"service manual"
Contents
1. Glide rings e Brake pads Disc brake rotors e Aero bar pads e Rubber moving parts e Chains e Wheel braking surfaces e Corrosion e Foam rings e Sprockets e Bottomout pads Tools e Rear shock mounting hardware e Drivers e Bearings e Motors and main seals e Shifter and brake cables inner e Bearing races e Batteries e Upper tubes stanchions and outer e Pawls Notwithstanding anything else set forth herein the battery pack and charger warranty does not include damage from power surges use of improper charger improper maintenance or such other misuse This warranty shall not cover damages caused by the use of parts of different manufacturers This warranty shall not cover damages caused by the use of parts that are not compatible suitable and or authorised by SRAM for use with SRAM components This warranty shall not cover damages resulting from commercial rental use TABLE OF CONTENTS REAR HUB SERVICE Eu u uu a d en u B ee a n i o ta o a l lk ra nl ka n na 5 Oh D PO EP y Eu see xa Zamaa ere eee ee ee mee ere eee hos eee rene eee eet me 5 FEPCACEREDI FRAR T 5 5 ee ee Pee eee ne pe eo eee oo o 5 PEAR RUR E O T ED VE WN xu een ernment rene ee meee ee eT eee eer eau linea eee ataqa 6 FPE oP OPE PE od Gig ee 0 A mD u ee une eee eee eee ee ee 7 E EC D EE IN EFI yaluu u ee een m E ae 10 DRIVER BOD BEAR IN TACCA NON Pee nt en Pe o bedna see sona Pe erry Pee ce eee sada u eee nee earner ee eee ree ee ee 15 REAR HUB TE Ill INS2. 7 Apply a thin layer of SRAM Butter to the bearing bores on either side of the hub Install a new 6903 bearing into the drive side of the hub 6903 Bearing 3 Slide the SRAM 6903 bearing press tool onto the threaded rod of the Wheels Manufacturing Press Sealed Bearing Press tool Insert the threaded rod of the bearing press through the non drive side of the hub shell Slide the SRAM 6903 bearing press tool onto the threaded rod Thread the bearing press handle onto the threaded rod Turn the threaded handle clockwise to press the bearing into the hub until it is hand tight NOTICE Do not overtighten the bearing SRAM 6903 bearing press tool Remove the bearing press tool Insert the spacer tube through the non drive side of the hub Rear Hub Bearing Installation 16 Insert a new 6903 bearing into the non drive side of the hub NOTICE The spacer tube can be crushed during bearing installation if it is not aligned with the inside race of each bearing Slide a SRAM 6903 bearing press tool onto the threaded rod of the Wheels Manufacturing Press 1 Sealed Bearing Press tool Insert the threaded rod of the bearing press through the drive side of the hub shell Slide the second SRAM 6903 bearing press tool onto the threaded rod Thread the bearing press handle onto the threaded rod Turn the threaded handle clockwise to press the bearing into the hub until it is hand tight NOTICE Do not overtighten the
3. bearing Applying excessive force while installing the second bearing may result in damage to one or both bearings Remove the bearing press tool Install a new bearing shield onto the non drive side Use the SRAM Butter grease syringe to dispense 1 gram of grease onto the ratchet ring Then using your finger or a brush to spread the grease around the ratchet ring ao N 7 P 7 GY j Y F 4 B ANA B 6903 Bearing SRAM 6903 Bearing Press tool SRAM Butter Rear Hub Bearing Installation 17 EJ Insert the axle through the driver body Make sure the black dust shield is installed on the axle on the outboard side Make sure the driver body seal is seated into the seal groove on the axle Slide the axle and driver body ratchet side first into the rear drive side hub shell Use your fingers to compress the pawls to allow the driver body to fully seat inside the hub shell Thread the cap nut onto the non drive side axle by hand Insert a torque wrench with a 5 mm hex bit socket into the drive side axle while holding the non drive side cap nut with a 20 mm hex bit socket and socket wrench Hold the cone wrench in place and use the torque wrench to tighten the cap nut to 10 N m 88 5 in Ib t Q 7 A a 20 mm hex bit 10 N m 88 5 in Ib 5 mm hex bit Rear Hub Bearing Installation 18 Front Hub Service You can service
