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1. IRF Technical Manual Gear Hub Systems 2009 Rev A REASSEMBLY HUB see Fig 1 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 fi
2. lamp the drive side of the axle with the two flats of the axle in a vise nscrew both nuts 6 from the axle Wrench size 22 mm For the no brake hub version the locknut and the underlying adjusting cone should be unscrewed from the axle Wrench size 17 mm a version with back pedal brake Take off the lever cone 7 and the ball retainer 8 Lubrication and assembly details can be found in the following column Work on the brake segments hub version with back pedal brake and ball retainer on the drive side x Dismantle the hub as previously de scribed Work on brake cone adjusting ASSEMBLING THE HUB For a gear unit change Clamp the new gear unit on the drive side of the axle in the vise Clean the parts after dismantling The parts can be degreased in a cleaning bath Lubricating the parts Caution Use only SRAM special grease part no 0369 135 200 201 and commercially available cycle oil Lubricate ball retainers and ball tracks only with SRAM Ball Bearing Grease Part no 0369 001 015 Work on the brake segments hub version with back pedal brake and ball retainer on the drive side Lubrication am _ Grease the ball track 12 of the driver and the ball retainer 13 with SRAM Ball Bearing Grease part no 0369 001 015 nsert the ball retainer 13 with the balls pointing upwards towards the driver 12 Lubrication ay Oil both pawls 15 of the planetary gear
3. REASSEMBLY HUB see Fig 1 Lubrication see MAINTENANCE LUBRICATION e Clamp axle with internal thread up wards 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 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 thi
4. 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 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SRAMI S7 MAINTENANCE So FO FREED Technical Manual Gear Hub Systems 2009 Rev A REASSEMBLY HUB 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 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
5. Truvativ HG EXA Drive HG PG EXA Drive HG PG EXA Drive HG PG EXA Drive HG PG EXA Drive HG PG EXA Drive b X LTA X Yi ia ly X i l gt X ees i X WA ma 6 65 mm 6 35 mm 6 65 mm 6 65 mm 6 65 mm Step Cylindrical CrossStep Step Step 9000 N 9000N jooon n won Silver Nickel Plated Silver Nickel Plated Silver Nickel Plated Grey Polished Silver Nickel Plated Silver Nickel Plated Grey Polished Grey Polished Silver Nickel Plated Silver Nickel Plated Connecting Method Power Link 9spd or Pin I Power Link 9spd only Power Link 9spd only Power Link 9spd or Pin Power Link 9spd or Pin 1 Caution Hollow Pin and Cross Step chains connecting method with Power Link only no pin PC 890 PC 870 PC 850 PC 830 Saltshaker PC 830 Application MTB Road MTB Road MTB Road MTB Road MTB Road Compatibility Front Compatibility Rear Dimension Length Riveting Chrome Hardened Push Power Min Tensile Strength Weight 114 links E External Pin Plate 2 Internal Pin Plate Connecting Method HG IG PG EXA Drive HG IG PG EXA Drive HG IG PG EXA Drive HG IG PG EXA Drive HG IG PG EXA Drive HG IG PGII EXA Drive HG IG PGII EXA Drive HG IG PGII EXA Drive HG IG PGII EXA Drive HG l6 PGII EXA Drive LX sg hy X sy hy X sp IX sy 1i X sp 6 92 mm 6 92 mm 6 92 mm S
6. e Remove planetary gear carrier 10 and thrust washer 11 e Clamp other axle end e 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 Technical Manual Gear Hub Systems 2009 Rev A S RAIM SRAMI P5 MAINTENANCE Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A REASSEMBLY HUB see Fig 1 Lubrication see MAINTENANCE LUBRICATION Clamp axle with internal thread up wards 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 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 retain in
7. lt 0 045 Q m shall be used for the electrical connection of lighting equipment and for electrical supply systems 17 mm es Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A IES Model D324 N D330 N D324 N 74 D330 N 74 Version Standard lt Standard amp Output 2 4 Watt 3 0 Watt Voltage 6V lt 6V lt Wheel g 400 720 mm 16 28 300 720 mm 12 28 D Over Locknut Dim OLD 100mm amp 74mm lt 2 Material Steel lt Steel Holes 36 lt 20 Hole Diameter 2 5mm 2 5mm lt D Hole Reference g 71mm e 71mm e 3 a Flange Width 3 4mm lt 3 4 mm lt 3 Flange Distance F F F 28mm F 28mm F 20 5 mm F 20 5 mm O Offset 6 5 mm 0mm Bearing Cartridge lt Cartridge lt Sealing Double Sealed e Double Sealed e Efficiency 65 at 15 km h 65 at 15 km h lt Weight 556 g 519 g 607 g 575g 500 g N A Finish Hub Shell Alum silver or black painted Aluminum silver painted OVERVOLTAGE PROTECTION Caution To protect the bulbs against overvolt age e g if one lamp breaks down the lighting system must be designed so that at a load of 60 Q are not exceeded If your system doesn t have an overvoltage protection we recommend the SRAM overvoltage protection cable Part 92 2015 003 000 Fig 2 99 I LIGHT DYNAMO HUBS D7 D3 SERIES ASSEMBLY 100 ASSEMBLING THE HUB Caution The dropouts of the fork must be paral
8. p MANA the brake sleeve 8 Advice The brake sleeve must be renewed if as a result of wear the pattern on its outer surface is scarcely visible Lubrication and assembly details can be found on the following page Work on the roller guide ring and rollers Hub version with back pedal brake Dismantle the hub as previously de scribed work on brake cone adjusting cone and ball retainer and work on brake sleeve emove the hub shell by jerking up PO vere ayer The outer large dust cap 9 is a very tight fit Its removal will result in it being damaged Replace with a new cap during reassembly The gear unit can be removed by tap ping a rubber mallet on the axle on the non drive side of the shell To do this remove the hub from the vise sm the circlip 10 ais lake off the washer 11 and take the 6 rollers 12 out of the roller guide ring E BEM off the roller guide ring 13 Caution Further dismantling is not per mitted as otherwise the gear unit comes apart Reassembly could then only be undertaken by SRAM Lubrication and assembly details can be found on the following page Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 9 MAINTENANCE TI A ni So FE FAITE Technical Manual Gear Hub Systems 2009 Rev A ASSEMBLING THE HUB NOT DRIVE SIDE Work on the roller guide ring and rollers the roller
9. planetary gear carrier into its final posi tion ar The planetary gears 51 must be flush with the ring gear teeth 52 Maintain the system in this position Pon the washer 53 and fit the circlip 54 Caution The opening of the circlip must be located over the axle flat 55 Complete hub assembly as described on page 34 under ASSEMBLING THE HUB 39 I MIOTION 3 MAINTENANCE DISMANTLING THE GEAR a version with back pedal brake UNIT Gear hubs as of August 2007 Take off the driver 15 and the con Gear hubs until July 2007 see page 36 trol washer 16 beneath it Take off the coupling piece 17 and shift bush 18 Remove the gear unit as described on page 34 ot version without brake Take off the driver 15 and the con Bs emove the retaining ring 1 and trol washer 16 beneath it Take off the Cin PT take off the washer 2 and planetary coupling piece 17 and shift bush 18 gear carrier 3 beneath it Work on the thrust block EDEM off the ring gear 4 Advice and washer 5 The thrust block only requires atten tion if the shift cable has torn off e off the pawl carrier 6 BIB Unscrew the red grub screw 19 Advice from the axle Press on the pawls 7 to make Caution removal easier The grub screw is spring force loaded Clamp the hub with the other axle side Take the spring 20 and spacer bolt 21 in the vise out of the axle ake of
10. 51 DUALDRIVE MAINTENANCE Lubricate the shifting joints regularly When disassembled use a waterproof grease 52 REMOVE WHEEL e 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 19 Fig 1 Dismantle wheel DISMANTLING HUB see Figure 1 e Dismantle cassette lock nut with cassette tool Park Tool FR 5 or SRAM Part No 4624 411 010 e 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 e Dismantle retaining washer 5 remove washer 6 planetary gear carrier 7 and gear ring 8 e Squeeze down pawls and remove pawl carrier 10 with washer 9 and ball retainer 15 e Clamp other axle end longer axle thread Dismantle lock nut 18 and cone 17 e Remove driver 16 compression spring 14 and shift sleeve 12 with bushing 13 REASSEMBLY HUB see Fig 1 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 14 and driver 16 Mount cone 17 and lock nut 18 Tightening torque 15 20 Nm 1
11. I MIOTION 3 MAINTENANCE z 111 Technical Manual Gear Hub Systems 2009 Rev A ASSEMBLING THE GEAR UNIT Gear hubs until July 2007 Gear hubs as of August 2007 see page 41 Clean the parts after dismantling Caution The planetary gear carrier and the driver should only be cleaned on the out side using a paint brush so that they are not degreased Cleaning in a cleaning bath is not permitted The remaining parts can be degreased in a cleaning bath Lubricating the parts Caution Use only SRAM special grease part no 0369 135 200 201 Lubricate ball retainers and ball tracks only with SRAM Ball Bearing Grease Part no 0369 001 015 Work on the thrust block assembly of the axle lace the thrust block in the shift sleeve 1 Advice The tapped hole 2 of the thrust block must be located on the axle side with the long slit 3 This subsequently allows the shift cable to run through the long slit 4 Turn the circlip through 90 degrees to secure the thrust block ert the spacer bolt 5 and spring 6 in the axle Turn the red grub screw 7 so it is flush with the axle Vili Qa i Assembling the gear unit Lubrication ay Lightly grease the axle and grease e toothing 8 Use only SRAM spe cial grease part no 0369 135 200 201 Place a drop of oil on the thrust block 9 the shift bush 10 with the crown toothing
12. The side with the balls must point down wards Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 9 MAINTENANCE So FE FREED Technical Manual Gear Hub Systems 2009 Rev A caste version with back pedal brake Fit the lever cone 19 By turning to the left and right bring the lever cone 19 into its final position The locating lugs 20 of the lever cone will then lie in the recesses 21 of the brake sleeve De version with back pedal brake Screw the large axle nut 22 with the projection 23 downwards onto the axle Wrench size 27 mm Hub versions without brake and disc brake screw the adjusting cone onto the axle Wrench size 13 mm 7 the bearing in a play free manner and tighten using nut 24 Wrench size 17 mm Tightening torque 15 20 Nm 133 177 in lbs Caution Test the play of the bearing and correct if required Clamp the hub with the other axle side in the vise ress the large outer plastic dust cap 25 onto the hub until it engages Advice Use a new dust cap after each dismantling lace the small inner dust cap 26 onto the driver The curvature must point to the outside prase the sprocket 27 onto the driver PE Moun the sprocket circlip 28 onto the driver Check for proper seating of the circlip Remove the hub from the vise Fitthe rear wheel into the rear frame as described on page 13 Adjust the g
13. a correct and trouble free manner Reach adjust of the hand brake lever so that you can operate the brake lever on the shifter comfortably set the reach to match your hand size oD a 2 mm Allen key to set the dis tance between the brake lever and the handlebar Caution Every time you adjust the reach check and correct the brake cable tension to ensure good brake performance Onur Read and observe the operating manual and technical documentation of the brake manufacturer I MIOTION 9 OPERATION 10 SHIFTING hift gears by turning the twist shifter on the right side of the han dlebar You can shift gear while stationary or when riding Ensure you shift to a lower gear in plenty of time before hills The quickest and smoothest gear shifts are achieved by shifting while pedaling using only a low force BRAKING When descending long and steep hills always use the second front brake as well to prevent overheating of the brakes Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes Caution Excessive heating of the hub caused by back pedal braking may result in loss of lubricant and cause sharper braking Relubricating of the brake sleeve with special grease is then necessary See DISMANTLING ASSEMBLY OF THE HUB NOT DRIVE SIDE page 16 Reach adjust of the hand brake lever so that y
14. 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 posi tion tighten up the knurled bolt 3 Fig 5 by hand 0 3 Nm 2 7 in bs ADJUSTMENT e Be sure to reset rotational shifter from 4th to 3th gear e Match up the marks in the Clickbox viewing window 4 Fig 6 by turning the barrel adjuster 5 Caution Check that all the brake system components are functioning properly 67 SRAMP P5 MAINTENANCE lt Wi SN SRAM P5 mounting aid Part No 65 0524 300 000 Ei Cx lif Mt LP ia NS j 68 REMOVE WHEEL s e Place shifter in gear position 2 e 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 e Remove wheel DISMANTLING HUB see Fig 1 e Remove circlip 36 sprocket 35 and dust cap 34 e Clamp hub with sprocket side facing downwards with the two axle flats e Unscrew both locknuts 1 e 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 e Remove brake cone 7 e Remove retaining washer 8 thrust washer 9
15. 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 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 faci
16. temperature range of 5 C to 30 C e 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 ts 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 regula tions e Only ever use the right Sparc charging unit with the corresponding Sparc bat tery So FO FREED Technical Manual Gear Hub Systems 2009 Rev A STORING THE BATTERY 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
17. 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 DISMANTLING HUB see Fig 1 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 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 e 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 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SRAMP P5 CARGO MAINTENANCE So FO FREED Technical Manual Gear Hub Systems 2009 Rev A
18. 11 facing downwards to wards the axle Place the coupling piece 12 with the lugs 13 downwards on to the shift bush E version with back pedal brake Place the control washer 14 with the bent up ends 15 facing upwards on the coupling piece 16 Hub version without brake Place the large washer on the coupling piece Lubrication amp Oil the 4 pockets for the pawls 17 and the driver pawl spring 18 Grease the ball retainer 19 with SRAM Ball Bearing Grease part no 0369 001 015 eat the driver 20 on the control washer 21 The pawls 22 must lie in the recesses of the control washer R JIN the spring 23 and the fixed cone 24 onto the axle Fit the threaded bushing 25 and tighten with a torque of 15 20 Nm 133 177 in lbs Wrench size 13 mm N Lubrication On the axle side with the recess 26 a the shift cable the opening 27 on the fixed cone must be filled with grease Use only SRAM special grease part no 0369 135 200 201 ush the shift cable on the side of the recess 28 into the fixed cone and secure it by turning in a clockwise direction minimum of 7 full turns Turn only until hand tight se the plastic protective cap 29 Clamp the hub with the other axle side in the vise 37 I MIOTION 3 MAINTENANCE i Ceo 7 ila A Lubrication ay Apply a drop of oil on both bearing ae 30 of the
19. Grip 5 Shifter Type Twist Shifter mit Clickbox Cable Length 1500 mm 1900 mm Gear Indication Window Clamping Diameter 22 1 22 3 mm Straight handlebar ends Length of shifter 76mm Weight N A Housing Glass filled PA Grip PP Grip Cover Minimum necessary length for shifter and handlebar grip 150 mm J rm mmj O Thermoplastic elastomer Overmolded Clamping Collar Aluminum SRAM P5 ASSEMBLY ASSEMBLY HUB e Lace the wheel as normal See spoke length table e Place the dust cap 1 Fig 1 and sprocket 2 on the driver Advice When fitting a straight sprocket not an offset version the beadings of the sprocket must lie against the dust cap e Push sprocket circlip 3 Fig 2 onto the cone of tool sleeve 4 Pvlace 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 Spoke length table Tire Size Cross Length 151 mn 232 m n 259 m n 3 Grs 26x19 dk asm p arsa awis ex asm as Brea 2erx 1x17 ex U 289 mn ass an dB fsm 32 622 a ex aemm amn araa poo feen 32 630 27 x1 Ti 294 mm Mounting Tool Part No 0582 104 000 Spoke lengths are approximate values They must be checked through lacing attempts and adjusted accordingly 66 Technical Manu
20. Locknut Dim OLD 135mm Length L 186mm Ends Diameter M 10x1 Shifter i MOTION 9 IBS SL and i MOTION 9 SL 103 6 HR I MOTION 9 disc brake compatib i MOTION 9 without brake ga without 135 mm 186 mm M 10x1 min 4mm max 10mm 36 or 32 2 8 mm 93 6 mm F 265mm F 31 5mm amp e lt amp amp lt lt amp e e amp lt lt 4 min 1 73 xWe and x and x 18 19 20 21 22 teeth 18 19 20 21 22 teeth lt Disc brake compatible Tandem Not suitable for tandems transport bicycles or similar amp 1 960 g 1 960 g Aluminum Satin matt Lux anodized Satin matt Lux anodized I MIOTION 9 TECHNICAL DATA ASSEMBLY REQUIREMENTS J rm m E V J m lt m r mi 7J UJ 113 7 Shifter i MOTION 9 IBS SL Version Shift cable lengths Shifter type Mounting location Compat Gear hub Gear indicator Barrel adjuster Clamping diameter Straight handlebar ends Cable routing Compatibility n Ratio t Cable path Reach Adjust Adjusting screw Lever size Material Weight Shift cable T Housing Grip cover Frame clamp Finish Version Mounting location Clamping diameter Compatibility Ratio Cable path Reach Adjust Adjusting screw Lever size Weight Housing T Lever Frame clamp Finish Shifter i MOTION 9 SL i MOTION 9 IBS SL i MOTION 9 IBS
21. MAINTENANCE NIL EBI im 36 j CA GdiawmRmWHHi SC ee C IP TI Ge DISMANTLING THE GEAR Work on the thrust block UNIT Gear hubs until July 2007 Gear Advice hubs as of August 2007 see page 40 The thrust block only requires atten tion if the shift cable has torn off Remove the gear unit as described on Unscrew the red grub screw 17 page 34 from the axle m the retaining ring 1 and Caution take off the washer 2 and planetary The grub screw is spring force gear carrier 3 beneath it loaded Take the spring 18 and spacer bolt 19 out of the axle EDEM off the ring gear 4 and washer 5 a off the pawl carrier 6 nue Press on the pawls 7 to make removal easier urn the circlip 20 and take the thrust block 21 out of the axle Lubrication and assembly details can be found on the following page Clamp the hub with the other axle side in the vise ake off the plastic protective cap 8 Undo the shift cable 9 by turning in an anticlockwise direction and pull it out of the axle ape the threaded bushing 10 from the axle Wrench size 13 mm Take off the fixed cone 11 and spring 12 from the axle sips version with back pedal brake Take off the driver 13 and the con trol washer 14 beneath it Take off the coupling piece 15 and shift bush 16 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM
