dust cap (33).
• Clamp hub with the two axle flats
sprocket side facing downwards.
• Remove electric drive (4) (see left column).
• Unscrew the locknuts (1+2).
• Remove plate (6) and 2 washers (5).
• Remove hub shell (7).
• Remove circlip (8) and washer (9).
• Remove planetary gear carrier (10) and
circlip (11).
• Clamp other axle end.
• Unscrew fixed cone (32).
• Remove driver (31), compression spring
(29), large compression spring (27) and
ball retainer (30). – Withdraw gear ring
(26) and coupling gear (25) and remove
cover (28) from the coupling gear.
• Take out thrust block (24), (to do this
compress the spring). Remove spring (22)
and the two covers (23/21).
• Dismantle retaining washer (20), washer
(19), conical compression spring (18),
and the large sun gear (13).
• Clamp other axle end.
• Unscrew grey grub screw (14) – dismantle spring (15), guide bolt (16) and thrust
block (17).
• Remove small sun gear (12).
Technical Manual 2006
SPARC
MAINTENANCE
3
2
3
1
4
1
2
5
6
80 ±0,5 mm
2 +1 mm
R E A S S E M B LY H U B
CABLE CHANGE
see Fig. 1
Dismantling shifter cable:
• Place shifter in gear position “1“.
• Do not remove the Clickbox from the axle
end.
• Unscrew the adjusting screw (1, Fig. 3)
completely. Unscrew the cover screw (2),
brush aside the adjusting screw (1) and
remove the cover (3).
• Withdraw shifter cable and clamping
bolt (1, Fig. 4) upwards, loosen clamp
and pull clamping piece from the cable.
• Slightly lift the grip cover (Fig. 5), push
the cable out and discard.
Lubrication see “LUBRICATION GEAR HUB“,
next page.
• Clamp axle with small internal thread
upwards.
• Position small sun gear (12) with crown
gears to the front.
• Position thrust block (17) in the slotted
hole (is laterally guided when the sun
gear is mounted).
• Locate bolt (16), then spring (15) in the
axle and screw in grey grub screw (14)
until it is flush with the axle end.
• Clamp other axle end. Fit large sun gear
(13). Position conical compression
spring (18), with the large diameter first.
Compress spring and fit washer (19) and
retaining washer (20).
• Assemble cover (21), compression
spring with 7 turns (22) and the second
cover (23, insides to the spring).
• Compress spring and position thrust
block (24) (it is the same both sides) in
the center of the slotted hole.
• Position coupling gear (25) with carrier
plate facing downwards.
• Fit cover (28, inside to the spring) for
compression spring.
• Position gear ring (26) over the teeth of
the coupling gear.
• Place ball retainer (30), with balls below
on the gear ring.
• Position large compression spring (27)
on gear ring.
• Mount compression spring with 13 turns
(29) on the axle. (Is supported in the
coupling wheel by the cover.)
• Locate driver (31), press it down and
screw on fixed cone (32). Tightening
torque 20 Nm.
• Clamp other axle end.
• Push on thrust washer (11) and fit
planetary gear carrier (10). In doing this:
Position mounting aid (Fig. 2) on the
planetary gear carrier so that the (X)
markings on the three planetary gears
match with the mounting aid.
• Insert planetary gear carrier, place
thrust washer (9) and mount circlip (8) in
recess.
Remove the mounting aid.
1
Advice:
If the gears are not accurately installed
the hub may be tight to move.
This could lead to damage to the gearwheels in operation.
7
• Mount hub shell (7), with a slight
counterclockwise turn.
• Fit plate (6) and 2 washers (5).
• Screw on counternuts (2+1), tightening
torque 15 – 20 Nm (133 – 177 in.lbs.).
• Reassemble electric drive.
Assembly shifter cable:
• Route new cable through shifter housing
and pull cable to seat cable head
completely into cable recess.
Feed the cable through the new cable
housing and adjusting screw.
• Position clamping bolt (1, Fig. 6) at a
distance of 80 mm, tighten up with
1.5 Nm (13 in.lbs.) and cut off cable ends
to 2 – 3 mm. For positioning the clamping
bolt use adjust gauge (Fig. 7). (Part. No.
65 0324 107 000)
• Locate clamping bolt (1, Fig. 4) and place
shifter cable around the carrier cylinder
(counter-clockwise winding).
• Position the cover (3, Fig. 3) and tighten
up with the cover screw (2).
Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.).
Screw in the adjusting screw (1)
completely.
Advice:
• If you want to remove the Clickbox from
the axle end for changing the cable, do
as follows:
– Place shifter in gear position “1“.
– Loosen the knurled screw and pull the
Clickbox off the axle.
– Now it’s essential to push the end (1,
Fig. 7) of the adjust gauge completely
into the Clickbox and tighten up the
knurled bolt (so that you maintain the
initial tension of the spring inside the
Clickbox).
– Change cable as per description
above.
• If you remove the Clickbox from the
axle and change the cable without
using the end of the adjust gauge, then
you will lose the initial tension of the
spring inside the Clickbox. In this case
you must assemble the cable by placing
it around the carrier cylinder with an
additional winding (Fig. 4).
ADJUSTMENT
• Be sure to reset rotational shifter from
4th to 3rd gear.
• Match up the marks in the Clickbox
viewing window (Fig. 3) by turning the
adjusting screw (1).
1
Technical Manual 2006
49
SPARC
MAINTENANCE
LUBRICATION GEAR HUB
8
Cleaning of parts:
• All parts – except for the planetary gear
carrier – can be degreased in a cleaning
bath.
• The planetary gear carrier only needs to
be cleaned on the outside with a brush
so as not to degrease the planetary gear
bearing.
16,8 V NiMH battery
open
closed
9
Lubrication of parts:
Use only SRAM grease (Part No. 0369 135 200/
...201) and standard bicycle oil.
• To lubricate the bearing points on
the planetary gear sets, position the
planetary gear carrier on its crown and
apply 2 – 3 drops of oil to the bearing
bolts – at the same time turning the
planetary gears so that the bearing
points are completely wet.
• Oil axle through the axle bore and axle
slot, apply a thin coating of grease to the
outside.
• Oil the inside of the sun gears, grease
the outside teeth (fill the gaps in the
teeth).
• Oil outside teeth and carrier plate on
the coupling gear and lightly grease the
borehole from right and left.
• Do not apply grease to ring gear but just
oil the pawl pockets.
