CONTENTS GEAR HUB SYSTEMS

Transcription

1 CONTENTS GEAR HUB SYSTEMS GEAR HUBS AND SHIFTERS DualDrive Spectro S7 Spectro P CARGO Spectro P Cargo 9 Spectro T 7 Sparc SPECTRO SYSTEM COMPONENTS i-brake Two-Axis Brake Lever SmartBar Power Chain 7 SUPPORT Distributors 78 Who to call / SRAM year warranty / Spare Parts 80

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3 DUALDRIVE TECHNICAL DATA /ASSEMBLY REQUIREMENTS Expanded gear range Efficient design Stand-still shifting (mode selector) Single chainring design Sealed system Easy wheel removal ESP : actuation ratio technology Improved material use Outward facing limit screws Low system weight Chainline. 8 7 Version for i-brake: see i-brake, page. Cycle frame: The strength must be such that with a maximum braking torque of 0 Nm (00 in.lbs.) on the rear wheel no residual deformation can occur on the rear structure. Not suitable for tandems, trademen s delivery bicycles and similar. H U B S Spoke Axle Finish Ratio DualDrive 7/ without brake DualDrive 7/ i-brake compatible DualDrive 7/ disc brake compatible Part No. Brake None Interface for new i-brake Interface for Disc brakes Over Locknut Dim. mm mm mm Length 8. mm 8. mm 8, mm Ends Diameter FG 0. FG 0. FG 0. Holes Hole Diameter. mm. mm. mm Hole Ref. ø 7 mm 7 mm 7 mm Flange Dist. to / OLD mm / 8 mm mm / 8 mm mm / 8 mm Totally 7 % (7spd) / % (spd) Totally hub 8 % Speed 7 % Speed 00 % Speed % Chainline mm mm mm Crankset / 8 Teeth Cogset 8 / 9 Speed, -/ Teeth Cogset Compatib. DualDrive 7 / DualDrive Shifter Compatib. DualDrive 7 / DualDrive Sealing Extra sealed Tandem compatib. Disc compatib. SRAM / Magura / Hayes / Shimano Weight 970 g 970 g 970 g Hub Shell Aluminum Aluminum Aluminum Shifting device Composite Composite Composite

4 DUALDRIVE TECHNICAL DATA /ASSEMBLY REQUIREMENTS D E R A I L L E U R S DualDrive 7 DualDrive Part No. Speeds 9 8 Shifter Compatibility DualDrive 7 DualDrive Cage Length Short, 7 mm Short, 7 mm Sprocket, max. Teeth Teeth Sprocket, min. Teeth Teeth Pulleys Exchangeable / Bushing Exchangeable / Bushing Direct Mount Weight 0 g 0 g Knuckles Grilon Composite silver Grilon Composite silver Outer Link Aluminum Grilon Composite silver Design Inner Link Steel / Zinc coat Steel / Zinc coat Outer Cage Forged Aluminum Grilon Composite black Inner Cage Grilon Composite black Grilon Composite black Hanger Bolt Aluminum Steel C A S Ṣ Design DualDrive 7 DualDrive Part No. Largest Cog Teeth Teeth Speeds 9 8 Cogs ////8///8/ ////8/// Spacers Blue Black Chain compatib. 9spd, HG/IG/PG II comp. 8spd, HG/IG/PG II comp. Weight 0 g 70 g Cogs SAPH 0 steel Screws Steel / Zinc Coat Finish Matte Nickel Plated Chrome S H I F T E R S Design Compat. DualDrive 7 DualDrive Part No. Clickbox Cable 00 mm 00 mm 00 mm 700 mm 00 mm 00 mm 00 mm 00 mm 700 mm 00 mm Shifter Type SRS Twistring-Thumbshifter-Combo (in) SRS Twistring-Thumbshifter-Combo (in) Arrangement Handlebar, right Handlebar, right Gear Hub DualDrive DualDrive Derailleur DualDrive 9spd DualDrive 8spd Gear Indication Der. Window Printed Riding Mode Indic. Printed Printed Barrel Adj. Gear Hub None None Barrel Adj. Derailleur Indexing Indexing Clamping Diameter. mm. mm Handlebar, Straight Area Minimum length = 0mm Minimum length = 0mm Cable Routing, Gear Hub Continuous housing (preassembled) Continuous housing (preassembled) Cable Routing, Der. Open or continuous Open or continuous Weight N/A N/A Cables Stainless steel Stainless steel Housing Glass filled PA Silver painted Glass filled PA Silver painted Grip Cover Thermoplastic elastomer, Overmolded Thermoplastic elastomer, Overmolded Clamping Collar Aluminum Aluminum Clickbox Composite Composite

5 DUALDRIVE TECHNICAL DATA /ASSEMBLY REQUIREMENTS Cable routing DualDrive 7 DualDrive Hub cable Along chainstay only Along chainstay only Derailleur cable Along chainstay only Along chainstay or along seatstay Cable attachement see Fig. Cable housing Attachement points Cable stops Hub Continuous / / / (see Fig. ) Derailleur Continuous / / / / (see Fig. ) Open / (Fig. ) CABLE HOUSING FOR DERAILLEUR Rear cable stop position Rear housing length (only DualDrive 7) R R A X L 90 Length X min. 90 mm. Cable stop below or beside chainstay. X L (mm) X (mm) Example: Distance X = 00 mm cable housing length L = 0 mm. 0 CABLE HOUSING Use only new high quality cable and com-pressionless cable housing with end caps. When choosing cable housing lengths, be sure to allow enough housing for an extreme turn of the handlebars in both directions. Note also, that different stem lengths and cable stop positions effects cable housing length. DROPOUT Only flat and no off-set versions. Dropout thickness: 7 8 mm. Vertical or horizontal dropout slot. Dropouts must be parallel. Dropout dimensions: see Fig. and. L 8 0 X A 0 0 R 8. max 8. max R.... Recommended cranks: Cyclone: DualDrive crank for chainguard, T, Part No. CPI-0 (chain guide fork necessary). DualDrive crank for Trekking, T, Part No. CY-00W. DualDrive crank for MTB, T, Part No. CF-00W. Truvativ: CR-0-XF-SS or CR-0-XF-SSA DualDrive crank supplier: Cyclone Precision Inc. P.O. Box - Nantou 0 Taiwan Tel.: Fax: justin@cpi-cw.com.tw or Truvativ CHAIN GUIDE FORK It prevents chain from jumping off front chainring, is bolted inside the chain case (, Fig. ). da max. 0 mm CRANKSET Bicycle without chain case: Use a chain guard disc (at the outer surface of chainring, material no resin) Use only standard chainring version (nonshifting teeth). Chainline = mm. HANDLEBAR Diameter:. mm. Minimum length of straight area for shifter: 0 mm. Recommended are handlebars in curved design.

6 DUALDRIVE ASSEMBLY DualDrive 7 mm 8 0 Nm 70 8 in.lbs. DualDrive ASSEMBLY HUB Spoke the hub as normal. Place spoke protector disc (, Fig. ) on shoulder of hub, fit cassette () onto driver profile. Screw lock nut () with cassette tool (Park Tool FR- or SRAM Part No. 00), tightening torque: 0 Nm (0 in.lbs.). Screw shifting rod () into the hub axle and tighten it with 0. Nm (.8 in.lbs.). Fit wheel in dropouts. Place retaining washers (Fig. ) on both sides of the axle the serrations must bear against the dropout. Version for horizontal dropouts (): the lug must engage in the dropout slot. Version for vertical dropouts (): without lug. Tighten up axle nuts. Tightening torque 0 0 Nm ( 0 in.lbs.). ASSEMBLY DERAILLEUR Advice: Check the rear derailleur hanger alignment. A bent rear derailleur hanger will result in inaccurate index shifting. Outboard side impacts are the most common causes of this type of damage. Attach the rear derailleur to the frame s rear derailleur hanger using a mm hex head wrench (Fig. ). Check that the b-adjust washer tab (b-adjust screw at DualDrive ) is clear of the rear derailleur dropout tab (Fig. ). Tighten the mm hex hanger bolt to 8 0 Nm (70 8 in.lbs.). CHAIN LENGTH A properly measured chain will prevent accidentally shifting to the largest chain ring and cog combination. This type of accidental shifting may cause harmful binding or seizure of the chain and potentially cause severe damage. ASSEMBLY SHIFTER Slide the shifter (, Fig. ) onto the handlebar. Rotate the shifter until the barrel adjuster () is beneath (but out of the way of) the brake lever. Tighten the mm hex clamp bolt () to.9 Nm (7 in.lbs.). Slide the handlebar grip () onto the handlebar. Check that the shifter and brake lever function properly and are unobstructed. Handlebar grips provide an axial safety function. For this reason, they should be mounted in such a way as to make sure they do not slip off handlebar. Never use lubricants or solvents to install handlebar grips. Never ride without the handlebar grips this can result in severe injury or death. INSTALLING CLICKBOX Fit the cable and avoid small radius. Cable attachment points see Page / Fig.. Cable housing must be movable inside attachment. Place shift lever in uphill riding mode / gear position (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 (Fig. 8). Match up the marks in the Clickbox viewing window by twisting the barrel adjuster. + ( Links) Bypassing the rear derailleur, run the chain around the largest cog/large chainring combination (Fig. ). For rear suspension frames, position the rear suspension for the greatest chain length required. Add LINKS or link + Power Link to this length for proper chain length.

7 DUALDRIVE ASSEMBLY 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 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 mm hex wrench, turn the b-adjust screw until the chain gap equals approximately mm ( / ) from tip of the cog to tip of upper guide pulley (Fig. 0). Turn the b-adjust screw clockwise to increase the chain gap. Turn the b-adjust screw counterclockwise to decrease the chain gap. Advice: Do not use the b-adjust screw to adjust the rear derailleur to act as a chaintensioning device or to prevent chain suck. This increases the chain gap causing poor shifting performance. Index shifting adjustment: Check that the chain and the rear derailleur are in the smallest cog position. Measure and cut the rear piece of cable housing. Make sure that it is not too short or long (DualDrive 7: see page 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 (, Fig. ) clockwise fully into the shifter, then turn counterclockwise 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. ). Tighten the mm hex cable anchor bolt to Nm ( in.lbs.). Rapidly shift the chain and derailleur up and down the cassette several times. If the cable slips repeat the two former steps. Shift the chain to the smallest cog. While pedaling, move the shifter up one detent. If the chain hesitates or does not shift to the second cog, increase the cable tension by turning the shifter barrel adjuster counterclockwise. If the chain shifts beyond the second cog, decrease the cable tension by turning the shifter barrel adjuster clockwise. Repeat the two former steps until shifting and cable tension is accurate. While turning the crank, shift the chain up and down the cassette and chain rings several times to ensure that your derailleur is indexing smoothly. 0 mm ( / ") mm mm Nm in.lbs. 7

8 DUALDRIVE MAINTENANCE Lubricate the shifting joints regularly When disassembled use a waterproof grease REMOVE WHEEL Rotate the twist shifter to the highest gear position (speed 8/9 ). Place shift lever in uphill riding mode / gear position (Fig. ). Push Clickbox button down (Fig. ). Pull Clickbox off the axle. Screw out shifting rod (0, Fig. ). Dismantle wheel. DISMANTLING HUB see Figure Dismantle cassette lock nut with cassette tool (Park Tool FR- or SRAM Part No. 00). Remove cassette and spoke protector disc. Clamp hub with the two axle flats (driverside facing downwards). Remove cap (), unscrew lock nut (), screwed adjusting cone () and hub shell (). Dismantle retaining washer (), remove washer (), planetary gear carrier (7) and gear ring (8). Squeeze down pawls and remove pawl carrier (0) with washer (9) and ball retainer (). Clamp other axle end (longer axle thread). Dismantle lock nut (9) and cone (8). Remove driver (7), compression spring (), coupling gear clutch () and shift sleeve () with bushing (). REASSEMBLY HUB see Fig. Lubrication see LUBRICATION. Clamp axle with the two axle flats (longer axle thread). Fit shift sleeve (), bushing () with small diameter first, compression spring (), coupling gear clutch (), and driver (7). Mount cone (8) and lock nut (9). Tightening torque 0 Nm ( 77 in.lbs.). Clamp other axle end (driver side facing downwards). Mount ball retainer (), pawl carrier (0) and washer (9). Press pawls against spring force and mount gear ring (8) with smaller diameter first. Rotate gear ring counterclockwise until pawls engage inside the gear ring. Fit planetary gear carrier (7) and washer (). Press and rotate planetary gear carrier until axle groove is visible. Mount retaining washer (). Mount hub shell () with a slight counterclockwise turn. Mount adjusting cone (). Screw on counternut (), adjust bearings to be free of play and tighten with a torque of 0 ( 77 in.lbs.). Mount cap (). Unclamp hub and mount shifing rod (0) with a torque of 0, Nm (.8 in.lbs.). Mount spoke protector disc and cassette. 8

