hub service guide 1
Contents
1. INOUSTRY NINE COMPONENT RY Hub Service Guide Rear Mtn Hub Section 1 Bearing Play Adjustment Industry Nine wheels are equipped with the highest quality ABEC5 bearings from the factory Over time all bearings will wear developing some lateral play Occasionally during the break in process as bearings and other parts of the assembly seat more firmly unsatisfactory lateral play may also develop 1 1 Required Tools Adjustment will require a 1 5mm allen wrench and may be performed with the wheel installed or removed from the bicycle NOTE Due to the preloading nature of 10 and 12 mm through axle designs it is recommended that these hubs be adjusted while installed on the bike 1 2 Adjustment Find the 1 5mm allen head setscrew in the non drive side dustcap fig 1 Loosen the sefscrew 2 full turns to ensure the end of the screw Clears the surface of the axle The dustcap should turn freely once the seftscrew is loosened If not use the allen wrench to gently apply enough leverage to turn the dustcap If fhe dustcap seems stuck attempt to loosen it first by applying counterclockwise force looking from the disc side Tighten the dusfcap by hand until it stops against the disc side bearing Do not apply excessive torque as this will cause premature bearing failure Once freeplay is removed and dustcap is finger tight gently tighten the setscrew This is a 3mm thread on a pointed setscrew and as such requires very little2. Hub Reassembly Bearings are best installed in hubshell and cassette body using an arbor press If a press is not available care must be taken using other methods to ensure the bearings are pressed in their respective bores completely straight When pressing bearings into bores find a socket or other cylindrical object fo apply pressure to only the outer race of the bearing as pressing the inner races or dust seals will damage the bearings Likewise when pressing bearings onfo the outside of bearing journals apply pressure only fo the inner race If using a bench vise soft metal or flat non toothed jaws are recommended Ensure all bearing mating surfaces are clean and free of grit or dirt prior to installation A very light coat of grease is always recommended Bearing retainer clip Fig 6 Fig 7 Fig 8 3 1 Bearing Installation To install the 61903 29 5 bearings in the cassette body slip the first bearing in past the threads until it begins to press Then use the 7075 bearing spacer atop the bearing fo press if in until the end of the spacer is flush with the end of the cassette body fig 7 Place the second bearing on the end of the spacer and press it in unfil it is also flush Using the appropriately sized socket or an old bearing continue to press the outer bearing until both bearings and spacer are firmly seated in the bearing bore The large 40mm x 52mm 61808 bearing is installed on the back of the fr eehub bo
3. installation fig 11 If available it is also recommended fo apply a tiny drop of medium strength Loctite to each of the similarly sized pawl spring retaining screws page 4 INOUSTRY NINE COMPONENT R Y One at a time reinstall the springs Place the spring in ifs recess on the freehub body Note that the spring is shaped such that if can only be properly installed in one orientation Ensure that the radiused corner of the spring is oriented toward the large 61808 bearing fig 12 Install the screw carefully ensuring if does not cross thread As the screw is tightened gently apply pressure on the pawl and spring towards the back of the pawl pocket to ensure the pawl remains fully engaged in the pocket and the spring is not twisted away from the large bearing fig 13 These screws are size 0 80 using a 050 1 2mm allen wrench and as such require a tiny amount of torque lt 3 in lb Tighten no more than 1 10 of a turn past snug Repeat the process until the desired number of pawls are in place 3 pawls for 6 degrees or 6 pawls for 3 degrees before engagement Once the pawls and springs are installed the freehub assembly may be reinstalled in the hub ote e eee Insert radiused edge of spring into the radiused pocket of i cassette body errr rrr Fig 13 3 3 Drive Mechanism Installation If old grease has been cleaned or the mechanism has been degreased apply a liberal amount of light