• Regrease ball retainer, line ball bearing
running tracks with grease.
16,8 V NiMH battery
4
3
10
Advice:
Do not use high-pressure water when
cleaning (e.g. strong water jets, highpressure cleaners etc.) – if water
penetrates it could lead to functional
problems.
2
1
12 V lead battery
BATTERY CHANGE
closed
11
open
12 V lead battery
2
1
3
16,8 V NiMH battery
(see Fig. 8 and 9)
Disassembly:
• Apply fingertip pressure onto the tap and
pull battery cable plug off the battery
box.
• Turn quick releases to the „open“
position (Fig. 8) and pull them outward.
• Take off battery box from luggage
carrier.
• Unscrew the 4 bottom screws (slotted
screwdriver / Torx T10) and take off
battery box cover.
• Hang out stirrup (3, Fig. 9).
• Take out battery and pull off plug (1) and
cable shoe (2) from card modul.
Reassembly:
• Connect plug and cable shoe of new
battery to card modul:
– white plug with red and black cable (1,
Fig. 9)
– cable shoe with yellow cable (2)
and put battery inside.
• Assemble stirrup (3) (bulge downward).
Pay attention of correct cable routing
(Fig. 9).
• Mount battery box cover by the 4 screws.
• Pull both Quick Releases outward and
turn them to the „open“ position (Fig. 8).
• Position battery box onto luggage
carrier struts.
• Push Quick Releases inwards and turn
them to the „closed“ position (Fig. 8).
• Slide plug of battery cable in the slot of
the battery box until it snaps in.
Advice:
Use only batteries as specified by SRAM.
12 V lead battery
(see Fig. 10 and 11)
Disassembly:
• Apply fingertip pressure onto the tap and
pull battery cable plug off the battery
box.
• Turn quick releases to the „open“
position (Fig. 10) and pull them outward.
• Take off battery box from luggage
carrier.
• Unscrew the 4 bottom screws (slotted
screwdriver / Torx T10) and take off
battery box cover.
• Hang out stirrup (3, Fig. 11).
• Take out battery and pull off plugs (1+2)
from battery.
Advice:
Do not pull off any plug from card modul.
Reassembly:
• Connect plugs to new battery:
– black cable: Negative Pole (1, Fig. 11)
– red cable: Positive Pole (2)
and put battery inside.
• Assemble stirrup (3) (bulge downward).
Pay attention of correct cable routing
(Fig. 11).
• Mount battery box cover by the 4 screws.
• Pull both Quick Releases outward and
turn them to the „open“ position (Fig. 10).
• Position battery box onto luggage
carrier struts.
• Push Quick Releases inwards and turn
them to the „closed“ position (Fig. 10).
• Slide plug of battery cable in the slot of
the battery box until it snaps in.
Advice:
Use only batteries as specified by SRAM.
4
50
Technical Manual 2006
SPARC
MAINTENANCE
C H A R G I N G T H E B A T T E R Y S T O R I N G T H E B AT T E RY
REMOTE CONTROL UNIT
• Insert the plug of the charger into the
socket of the battery box.
• Insert the charger into an electric mains
socket.
Do not disassemble the remote control
unit.
The LED will glow red during charging,
changing to green when the battery is fully
recharged.
When not in use always withdraw the
plugs from the socket and the battery box
Caution:
• Recharge the battery at least every 3
months.
• The battery must only be charged in a
temperature range of +5°C to +30°C.
• Only charge the battery in the operating
position.
• Only use in dry internal areas.
• Do not use in rooms (garages) with an
explosion risk.
• Do not dismantle the charging unit and
battery box yourself.
Incorrect assembly can lead to
electric shock or fire.
• The charging unit should not get into
the hands of children.
• Charging should only be carried out in
sufficiently well ventilated areas.
• When not in use always withdraw the
plugs from the socket and the battery
box (do not pull on the cables).
• Regularly check the cable and protect it
from sharp edges. If it is damaged have
it renewed immediately by a specialist
workshop.
• Protect the unit from oil, grease,
aggressive cleaning agents and paint
thinners since they can destroy the
housing.
• If it falls, from a bench for example, the
unit must immediately be given a safety
check by a specialist workshop. This is
also necessary if contact pins become
loose.
• The battery must never be burned. Risk
of explosion!
• The battery must be disposed of according to the waste disposal regulations.
• Only ever use the right Sparc charging
unit with the corresponding Sparc battery.
Technical Manual 2006
The battery box should be stored fully
charged in a dry and cool place. Remove
the plug of the battery cable from the box.
All batteries are shipped with an additional
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.
You can identify the next necessary charge
date at a glance (at least 3 months after
last charge).
TROUBLESHOOTING
Problem
Gear hub:
Shifting difficulties
Pedals are carried forward
when freewheeling
Cause
Remedy
Damaged control cable
Incorrect gear setting
To much additional axle
attachments between hub
and axle nut
Bearings set too tight
Loose lock nuts
Replace control cable
Adjust shifting system
Beginning of axle thread
must be visible in front of
the axle nut
Readjust bearings
Tighten lock nuts
(15 – 20 Nm)
Reduce chain tension
Chain is overtensioned
Electric system:
Electric drive does not work Remote control in position OFF Switch to ECON or SPEED
Replace remote control
Remote control defect
Slide all plugs completely
Plugs not engaged
in slots
Replace defect cables
Cable defect
Charch battery
Battery discharged
Battery inside not connected Connect battery inside box
Replace battery
Battery defect
Replace fuse (4, Fig. 9/11) in
Fuse blasted
battery box:
– 15 A for 16,8 V NiMH battery
– 25 A for 12 V lead battery
Replace electric drive
Electric drive defect
Take out foreign body
Foreign body in electric
Electric drive emits
drive
unusual noise
Replace electric drive
Electric drive defect
51
52
Technical Manual 2006
i-BRAKE AND COMPATIBLE HUBS
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
Caution:
• There is a risk of accident if unsuitable
forks or frames are used (see page 55).
• Only 24”/26”/28” wheels are suitable
for use.
• The total weight of the bicycle with rider
and baggage may not exceed 125 kilograms.
• 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.
9.5
15
16
52
142
165
8.5
33.6
17.4
16.6
51
NEW
NEW
Kühlscheiben-ø, D
Spoke
Axle
Hub
L
IB 60 front
IB 40 front
155 mm
135 mm
Front Hub HB 40 IB
i-LIGHT hub D724 IB i-LIGHT hub D730 IB Front Hub HB 40 IB
i-LIGHT hub D724 IB i-LIGHT hub D730 IB
Over Locknut Dim.