9 DUALDRIVE MAINTENANCE LUBRICATION GEAR HUB Hubs are provided with permanent lubrication and maintenance-free under normal conditions. CABLE CHANGE Advice: Use only new high quality cable and compressionless cable housing with end caps Cleaning of parts: All parts except the planetary gear carrier and the driver can be degreased in a cleaning bath. Planetary gear carrier and driver only need to be cleaned on the outside with a brush so as not to degrease the bearings. Lubrication of parts: Use only SRAM grease (Part No. 09 0) and standard bicycle oil. To lubricate the bearing points on the planetary gear sets, position the planetary gear carrier pawls upside and apply drops of oil to the bearing bolts at the same time turning the planetary gears so that the bearing points are completely wet. Oil axle slot, apply a thin coating of grease to the outside. Grease the teeth of the axle (fill the gaps). Apply grease to gear ring teeth but just oil the pawls and pawl teeth. Oil pawl carrier pawls and pawl bearings. Oil cartridge bearing. Regrease ball retainers, line ball bearing running tracks with grease. For version with mounted i-brake use only the new highly heat-proof SRAM grease Typ B (Part No.: g / 00g 09 0). Do not use high-pressure water when cleaning the gear hub (e.g. strong water jets, high-pressure cleaners etc.) if water penetrates it could lead to functional problems. LUBRICATION REAR DERAILLEUR Do not use solvants or corrosive materials to clean the components. Lubricate the shifting joints regularly (Fig. ). Grease any cable guides (e.g. beneath the bottom bracket). Twist shifter (rear derailleur): Detach the cable from the derailleur. Cut cable off cm (") from shifter barrel adjuster. Discard old cable and cable housing. Remove screw (, Fig. ) and pull open the cable change sleeve (). Rotate the shifter fully in the cable release direction (gear position 8/9 ). Look for cable head entry (, Fig. ). Push cable up/out of the shifter and discard. Feed the new cable through the cable entry and out the barrel adjuster (). Pull cable snug. Install cable change sleeve (, Fig. ). 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 (, Fig. ) in uphill riding mode / gear position. Snap open Clickbox-cover (8, Fig. 7) (no need to move Clickbox from the axle end). Unscrew clamping bolt (9). Remove the shifter escape hatch (, Fig. ). Remove and discard the old cable. Feed the new cable through the cable entry (7, Fig. ), 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 (0, Fig. 7). Tighten the mm hex cable anchor bolt to Nm ( in.lbs.). Cut off cable end to mm. Snap in Clickbox-cover. Place thumb shift lever in standard riding mode / gear position. Match up the marks in the Clickbox viewing window (, Fig. 7) by turning the barrel adjuster (). 8 9 mm Nm in.lbs. 9

10 DUALDRIVE MAINTENANCE TROUBLESHOOTING Problem Hub: Shifting difficulties Pedals are carried forward when freewheeling Derailleur: 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. Rough shifting behavior. Chain jumps two gears on small sprocket Delayed shifting onto larger sprocket Delayed shifting onto smaller sprocket Cause Incorrect gear setting Bearings set too tight Loose lock nuts Rear frame dropouts non parallel High gear limit screw is not adjusted properly. High gear limit screw is not adjusted properly. Low gear limit screw is not adjusted properly. Rear derailleur or derailleur hanger is bent. Clearance between guide pulley / sprocket is too large. Clearance between guide pulley / sprocket is too small. Shift cable insufficiently tensioned. Shift cable insufficiently tensioned. Shift cable is too tight. Excessive cable friction, pinched or poorly routed cable. Remedy Adjust shifting system, oil control cable, check that cable stop is fastened correctly. Re-adjust bearing Tighten lock nuts ( 0 Nm, 77 in.lbs.) Bend / reorient dropouts Turn in screw H until the guide pulley is aligned with the smallest sprocket. Unscrew screw H until the guide pulley is aligned with the smallest sprocket. Turn in screw L until the guide pulley is aligned with the largest sprocket. Straighten or replace. Adjust b-adjust screw by rotating counterclockwise. Adjust b-adjust screw by rotating clockwise. Turn barrel adjuster on the shifter counterclockwise. Turn barrel adjuster on the shifter counterclockwise. Turn barrel adjuster on the shifter clockwise. Lubricate or replace cable and housing. Check for excessive bending of cable housing. 0

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13 SPECTRO S7 TECHNICAL DATA /ASSEMBLY REQUIREMENTS Comfort Action Shifting Improved Ergonomics Short Rotation Optimal Gear Ratio Spectro Design Matte Chrome Finish Improved Brake Performance Most Efficient Hub In Its Class L Version with Coaster Brake Version for i-brake: see i-brake, page. / OLD OLD C D E HR DS Spectro S7 hubs are not suitable for tandems, trademen s delivery bicycles and similar. T Cycle frame: The strength must be such that with a maximum braking torque of 0 Nm (00 in.lbs.) on the rear wheel no residual deformation can occur on the rear structure. A max F F A max Ø 7. R 00 H U B S MH 7 MH 7 MH 70 Part No. Brake Coaster Drum D NL None Over Locknut Dim., OLD 0 mm mm 0 mm Length, L 8. mm 88. mm 8. mm Axle Spoke Chain Gear Hub Ratio Finish Ends Diameter, T FG 0. FG 0. FG 0. Dropout Width Dim. A max. =. mm / A max. = mm A max. =. mm / A max. =. mm A max. =. mm / A max. = 0 mm Holes Hole Diameter, DS.0 mm.9 mm.0 mm Hole Ref. ø, HR 7 mm 89 mm 7 mm Flange Dist. to / OLD F = mm / F = mm F =.8 mm / F =.7 mm F = mm / F = mm Totally 0 % Speed 7 % Speed 8 % Speed 8 % Speed 00 % Speed % Speed 8 % Speed 7 7 % Usable Dimensions / "x / 8 " or / "x / " / "x / 8 " or / "x / " / "x / 8 " or / "x / " Line, C/D/E / / 8 mm. /. / 9. mm / / 8 mm Ratio ", ", 8"=.8.90 / 0"=.8.00 Shifter Compatib. Spectro Grip 7 Clickbox Compatib. Clickbox S7 Tandem Compatib. Weight 7 g 77 g g Hub Shell Material Steel Aluminum Steel Finish Matt Chrome Plated Clear Coat Matt Chrome Plated

14 SPECTRO S7 TECHNICAL DATA /ASSEMBLY REQUIREMENTS S H I F T E R S NEW Spectro Grip 7 Part No. Shifter Type Gear Indication Clamping Diameter Handlebar, Straight Area Design Twist Shifter Cable 00 mm 00 mm 00 mm 700 mm 800 mm 900 mm 00 mm Weight Housing Grip Grip Cover Clamping Collar Window. mm Minimum length = 0mm 89g Glass filled PA PP Thermoplastic elastomer, Overmolded Aluminum SPECTRO S7 ASSEMBLY Mounting Tool Part No ASSEMBLY HUB Lace the wheel as normal. See spoke length table. Place the dust cap (, Fig. ) and sprocket () on the driver. Push sprocket circlip (, Fig. ) onto the cone of tool sleeve (). Place tool sleeve with large diameter on the driver. Push the spring end of sliding sleeve () of the tool over the tool sleeve. Thrust sliding sleeve in direction (), this forces circlip into the recess of the driver. Remove tool and check that the circlip is seated correctly. Turn dust cap (7, Fig. ) until the three lugs (8) are between the three beads (9) on the sprocket (0). Position dust cap and push towards sprocket until it is felt to lock into place. Placing the wheel in the rear frame. Mount the chain. Fit non-turn washer (, Fig. ) to the outside of the dropout (hub side opposite the sprocket). The serrations must bear against the dropout and the lug must engage in the dropout slot. On the sprocket side fit the protective bracket (, Fig. ) directly below the fixing nut. Tightening torque on acorn or hex nuts 0 0 Nm ( 0 in.lbs.). Mount the brake lever using a suitable frame clamp (, Fig. ). 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: Nm (8 7 in.lbs.) Spoke length table: Tire Size Cross Length MH 7/70 Length MH " x.7 x x 8 mm 79 mm 7 90 " x / 8 x mm mm 7 07 " x.7 x x mm 9 mm 7 0 " x / 8 x mm 8 mm 7 9 " x.7 x x 9 mm mm 7 90 " x / 8 x 7 mm 7 mm 7 8" x.7 x 89 mm 8 mm 7 8"x / 8 x / 8 x 89 mm 8 mm 8 8"x / 8 x 89 mm 8 mm 8"x / 8 x / x 89 mm 8 mm 8 0 7"x / fifty x 9 mm 9 mm 0 7" x / x 9 mm 9 mm Spoke lengths are approximate values. They must be checked through lacing attempts and adjusted accordingly.

15 SPECTRO S7 ASSEMBLY Advice: If a different protective bracket (, Fig. ) is used the thickness of the attachment plate must be max. mm. Do not use additional washers. A minimum of thread turn must be visible in front of the axle nut! ADJUSTMENT Be sure to reset rotational shifter from th. to th gear. Match up the marks in the Clickbox viewing window (, Fig. ) by turning the adjusting screw (). NEW NEW 7 ASSEMBLY SHIFTERS Slide shifter (, Fig. ) onto handlebar. Mount fixed grip () onto end of handlebar. Slide shifter against fixed grip, adjust shifter on handlebar and tighten with bolt () with a torque of. Nm ( in.lbs.). Check that the shifter and brake lever function properly and are unobstructed (realign if necessary). Fixed grips provide an axial safety function. For this reason, they should be mounted in such a way as to make sure they do not slip off handlebar. Never use lubricants or solvents to install fixed grips. Never ride without the fixed grips. The turning grip may loosen from housing and slip off handlebar this can result in severe injury or death. CONNECTING DRUM BRAKE Only use brake levers with a cable moving distance of at least mm and a minimum leverage of.8. Fit cable stop (, Fig. 9) with adjusting bolt () and nut () and insert into the slot on the brake anchor plate. Turn adjusting bolt down by approx. / and route the brake cable from the brake handle. Push lower brake cable end through adjusting bolt () and insert lower cable housing end into adjusting bolt. Thread brake cable end () into fork unit (). Tighten screw () 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 () When fitting the cable avoid small radius. Attach the cable times to the down tube (, Fig. 7). Last attachment point is on the lower rear wheel fork (, Fig. 7) immediately behind the chain wheel. Cable housing must be movable inside attachment. INSTALLING CLICKBOX Insert shift rod (, Fig. 8) in shift tube () (oil parts lightly) and then push into axle bore as far as the stop. Turn slot () in shift tube to a position where it is easily visible. Push locating sleeve () with guiding rib () to the front onto the hub axle making sure that the internal lug () is guided in the slot () of the shift tube until it can be felt and heard to engage. Turn locating sleeve on the axle until the guiding rib () is facing roughly upwards. Push on Clickbox (, Fig. ) to the stop on the hub axle. The guiding rib (, Fig. 8) of the locating sleeve thereby engages in the slot on the housing. In the end position tighten up the knurled bolt (, Fig. ) by hand. Assembly can be performed independently of the gear setting but it is best done at shifter position. For NL version drum brake hub with special lever (8), only use original NL brake cable (fork unit () is not suitable). ADJUSTMENT DRUM BRAKE Unscrew adjusting screw (, 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 (). 8

16 SPECTRO S7 MAINTENANCE SACHS Spectro S7 mounting aid Part No REMOVE WHEEL Loosen the knurled screw and pull the Clickbox off the axle. Disengage the location sleeve and pull it off. Remove shift rod/tube out of the axle bore. Remove wheel. DISMANTLING HUB see Fig. Remove cover (), spring () and cover (). Dismantle retaining washer (). Remove thrust washer () and plastic profile washer (). Unscrew grub screw () ( It is subject to spring pressure) and dismantle the long compression spring (7) guide pin (8), thrust block (9) and the short compression spring (0). X Remove circlip (8), sprocket (7) and dust cap () as normal. Withdraw locating sleeve () (latched) Take out shift rod/tube (0/). Clamp hub by the axle between aluminum jaws with sprocket side facing downwards. Unscrew both locknuts (). Remove lever cone () ball retainer () and brake shell (). Withdraw hub sleeve () upwards. Unscrew brake cone () from flat thread. Take out retaining washer (7) and thrust washer (8). Remove planetary gear carrier (9), washer (0) compression spring () and the three sun gears (,, ). Clamp other axle end. Unscrew fixed cone (). Remove driver (), compression spring () with cover (), large compression spring (0), ball retainer (), gear ring (9) and coupling gear (8). Compress spring () and remove thrust block (7). REASSEMBLY HUB see Fig. Lubrication see MAINTENANCE/ LUBRICATION. Insert into the axle (on the side with the internal thread): Short compression spring (0). Thrust block (9) it is the same both sides. Guide rod (8) it is the same both sides. Long compression spring (7). Compress spring and fit grub screw (). Clamp axle, end for clickbox facing upwards. Fit plastic profile washer () with its large diameter upwards. Fit thrust washer () and retaining washer (). Locate cover (), compression spring () with 7 turns, cover (, insides to the spring). Compress spring and position thrust block (7) it is the same both sides centrally in the axle.