22. Rev A 22 1 22 3 73 Shifter SRAM T3 BANDIX SRAM T3 BANDIX for kids 2158 mm Capped Compressionless with Resin Liner inside SRS twist shifter Right side of handlebar SRAM T3 Printed None 22 1 22 3 mm Minim necessary length for shifter and handlebar grip 155 mm 65g Stainless or galvanized steel PA Thermoplastic elastomer Aluminum Black 81 SRAMI T3 ASSEMBLY Mounting Tool Part No 0582 104 000 30 40 Nm 266 350 in bs 82 ASSEMBLY HUB e Lace the wheel as normal See spoke length table Place the dust cap 1 Fig 1 and sprocket 2 on the driver Advice When fitting a straight sprocket not an offset version the beadings of the sprocket must lie against the dust cap 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 5 Fig 5 into the axle end Placing the wheel in the rear frame Mount the chain Slide one
23. SRAM Grip 5 e Z Clickbox Clickbox P5 e e 2 Scheibenbremse 6 holes Hand Brake Lever Disc brake compatible Tandem Suitable for tandems transport bicycles or similar lt Weight 1495 g 1536 g 1390 g Hub Shell Material Steel Aluminum Steel Finish Matt Chrome Plated Clear Coat Matt Chrome Plated IRF Technical Manual Gear Hub Systems 2009 Rev A 73 SRAMP P5 CARGO TECHNICAL DATA ASSEMBLY REQUIREMENTS SRAM Grip 5 Drawing see Page 66 Shifter Type Twist Shifter mit Clickbox Cable Length 1500mm 1600mm 1700mm 1800mm 1900mm Gear Indication Window Clamping Diameter 22 1 22 3 mm J rm m Clamping Collar Aluminum Minimum necessary length for shifter and handlebar grip 150 mm Handlebar Straight Area Length of shifter 76mm Weight N A Housing Glass filled PA Grip PP Grip Cover Thermoplastic elastomer Overmolded SRAM P5 CARGO MONTAGE ASSEMBLY HUB 2 Lace the wheel as normal See spoke length table Place the dust cap 1 Fig 1 and sprocket 2 on the driver Advice When fitting a straight sprocket not an offset version the beadings of the sprocket must lie against the dust cap 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
24. Systems 2009 Rev A GEAR ADJUSTMENT Before adjusting the gears shift several times between 1st and 9th gears and then back again so that the shift cable seats itself correctly aS the twist shifter from 7th to 6th gear o make adjustments use the barrel adjuster 1 on the shifter Soe barrel adjuster 2 on the con necting tube aie the barrel adjuster until the yellow red marks 3 in the window of the gear hub are aligned FITTING THE BRAKE CABLE Caution The brake lever on the i MOTION IBS shifter and the brake lever i BRAKE 60 BL is only compatible with the fol lowing brakes Avid BB Disc and Linear Pull compatible brakes O ince Make sure that the cable housing length is sufficient to permit turning of the handlebar over its full range Also bear in mind the effect of adjust able handlebars and stems on the cable housing length Always use new high quality cables and compressionless cable housings with end caps ee the cable adjustment screw 1 and the counter nut 2 so that the cable slot is aligned with the slot on the bottom of the brake lever housing rae the brake lever to the handlebar and guide the inner cable into the housing Hook the nipple 3 of the inner cable into the recess 4 in the brake lever Follow the brake manufacturer s in structions when fitting the brake cable and adjusting the brakes Caution Check that the brake is operating in
25. Turn the twist shifter to 3rd gear e Detach the cable from the locating sleeve Remove the cable housing Cut the cable off 15 cm 6 from the shifter bar rel adjuster Discard the old cable and cable housing Remove the cap 1 Fig 3 from the shifter The nipple 2 of the inner cable is now visible Push or pull the old inner cable out of the shifter Fig 4 e g using a small screwdriver Guide the new inner cable into the cable inlet through the shifter and the new cable housing Insert the cap in the shifter Feed the shifter cable into the locating sleeve 5 Fig 5 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 5 loosely onto small pull rod 3 ADJUSTMENT e 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 5 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 return pulley 4 Check e Place shifter in gear position 1 while moving the crank e Setting too loose In gear position 1 the tension chain can be pulled out of the return pulley by hand e Setting too tight It
26. and trouble free operation of the shift system and brakes 28 FITTING THE SHIFT CABLE ye Make sure that the cable housing length is sufficient to permit turning of the handlebar over its full range Also consider the influence of adjust able handlebars and stems on the cable housing length PE asten the cable housing on the frame ay ines The cable housing must be free to move at the securing points Avoid tight bends when routing the shift cable ake sure that the shifter is set to PS s gear Pep Mae the connection between shift er and rear wheel hub by hooking the connection lug 1 onto the shift ca ble nipple 2 lug the plastic retainer 3 onto the cable stop bracket 4 Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes Technical Manual Gear Hub Systems 2009 Rev A SRAM I MIOTION 3 ASSEMBLY So FE FREED Technical Manual Gear Hub Systems 2009 Rev A GEAR ADJUSTMENT Before adjusting the gears shift several times between 1st and 3rd gears and then back again so that the shift cable seats itself correctly Ss the twist shifter to 3rd gear Aires The shift cable should be adjusted so that it is free from play when 3rd gear is selected i e it must be pulled out as far as it will go sae should not be possible to pull the shift cable further out of the gear hub by pu
27. block in the shift sleeve 1 Advice The tapped hole 2 of the thrust block must be located on the axle side with the long slit 3 This subsequently allows the shift cable to run through the long slit Turn the circlip through 90 degrees to secure the thrust block ert the spacer bolt 4 and spring 5 in the axle Turn the red grub screw 6 so itis flush with the axle Assembling the gear unit Lubrication ay Lightly grease the axle and grease e toothing 7 Use only SRAM spe cial grease part no 0369 135 200 201 Place a drop of oil on the thrust block 8 the shift bush 9 with the crown toothing 10 facing downwards to wards the axle Place the coupling piece 11 with the lugs 12 downwards on to the shift bush E version with back pedal brake Place the control washer 13 with the bent up ends 14 facing upwards on the coupling piece 15 Hub version without brake Place the large washer on the coupling piece Lubrication ay Oil the 4 pockets for the pawls 16 and the driver pawl spring 17 Grease the ball retainer 18 with SRAM Ball Bearing Grease part no 0369 001 015 eat the driver 19 on the control washer 20 The pawls 21 must lie in the recesses of the control washer ush the spring 22 the fixed cone 23 the spacer sleeve 24 and the cable guide bush 25 onto the axle OS these The slotted side 26 of the spacer sl
28. 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 91 SPARC MAINTENANCE Sparc mounting aid Part No 65 3024 001 000 a C N AN al f NS gl 92 G ANN e A A gt REMOVE WHEEL E 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 LECTRIC 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 rotat
29. carrier For the hub version with back pedal brake place a drop of oil on the 5 rollers 14 a grease the inside of the hubshell eith SRAM special I MIOTION 3 MAINTENANCE CCC E l N T 15 20 Nm gt 5 133 177 in lbs z AFA Technical Manual Gear Hub Systems 2009 a version with back pedal brake Turn the shell in a clockwise direc tion as far as it will go This ensures that the rollers 19 of the brake can fall back and that the brake segments can be mounted Hub version with back pedal brake Lubrication amp 2 Clean the brake segments and completely coat the outer surfaces with grease Caution Use only SRAM special grease part no 0369 135 200 201 nserting the brake segments The recesses 20 must point up wards At first insert the brake segment so that the bevel 21 is visible from above A Advice The brake segment lie against the angled spring end 22 Insert the second brake segment ra The brake segments must be renewed if as a result of wear the grooves on the outer surface are scarcely visible Gi r Ce Work on the brake cone adjusting cone and ball retainer of the non drive side Lubrication on J Clean the ball retainer 23 and grease it using SRAM Ball Bearing Grease part no 0369 001 015 nsert the ball retainer 23 The
30. from the vise Clamp the new gear unit on the drive side of the axle in the vise Caution Use only SRAM special grease part no 0369 135 200 201 Lubricate ball retainers and ball tracks only with SRAM Ball Bearing Grease Part no 0369 001 015 Lubrication am Lightly grease the ball tracks 11 HENA the toothing 12 on the inside of the hubshell Hub version with back pedal brake Lightly grease the brake cylinder 13 osition the hub shell Turning slightly to the left right eases posi tioning Ensure that the hub shell is correctly seated on the ball retainer 14 version with back pedal brake Turn the shell in a clockwise direc tion until it reaches the stop This en sures that the rollers 15 of the brake can fall back and that the brake sleeve can be mounted Hub version with back pedal brake Lubrication am J Clean the brake sleeve and com pletely coat its outer surface only with grease Caution Use only SRAM special grease part no 0369 135 200 201 nsert the brake sleeve The side with only one recess must point downwards The angled spring end 16 must be positioned in this recess 17 Advice The brake sleeve must be renewed if as a result of wear the pattern on its outer surface is scarcely visible Lubrication am J Clean the ball retainer 18 and grease it using SRAM Ball Bearing Grease part no 0369 001 015 nsert the ball retainer 18
31. front DROPOUT chainring is bolted inside the chain case Only flat and no off set versions 1 Fig 4 Dropout thickness 7 8 mm Vertical or horizontal dropout slot A Dropouts must be parallel HANDLEBAR Diameter 22 3 mm Minimum length of straight area for shifter 28 6 10 25 30 8 5 max 11 5 13 5 150 mm 30 7 5 10 25 30 8 5 max 11 5 13 5 Check the compatibility of intended handlebars and brake levers Dropout dimensions see Fig 2 and 3 g max 220 mm IRF Technical Manual Gear Hub Systems 2009 Rev A 49 DUALDRIVE ASSEMBLY DualDrive 24 DualDrive 27 Clee eL 4 Links 50 ASSEMBLY HUB e Lace the wheel as normal e 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 bs Screw shifting rod 1 Fig 2 into the hub axle and tighten it with 0 2 Nm 1 8 in Ibs Fit wheel in dropouts e Hub versions for i BRAKE and Disc Brake Advice Read and observe the corresponding technical documentation for assem bling the disc of the disc brake Caution Plane faces of the hub and the disc and the threaded holes of the hub must be clean and free from oily and greasy substances Place one retaining washer without lug 2 Fig 2 on right
32. guide ring 1 on the gear unit O The ne The two lugs 2 of the roller guide ring must mesh in the long recesses 3 ROJNAMA the 6 rollers 4 in the roller guide ring Lubrication Oil the 6 rollers and the two pawls 5 of the roller guide ring Use only standard bicycle oil lace the washer 6 on the roller guide ring and fit the circlip 7 osition the hub shell Turning slightly to the left right eases posi tioning Ensure that the hub shell is correctly seated on the ball retainer 8 version with back pedal brake Turn the shell in a clockwise direc tion as far as it will go This ensures that the rollers 9 of the brake can fall back and that the brake sleeve can be mounted Work on the brake jacket Hub version with back pedal brake Lubrication ay J Clean the brake sleeve and com pletely coat its outer surface only with grease Caution Use only SRAM special grease part no 0369 135 200 201 nsert the brake sleeve The side with only one recess must point downwards The angled spring end 10 must be positioned in this recess 11 OD then The brake sleeve must be renewed if as a result of wear the pattern on its outer surface is scarcely visible Work on the brake cone adjusting cone and ball retainer Lubrication a J Clean the ball retainer 12 and grease it using SRAM Ball Bearing Grease part no 0369 001 015 nsert the ball retainer 12 T
33. mm the gear unit from coming apart ake off the fixed cone 8 together Advice the washer 9 above it On the drive side of the hub work aie only be carried out on the fol a off the lowing parts ball retainer 10 fixed cone 1 with ball retainer 2 Caution Further dismantling is not per mitted as otherwise the gear unit comes Work on the fixed cone and ball retainer apart Reassembly could then only be undertaken by SRAM the circlip 3 sprocket 4 and the small outer dust cap 5 Lubrication and assembly details can be found on the following page Caution The large outer plastic dust cap 6 e remain fitted to prevent the gear unit from coming apart Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 9 MAINTENANCE 15 20 Nm 133 177 in bs IRF Technical Manual Gear Hub Systems 2009 Rev A ASSEMBLING THE HUB DRIVE SIDE Work on the fixed cone and ball retainer Lubrication am J Clean the ball retainer 1 and grease it using SRAM Ball Bearing Grease part no 0369 001 015 nsert the ball retainer 1 The side with the balls must point down wards ush the fixed cone 2 onto the axle O the ne The lug 3 of the fixed cone must mesh in the axle recess 4 lace the washer 5 on top of it crew the nut 6 onto the axle Wrench size 17 mm tightening torque 15 20 Nm 133 177 in lbs lace the small inner dus
34. on left axle ends 1 Fig 4 The serra tions must bear against the dropout and the lug must engage in the dropout slot 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 bs 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 ASSEMBLY SHIFTER 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 the shifter 1 Fig 6 onto the handlebar Slide the handlebar grip 2 onto the handlebar Caution Never use lubricants or solvents when fitting handlebar grips They have a safety function and must not come free from the handlebar Place the shifter on the handlebar grip and position so that you can use it comfortably Tighten the clamping bolt 3 3 mm Allen key torque 3 5 4 Nm 31 35 in lbs Caution Check that shifter and brake lever can be easily operated if necessary realign Never ride without handlebar grips The turning grip of the twist shifter could become loose This can result in severe injuries When fitting the cable 1 Fig 7 avoid sm
35. pawl carrier Oil the pawl spring 31 PeR nseri the pawl carrier 32 in the shift bush The leg 33 of the shift bush lies in the two large recesses 34 of the pawl carrier Advice Press on the pawls 35 to make insertion easier lace the washer 36 on the pawl carrier Lubrication ay _ Apply a drop of oil to both bearing olts 37 of the ring gear Apply a little grease to the pawl teeth 38 and grease the ring gear teeth 39 Use only SRAM special grease part no 0369 135 200 201 Lubrication ay _ Apply a drop of oil on the three Sos bolts 40 of the planetary gear carrier and oil the contact sur face 41 Oil the pawl pockets 42 and the pawl spring 43 Grease the seat of the friction spring 44 with SRAM special grease part no 0369 135 200 201 Oil the end surface 45 atch the profile of the pawl carrier 46 to that of the coupling piece 47 Press the pawl carrier down pull on the shift cable and hold the system in this position for the next work step Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 3 MAINTENANCE TS uy t TU iD R FREED Technical Manual Gear Hub Systems 2009 Rev A ig while holding the system in posi tion the larger diameter ring gear 48 downwards over the pawls 49 of the driver Maintain the system in this position a the planetary gear carrier 50 By turning to the left and right bring the
36. same length e Initial assembly Shorten the chain to the length speci fied by the derailleur manufacturer SRAM derailleurs e Place the chain over largest front chainwheel and largest rear sprocket Fig 7 For rear suspension frame position the rear suspension for the greatest chain length required e Add 2 links or 1 link Power Link Fig 7 Closing chain with Power Link Caution Use Power Link only with SRAM chains Use only Power Link to close Hollow Pin chains and Cross Step chains no Pin Use only as specified to avoid mate rial damage or the rider to fall off his bicycle resulting in injury Power Link G gold coloured for PC 991 Hollow Pin PC 991 Cross Step PC 991 PC 971 PC 951 Power Link S silver coloured for PC 890 PC 870 PC 850 PC 830 Power Link SS2 light grey coloured for PC 830 Saltshaker Power Link SS1 light grey coloured for PC 10 Saltshaker Power Link G grey coloured for PC 10 o Closing e Fit chain bring the ends together and insert both halves of the Power Link into the chain ends Fig 8 e Press both halves of the Power Link together Fig 9 and lock in place by pulling the chain apart Fig 10 Opening Press both plates of the Power Link together Fig 9 while sliding the chain ends together unlock Remove the two halves of the link from the chain ends Caution e Always use a new Power Link when fitting a new chain e Failure to shor
37. side with the balls must point down wards EE version with back pedal brake Fit the lever cone 24 By turning to the left and right bring the lever cone 24 into its final position The locating lugs 25 of the lever cone will then lie in the recesses 26 of the brake segments crew an axle nut 27 onto the axle Wrench size 22 mm Hub versions without brakes and i BRAKE screw the adjusting cone onto the axle Wrench size 17 mm on the bearing in a play free manner and tighten using nut 28 Wrench size 22 mm Tightening torque 15 20 Nm 133 177 in lbs Test the play of the bearing and correct if required Clamp the hub with the other axle side in the vise the dust cap 29 onto the driver The curvature must point to the out side lace the sprocket 30 on the driver For offset i e transversely displaced sprockets the sprocket should be mounted with the toothing to the inside the curvature must point outwards Sc the sprocket circlip 31 onto the driver Advice Ensure that the plastic protective cap 32 is not damaged Check for proper seating of the circlip Remove the hub from the vise Fit the rear wheel into the rear frame as described on page 33 Adjust the gears as described on page 32 Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes 35 I MIOTION 3
