Illustrated Bicycle Maintenance.pdf

Contents

Acknowledgments

Introduction

Anatomy of a Road Bike

Anatomy of a Mountain Bike

Crankarm Adjustment

Bottom Bracket Overhaul

Removal and Installation of a

Shimano Octalink Crankset

Chainring Maintenance

Sealed-Bearing Cartridge-Style

Bottom Bracket Installation

Removal and Installation of

Two-Piece Cranksets

114

116

122

CHAPTER 1

124

126

Home Bicycle Repair

Boxing a bike

1 5

128

CHAPTER 2

Frames

CHAPTER 7

Freewheels and Cassettes

CHAPTER 3

Suspension

1 31

Freewheel Maintenance

Cassette Removal and

138

Basic Suspension Adjustment

140

Cassette Cog Disassembly

Freewheel Removal and Replacement

CHAPTER 4

Wheels and Tyres

Wheel Removal and Remounting

Clincher Removal, Repair

and Remounting

UST Tubeless Tyre Removal,

Repair and Remounting

Tubular Removal, Repair

and Remounting

Rim Maintenance and Repair

Spoke Maintenance and Replacement

Truing Wheels

142

Freewheel Cog Removal

143

and Replacement

CHAPTER 8

Chains

Chain Maintenance and Repair

1 45

152

CHAPTER 9

Shift Levers

1 55

Braze-On Shifter Installation

161

Bar-End Shifter Installation

1 64

CHAPTER 5

Hubs

Brake-Lever Shift Lever Installation

1 66

Removal, Installation and Service

Mountain Bike Thumb Shifter Removal

1 68

Adjusting Cone-and-Locknut

1 70

Type Hubs

Cone-and-Locknut Type

and Installation

Three-Speed-Type Shifter Removal

1 71

Hub Overhaul

Overhauling and Adjusting a

and Installation

Campagnolo Hub Equipped

with an Oversize Axle

Lubricating Sealed Cartridge Bearings

1 01

CHAPTER 10

Front Derailleurs

1 73

Front Derailleur Basic Maintenance

1 77

CHAPTER 6

Cranksets

Front Derailleur Installation

179

1 03

Front Derailleur Adjustment

182

Basic Cassette and

Twist-Grip Mountain Bike Shifter

CHAPTER 11

Rear Derailleurs

Rear Derailleur Removal

and Installation

Rear Derailleur Cleaning and

Lubrication

Rear Derailleur Adjustment

Direct-Pull Cantilever

(V-Brake) Adjustment

Brake Pad Maintenance

252

185

1 92

254

1 94

CHAPTER 14

Handlebars and Stems

Handlebar and Stem Adjustment

Removing and Installing

Road Stem and Bar for

Threadless Headset

Taping a Handlebar

Installing Mountain Bike Stem

and Grips

257

265

268

1 96

CHAPTER 12

Headsets

Threaded Headset Adjustment

Threaded Headset Overhaul

Threadless Headset Adjustment

and Overhaul

199

208

210

214

270

272

CHAPTER 15

Saddles and Seatposts

Saddle Installation and Adjustment

CHAPTER 13

Brakes

Brake Lever Adjustment and Removal

Brake Cable Installation

Mountain Bike Lever

and Cable Installation

Aero Lever and Cable Installation

Sidepull Installation

Basics of Disc Brake Maintenance

Mechanical (Cable-Actuated)

Disc Brake Installation and

Setup (Avid and similar)

Hydraulic Disc Brake Installation

and Setup (Hayes and similar)

Hydraulic Disc Brake Installation

and Setup (Shimano, Hope,

Magura and similar)

Cantilever Installation

and Adjustment

217

232

233

237

275

281

CHAPTER 16

Pedals

287

Mountain Bike Clipless

294

Pedal Maintenance

Shimano SPD Pedal Bearing Overhaul 296

Conventional Pedal

238

240

242

244

298

Repair and Maintenance

Look Pedal Bearing Overhaul

300

246

CHAPTER 17

Gears

303

248

250

Glossary

Resources

Index

310

315

316

Acknowledgments

This, the fifth edition of Bicycling Magazine's Illustrated Bicycle Maintenance, would never have been

possible without the help of dozens of people and organizations. This book has been a collaborative

effort between the author and many talented and knowledgeable mechanics and product designers, as well

as photographers, artists and editors.

There is hardly time or space to personally thank everyone who has been involved, but here appear a

handful of key people whove gone to great lengths to ensure that this is the most comprehensive and

up-to-date resource of bicycle maintenance available.