17 SPECTRO S7 MAINTENANCE NEW NEW NEW NEW + mm 9 ±0, mm Clamp other axle end. Fit large sun gear (), with deflector bevels upwards. Position medium sun gear (), with deflector bevels upwards. Fit small sun gear () with recesses in front, thrust block engages in the slots. Position smallest compression spring (). Fit mm thick washer (0). Fit planetary gear carrier (9). Place the mounting aid(fig. ) on the planetary gear carrier such that the markings (X) on the 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 (8) and retaining washer (7) in the undercut. Only 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. Reclamp axle (Clickbox end facing upwards) Fit coupling gear (8) with carrier plate downwards Push ring gear (9) over the coupling gear. Locate large spring (0). Fit largest ball retainer () with balls underneath. Fit cover (, inside to the spring). Assemble the compression spring () with turns. Position driver () push it down and screw on fixed cone () to the stop, tightening torque 0 Nm (77 in.lbs.). Clamp other axle end. Screw brake cone () onto the flat thread. Assemble hub sleeve with a slight counter-clockwise movement. Insert brake shell () retaining lugs upwards, thereby the friction spring on the brake cone must engage in the slot on the brake shell. Locate ball retainer () (balls underneath), position lever cone (), thereby turn it clockwise until the retaining lugs engage. Screw on locknuts (), adjust bearing so that there is no play and lock nuts together with 0 Nm ( 77in.lbs.). Advice: The dismantly and reassembly of the hub types MH 70 / MH 7 should be carried out in the same way. Differences: Instead of brake shell/cone a click-andpawl carrier is installed on the planetary gear carrier here. Without flat thread fixed with a retaining washer. CABLE CHANGE Dismantling shifter cable: Place shifter in gear position "". Do not remove the Clickbox from the axle end. Unscrew the adjusting screw (, Fig. ) completely. Unscrew the cover screw (), brush aside the adjusting screw () and remove the cover (). Withdraw shifter cable and clamping bolt (, Fig. ) upwards, loosen clamp and pull clamping piece from the cable. Slightly lift the grip cover (Fig. ), push the cable out and discard. Assembly shifter cable: Route new cable through shifter housing and pull cable to seat cable head completely into cable recess. Feed the cable through the new cable housing and adjusting screw. Position clamping bolt (, Fig. ) at a distance of 9 mm, tighten up with. Nm ( in.lbs.) and cut off cable ends to mm. Locate clamping bolt (, Fig. ) (srew head not visible) and place shifter cable around the carrier cylinder (counterclockwise winding). Insert the square nut of the adjusting bolt () in the housing and completely screw in the knurled bolt. Position the cover (, Fig. ) and tighten up with the cover screw (). Torque Nm (..0 in.lbs.). Screw in the adjusting screw () completely. ADJUSTMENT Be sure to reset rotational shifter from th. to th gear. Match up the marks in the Clickbox viewing window (, Fig. ) by turning the adjusting screw (). 7

18 SPECTRO S7 MAINTENANCE DRUM BRAKE Install brake anchor plate (or exchange it): Place thrust washer (8, Fig. 7) over the axle on the adjusting cone and fit complete brake anchor plate. Position washer (9) distance sleeve (0) and screw on locknut (). 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 0 Nm ( 77 in.lbs.). ADJUSTMENT DRUM BRAKE Unscrew adjusting screw (, Fig. 7) 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 (). Check that all the brake system components are functioning properly! 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. For version with mounted i-brake use only the new highly heat-proof SRAM grease Typ B (Part No.: g / 00g 09 0). MAINTENANCE / LUBRICATION The Spectro hubs are provided with permanent lubrication and under normal conditions is maintenance-free. If the coaster brake is loaded excessively its effect can be too strong, the hub may lock. In such a case the brake shell should be lubricated with a special grease (Part No. 09 0). Renew brake shell, when rhombic pattern is worn out. Cleaning of parts: All parts except for the planetary gear carrier can be decreased 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. Do not use high-pressure water when cleaning the gear hub (e.g. strong water jets, high-pressure cleaners etc.) if water penetrates it could lead to functional problems. Lubrication of parts: To lubricate the bearing points on the planetary gear sets, position the planetary gear carrier on its crown and apply 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. TROUBLESHOOTING Problem Shifting difficulties Pedals are carried forward when freewheeling Hub locks when braking (coaster brake) Cause Damaged control cable Incorrect gear setting To much additional axle attachments between hub and axle nut Bearings set too tight Loose lock nuts Chain is overtensioned Brake shell has run dry Remedy Replace control cable Adjust shift. system Axle end must protrude by min. thread turn Re-adjust bearings Tighten lock nuts ( 0 Nm) Reduce chain tension Wash out hub sleeve, repolish and relubricate brake cylinder, renew brake shell 8

19 SPECTRO S7 MAINTENANCE 9

20 0

21 SPECTRO P TECHNICAL DATA /ASSEMBLY REQUIREMENTS Comfort Action Shifting Improved Ergonomics Short Rotation Optimal Gear Ratio Spectro Design Matte Chrome Finish Improved Brake Performance Most Efficient Hub In Its Class L Version with Coaster Brake Version for i-brake: see i-brake, page. Version Spectro P Cargo: see page 9. / OLD OLD C D E HR DS Spectro P hubs are not suitable for tandems, trademen s delivery bicycles and similar. T Cycle frame: The strength must be such that with a maximum braking torque of 0 Nm (00 in.lbs.) on the rear wheel no residual deformation can occur on the rear structure. A max. F F A max. Ø 7. R 00 H U B S MH MH MH 0 Part. No. Brake Coaster Drum D NL NL None Over Locknut Dim., OLD mm mm mm Length, L 7 mm 79 mm 7 mm Axle Spoke Chain Gear Hub Ratio Finish Ends Diameter, T FG 0. FG 0. toothed cone FG 0. FG 0. Dropout Width Dim. A max. =. mm / A max. =. mm A max. =. mm / A max. =. mm A max. =. mm / A max. = 0. mm Holes Hole Diameter, DS.0 mm.9 mm.0 mm Hole Ref. ø, HR 7 mm 89 mm 7 mm Flange Dist. to / OLD F = 8. mm / F = 9. mm F = 0. mm / F = 9. mm F = 9 mm / F = 9 mm Totally 9 % Speed % Speed 78 % Speed 00 % Speed 8 % Speed 8 % Usable Dimensions / "x / 8 " or / "x / " / "x / 8 " or / "x / " / "x / 8 " or / "x / " Line, C/D/E 9 /. / mm. / 8. /. mm 9 /. / mm Ratio ", ", 8"=.8.9 / 0"=.8.0 Shifter Compatib. Spectro Grip Clickbox Compatib. Clickbox P Tandem Compatib. Weight 9 g g 0 g Hub Shell Material Steel Aluminum Steel Finish Matt Chrome Plated Clear Coat Clear Coat Black Painted Matt Chrome Plated

22 SPECTRO P TECHNICAL DATA /ASSEMBLY REQUIREMENTS S H I F T E R S NEW Spectro Grip Part No. Shifter Type Gear Indication Clamping Diameter Handlebar, Straight Area Design Twist Shifter Cable 00 mm 00 mm 00 mm 700 mm 800 mm 900 mm 000 mm 00 mm Weight Housing Grip Grip Cover Clamping Collar Window. mm Minimum length = 0mm 89g Glass filled PA PP Thermoplastic elastomer, Overmolded Aluminum SPECTRO P ASSEMBLY Mounting Tool Part No ASSEMBLY HUB Lace the wheel as normal. See spoke length table. Place the dust cap (, Fig. ) and sprocket () on the driver. Push sprocket circlip (, Fig. ) onto the cone of tool sleeve (). Place tool sleeve with large diameter on the driver. Push the spring end of sliding sleeve () of the tool over the tool sleeve. Thrust sliding sleeve in direction (), this forces circlip into the recess of the driver. Remove tool and check that the circlip is seated correctly. Turn dust cap (7, Fig. ) until the three lugs (8) are between the three beads (9) on the sprocket (0). Position dust cap and push towards sprocket until it is felt to lock into place. Placing the wheel in the rear frame. Mount the chain. Fit non-turn washer (, Fig. ) to the outside of the dropouts. The serrations must bear against the dropout and the lug must engage in the dropout slot. On the sprocket side fit the protective bracket (, Fig. ) directly below the fixing nut. Tightening torque on acorn or hex nuts 0 0 Nm ( 0 in.lbs.). Mount the brake lever using a suitable frame clamp (, Fig. ). 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: Nm (8 7 in.lbs.) Spoke length table: Tire Size Cross Length MH /0 Length MH 7 0 0" x.7 x x 8 mm 79 mm 7 90 " x / 8 x mm mm 7 07 " x.7 x x mm 9 mm 7 0 " x / 8 x mm 8 mm 7 9 " x.7 x x 9 mm mm 7 90 " x / 8 x 7 mm 7 mm 7 8" x.7 x 89 mm 8 mm 7 8"x / 8 x / 8 x 89 mm 8 mm 8 8"x / 8 x 89 mm 8 mm 8"x / 8 x / x 89 mm 8 mm 8 0 7"x / fifty x 9 mm 9 mm 0 7" x / x 9 mm 9 mm Spoke lengths are approximate values. They must be checked through lacing attempts and adjusted accordingly.

23 SPECTRO P ASSEMBLY Advice: If a different protective bracket (, Fig. ) is used the thickness of the attachment plate must be max. mm. Do not use additional washers. A minimum of thread turn must be visible in front of the axle nut! ADJUSTMENT Be sure to reset rotational shifter from th. to th gear. Match up the marks in the Clickbox viewing window (, Fig. ) by turning the adjusting screw (). NEW NEW ASSEMBLY SHIFTERS Slide shifter (, Fig. ) onto handlebar. Mount fixed grip () onto end of handlebar. Slide shifter against fixed grip, adjust shifter on handlebar and tighten with bolt () with a torque of. Nm ( in.lbs.). Check that the shifter and brake lever function properly and are unobstructed (realign if necessary). Fixed grips provide an axial safety function. For this reason, they should be mounted in such a way as to make sure they do not slip off handlebar. Never use lubricants or solvents to install fixed grips. Never ride without the fixed grips. The turning grip may loosen from housing and slip off handlebar this can result in severe injury or death. When fitting the cable avoid small radius. Attach the cable times to the down tube (, Fig. 7). Last attachment point is on the lower rear wheel fork (, Fig. 7) immediately behind the chain wheel. Cable housing must be movable inside attachment. INSTALLING CLICKBOX Insert shift rod (, Fig. 8) in shift tube () (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 () in shift tube to a position where it is easily visible. Push locating sleeve () with guiding rib () to the front onto the hub axle making sure that the internal lug () is guided in the slot () of the shift tube until it can be felt and heard to engage. Turn locating sleeve on the axle until the guiding rib () is facing roughly upwards. Push on Clickbox (, Fig. ) to the stop on the hub axle. The guiding rib (, Fig. 8) of the locating sleeve thereby engages in the slot on the housing. In the end position tighten up the knurled bolt (, Fig. ) by hand. Assembly can be performed independently of the gear setting but it is best done at shifter position. CONNECTING DRUM BRAKE Only use brake levers with a cable moving distance of at least mm and a minimum leverage of.8. Fit cable stop (, Fig. 9) with adjusting bolt () and nut () and insert into the slot on the brake anchor plate. Turn adjusting bolt down by approx. / and route the brake cable from the brake handle. Push lower brake cable end through adjusting bolt () and insert lower cable housing end into adjusting bolt. Thread brake cable end () into fork unit (). Tighten screw () 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 (). For NL version drum brake hub with special lever (8), only use original NL brake cable (fork unit () is not suitable). ADJUSTMENT DRUM BRAKE Unscrew adjusting screw (, 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 ().