38. 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 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 from tip of the cog to tip of upper guide pulley Fig 10 Turn the b adjust screw clockwise to increase the chain gap Turn the b adjust screw counterclock wise to decrease the chain gap Advice Do not use the b adjust screw to adjust the rear derailleur to act as a chain tensioning device or to prevent chain suck This increases the chain gap causing poor shifting performance MO Index shifting adjustment Check that the chain and the rear derail leur are in the smal
39. visib between hub le in front of and axle nut the axle nut Pedals are Bearings Re adjust carried set too tight bearings forward Loose Tighten when free lock nuts lock nuts wheeling 15 20 Nm Chain is over Reduce chain tension Hub locks Brakeseg Wash out tensioned when ments has hub sleeve braking run dry repolish and coaster relubricate brake brake cylinder renew brake segments Coaster Incorrect Fit friction brake mounted fric spring in without tion spring 3 correct way function Fig 1 Page 76 79 SRAM T3 TECHNICAL DATA ASSEMBLY REQUIREMENTS GEAR HUBS 1 2 OLD Caution Not suitable for tandems transport bicycles and similar Cycle frame e Dropouts must be parallel e Slot width at rear dropout 10 mm e The strength must be such that with a maxi mum braking torque of 250 Nm 2200 in lbs on the rear wheel no residual deformation can occur on the rear structure Version with Coaster Brake SRAM T3 with coaster brake SRAM T3 without brake Type MH3115 MH 3105 Brake Coaster Without brake Over Locknut Dim OLD 118mm 117 mm Length L 155 or 166mm 155 mm or 166 mm Ends Diameter T FG 10 5 FG 10 5 G Holes 36 or 28 36 or 2 Hole Diameter DS 3 0mm 3 0 mm A Hole Ref ge HR 58mm 58 mm Flange Dist to OLD F 24 5 mm F 25 5mm F 24 5mm F 25 5mm R Totally
40. 1 3x ____ _ __ 292 mm __ 282 mm __ 297 mm 32 630 21 x1 3x 297 mm Spoke lengths are approximate values They must be checked through lacing attempts and adjusted accordingly Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SRAM T3 ASSEMBLY Sy FO FREED Technical Manual Gear Hub Systems 2009 Rev A FITTING THE SHIFTER Caution Because of a risk of fracturing following types of handlebars are not suited thin walled aluminum handlebars e g Hyperlite handlebars carbon handlebars Slide the shifter 1 Fig 7 onto the handlebar Slide the handlebar grip 2 Fig 7 onto the handlebar Caution Never use lubricants or solvents when fitting handlebar grips They have a safety function and must not come free from the handlebar Place the shifter on the handlebar grip Fig 7 and position so that you can use it comfortably Tighten the clamping bolt 3 2 5 mm Allen wrench torque 2 Nm 15 in Ibs Caution Check that shifter and brake lever can be easily operated if necessary realign Never ride without handlebar grips The turning grip of the twist shifter could become loose This can result in severe injuries Caution Before setting out on any ride always check the correct and trouble free opera tion of the shift system and brakes FITTING THE SHIFT CABLE Advice Make sure that the cable housing length ts sufficient to permit tur
41. 15 onto the flat thread for types MH 3105 mount pawl carrier b and secure in place using safety washer c Fit hub shell 5 turning it counter clockwise 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 Ol 444 cone 9 Adjust the hub clearance by screwin 4 FL on hexagonal nut 1 until the hub shell COLIC runs free of play but not under tension j 1 Lock with a second nut to a tightening 3 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 clear ance is set with adjusting cone D as for type MH 3115 Caution Check that all the brake system compo nents are functioning properly Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A CHANGING THE SHIFT CABLE Advice Always use new high quality cables and compressionless cable housings with end caps e
42. 186 Gear steps e Speed1 0 734 AR e i Speed2 1 000 36 lt oO Speed3 1 362 36 lt U Line C D E C 44 5 mm D 41 5 mm E 38 5 mm C 44mm D 41 mm E 38 mm B Ratio 24 26 28 2 0 2 4 20 2 0 2 5 min 2 0 S Dimensions Jx and x Xu and Xx E Sprocket 16 24 Teeth outward offset Chain Line C 16 18 Teeth straight Chain Line D 16 24 Teeth inward offset Chain Line E Shifter SRAM T3 SRAM Bandix 3 7 Tandem Not suitable for tandems transport bicycles or similar Weight 1182g 911g A Hub Shell Material Steel Steel iz Finish Matt Chrome Plated Matt Chrome Plated 80 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SRAM T3 TECHNICAL DATA ASSEMBLY REQUIREMENTS SHIFTERS QyUmMan LN 22 1 22 3 Shifter SRAM T3 Version Shift cable lengths Comp Cable Housing Shifter type Assembly location Compat gear hub Gear indicator Barrel adjuster Clamping diameter Straight handlebar ends Weight Shift cable Housing Grip cover Frame clamp Finish SRAM T3 shifter SRAM T3 2200 mm Capped Compressionless with Resin Liner inside SRS twist shifter Right side of handlebar SRAM T3 Window None 22 1 22 3 mm Minim necessary length for shifter and handlebar grip 150 mm 58 g Stainless or galvanized steel Plastic injection molding Thermoplastic elastomer Aluminum Black Sy FE FREED Technical Manual Gear Hub Systems 2009
43. 3 3 i MOTION 3 25 AMO DualDrive 46 SRAM S7 57 BB sRAM P5 65 PS SRAM P5 Cargo 13 SRAM T3 80 CZ Sparc 89 GEAR HUB SYSTEM COMPONENTS Brake Lever 96 i LIGHT Dynamo Hubs 98 Power Chain 102 SRAM Komfy Hydraulic Disc Brake See Technical Manual AVID Juicy 5 SUPPORT f Distributors Spare Parts 106 So FE FAITE Technical Manual Gear Hub Systems 2009 Rev A Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 9 TECHNICAL DATA ASSEMBLY REQUIREMENTS av Version with back pedal brake N S lt Dropout Width Dim A min 4mm max 10mm Chainline CL 48 8 mm Ratio 1 73 1 90 Dimensions x and x Sprocket 18 19 20 21 22 teeth G Holes 36 or 32 Hole Diameter DS 2 8 mm E Hole Ref HR 93 6 mm T Flange Dist to OLD F 265mm F 31 5mm R Overall 340 Gangsprung 1st gear 0 542 SL 2nd gear 0 621 14 gt 3rd gear 0 727 17 B 4th gear 0 853 17 5th gear 1 000 17 E 5 6th gear 1 172 17 N 7th gear 1 375 17 A 8thgear 1 611 17 B 9th gear 1 844 14 E N Disc Brake Hand brake lever p 1 E x Weight 2 400 g Mat Hub shell Aluminum Surface Satin matt Lux anodized IRF Technical Manual Gear Hub Systems 2009 Rev A i MOTION 9 with back pedal brake Speeds 9 Brake With back pedal brake Over
44. 33 177 in lbs Clamp other axle end driver side facing downwards Mount ball retainer 15 pawl carrier 10 and washer 9 Press pawls against spring force and mount gear ring 8 with smaller diam eter 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 shifting rod 19 with a torque of 0 2 Nm 1 8 in lbs Mount spoke protector disc and cassette Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM DUALDRIVE MAINTENANCE Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A LUBRICATION GEAR HUB Hubs are provided with permanent lubrication and maintenance free under normal conditions Cleaning of parts e All parts except the planetary gear carrier and the driver can be degreased in a cleaning bath e Planetary gear carrier and driver only need to be cleaned on the outside with a brush so as not to degrease the bear ings Lubrication of parts Use only SRAM special grease part no 0369 135 200 201 Lubri
45. 8 0 94 5 18Z 22T g 87 7 g 103 6 SHIFT CABLE ROUTING Shift cable routing only along the chainstay Only continuous cable housing no open cable routing See the adjoining figure for attachment points 6 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 9 ASSEMBLY f GRI 722222255 N yf n k A gt Khris 350 in lbs e IRF Technical Manual Gear Hub Systems 2009 Rev A ASSEMBLY THE HUB Spoke the hub as normal ee the dust cap 1 onto the driver The curvature must point to the out side e the sprocket 2 onto the driver E Moun the sprocket circlip 3 onto the driver Check for proper seating of the circlip Hub version for Disc Brake O ue Read and observe the corre sponding technical documentation for assembling the disc of the disc brake Caution Plane faces of the hub and disc and the threaded holes of the hub must be clean and free from oily and greasy substances Place the rear wheel into the rear frame lide one retaining washer each 4 onto each axle end The correct ver sion is shown in the table on page 5 The serrated face of the retaining washer must lie against the frame dropout Where retaining washers have locating lugs these must engage in the frame dropouts Ss fit the axle nut on the drive side and tighten to a torque of 40 Nm 350 in Ibs Then fit the ax
46. A max 12 mm Holes 36 Hole Diameter DS 3 0mm G HoleRef 9 HR 75mm E Flange Dist to 0LD F 33mm F 34mm A Totally 303 Gear steps Speed1 0 574 RE R Speed2 0 677 18 e Speed3 0 809 19 H Speed4 1 000 24 o Speed5 1 236 24 U Speed 6 1 476 19 B Speed7 1 742 18 S Usable Dimensions x or x Line C D E C 54mm D 51mm E 48mm Shifter SRAM Grip 7 Clickbox Clickbox 7 gt eo 2 E Weight 1714g Hub Shell Material Steel Finish Matt Chrome Plated or Black IRF Technical Manual Gear Hub Systems 2009 Rev A SRAM S7 without brake MH 7205 Without brake 130 mm 183 4 mm FG 10 5 A max 12 5 mm A max 10 mm 36 3 0 mm 75mm F 33mm F 34mm lt TIT IT IT IT IA A X A or l X a C 54mm D 51 mm E 48 mm Ratio 24 26 28 1 83 1 90 20 1 83 2 00 min 1 83 Sprocket 16 24 Teeth outward offset Chain Line C 18 Teeth straight CL D 19 24 Teeth inward offset CL E E Tandem Not suitable for tandems transport bicycles or similar 1556 g Steel Matt Chrome Plated or Black Version with Coaster Brake 83 57 SRAMI S7 TECHNICAL DATA ASSEMBLY REQUIREMENTS SHIFTER SRAM Grip 7 Shifter Type Twist Shifter mit Clickbox Cable Length Black housing 1400 mm 1750 mm Gear Indication Window Clamping Diameter 22 1 22 3 mm Straight han
47. E HUB page 34 WEAR PARTS Brake liners or brake segments brake cables shift cables handlebar grips sprockets and bike chains are wear parts Please check these parts regularly and re place them well before they are worn out Other topics Page GEAR ADJUSTMENT 32 REMOVING THE REAR WHEEL 32 FITTING THE REAR WHEEL 33 EXCHANGING THE GEAR UNIT 34 DISMANTLING AND ASSEMBLING THE HUB 34 DISMANTLING AND ASSEMBLING THE GEAR UNIT 36 CHANGING THE SHIFT CABLE 44 TROUBLESHOOTING 45 31 I MIOTION 3 MAINTENANCE 32 GEAR ADJUSTMENT the twist shifter to 3rd gear Advice The shift cable should be adjusted so that it is free from play when 3rd gear is selected i e it must be pulled out as far as it will go should not be possible to pull the shift cable further out of the gear hub by pulling on the plastic retainer 1 Shift cable has too much play Turn the twist shifter to 1st gear so the shift cable play by turning the barrel adjuster 2 on the shifter Shift cable is too tight taut Either the shifter cannot select 3rd gear or the gear hub does not shift to 1st gear or shifts constantly between 1st and 2nd gears Turn the twist shifter to 1st gear HEE Re ue the shift cable tension with the aid of the the barrel ad juster 2 on the shifter Turn the twist shifter to 3rd gear and check once again that there is no play in the shift cable REMOVING THE REAR WHEEL the twis
48. LD Length L Type Material Ends Diameter Holes Hole Diameter Hole Reference Flange Width Flange Distance F F Offset Bearing es N Sealing Homologation Efficiency Weight Finish Hub Shell D724 N D730 N D724 D D730 D Standard gt Disc Brake compat 6 holes 24 Wat 20 Wat 6V 6V lt 400 720 mm 16 28 400 720 mm 16 28 100 mm 100 mm Steel Steel 36 32 36 32 2 5mm lt 2 5mm lt 11mm lt 11mm lt 3 4mm 3 4mm F 28mm F 28mm F 18 mm F 31mm 0 mm lt 6 5mm lt Cartridge Cartridge Double Sealed lt Double Sealed lt KBA homologation for versions with 3 0 Watt KBA Kraftfahrtbundesamt eman 70 at 15 km h 70 at 15 km h 557 g eso NA og 15576 508 WA 580 g Aluminum silver or black anodized 1 Caution Quick release braking load min 10000 N 2250 Ibs 98 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I LIGHT DYNAMO HUBS TECHNICAL DATA ASSEMBLY REQUIREMENTS D7 D3 SER Homologation KBA homologation for versions with 3 0 Watt KBA Kraftfahrtbundesamt Germany Caution Quick release braking load min 10000 N 2250 Ibs CABLE REQUIREMENTS Recommended wire specifications Inner wire size AWG 22 Diameter approx 0 8 mm Wire insulation 1 8 2 mm Remove insulation by 17 mm Fig 1 Advice Cables with a minimum cross sec tion of 0 4 mm and a cable resistance of
49. LE Advice Always use new high quality cables and compressionless cable housings with end caps e Turn the twist shifter to 1st gear Advice Do not remove the Clickbox from the axle end Unscrew the barrel adjuster 1 Fig 5 completely Unscrew the cover screw 2 brush aside the barrel adjuster 1 and remove the cover 3 Withdraw the shifter cable and clamping bolt 1 Fig 6 upwards loosen the clamp screw with a 2 5 mm Allen key and pull the clamping piece from the cable Remove and discard the old cable hou sing Remove the cap 1 Fig 7 from the shifter The nipple of the inner cable is now visible Push or pull the old inner cable Fig 7 out of the shifter e g using a small screwdriver Guide the new inner cable into the cable inlet through the shifter and the new cable housing Pull the cable tight Insert the cap in the shifter Position clamping bolt 1 Fig 8 at a distance of 90 mm Advice For positioning the clamping bolt use adjust gauge Fig 9 Part No 65 0324 107 000 Tighten the clamping screw with a 2 5 mm Allen key Tightening torque 1 5 Nm 13 in lbs Cut off the cable end to 2 3 mm 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 barrel adjuster 1 com pletel
50. Remove tool and check that the circlip is seated correctly Mounting Tool Part No 0582 104 000 Spoke length table Tire Size Cross 37 540 24 x 14 28 822 28 x11 32 630 21 x1 3 x and adjusted accordingly 14 Length MH 5215 179 m n 225 mm 232 mm 251 mm 259 mm 215 mm 289 mm 289 mm 289 mm 289 mm 294 mm 294 mm 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 Hub versions for Disc Brake Advice Read and observe the corresponding technical documentation for assemb ling the disc of the disc brake Caution Plane faces of the hub and the disc and the threaded holes of the hub must be clean and free from oily and greasy substances Placing the wheel in the rear frame Fit new retaining washer 3 5 mm thick on left axle end 1 Fig 4 The serrations must bear against the dropout and the lug must engage in the dropout slot Length MH 5225 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 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SRAMP P5 CARGO ASSEMBLY IRF Technical Manual Gear Hub Systems 2009 Rev A On the sprocket side fit the protective bracket 1 Fig 5 directly below the a
51. SW9 SAS qnu 188p usibue jenuewW JeXIUYI9 SN NZ Caution This Technical Manual is intended for qualified bicycles dealers and bicycle factories only SRAM ORIGINAL PARTS Caution The SRAM Warranty policy does not cover damages caused by the use of non SRAM parts Use only SRAM parts with SRAM components Installation of parts and accessories not originally intended could result in less than optimal performance and or injury For in depth service information on SRAM products refer to our website at www sram com Contact your local SRAM distributor or dealer for ordering information Information contained in this publication is subject to change at any time without prior notice Your product s appearance may vary from the diagrams contained in this catalog REPAIR WORK Caution Unauthorized work may result in its malfunc tioning which may endanger you and could lead to invalidation of the warranty TRADEMARKS This publication includes trademarks and registered trademarks of SRAM Corporation designated by the symbols and respectively Copyright 2008 SRAM Corporation Publ No 95 3115 010 000 E Rev A Information may be enhanced without prior notice Released August 2008 EXA Drive is a trademark of Campagnolo S R L Grilon is a trademark of EMS Chemie AG HG IG are trademarks of Shimano Inc TABLE OF CONTENTS GEAR HUB SYSTEMS GEAR HUBS AND SHIFTERS og i MOTION 9
52. UB see page 34 yee Read and observe the operating manual and technical documentation of the brake manufacturer Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 3 MAINTENANCE IRF Technical Manual Gear Hub Systems 2009 Rev A CLEANING Your SRAM i MOTION 3 components are well protected against adverse envi ronmental effects However do not use water under pressure Such as pressure washers or water jets for cleaning to prevent malfunctions due to water pen etration During winter use you should clean your bike more frequently to prevent salt damage Do not use any corrosive cleaning agents Clean dirty chains before oiling Allow cleaner to work for only a few minutes before rinsing off with water Do not oil chain until completely dry x w LUBRICATION The rear wheel hub is provided with per manent lubrication and is maintenance free under normal conditions When dismantling assembling the gear unit observe the lubrication guidelines See DISMANTLING ASSEMBLING THE HUB from page 34 Regular will extend the chain s service life REPAIR WORK Caution Unauthorized work on the i MOTION 3 system may result in its malfunctioning which may endanger you and could lead to invalidation of the warranty Back pedal brake If braking is too sharp the brake sleeve has to be re lubricated with special grease See DISMANTLING ASSEM BLING TH
53. additional documentation about the last charging date within our SRAM facility This docu mentation 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 Cause Problem Gear hub Shifting difficulties Incorrect gear setting To much additional axle at tachments between hub and axle nut Pedals are carried forward when freewheeling Electric system Electric drive does not work Fuse blasted Electric drive emits unusual noise Damaged control cable 2 REMOTE CONTROL UNIT Do not disassemble the remote control unit PROTECTION AGAINST OVERHEATING At high thermal load all lights will start flashing prior to the eventually necessary protection shutt off of the drive unit After cooling down the regular funtion of the system will be restored Remedy Replace control cable Adjust shifting system Beginning of axle thread must be visible in front of the axle nut Bearings set too tight Readjust bearings Loose lock nuts Tighten lock nuts 15 20 Nm Chain is overtensioned Reduce chain tension Remote control in position OFF Switch to ECON or SPEED Remote control defect Replace remote control Plugs not engaged Slide all plugs completely in slo