100 mm
100 mm
100 mm
Length, L
108 mm
140 mm
108 mm
140 mm
108 mm
140 mm
108 mm
140 mm
108 mm
140 mm
108 mm
140 mm
Type
Hollow
Solid
Hollow
Solid
Hollow
Solid
Hollow
Solid
Hollow
Solid
Hollow
Solid
Material
Steel
Ends Diameter
9 mm
Holes
100 mm
Steel
M 9x1
9 mm
100 mm
Steel
M 9x1
9 mm
Steel
M 9x1
Steel
M 9x1
Steel
M 9x1
Spoke Diameter
2 mm
2 mm
2 mm
2 mm
2 mm
2 mm
54 mm
80 mm
80 mm
54 mm
80 mm
80 mm
Bearing
Cartridge
Cartridge
Cartridge
Cartridge
Cartridge
Cartridge
Sealing
Lip Seal / Labyrinth / Dust Cap
Version D
Weight (complete)
943 g
Brake Drum
—
M 9x1
36
Lip Seal / Labyrinth / Dust Cap
—
—
—
—
—
—
—
—
—
Linear Pull compatible Linear Pull compatible Linear Pull compatible Linear Pull compatible Linear Pull compatible Linear Pull compatible
Brake anchor plate
Hub Shell
—
36
9 mm
Hole Reference ø
—
36
9 mm
36
Tandem Compatib.
36
9 mm
100 mm
36
Compat. brake lever
Finish
H
U
B
S
100
D
i-BRAKE System for Front Hubs
Brake Model
F
R
O
N
T
111
Version D
955 g
1552 g
Version D
1556 g
NV
Version D
1582 g
913 g
Version D
925 g
1522 g
Version D
1526
NV
1589 g
Aluminum, anodized Aluminum, anodized Aluminum, anodized Aluminum, anodized Aluminum, anodized Aluminum, anodized
Stainless steel
Technical Manual 2006
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
53
18
i-BRAKE AND COMPATIBLE HUBS
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
GW
L
110
Caution:
• There is a risk of accident if unsuitable forks or
frames are used (see page 55).
• Only 24”/26”/28” wheels are suitable for use.
• The total weight of the bicycle with rider and baggage
may not exceed 125 kilograms.
• 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.
5
4
52
100
NEW
NEW
Brake Model
54
Axle
Length, L
Ends Diameter
SRAM S7
SRAM P5
i-BRAKE for DualDrive
i-BRAKE for SRAM S7
i-BRAKE for SRAM P5
SRAM T3
i-BRAKE for SRAM T3
Comfort / City / Trekking
➔
➔
➔
DD 27 / 24 i-BRAKE comp.
SRAM S7 i-BRAKE comp. SRAM P5 i-BRAKE comp. SRAM T3 i-BRAKE compatible
135 mm
135 mm
126 mm
118 mm
182.6 mm
188.5 mm
179 mm
166 mm
FG 10.5
FG 10.5
FG 10.5
FG 10.5
36
36
36
36
Hole Diameter
2.6 mm
3 mm
3 mm
3 mm
Hole Reference ø
67 mm
75 mm
75 mm
58 mm
—
—
—
—
➔
Holes
Tandem Compatib.
Linear Pull compatible
➔
➔
Brake anchor plate
Version D
Version D
Version D
Version D
Weight (complete)
1640 g
2164 g
1920 g
1554 g
Compat. brake lever
Finish
H
U
B
S
Hub
Over Locknut Dim., OLD
Spoke
G
E
A
R
Performance Level
DualDrive
Hub Shell
Brake Drum
Aluminium, anodisiert
Steel, matt chrome plated Steel, matt chrome plated Steel, matt chrome plated
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Technical Manual 2006
i-BRAKE AND COMPATIBLE HUBS
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
1
R 52
R 145
1
max. 6
min. 5
16
100
FRONT FORK
REQUIREMENTS
HAND BRAKE LEVER
COMPATIBILITY
Strength:
The strength must be such that with a maximum braking torque of 300 Nm (2700 in.lbs.)
on the wheel no residual deformation can
occur on the front fork.
• Use only Linear Pull compatible hand
brake levers.
• Leverage must be 1.9 – 2.1.
• Cable pull of at least 25 mm.
• Hand brake lever with adjustable leverage:
Einstellung so, daß vorgenannte Werte für
die Übersetzung und den Zugweg erreicht
werden.
Dimensions:
Important dimensions for front forks are
shown in Fig. 1.
Fork dropouts must be parallel.
Brake arm anchor boss (1, Fig. 1):
Brazed-on or screwed (suspension forks)
Warning:
Don’t use brake arm clamps (Fig. 2).
BRAKE CABLES
Mudguard and luggage carrier attachment:
Mounting screws should not collide with
i-BRAKE (Fig. 3).
REAR FRAME
REQUIREMENTS
2
Warning:
There is a risk of accident if unsuitable
brake levers are used.
Strength:
The strength must be such that with a maximum braking torque of 250 Nm (2200 in.lbs.)
on the rear wheel no residual deformation
can occur on the rear structure.
• Use only new high quality cable and
cable housing.
• When choosing cable housing lengths,
be sure to allow enough housing for an
extreme turn of the handlebars in both
directions.
• Note also that different stem lengths
effect cable housing length.
Dimensions:
Important dimensions for rear frames see
previous page.
Rear fork dropouts must be parallel.
Mudguard and luggage carrier attachment:
Mounting screws should not collide with
i-BRAKE (Fig. 3).
3
Technical Manual 2006
55
i-BRAKE AND COMPATIBLE HUBS
ASSEMBLY
A S S E M B LY
1
• Lace the wheel as normal. 3-cross only.
2
3
1
2
Caution:
• Plane faces of brake drum and hub must
be clean and free from oily and greasy
substances.
• Internal area of the brake drum and
brake lining material must be free of
dirt and oil or other substances containing grease. Danger of accident!
• Tighten up axle nuts, torque 30 – 40 Nm
(270 – 350 in.lbs.).
• Slide brake drum (1, Fig. 1) onto centering
seat (2) and fasten crosswise with
appropriate four cylinder head screws (3),
(or four countersunk screws for version
DualDrive). Torx T25, tightening torque
5.5 – 6 Nm (49 – 53 in.lbs.).