4. 3 Slide a SRAM 6803 bearing press tool onto the threaded rod of the Wheels Manufacturing Press 1 Sealed Bearing Press tool Insert the threaded rod of the bearing press through the drive side of the hub shell Slide the second SRAM 6803 bearing press tool onto the threaded rod Thread the bearing press handle onto the threaded rod nnn yy To prevent damage to the bearing only use a bearing press tool that contacts both the inner and outer races of the bearing Do not use a bearing press tool that contacts only one race SRAM 6803 Da press tool Remove the bearing press tool 3 Insert the axle through the hub shell assembly and through the installed bearing Front Hub Assembly 22 4 Insert a new 6803 bearing into the non drive side bearing bore of the front hub 5 Slide a SRAM 6803 bearing press tool and a 17 mm over axle bearing spacer onto the threaded rod of the Wheels Manufacturing Press 1 Sealed Bearing Press tool Insert the threaded rod of the bearing press through the drive side of the hub shell Slide the second SRAM 6803 bearing press tool and second 17 mm over axle bearing space onto the threaded rod re e M SRAM 6803 Bearing press tool WA if 4 a Thread the bearing press handle onto the threaded rod Turn the threaded handle clockwise to press the bearing into the hub until it is hand tight NOTICE Do not over tighten the bearing To prevent damage to the bearin
5. GEN 0000000004724 Rev B 2015 SRAM LLC SRAM LLC WARRANTY EXTENT OF LIMITED WARRANTY Except as otherwise set forth herein SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after original purchase This warranty only applies to the original owner and is not transferable Claims under this warranty must be made through the retailer where the bicycle or the SRAM component was purchased Original proof of purchase is required Except as described herein SRAM makes no other warranties guaranties or representations of any type express or implied and all warranties including any implied warranties of reasonable care merchantibility or fitness for a particular purpose are hereby disclaimed LOCAL LAW This warranty statement gives the customer specific legal rights The customer may also have other rights which vary from state to state USA from province to province Canada and from country to country elsewhere in the world To the extent that this warranty statement is inconsistent with the local law this warranty shall be deemed modified to be consistent with such law under such local law certain disclaimers and limitations of this warranty statement may apply to the customer For example some states in the United States of America as well as some governments outside of the United States including provinces in Canada may a Preclude the disclaimers and limitations of this w
6. TACEA TION nE ee ee 16 FRONT HUB SERVICE u u uuu uuu naaa aaa Saa aa ia iaaea Aaa aaia iiaiai 19 TOOLS NE EDEC FOR SERVICE u 2 uuu N E E een 19 FRONT HUB E PLO PEP EV pe N E E E 19 REPLACEMENT PART u uuu umat Sma A A E EE RAA 19 FRONT HOUS DLA EMBIL P naa E aE RARE 20 FRONT AHORA EMBLET ZO 22 Table of Contents 3 SAFETY FIRST We care about YOU Please always wear your safety glasses and protective gloves when servicing ZIPP products Protect yourself Wear your safety gear Rear Hub Service You can service your hub while the hub is still in the wheel However if your spokes or rim are damaged you can remove the hub from the wheel which will make servicing your hub easier To remove the hub use a sooke wrench to detension the spokes then use a pair of metal snips to cut the spokes remove the hub from the wheel and remove the spoke ends from the hub not pictured Tools Needed for Service e Safety glasses SRAM Butter e Clean lint free rags e Grease brush Nitrile gloves Torque wrench 5mm hex wrench e Needle nose pliers e 20 mm hex bit socket Pick 5mm hex bit socket Grease syringe e Socket wrench e Enduro Universal Blind Hole Bearing Puller Set e Wheels Manufacturing Press 1 Sealed Bearing Press Kit 17 mm slide hammer bearing puller attachment 2 6803 Adapters from Press 1 Kit e Flat blade screwdriver Replacement Parts Driver body seal e 2 6803 and 2 6903 Hub bearings e Flat wa
