Wheel service manual
Contents
1. Cassette side cap nut 1 PC Non Cassette Cassette Cassette side cap nut 1 Aan side cap nut side cap nut 1 Disassem bly A Use the allen Key to hold the Axle D Use Wrench to hold the lock nut and the B Use the wrench to hold the lock nut Allen key to hold the axle apply the force C Apply force in different directions in order to the tools opposite directions to remove Wrench 17mm to take off the lock nut of the the lock nut off the side cap Cassette Side of non Cassette side Wrench 17mm Allen key 5mm Allen key 5mm ed 2 1 9 LUE ENESE Installation Instructions D After you take off the right and left Side cap you can take off the free hub body And Switch the freebody from shimano to be Campagnolo nsi Outs Wc 2 Assembly E Fasten the Campagnolo free hub body into the hub body Please add some grease before assembly using Pro Lite grease And make sure the seal in place Seal installment x Incorrect Correct F When screwing the side cap onto the Axle for cassette side please make sure you use Campagnolo type cap nut on non cassette side and new campagnolo cap nut on cassette side Campagnolo Bid sn Campagnolo Side cap 15 30 mm 16 60 mm Shimano Side cap Shimano Side cap 15 60 mm2. lf you puncture and need to change the tyre its best you carry a spare that has been used These will have traces of glue on them and then you can simply put the tyre on pump it and ride home Remember not to corner too hard and you will need to re glue a new tyre on later There is loads of good information on the internet with diagrams you can research as well and most tyre makers will have detailed instructions as well DONT use Fast Tack glue from 3m or any similar product we have seen tyres that are so well glued on with this stuff is shreds the carbon trying to get the tyre off If in doubt consult your local bike shop or tyre maker for advice on the best glue to use Many riders during the off season will take off the tyres and let the glue dry out be careful if you do this and decide to sand paper the hardened glue you will damage the carbon with sanding There are latex removers that are solvent free on the market that can be used We have found that TUFO tape works well but in 30 degrees it will become very sticky so carry a spare roll when you are out riding to replace the one on the rim if you puncture Check out WWW pro lite net for up to date information or email steve pro lite net for any technical questions you can t find an answer for here We build wheels the hard way BY HAND PRrRO LI ils e Spokes Replacement e Spoke Tensiometer e Spoke Tension e Spoke Database e Installation Instruction
3. md gt 9 1 1715 wwwy pro lte net On tubular rims also use our specific pad produced specifically for this rim don t let people tell you they use other pads without problems carbon rims might look the same but they are often very different and saving some small money on pads could wreck your rims We do NOT recommend Campagnolo brake pads These have a very low melting point and might melt excessively under heavy braking leaving a residue on the rim which is very difficult to clean For optimal performance Pro Lite carbon brake pads provide the ideal balance of feel and stopping power these will keep rims cool under braking Pro Lite brake pads are the only pads specific to all our rims we cannot be responsible for the effects of non Pro Lite pads used on our rims NOTE For cyclocross applications and cantilever brakes we recommend using Kool Stop black pads on our alloy carbon rims For up to date advice we do recommend contacting Martin Eadon at X Gear in the UK for the latest developments on pads BRAKE PADS for CLINCHER WHEELSETS We recommend using Pro Lite Carbon alloy rim brake pads with any of our aluminium braking surface right down to the Como clincher wheels Other brand standard brake pads will work but they do cause premature wear to the braking surface due to the use of abrasives such as aluminium oxide in the pads As discussed with our tubular rims we do not recommend using Campagnolo pads Goo