4. the disc side adjusting dusfcap from the axle by first loosening the 1 5mm allen sefscrew in the dustcap 2 full turns Remove the dustcap by unscrewing if counter clockwise until it comes free of the axle Place it to one side page 2 INOUSTRY NINE COMPONENT R Y Next remove the drive side steel endcap by placing a 5mm allen in each end of fhe axle and unscrewing the drive side end Also remove the axle spacer by sliding it off the drive end of the axle Place these fo one side The freehub mechanism is pressed into the hubshell To remove it support the hubshell to the outside of the large back flange of the freehub This can be done by padding a bench vise opened far enough to clear the freehub or with two wood or plastic blocks supporting the hub above a bench Alternatively the hub may be supported by the hand not wielding the hammer fig 2 amp 3 Remove the freehub mechanism by genfly tapping the non drive disc side end of the axle with a soft faced hammer fig 2 Take care fo ensure the mechanism remains straight in its bore as if comes out or pawl spring damage may occur Again GENTLY tap the non drive end of the axle until the large bearing comes free of the hub The axle will slide all the way through the hub and come out the drive side with the freehub Firmly grasp the large end of the axle and slide it out of the fr eehub bearings Fig 4 depicts the freehub assembly and axle clear of the hub 2 3 Pawl and Spring R
5. dy by first starting the bearing past the retaining ring groove The bearing journal is slightly undersized for the first millimeter to aid in starting the bearing straight The bearing can often be completely installed with firm hand pressure If a press is necessary find a cylindrical piece of material a short piece of 2 PVC pipe works well that fits on the inner race of the bearing and gently press it on the freehub until the retaining ring will ft in its groove fig 8 Install the retaining clip ensuring if is completely seated in its groove by firmly pushing it down into the groove starting at one end of the clip and working completely around to the other end fig 9 To install the 61804 bearing in the non drive end of the hub start the bearing into the end of its bore by hand Find an appropriately sized socket or use the old bearing to carefully press the bearing until it is firmly seated in its bore fig 10 Work carefully to ensure the bearing remains completely straight during the entire process Pad the drive end of the hubshell with a non marring material such as plastic or wood to ensure the freehub bearing bore is not deformed Once the bearings are installed the pawls and springs may be reinstalled on the freehub body Fig 9 Fig 11 3 2 Pawl and Spring Installation If the pawls and freehub body have been degreased apply a small dab of grease to each pawl pocket fo assist in keeping the pawls in place during spring
6. emoval The pawls must be removed in order to replace the large 61808 bearing It is also recommended that they be removed annually for thorough cleaning and regreasing If they appear fo be well greased and free of contamination if is not necessary fo remove them from the mechanism for simple inspection or addition of grease Establish a clean solid working area as some parts are very small One af a time remove each spring retaining screw using a 050 allen wrench Then remove the spring and pawl faking care not fo lose any of the tiny screws Place these parts far out of the reach of swiping rags and mishandled tools To change from 3 degree to 6 degree engagement simply remove three alternating pawls and springs leaving one set of three pawls in place in an equilateral friangle fig 5 Alternatively to change from 6 degree to 3 degree engagement replace the missing three pawls and springs following the instructions in section 3 2 Pawl and Spring Installation wy f AN 4 2 4 Bearing Removal At this point the two 61903 29 5 bearings inside the cassette body and the 61804 bearing in the disc side of fhe hub may be r emoved using a press or soft metal drift punch A rod or socket with a diameter of 18mm will allow easy removal of both cassette body bearings from the back Ensure the cassette body is well padded when supported in a press or bench vise to prevent damage NOTE Removal of beari
7. ge will be flush with the edge of the hubshell fig 16 Once the drive mechanism has been reassembled the rear axle may be reinstalled Drive ring slot 1 of 6 Fig 16 Fig 14 3 4 Axle Installation Begin by replacing the adjusting dustcap on the axle Thread it on clockwise until the outer edge of the dustcap ish flush with the end of the axle Slide the axle into the hub from the disc end unfil the adjusting cap stops against fhe bearing Slide the axle spacer on the drive end of the axle and reinstall the stainless steel endcap Tighten gently to 4 Nm 35 in lb using a 5mm allen wrench in each end of fhe axle Push the axle back to the disc side by hand or by gently tapping the drive end on a workbench Hand tighten the adjusting dustcap against the disc side bearing Adjust bearing freeplay by following the instructions in Section 1 Bearing Play Adjustment