• Turn release lever (8) outwards until it
is at least at a right angle to the bike
(position “OPEN“).
• Slide brake anchor plate (4, Fig. 2) onto
centering seat (5) without tilting it.
• Turn release lever (8) to the “closed“
position (10) (the word “CLOSE” is visible
from the outside).
After closure, the release lever should
be parallel to the fork. If the release
lever can be closed relatively easily,
the tension force is inadequate.
In this case, open release lever again,
tighten adjusting nut (9) slightly and
close release lever again.
If considerable force is required to
close the lever, open the lever again,
undo the adjusting nut slightly and
close lever again.
Front hubs:
• Apply steel washer (6, Fig. 2) and lock
nut (7), minted side outwards.
Wrench 15 mm, tightening torque
15 – 20 Nm (133 – 177 in.lbs.).
7 6
4
5
Gear hubs:
• Apply steel/resin washer (6, Fig. 2).
Lock nut (7) must not be used.
Front hubs and Gear hubs:
Advice:
The wheel must turn freely.
3
2
1
Fastening wheel / solid axle:
• Fit washers resp. retaining washers (3,
Fig. 4) to the axle ends.
• Placing the wheel in fork ends.
Guide the top end of brake anchor plate
into the brazing part of the front fork
resp. fit frame clamp to fasten the brake
anchor plate at rear fork.
Caution:
Mount the brake anchor plate between
the two straps of the frame clamp (Fig. 4).
The clamp must be seated on the rear
fork with no play.
Use a self-locking nut! Hex screw,
property class 8.8.
Tightening torque: 7 – 8 Nm (62– 70 in.lbs.).
Fastening wheel / quick release (Fig. 5):
• Only use quick release devices with the
correct length.
• Position quick release opposite to the
brake.
• Tighten adjusting nut (9) as much as
possible by hand.
Warning:
• Do not tighten wheel by turning the
quick release lever clockwise (Fig. 6)!
• Only use hand force.
• By incorrectly mounting the skewer or
the wheel in the dropout, or by wrongly
adjusting the closing force, the wheel
may come loose and fall off during
the ride. This may lead to severe rider
injury or death.
4
3
4
56
Technical Manual 2006
i-BRAKE AND COMPATIBLE HUBS
ASSEMBLY
5
closed
9
10
CONNECTING i-BRAKE
ADJUSTMENT i - B R A K E
• Screw adjusting screw (2, Fig 7) with
lock nut (2) completely into the cable
stop (1) and insert into the slot on the
brake anchor plate.
• Unscrew adjusting screw (1, Fig. 9) until
the brake pads drag lightly.
• Route the brake cable.
• Push brake cable end through adjusting
screw.
• Insert cable housing end into adjusting
screw.
8
• Attach the bellows to the adjustment
screw.
open
• Thread brake cable end into link and
under the washer (5) and tighten nut (6)
slightly (hex wrench 5 mm).
Caution:
Ensure that the brake cable lies in the
notch of the link.
6
• Attach link (5, Fig. 8) to brake lever (6).
Caution:
Curved side of the link should be outside and hex nut should point away
from brake.
Use outer standard position “125 kg”
(overall weight).
• Pull brake cable end tight with pliers so
that link can still be attached and
removed (important for changing wheel).
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock with nut (2).
Caution :
• Check that all the brake system
components are functioning properly.
• Please take particular note that the total weight of the bicycle with cyclist
and baggage may not exceed 125 kilograms.
• The i-BRAKE is not useable for tandems,
transport bicycles, and similar loads.
• Only 24”/26”/28” wheels are
suitable for use.
• The i-BRAKE must be mounted on the
left side of the bicycle (viewed from the
rear end).
• There is a risk of accident if unsuitable
forks or frames are used.
• There is a risk of accident if unsuitable
hand brake levers are used.
• Installation of parts and accessories
not originally intended could result in
less than optimal performance and/or
injury.
• Tighten nut (6, Fig. 7), torque 7 – 8 Nm
(62 – 70 in.lbs.). Counter the screw with
a 10 mm wrench.
7
2
Advice:
Put the link in the position first that is
closest to the total weight of the bicycle
with cyclist and baggage.
Positioning of link can be changed to
personal preferences, but we advise to
use according to weight.
Make sure you use the same position
after changing the wheel.
3
1
4
9
1
6
5
2
8
6
5
Technical Manual 2006
57
i-BRAKE AND COMPATIBLE HUBS
MAINTENANCE
1
2
REMOVING THE WHEEL
MOUNTING THE WHEEL
Caution:
After cycling, the brake and hub should
not be touched. Danger of getting burns!
• Placing the wheel in fork ends.
Front wheel:
Guide the top end of the brake anchor
plate (1, Fig. 3) into the brazing part of the
front fork (2).
• Detach the link (1, Fig. 1) on the brake
lever (if necessary, screw the adjustment screw (2) in somewhat until the link
can be detached).
Attaching a wheel with axle nuts:
Front and rear wheel:
• Slide the washers (3, Fig. 4) onto the ends
of the axles.
• Grab the adjustment screw (2) and
remove the entire brake cable unit from
the brake anchor plate.
• Mount the axle nuts (4) and tighten
them with a torque of 30 – 40 Nm
(270 – 350 in.lbs.).
• Rear wheel only: Remove the screw (4,
Fig. 2) on the frame clamp.
1
Rear wheel:
Before tightening the axle nuts attach
the brake anchor plate to the frame using
a suitable frame clamp.
Caution:
Mount the brake anchor plate between
the two straps of the frame clamp (Fig. 4).
The frame clamp must be seated on the
rear fork with no play. Use a self-locking
nut! Screw M6, property class 8.8.
Torque: 7 – 8 Nm (62 – 70 in.lbs.).
• Attachment using axle nuts:
To remove the wheel, remove both axle
nuts (3).
3
• Attachment using quick-release:
To remove the wheel, open the quickrelease lever.
2
3
4
3
4
2
1
3
4
58
Technical Manual 2006
i-BRAKE AND COMPATIBLE HUBS
MAINTENANCE
Attaching a wheel with quick release:
• Only use quick release devices with the
correct length.
5
• Position quick release lever
opposite to the brake.
closed
6
7
• Turn release lever (5, Fig. 5) outwards
until it is at a right angle to the bike
(position „OPEN“).