54. ain can be pulled out of the return pulley by hand e Setting too tight It is difficult to place the shift lever in gear position 1 e If required readjust the shift mechanism in third gear Caution Before setting out on any ride always check the correct and trouble free opera tion of the shift system and brakes 83 SRAMP T3 MAINTENANCE Coaster brake MH 3115 REMOVE WHEEL Apply fingertip pressure onto the metal key of locating sleeve to release it from the pull rod Remove return pulley Screw off both axle nuts and remove retaining washers Remove wheel 1 DISMANTLING HUB see Fig 1 AERO Unscrew indicator chain 23 remove circlip 21 sprocket 20 dust cap 19 23 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 car rier 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 2 Without brake MH 3105 a block must be aligned Remove the gear ring 11 from the axle RARARARARA 256 SS HS S
55. al Gear Hub Systems 2009 Rev A SRAM SRAMI P5 ASSEMBLY 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 Fit new retaining washer 3 5 mm thick on left axle end 1 Fig 4 The serrations must bear against the dropout and the lug must engage in the dropout slot 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 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 Ibs Advice Ifa 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 Caution Check that all the brake system components are functioning properly ASSEMBLY SHIFTER 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 leng
56. all 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 NSTALLING 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 mak ing 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 posi tion tighten up the knurled bolt 3 Fig 5 by hand 0 3 Nm 2 7 in bs 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 barrel adjuster 5 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SPARC ASSEMBLY 10 Ey IRF Technical Manual Gear Hub Systems 2009 Rev A ASSEMBLY BATTERY BOX Pull both quick releases outward and turn them to the open position Fig 9 Position battery box onto luggag
57. an occur on the rear structure TT A max SRAM P5 with coaster brake Type MH5215 Brake With coaster brake Over Locknut Dim OLD 122mm Length L 175mm Ends Diameter T Dropout Width Dim A max 12 5 mm A max 11 5 mm So FE FREED Technical Manual Gear Hub Systems 2009 Rev A SRAM P5 without brake MH 5205 Without brake 122 mm 175mm FG 10 5 FG 10 5 toothed cone FG 10 5 A max 12 5 mm A max 10 5 mm Holes 36 36 G Hole Diameter DS 3 0 mm 3 0 mm E G Hole Ref HR 75mm 75mm A Flange Dist to OLD F 28 5mm F 29 5mm F 29mm F 29mm R Totally 251 Gear steps Speed1 0 633 ar e ps Speed2 0 781 23 lt Speed3 1 000 28 lt U o Speed4 1 281 28 Speed5 1 579 23 B Usable Dimensions 1 x or x 1X OF Xu S Line C D E C 49 mm D 45 5 E 43 mm C 49 mm D 45 5 mm E 43 mm Ratio 24 26 28 1 8 1 9 20 1 8 2 0 min 1 8 Sprocket 16 24 Teeth outward offset Chain Line C 16 18 Teeth straight Chain Line D 18 24 Teeth inward offset Chain Line E E Shifter SRAM Grip 5 E Clickbox Clickbox P5 S Tandem Not suitable for tandems transport bicycles or similar Weight 1495g 1330 g Hub Shell Material Steel Steel Finish Matt Chrome Plated Matt Chrome Plated 65 SRAMP P5 TECHNICAL DATA ASSEMBLY REQUIREMENTS SHIFTER SRAM
58. and guide the new inner cable into the housing Hook the nipple 3 of the inner cable into the recess 4 in the brake lever Follow the brake manufacturer s in structions when fitting the brake cable and adjusting the brakes Caution Check that the brake is operating in a correct and trouble free manner Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM i MOTION 9 ji MAINTENANCE Ba TROUBLESHOOTING Problem Cause Remedy Shifting difficulties Incorrect gear adjustment Adjust the gears Page 12 The shift cable for the cable housing is damaged Renew the shift cable and cable housing Page 20 The connecting tube is touching the bike frame The connecting tube must be freely connected to or is twisted the hub without being twisted Remove the cause of twisting e g by correctly aligning the rear wheel The connecting tube is twisted The connecting tube must be freely connected to Left and right retaining washers have been the hub without being twisted interchanged Fit the correct retaining washers Incorrect retaining washers fitted Page 5 The pedals go forwards when freewheeling The chain tension is too tight Slacken the chain tension The bearing adjustment is too tight Readjust the bearing Page 15 Locknut of the lever cone adjusting cone is Readjust the bearing and tighten the locknut loose Page 15 figure 12 no 24 The back pedal brake is too sharp or locked The b
59. ar 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 wa ter penetrates it could lead to functional problems Lubrication of parts Use only SRAM special grease part no 0369 135 200 201 Lubricate ball retainers and ball tracks only with SRAM Ball Bearing Grease Part no 0369 001 015 To lubricate the bearing points on the planetary gear sets position the plan etary gear carrier on its crown and ap ply 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 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 e Spread grease on the complete sur faces inside and outside of the 3 brake segments Regrease ball retainer and insert into lever cone slightly grease cone surface of the lever cone Lin
60. ater jets high pressure cleaners etc if water penetrates it could lead to functional problems BATTERY CHANGE 16 8 V NiMH battery see Fig 8 and 9 Disassembly e Apply fingertip pressure onto the tap and pull battery cable plug off the bat tery box Turn quick releases to the open posi tion Fig 8 and pull them outward Take off battery box from luggage car rier Unscrew the 4 bottom screws slotted screwdriver Torx T10 and take off battery box cover e Hang out stirrup 3 Fig 9 Take out battery and pull off plug 1 and cable shoe 2 from card modul Reassembly e 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 car rier 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 e Apply fingertip pressure onto the tap and pull battery cable plug off the bat tery box Turn quick releases to the open p
61. axle end drive side The serrations must bear against the dropout Place one retaining washer with lug 3 Fig 2 new version 3 5 mm thick on left axle end non drive side The lug must engage in the dropout slot On vertical dropouts fit one retaining washer without lug on each axle end The serrations must bear against the dropout Tighten up axle nuts Tightening torque 30 40 Nm 266 350 in lbs ASSEMBLY DERAILLEUR Advice Check the rear derailleur hanger alignment A bent rear derailleur hanger will result in inaccurate index shifting e 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 CHAIN LENGTH e 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 e Add 4 LINKS or 3 link Connecting Link to this length for proper chain length ASSEMBLY SHIFTER 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 le
62. ble G Totally 573 27spd 573 27spd 539 24spd A Totally hub 186 Gear steps amp R Speed1 0 734 J lt Speed2 1 000 36 Speed3 1 362 36 lt H Chainline 45mm 42mm U Usable Dimensions x eae ADA B Crankset 33 38 Teeth e Cogset 11 34 Teeth 12 32 Teeth S Cogset DualDrive 27 DualDrive 24 Shifter DualDrive 27 DualDrive 24 5 Disc brake 6 holes Tandem Not suitable for tandems transport bicycles or similar Sealing Extra sealed Weight 970 g 985 g Hub Shell Aluminum silver anodized Aluminum silver anodized Shifting device Composite Composite Technical Manual Gear Hub Systems 2009 Rev A SRAT DUALDRIVE TECHNICAL DATA ASSEMBLY REQUIREMENTS SHIFTERS J rm m 0 z FAITE Technical Manual Gear Hub Systems 2009 Rev A Shifter DualDrive 27 Version Clickbox Cable Shifter Type Arrangement Gear Hub 8 F Derailleur Gear Indication Der Riding Mode Indic Barrel Adj Gear Hub Barrel Adj Derailleur Clamping Diameter Straight handlebar ends Cable Routing Gear Hub Cable Routing Der Weight Cables Housing Grip Cover Clamping Collar Clickbox DualDrive single sided shifter Shifter DualDrive 24 MO DualDrive 27 DualDrive 24 1400 mm 1500 mm 1600 mm 1700 mm 2100 mm SRS Twistring Thumbshifter Combo 2in1 Right side of handlebar DualDrive 27 DualDrive 27 Windo
63. c brake should be carried out in the same way Differences Instead of brake segments cone a click and pawil carrier is installed on the planetary gear carrier 71 SRAME P5 CARGO MAINTENANCE 2 mm 80225 mm SRI SPECTRO 78 CHANGING THE SHIFT CABLE Advice Always use new high quality cables and compressionless cable housings with end caps e Turn the twist shifter to 1st gear Advice Do not remove the Clickbox from the axle end Unscrew the barrel adjuster 1 Fig 4 completely Unscrew the cover screw 2 brush aside the barrel adjuster 1 and remove the cover 3 Withdraw the shifter cable and clamping bolt 1 Fig 5upwards loosen the clamp screw with a 2 5 mm Allen key and pull the clamping piece from the cable Remove and discard the old cable hou sing Remove the cap 1 Fig 6 from the shifter The nipple of the inner cable is now visible Push or pull the old inner cable Fig 6 out of the shifter e g using a small screwdriver Guide the new inner cable into the cable inlet through the shifter and the new cable housing Pull the cable tight Insert the cap in the shifter Position clamping bolt 1 Fig 7 at a distance of 80 mm Advice For positioning the clamping bolt use adjust gauge Fig 9 Part No 65 0324 107 000 Tighten the clamping screw with a 2 5 mm Allen key Tightening torque 1 5 Nm 13 in lbs Cut o
64. cate ball retainers and ball tracks only with SRAM Ball Bearing Grease Part no 0369 001 015 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 bear ings Oil cartridge bearing Regrease ball retainers line ball bear ing 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 wa ter penetrates it could lead to functional problems LUBRICATION REAR DERAILLEUR e Do not use solvants or corrosive materi als to clean the components e Lubricate the shifting joints regularly Fig 3 e Grease any cable guides e g beneath the bottom bracket MO 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 bar rel adjuster Discard old cable and cable housing Remove screw 1 Fig 4 and pull open the cable change sleeve 2 Rotate the shi
65. con necting tube Screw the barrel adjuster 11 as far as it will go onto the connecting tube aah sure that the shifter is set to 1st gear 13 in lbs Artikel Nr 00 0991 002 000 Lore no annona 2 mm 1 5 Nm 13 in lbs zl RD une K R FREED Technical Manual Gear Hub Systems 2009 Rev A lide the quick release fastener 12 on the connecting tube to the right The opening 13 should now be visible we the connection by sliding the opening of the connecting tube onto the catch 14 on the hub lide the quick release fastener 15 on the connecting tube to the left until it snaps into place The connection is now locked Adjust the gears as described on page 12 Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes 21 I MIOTION 9 MAINTENANCE 22 CHANGING THE BRAKE CABLE Advice Always use new high quality cables and compressionless cable housings with end caps Loosen the inner cable from the brake the cable adjustment screw 1 and the counter nut 2 so that the cable slot is aligned with the slot on the bottom of the brake lever housing em the brake lever to the handlebar and unhook the nipple 3 of the inner cable from the recess 4 in the brake lever Remove the old brake cable completely em the brake lever to the handlebar
66. d HG IG PC comp 410 g 280 g SAPH 440 Stahl Steel Zinc Coat e Chrome matt Chrome Technical Manual Gear Hub Systems 2009 Rev A S RAIM DUALDRIVE TECHNICAL DATA ASSEMBLY REQUIREMENTS SO Cable routing 1 DualDrive 27 DualDrive 24 Hub cable Along chainstay only Derailleur cable Along chainstay only Cable attachement siehe Bild 1 Cable housing Attachement points Cable stops Hub Continuous Derailleur Continuous 1 2 3 4 5 see Fig 1 Open 2 CABLE HOUSING FOR DERAILLEUR Rear cable stop position Rear housing length 200 180 160 140 120 R2 E L gt 100 10 120 130 R1 X mm aa Xx 90 Length X min 90 mm Example Distance X 100 mm gt cable Cable stop below or beside chainstay housing length L 140 165 mm CABLE HOUSING CRANKSET 3 e Use only new high quality cable and Bicycle without chain case com pressionless cable housing with Use a chain guard disc at the outer end caps surface of chainring material no resin When choosing cable housing lengths Use only standard chainring version non be sure to allow enough housing for an shifting teeth extreme turn of the handlebars in both Number of teeth 33 38 directions Note also that different stem lengths Chainline 45 mm and cable stop positions effect cable housing length 39 gt CHAIN GUIDE FORK It prevents chain from jumping off
67. dlebar ends Length of shifter Weight N A Housing Glass filled PA black or grey Grip PP Grip Cover Minimum necessary length for shifter and handlebar grip 150 mm 76mm J rm mmj O Thermoplastic elastomer Overmolded Clamping Collar Aluminum SRAM S7 ASSEMBLY ASSEMBLY HUB e Lace the wheel as normal See spoke length table e Place the dust cap 1 Fig 1 and sprocket 2 on the driver Advice When fitting a straight sprocket not an offset version the beadings of the sprocket must lie against the dust cap 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 2 4 3 Spoke length table Tire Size Cross Length 47 406 20 x 1 75 x 2 3x 181 mm Montagewerkzeug 37 490 22X1 3x 225 mm Art Nr 0582 104 000 47 507 24 x 1 75x2 3 x 232 mm 37 540 24 x 1 3X 251 mm 47 559 26 x 1 75 xX 2 3x 259 mm 3 37 590 26 x 17 3x 275 mm 41 622 28 x 1 75 3x 289 mm 37 622 28 x 13X1 3x 289 mm 28 622 28 X14 3x 289 mm 32 622 28 x 1 x1 3x 289 mm 28 630 21 x 1 fifty 3x 294 mm 32 630 271 x1 3x 294 mm Spoke lengths are approximate values They must be checked through lacing attempts and adjusted accordi
68. dlebars in both directions Note also that different stem lengths and handlebar positions effects cable housing length Slide the shifter 1 Fig 6 onto the handlebar Slide the handlebar grip 2 onto the handlebar Caution Never use lubricants or solvents when fitting handlebar grips They have a safety function and must not come free from the handlebar Place the shifter on the handlebar grip and position so that you can use It com fortably Tighten the clamping bolt 3 3 mm Allen key torque 3 5 4 Nm 31 35 in Ibs Caution Check that shifter and brake lever can be easily operated if necessary realign Never ride without handlebar grips The turning grip of the twist shifter could become loose This can result in severe injuries When fitting the cable avoid small radi us 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 NSTALLING CLICKBOX 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 mak ing sure that the internal lug 5 is guid ed in the slot 6 of the shift tube until it can be felt and heard to engag
69. e Turn locating sleeve on the axle until the guiding rib 4 is facing roughly upwards Place shifter in gear position 1 Push on Clickbox 2 Fig 5 to the stop on the hub axle The guiding rib 4 Fig 8 of the locating sleeve thereby engag es 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 5th to 4th gear Match up the marks in the Clickbox viewing window 4 Fig 6 by turning the barrel adjuster 5 Caution Check that all the brake system components are functioning properly 59 SRAMI S7 MAINTENANCE 60 REMOVE WHEEL 2 e 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 DISMANTLING HUB see Fig 1 Remove circlip 39 sprocket 38 and dust cap 37 as normal Clamp hub by the axle between alu minum jaws with sprocket side facing downwards Unscrew both locknuts 1 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
70. e 9 LY ese g mak 9 J Advice The dismantly and reassembly of the hubs without brake should be carried out in the same way Fig 2 Differences e There is no brake sleeve 4 and brake cone 6 e The planet carriers a have a cylindri cal 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 are fitted 84 Technical Manual Gear Hub Systems 2009 Rev A SRANI SRAME T3 MAINTENANCE REASSEMBLY HUB 3 see Fig 1 2 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 4 tightening torque 15 20 Nm 133 177 in lbs Turn hub over and slide on planet car rier 9 thrust washer X must first be fitted for types MH 3105 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 31
71. e ball bearing running tracks and brake cylinder in hub shell with grease Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A TROUBLESHOOTING Problem Cause Remedy Shifting Damaged Replace difficulties control cable control cable Incorrect Adjust shift gearsetting system To much ad Beginning of ditional axle axle thread attachments must be visib between hub le in front of and axle nut the axle nut Pedals are Bearings Re adjust carried set too tight bearings forward Loose Tighten when free lock nuts lock nuts wheeling 15 20 Nm Chain is over Reduce tensioned chain tension Hub locks Brake seg Wash out when ments has hub sleeve braking run dry repolish and coaster relubricate brake brake cylinder renew brake segments Coaster Incorrect Fit friction brake mounted fric spring in without tion spring 3 correct way function Fig 1 Page 60 63 64 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SRAMI P5 TECHNICAL DATA ASSEMBLY REQUIREMENTS Version SRAM P5 Cargo see page 73 Caution Not suitable for tandems transport Version with coaster brake bicycles and similar Cycle frame 35 e Dropouts must be parallel e Slot width at rear dropout 10 mm The strength must be such that with Zs taisi a maximum braking torque of 250 Nm 2200 in lbs on the rear wheel no residual deformation c
72. e car rier 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 Advice Closed elements such as brazed on eye bolts are not suitable because plug will not pass through STORING BATTERY BOX 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 docu mentation 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 lt ASSEMBLY REMOTE CON TROL UNIT e Slide remote control unit 1 Fig 10 onto handlebar e Mount brake lever 2 and fixed grip 3 e 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