8. grease to the drive ring cavity and pawl mechanism fig 14 Drive mechanisms are factory assembled with DuMonde Tech Freehub Grease 1 oz containers are available directly from us or DuMonde Tech If unavailable Slick Honey Rock n Roll Super Slick or Dumonde Tech liquid grease will work To ease reassembly of the drive mechanism there are six slots milled into the circumference of the drive ring fig 15 These accept the pawls and simplify the reengagement of the pawls in the drive ring Begin reassembly by visually lining up the pawls with these slots Once lined up gently push the pawl mechanism info the bore by hand approximately 1 millimeter until it the pawls stop against the drive ring The large bearing bore is slightly oversized at the outer end fo ease sfraight installation Continue the process by rotating the freehub backwards freewheeling to engage the pawls in the drive ring Feel and listen carefully for smooth consistent pawl ratcheting Once the pawls are engaged push the freehub body into the hubshell by hand approximately another millimeter until the bearing begins fo press fit Once again verify the smooth operation of the pawl mechanism Complete the process by pressing the assembly into the hub until it is fully seated Use the utmost caution fo ensure the assembly remains absolutely parallel to ifs center axis or pawl spring damage will occur When the freehub is fully seated the largest diameter of the freehub flan
9. ngs using a drift punch will usually damage them rendering them useless The spacer between the 61903 29 5 bearings should slide out easily by hand once the outer bearing is r emoved If the large 61808 bearing exhibits play or roughness it should also be replaced In order to remove this bearing from the freehub body the six pawls and their respective springs must first be removed Please refer to Section 2 32 Pawl and Spring Removal prior fo attempting to remove the 40x52mm 61808 bearing To remove the 61808 bearing first remove its retaining clip by GENTLY and CAREFULLY prying one end free of its groove using the point of a scribe jeweler s screwdriver or knife USE CARE to not stab yourself Once one end of the clip is lifted free gently work it out of the groove all the way around fo the other end taking care not to twist or otherwise mangle the retaining clip Once free of ifs groove remove the clip and place if fo one side page 3 INOUSTRY NINE COMPONENT RY Remove the bearing by repeatedly firmly tapping the back of the freehub against a hard surface non marring such as a wooden or formica benchtop fig 6 Inertia will cause the bearing to slide free of the freehub body DO NOT use a metal or concrete surface fo accomplish this as it will damage the aluminum freehub Often the bearing can be removed using one s fingernails behind the outer race Take care not to peel your nails back attempting this Section 3
10. torque 1 0 Nm 8 8 in lb A good rule of thumb is 1 8 turn past the point at which the screw contacts the axle If lateral play remains after performing this adjustment please continue to bearing replacement as the bearings have probably exceeded their service life 1 5mm set screw Fig 1 Section 2 Freehub Drive Mechanism Service The recommended inspection and service interval for Industry Nine s patented drive mechanism is annually This is a recommendation only and may have to be adjusted for severe climates wet environments frequency of riding etc It is recommended to service the drive mechanism during bearing replacement as if must be disassembled to perform this maintenance 2 1 Required Tools Tools required for service 1 5 mm allen wrench two 2 5mm allen wrenches a soft faced plastic or brass hammer and a soft metal such as brass or aluminum drift punch or rod approximately 6 long x 1 2 diameter A hard benchtop material such as formica or metal will also prove convenient Removal of the pawls and springs will require a 050 allen wrench which is usually the smallest in an English set These 050 allen wrenches are also available from Industry Nine for the cost of postage A scribe or very small jeweler s screwdriver will be required for retaining clip removal 2 2 Disassembly Remove the wheel from the bike and the cassette from the freehub body If is not necessary to remove the disc rotor Remove
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