• Tighten adjusting nut (6) as much as
possible by hand.
• Turn release lever to the closed position (7)
(the word “CLOSE” is visible from the
outside).
After closure, the release lever should
be parallel to the fork. If the release
lever can be closed relatively easily, the
tension force is inadequate.
In this case, open release lever again,
tighten adjusting nut (6) slightly and
close release lever again.
If considerable force is required to close
the lever, open the lever again, undo the
adjusting nut slightly and close lever
again.
5
open
6
CONNECTING THE BRAKE
• Fit cable stop (1, Fig. 7) with adjusting
bolt (2) and nut (3) and insert into the
slot (4) the brake anchor plate.
• Attach link (5) to brake lever (6). Use
outer standard position “125 kg” (overall
weight).
Put the link in the position first that is
closest to the total weight of the bicycle
with cyclist and baggage.
Positioning of link can be changed to
personal preferences, but we advise to
use according to weight.
Make sure you use the same position after changing the wheel.
• Attach the bellows to the adjustment
screw (Fig. 8).
• Check the brake adjusting.
See “ADJUSTING THE BRAKE“.
Caution:
Check whether the brake functions
correctly.
Caution:
• Do not tighten the wheel by turning the
release lever clockwise (Fig. 6).
• Only use hand force.
• By incorrectly mounting the skewer or
the wheel in the dropout, or by wrongly
adjusting the closing force, the wheel
may come loose and fall off during the
ride. This may lead to severe rider injury or death.
7
2 3
1
4
6
5
8
Technical Manual 2006
59
i-BRAKE AND COMPATIBLE HUBS
MAINTENANCE
BRAKE CABLE CHANGE
9
Disassembling the brake cable :
• Detach the link (1, Fig. 9) on the brake lever (if necessary, screw the adjustment
screw (2) in somewhat until the link can
be detached).
2
• Remove the nut (3) on the link and
remove the entire old brake cable.
Assembling the brake cable:
• Mount the new brake cable and new
cable housing.
Advice:
• Only use new, high-quality brake cables
and compression-free cable housings.
• Ensure that the length of the cable
housings allow a maximum turn of the
handlebar.
3
1
• Screw adjusting screw (5, Fig 10) with
lock nut (6) completely into the cable
stop (4) and insert into the slot (7) on the
brake anchor plate.
10
• Push brake cable end through adjusting
screw.
5
6
• Insert cable housing end into adjusting
screw.
4
• Attach link (10, Fig. 11) to brake lever (11).
Caution:
Curved side of the link should be outside and hex nut should point away
from brake.
Use outer standard position “125 kg”
(overall weight).
• Pull brake cable end tight with pliers so
that link can still be attached and
removed (important for changing wheel).
• Tighten nut (9, Fig. 10), torque 7 – 8 Nm
(62 – 70 in.lbs.). Counter the screw with
a 10 mm wrench.
Advice:
Put the link in the position first that is
closest to the total weight of the bicycle
with cyclist and baggage.
Positioning of link can be changed to
personal preferences, but we advise to
use according to weight.
Make sure you use the same position
after changing the wheel.
• Check the brake adjusting.
See “ADJUSTING THE BRAKE“.
Caution:
Check whether the brake functions
correctly.
• Attach the bellows to the adjustment
screw.
7
• Thread brake cable end into link and
under the washer (8) and tighten nut (9)
slightly (hex wrench 5 mm).
Caution:
Ensure that the brake cable lies in the
notch of the link.
9
8
11
11
60
10
Technical Manual 2006
i-BRAKE AND COMPATIBLE HUBS
MAINTENANCE
12
1
2
ADJUSTMENT i - B R A K E
MAINTENANCE
Readjust the brake if the hand brake lever
can be pulled close to the handlebar (for
example, after the braking-in time or after
long use).
Under normal circumstances, your i-BRAKE
is maintenance-free and well-protected
against external environmental influences.
• Unscrew adjusting screw (1, Fig. 12) until the brake pads drag lightly.
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock with nut (2).
Caution :
Check that all the brake system
components are functioning properly.
4
3
WEAR INSPECTION
If the brake lining is worn, the complete
brake anchor plate must be replaced.
Inspection:
With your finger, press brake lever (3, Fig. 12)
forcefully against the spring resistance. If
the upper edge of the brake lever reaches
the "LIMIT" mark of the wear display (4),
complete brake anchor plate must be
replaced.
13
• To avoid malfunctions caused by water
entering the components, you should not
use high-pressurized water for cleaning
(i.e. high-pressure cleaners or strong
water jets).
• Do not use any agressive cleansers,
gasoline, petroleum or similar for
cleaning.
• After cleaning your bicycle, you should
do a test braking so that any moisture in
the brake system can be eliminated.
• During the winter season, you should
clean your bicycle in shorter intervals so
that winter road salt cannot cause any
damage.
Caution :
The complete brake anchor plate absolutely must be replaced if oil or other
greasy substances have contaminated the
brake lining. An oily brake lining reduces
the braking performance up to a complete
brake failure. Accidents with serious injuries may result.
DISMANTLING i-BRAKE
Caution:
• Internal area of the brake drum and
brake lining material must be free of
dirt and oil or other substances
containing grease.
Danger of accident!
• Plane faces of brake drum and hub must
be clean and free from oily and greasy
substances.
4 5
6
Front hubs:
– Unscrew lock nut (4, Fig. 13) and
remove steel washer (5).
14
Gear Hubs:
– Remove steel/resin washer (5, Fig. 13).
• Remove brake anchor plate (6).
• Unscrew four screws (7, Fig. 14) (Torx
T25) and remove brake drum (8).
Caution:
Do not disassemble the brake anchor plate
7
8
R E A S S E M B LY i - B R A K E
see “ASSEMBLY“
Technical Manual 2006
61
62
Technical Manual 2006
SRAM VT 5000 / VT 3000
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
Typ VT 5000
14
21,5
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.
M9x1
Version D
Warning:
• There is a risk of accident if unsuitable
forks are used!
• Not suitable for tandem use.
• Wheel size: only 24"/26"/28" wheels are
suitable for use.
100
136
VT 5000
Part No.
Axle
Spoke
B
R
A
K
E
Version NL
VT 3000
—
—
—
Version D
Version NL
Version D
❘—
—
Version NL
Over Locknut Dim.