24 SPECTRO P MAINTENANCE Spectro P mounting aid Part No REMOVE WHEEL Loosen the knurled screw and pull the Clickbox off the axle. Disengage the location sleeve and pull it off. Remove shift rod/tube, if necessary pull shift rod outwards and unscrew in a counter-clockwise direction. Remove wheel. DISMANTLING HUB see Fig. Take out thrust block (), (to do this compress the spring). Remove spring () and the two covers (/). Dismantle retaining washer (0), washer (9), conical compression spring (8), and the large sun gear (). Clamp other axle end (thrust block visible). Unscrew grub screw () Dismantle spring (), guide bolt () and thrust block (7). Remove small sun sun gear (). X Remove circlip (), sprocket () and dust cap (). Clamp hub with sprocket side facing downwards with the two axle flats. Unscrew the two locknuts (). Remove lever cone (), ball retainer () and brake shell (). Withdraw hub sleeve () upwards. Unscrew brake cone () from flat thread. Remove retaining washer (7), thrust washer (8). Remove planetary gear carrier (9) and thrust washer (0). Clamp other axle end. Unscrew fixed cone (). Remove driver (), compression spring (9), large compression spring (7) and ball retainer (0). Withdraw gear ring () and coupling gear () and then remove cover (8) from the coupling gear. REASSEMBLY HUB see Fig. Lubrication see MAINTENANCE/ LUBRICATION. Clamp axle with internal thread upwards. Position small sun gear () with crown gears to the front. Position thrust block (7) in the slotted hole (is laterally guided when the sun gear is screwed in). Locate bolt (), then spring () in the axle and screw in grub screw () until it is flush with the axle. Reclamp axle. Fit large sun gear () (it is the same both sides). Position conical compression spring (8), with the large diameter first. Press spring together and fit washer (9) and retaining washer (0).

25 SPECTRO P MAINTENANCE NEW NEW NEW Assemble cover (), compression spring with 7 turns () and the second cover (, insides to the spring). Compress spring and position thrust block () (it is the same both sides) in the center of the slotted hole. Position coupling gear () with carrier plate facing downwards. Fit cover (8, inside to the spring) for compression spring. Position gear ring () over the teeth of the coupling gear. Place ball retainer (0), with balls below on the gear ring. Position large compression spring (7) on gear ring. Mount compression spring with turns (9) on the axle. (Is supported in the coupling wheel by the cover). Locate driver (), press it down and screw on fixed cone () as far as the stop. Tightening torque 0 Nm. (Then reclamp hub.) Push on thrust washer (0) and fit planetary gear carrier (9). In doing this: Position mounting aid (Fig. ) on the planetary gear carrier so that the (X) markings on the threeplanetary gears match with the mounting aid. Insert planetary gear carrier, place thrust washer (8) on it and mount retaining washer (7) in recess. Only 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 gearwheels in operation. For lubrication of the hub see MAINTENANCE/LUBRICATION. Screw brake cone () onto flat threads. Mount hub sleeve (), with a slight counter-clockwise turn. Locate brake shell () with retaining lugs uppermost, then the friction spring on the brake cone must engage with the slot on the brake shell. Insert ball retainer () with balls below. Position lever cone () in doing this turn it clockwise until the retaining lugs engage. Screw on counternuts (), adjust bearings to be free of play and tighten lock nuts. Tightening torque 0 Nm ( 77in.lbs.). CABLE CHANGE Dismantling shifter cable: Place shifter in gear position "". Do not remove the Clickbox from the axle end. Unscrew the adjusting screw (, Fig. ) completely. Unscrew the cover screw (), brush aside the adjusting screw () and remove the cover (). Withdraw shifter cable and clamping bolt (, Fig. ) upwards, loosen clamp and pull clamping piece from the cable. Slightly lift the grip cover (Fig. ), push the cable out and discard. Assembly shifter cable: Route new cable through shifter housing and pull cable to seat cable head completely into cable recess. Feed the cable through the new cable housing and adjusting screw. Position clamping bolt (, Fig. ) at a distance of 8 mm, tighten up with. Nm ( in.lbs.) and cut off cable ends to mm. Locate clamping bolt (, Fig. ) (srew head not visible) and place shifter cable around the carrier cylinder (counterclockwise winding). Insert the square nut of the adjusting bolt () in the housing and completely screw in the knurled bolt. Position the cover (, Fig. ) and tighten up with the cover screw (). Torque Nm (..0 in.lbs.). Screw in the adjusting screw () completely. ADJUSTMENT Be sure to reset rotational shifter from th. to th gear. Match up the marks in the Clickbox viewing window (, Fig. ) by turning the adjusting screw (). NEW + mm 8 ±0, mm Advice: The dismantly and reassembly of the hub types MH 0 / MH should be carried out in the same way. Differences: Instead of brake shell/cone a click-andpawl carrier is installed on the planetary gear carrier here. Without flat thread fixed with a retaining washer.

26 SPECTRO P MAINTENANCE DRUM BRAKE Install brake anchor plate (or exchange it): Place thrust washer (8, Fig. 7) over the axle on the adjusting cone and fit complete brake anchor plate. Position washer (9) distance sleeve (0) and screw on locknut (). 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 0 Nm ( 77 in.lbs.). ADJUSTMENT DRUM BRAKE Unscrew adjusting screw (, Fig. 7) 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 (). Check that all the brake system components are functioning properly! MAINTENANCE / LUBRICATION The Spectro hubs are provided with permanent lubrication and under normal conditions is maintenance-free. If the coaster brake is loaded excessively its effect can be too strong, the hub may lock. In such a case the brake shell should be lubricated with a special grease (Part No. 09 0). Renew brake shell, when rhombic pattern is worn out. Cleaning of parts: All parts except for the planetary gear carrier can be decreased 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. Do not use high-pressure water when cleaning the gear hub (e.g. strong water jets, high-pressure cleaners etc.) if water penetrates it could lead to functional problems. Lubrication of parts: To lubricate the bearing points on the planetary gear sets, position the planetary gear carrier on its crown and apply 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. For version with mounted i-brake use only the new highly heat-proof SRAM grease Typ B (Part No.: g / 00g 09 0). Advice: The Spectro P hubs complete with shifting component have been modified in such a way that the shifting forces are considerably lower than was previously the case. The new shifting component (shifter / Clickbox) is shown in Fig., page. Indentification of the new hubs: red grub screw (, Fig. ) in the left axle end and new spring () in the axle. In order to achieve the maximum reduction in shifting forces with a combination of new shifting component / old hub, the new spring () and the red grub screw () should be installed in the hub axle (see describtion REASSEMBLY HUB ).

27 SPECTRO P MAINTENANCE TROUBLESHOOTING Problem Shifting difficulties Pedals are carried forward when freewheeling Hub locks when braking (coaster brake) Cause Damaged control cable Incorrect gear setting To much additional axle attachments between hub and axle nut Bearings set too tight Loose lock nuts Chain is overtensioned Brake shell has run dry Remedy Replace control cable Adjust shift. system Axle end must protrude by min. thread turn Re-adjust bearings Tighten lock nuts ( 0 Nm) Reduce chain tension Wash out hub sleeve, repolish and relubricate brake cylinder, renew brake shell 7

28 8

29 SPECTRO P CARGO TECHNICAL DATA /ASSEMBLY REQUIREMENTS CARGO The Spectro P Cargo is suitable for tandems, trademen s delivery bicycles and similar. An additional external rear brake is necessary due to the high load. Tolerable stress: Axle load: max. 0 kilograms Torque/driver body: max. 8 Nm (70 in.lbs.), no continuous stress. Identification Spectro P Cargo: Yellow grub screw inside the axle end. L Version with Coaster Brake / OLD OLD C D E HR DS Version Spectro P for normal bikes: see page. T Cycle frame: The strength must be such that with a maximum braking torque of 0 Nm (00 in.lbs.) on the rear wheel no residual deformation can occur on the rear structure. A max. F F A max. Ø 7. R 00 H U B S NEW MH Cargo MH Cargo Part. No. Brake Coaster Drum D NL NL Over Locknut Dim., OLD mm mm Axle Spoke Gear Hub Ratio Chain Finish Length, L 7 mm 79 mm Ends Diameter, T FG 0. toothed cone FG 0. Dropout Width Dim. A max. =. mm / A max. =. mm A max. =. mm / A max. =. mm Holes Hole Diameter, DS.0 mm.9 mm Hole Ref. ø, HR 7 mm 89 mm Flange Dist. to / OLD F = 8. mm / F = 9. mm F = 0. mm / F = 9. mm Totally % Speed 7 % Speed 78 % Speed 00 % Speed 8 % Speed 0 % Usable Dimensions / "x / 8 " or / "x / " / "x / 8 " or / "x / " Line, C/D/E 9 /. / mm. / 8. /. mm Ratio ", ", 8"=.8.9 / 0"=.8.0 Shifter Compatib. Spectro Grip Clickbox Compatib. Clickbox P Tandem Compatib. Yes Yes Weight 9 g g Hub Shell Material Steel Aluminum Finish Matt Chrome Plated Clear Coat 9

30 SPECTRO P CARGO TECHNICAL DATA /ASSEMBLY REQUIREMENTS S H I F T E R S NEW Spectro Grip Part No. Shifter Type Gear Indication Clamping Diameter Handlebar, Straight Area Design Twist Shifter Cable 00 mm 00 mm 00 mm 700 mm 800 mm 900 mm 000 mm 00 mm Weight Housing Grip Grip Cover Clamping Collar Window. mm Minimum length = 0mm 89g Glass filled PA PP Thermoplastic elastomer, Overmolded Aluminum SPECTRO P CARGO ASSEMBLY Mounting Tool Part No ASSEMBLY HUB Lace the wheel as normal. See spoke length table. Place the dust cap (, Fig. ) and sprocket () on the driver. Push sprocket circlip (, Fig. ) onto the cone of tool sleeve (). Place tool sleeve with large diameter on the driver. Push the spring end of sliding sleeve () of the tool over the tool sleeve. Thrust sliding sleeve in direction (), this forces circlip into the recess of the driver. Remove tool and check that the circlip is seated correctly. Turn dust cap (7, Fig. ) until the three lugs (8) are between the three beads (9) on the sprocket (0). Position dust cap and push towards sprocket until it is felt to lock into place. Placing the wheel in the rear frame. Mount the chain. Fit non-turn washer (, Fig. ) to the outside of the dropouts. The serrations must bear against the dropout and the lug must engage in the dropout slot. On the sprocket side fit the protective bracket (, Fig. ) directly below the fixing nut. Tightening torque on acorn or hex nuts 0 0 Nm ( 0 in.lbs.). Mount the brake lever using a suitable frame clamp (, Fig. ). 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: Nm (8 7 in.lbs.) Spoke length table: Tire Size Cross Length MH /0 Length MH 7 0 0" x.7 x x 8 mm 79 mm 7 90 " x / 8 x mm mm 7 07 " x.7 x x mm 9 mm 7 0 " x / 8 x mm 8 mm 7 9 " x.7 x x 9 mm mm 7 90 " x / 8 x 7 mm 7 mm 7 8" x.7 x 89 mm 8 mm 7 8"x / 8 x / 8 x 89 mm 8 mm 8 8"x / 8 x 89 mm 8 mm 8"x / 8 x / x 89 mm 8 mm 8 0 7"x / fifty x 9 mm 9 mm 0 7" x / x 9 mm 9 mm Spoke lengths are approximate values. They must be checked through lacing attempts and adjusted accordingly. 0

31 SPECTRO P CARGO ASSEMBLY CARGO Advice: If a different protective bracket (, Fig. ) is used the thickness of the attachment plate must be max. mm. Do not use additional washers. A minimum of thread turn must be visible in front of the axle nut! ADJUSTMENT Be sure to reset rotational shifter from th. to th gear. Match up the marks in the Clickbox viewing window (, Fig. ) by turning the adjusting screw (). NEW NEW 7 ASSEMBLY SHIFTERS Slide shifter (, Fig. ) onto handlebar. Mount fixed grip () onto end of handlebar. Slide shifter against fixed grip, adjust shifter on handlebar and tighten with bolt () with a torque of. Nm ( in.lbs.). Check that the shifter and brake lever function properly and are unobstructed (realign if necessary). Fixed grips provide an axial safety function. For this reason, they should be mounted in such a way as to make sure they do not slip off handlebar. Never use lubricants or solvents to install fixed grips. Never ride without the fixed grips. The turning grip may loosen from housing and slip off handlebar this can result in severe injury or death. CONNECTING DRUM BRAKE Only use brake levers with a cable moving distance of at least mm and a minimum leverage of.8. Fit cable stop (, Fig. 9) with adjusting bolt () and nut () and insert into the slot on the brake anchor plate. Turn adjusting bolt down by approx. / and route the brake cable from the brake handle. Push lower brake cable end through adjusting bolt () and insert lower cable housing end into adjusting bolt. Thread brake cable end () into fork unit (). Tighten screw () 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 () When fitting the cable avoid small radius. Attach the cable times to the down tube (, Fig. 7). Last attachment point is on the lower rear wheel fork (, Fig. 7) immediately behind the chain wheel. Cable housing must be movable inside attachment. INSTALLING CLICKBOX Insert shift rod (, Fig. 8) in shift tube () (oil parts lightly) and then push into axle bore as far as the stop. Turn slot () in shift tube to a position where it is easily visible. Push locating sleeve () with guiding rib () to the front onto the hub axle making sure that the internal lug () is guided in the slot () of the shift tube until it can be felt and heard to engage. Turn locating sleeve on the axle until the guiding rib () is facing roughly upwards. Push on Clickbox (, Fig. ) to the stop on the hub axle. The guiding rib (, Fig. 8) of the locating sleeve thereby engages in the slot on the housing. In the end position tighten up the knurled bolt (, Fig. ) by hand. Assembly can be performed independently of the gear setting but it is best done at shifter position. For NL version drum brake hub with special lever (8), only use original NL brake cable (fork unit () is not suitable). ADJUSTMENT DRUM BRAKE Unscrew adjusting screw (, 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 (). 8