Heidi Rodale

Park Tool

Alan Daniels

Pedros

Aaron Murray

Phil Wood

Dan Lipow

Quality Bicycle Products

David Jones

RaceFace

Drew Frantzen

RockShox

Jim Langley

Seven Cycles

Kathy LeSage

Shimano

Mark Bowman

South Mountain Cycles, Emmaus, Pennsylvania

Matt Reigner

Specialized Bicycles

Mitch Mandel

SRAM

Nancy N. Bailey

Tarrytown Cycles, Tarrytown, NY

Nic Cheetham

Trek Bicycle Corp.

Rita Baker

Titec

Sarah S. Dunn

Tri-Flow

Ultimate Support Systems

Thank you to all the companies that loaned their

United Bicycle Institute

time, knowledge and products:

United Bicycle (Tool) Supply

Ace and Belmont Wheelworks, Somerville and Belmont, MA

And finally, Id like to thank some of the people

whove been influential and supportive, both in the

Answer-Manitou

making of this book and throughout my years as a

Avid

Bacchetta

writer and professional bicycle mechanic.

Bianchi USA

The Bicycle Museum of America

John and Jill Downs

Bike Sport, Tracce, Pennsylvania

Marjorie Howsen

Bontrager

Danielle Ciraulo

Burley Design Cooperative

John Allis

Campagnolo USA

Butch Balzano

Cane Creek Components

Michael Browne

Cannondale

Chipps Chippendale

Chris King Components

Ralph Cronin

Crank Brothers

Matt Eames

Euro-Asia Imports

Leif Erickson

Finish Line

Chris Fallon

FSA

Adrian Fletcher

Giant Bicycles

Clint Paige

Hayes Disc Brake

JuliRae Mitchell

Hope Technology

Jack Mowatt

Hutchinson

Ed Nasjleti

Independent Fabrication

Rob Reed

Iron Horse

Matt Roy

LeMond Bicycles

Merlyn Townley

Magura

Dave Weagle

Marzocchi

Karl Wiedermann

Maverick American

Tripp Wyckoff

Michelin

Introduction

Almost two decades ago, the first edition of this

book was published. Much has changed in those

years. But edition after edition, the goal of

Bicycling Magazine's Illustrated Bicycle Maintenance

has been to keep up with and anticipate the pace

of that change, and to be the definitive source of

bicycle maintenance and repair techniques for

cycling enthusiasts of every stripe.

The craft of bicycle mechanics, though well

developed and documented for over a century, is

still largely passed on from master to apprentice

through guidance and shared experience, in much

the same way as any other traditional craft is

taught. Through this text, you will benefit in the

same spirit from the knowledge and experience

of not just one, but several bicycle mechanics

who have helped to shape this guide over the

years. With, no doubt, hundreds of years' experi-

ence between them, you could not hope to find

yourself in better company.

Within the pages of this book, you will be

introduced to and get to know all the parts of

your bike.You will learn which components

perform what functions, and you will learn how

they all come together to make your bicycle

work.Tools and supplies will be explained,

lending you insight as to which ones you will

need and what, though perhaps less necessary,

can improve the speed, accuracy and ease of each

repair. Then, you will take all of this together and

discover how all those bits and pieces are kept in

top working order by cleaning, inspecting, lubri-

cating and adjusting.

A great deal of new information has been

added to this, the fifth edition, but not at the

expense of the old. Changes in technology occur

every year, but perhaps there has never been a

period where those changes have come as

quickly and as frequently as they have in the last

decade. The advent and evolutions of suspension

and disc brakes are clearly the most obvious

advancements in the way bicycles function, but

more subtle improvements in frame construction,

bearing design and component manufacture

have made the past few years an exciting and

challenging time for bicycle mechanics.

Still, there are a good many tried-and-tested

designs that have withstood the test of time and

that remain as functional today as they did

decades ago and these are highlighted and

explained in the same detail as the most current

technology. So, in this guide, you will find topics

of maintenance and repair covered for bicycles

ranging from the trusty 1970s ten-speed through

to the latest in dual-suspension mountain bikes.

Even if you don't intend to perform your own

repairs, knowing your bike, its component parts and

how they work together can dramatically improve

your cycling experiences. By learning to recognize

when something is out of kilter before it leads to a

more serious – and expensive – problem, you will

save time, money and possibly prevent injuries, too.

This book may be all the reference you need.

Then, there are those of you who want to save

even more by performing basic maintenance tasks

at home.You will likely be pleasantly surprised at

just how easy many of these procedures can be.

You will quickly learn that most components of a

bicycle are much more simple than they appear;

and that, with every new technique you learn and

apply, your savings will grow greater and greater.

Of course, there are those who want to go

even deeper. If you want to begin performing all

of your own routine bicycle maintenance, and

to explore the possibilities of taking on more

major repairs, this is the ideal first volume of an

entire library of guides, manuals and catalogues

that you can build, covering every minute detail

of bicycle maintenance.

Remember: the key to success lies not in

knowing the answers to everything, but in

knowing where to find them...

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