4. md a 19 WHEELSETS TECHNOLOGY GUIDE a d 9 ls Wheelset Technology Guide wwwy pro lte net Congratulations you have just purchased the best hand built wheels in the universe Pro Lite wheels represent more than 50 years of continuous experience by the founders of Pro Lite Our research and development department has over a hundred years of engineering experience ranging from fighter aircraft to building the largest heat treatment oven in the world You can be sure that unlike other wheels when you buy Pro Lite you are buying not just quality but years of experience both on and off the bike coupled with a dedication to quality that is un rivalled in the bicycle industry today The materials that go into to producing your wheels are very carefully selected from suppliers of materials to the military aerospace and space industries It s our job to make sure you get the best product money can buy At our factory each wheel is assembled by hand and we have no machines at all Certain brands claim they are selling you hand built wheels but actually they were assembled in a machine and then trued by hand because the machine cannot produce a high level wheel good enough to race on During the manufacture of your wheels the spoke tension on every spoke is checked six times before de stressing using DT Swiss spoke gauges These are not cheap items and ours are lucky to last two months before we replace them Every week they
5. Newton For Non Drive side Please ensure you adapt the DT gauge as per gauge instructions Right Side Non Drive Side Min 0 60 mm 900 Newton The different between Max value and Min 0 80 can t more than 0 20 mm 1100 Newton gt gt Spoke Tension GF zeeer Z Racing VVheelsets 77 00 Gavia Alloy Braccino Left Side Drive Side Freebody Min 0 30 mm Min 0 40 mm Measured value mm 900 Newton 1050 Newton By DT Tension Gauge Only Max 0 50 mm Max 0 60 mm 1200 Newton 1300 Newton Conversion of units 1 1 kg u m s2 1 Newton 10 N 1 kp 10 N 1 kgf 1 N 0 2248 Ibf For Non Drive side Please ensure you adapt the DT gauge as per gauge instructions Right Side ic NEU The different between Non Drive Side Max value and Min value can t more than 0 20 mm PRrRO LI ils SS Zee _L LZreiznzno Zoo Racing Wheelsets Stelivo Measured value mm By DT Tension Gauge Only Conversion of units 1 N 1 kg u m s2 1 Newton 10 N 1 kp 10 N 1 kof 1 N 0 2248 Ibf DT tleinis i o Como Left Side Drive Side Freebody Min 0 70 mm Min 0 80 mm 950 Newton 1100 Newton Max 0 90 mm Max 0 10 mm 1200 Newton 1400 Newton Right Side Non Drive Side Min 0 70 mm The different betwe
6. are re calibrated for precision Each wheel is inspected by no less than three people before the pass certificate is issued Our team of eight quality control managers are trained to do the things the hard way there is no short cut to perfection Please inspect and save all packing materials that came with your wheels If there is any damage to the packaging or to the wheels it is important to advise your dealer now Also make sure you register the warranty Your Pro Lite wheels are engineered designed and manufactured to aerospace specifications and tolerances and therefore require some special attention and care Basically we advise you not to try to adjust or replace any parts on the wheels that s why we have set up service centres and have trained mechanics who are authorised to service Pro Lite wheels Ask yourself this question would you let a local guy in his garage to pull out your kids teeth Or would you pay a dentist to do it You have invested your hard earned money in a set of Pro Lite wheels they will serve you well for many years to come as long as you have them serviced and repaired through the correct channels We build wheels the hard way BY HAND md gt 9 1 1715 a 2 QUICK RELEASE TENSION Your hubs are set to specific tensions in the front and rear This ensures the rolling resistance is far lower than other wheels When you tighten the quick release you exert a huge pres