73. ears as described on page 12 Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes 15 I MIOTION 9 MAINTENANCE DISMANTLING THE HUB NOT DRIVE SIDE Caution During dismantling one side of the hub must always remain closed to prevent the gear unit from coming apart d Advice 3 On the non drive side of the hub work may only be carried out on the following parts lever cone adjusting cone with ball re tainer 1 brake sleeve 2 Roller guide ring and rollers 3 Work on the brake cone adjusting cone and ball retainer lamp the drive side of the axle with the two flats of the axle in a vise e the nut 4 and the large axle nut 5 from the axle Wrench size 17 mm and 27 mm SRAM tool part no 00 0924 003 000 for wrench size 27 mm For the no brake hub version and disc brake the axle nut 4 and the underlying adjusting cone should be unscrewed from the axle Wrench size 17 mm and 13 mm so version with back pedal brake Take off the lever cone 6 and the ball retainer 7 a versions without brake and Disc Brake take the ball retainer 7 out Lubrication and assembly details can be found on the following page Work on the brake sleeve Hub version with back pedal brake Dismantle the hub as previously de scribed Work on brake cone adjusting cone and ball retainer
74. ed with the smallest sprocket High gear limit screw is not adjusted properly Unscrew screw H until the guide pulley is aligned with the smallest sprocket High gear limit screw Is not adjusted properly Turn in screw L until the guide pulley is aligned with the largest sprocket Rear derailleur or derailleur Straighten or replace hanger is bent Low gear limit screw is not adjusted properly Shift cable is too tight Turn barrel adjuster on the shifter clockwise Excessive cable friction Lubricate or replace cable pinched or poorly routed and housing Check for cable excessive bending of cable housing Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM DUALDRIVE O MAINTENANCE Ji I Fa I11 Technical Manual Gear Hub Systems 2009 Rev A 55 56 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SRAMI S7 TECHNICAL DATA ASSEMBLY REQUIREMENTS Caution Not suitable for tandems transport bicycles and similar Cycle frame Dropouts must be parallel e Slot width at rear dropout 10 mm e The strength must be such that with a maximum braking torque of 250 Nm 2200 in lbs on the rear wheel no min 13 5 residual deformation can occur on the rear structure SRAM S7 with coaster brake Type MH 7215 Brake With coaster brake Over Locknut Dim OLD 130mm Length L 183 4 mm Ends Diameter T FG 10 5 Dropout Width Dim A max 12 5mm
75. eel hub by hooking the connection lug 9 onto the shift ca ble nipple 10 lug the plastic retainer 11 onto the cable stop bracket 12 Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes 33 I MIOTION 3 MAINTENANCE ll retai dri nw a P EAG FA TEG grease Lightly grease the ball tracks 17 with with SRAM Ball Bearing Grease ake the hub shell 9 off in an up j AN Re E wards direction Take both brake jor TEEMU VET S WIIN each pora segments 10 out of the hub shell brake lightly grease the brake cylinder Take off the ball retainer 11 in an up pe Caution wards direction JER Advice Use only SRAM special grease When exchanging the gear unit pare NO A ted ad of th ll retainer is not dak nOeNeees zat the hub shell Turning slight Y ly to the left right eases positioning T Lubrication and assembly details can be ensure WALTA MUN snel found in the following column seated on the ball retainer 18 34 Technical Manual Gear Hub Systems 2009 Rev A SRANI EXCHANGING THE GEAR UNIT WORKING ON THE BACK PEDAL BRAKE DISMANTLING THE HUB Work on the brake cone adjusting cone and ball retainer of the non drive side gt off the locking bush 1 and the cable stop bracket 2 KIN the circlip 3 Caution The circlip is spring force loaded Take off the sprocket 4 and the dust cap 5
76. eeve and the guide surface 27 of the cable guide bush must be located on the axle side with the slit 28 for the shift cable Fit the threaded bushing 29 and tighten with a torque of 15 20 Nm 133 177 in lbs Wrench size 13 mm Lubrication dy Fill the opening 30 for the shift on the cable guide bush with grease Use only SRAM special grease part no 0369 135 200 201 R JIN the shift cable into the cable guide bush and secure it by turning in a clockwise direction minimum of 7 full turns Turn only until hand tight JIN the plastic protective cap 31 Clamp the hub with the other axle side in the vise 41 I MIOTION 3 MAINTENANCE i Ceo 2 a A Lubrication ay Apply a drop of oil on both bearing ae 32 of the pawl carrier Oil the pawl spring 33 Pem nseri the pawl carrier 34 in the shift bush The leg 35 of the shift bush lies in the two large recesses 36 of the pawl carrier Advice Press on the pawls 37 to make insertion easier lace the washer 38 on the pawl carrier Lubrication ay Apply a drop of oil to both bearing olts 39 of the ring gear Apply a little grease to the pawl teeth 40 and grease the ring gear teeth 40 Use only SRAM special grease part no 0369 135 200 201 Lubrication ay _ Apply a drop of oil on the three PR bearing bolts 42 of the planetary gear carrier and oi
77. ever ride without handlebar grips The turning grip of the twist shifter could become loose This can result in severe injuries 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 INSTALLING CLICKBOX e 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 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 posi tion tighten up the knurled bolt 3 Fig 5 by hand 0 3 Nm 2 7 in bs ADJUSTMENT e Be sure to reset rotational shifte
78. f the plastic protective cap 8 urn the circlip 22 and take the Undo the shift cable 9 by turning in thrust block 23 out of the axle an anticlockwise direction and pull it out of the axle Lubrication and assembly details can be found on the following page p the threaded bushing 10 but leave it on the axle with a couple of threads Wrench size 13 mm Lift the driver off one time to release the inboard spacer sleeve Take of the threaded bushing 10 the cable guide bush 11 the spacer sleeve 12 the fixed cone 13 and spring 14 from the axle 40 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIN I MIOTION 3 MAINTENANCE j CC TA b a iii am C i cae IRF Technical Manual Gear Hub Systems 2009 Rev A ASSEMBLING THE GEAR UNIT Gear hubs as of August 2007 Gear hubs until July 2007 see page 37 Clean the parts after dismantling Caution The planetary gear carrier and the driver should only be cleaned on the out side using a paint brush so that they are not degreased Cleaning in a cleaning bath is not permitted The remaining parts can be degreased in a cleaning bath Lubricating the parts Caution Use only SRAM special grease part no 0369 135 200 201 Lubricate ball retainers and ball tracks only with SRAM Ball Bearing Grease Part no 0369 001 015 Work on the thrust block assembly of the axle lace the thrust
79. ff the cable end to 2 3 mm Locate clamping bolt 1 Fig 5 and place shifter cable around the carrier cylinder counter clockwise winding Position the cover 3 Fig 4 and tighten up with the cover screw 2 Torque 0 35 0 45 Nm 3 1 4 0 in lbs Screw in the barrel adjuster 1 com pletely 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 5 Adjust the gears as described on page 67 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SRAMP P5 CARGO MAINTENANCE So FE FREED Technical Manual Gear Hub Systems 2009 Rev A DRUM BRAKE Install brake anchor plate or exchange it Place thrust washer 8 Fig 9 over the axle on the adjusting cone and fit com plete brake anchor plate Po
80. fter 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 52 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 50 Place thumb shift lever in standard rid ing mode gear position 2 Match up the marks in the Clickbox viewing window 11 Fig 7 by turning the barrel adjuster 12 53 DUALDRIVE MAINTENANCE TROUBLESHOOTING Problem Hub Shifting difficulties Pedals are carried forward when freewheeling Derail
81. g bush with the rubber insert 6 on the axle to permit an axial spoke arrange ment Automatic lacing machine Ensure an offset of 5 5 mm Alternatively a spacer sleeve part no 0399 110 000 is mountable on the drive side of the alxe the dust cap 1 onto the driver The curvature must point to the out side lace the sprocket 2 on the driver For offset i e transversely displaced sprockets the sprocket should be mounted with the toothing to the inside the curvature must point outwards sheen the sprocket circlip 3 onto the driver O ree Ensure that the plastic dust cap 4 is not damaged Check for proper seating of the circlip 7 7 30 40 Nm 266 350 in lbs 229 2 Zir TX le Hub version for Disc Brake Onna Read and observe the corre sponding technical documentation for assembling the disc of the disc brake Caution Plane faces of the hub and the disc and the threaded holes of the hub must be clean and free from oily and greasy substances ush the cable stop bracket 5 and then the locking bush with the rub ber insert 6 onto the axle end on the sprocket side Place the rear wheel into the rear frame lace one retaining washer 7 on each axle end The serrated face of the retaining wash er must lie against the frame dropout lign the cable stop bracket 8 paral lel to the frame strut 9 it the axle nuts 10 and
82. g 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 retain ing washer 9 in recess Now remove the mounting aid Advice If the gears are not accurately installed the hub may be tight to move This could lead to damage to the gear wheels 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 The plastic ring is onl
83. he cable tight Insert the cap in the shifter a Screw in the shifter barrel adjuster 6 as far as it will go Fitting the nipple without assembly tool ush the barrel adjuster 7 onto the inner cable Pull the inner cable tight and shorten by 82 mm measured from the front edge of the barrel adjuster ae the spring 8 onto the inner cable Guide the inner cable into the nipple 9 and tighten the clamping screw with a 2 mm Allen key Tight ening torque 1 5 Nm 13 in Ibs Fitting the nipple with assembly tool SRAM part no 00 0991 002 000 lamp the assembly tool in the vise ush the barrel adjuster 10 onto the inner cable Route the inner cable through the assembly tool and push the barrel adjuster onto the as sembly tool hread the spring onto the inner cable The spring should for ease of mounting be clamped as shown in the figure ull the inner cable tight and cut it off at the end of the assembly tool ift the inner cable slightly from the assembly tool and guide it into the nipple lace the nipple in the tool and and tighten the clamping screw with a 2 mm Allen key Tightening torque 1 5 Nm 13 in Ibs Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 9 MAINTENANCE Ape the cable end with the nipple into the connecting tube A Advice When doing this ensure that the flattened corner of the nipple matches the corresponding shape in the
84. he dynamo hub Push the connecting piece onto the connection terminal of the dynamo hub Caution Make sure that it is securely connected before using the dynamo hub Check Rotate the front wheel and check the lamp illumination Caution The dynamo hub generates an extremely high voltage Never touch the conntection terminal of the dynamo hub while riding or while the wheel is spinning This may cause an electric shock Caution Before setting out on any ride always check the correct and trouble free operation of the dynamo hub D7 D3 SERIES t MAINTENANCE e Do not disassemble the internal hub mechanism e Do not apply any lubricant to the inside of the hub otherwise the grease will come out and it may cause problems with conductivity Caution If the axle 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 axle nuts looser or too tight this could permanently damage the dynamo hub 101 POWER CHAIN TECHNICAL DATA ASSEMBLY REQUIREMENTS Z gt I0 WmMsSON Z gt I0 WMsSON 102 Application Max No of sprockets Compatibility Front Compatibility Rear Dimension Length Riveting Chrome Hardened Push Power Min Tensile Strength Weight 114 links External Pin Plate Internal Pin Plate Connecting Method Application Max No of sprockets Compatibility Front Compatibil
85. he right ndo the connection by removing the connecting tube in a downwards direction oosen the axle nuts 2 and take these and the underlying retaining washers 3 off If fitted unscrew 4 the frame clamp of the brake lever Remove the rear wheel Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 9 MAINTENANCE tty GULT Z27 aa ke 222 4 350 in lbs IRF Technical Manual Gear Hub Systems 2009 Rev A FITTING THE REAR WHEEL Place the rear wheel into the rear frame lace one retaining washer each 1 onto each axle end The serrated face of the retaining washer must lie against the frame dropout Where re taining washers have locating lugs these must engage in the frame drop outs ae fit the axle nut on the drive side and tighten to a torque of 40 Nm 350 in Ibs Then fit the axle nut 2 on the non drive side and tighten to a torque of 40 Nm 350 in Ibs f applicable mount the brake lever 3 between the two straps of the frame clamp 4 Caution The frame clamp must be fitted tightly on the frame without any play Use a self locking nut M6 Tightening torque 2 3 Nm 18 27 in lbs ul nna i sure that the shifter is set to 1st gear lide the quick release fastener 5 on the connecting tube to the right The opening 6 should now be visible ake the connection by sliding the FP opening of the connect
86. he side with the balls must point down wards aint version with back pedal brake Fit the lever cone 13 By turning to the left and right bring the lever cone 13 into its final position The locating lugs 14 of the lever cone will then lie in the recesses 15 of the brake sleeve Mem sun version with back pedal brake Screw the large axle nut 16 with the projection 17 downwards onto the axle Wrench size 27 mm Hub versions without brake and disc brake Screw the positioning cone onto the axle Wrench size 13 mm oso the bearing in a play free manner and tighten using nut 18 Wrench size 17 mm Tightening torque 15 20 Nm 133 177 in lbs Hub version i BRAKE Instead of the nut mount the centering bushing with the projection upwards onto the axle Wrench size 17 mm Caution Test the play of the bearing and correct if required Remove the hub from the vise Fit the rear wheel into the rear frame as described on page 13 Adjust the gears as described on page 12 Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes 17 I MIOTION 9 MAINTENANCE 18 DISMANTLING THE HUB lamp the non drive side of the axle DRIVE SIDE with the two flats of the axle ina vise Caution During dismantling one side of the nscrew nut 7 from the axle hub must always remain closed to prevent Wrench size 17
87. iameter 2 x 16 8 V DC engines E Straight handlebar ends 2 x 100 W max R Length of shifter Pedal controlled Weight Econ Speed None 135 mm R e E Cable Length mm 36 M Mode Selector 2 g mm C Mode Indication 194 mm O Clamping Diameter 251 N Cable Connection 63 18 100 128 158 2 x a or 2 x 32 49 5 mm only off set sprockets 1 7 2 6 Sparc Shifter Dropouts max 7 mm Over Locknut Dim OLD 135 mm Not suitable for tandems transport bicycles or similar 2450 g X O J gt J Weight Cable Length mm Battery Charger Charging time Luggage carrier comp Weight N Sparc Shifter Drawing see Page 66 Twist Shifter 1450 mm 1550 mm 1650 mm 1750 mm 1850 mm 1950 mm 2150 mm 2350 mm Window 22 1 22 3 mm Min necessary length for shifter a handlebar grip 150 mm 76mm N A Sparc Remote Control Unit 1500 1600 1700 1800 2000 Off Econ Speed Printed 22 1 22 3 mm 3 5 mm stereo jack 45g 2200 Sparc Battery Box 16 8 V 16 8 V 8 Ah NiMH battery 16 8V 2A 4 hours 30 minutes Struts 8mm dist 68 mm center to center parallel 2400 g Average speed 20 km h in the plain using a 28 inch wheel and assuming 75 watt input by the rider US version SPEED 15 miles ECON 21 miles The range achieved by a single battery charge depends on various factors These include drive mode the condition of the battery the road conditions and
88. ing 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 DISMANTLING GEAR HUB see Fig 1 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 dis mantle spring 15 guide bolt 16 and thrust block 17 e Remove small sun gear 12 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SPARC MAINTENANCE 2 mm 80295 mm ea im ___OQ L P E T R E
89. ing tube onto the catch 7 on the hub lide the quick release fastener 8 on the connecting tube to the left until it snaps into place The connection is now locked Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes 13 I MIOTION 9 MAINTENANCE EXCHANGING THE GEAR UNIT ew the circlip 1 Caution The circlip is spring force loaded Take off the sprocket 2 and the small outer dust cap 3 lamp the drive side of the axle with the two flats of the axle in a vise p the nut 4 and the large axle nut 5 from the axle Wrench size 17 mm and 27 mm SRAM tool part no 00 0924 003 000 for wrench size 27 mm For the no brake hub version and disc brake the axle nut 4 and the underlying adjusting cone should be unscrewed from the axle Wrench size 17 mm and 13 mm so version with back pedal brake Take off the lever cone 6 and the ball retainer 7 a versions without brake and Disc Brake take the ball retainer 7 out Hub version with back pedal brake Remove the brake sleeve 8 ae the hub shell 9 by jerking upwards Advice The outer large dust cap 10 is a very tight fit Its removal will result in it being damaged Replace with a new cap during reassembly The gear unit can be removed by tap ping a rubber mallet on the axle on the non drive side of the shell To do this remove the hub
90. integrated hand brake lever 1400 mm 1500 mm 1600 mm 1700 mm SRS Twist shifter with integrated brake lever right side of handlebar i MOTION 9 Window Indexed 22 1 22 3 mm eo N N N N Q 115 7 Brake lever SRAM BL 60 i MOTION 9 SL i MOTION 9 single shifter 1400 mm 1500 mm 1600 mm 1700 mm SRS Twist shifter right side of handlebar i MOTION 9 Window Indexed 22 1 22 3 mm Minimum necessary length for shifter and handlebar grip 150 mm Continuous cable housing pre assembled Linear Pull Avid BB Disc 2 32 24 mm Yes Yes 4 finger Aluminum forged 212g Stainless steel Cast aluminum Thermoplastic elastomer Aluminum Mercury silver painted SRAM BL 60 SRAM BL 60 left left side of handlebar 22 1 22 3 mm Linear Pull Avid BB Disc 2 32 24 mm Yes Yes 4 finger 95g Cast aluminum Aluminum forged Aluminum Mercury silver painted Continuous cable housing pre assembled 195 g Stainless steel Cast aluminum Thermoplastic elastomer Aluminum Mercury silver painted SRAM BL 60 right right side of handlebar Ji J 4 finger 95 g Vivi Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 9 TECHNICAL DATA ASSEMBLY REQUIREMENTS BEK CYCLE FRAME applied to the rear wheel Standard dropouts Frame strength must be such that the rear part of the frame does not u