7. arranty statement from limiting the statutory rights of the consumer e g United Kingdom b Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations For Australian customers This SRAM limited warranty is provided in Australia by SRAM LLC 1333 North Kingsbury 4th floor Chicago Illinois 60642 USA To make a warranty claim please contact the retailer from whom you purchased this SRAM product Alternatively you may make a claim by contacting SRAM Australia 6 Marco Court Rowville 3178 Australia For valid claims SRAM will at its option either repair or replace your SRAM product Any expenses incurred in making the warranty claim are your responsibility The benefits given by this warranty are additional to other rights and remedies that you may have under laws relating to our products Our goods come with guarantees that cannot be excluded under the Australian Consumer Law You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure LIMITATIONS OF LIABILITY To the extent allowed by local law except for the obligations specifically set forth in this warranty statement in no event shall SRAM or its third party suppliers be liable for direct indirect special incidental or co
8. ce the driver body seal 4 Press the driver body seal with the smooth side facing the driver body over the leaf spring and pawl carrier The driver body seal must be fully seated against the thin shoulder of the driver body Driver Body Bearing Removal 10 5 Insert the 17 mm Slide Hammer Bearing Puller slotted attachment through the outboard bearing Align the slotted attachment with the bottom of the bearing and tighten the slotted attachment to expand the puller inside the bearing NOTICE Do not over tighten the slotted attachment For more detailed assembly and usage see your bearing puller s manufacturer s instructions 17 mm Slide Hammer Bearing Puller Thread the rod of the bearing puller into the attachment Grip the slide hammer and forcefully pull away from the slotted attachment to remove the bearing from the driver body 11 SPD sx 17 mm Slide Hammer Bearing Puller Driver Body Bearing Removal 11 Use your fingers to remove the Inside Diameter ID spacer 11 SPD e Insert the 17 mm Slide Hammer Bearing Puller slotted attachment through the inboard bearing Align the slotted attachment with the bottom of the bearing and tighten the slotted attachment to expand the puller inside the bearing NOTICE Do not over tighten the slotted attachment For more detailed assembly and usage see your bearing puller s manufacturer s instructions Thread the rod of the bearing puller into the attac
9. eaded rod of the Wheels Manufacturing Press 1 Sealed Bearing Press tool Insert the threaded rod of the bearing press through the outboard side of the driver body Slide the SRAM 6803 bearing press tool onto the threaded rod Thread the bearing press handle onto the threaded rod Turn the threaded handle clockwise to press the bearing into the outboard bearing bore until it is hand tight Remove the bearing press tool NOTICE Do not overtighten the bearing SRA Eee De Applying excessive force while installing the second bearing may result in damage to one or both bearings 7 Use a syringe to apply a small amount of SRAM Butter into the pawl pocket SRAM BUTTER 1GRAM 1ML mt SRAM Butter Driver Body Bearing Installation 14 Insert the leaf springs into the spring slots Orient the long edge of each spring along the inside of the carrier so that it points clockwise Insert the pawls into the pawl slots You may need to use a pick or flat blade screwdriver to compress each leaf spring to assist with inserting the pawls Orient the cambered edge the edge that is slightly more curved of each pawl along the outside of the carrier so that it points counter clockwise Driver Body Bearing Installation 15 Rear Hub Bearing Installation NOTICE To prevent damage when pressing the bearings into the rear hub make sure that the bearing press adaptors contact both the inner and outer races of the bearing
10. g only use a bearing press tool that contacts both the inner and outer races of the bearing Do not use a bearing press tool that contacts only one race Thread the end caps onto the axle by hand until each end cap bottoms out on the bearing race Insert a 5 mm hex wrench into the drive side end cap Hold the hex wrench in place and use the torque wrench with a 5 mm hex socket to tighten the non drive side end cap to 5 Nem 45 in lb X This concludes the service for Zipp 404 hubs Front Hub Assembly 5 Nem 45 in lb M 25 I ye fee We will revolutionize the relationship that our users have with SRAM products cultivating a bond between the rider and bicycle Our technical communication will be delivered in innovative and exciting ways with deliberation and accuracy that inspires loyalty and trust across the globe SRAM TechCom Vision Statement WORLD HEADQUARTERS ASIAN HEADQUARTERS SRAM LLC SRAM Taiwan SRAM Europe EUROPEAN HEADQUARTERS 1333 North Kingsbury 4th Flr No 1598 8 Chung Shan Road Paasboswego 14 16 Chicago Illinois 60642 Shen Kang Hsiang Taichung City 3862ZS Nijkerk USA Taiwan R O C The Netherlands