100 mm
100 mm
100 mm
100 mm
Length
135 mm
135mm
135 mm
135 mm
Type
Solid
Solid
Solid
Solid
Material
Steel
Steel
Steel
Steel
Ends Diameter
M9x1
M9x1
M9x1
M9x1
Holes
Hole Diameter
Hole Reference ø
Hand Brake Lev. Comp.
Finish
D
R
U
M
Brake anchor plate
36
36
36
36
2.9 mm
2.9 mm
3 / 3.3 mm
3 / 3.3 mm
89 mm
89 mm
86 mm
86 mm
Bearing
Cartridge
Cartridge
Cartridge
Cartridge
Sealing
Lip Seal
Lip Seal
Lip Seal
Lip Seal
Weight
750 g
750 g
770 g
770 g
Aluminum
Finish
Clear Coat
Technical Manual 2006
➔
➔
❘—
➔
see page 64 / Cable moving distance 15 mm and leverage 3.8 – 4.2
Hub Shell Material
158
9,5
Aluminum / galvananized Steel
❘
Aluminum/Silver Silver
Silver
❘ Black
63
SRAM VT 5000 / VT 3000
ASSEMBLY
6
1
3
5
2
10
1
4
8
9
FITTING WHEEL IN
FRONT FORK
• Lace the wheel as normal.
• Placing the wheel in front fork. The
brake lever (1, Fig. 1) goes on the left
side viewed from behind the rear of the
bicycle. Guide the top end of brake
anchor plate (2) into the brazing part of
the fork if fitted. If there is no brazing
part, use VT pipe clamp (3).
• Slide washers or snap rings onto axle
ends.
• Fit axle nuts (4) with wrench 15 mm,
torque 30 – 40 Nm (266 – 350 in.lbs.).
• Tighten screw connections on VT pipe
clamp (5/6), torque approx. 3 Nm (27 in.lbs.).
Caution:
The clamp must be seated on the fork
with no play.
CONNECTING DRUM BRAKE
7
11
13
12
2
1
Caution:
Only use brake levers with a cable
moving distance of at least 15 mm and a
leverage of “i“ = 3.8 – 4.2 (Fig. 3).
• Fit cable stop (7, Fig. 1) with adjusting
bolt (8) and nut (9) and insert into the slot
on the brake anchor plate (10).
• Turn adjusting bolt down by approx. 2/3
and route the brake cable from the
brake handle.
• Push lower brake cable end through
adjusting bolt.
• Insert lower cable housing end into
adjusting bolt.
• Thread brake cable end (11) into fork
unit (12).
• Tighten screw (13) slightly.
• Attach fork unit to brake lever (1).
• Pull brake cable end taut with pliers
so that fork unit can still be attached and
removed (important for changing wheel).
• Tighten screw (13).
ADJUSTMENT DRUM BRAKE
• Unscrew adjusting screw (8, Fig. 1) until
the brake pads drag lightly.
• Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further so that
the brake once again brushes the wheel
as it turns.
• Lock hex nut (9)
Caution:
Check that all the brake system
components are functioning properly!
OPERATION
To get used to the new brake, operate the
brake lever carefully to acquire a feel for
the drum brake’s deceleration.
Caution:
• If the bicycle is left standing for long
periods, a rust film in the brake drum
may increase braking effect. For this
reason, start by braking gently a few
times the next time the bicycle is used
to remove the rust film. This will
prevent the brake from aggressive
braking.
• On long, steep downhill stretches, also
use the second brake (rear wheel)
alternately to prevent the brakes from
heating up excessively.
• Do not touch hub after cycling – risk of
burning!
Caution:
For NL version drum brake hub with
special lever (1, Fig. 2), only use original
NL brake cable (fork unit (12, Fig. 1) is
not suitable).
3
a
25
l
i =—
a
l
64
Technical Manual 2006
SRAM VT 5000 / VT 3000
MAINTENANCE
MAINTENANCE
• Bearings is sufficiently lubricated and
essentially maintenance-free.
• Cable housing without inner tube:
lubricate regularly.
Technical Manual 2006
Advice:
• Do not use high-pressure water when
cleaning the hub (e.g. strong water jets,
high-pressure cleaners etc.) – if water
penetrates the unit it could lead to
functional problems.
• Do not rinse hub with benzine, petroleum
etc. as this could produce impurities in
the brake pads.
Caution:
The brake anchor plate must be replaced
if oil or other substances containing
grease get into the brake pads. Oily brake
pads reduce braking effect and cause the
brake to fail completely. This may result
in accidents with extremely serious
injuries.
65
i-LIGHT
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
i-LIGHT Hub Dynamo
D
Y
N
A
M
O
D324s
D330s
Version
Standard
➔
Output
2.4 Watt
3.0 Watt
Voltage
6V
Wheel ø
W
W
NNEE
W
W
NNEE
D730s-ib and D724s-ib
➔
➔
i-BRAKE compatible
3.0 Watt
3.0 Watt
3,0 W (D724s-ib 2.4 Watt)
6V
6V
6V
6V
400 – 700 mm / 16” – 28” ➔
➔
➔
➔
➔
100 mm
100 mm
Length, L
➔
D330b
W
W
NNEE
D730s
Over Locknut Dim.
400 – 700 mm / 16” – 28”
140 mm
140 mm
108 mm
140 mm
140 mm
108 mm
Type
Solid
Solid
Hollow
Solid
Solid
Hohlachse Solid
Material
Steel
140 mm
➔
➔
➔
➔
➔
➔
➔
➔
➔
➔
108 mm
Hollow
Bearing
Cartridge
Sealing
Double Sealed
➔
➔
➔
➔
➔
➔
➔
➔
➔
—
—
—
—
—
—
—
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Aluminum
➔
Aluminum, black coated. Aluminum, anodized
Ends Diameter
Holes
Spoke
i
L
I
G
H
T
Axle
Model
FG 9.5
36
Spoke Diameter
2 mm
Hole Reference ø
80 mm
Flange Distance
60 mm
Offset
Tandem Compatib.
Weight
Finish Hub Shell
0 mm
Steel
M 9 x1
M 9 x1
➔
➔
➔
➔
➔
➔
➔
36
2 mm
80 mm
49 mm
6 mm
Cartridge
Double Sealed
Aluminum, anodized
i-LIGHT
ASSEMBLY
1
A S S E M B LY
• Align the front wheel with hub dynamo in
its mounting position.
The connection terminal of the hub
dynamo should be on the right side (when
the bicycle is facing forward) (Fig. 1).