91. is difficult to place the shift lever in gear position 1 e If required readjust the shift mechanism in third gear 85 SRAMI T3 MAINTENANCE 1 4mm 86 TECHNICHAL CHANGES Coaster Brake Improved braking in third gear after production date CW 38 96 In case of repair older hub models Fig 6 can be converted with a repair set Fig 7 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 return pulley by approx one chain link after braking the tension chain returns immediately to its normal position MAINTENANCE LUBRICATION Caution The SARM hubs are provided with permanent lubrication and are maintenance free under normal conditions 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 must be lubricated only with SRAM special grease Part No 0369 135 200 201 The brake shell must be renewed if as a result of wear the grooves on the outer surface are scarcely visible Cleaning of parts e All parts except for the planetary gear carrier can be degreased in a clean ing bath The planetary gear carrier only needs to be cleaned on the outside with a brush so as n
92. ity Rear Dimension Length e Riveting Chrome Hardened Push Power Min Tensile Strength Weight 114 links External Pin Plate Internal Pin Plate Connecting Method PC 1 Saltshaker Gear Hubs 1 Single Single PESA 7 8 mm Step No 800 N 8000 N 330 g Light Grey Light Grey Snap Lock or Pin PC 10 Saltshaker Gear Hubs MTB max 7 Single HG Single HG LA X Ta 6 92 mm Step No 1000 N 9000 N 300 g Light Grey Light Grey Power Link SS1 or Pin PC1Ni PC1 earns feens iPS sme fse TT TT singe fse TT TT TT TT ieee TT Wa OS 7a mm iam TT TT sep isha Snap Lock 3pcs Connection Link or Pin PC 10 Gens o m TTT TI smem TT TT TI singek TT TT TT A oo 6 92 mm Power Link G or Pin Technical Manual Gear Hub Systems 2009 Rev A S RAIM POWER CHAIN TECHNICAL DATA ASSEMBLY REQUIREMENTS Z gt I0 Jm E 0O Z gt I0 BWMsSON Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A Application Max No of sprockets Compatibility Front Compatibility Rear Dimension Length Riveting Chrome Hardened Push Power Min Tensile Strength Weight 114 links External Pin Plate Internal Pin Plate o PC 991 PC 991 Hollow Pin PC 991 Cross Step PC 971 PC 951 MTB Road MTB Road MTB Road MTB Road MTB Road Truvativ HG EXA Drive Truvativ HG EXA Drive Truvativ HG EXA Drive Truvativ HG EXA Drive
93. l chicago il 60622 phone 1 312 664 8800 fax 1 312 664 8826 www sSsra m c om european headquarters SRAM europe basicweg 12 d 3821 br amersfoort the netherlands phone 31 33 450 6060 fax 31 33 457 0200 asian headquarters SRAMI taiwan no 1598 8 chung shan rd shen kang hsiang taichung county 429 taiwan r o c phone 886 4 2561 3678 fax 886 4 2561 3686
94. l the contact sur face 43 Oil the pawl pockets 44 and the pawl spring 45 Grease the seat of the friction spring 46 with SRAM special grease part no 0369 135 200 201 Oil the end surface 47 atch the profile of the pawl carrier 48 to that of the coupling piece 49 Press the pawl carrier down pull on the shift cable and hold the system in this position for the next work step Technical Manual Gear Hub Systems 2009 Rev A S RAIM I MIOTION 3 MAINTENANCE ill Aiii D Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A ig while holding the system in posi tion the larger diameter ring gear 50 downwards over the pawls 51 of the driver Maintain the system in this position a the planetary gear carrier 52 By turning to the left and right bring the planetary gear carrier into its final posi tion Advice The planetary gears 53 must be flush with the ring gear teeth 54 Maintain the system in this position Porn the washer 55 and fit the circlip 56 Caution The opening of the circlip must be located over the axle flat 57 Complete hub assembly as described on page 34 under ASSEMBLING THE HUB 43 I MIOTION 3 MAINTENANCE 44 CHANGING THE SHIFT CABLE Advice Always use new high quality cables and compressionless cable housings with end caps eee the twist shifter to 1st gear e the plastic retainer 1 fr
95. le nut 5 on the non drive side and tighten to a torque of 40 Nm 350 in Ibs f applicable mount the brake lever 6 between the two straps of the frame clamp 7 Caution The frame clamp must be fitted tightly on the frame without any play Use a self locking nut M6 Tightening torque 2 3 Nm 18 27 in lbs Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes I MIOTION 9 ASSEMBLY 31 35 in Ibs FITTING THE SHIFTER lide the shifter 1 onto the han dlebar lide the handlebar grip 2 onto the handlebar Caution Never use lubricants or solvents when fitting handlebar grips They have a safety function and must not come free from the handlebar lace the shifter on the handlebar grip and position so that you can use it comfortably Tighten the clamping bolt 3 3 mm Allen key torque 3 5 4 Nm 31 35 in lbs Caution Check that shifter and brake lever can be easily operated if necessary realign Never ride without handlebar grips The turning grip of the twist shifter could become loose This can result in severe injuries Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes unui M l u A AA yl Zi iy FITTING THE SHIFT CABLE One Make sure that the cable housing le
96. lease lever to the closed position 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 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 A Caution o not tighten the wheel by turning the release lever clockwise 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 Gear Hub Systems 2009 Rev A S RAIM I LIGHT DYNAMO HUBS ASSEMBLY MAINTENANCE z F1 I13 Technical Manual Gear Hub Systems 2009 Rev A CONNECTING THE CABLES e Strip the insulation off of the wire aproximately 17 mm wist the cable wires before connecting R NA the cables through the two holes of the inner connecting piece Bend the cable wires and run them along the grooves a the inner piece with cable wires into the outer piece Advice When doing this ensure that the flattened corner of the inner peace matches the corresponding shape in the outer piece ante the cable with t
97. lel e Lacing the hub as normal e Hub version for Disc Brake Advice Read and observe the corresponding technical documentation for assembling the disc of the disc brake Caution Plane faces and threaded holes of the hub must be clean and free from oily and greasy substances Place the front wheel into the front fork ly aie The connection terminal of the dynamo hub should be on the right side viewed from behind the rear of the bicycle The connection terminal should tend upwards or backwards Fastening wheel solid axle lace one retaining washer 1 on each axle end eE the axle nuts 2 Tighten the axle nuts while alternating between sides to course that the dynamo hub connection terminal do not turn away from the correct orientation The recommended axle nut tightening torque is 20 Nm 177 in bs Caution If the axle 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 axle nuts looser or too tight this could permanently damage the dynamo hub Fastening wheel quick release e Only use quick release devices with the correct length Position quick release opposite to the brake Disc Brake version Turn release lever outwards until it is at least at a right angle to the bike position OPEN Tighten adjusting nut on the end of the skewer as much as possible by hand e re
98. lest cog position Measure and cut the rear piece of cable housing Make sure that it is not too short or long see page 49 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 e Repeat the two former steps until shift ing and cable tension is accurate e 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
99. leur Chain jumps from smallest sprocket to frame dropout Difficult or impossible to shift chain onto smallest sprocket Chain jumps over largest sprocket and falls between the spokes and largest sprocket or inner cage plate scrapes on spokes Delayed shifting Clearance between guide Adjust b adjust screw by pulley sprocket is too large rotating counterclockwise Rough shifting behavior Clearance between guide Adjust b adjust screw by pulley sprocket is too small rotating clockwise Shifts more gears onto small Shift cable insufficiently Turn barrel adjuster on the er sprockets as intented tensioned shifter counterclockwise Delayed shifting onto Shift cable insufficiently Turn barrel adjuster on the larger sprocket tensioned shifter counterclockwise Delayed shifting onto smaller sprocket 54 Cause Remedy Incorrect gear setting Adjust shifting system oll control cable check that cable stop is fastened correctly Reduce dimension of axle attachments To much additional axle at tachments between hub and axle nut on clickbox side Shifting rod is not screwed completely into the axle Screw in shifting rod com pletely and tighten it with a torque of 0 2 Nm 1 8 in lbs Bearings set too tight Re adjust bearing Loose lock nuts Tighten lock nuts 15 20 Nm 133 177 in bs Rear frame dropouts non Bend reorient dropouts parallel Turn in screw H until the guide pulley is align
100. lling on the plastic retainer 1 Shift cable has too much play Turn the twist shifter to 1st gear Po the shift cable play by turning the barrel adjuster 2 on the shifter Shift cable is too tight taut Either the shifter cannot select 3rd gear or the gear hub does not shift to 1st gear or shifts constantly between 1st and 2nd gears Turn the twist shifter to 1st gear educe the shift cable tension with the aid of the barrel adjust er 2 on the shifter Turn the twist shifter to 3rd gear and check once again that there is no play in the shift cable 29 I MIOTION 3 OPERATING 30 SHIFTING hift gears by turning the twist shift er on the right side of the handlebar You can shift gear while stationary or when riding Ensure you shift to a lower gear in plenty of time before hills The quickest and smoothest gear shifts are achieved by shifting while pedaling using only a low force BRAKING When descending long and steep hills al ways use the second front brake as well to prevent overheating of the brakes Caution Before setting out on any ride al ways check the correct and trouble free operation of the shift system and brakes Caution Excessive heating of the hub caused by back pedal braking may result in loss of lubricant and cause sharper braking Relubricating of the brake sleeve with special grease is then necessary See DISMANTLING ASSEMBLING THE H
101. must be parallel e Slot width at rear dropout 10 mm e 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 SRAM P5 Cargo with coaster brake SRAM P5 Cargo with drum brake SRAM P5 Cargo disc brake compatible Typ MH 5215 Cargo MH 5225 Cargo Brake With coaster brake With drum brake Version D Adaptor for disc brake Over Locknut Dim OLD 122mm 126 mm 125 mm Length L 175mm 179 mm 179 mm Ends Diameter T FG 10 5 toothed cone FG 10 5 FG 10 5 MH 5225 Cargo O With drum brake Version D 128mm _ Imm O P6105 O O Dropout Width Dim A max 12 5mm A max 11 5 mm A max 12 5mm A max 11 5 mm Holes 36 36 2 Hole Diameter DS 3 0mm 3 0 mm G Hole Ref g amp HR 75mm 9mm SY 75mm Flange Dist to OLD F 28 5mm F 29 5mm F 28 5mm F 29 5mm A Totally 224 Gear steps Speed1 0 667 T lt R r Speed2 0 778 17 lt Speed3 1 000 29 e amp p 2 Speed4 1 286 29 lt Speed 5 1 500 17 lt Usable dimensions Vex oF Ych xg OF I e Line C D E C 49 mm D 45 5 mm E 43 mm C 51 B mm D 48 5 mm E 45 5 mm C 50 mm D 47 mm E 44mm S Ratio 24 26 28 1 8 1 9 20 1 8 2 0 min 1 8 Sprocket 16 24 Teeth outward offset Chain Line C 16 18 Teeth straight Chain Line D 18 24 Teeth inward offset Chain Line E Shifter
102. ndergo any permanent deformation when a max braking torque of 250 Nm 2200 in lbs is 30 15 r UD as l 10 mm 10 mm DROPOUTS Only flat and not off set versions Dropout thickness 4 10 mm The dropouts must be parallel Dropout dimensions see figures on right RETAINING WASHERS Vertical dropout Dropout open towards rear Rohloff dropout 10 mm The following table shows the permissible combinations of dropout and retaining washer Type of dropout Necessary Retaining washer on the left axle end non drive side Necessary Retaining washer on the right axle end drive side CRANKSET The crankset and bottom bracket speci fications must conform to the following details A 48 8 mm 5 mm B 48 8 mm rear chainline as F e 15L blue dot 67L dark brown 180L orange dot 75L ocher dot 15 o Sa 67 Xa Di lt lt lt lt lt 15R red dot 30R green dot 67R pastel blue 180R purple dot 75R light purple dot So FE FREED Technical Manual Gear Hub Systems 2009 Rev A 5 I MIOTION 9 TECHNICAL DATA ASSEMBLY REQUIREMENTS FRAME AND CHAIN GUARD For the frame and chain guard layout the dimensions listed below have to be considered _ _ _ _ S g 54 5 7
103. nell cantilever brakes those with arms measuring less than 76 mm and utilizing a non linear straddle cable Use of SRAM Brake Levers with conventional cantilever brakesets drum brakes or roller brakes will result in faulty braking performance yo ie PS oo v 16 108 Nm Do not use conventional cantilever brakes Designed for use with linear pull brakes Technical Manual Gear Hub Systems 2009 Rev A S RAIM BRAKE LEVER SRAM BL 60 ASSEMBLY MAINTENANCE 2 2 5 Nm 18 22 in lbs So FE FREED Technical Manual Gear Hub Systems 2009 Rev A FITTING THE BRAKE LEVER Slide the brake lever onto the handlebar So the clamping bolt 3 mm Allen key torque 2 2 5 Nm 18 22 in Ibs FITTING THE BRAKE CABLE Caution The SRAM BL 60 brake lever is only compatible with the following brakes Avid BB Disc and Linear Pull compatible brakes Os ince Make sure that the cable housing length is sufficient to permit turning of the handlebar over its full range Also bear in mind the effect of adjust able handlebars and stems on the cable housing length Always use new high quality cables and compressionless cable housings with end caps EE ur the cable adjustment screw 1 and the counter nut 2 so that the cable slot is aligned with the slot on the bottom of the brake lever housing e the brake lever to the handlebar and guide the inner cable into
104. ng downwards Assemble hub shell 6 with a slight counter clockwise movement In case the hub shell jams position the plastic ring Fig 3 correctly The plastic ring is only fitted to some hub versions Screw brake cone 7 clockwise onto the planetary gear carrier 10 until it stops Insert 3 brake segments 5 Turn in friction spring 3 counterclock wise 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 re cesses 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 Ibs Caution Check that all the brake system components are functioning properly Advice Dismantling and reassembly of hub ver sion without brake should be carried out in the same way Differences Instead of brake segments cone a click and pawil carrier is installed on the planetary gear carrier 61 SRAMI S7 MAINTENANCE 2 mm 90 mm SRA SPECTRO 62 CHANGING THE SHIFT CAB
105. ngly 58 Technical Manual Gear Hub Systems 2009 Rev A S RAIM SRAMI S7 ASSEMBLY IRF Technical Manual Gear Hub Systems 2009 Rev A 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 Fit new retaining washer 3 5 mm thick on left axle end 1 Fig 4 The serrations must bear against the dropout and the lug must engage in the dropout slot Fit the hoop guard 1 Fig 5 on the right axle side drive side No additional washers or any acces sories are permitted Advice If a different protective bracket is used the thickness of the attachment plate must be max 3 mm At least the beginning of the axle thread must be visible in front of the axle nut Mount the axle nuts Tightening torque on axle nuts 30 40 Nm 266 350 in lbs Version with coaster brake Mount the brake lever using a suitable frame clamp 2 Fig 4 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 Ibs Caution Check that all the brake system components are functioning properly ASSEMBLY SHIFTER Advice When choosing cable housing lengths be sure to allow enough housing for an extreme turn of the han
106. ngth is sufficient to permit turning of the handlebar over its full range Also bear in mind the effect of adjust able handlebars and stems on the cable housing length Always use new high quality cables and compressionless cable housings with end caps pee the cable housing to the frame ayers The cable housing must be free to move at the securing points Avoid tight bends when routing the shift cable aah sure that the shifter is set to 1st gear lide the quick release fastener 4 on the connecting tube to the right The opening 5 should now be visible PE Make the connection by sliding the opening of the connecting tube onto the catch 6 on the hub lide the quick release fastener 7 on the connecting tube to the left until it snaps into place The connection is now locked Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes FITTING THE BRAKE LEVER SRAM BL 60 Slide the brake lever onto the handlebar Tighten the clamping bolt 3 mm Allen key torque 2 2 5 Nm 18 22 in lbs Technical Manual Gear Hub Systems 2009 Rev A S RAIM I MIOTION 9 ASSEMBLY Qs A zan LLJ AR O as J P5 H Ka 4 ke we PVA 7T IE SH BSS f musi a SF uu MAMA 4 Wi 0_7 pilili ga il piil lll ie pill z 111 Technical Manual Gear Hub
107. ning of the handlebar over its full range Also consider the influence of adjust able handlebars and stems on the cable housing length Fasten the cable housing on the frame Advice In case of continuous cable housing the cable housing must be secured in equidistant intervals on the frame and must be free to move at the securing points When fitting the cable avoid small radius Use only compressionless cable housings with resin liner inside and capped Advice To avoid malfunction the cable frictional force must not exceed 6 N 1 4 Ibs e Feed the shifter cable into the locating sleeve 5 Fig 9 fix at the appropriate length cable stop bracket see Fig 10 using the clamping bolt 1 Allen 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 9 loosely onto small pull rod 3 Adjustment e Place the shifter in gear position 3 Move the crank to check that the gear is engaged e 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 9 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 return pulley 4 Check e Place shifter in gear position 1 while moving the crank e Setting too loose In gear position 1 the tension ch
108. om the cable stop bracket 2 TE DENA connection between shift er and rear wheel hub by unhooking the connection lug 3 from the shift ca ble nipple 4 lace the plastic retainer and the connection lug in the assembly tool SRAM part no 00 0391 017 000 Unscrew the nut wrench size 8 mm Kine You may want to clamp the as sembly tool in a vise ake the nut 5 and the underlying washer 6 off Take off the connec tion lug and the plastic retainer from the shift cable So sure that the shifter is set to 1st gear ae the cap 7 from the shifter The nipple 8 of the inner cable is now visible ush or pull the old inner cable out of the shifter e g using a small screwdriver Guide the new inner cable into the cable inlet through the shifter and the new cable housing Pull the cable tight Insert the cap in the shifter o in the shifter barrel adjuster 9 at the shifter in a clockwise direc tion as far as it will go then turn coun terclockwise 2 full turns Fitting the connection lug with assembly tool SRAM part no 00 0391 017 000 aire You may want to clamp the as sembly tool in a vise T NA the plastic retainer and the connection lug with fitted washer and nut onto the inner cable Place the plastic retainer and the con nection lug in the assembly tool ull the inner cable tight and cut it off directly at the connection lug a the connection lug to