32 SPECTRO P CARGO MAINTENANCE Spectro P mounting aid Part No X REMOVE WHEEL Loosen the knurled screw and pull the Clickbox off the axle. Disengage the location sleeve and pull it off. Remove shift rod/tube. Remove wheel. DISMANTLING HUB see Fig. Remove circlip (), sprocket () and dust cap (). Clamp hub with sprocket side facing downwards with the two axle flats. Unscrew the two locknuts (). Remove lever cone (), ball retainer () and brake shell (). Withdraw hub sleeve () upwards. Unscrew brake cone () from flat thread. Remove retaining washer (7), thrust washer (8). Remove planetary gear carrier (9) and thrust washer (0). Clamp other axle end. Unscrew fixed cone (). Remove driver (), compression spring (9), large compression spring (7) and ball retainer (0). Withdraw gear ring () and coupling gear () and then remove cover (8) from the coupling gear. Take out thrust block (), (to do this compress the spring). Remove spring () and the two covers (/). Dismantle retaining washer (0), washer (9), conical compression spring (8), and the large sun gear (). Clamp other axle end (thrust block visible). Unscrew grub screw () Dismantle spring (), guide bolt () and thrust block (7). Remove small sun sun gear (). REASSEMBLY HUB see Fig. Lubrication see MAINTENANCE/ LUBRICATION. Clamp axle with internal thread upwards. Position small sun gear () with crown gears to the front. Position thrust block (7) in the slotted hole (is laterally guided when the sun gear is screwed in). Locate bolt (), then spring () in the axle and screw in grub screw () until it is flush with the axle. Reclamp axle. Fit large sun gear () (it is the same both sides). Position conical compression spring (8), with the large diameter first. Press spring together and fit washer (9) and retaining washer (0).

33 SPECTRO P CARGO MAINTENANCE CARGO NEW NEW NEW Assemble cover (), compression spring with 7 turns () and the second cover (, insides to the spring). Compress spring and position thrust block () (it is the same both sides) in the center of the slotted hole. Position coupling gear () with carrier plate facing downwards. Fit cover (8, inside to the spring) for compression spring. Position gear ring () over the teeth of the coupling gear. Place ball retainer (0), with balls below on the gear ring. Position large compression spring (7) on gear ring. Mount compression spring with turns (9) on the axle. (Is supported in the coupling wheel by the cover). Locate driver (), press it down and screw on fixed cone () as far as the stop. Tightening torque 0 Nm. (Then reclamp hub.) Push on thrust washer (0) and fit planetary gear carrier (9). In doing this: Position mounting aid (Fig. ) on the planetary gear carrier so that the (X) markings on the threeplanetary gears match with the mounting aid. Insert planetary gear carrier, place thrust washer (8) on it and mount retaining washer (7) in recess. Only 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 gearwheels in operation. For lubrication of the hub see MAINTENANCE / LUBRICATION. Screw brake cone () onto flat threads. Mount hub sleeve (), with a slight counter-clockwise turn. Locate brake shell () with retaining lugs uppermost, then the friction spring on the brake cone must engage with the slot on the brake shell. Insert ball retainer () with balls below. Position lever cone () in doing this turn it clockwise until the retaining lugs engage. Screw on counternuts (), adjust bearings to be free of play and tighten lock nuts. Tightening torque 0 Nm ( 77in.lbs.). CABLE CHANGE Dismantling shifter cable: Place shifter in gear position "". Do not remove the Clickbox from the axle end. Unscrew the adjusting screw (, Fig. ) completely. Unscrew the cover screw (), brush aside the adjusting screw () and remove the cover (). Withdraw shifter cable and clamping bolt (, Fig. ) upwards, loosen clamp and pull clamping piece from the cable. Slightly lift the grip cover (Fig. ), push the cable out and discard. Assembly shifter cable: Route new cable through shifter housing and pull cable to seat cable head completely into cable recess. Feed the cable through the new cable housing and adjusting screw. Position clamping bolt (, Fig. ) at a distance of 8 mm, tighten up with. Nm ( in.lbs.) and cut off cable ends to mm. Locate clamping bolt (, Fig. ) (srew head not visible) and place shifter cable around the carrier cylinder (counterclockwise winding). Insert the square nut of the adjusting bolt () in the housing and completely screw in the knurled bolt. Position the cover (, Fig. ) and tighten up with the cover screw (). Torque Nm (..0 in.lbs.). Screw in the adjusting screw () completely. ADJUSTMENT Be sure to reset rotational shifter from th. to th gear. Match up the marks in the Clickbox viewing window (, Fig. ) by turning the adjusting screw (). functional problems. NEW + mm 8 ±0, mm Advice: The dismantly and reassembly of the hub types MH 0 / MH should be carried out in the same way. Differences: Instead of brake shell/cone a click-andpawl carrier is installed on the planetary gear carrier here. Without flat thread fixed with a retaining washer.

34 SPECTRO P CARGO MAINTENANCE DRUM BRAKE Install brake anchor plate (or exchange it): Place thrust washer (8, Fig. 7) over the axle on the adjusting cone and fit complete brake anchor plate. Position washer (9) distance sleeve (0) and screw on locknut (). 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 0 Nm ( 77 in.lbs.). ADJUSTMENT DRUM BRAKE Unscrew adjusting screw (, Fig. 7) 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 (). Check that all the brake system components are functioning properly! MAINTENANCE / LUBRICATION The Spectro hubs are provided with permanent lubrication and under normal conditions is maintenance-free. If the coaster brake is loaded excessively its effect can be too strong, the hub may lock. In such a case the brake shell should be lubricated with a special grease (Part No. 09 0). Renew brake shell, when rhombic pattern is worn out. Lubrication of parts: To lubricate the bearing points on the planetary gear sets, position the planetary gear carrier on its crown and apply 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. Cleaning of parts: All parts except for the planetary gear carrier can be decreased 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. Do not use high-pressure water when cleaning the gear hub (e.g. strong water jets, high-pressure cleaners etc.) if water penetrates it could lead to functional problems.

35 SPECTRO P CARGO MAINTENANCE CARGO TROUBLESHOOTING Problem Shifting difficulties Pedals are carried forward when freewheeling Hub locks when braking (coaster brake) Cause Damaged control cable Incorrect gear setting To much additional axle attachments between hub and axle nut Bearings set too tight Loose lock nuts Chain is overtensioned Brake shell has run dry Remedy Replace control cable Adjust shift. system Axle end must protrude by min. thread turn Re-adjust bearings Tighten lock nuts ( 0 Nm) Reduce chain tension Wash out hub sleeve, repolish and relubricate brake cylinder, renew brake shell

36

37 SPECTRO T TECHNICAL DATA /ASSEMBLY REQUIREMENTS Comfort Action Shifting Easy Adjust Superior Quality Spectro Design Matte Chrome Finish Improved Brake Performance Most Efficient Hub In Its Class / OLD L OLD C D E Version with Coaster Brake HR DS T Ø 7. Version for i-brake: see i-brake, page. Spectro T hubs are not suitable for tandems, trademen s delivery bicycles and similar. F F Cycle frame: The strength must be such that with a maximum braking torque of 0 Nm (00 in.lbs.) on the rear wheel no residual deformation can occur on the rear structure. R 00 H U B S MH MH MH 0 Part No. Brake Coaster Drum D NL None Over Locknut Dim., OLD 8 mm 8 mm 7 mm Length, L / mm mm mm mm Ends Diameter, T FG 0. FG 0. FG 0. Axle Spoke Gear Hub Ratio Chain Finish Holes 8 Hole Diameter, DS.0 mm.8 mm.0 mm Hole Ref. ø, HR 8 mm 89 mm 8 mm Flange Dist. to / OLD F =. mm / F =. mm F =. mm / F =. mm F =. mm / F =. mm Totally 8 % Speed 7 % Speed 00 % Speed % Line, C/D/E. /. / 8. mm. /. / 8. mm / / 8 mm Ratio ", ", 8"=.0. / 0"=.0. Shifter Compatib. Spectro Grip / Spectro Bandix Tandem Compatib. Weight 8 g 70 g 9 g Hub Shell Material Steel Aluminum Steel Finish Matt Chrome Plated Silver Painted Matt Chrome Plated S H I F T E R S Spectro Grip (for adults) Part No. Shifter Type Twist Shifter Twist Shifter Comp. Cable Housing Cable ø. mm 000 mm 00 mm ø. mm Capped, Compressionless with Resin Liner inside Gear Indication Printed Printed Barrel Adjuster Indexing Indexing Clamping Diameter. mm. mm Spectro Bandix (for kids) Handlebar, Straight Area Minimum length = mm Minimum length = mm Design NEW Weight 8 g 8 g Housing PA PA Grip PA PA Grip Cover Thermoplastic elastomer Thermoplastic elastomer Clamping Collar Aluminum Aluminum NEW 7

38 SPECTRO T ASSEMBLY 9 0 Mounting Tool Part No ASSEMBLY HUB Lace the wheel as normal. See spoke length table. Place the dust cap (, Fig. ) and sprocket () on the driver. Push sprocket circlip (, Fig. ) onto the cone of tool sleeve (). Place tool sleeve with large diameter on the driver. Push the spring end of sliding sleeve () of the tool over the tool sleeve. Thrust sliding sleeve in direction (), this forces circlip into the recess of the driver. Remove tool and check that the circlip is seated correctly. Turn dust cap (7, Fig. ) until the three lugs (8) are between the three beads (9) on the sprocket (0). Position dust cap and push towards sprocket until it is felt to lock into place. Screw tension chain (, Fig. ) into the axle end. Placing the wheel in the rear frame. Mount the chain. After positioning the wheel in the rear fork fit non-turn washer (, Fig. ) to the outside of the dropout (hub side opposite the sprocket). The serrations must bear against the dropout and the lug must engage in the dropout slot. Tighten up special type axle nut (, Fig. ) and axle nut at other axle end. Tightening torque 0 0 Nm ( 0 in.lbs.). Guide tension chain () trough deflection pulley (). Position deflection pulley at axle nut and push until it is felt to lock into place. In case of stiff assembly, grease housing resp. nut (for instance Molykote PG0). Turn deflection pulley until the yellow area is at the top (, Fig. ). Advice: The Spectro T hubs have been modified for the series launch of the new deflection pulley. Identification: yellow counter nut on the driving end of the axle and modified compression spring ( resp., Fig. / Page 0) In order to prevent malfunctions, these modified hubs may no longer be combined with the chain guide nut. The deflection pulley can also be used for the previous hub version (silver-coloured counter nut on the axle). In order to achieve the maximum reduction in shifting forces with this combination, the new, modified compression spring should be installed (description see REASSEMBLY HUB ). Only install additional axle attachments (e.g. struts) between nut and retaining washer. Cable stop bracket: dimensions see Fig. 9. Axle end must protrude by min. mm to max. mm beyond the nut (, Fig. ). Mount the brake lever using a suitable frame clamp (, Fig. ). 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: Nm (8 7 in.lbs.). Spoke length table: Tire Size Cross Length MH /0 Length MH 8 / Holes 8 / Holes Holes 7 0 0" x.7 x x / x 8 mm / 8 mm 7 90 " x / 8 / x / 8 mm 7 07 " x.7 x x / x mm / mm 7 0 " x / 8 / x / mm 7 9 " x.7 x x / x 8 mm / mm mm 7 90 " x / 8 / x / mm 7 mm 7 8" x.7 x / x 89 mm / 9 mm 8 mm 8 8"x / 8 / x / 9 mm 8 mm 8"x / 8 x / / x / 9 mm 8 mm 7 8"x / 8 x / 8 / x / 9 mm 8 mm 8 0 7"x / fifty / x / 97 mm 87 mm 0 7" x / / x / 97 mm 87 mm Spoke lengths are approximate values. They must be checked through lacing attempts and adjusted accordingly. 8