11. hment Grip the slide hammer and forcefully pull away from the slotted attachment to remove the bearing from the driver body 17 mm Slide Hammer Bearing Puller Driver Body Bearing Removal 12 Driver Body Bearing Installation NOTICE To prevent damage when pressing the bearings into the driver body hub make sure that the drift contacts both the inner and outer bearing races Apply a thin layer of SRAM Butter to the bearing bores SRAM Butter Install anew 6803 bearing into the inboard side of the driver body 6803 Bearing Z Slide the Wheels Manufacturing 6803 adapter onto the threaded rod of the Wheels Manufacturing Press 1 Sealed Bearing Press tool Insert the threaded rod of the bearing press through the inboard side of the driver body Slide the SRAM 6803 bearing press tool onto the threaded rod Thread the bearing press handle onto the threaded rod WWW Turn the threaded handle clockwise to press the bearing into the outboard bearing bore until it is hand tight Remove the bearing press tool NOTICE Do not overtighten the bearing SRAM 6803 Bearing Press tool Driver Body Bearing Installation 13 4 Insert the ID spacer tube Align the ID spacer tube with the inside race of the previously installed bearing ID spacer tube 5 Install anew 6803 bearing into the outboard side of the driver body SRAM 6803 Bearing press tool Slide a Wheels Manufacturing 6803 bearing press tool onto the thr
12. lotted attachment through the non drive side bearing Align the slotted attachment with the bottom of the bearing and tighten the slotted attachment to expand the puller inside the bearing NOTICE Do not over tighten the slotted attachment Over tightening the bearing puller can damage the hub shell or bearing For more detailed assembly and usage see your bearing puller s manufacturer s instructions 17 mm Slide Hammer Bearing Puller Thread the rod of the bearing puller into the attachment Grip the slide hammer and forcefully pull away from the slotted attachment to remove the bearing from the hub shell 6 Remove the bearing from the slide hammer bearing puller 17 mm Slide Hammer Bearing Puller Rear Hub Bearing Removal 8 Remove the bearing spacer tube EJ Repeat steps 6 and 7 to remove the drive side bearing Rear Hub Bearing Removal 9 Driver Body Bearing Removal Use your fingers or a pick to carefully remove the pawls and leaf springs Inspect the pawls and leaf springs for signs of damage or wear NOTICE If any of the pawls or leaf springs exhibit signs of damage or wear replace all of them Otherwise remove any grease on the pawls and leaf springs with a clean rag Use a lint free rag to clean the driver body and pawl slots Remove any grease on the driver body seal with a clean rag Inspect the driver body seal for signs of damage or wear If there are any signs of damage or wear repla
13. nsequential damages LIMITATIONS OF WARRANTY This warranty does not apply to products that have been incorrectly installed and or adjusted according to the respective SRAM user manual The SRAM user manuals can be found online at sram com rockshox com avidbike com truvativ com or Zipp com This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturers specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design This warranty does not apply when the product has been modified including but not limited to any attempt to open or repair any electronic and electronic related components including the motor controller battery packs wiring harnesses switches and chargers This warranty does not apply when the serial number or production code has been deliberately altered defaced or removed This warranty does not apply to normal wear and tear Wear and tear parts are subject to damage as a result of normal use failure to service according to SRAM recommendations and or riding or installation in conditions or applications other than recommended Wear and tear parts are identified as e Dust seals e Stripped threads bolts aluminium Handlebar grips e Transmission gears e Bushings titanium magnesium or steel e Shifter grips e Spokes Air sealing o rings e Brake sleeves e Jockey wheels e Free hubs