• Assemble fender stays and basket stays.
Make sure that the hub washer and hub
nut have been put on in the correct order
(Fig. 2).
2
Fastening wheel / solid axle:
• Tighten the hub nut.
– Tighten the left and right hub nuts alternately, little by little, to course that the
hub dynamo connection terminal do not
turn away from the correct orientation.
– The recommended hub nut tightening
torque is 20 Nm (177 in.lbs.).
Fastening wheel / quick release:
• Only use quick release devices with the
correct length.
• Position quick release opposite to the
brake (i-BRAKE version).
• Turn release lever outwards until it is at
least at a right angle to the bike (position
“OPEN“) (Fig. 3).
66
• Tighten adjusting nut on the end of the
skewer as much as possible by hand.
• Turn release lever to the “closed“ position
(the word “CLOSE” is visible from the
outside) (Fig. 3).
• After closure, the release lever should be
parallel to the fork. If the release lever can
be closed relatively easily, the tension
force is inadequate.
In this case, open release lever again,
tighten adjusting nut slightly and close
release lever again.
• If considerable force is required to close
the lever, open the lever again, undo the
adjusting nut slightly and close lever
again.
Caution:
• Do not tighten the wheel by turning the
release lever clockwise (Fig. 4).
• Only use hand force.
• By incorrectly mounting the skewer or
the wheel in the dropout, or by wrongly
adjusting the closing force, the wheel
may come loose and fall off during the
ride. This may lead to severe rider injury or death.
Technical Manual 2006
i-LIGHT
ASSEMBLY / MAINTENANCE
3
CONNECTING CABLES
MAINTENANCE
• Recommended wire specifications:
Inner wire size (AWG) 22 / Diameter
approx. 0.8 mm.
Insulation 1.8 – 2mm.
• Do not disassemble the internal hub mechanism.
• Twist the cable wires before connecting
(Fig. 5).
• Connect the cables. Bend the cable wires
run them along the grooves (Fig. 6).
Pay attention to a correct polarity. The
system doesn’t work in case of wrong
connection .
Kontrolle:
Rotate the front wheel and check the lamp
illumination.
4
• Do not apply any lubricant to the inside of
the hub, otherwise the grease will come
out and it may cause problems with
conductivity.
• Compatible bulbs:
Front lamp 6 V, 2.4 W
Tail lamp 6 V, 0.6 W
Caution:
If the hub nuts are screwed on too tight, or
if one or the other is screwed tighter or
looser than the other, the hub axle may be
forced to turn. Making the hub nuts looser
or too tight, this could permanently damage
the hub axle.
Advice:
Hubs equipped with i-BRAKE:
Please read the i-BRAKE documentation.
NO!
5
6
Technical Manual 2006
67
POWER CHAINS
TECHNICAL DATA / ASSEMBLY REQUIREMENTS
PC 991
P
O
W
E
R
Application
Max. No. of sprockets
Pin
MTB / Road
9 only
9 only
HG /PG / EXA-Drive
HG / PG /EXA-Drive
HG / PG /EXA-Drive
1
1
1
Riveting
Chrome Hardened
Min. Tensile Strength
Design
MTB / Road
9 only
HG /PG / EXA-Drive
/2" x 11/128"
/2" x 11/128"
/2" x 11/128"
/2" x 11/128"
/2" x 11/128"
6.65 mm
6.35 mm
6.65 mm
6.65 mm
6.65 mm
Step
Cylindrical
Cross Step
Step
Step
Yes
Yes
Yes
Yes
Yes
2000 N / 450 lbs.
2000 N / 450 lbs
2500 N / 562 lbs.
2000 N / 450 lbs.
2000 N / 450 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
Weight (114 links)
297 g
279 g
297 g
297 g
297 g
External Pin Plate
Nickel Plated
Nickel Plated
Nickel Plated
Nickel Plated
Grey
Nickel Plated
Nickel Plated
Nickel Plated
Grey
Grey
Power Link Gold or Pin
Power Link Gold
Power Link Gold
Power Link Gold or Pin
Power Link Gold or Pin
Internal Pin Plate
Caution: Hollow Pin and Cross step chains connecting method: with Power Link only (no pin)!
Application
Max. No. of sprockets
Pin
PC 48
PC 38 Saltshaker
PC 38
MTB
MTB
MTB / Road
MTB / Road
max. 8
max. 8
max. 8
max. 8
HG / IG / PG / EXA-Drive
HG / IG / PG / EXA-Drive
HG / IG / PG / EXA-Drive
HG / IG / EXA-Drive
HG / IG / EXA-Drive
Compatibility Rear
HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive
Riveting
Chrome Hardened
Push Power
Min. Tensile Strength
Design
PC 58
MTB
max. 8
Dimension
1
/2" x 3/32"
1
/2" x 3/32"
1
/2" x 3/32"
1
/2" x 3/32"
1
/2" x 3/32"
7.1 mm
7.1 mm
7.1 mm
7.1 mm
7.1 mm
Cross Step 2
Step
Step
Step
Step
Yes
Yes
Yes
2000 N / 450 lbs.
1500 N / 340 lbs.
1500 N / 340 lbs.
1100 N / 247 lbs.
1300 N / 292 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
Weight (114 links)
307 g
307 g
307 g
307 g
307 g
External Pin Plate
Silver / Nickel Plated
Silver / Nickel Plated
Grey / Polished
Light Grey
Grey / Polished
Grey / Polished
Light Grey
Internal Pin Plate
Application
Max. No. of sprockets
Silver / Nickel Plated
Grey / Polished
Power Link Silver
Power Link Silver or Pin Power Link Silver or Pin Power Link SS2 or Pin
Grey / Polished
PC 10 Saltshaker
PC 10
PC 1 Saltshaker
PC 1 Ni
PC 1
MTB
MTB
Gear Hubs
Gear Hubs
Gear Hubs
Power Link Silver or Pin
8/7/6
7/6
1
1
1
Compatibility Front
Single / HG
Single / HG
Single
Single
Single
Compatibility Rear
Single / HG
Single / HG
Single
Single
Single
1
1
1
1
1
Dimension
Length
Pin
PC 68
Compatibility Front
Riveting
Push Power
Min. Tensile Strength
3
/2" x /32"
3
/2" x /32"
1
/2" x /8"
1
/2" x /8"
/2" x 1/8"