39 SPECTRO T ASSEMBLY 7 NEW max. 0 min. mm min. 90 mm. mm.7 Nm in.lbs. min. mm ASSEMBLY SHIFTERS Slide shifter (, Fig. 7) onto handlebar. Add thrust washer (). Mount fixed grip () onto end of handlebar. Without applying pressure, slide shifter against fixed grip, adjust shifter on handlebar and tighten with bolt (). Allen key. Nm, torque,7 Nm ( in.lbs.) Not recommended for use on thin walled aluminum handlebars such as Hyperlite type handlebars. Check that the shifter and brake lever function properly and are unobstructed (realign if necessary). Fixed grips provide an axial safety function. For this reason, they should be mounted in such a way as to make sure they do not slip off handlebar. Never use lubricants or solvents to install fixed grips. Never ride without the fixed grips. The turning grip may loosen from housing and slip off handlebar this can result in severe injury or death. INSTALLING CABLE When fitting the cable avoid small radius. Use only compressionless cable housings with resin liner inside and capped. Screw the cable stop clamp and cable pully clamp on the down tube or seat tube. Secure the lubricated shift cable at equidistant intervals on the frame (in case of continuous cable housing). Feed the shifter cable into the locating sleeve (, Fig. 8), fix at the appropriate length (cable stop bracket: see Fig. 9) using the clamping bolt (). Allan key. mm, tightening torque. Nm ( in.lbs.). Shorten any cable which is sticking out. Connect to the hub: push locating sleeve (, Fig. 8) loosely onto small pull rod (). ADJUSTMENT Place the shifter in gear position "". 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 (, Fig. 8) onto the small pull rod () until the control cable is taut. Make sure that you don t pull the indicator chain out of the deflection pulley (). Check: Place shifter in gear position "" while moving the crank. Setting too loose: In gear position "" the tension chain can be pulled out of the deflection pulley by hand. Setting too tight: It is difficult to place the shift lever in gear position "". If required, readjust the shift mechanism (in third gear). CONNECTING DRUM BRAKE Only use brake levers with a cable moving distance of at least mm and a minimum leverage of.8. Fit cable stop (, Fig. 0) with adjusting bolt () and nut () and insert into the slot on the brake anchor plate. Turn adjusting bolt down by approx. / and route the brake cable from the brake handle. Push lower brake cable end through adjusting bolt () and insert lower cable housing end into adjusting bolt. Thread brake cable end () into fork unit (). Tighten screw () 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 (). For NL version drum brake hub with special lever (8), only use original NL brake cable (fork unit () is not suitable). 7 ADJUSTMENT DRUM BRAKE Unscrew adjusting screw (, Fig. 0) 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 (). 8 9

40 SPECTRO T MAINTENANCE REMOVE WHEEL MH / Coaster brake Apply fingertip pressure onto the metal key of locating sleeve to release it from the pull rod. Remove deflection pulley. Screw off both axle nuts and remove retaining washers. Remove wheel. 0 DISMANTLING HUB see Fig. 9 Unscrew indicator chain (), remove circlip (), sprocket (0), dust cap (9) and clamp axle (0) on the driver side. 9 Unlock hexagonal nuts () and unscrew. Remove brake arm (), ball retainer () and brake sleeve () and remove hub 7 8 shell (). Remove safety washer (7), thrust washer (8) and then the planet carrier (9) complete with brake cone (). Unscrew the brake cone from the planet carrier. Clamp other axle end. a x Loosen the lock nut () and fixed cone MH 0 / without brake b (8) and remove. Remove driver (7), compression springs c ( and ) and ball retainer (). Push the sliding key () through the large bore in the coupling wheel of the ring gear () the bore and thrust block must be aligned. d e Remove the gear ring () from the axle. Advice: The dismantly and reassembly of the hub types MH 0 / MH should be carried out in the same way (Fig. / ). MH / Drum brake c b a x Differences There is no brake sleeve () and brake cone (). The planet carriers (a) have a cylindrical shaft instead of a flat thread, which houses a pawl carrier (b) held by a safety washer instead of the brake cone. Further differences: instead of a lever cone () for type MH, an adjusting cone (d) with dust cap (e) for type MH 0 and a small adjusting cone (D) and corresponding ball retainer (f) for type MH are fitted. D f 0

41 SPECTRO T MAINTENANCE REASSEMBLY HUB see Fig. / / CABLE CHANGE see Fig. : NEW 7 Ø, mm Ø, mm Lubrication see MAINTENANCE/ LUBRICATION. Clamp the hub axle (0) with the slot for thrust block upwards), fit ring gear () and align the large bore in the coupling wheel with the slot. Position the radius of the sliding key () facing downwards and turn the coupling wheel slightly. Fit the compression springs ( and ). Place ball retainer with balls in () on ring gear (), mount driver (7), fit fixed cone and lock with hexagonal nut (), tightening torque 0 Nm ( 77 in.lbs). Turn hub over and slide on planet carrier (9) thrust washer (X) must first be fitted for types MH 0/. (For type MH, 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 (, type MH ) onto the flat thread for types MH 0/ mount pawl carrier (b) and secure in place using safety washer (c). Fit hub shell () turning it counterclockwise slightly to get past the stop notches until the shell runs cleanly onto the ball retainer. For type MH, insert the brake sleeve () so that the spring end of the friction spring on the brake cone () sits in one of the two slots on the brake sleeve. Insert the ball retainer and fit the lever cone move the lever cone lightly until the lugs on the brake lever catch in the grooves on the adjusting cone. Adjust the hub clearance by screwing on hexagonal nut () until the hub shell runs free of play but not under tension. Lock with a second nut to a tightening torque of 0 Nm ( 77 in.lbs.). For type MH 0 insert ball retainer (), mount adjusting cone (d) with dust cap (e) and hexagonal nuts (). Adjust the hub clearance as for type MH. For type MH, the ball retainer (f) and dust cap (pressed in) normally remain in the hub shell. The hub clearance is set with adjusting cone (D) as for type MH. For notes on fitting the brake carrier, please refer to mounting drum brake. Dismantling shifter cable: Use only new cable and compressionless cable housing Detach the cable from the internal hub. Remove the cable housing. Cut the cable off cm (") from the shifter barrel adjuster. Discard the old cable and cable housing. Line up the gear number mark with the indicator mark. From the edge, pull open the cable change hatch (Fig. ). Remove and discard the rest of the old cable. Assembly shifter cable: Feed the new cable through the shifter. Feed the cable through the new cable housing and stops. Feed the shifter cable into the locating sleeve (, Fig. 7), fix at the appropriate length using the clamping bolt (). Allan key. mm, tightening torque. Nm ( in.lbs.). Shorten any cable which is sticking out. Connect to the hub: push locating sleeve (, Fig. 7) loosely onto small pull rod (). ADJUSTMENT Place the shifter in gear position "". 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 (, Fig. 7) onto the small pull rod () until the control cable is taut. Make sure that you don t pull the indicator chain out of the deflection pulley (). Check: Place shifter in gear position "" while moving the crank. Setting too loose: In gear position "" the tension chain can be pulled out of the deflection pulley by hand. Setting too tight: It is difficult to place the shift lever in gear position "". If required, readjust the shift mechanism (in third gear).

42 SPECTRO T MAINTENANCE DRUM BRAKE Instal brake anchor plate (or exchange it): Place thrust washer (8, Fig. 8) over the axle on the adjusting cone and fit complete brake anchor plate. Position washer (9) distance sleeve (0) and screw on locknut (). 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 0 Nm ( 77 in.lbs.). ADJUSTMENT DRUM BRAKE Unscrew adjusting screw (, Fig. 8) until the brake pads drag lightly. Actuate the hand brake lever forcefully several times and then, if necessary, turn the adjusting screw further in just until the wheel starts spinning freely. Lock hex nut (). Check that all the brake system components are functioning properly! MAINTENANCE / LUBRICATION Coaster Brake: Improved braking in third gear after production date CW 8/9 In case of repair, older hub models (Fig. ) can be converted with a repair set (Fig. ). It is important that all three parts are replaced at the same time new, reinforced compression springs, planet carrier with lugs and ring gear with lugs on the driving plate. A change with of the new or converted hubs: When braking in third gear, the tension chain moves out of the deflection pulley by approx. one chain link after braking, the tension chain returns immediately to its normal position. The Spectro hubs are provided with permanent lubrication and are maintenancefree under normal conditions. For type MH, however, particularly high loading of the coaster brake can cause it to overcompensate. In this case, apply special grease (Part No. 09 0) to the brake sleeve or replace it. Renew brake shell, when rhombic pattern is worn out. Cleaning of parts: All parts except for the planetary gear carrier can be decreased in a cleaning bath. The planetary gear carrier only needs to be cleaned on the outside with a brush so as not to degrease the planetary gear bearing. Lubrication of parts: To lubricate the bearing points on the planetary gear sets, position the planetary gear carrier on its crown and apply 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. For version with mounted i-brake use only the new highly heat-proof SRAM grease Typ B (Part No.: g / 00g 09 0). Do not use high-pressure water when cleaning the gear hub (e.g. strong water jets, high-pressure cleaners etc.) if water penetrates it could lead to functional problems.

43 SPECTRO T MAINTENANCE TROUBLESHOOTING Problem Shifting difficulties Pedals are carried forward when freewheeling Ccoaster brake: Hub locks when braking Pedals yield slowly during braking (does not impair safety). Cause Incorrect gear setting Bearings set too tight Loose lock nuts Chain is overtensioned Brake shell has run dry Brake cone / brake sleeve Remedy Adjust shifting system, oil control cable, check that cable stop is fastened correctly. Re-adjust bearing Tighten lock nuts ( 0 Nm) Reduce chain tension Wash out hub sleeve, repolish and relubricate brake cylinder, renew brake shell Replace brake cone and brake sleeve

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45 SPARC TECHNICAL DATA /ASSEMBLY REQUIREMENTS Not suitable for tandems, tradesmen s delivery bicycles and similar. H U B Axle V max. Electric Drive Spoke Gear Hub Ratio Sparc hub Part No. Engine Type x V DC engines Power x 00 W max. Assist Type Pedal controlled Assist Ratio Econ / Speed Econ Mode 8 km/h (8") Speed Mode km/h (8") Brake None Over Locknut Dim. mm Length 90 mm Ends Diameter FG 0. Holes Hole Diameter.7 mm Hole Reference ø 9 mm Totally 9 % Speed % Speed 78 % Speed 00 % Speed 8 % Speed 8 % Usable Dimension / "x / 8 " or / "x / " S H I F T E R R E M. C O Ṇ B Ạ Sparc Shifter Part. No. Shifter Type Twist Shifter Cable 00 mm 00 mm 700 mm Gear Indication Window Clamping Diameter. mm Handlebar, Straight Area Minimum length = 0mm Weight 70 g Sparc Remote Control Unit Part. No. Cable 00 mm 00 mm 700 mm 800 mm 00 mm Mode Selector Off / Econ / Speed Mode Indication Printed Clamping Diameter. mm Cable Connection. mm stereo jack Weight g Sparc Battery Box Part No. Cable 0 mm 70 mm 80 mm 00 mm 90 mm Chain Line 9. mm (only off-set sprockets) Ratio ", ", 8"=.7.9 / 0"=.. Shifter Compatib. Sparc Shifter Frame Compatib. Dropouts max. 7 mm / OLD mm B O X Battery V / 7Ah lead battery Charger V /.A V /.0A Charging time hours minutes hours 0 minutes Luggage carrier comp. Struts: ø 8 mm / dist. 8 mm center to center / parallel Weight 00 g Weight 000 g

46 SPARC ASSEMBLY 9 0 Mounting Tool Part No LACING THE WHEEL -cross only. All spoke heads must be positioned at the outside of the spoke flange. Spoke tension about 000 N recommended. ASSEMBLY HUB Place the dust cap (, Fig. ) and sprocket () on the driver. Toothing close to the hub (only sprocket version off-set). Push sprocket circlip (, Fig. ) onto the cone of tool sleeve (). Place tool sleeve with large diameter on the driver. Push the spring end of sliding sleeve () of the tool over the tool sleeve. Thrust sliding sleeve in direction (), this forces circlip into the recess of the driver. Remove tool and check that the circlip is seated correctly. Turn dust cap (7, Fig. ) until the three lugs (8) are between the three beads (9) on the sprocket (0). Position dust cap and push towards sprocket until it is felt to lock into place. Placing the wheel in the rear frame. Mount the chain. Fit non-turn washer (, Fig. ) to the outside of the dropouts. The serrations must bear against the dropout and the lug must engage in the dropout slot. On the sprocket side fit the protective bracket (, Fig. ) directly below the axle nut. Tightening torque on acorn or hex nuts 0 0 Nm ( 0 in.lbs.). Advice: If a different protective bracket is used the thickness of the attachment plate must be max. mm. Do not use additional washers. A minimum of thread turn must be visible in front of the axle nut! ASSEMBLY SHIFTER Slide shifter (, Fig. ) onto handlebar. Add thrust washers (). Mount fixed grip () onto end of handlebar. Without applying pressure, slide shifter against fixed grip. Adjust shifter on handlebar and tighten with bolt () with a torque of. Nm ( in.lbs.). Check that the shifter and brake lever function properly and are unobstructed (realign if necessary). Fixed grips provide an axial safety function. For this reason, they should be mounted in such a way as to make sure they do not slip off handlebar. Never use lubricants or solvents to install fixed grips. Never ride without the fixed grips. The turning grip may loosen from housing and slip off handlebar this can result in severe injury or death. When fitting the cable (, Fig. 7) avoid small radius. Last attachment point is on the lower rear wheel fork (, Fig. 7) immediately behind the chain wheel. Cable housing must be movable inside attachment. INSTALLING CLICK BOX Insert shift rod (, Fig. 8) in shift tube () (oil parts lightly) and then push into axle bore as far as the stop. Turn slot () in shift tube to a position where it is easily visible. Push locating sleeve () with guiding rib () to the front onto the hub axle making sure that the internal lug () is guided in the slot () of the shift tube until it can be felt and heard to engage. Turn locating sleeve on the axle (7) until the guiding rib () is facing roughly upwards. Push on clickbox (, Fig. ) to the stop on the axle. The guiding rib (, Fig. 8) of the locating sleeve thereby engages in the slot on the housing. In the end position tighten up the knurled bolt (, Fig. ) by hand. Assembly can be performed independently of the gear setting but it is best done at shifter position. ADJUSTMENT HUB Be sure to reset rotational shifter from th. to rd gear. Match up the arrow marks in the Clickbox viewing window (, Fig. ) by turning the adjusting screw ().