14. sher Driver body Driver body pawls Driver body leaf springs For part numbers please refer to the Zipp Spare Parts Catalog in the Support section of www zipp com SAFETY INSTRUCTIONS Always wear nitrile gloves when working with bicycle grease Rear Hub Service 5 Rear Hub Exploded View ae shield a Bearing z hub Vom K i tube oo Bearing es Bearing A washer m k gt Diameter Spacer k 7 Axle z Dust Shield 6803 Bearing Cap nut Driver body seal Driver body Rear Hub Exploded View 6 Rear Hub Bearing Removal Insert a 5 mm hex wrench into the axle while holding the non drive side cap nut with a 20 mm hex bit socket and socket wrench Hold the socket wrench in place and use the hex wrench to turn the non drive side cap nut counter clockwise to remove it 2 Use your fingers to remove the driver body assembly from the hub shell Remove the axle by hand from the driver body A flat washer rests on the bearing located on the side of the driver body with the pawls and leaf springs If this washer falls off when you remove the axle set it aside until you are ready for assembly Use your finger to remove the bearing shield from the non drive side of the hub K D a L k 2 A T K a Q 5 mm Hex 20 mm hex bit Rear Hub Bearing Removal 7 5 Insert the 17 mm Slide Hammer Bearing Puller s
15. t Z Clamp the axle into the Park Tool AV 5 Axle and Spindle Vise Use a 5 mm hex wrench to unthread and remove the end cap NOTICE Do not damage the axle threads va gt gt gt ny as AV 5 Axle and Spindle Vise 4 Insert the 17 mm Slide Hammer Bearing Puller slotted attachment through the outboard bearing Align the slotted attachment with the bottom of the bearing and tighten the slotted attachment to expand the puller inside the bearing NOTICE Do not over tighten the slotted attachment For more detailed assembly and usage see your bearing puller s manufacturer s instructions 17 mm Slide Hammer Bearing Puller Front Hub Disassembly 20 5 Thread the shaft of the bearing puller into the attachment Forcefully pull back on the slide of the bearing puller to remove the bearing from the hub shell Remove the bearing from the slide hammer bearing puller Use a lint free rag to remove any existing grease a Slide Hammer Bearing Puller Front Hub Disassembly 21 Front Hub Assembly Apply a thin layer of SRAM Butter to the outside of each new bearing and each bearing bore 2 Install the drive side bearing first Insert a new 6803 bearing into the drive side bearing bore of the front hub Bearing 6803 Turn the threaded handle clockwise to press the bearing into the v hub until it is hand tight 1g re Q NOTICE NW SM Do not overtighten the bearing i
16. your hubs while the hub is still in the wheel However if your spokes or rim are damaged you can remove the hub from the wheel which will make servicing your hub easier Use a spoke wrench to detension the spokes and then use a pair of metal snips to cut the spokes remove the hub from the wheel and remove the spoke ends from the hub Tools Needed for Service Safety glasses Nitrile gloves Clean lint free rags 2 5 mm hex wrenches 5 mm hex bit socket Enduro Universal Blind Hole Bearing Puller Set Plastic mallet Torque wrench Replacement Parts 2 6803 Hub bearings Wheels Manufacturing Press 1 Sealed Bearing Press Kit 2 6803 Adapters from Press 1 Kit 2 17 mm Spacers from Press 1 Kit SRAM Butter Grease brush 17 mm slide hammer bearing puller Bench vise Axle and Spindle Vise Insert For part numbers please refer to the Zipp Spare Parts Catalog in the Support section of www zipp com SAFETY INSTRUCTIONS Always wear nitrile gloves when working with bicycle grease Front Hub Exploded View End cap 6803 Bearing Hub shell 6803 Bearing End cap Front Hub Service 19 Front Hub Disassembly Insert a 5 mm hex wrench into both end caps Hold one wrench in place while turning the other wrench counter clockwise to remove the end cap 2 Use a plastic mallet to gently tap exposed axle end to dislodge the bearing Remove the bearing and slide the axle out of the hub shell Plastic mallo
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