7. deflection in mm Using the measured value you may establish the spoke tension in Newton N from the included charts and graph Correct spoke tension The tension of the spokes stipulates the load capacity of the wheel A wheel with an optimally high spoke tension is more stable than a wheel with lower spoke tension There is no reference value for spoke tension on wheels as the optimal spoke tension depends on the rim the spoke type and the number of spokes In addition to the load capacity a dished true and round wheel is achieved with the right spoke tension The result of a too low spoke tension is that under a maximum load some spokes may become loose the nipples may start to back out and you will have to re true the wheel continuously Too low spoke tension has a negative influence on the lifespan of the spokes because the low tension will cause the spokes to load and unload unevenly resulting in excess fatigue Conversion of units 1 N 1 kg u m s2 1 Newton 10 N 1 kp 10 N 1 kof 1 N 0 2248 Ibf Picture 1 Picture 2 24 21 Pei Spoke Tensiometer PRO LITE SOLUTION Adaption of DT gauge to read tension on PRO Lite Wheels Orginal DT Gauge n7 With PRO Lite Adaption 0 14 mm x 9 6 mm Id x 6 mm 0 oT tensio O ATTENTION To obtain the correct value of spoke tension from the DT gauge on non drive side spokes and Bolzano large flange hub You need to add a wash
8. l fF ft _ sit ft ft vot 7 ff ff _ rot LL ft ft ft ft ft ft ft l rot rot ft ft fer l1 iol 1 l1 l1 rol _ fT _ rol om fT lll roi pom iol rr fd iol Lo wA L1 o Lo ____ lel rol _ Pat ft ft dL Ll lll oof __ _ _ ft ff d JA ft ft _ oe LLL A _ LL asol JIA o T fF fF ft _ not A 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 spoke tension e co NO md 2 1 0 LUE ENESE pd Gavia Carbon Measured value mm By DT Tension Gauge Only Conversion of units 1 N 1 kg u m s2 1 Newton 10 N 1 kp 10 N 1 kof 1 N 0 2248 Ibf 72 Racing VVheelsets LC C TE ep vicenza Left Side Drive Side Freebody Min 0 60 mm Min 0 70 mm 900 Newton 1000 Newton Max 0 80 mm Max 0 90 mm 1100 Newton 1300
9. the spokes starting at number one and work around half a turn at a time to achieve the tension listed in the chart attached Do not try to tension too quickly as you will overload the spokes 16 Check tension on all spokes each full rotation of tensioning and mark on a chart the results Correct to even tension after each rotation until achieving full tension 17 It is also recommended that after each rotation of tension you take the wheel out of the jig and de stress the spokes We build wheels the hard way BY HAND i Q 3 3 We build wheels the hard way BY HAND 2d 2 1 Lei Spoke Tensiometer Handling use of the DT tensiometer Handling use of the DT tensiometer Before you use the DT tensiometer to perform a measurement the dial gauge has to be set to rest at the zero position You proceed as follows 1 Hold the tensiometer so that the compression spring 4 can press the lever arm 2 all the way to the stop 5 rest position 2 Make sure that the small pointer 3d of the mm graduation 3e is exactly on zero If this does not occur the dial gauge 3 has to be adjusted so that the small pointer 3d of the mm graduation is exactly on zero adjust the dial gauge 3 gently unlock the stop screw 6 with the included 2 5 mm hex wrench Once the dial gauge 3 is in the right position the stop screw 6 has to be tightened again Do not tighten the stop screw too
10. 5 074 S a2 ll LLL Lo LL bump E 8 _____ _ __ rot LLL LE dL as coi LL LL Ll Ld ter mm ___ Lo LL LLL 106 oe LLL Loam ft ___ ____ Lh LLL La ft _ _ _ 116 oot tA ___ ___ LL LL LL LLL d dl ll 120 ______ __ __ ___ __ _ __ 124 ve not ia ___ ___ _ Ll LLL Li ds 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 opoke tension N LUU LE Spoke Double Butted Aero 2 0 0 9 t 2 2 w Braccino Gavia Alloy 1 00 Pro Lite DB Aero 2 0 0 9 x 2 2 mm measured value 61 0 80 0 40 c UD c O Q Measured value mm 0 30 0 20 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 tension Spoke Aero 0 2 0 1 5 t 2 3 w Pro Lite Aero 2 01 5 x 2 3 mm measured value mm Z 2 e Measured value mm Pu Rosa Alloy 2 50 soot ff _ 2301 _ ff 2201