47 SPARC ASSEMBLY ASSEMBLY BATTERY BOX Pull both quick releases outward and turn them to the open position (Fig. 9). Position battery box onto luggage carrier struts (, Fig. 7). Push quick releases inwards and turn them to the closed position. 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. ASSEMBLY REMOTE CONTROL UNIT Slide remote control unit (, Fig. 0) onto handlebar. Mount brake lever () and fixed grip (). Adjust remote control unit on handlebar and tighten the bolt () with a torque of. Nm ( in.lbs.). Slide plug of remote control cable in the slot () 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. 9 Check: Switch remote control to Speed position and rotate the rear wheel. At least green and red LED must gleam. If not, assemble plugs again completely. If not, assemble plugs again completely / right. closed open 0 7

48 SPARC MAINTENANCE Sparc mounting aid Part No X REMOVE WHEEL 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 (0, Fig. ) and pull the Clickbox off the axle. Disengage the locating sleeve and pull it off. Remove shift rod/tube (7/), pull shift rod out of the axle bore. Remove wheel. ELECTRIC DRIVE Remove: Unscrew resin nut (, Fig. ). Remove electric drive (). Do not disassemble and do not lubricate the electric drive. Reassembly: Position electric drive onto hub. While rotating the electric drive push it inside until the two small inside pins engage in corresponding small holes (). Check: The thread must be visible at least 8 mm. Screw on resin nut () with a torque of Nm (7 in.lbs.). DISMANTLING GEAR HUB see Fig. Remove circlip (), sprocket () and dust cap (). Clamp hub with the two axle flats sprocket side facing downwards. Remove electric drive (). Unscrew the locknuts (+). Remove plate () with washer (). Remove hub shell (7). Remove circlip (8) and washer (9). Remove planetary gear carrier (0) and circlip (). Clamp other axle end. Unscrew fixed cone (). Remove driver (), compression spring (9), large compression spring (7) and ball retainer (0). Withdraw gear ring () and coupling gear () and remove cover (8) from the coupling gear. Take out thrust block (), (to do this compress the spring). Remove spring () and the two covers (/). Dismantle retaining washer (0), washer (9), conical compression spring (8), and the large sun gear (). Clamp other axle end. Unscrew grey grub screw () dismantle spring (), guide bolt () and thrust block (7). Remove small sun gear (). 8

49 SPARC MAINTENANCE + mm 8 ±0, mm mm REASSEMBLY HUB see Fig. Lubrication see LUBRICATION GEAR HUB, next page. Clamp axle with small internal thread upwards. Position small sun gear () with crown gears to the front. Position thrust block (7) in the slotted hole (is laterally guided when the sun gear is mounted). Locate bolt (), then spring () in the axle and screw in grey grub screw () until it is flush with the axle end. Clamp other axle end. Fit large sun gear (). Position conical compression spring (8), with the large diameter first. Compress spring and fit washer (9) and retaining washer (0). Assemble cover (), compression spring with 7 turns () and the second cover (, insides to the spring). Compress spring and position thrust block () (it is the same both sides) in the center of the slotted hole. Position coupling gear () with carrier plate facing downwards. Fit cover (8, inside to the spring) for compression spring. Position gear ring () over the teeth of the coupling gear. Place ball retainer (0), with balls below on the gear ring. Position large compression spring (7) on gear ring. Mount compression spring with turns (9) on the axle. (Is supported in the coupling wheel by the cover.) Locate driver (), press it down and screw on fixed cone (). Tightening torque 0 Nm. Clamp other axle end. Push on thrust washer () and fit planetary gear carrier (0). In doing this: Position mounting aid (Fig. ) 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 gearwheels in operation. Mount hub shell (7), with a slight counterclockwise turn. Fit plate () and washer (). Screw on counternuts (+), tightening torque 0 Nm ( 77 in.lbs.). Reassemble electric drive. CABLE CHANGE Dismantling shifter cable: Place shifter in gear position "". Loosen clamping bolt (, Fig. ) on the shifter and slide the complete shifter inwards towards the middle of handlebar 0 mm or more. (It may be necessary to loosen and move the brake lever.) Separate housing () from turning grip (). Unscrew bolt (, Fig. ), remove cap (). Withdraw shifter cable and clamping bolt (, Fig. ) upwards, loosen clamp and pull clamping piece from the cable. Remove the old cable (, Fig. ). Assembly shifter cable: Route new cable through shifter housing and pull cable to seat cable head completely into cable recess. Reassemble shifter by aligning four tabs on shifter housing with matching recesses on turning grip and snap together (Fig. ). Feed the cable through the new cable housing and adjusting screw. Position clamping bolt (, Fig. ) at a distance of 8 mm, tighten up with. Nm ( in.lbs.) and cut off cable ends to mm. Locate clamping bolt (, Fig. ) (srew head not visible) and place shifter cable around the carrier cylinder (counterclockwise winding). Insert the square nut of the adjusting bolt () in the housing and completely screw in the knurled bolt. Position cap (, Fig.) and tighten up with bolt. Advice: To set the clamping bolt / adjusting screw distance a setting piece can be used (Part No ). ADJUSTMENT Be sure to reset rotational shifter from th. to rd gear. Match up the arrow marks in the Click Box viewing window (, Fig. ) by turning the adjusting screw (). 9

50 SPARC MAINTENANCE 7 8 closed open LUBRICATION GEAR HUB Cleaning of parts: All parts except for the planetary gear carrier can be decreased in a cleaning bath. The planetary gear carrier only needs to be cleaned on the outside with a brush so as not to degrease the planetary gear bearing. Lubrication of parts: Use only SRAM grease (Ref. No. 09 0) and standard bicycle oil. To lubricate the bearing points on the planetary gear sets, position the planetary gear carrier on its crown and apply 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 water jets, high-pressure cleaners etc.) if water penetrates it could lead to functional problems. If the cycle is not used for a lengthy period, set shifting lever to gear position so that the system is not strained. BATTERY CHANGE Disassembly: Apply fingertip pressure onto the tap and pull battery cable plug off the battery box. Turn quick releases to the open position (Fig. 7) and pull them outward. Take off battery box from luggage carrier. Unscrew the bottom screws (slotted screwdriver / Torx T0) and take off battery box cover. Hang out stirrup (, Fig. 8). Take out battery and pull off plugs (+). Advice: Do not pull off any plug from card modul. Reassembly: Connect plugs to new battery: black cable: Negative Pole (, Fig. 8) red cable: Positive Pole () and put battery inside. Assemble stirrup () (bulge downward). Mount battery box cover by the screws. Pull both Quick Releases outward and turn them to the open position (Fig. 7). Position battery box onto luggage carrier struts. Push Quick Releases inwards and turn them to the closed position. Slide plug of battery cable in the slot of the battery box until it snaps in. Advice: Use only batteries as specified. Battery charging: see Sparc Instruction Manual Publ. No. 00. REMOTE CONTROL UNIT Do not disassemble the remote control unit. 0

51 SPARC MAINTENANCE TROUBLESHOOTING Problem Gear hub: Shifting difficulties Pedals are carried forward when freewheeling Electric system: Electric drive does not work Electric drive emits unusual noise Cause Damaged control cable Incorrect gear setting To much additional axle attachments between hub and axle nut Bearings set too tight Loose lock nuts Chain is overtensioned Remote control in position OFF Remote control defect Plugs not engaged Cable defect Battery discharged Battery inside not connected Battery defect Fuse blasted Electric drive defect Foreign body in electric drive Electric drive defect Remedy Replace control cable Adjust shifting system Axle end must protrude by min. thread turn Readjust bearings Tighten lock nuts ( 0 Nm) Reduce chain tension Switch to ECON or SPEED Replace remote control Slide all plugs completely in slots Replace defect cables Charch battery Connect battery inside Replace battery Replace fuse (, Fig. 8) in battery box ( A) Replace electric drive Take out foreign body Replace electric drive

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53 i-brake AND COMPATIBLE HUBS TECHNICAL DATA /ASSEMBLY REQUIREMENTS Simple and efficient design Modular configuration Stainless steel drum Sealed system Linear pull compatible 9. There is a risk of accident if unsuitable forks or frames are used (see Page )! The total weight of the bicycle with rider and baggage may not exceed kilograms. Not suitable for tandems, tradesmen s delivery bicycles and similar. The i-brakes must go on the left side viewed from behind the rear of the bicycle. 8 Axle Part No. Spoke Finish F R O N T H U B S NEW i-brake System for Front Hubs Brake Model i-brake CD (large cooling disc) i-brake CD (large cooling disc) i-brake (small cooling disc) Brake Hub Over Locknut Dim. 00 mm 00 mm 00 mm Length 0 mm 0 mm 0 mm Type Hollow Hollow Solid Material Steel Steel Steel Ends Diameter 9 mm 9 mm M9x Holes Diameter mm mm mm Hole Reference ø 9 mm 9 mm 9 mm Bearing Cartridge Cone Cone Sealing Lip Seal / Labyrinth / Dust Cap Dust Cap Dust Cap Tandem Compatib. Compat. brake lever Linear Pull compatible, Two-Axis Linear Pull compatible, Two-Axis Linear Pull compatible, Two-Axis Brake anchor plate Version D Version D Version D Total Weight 70 g 70 g 70 g Hub Shell Aluminum, painted Aluminum, painted Aluminum, painted Brake Drum Stainless steel Stainless steel Stainless steel

54 i-brake AND COMPATIBLE HUBS TECHNICAL DATA /ASSEMBLY REQUIREMENTS There is a risk of accident if unsuitable forks or frames are used (see Page )! The total weight of the bicycle with rider and baggage may not exceed kilograms. Not suitable for tandems, tradesmen s delivery bicycles and similar. The i-brakes must go on the left side viewed from behind the rear of the bicycle. C A S Ṣ H U B S NEW Axle Part No. Spoke Finish i-brake System for Cassette Hubs Brake Model i-brake CD (large cooling disc) i-brake CD (large cooling disc) Brake Hub Speeds 9/8 9/8 Driver Type Cassette Cassette Over Locknut Dim. mm mm Length 77 mm 77 mm Type Hollow Solid Material Steel Steel Ends Diameter M0x M0x Holes Diameter mm mm Hole Reference ø 9 mm 9 mm Bearing Cartridge Cone Sealing Lip Seal / Labyrinth / Dust Cap Dust Cap Tandem Compatib. Compat. brake lever Linear Pull compatible, Two-Axis Linear Pull compatible, Two-Axis Brake anchor plate Version D Version D Total Weight 000g 000gg Hub Shell Aluminum, painted Aluminum, painted Brake Drum Stainless steel Stainless steel

55 i-brake AND COMPATIBLE HUBS TECHNICAL DATA /ASSEMBLY REQUIREMENTS G E A R H U B S NEW Axle Part No. Spoke Finish DualDrive Spectro S7 Spectro P Spectro T Brake Model i-brake CD (for DualDrive) i-brake CD i-brake i-brake i-brake Brake Hub Over Locknut Dim. mm mm mm 8 mm Length 77 mm 88. mm 79 mm mm Ends Diameter FG 0. FG 0. FG 0. FG 0. Holes Hole Diameter. mm.9 mm.9 mm.8 mm Hole Reference ø 7 mm 7 mm 89 mm 89 mm Tandem Compatib. Compat. brake lever Linear Pull compatible, Two-Axis Linear Pull compatible, Two-Axis Lin.P. comp.,two-axis Lin.P. comp.,two-axis Brake anchor plate Version D Version D Version D Version D Total Weight N/A N/A N/A N/A Hub Shell Aluminum Steel Steel Steel Brake Drum Stainless steel Stainless steel Stainless steel Stainless steel R 8 R min. max FRONT FORK REQUIREMENTS Strength: The strength must be such that with a maximum braking torque of 00 Nm (700 in.lbs.) on the wheel no residual deformation can occur on the front fork. Dimensions: Important dimensions for front forks are shown in Fig.. Fork dropouts must be parallel. Brake arm anchor boss (, Fig. ): Brazed-on or screwed (suspension forks) Warning: Don t use brake arm clamps (Fig. ). Mudguard and luggage carrier attachment: Mounting screws should not collide with i-brake (Fig. ). REAR FRAME REQUIREMENTS Strength: The strength must be such that with a maximum braking torque of 0 Nm (00 in.lbs.) on the rear wheel no residual deformation can occur on the rear structure. Dimensions: Important dimensions for rear frames see previous page. Rear fork dropouts must be parallel. Mudguard and luggage carrier attachment: Mounting screws should not collide with i-brake (Fig. ). HAND BRAKE LEVER COMPATIBILITY Use only Linear Pull compatible hand brake levers. For example SRAM -Axis / 9.0SL / 9.0 / 7.0 /.0. Leverage must be.9.. Cable pull of at least mm. Hand brake lever with adjustable leverage: Adjust the leverage to get above described values of leverage and cable pull. (SRAM 9.0SL / 9.0 / 7.0 adjust to smallest leverage, that means max. cable pull.) Warning: There is a risk of accident if unsuitable brake levers are used. BRAKE CABLES Use only new high quality cable and cable housing. When choosing cable housing lengths, be sure to allow enough housing for an extreme turn of the handlebars in both directions. Note also that different stem lengths effect cable housing length.