109. on of parts Use only SRAM special grease part no 0369 135 200 201 Lubricate ball retainers and ball tracks only with SRAM Ball Bearing Grease Part no 0369 001 015 To lubricate the bearing points on the planetary gear sets position the plane tary 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 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 e Spread grease on the complete sur faces 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 TROUBLESHOOTING Problem Cause Remedy Shifting Damaged Replace difficulties control cable control cable Incorrect Adjust shift gear setting system To much ad Beginning of ditional axle axle thread attachments must be
110. orized work on the i MOTION 9 system may result in its malfunctioning which may endanger you and could lead to invalidation of the warranty Back pedal brake If braking is too sharp the brake sleeve has to be re lubricated with special grease See DISMANTLING ASSEMBLY OF THE HUB NOT DRIVE SIDE page 16 WEAR PARTS Brake liners or brake sleeve brake cables shift cables handlebar grips sprockets and bike chains are wear parts Please check these parts regularly and replace them well before they are worn out Other topics Page GEAR ADJUSTMENT 12 REMOVING THE REAR WHEEL 12 FITTING THE REAR WHEEL 13 EXCHANGING THE GEAR UNIT 14 DISMANTLING AND ASSEMBLING THE HUB 16 CHANGING THE SHIFT CABLE 20 CHANGING THE BRAKE CABLE 22 TROUBLESHOOTING 23 11 I MIOTION 9 MAINTENANCE gt a LL 7 i pilli puill a yili yiilli 12 EE A a J a A My fof S 270 NZ 2 GEAR ADJUSTMENT the twist shifter from 7th to 6th gear o make adjustments use the barrel adjuster 1 on the shifter ea the barrel adjuster 2 on the con necting tube A ern the barrel adjuster until the yel low red marks 3 in the window of the gear hub are aligned N A H ji P v REMOVING THE REAR WHEEL E the twist shifter to 1st gear lide the quick release fastener 1 on the connecting tube to t
111. osi tion 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 e 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 car rier 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 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SPARC MAINTENANCE CHARGING THE BATTERY e Insert the plug of the charger into the socket of the battery box e Insert the charger into an electric mains socket 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 ina
112. ot to degrease the planetary gear bearing Lubrication of parts Use only SRAM special grease part no 0369 135 200 201 Lubricate ball retainers and ball tracks only with SRAM Ball Bearing Grease Part no 0369 001 015 To lubricate the bearing points on the planetary gear sets position the plan etary gear carrier on its crown and ap ply 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 wa ter penetrates it could lead to functional problems Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SRAM T3 MAINTENANCE TROUBLESHOOTING Problem Cause Remedy Shifting difficulties Incorrect gear setting Adju
113. otal chain failure material damage or the rider to fall off his bicycle resulting in injury Worn sprockets should also be re placed when a new chain is fitted Closing chain with 3pcs Connection Link e 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 4 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 4 Slide retaining spring in the direction of arrow 4 Fig 5 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 6 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 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM POWER CHAIN ASSEMBLY MAINTENANCE 2 links 10 Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A PC 991 PC 971 PC 951 PC 890 PC 870 PC 850 PC 830 PC 10 1 2 X 3 32 UND 1 2 X 11 128 Chain length A chain tool will be required to shorten the chain e Replacing a worn chain Measure the worn chain and shorten the new to the
114. ou can operate the brake lever on the shifter comfortably set the reach to match your hand size a 2 mm Allen key to set the dis tance between the brake lever and the handlebar Caution Every time you adjust the reach check and correct the brake cable tension to ensure good brake performance Or Vedan Read and observe the operating manual and technical documentation of the brake manufacturer Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 9 MAINTENANCE IRF Technical Manual Gear Hub Systems 2009 Rev A CLEANING Your SRAM i MOTION 9 components are well protected against adverse environ mental effects To prevent water ingress and any resul tant malfunctioning do not use pressur ized water e g pressure washers for cleaning During winter use you should clean your bike more frequently to prevent salt damage Do not use any corrosive cleaning agents Clean dirty chains before oiling Allow cleaner to work for only a few minutes before rinsing off with water Do not oil chain until completely dry LUBRICATION The rear wheel hub is provided with per manent lubrication and is maintenance free under normal conditions When dismantling assembling the gear unit observe the lubrication guidelines See DISMANTLING ASSEMBLY OF THE HUB from page 16 Regular lubrication will extend the chain s service life REPAIR WORK Caution Unauth
115. ox from the axle end Unscrew the barrel adjuster 1 Fig 5 completely Unscrew the cover screw 2 brush aside the barrel adjuster 1 and remove the cover 3 Withdraw the shifter cable and clamping bolt 1 Fig 6 upwards loosen the clamp screw with a 2 5 mm Allen key and pull the clamping piece from the cable Remove and discard the old cable hou sing Remove the cap 1 Fig 7 from the shifter The nipple of the inner cable is now visible Push or pull the old inner cable Fig 7 out of the shifter e g using a small screwdriver Guide the new inner cable into the cable inlet through the shifter and the new cable housing Pull the cable tight Insert the cap in the shifter Position clamping bolt 1 Fig 8 at a distance of 80 mm Advice For positioning the clamping bolt use adjust gauge Fig 9 Part No 65 0324 107 000 Tighten the clamping screw with a 2 5 mm Allen key Tightening torque 1 5 Nm 13 in lbs Cut off the cable end to 2 3 mm 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 barrel adjuster 1 com pletely 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 knu
116. particularly the cyclist s own effort IRF Technical Manual Gear Hub Systems 2009 Rev A SPARC ASSEMBLY Mounting Tool Part No 0582 104 000 90 LACING THE WHEEL Version 28 26 1 cross only All spoke heads must be positioned either at the outside or the inside of the respec tive 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 ASSEMBLY HUB 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 Fit new retaining washer 3 5 mm thick
117. r attachment points 26 Shifter i MOTION 3 BANDIX Shift cable Stainless or galvanized steel i MOTION 3 BANDIX for kids Shift cable lengths 1400 mm 1500 mm 1600 mm 1700 mm 2200 mm 1400 mm 1500 mm 1600 mm 2200 mm SRS twist shifter Right side of handlebar i MOTION 3 Window Indexed 22 1 22 3 mm Straight handlebar ends Minimum necessary length for shifter and handlebar grip 150 mm Cable routing Continuous cable housing pre assembled Continuous cable housing pre assembled 58 g Stainless or galvanized steel Plastic injection molding Thermoplastic elastomer Aluminum Silver painted FRAME AND CHAIN GUARD For the frame and chain guard layout the dimensions listed below have to be considered 7 SSS TOZE SS Ss NR SSS MW cS N SR DK Sa LLANARS i z IN SN Technical Manual Gear Hub Systems 2009 Rev A S RAIM I MIOTION 3 ASSEMBLY SS BMF Cy g 7 LLN R j Y Z 4 M d LD D Ii r gt gt A gt N ye A gt e A Y N WAN Gaye 9 oe AA SS Y 4 SRAT Technical Manual Gear Hub Systems 2009 g Ly ee CS ee Ss 27 ASSEMBLING THE HUB Lacing the hub Lacing by hand Place the cable stop bracket 5 figure 4 and the lockin
118. r from Ath to 3rd gear e Match up the marks in the Clickbox viewing window 4 Fig 6 by turning the barrel adjuster 5 CONNECTING DRUM BRAKE Caution Only use brake levers with a cable moving distance of at least 15mm and a leverage of i 3 8 4 2 Fig 9 e 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 7 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 ADJUSTMENT DRUM BRAKE e Unscrew adjusting screw 2 Fig 10 until the brake pads drag lightly e 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 e Lock hex nut 3 Caution Check that all the brake system components are functioning properly 19 SRAME P5 CARGO MAINTENANCE SRAM P5 mounting aid Part No 65 0524 300 000 Ei Gs m a NS j 16 REMOVE WHEEL Place shifter in gear position 2 Loosen the knurled screw 41 Fig
119. r hub e g strong water jets high pressure cleaners etc if wa ter penetrates it could lead to functional problems Lubrication of parts Use only SRAM special grease part no 0369 135 200 201 Lubricate ball retainers and ball tracks only with SRAM Ball Bearing Grease Part no 0369 001 015 To lubricate the bearing points on the planetary gear sets position the plan etary gear carrier on its crown and ap ply 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 e 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 e Spread grease on the complete sur faces 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 IRF Technical Manual Gear Hub Systems 2009 Rev A TROUBLESHOOTING Problem Cause Remedy Shif
120. rake sleeve is no longer lubricated Lubricate the brake cylinder of the hub shell and the brake sleeve if necessary renew Page 16 Work on the brake sleeve Grinding noise Dust cap incorrectly fitted or defective Fit the dust cap correctly if necessary renew Page 15 figure 13 no 25 R FaIT113 Technical Manual Gear Hub Systems 2009 Rev A 23 24 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 3 TECHNICAL DATA ASSEMBLY REQUIREMENTS CYCLE FRAME Frame strength must be such that the rear part of the frame does not undergo any permanent deformation when a max braking torque of 250 Nm 2200 in lbs is applied to the rear wheel DROPOUTS e Only flat and no off set versions Dropout thickness 4 8 mm e Dropouts must be parallel e Slot width at rear dropout max 10 mm Speeds 3 Over Locknut Dim OLD 130mm Length L Ends diameter M 10x1 Holes 28 32 36 Hole diameter 3 0 mm Hole ref HR 70mm Flange Dist to 1 2 OLD Overall 186 1st gear 0 734 2nd gear 1 000 3rd gear 1 362 es N Dimensions VCI JPM Sprocket i MOTION 3 w back pedal brake Brake With back pedal brake 178 mm and 168 mm Dropout Width Dim A min 4mm max 8 mm F 27 3 mm F 27 6 mm Chainline CL 44 0 mm straight sprocket 40 5 mm offset sprocket Ratio 24 26 28 2 0 2 4 20 2 D 2 b i X Ta a nd A X Te 16 17 18 teeth straight 19 20 21 tee
121. retaining washer 3 5 mm thick 1 Fig 4 each axle end The serrations must bear against the dropout of the frame and the lug must engage in the dropout of the frame Mount the special type axle nut 4 Fig 5 on the right axle side drive side and the axle nut at the other axle end Tightening torque 30 40 Nm 266 350 in Ibs Spoke length table Tire Size Cross 28 36 Holes 28 e Guide tension chain 5 Fig 5 through return pulley 6 e Position return pulley at axle nut 4 Fig 5 and push until it is felt to lock into place Turn return pulley until the circular area is at the top 7 Fig 6 Caution e Only install additional axle attach ments 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 4 Fig 5 Hub version with coaster brake Mount the brake lever 3 Fig 4 between the two straps of the frame clamp 4 Caution Use a suitable 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 Ibs Caution Check that all the brake system compo nents are functioning properly Length 36 Holes 182 mm 184 m n ara ran TE rax TT T Z 7228 nn 234 m n 235 m n asan Tarxan TE rax TT TIJE 288 nn 258 m n 262 m n Garsa ean rax T TIJE 7254mm 289 m n 282 mm 7292 mm 32 622 28 x1 x
122. rled screw and pull the Clickbox off the axle Now it s essential to push the end 1 Fig 9 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 Adjust the gears as described on page 67 Technical Manual Gear Hub Systems 2009 Rev A SRAI SRAMI P5 MAINTENANCE MAINTENANCE LUBRICATION Caution The SARM hubs are provided with permanent lubrication and are mainte nance free under normal conditions 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 must be lubricated only with SRAM spe cial grease Part No 0369 135 200 201 Renew brake segments when rhombic pattern Is worn out Cleaning of parts e All parts except for the planetary gear carrier can be degreased in a clean ing 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 gea
123. s 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 Advice If the gears are not accurately installed the hub may be tight to move This could lead to damage to the gear heels in operation e Assemble hub shell 6 with a slight counter clockwise movement e Screw brake cone 7 clockwise onto the planetary gear carrier 10 until it stops e Insert 3 brake segments 5 Turn in friction spring 3 counterclock wise into the lever cone 2 inlying winding of the spring has to lie against the lever cone Fig 3 Insert ball retainer 4 balls are facing upwards into lever cone 2 the 3 re cesses 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 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 Ibs Caution Check that all the brake system compo nents are functioning properly Advice Dismantling and reassembly of hub types with drum brake and dis
124. sition was her 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 ADJUSTMENT DRUM BRAKE e Unscrew adjusting screw 2 Fig 9 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 compon ents are functioning properly MAINTENANCE LUBRICATION Caution The SARM hubs are provided with permanent lubrication and are mainte nance free under normal conditions 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 must be lubricated only with SRAM spe cial grease Part No 0369 135 200 201 Renew brake segments when rhombic pattern is worn out Cleaning of parts e 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 wa ter penetrates it could lead to functional problems Lubricati
125. st shifting system oil control cable check that cable stop is fastened correctly Pedals are carried forward Bearings set too tight Re adjust bearing when freewheeling Loose lock nuts Tighten lock nuts 15 20 Nm Chain is overtensioned Reduce chain tension Ccoaster brake Hub locks when braking Brake shell has run dry Wash out hub sleeve repo lish and relubricate brake cylinder renew brake shell Pedals yield slowly during Brake cone brake sleeve Replace brake cone and brake braking does not impair sleeve safety Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A 87 Technical Manual Gear Hub Systems 2009 Rev A SRAI SPARC TECHNICAL DATA ASSEMBLY REQUIREMENTS Wheel g x Econ Mode Speed Mode 2 Econ Mode Speed Mode S Engine Type a Power Assist Type TI Assist Ratio Brake Over Locknut Dim Length Ends Diameter Holes Hole Diameter Hole Reference Totally Speed 1 2 3 4 5 Usable Dimension VUCI Dm amp Line Ratio Shifter Compatib Frame Compatib Tandem Weight 190 Caution Not suitable for tandems transport bicycles and similar 2 1 Cycle frame Dropouts must be parallel 49 5 e Slot width at rear dropout 10 mm Sparc hub 16 8 V S 28 26 26 USA Shifter Type 22 km h 26 km h H Cable Length 25 km h 32 km h ca 35 km F Gear Indication ca 25 km T Clamping D
126. t 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 Advice If the gears are not accurately installed the hub may be tight to move This could lead to damage to the gear wheels in operation 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 lt CHANGING THE SHIFT CABLE Advice Always use new high quality cables and com pressionless cable housings with end caps e Turn the twist shifter to 1st gear Advice Do not remove the Clickbox from the axle end e Unscrew the barrel adjuster 1 Fig 3 completely Unscrew the cover screw 2 brush aside the barrel adjuster 1 and remove the cover 3 Withdraw the shifter cable and clamping bolt 1 Fig 4 upwards loosen the clamp screw with a 2 5 mm Allen key and pull the clamping piece from the cable Remove and discard the old cable housing Remove the cap 1 Fig 5 from the shifter Push or pull the old inner cable Fig 5 out of the shifter e g using a small screwdriver Guide the new inner cable into the cable inlet through the shifter and the new cable ho
127. t Slacken the chain tension The bearing adjustment is too tight Readjust the bearing Page 35 Locknut of the lever cone adjusting cone is Readjust the bearing and tighten the locknut loose Page 35 figure 12 no 28 The back pedal brake is too sharp or locked The brake segments are no longer lubricated Lubricate the brake cylinder of the hub shell and the brake segments if necessary renew Page 34 Work on the brake segments I Fa I11 Technical Manual Gear Hub Systems 2009 Rev A 45 DUALDRIVE TECHNICAL DATA ASSEMBLY REQUIREMENTS GEAR HUBS Caution Not suitable for tandems transport bicycles and similar Cycle frame e Slot width at rear dropout 10 mm e The strength must be such that with a maximum braking torque of 250 Nm 2200 in lbs on the rear wheel no re sidual deformation can occur on the rear structure Version Speeds DualDrive II 27 Brake Without brake Over Locknut Dim 135mm Length 182 6 mm Ends Diameter FG 10 5 Holes 36 or 28 lt b 2 Hole Ref g 67mm Flange Dist to OLD 33 mm 18 mm DualDrive Il Without brake DualDrive II 24 DualDrive Il 27 DualDrive II 24 Hole Diameter 2 6 mm 28 holes also available in 2 8 mm DualDrive Il Disc brake compatible Adaptor for Disc brake 135 mm 182 6 mm FG 10 5 36 or 32 2 6mm 67 mm 33 mm 18 mm 46 Hand Brake Lever Disc brake compati