11. L the axle and turning opposite each other standard right hand threads 8 2 Unthread and remove the left hand 3 Slide the free hub body and hollow axle together out of the main hub shell LD 5 VV h Note sure to remove the inner shim which is located inside the free body 4 Losen the lock ring and Slide off the black spacer from hub shell Please keep the metal spacer on thread section of hub shell 5 Undo all parts from assembled track axle kit 6 Insert the Track slide axle into the road drive side of the hub 7 Reassembly the Track axle kit as following drawing 3 8 Keep the metal spacer between sprocket and hub shell 9 Tighten down the T type nut and fasten the anti slip lock nut R H D B acing Hu B I Hollow Axle for QR Hii Inner E acer Long Body Short Side cover ey Side Cover Spacer Lock Ring M10XP1 0 1 f N 7 Slid Axle 7 Anti slip Nut Metal T type nut iud Side Cover Nut Anti slip Nut Short Long T type nut q Cover Sprocket Sleeve Lock Ring PRO LI Ll Installation Instructions Installation Instructions Anti slip Nut Disassemble the rear hub by inserting a 5mm allen key in both side of the axle and turning opposite each other standard right hand threads Unthread and remove the left hand end cap Slide the free hub body and hollow axle together out of the m
12. Sretee Stelivo Braccino Switch Shimano free hub body to Campagnolo free hub body Need Following Campagnolo gt Allen key 5mm 2 side Cap Campagnolo Free hub body 1 PC Side Cap 1 PC Campagnolo Free hub body 1 Disassembly C After you take off the right and left Side cap A Use the allen Key to hold the Axle on both side you can take off the free hub body And Switch the freebody from Shimano to be Campagnolo B Apply force in different directions in order to take off the lock nut of the Cassette Side Allen key 5mm PRO de e E Th Allen key 5mm PFrO LiT l Installation Instructions 2 Assembly F When screwing the side cap onto the Axle for cassette side please make sure you use Campy type cap nut This one always come with spare freebody ipli Campagnolo Side cap 9 Shimano C Side cap Correct D Fasten the Campagnolo free hub body into the hub body Please add some grease before assembly using Pro Lite grease And make sure the seal is in place Seal installment Incorrect en UN FK Different Tighten the cap of non cassette side Campagnolo PRO Side cap Shimano un Side cap Installation Instructions Switch Shimano freebody to Campagnolo freebody 2 6 Luciano Need Following Campagnolo fee hub body gt Allen key 5mm 1 PC Wrench 17mm 1 PC Qe c p gt CAMPY Free hub body 1PC gt
13. Why do my hubs have play in them You might notice that your Pro Lite hubs feel as though there is some play in them while the bike has no rider on it This can often be felt by holding the front wheel in one hand and the handlebars in another and rocking toward each other to see if there is any play at the hubs This will disappear when the rider is on board the bike If the rider says you can hear the rim rub the brake blocks when climbing out of the saddle then the bearings need to be re set Our experience shows that this is due to someone not re setting the cones on the hubs correctly after taking them apart Remember if it is not broken don t try to fix it Rocking feeling on Bolzano hubs Although this condition is highly undesirable in any hub with angular contact or cup and cone bearings this is intentionally designed into our Bolzano design hub and bearings This eliminates any side loading of the bearings reducing both friction and rolling resistance In addition tightening the quick release the hub will not add any additional friction to the system you can t over tighten an angular contact bearing the same cannot be said for cup and cone hubs Our hubs are designed to ensure the lowest possible We build wheels the hard way BY HAND md gt 9 1 1715 a 2 rolling resistance and thus the fastest possible ride Although the play can feel disconcerting while tuning up your bi