56 i-brake AND COMPATIBLE HUBS ASSEMBLY ASSEMBLY Internal area of the brake drum and brake lining material must be free of dirt and oil or other substances containing grease. Danger of accident! Fastening wheel / solid axle: Fit washers resp. retaining washers to the axle ends. Tighten up axle nuts, torque 0 0 Nm (70 0 in.lbs.). 7 Lace the wheel as normal. -cross only. Plane faces of brake drum and hub must be clean and free from oily and greasy substances. Slide brake drum (, Fig. ) onto centering seat () and fasten crosswise with appropriate four screws (), torque, Nm (9 in.lbs.). Slide brake anchor plate (, Fig. ) onto centering seat () without tilting it. Front hubs and rear cassette hubs: Apply steel washer () and lock nut (7), minted side outwards. Wrench mm, torque 0 Nm ( 77 in.lbs.). Gear Hubs: Apply steel/resin washer (). Lock nut (7) must not be used. Advice: The wheel must turn freely. Placing the wheel in fork ends. Guide the top end of brake anchor plate into the brazing part of the front fork resp. fit frame clamp to fasten the brake anchor plate at rear fork. Mount the brake anchor plate between the two straps of the frame clamp. The clamp must be seated on the rear fork with no play. Use a self-locking nut! Hex screw, property class 8.8. Tightening torque: 7 8 Nm ( 70 in.lbs.). Fastening wheel / quick release (Fig. ): Only use quick release devices with the correct length. Position quick release opposite to the brake. Turn release lever (8) outwards until it is at least at a right angle to the bike (position open ). Tighten adjusting nut (9) as much as possible by hand. Turn release lever (8) to the closed position (0) (the word close is visible from the outside). After closure, the release lever should be parallel to the fork. If the release lever can be closed relatively easily, the tension force is inadequate. In this case, open release lever again, tighten adjusting nut (9) slightly and close release lever again. If considerable force is required to close the lever, open the lever again, undo the adjusting nut slightly and close lever again. Warning: Do not tighten wheel by turning the quick release lever clockwise (Fig. )! Only use hand force with the skewer. 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. closed open

57 i-brake AND COMPATIBLE HUBS ASSEMBLY CONNECTING i-brake Screw nut (, Fig. ) completely onto adjusting screw () and insert into the hole of the brake anchor plate. Route the brake cable. Push brake cable end through adjusting screw. Insert cable housing end into adjusting screw. Thread brake cable end (, Fig. ) into link () and tighten screw () slightly (hex wrench mm). Ensure that the brake cable lies in the notch of the link. Attach link to brake lever (). Pull brake cable end tight with pliers so that link can still be attached and removed (important for changing wheel). Tighten screw (), torque 7 8 Nm ( 70 in.lbs.). Counter the screw with a 0 mm wrench. ADJUSTMENT i-brake Unscrew adjusting screw (, Fig. ) 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. Check that all the brake system components are functioning properly. The i-brake requires a braking-in period to achieve maximum braking power. 7 7

58 i-brake AND COMPATIBLE HUBS MAINTENANCE ADJUSTING THE BRAKE Readjust the brake if the hand brake lever can be pulled close to the handlebar (for example, after the run-in time or after long use). Unscrew adjusting screw (, Fig. ) 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. Before riding your bicycle, always check if the brakes function without problems. WEAR INSPECTION If the brake lining is worn, the complete brake anchor plate must be replaced. Inspection: With your finger, press brake lever (, Fig. ) forcefully against the spring resistance. If the upper edge of the brake lever reaches the "LIMIT" mark of the wear display (), complete brake anchor plate must be replaced. DISMANTLING i-brake Internal area of the brake drum and brake lining material must be free of dirt and oil or other substances containing grease. Danger of accident! Plane faces of brake drum and hub must be clean and free from oily and greasy substances. Front hubs and rear cassette hubs: Unscrew lock nut (, Fig. ) and remove steel washer (). Gear Hubs: Remove steel/resin washer (, Fig. ). Remove brake anchor plate (). Unscrew four screws () and remove brake drum. Do not disassemble the brake anchor plate. REASSEMBLY i-brake see ASSEMBLY REMOVING THE WHEEL Detach the link (, Fig. ) on the brake lever (if necessary, screw the adjustment screw () in somewhat until the link can be detached). Grab the adjustment screw () and remove the entire brake cable unit from the brake. Rear wheel only: Remove the screw (, Fig. ) on the frame clamp. Attachment using axle nuts: To remove the wheel, remove both axle nuts (). Attachment using quick-release: To remove the wheel, open the quickrelease lever. 8

59 i-brake AND COMPATIBLE HUBS MAINTENANCE MOUNTING THE WHEEL Insert the wheel in the dropouts. Front wheel (Fig. ): Insert the upper end of the brake anchor plate () into the brake boss of the front wheel fork (). Rear wheel (Fig. ): Attach the brake anchor plate to the frame using a suitable frame clamp. Mount the brake anchor plate between the two straps of the frame clamp. The clamp must be seated on the rear fork with no play. Use a self-locking nut! Hex screw, property class 8.8. Tightening torque: 7 8 Nm ( 70 in.lbs.). Attaching a wheel with axle nuts: Slide the washers (, Fig. ) onto the ends of the axles. Mount the axle nuts () and tighten them with a torque of 0 0 Nm (70 0 in.lbs.). Attaching a wheel with quick-release: Only use quick-release devices with the correct length. Turn release lever (, Fig. 7) outwards until it is at a right angle to the bike. Tighten adjusting nut () as much as possible by hand. Turn release lever to the closed position (7) (the word close is visible from the outside). After closure, the release lever should be parallel to the fork. If the release lever can be closed relatively easily, the tension force is inadequate. In this case, open release lever again, tighten adjusting nut () 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. Warning: Do not tighten the wheel by turning the release lever clockwise (Fig. 8)! Close the quick release lever by hand only. If the quick release or the wheel is mounted incorrectly in the dropouts or if the locking force is incorrectly set, the wheel could become loose and fall off while in motion. This could result in serious injuries. 7 8 closed 7 open 9

60 i-brake AND COMPATIBLE HUBS MAINTENANCE CONNECTING THE BRAKE Attach the entire brake cable unit to the brake anchor plate (9, Fig. 9) using the adjustment screw (8). Attach the link (0) to the brake lever (). Attach the bellows to the adjustment screw. Check the brake adjusting. See ADJUSTING THE BRAKE. Check whether the brake functions correctly. BRAKE CABLE CHANGE Disassembling the brake cable: Detach the link (, Fig. ) on the brake lever (if necessary, screw the adjustment screw () in somewhat until the link can be detached). Remove the nut () on the link and remove the entire old brake cable. Advice: Only use new, high-quality brake cables and compression-free cable housings. Ensure that the length of the cable housings allow a maximum turn of the handlebar. Assembling the brake cable: Mount the brake cable and cable housing. Insert the adjustment screw (, Fig. ) on the brake anchor plate () and screw this completely in. Push the end of the brake cable through the adjustment screw. Place the end of the cable housing in the adjustment screw. Push the brake cable through the bellows. Thread the end of the brake cable into the link under the clamping washer () and tighten the nut somewhat (7). Ensure that the brake cable lies in the notch of the link. Attach the link (8, Fig. ) to the brake lever (9). Use pliers to pull the end of the cables so that the link can still be attached and detached (important for wheel removal). Tighten the nut with a torque of 7 8 Nm ( 70 in.lbs.). Counter the screw with a 0 mm wrench. Slide the bellows onto the adjustment screw (Fig. ). Check the brake adjusting. See ADJUSTING THE BRAKE. Check whether the brake functions correctly. 7 0

61 i-brake AND COMPATIBLE HUBS MAINTENANCE MAINTENANCE While lubricating the bearings from i-brake hubs use only the new highly heat-proof SRAM grease Typ B (Part No.: g / 00g 09 0). Do not use high-pressure water when cleaning the hub (e.g. strong water jets, high-pressure cleaners etc.) if water penetrates it could lead to functional problems. Do not rinse hub with benzine, petroleum etc. as this could produce impurities in the brake linings. 9 8 The brake anchor plate must be replaced if oil or other substances containing grease get into the brake linings. Oily brake linings reduce braking effect and cause the brake to fail completely. This may result in accidents with extremely serious injuries.

62 TWO-AXIS BRAKE LEVER TECHNICAL DATA / ASSEMBLY REQUIREMENTS T W OĀ X I S Two-Axis Part No. Brake Lever Left Right Lever Size Finger Brake Compatibility i-brake / Linear Pull Leverage Adjust Single Position Cable Pull 8 mm Pivot Bushing I-Glide Design Reach Adjust Yes Yes Barrel Adjuster Ergonomic Indexing Ergonomic Indexing Clamping Diameter. mm. mm Weight g g Housing Grilon Composite Lever Forged Aluminum SRAM Brake Levers are designed for use with i-brakes and linear-pull brakes. Do not use SRAM Brake Levers with conventional cantilever brakes (those with arms measuring less than 7 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 mm Designed for use with linear-pull brakes. Do not use conventional cantilever brakes. CABLE HOUSING Use only new brake cable and cable housing. When choosing cable housing lengths, be sure to allow enough housing for an extreme turn of the handlebars in both directions. Note also, that different stem lengths and cable stop positions effects cable housing length.

63 TWO-AXIS BRAKE LEVER ASSEMBLY / MAINTENANCE BRAKE LEVER ANATOMY clamp barrel adjuster clamp bolt lever reach adjustment screw INSTALLATION When sliding the brake lever onto the handlebar, allow enough room for the shifter, the handlebar grip, and the bar end. Using a mm hex wrench, tighten the clamp bolt to. Nm (0 in.lbs.) (Fig. ). Be careful not to over tighten! Line up the barrel adjuster and the brake lever housing cable slots. Pull on the lever and push the brake cable head through the opening in the brake lever housing (Fig. ). Install the brake cable head into the cable socket in the lever. Set up the brakes and brake pads per brake instructions. Actuate each brake lever 0 times. REACH ADJUSTMENT Using a mm hex wrench (Fig. ): Turn the reach adjustment screw clockwise to bring the lever closer to the handlebars. Turn the screw counterclockwise to move the lever further away. After any adjustment to the reach always check the brake cable tension to ensure proper brake system performance. Readjust the cable tension if necessary. mm. Nm 0 in.lbs. Check that all the brake system components are functioning properly! mm

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65 SMARTBAR TECHNICAL DATA / ASSEMBLY REQUIREMENTS New Style ErgoFit allows for height, reach, and rise adjustment ErgoFunction improved control, enhanced ergonomics and safety Upgradeable full suite of integrated accessories Q U I L L Shifter SmartBar Quill Stem Part No. Stem diameter Stem diameter / 8 Rear, 9spd Rear, 8spd Front, Micro Adjust Front, Index C L A M P Shifter SmartBar Clamp-On Stem Part No. Stem diameter Stem diameter / 8 Rear, 9spd Rear, 8spd Front, Micro Adjust Front, Index