128. t cap 7 onto the driver The curvature must point to the outside the sprocket 8 onto the driver ar the sprocket circlip 9 onto the driver Check for proper seating of the circlip Remove the hub from the vise Fit the rear wheel into the rear frame as described on page 13 Adjust the gears as described on page 12 Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes 19 I MIOTION 9 MAINTENANCE we Ban lam J te N Y CHANGING THE SHIFT CABLE Advice Always use new high quality cables and compressionless cable housings with end caps the twist shifter to 1st gear lide the quick release fastener 1 on the connecting tube to the right ndo the connection by removing the connecting tube in a downwards direction nscrew the barrel adjuster 2 from the connecting tube and pull the connecting tube from the shift cable se a2 mm Allen key to loosen the clamping screw 3 in the nipple and pull this and the spring 4 behind it off the inner cable Sh sure that the shifter is set to 1st gear se the cap 5 from the shifter The nipple of the inner cable is now visible ush or pull the old inner cable out of the shifter e g using a small screwdriver Guide the new inner cable into the cable inlet through the shifter and the new cable housing Pull t
129. t shifter to 1st gear the plastic retainer 1 from the cable stop bracket 2 aap ee connection between shift er and rear wheel hub by unhooking the connection lug 3 from the shift ca ble nipple 4 oer the axle nuts 5 before re moving them together with the un derlying retaining washers 6 If applicable remove the brake lever screw 7 from the frame clip Remove the rear wheel Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM I MIOTION 3 MAINTENANCE IR FAITE Technical Manual Gear Hub Systems 2009 Rev A FITTING THE REAR WHEEL f dismantled push the cable stop bracket 1 and then the locking bush with the rubber insert 2 onto the axle end on the sprocket side Place the rear wheel into the rear frame lace one retaining washer 3 on each axle end The serrated face of the retaining wash er must lie against the frame dropout lign the cable stop bracket 4 paral lel to the frame strut 5 it the axle nuts 6 and tighten these while alternating between sides Tightening torque 30 40 Nm 266 350 in lbs f applicable mount the brake lever 7 between the two straps of the frame clamp 8 Caution The frame clamp must be fitted tightly on the frame without any play Use a self locking nut M6 Tightening torque 2 3 Nm 18 27 in lbs e sure that the shifter is set to 1st gear So the connection between shift er and rear wh
130. ten 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 Worn sprockets should also be re placed when a new chain ts fitted Closing standard version with clamping pin Fit chain bring the two ends together and press pin through with assembly tool Fig 6 The pin must extend by the same amount at both outer plates It must be possible to move the connecting link slightly MAINTENANCE CARE e Clean dirty chains before oiling Do not use any acidic agents Cleaning agent must be rinsed off after a few minutes with water Apply oil after chain is com pletely dried Regular lubrication will extend the chain s service life Apply oil to the chain links rollers and allow to work in 105 SUPPORT f DISTRIBUTORS SPARE PARTS 4 DISTRIBUTORS Please check http www sram com en locator distributors php for full contact information SPARE PARTS You can find an extensive spare parts program in SRAM s Spare Parts Catalog for Gear Hub Systems Model Year 2009 Part Number 95 3115 009 000 106 SRAM ORIGINAL PARTS Caution Installation of parts and accessories not originally intended could result in less than optimal performance and or injury Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM world headquarters SRAM corporation 1333 n kingsbury st 4th f
131. tep Step Step Step Step 9000 N ooon eoon 90000 3109 sig os oaos awg Silver Nickel Plated Grey Polished Silver Nickel Plated Grey Polished Power Link S only Power Link S or Pin Power Link S or Pin Power Link SS2 or Pin Power Link S or Pin 103 POWER CHAIN ASSEMBLY 104 PC 1 1 2 X 1 8 Chain length A chain tool will be required to shorten the chain Replacing a worn chain Measure the worn chain and shorten the new to the same length Initial assembly Shorten the chain to the length speci fied by the drivetrain manufacturer SRAM components Place the chain over front chainwheel and rear sprocket Fig 1 For rear suspension frame position the rear suspension for the greatest chain length required Closing chain with Snap Lock e Fit the shortened chain bring the ends together and connect with the Snap Lock Place the outer plate on one pin Fig 2 e Gently flex the chain until the outside connector plate snaps into position over the second pin Fig 3 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 e Snap Lock is for one time use only e Always use a new Snap Lock when fitting a new chain Use Snap Lock only with SRAM chains Failure to shorten the chain properly or to lock it exactly into place may cause damage to the chain and eventually t
132. th Slide the shifter 1 Fig 6 onto the handlebar Slide the handlebar grip 2 onto the handlebar Caution Never use lubricants or solvents when fitting handlebar grips They have a safety function and must not come free from the handlebar Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A e Place the shifter on the handlebar grip and position so that you can use it comfortably Tighten the clamping bolt 3 3 mm Allen key torque 3 5 4 Nm 31 35 in bs Caution Check that shifter and brake lever can be easily operated if necessary realign Never ride without handlebar grips The turning grip of the twist shifter could become loose This can result in severe injuries 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 NSTALLING CLICKBOX 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 mak ing sure that the internal lug 5 is guid ed 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
133. th offset T 32 Version with back pedal brake i MOTION 3 disc brake compatib i MOTION 3 without brake 3 Without brake 130mm 178 mm and 168 mm M 10x1 M 10x1 min 4mm max 8 mm 32 38 3 0 m n 70mm F gt 27 3 mm_ F gt 27 6 m n Gear steps amp Ag 36 amp 36 amp lt min 2 0 Wx and x Ux and x z Shifter SRAM i MOTION 3 SRAM i MOTION 3 DiscBrake Hand brake lever Tandem Not suitable for tandems transport bicycles or similar lt Weight 1 390 g 1 210 g 1 120 g Mat Hub shell Steel Steel Finish Pearl Nickel Chrome Pearl Nickel Chrome Pearl Nickel Chrome So FE FREED Technical Manual Gear Hub Systems 2009 Rev A 25 I MIOTION 3 TECHNICAL DATA ASSEMBLY REQUIREMENTS SHIFTERS 22 1 22 3 22 1 22 3 Shifter i MOTION 3 i MOTION 3 shifter Version i MOTION3 Shifter type SRS twist shifter Assembly location Right side of handlebar Compat gear hub i MOTION3 Gear indicator Window Barrel adjuster Indexed Clamping diameter 22 1 22 3 mm Weight 58g J rm i m 009 Housing Plastic injection molding Grip cover Thermoplastic elastomer T D wa Frame clamp Aluminum Finish Silver painted SHIFT CABLE ROUTING e Shift cable routing only along the chain stay e Only continuous cable housing no open cable routing See the adjoining figure fo
134. the housing Hook the nipple 3 of the inner cable into the recess 4 in the brake lever Follow the brake manufacturer s in structions when fitting the brake cable and adjusting the brakes Caution Check that the brake is operating in a correct and trouble free manner Reach adjust of the hand brake lever so that you can operate the brake lever on the shifter comfortably set the reach to match your hand size a 2mm Allen key to set the dis tance between the brake lever and the handlebar Caution Every time you adjust the reach check and correct the brake cable tension to ensure good brake performance O aa a Read and observe the operating manual and technical documentation of the brake manufacturer USE Caution Before riding always check that all brake system components are function ing properly Q Advice On your ride with your new bicycle actuate the hand brake lever carefully to become familiar with the braking performance MAINTENANCE A Advice Clean the brake lever using only water and mild soap 97 I LIGHT DYNAMO HUBS D7 D3 SERIES TECHNICAL DATA ASSEMBLY REQUIREMENTS ANNO O O N Caution The dynamo hub generates an extremely high voltage Never touch the conntection terminal of the dynamo hub while riding or while the wheel is spinning This may cause an electric shock Model Version Output Voltage Wheel g Over Locknut Dim O
135. the left and tighten the nut Tightening torque 3 4 Nm 27 35 in lbs Wrench size 8 mm Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM i MIOTION 3 ji MAINTENANCE Fitting the connection lug without an as SD ake the connection between shift e sembly tool r and rear wheel hub by hooking ol the plastic retainer and the the connection lug onto the shift cable connection lug with fitted washer nipple and nut onto the inner cable Fit the plastic retainer on the cable stop lug the plastic retainer onto the ca bracket Hook the connection lug onto ble stop bracket the hub shift cable nipple Pull the inner cable tight and securely Adjust the gears as described on page tighten the nut of the connection lug 32 Unhook the connection lug again and cut off the projecting excess cable so it Caution is as short as possible Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes TROUBLESHOOTING Problem Cause Remedy Shifting difficulties Incorrect gear adjustment Adjust the gears Page 32 The shift cable or the cable housing is damaged Renew the shift cable and cable housing Page 44 Shift cable of the hub is not screwed in com Screw in completely the shift cable of the hub pletely minimum of 7 full turns Page 37 or 41 figure 8 Turn only until hand tight The pedals go forwards when freewheeling The chain tension is too tigh
136. tighten these while alternating between sides Tightening torque 30 40 Nm 266 350 in bs f applicable mount the brake lever 11 between the two straps of the frame clamp 12 Caution The frame clamp must be fitted tightly on the frame without any play Use a self locking nut M6 Tightening torque 2 3 Nm 18 27 in lbs Caution Before setting out on any ride always check the correct and trouble free operation of the shift system and brakes 21 I MIOTION 3 ASSEMBLY E 2 FITTING THE SHIFTER Caution Because of a risk of fracturing following types of handlebars are not suited thin walled aluminum handlebars e g Hyperlite handlebars carbon handlebars lide the shifter 1 onto the handle bar lide the handlebar grip 8 onto the handlebar Caution Never use lubricants or solvents when fitting handlebar grips They have a safety function and must not come free from the handlebar lace the shifter on the handlebar grip and position so that you can use it comfortably Tighten the clamping bolt 3 2 5 mm Allen wrench torque 2 Nm 15 in Ibs Caution Check that shifter and brake lever can be easily operated if necessary realign Never ride without handlebar grips The turning grip of the twist shifter could become loose This can result in severe injuries Caution Before setting out on any ride always check the correct
137. ting Damaged Replace difficulties control cable control cable Incorrect Adjust shift gearsetting system To much ad Beginning of ditional axle axle thread attachments must be visib between hub le in front of and axle nut the axle nut Pedals are Bearings Re adjust carried set too tight bearings forward Loose Tighten when free lock nuts lock nuts wheeling 15 20 Nm Chain is over Reduce tensioned chain tension Hub locks Brake seg Wash out when ments has hub sleeve braking run dry repolish and coaster relubricate brake brake cylinder renew brake segments Coaster Incorrect Fit friction brake mounted fric spring in without tion spring 3 correct way function Fig 1 Page 68 71 72 Technical Manual Gear Hub Systems 2009 Rev A SRAI SRAMI P5 CARGO PS TECHNICAL DATA ASSEMBLY REQUIREMENTS Caution Version with coaster brake The SRAM P5 Cargo is suitable for tan dems transport bicycles and similar An additional external rear brake is necessary due to the high load 83 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 Version SRAM P5 for normal bikes see page 65 1 A max 12 Cycle frame Dropouts
138. ts Replace defect cables Charge battery Connect battery inside box Replace battery Replace fuse 4 Fig 9 11 in battery box 15 A for 16 8 V NiMH battery 25 A for 12 V lead battery Electric drive defect Replace electric drive Foreign body in electric Take out foreign body drive Electric drive defect Replace electric drive 95 BRAKE LEVER SRAMP BL 60 TECHNICAL DATA ASSEMBLY REQUIREMENTS 22 1 22 3 Version Frame clamp SRAM BL 60 B SRAM BL 60 left R Mounting location left side of handlebar Clamping diameter 22 1 22 3 mm A Compatibility Linear Pull Avid BB Disc K Ratio 2 32 E Cable path 24mm Reach Adjust Yes L Adjustingscrew Yes E Lever size 4 finger V Weight 95g E Housing Cast aluminum R E Lever Aluminum forged Aluminum SRAM BL 60 right right side of handlebar TIT ITI TIT IA 4 finger 95g 1 Finish Mercury silver painted CABLE AND CABLE HOUSING iy ince Make sure that the cable housing length is sufficient to permit turning of the handlebar over its full range Also bear in mind the effect of adjust able handlebars and stems on the cable housing length Always use new high quality cables and compressionless cable housings with end caps 96 tT T tT Caution SRAM BL 60 brake levers are de signed for use with Avid BB Disc Brakes and Linear Pull compatible brakes Do not use SRAM Brake Levers with conventio
139. up the marks in the Clickbox viewing window Fig 3 by turning the adjusting screw 1 93 SPARC MAINTENANCE S 16 8 V NiMH battery closed eT ae O 16 8 V NiMH battery 1 O 12 V lead battery 11 94 LUBRICATION GEAR HUB Cleaning of parts e All parts except for the planetary gear carrier can be degreased in a clean ing 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 special grease part no 0369 135 200 201 Lubricate ball retainers and ball tracks only with SRAM Ball Bearing Grease Part no 0369 001 015 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 Advice Do not use high pressure water when cleaning e g strong w
140. using Insert the cap in the shifter Position clamping bolt 1 Fig 6 at a distance of 80 mm Advice For positioning the clamping bolt use adjust gauge Fig 7 Part No 65 0324 107 000 Tighten the clamping screw with a 2 5 mm Allen key Tightening torque 1 5 Nm 13 in lbs Cut off the cable end to 2 3 mm e 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 Ibs Screw in the barrel adjuster 1 completely Advice e lf 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 e 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 e Be sure to reset rotational shifter from Ath to 3rd gear e Match
141. vers for proper operation If there is interference between shifters and brake levers re adjust lever and shifter placement Slide the shifter 1 Fig 6 onto the handlebar Rotate the shifter until the barrel ad juster 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 NSTALLING CLICKBOX Fit the cable and avoid small radius Cable attachment points see Page 49 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 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM DUALDRIVE ASSEMBLY Sy FE FREED Technical Manual Gear Hub Systems 2009 Rev A DERAILLEUR ADJUSTMENT 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
142. w Printed None Indexing 22 1 22 3 mm Minimum necessary length for shifter and handlebar grip 150 mm Continuous housing preassembled Open or continuous N A Stainless steel Glass filled PA Silver painted Thermoplastic elastomer Aluminum Composite lt DualDrive 24 DualDrive 24 Printed Printed e e lt amp TIT TIT TIT 4 DUALDRIVE TECHNICAL DATA ASSEMBLY REQUIREMENTS J C rm r J r r i i r 9 0 gt gt O 48 Speeds Shifter Compatibility Cage Length Sprocket max Sprocket min Pulleys Direct Mount Weight Upper Knuckle Lower Knuckle Outer Link Inner Link Outer Cage Inner Cage Hanger Bolt Largest Cog Speeds Cogs Spacers Chain compatib Weight Cogs Screws Finish DualDrive 27 9 8 DualDrive 27 Short 75 mm 34 Teeth 11 Teeth Exchangeable Bushing Yes 258 g Aluminum forged Grilon Composite silver Aluminum Steel Zinc coat Aluminum forged Grilon Composite black Aluminum DualDrive 27 34 Teeth 9 11 13 15 17 20 23 26 30 34 Dark Gray 9spd HG IG PC comp DualDrive 24 9 8 DualDrive 24 Short 75 mm 32 Teeth 11 Teeth Exchangeable Bushing Yes 265g Aluminum forged Grilon Composite silver Grilon Composite silver Steel Zinc coat Grilon Composite black Grilon Composite black Steel DualDrive 24 32 Teeth 8 11 12 14 16 18 21 26 32 Black 8sp
143. xle nut Tightening torque on axle nuts 30 40 Nm 266 350 in Ibs 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 Ibs Advice Ifa 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 Caution Check that all the brake system compo nents are functioning properly ASSEMBLY SHIFTER 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 the shifter 1 Fig 6 onto the handlebar Slide the handlebar grip 2 onto the handlebar Caution Never use lubricants or solvents when fitting handlebar grips They have a safety function and must not come free from the handlebar Place the shifter on the handlebar grip and position so that you can use it comfortably Tighten the clamping bolt 3 3 mm Allen key torque 3 5 4 Nm 31 35 in lbs Caution Check that shifter and brake lever can be easily operated if necessary realign N
144. y 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 9 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 Adjust the gears as described on page 59 Technical Manual Gear Hub Systems 2009 Rev A Sa RAIM SRAMI S7 MAINTENANCE MAINTENANCE LUBRICATION Caution The SARM hubs are provided with permanent lubrication and are mainte nance free under normal conditions 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 must be lubricated only with SRAM spe cial grease Part No 0369 135 200 201 Renew brake segments when rhombic pattern Is worn out Cleaning of parts e All parts except for the planetary gear carrier can be degreased in a clean ing bath The planetary ge
145. y fitted to some hub versions Screw brake cone 7 clockwise onto the planetary gear carrier 10 until it stops Insert 3 brake segments 5 Turn in friction spring 3 counterclock wise 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 re cesses 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 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 Ibs Caution Check that all the brake system components are functioning properly Advice Dismantling and reassembly of hub ver sion without brake should be carried out in the same way Differences Instead of brake segments cone a click and pawil carrier is installed on the planetary gear carrier 69 SRAMP P5 MAINTENANCE 2 mm 802 5mm ERAAI SPECTRO 70 CHANGING THE SHIFT CABLE Advice Always use new high quality cables and compressionless cable housings with end caps e Turn the twist shifter to 1st gear Advice Do not remove the Clickb

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