6.9 mm
6.9 mm
7.8 mm
7.8 mm
7.8 mm
Step
Step
Step
Step
Step
1000 N / 225 lbs.
1000 N / 225 lbs.
800 N / 180 lbs.
800 N / 180 lbs.
800 N / 180 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
9000 N / 2023 lbs.
Weight (114 links)
300 g
300 g
330 g
330 g
330 g
External Pin Plate
Light Grey
Brown
Light Grey
Silver / Nickel Plated
Brown
Internal Pin Plate
Light Grey
Brown
Light Grey
Silver / Nickel Plated
Brown
Power Link SS1 or Pin
Power Link Grey or Pin
Snap Lock or Pin
Snap Lock, 3pcs Connection Link or Pin
Connecting Method
68
MTB / Road
9 only
1
Push Power
Design
C
H
A
I
N
S
MTB / Road
9 only
1
Connecting Method
P
O
W
E
R
MTB / Road
NEW
NEW
HG /PG / EXA-Drive
Length
C
H
A
I
N
S
PC 951
Compatibility Rear
Connecting Method 1
P
O
W
E
R
NEW
NEW
Truvativ / HG / EXA-Drive Truvativ / HG / EXA-Drive Truvativ / HG / EXA-Drive Truvativ / HG / EXA-Drive Truvativ / HG / EXA-Drive
Length
1
PC991 Hollow Pin NEW
NEW PC991 Cross Step NEW
NEW PC 971
Compatibility Front
Dimension
C
H
A
I
N
S
NEW
NEW
Technical Manual 2006
POWER CHAINS
ASSEMBLY / MAINTENANCE
PC 991 / PC 971 / PC 951 /
PC 68 / PC 58 / PC 48 / PC 38 /
PC 10
( 1 / 2 " x 3/ 32 " A N D 1 / 2 " x 11 / 128 " )
1
+
(2 Links)
2
Chain length:
• Shorten chain to the length specified by
the derailleur manufacturer.
SRAM derailleurs:
• Place chain over largest front chainwheel and largest rear sprocket and add
2 links or 1 link + Power Link (Fig. 1).
• For rear suspension frame, position the
rear suspension for the greatest chain
length required.
Closing standard version with clamping pin:
Fit chain, bring the two ends together and
press pin (Fig. 2) through with assembly tool.
The pin must extend by the same amount
at both outer plates. It must be possible to
move the connecting link slightly.
3
Power Link connecting links:
Caution:
• Use only for SRAM chains, use as specified,
to avoid material damage or the rider to
fall off his bicycle resulting in injury.
• Use only Power Link for closing Hollow
Pin and Cross Step chains (no pin).
4
Power Link Gray
gray coloured
for PC 10
Power Link SS1
light gray coloured
(SaltShaker 1)
for PC 10 SaltShaker
Power Link Silver silver coloured
for PC68, PC58, PC48, PC38
Power Link SS2
light gray coloured
(SaltShaker 2)
for PC 38 SaltShaker
Power Link Gold gold coloured
for PC 991, PC 971, PC 951
5
6
Closing:
• Fit chain, bring the ends together and
insert both halves of the Power Link into
the chain ends. (Fig. 3)
• Press both halves of the Power Link
together (Fig. 4) and lock in place by
pulling the chain apart. (Fig. 5)
7
8
Opening:
• Press both plates of the Power Link
together (Fig. 4) while sliding the chain
ends together (unlock). Remove the two
halves of the link from the chain ends.
1
2
3
9
4
Technical Manual 2006
Caution:
Always use a new Power Link when
fitting a new chain. Failure to shorten the
chain properly or to lock it exactly into
place may cause damage to the chain and
eventually total chain failure, material
damage or the rider to fall off his bicycle
resulting in injury.
PC 1
( 1 /2 " x 1 /8 " )
Closing chain with Snap Lock:
• Fit the shortened chain, bring the ends
together and connect with the Snap Lock.
Place the outer plate on one pin (Fig. 6).
• Gently flex the chain until the outside
connector plate snaps into position over
the second pin (Fig. 7).
Caution:
• Make sure plate is fully seated in the
pin channel and plates are parallel to
each other.
• If movement of the connector plate is
noticed a new Snap Lock must be used.
• Always use a new Snap Lock when
fitting a new chain. Failure to shorten
the chain properly or to lock it exactly
into place may cause damage to the
chain and eventually total chain failure,
material damage or the rider to fall off
his bicycle resulting in injury.
Closing chain with 3pcs Connection Link:
• Fit the shortened chain, bring the two
ends together and connect with the
chain lock. The chain lock consists of an
outer plate with pins (1, Fig. 8), an outer
plate (2) and a retaining spring (3).
• Insert outer plate with pins (1) into the
chain ends, attach outer plate (2) and
press chain lock together (1+2).
• Attach retaining spring (3) with the
closed end of the retaining ring pointing
in the direction of chain travel (Fig. 9).
• Slide retaining spring in the direction
of arrow (4, Fig. 9) to engage it in the
grooves in the pins.
Closing standard version with clamping pin:
Fit chain, bring the two ends together and
press pin (Fig. 2) through with assembly
tool. The pin must extend by the same
amount at both outer plates. It must be
possible to move the connecting link
slightly.
MAINTENANCE
• Regular lubrication will extend the
chain's service life.
• Apply oil to the chain rollers and allow
to work in.
Clean dirty chains before oiling. Do not
use any grease-dissolving or acidic
agents. Cleaning agent must be rinsed
off after a few minutes with water.
• Apply oil after chain is completely dried.
69
NOTICES
70
Technical Manual 2006
NOTICES
Technical Manual 2006
71
✆
SUPPORT
WHO TO CALL / SPARE PARTS
WHO TO CALL
NORTH AMERICA
In warranty cases or need of
technical support help, please
contact the appropriate locations.
Dealer Helpdesk Number:
(800)-346-2928
EUROPE
Please contact your local distributor.
SPARE PARTS
SRAM ORIGINAL PARTS
You can find an extensive spare parts
program in SRAM’s Spare Parts List
Model Year 2006 · Publ. Number 8506.
Caution:
Installation of parts and accessories not originally intended
could result in less than optimal performance and/or injury.
72
Technical Manual 2006
www.sram.com
www.rockshox.com
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
Shen Kang Hsiang, Taichung
County 429
Taiwan
phone: +886-4-2561-3678
fax: +886-4-2561-3686