14. ain hub shell Note Be sure to remove the inner shim which is located inside the free body Losen the lock ring and Slide off the black spacer from hub shell Please keep the metal spacer on thread section of hub shell Undo all parts from assembled track axle kit Insert the Track slide axle into the road drive side of the hub Reassembly the Track axle kit as following drawing 3 Keep the metal spacer between sprocket and hub shell Tighten down the T type nut and fasten the anti slip lock nut Track Hub T type nut Short Cover spacer Side Cover Anti slip Nut Long T type nut Spocket Sleeve Lock Ring 2 1 Hub Racing Hub PRO LUUIE ww pro lite ne PRO LITE Metal Inner Spacer Shim Free Long Alloy Body Side cover Spacer Lock Ring PRO LIVE www pro lite net MAMMA Hollow Axle for QR Short Side Cover 24 219 Linia E Installation Instructions Switch Shimano free hub body to Campagnolo free hub body Bolzano H u D Need Following 1 Washer gt Allen key 5mm 1 PC Wrench 17mm 1 PC Campagnolo Free hub body 1PC Campagnolo Free hub body Washer no B 1 PC E When you disassemble the non cassette side you will find there are 3 parts oleeve spacer and a side cap 1 Disassembl y D Use Wrench to hold the lock nut and the Allen key to hold the axle apply the force to the tools in
15. b Take awayff the washer no a from the axle ATTENTION Seal installment I Fasten the axle into hub body Free hub body Correct J Fasten the Campagnolo free aa hub body into the hub body Please add some grease before Washer a assembly using Pro Lite grease Location for Shimano free hub body And make sure the seal is in place Free hub body AXLE K After fastening the free hub body please put body as shown below Washer the washer b into the free hub Washer B will come with spare freebody together Location for Campagnolo free hub body LO ir le Washer b Cassette Side Cap CO Campagnolo Freebody Washer b Body ad a d 9 daing Installation Instructions When screwing the side cap onto the axle please make sure the washer b is in the right location the side cap on axle Cassette Side Cap Tighten the cap on the cassette side Fasten the sleeve for non cassette side ATTENTION For Campagnolo You don t need the Alloy spacer Just fasten the side cap directly after the sleeve Sleeve Alloy Spacer Side cap Finally use the tools to tighten both side caps Alloy Spacer Only for Shimnao Shimano C B Campagnolo KP i off the Alloy Spacer For Compagnolo Free hub bidy ATTENTION VQ Installation Instructions ad a d 9 daing g E Crecetare
16. d options include Kool Stop black We build wheels the hard way BY HAND ad gt 2 1 1715 wwy pro lte net CARE AND CLEANING Be very careful in what you put on your rims it is so easy to use the wrong cleaner and damage the epoxy resin and decals also We cannot be responsible for damage to your rims by using the wrong type of cleaner Soapy water is normally all you need anything solvent based will damage the rim There are cleaners on the market around the world that specifically say they will not damage the epoxy resin but always recommend you contact them to check they will work on carbon rims Removal of glue from your rim on tubular rims is something you must do very carefully It is not something you need to do on a regular basis as the build up of glue will help ensure when riding in very hot conditions you have all the grip you could need It also helps when changing a puncture to get you home if you have forgotten your rim tape with the spare tyre HUBS Pro Lite hubs are machined to amazingly high standards We are in an amazing position compared to other manufacturers we never get warranty issues with them Why You might ask Well the answer is simple Every hub on assembly if torque to a special tension unique to each of the hubs we use This means that while we are building them into wheels we apply a great deal of pressure to the flange This effectively stretches the hub and reduces the friction on the bearing su
17. e best tyres you can afford and pump them up hard Even on our test bikes we will fit cheap tyres that say 110 psi max pressure We always pump them up to 150 psi minimum without problems FITTING A TUBULAR ITS EASY AS TAKING A LEAK Don t let people tell you it s hard we are yet to find a clincher tyre that can be taken off and a new tube fitted any quicker than a tubular tyre being removed and replaced Why do so many European pro s ride tubular tyres Because they are faster than clinchers give better handling and are much easier for mechanics to change Despite what you might have heard gluing a tubular tyre onto a rim is not difficult With practice changing a flat tyre with a tubular is also fast and easy It s like learning to clean your teeth Gluing a tubular is a task best learned by watching an experienced person Just ask someone who uses them regularly a local bike shop and ask to watch one being fitted If you don t have access to the above try these simple guidelines For best results read the instructions below When fitting on to a new rim for the first time we recommend you support the wheel either in a vice or a wheel jig Apply a nice thin layer of glue and leave it for 20 minutes to cure Apply a second layer of glue and leave for 24 hours We build wheels the hard way BY HAND md gt 9 1 1715 a 2 If using rim tape apply the tape and leave for 3 4 hours to cure a li
18. en 950 Newton Max value and Min value Max 0 90 mm can t more than 0 20 mm 1200 Newton 24d 2 1 9 Lei Track VVheelsets Rosa Carbon O Front Rear Left Side Min 0 70 mm 950 Newton Drive Side Sprocket Min 0 70 mm 950 Newton Max 0 90 mm Max 0 90 mm 1200 Newton 1200 Newton Measured value mm By DT Tension Gauge Only Conversion of units B 1N21kgu m s2 1 Newton 10N 1 kp 10 N 1 kof 1 N 0 2248 Ibf Right Side Min 0 70 mm Non Drive Side Min 0 70 mm 950 Newton 950 Newton Max 0 90 mm Max 0 90 mm 1200 Newton 1200 Newton ad a 1 9 EE ii Ei Rosa Alloy Track VVheelsets oT tensio Measured value mm By DT Tension Gauge Only Conversion of units 1 N 1 kg u m s2 1 Newton 10 1 kp 10 N 1 kgf 1 N 0 2248 Ibf Left Side Min 1 30 mm 1030 Newton Max 1 50 mm 1270 Newton Drive Side Sprocket Min 1 30 mm 1030 Newton Max 1 50 mm 1270 Newton Right Side Min 1 30 mm 1030 Newton Max 1 50 mm 1270 Newton Non Drive Side Min 1 30 mm 1030 Newton Max 1 50 mm 1270 Newton PFO 7 Installation Instructions Installation Instructions 22 2 in 1 Hub 1 Disassemble the rear hub by inserting 5mm allen key in both side of 7 ECE L
19. er as shown 6 mm thick washer Is needed ad a 1 9 Fg Shape W Width T Thickness Spoke Tenstion Data foil Sde __ Shape DT Gauge Vale mm mm mm Lacing DT Gauge Value mm Tension N DT Gauge Value mm Tension N Aero 32 10 2X X 1 030 050 0 30 0 50 900 1200 3X 02 040 060 1050 1320 QD 20 10t 32w 23 09 2X 030050 hen 32 Road BRACCIANO 20 16 09U22w Aero 23 09 Radial 030 150 0 30050 900 1200 3x 020 40080 1050 1320 20 10t 32w Aero 32 10 20 15023 1030 1270 c r Spoke Aero 22 0 1 0 t 3 2 w Gavia carbon Vicenza Stelivo Luciano Como Rosa Carbon 2 50 Pro Lite Aero 2 40 Et 2 0 1 0x3 2mm Measured value soi tt tf ft ft ft ft tt lulu mm 2201 Lo ft ft 500 0 19 _ __ 227 M rol A olh LL LL LL ft ___ __ _ __ 800 0 56 _ __ __ LLL __ tf __ __ __ __ __ _ 850 0 61 o 1 50 __ _ LL LL w 065 _ __ 5 960 0 70 2 igi _ _ er __
20. g would you use cooking oil NO this is the same when it comes to rim tapes Pro Lite rim tapes are made to the very highest standards and will withstand over 250 PSI they also grip perfectly to the rim and will not move or curl up One of the biggest problems with clinchers is the pinch puncture usually caused by poor quality rim tapes If you need to remove the rim tape or replace it make sure you use pure alcohol to clean the rim first to ensure good adhesion and grip TYRE PRESSURE There is so much garbage talked about the ideal tyre pressure you can write a lifetimes reading on the subject The bottom line is what do the pro s do They get their tyres pumped up as hard as they can go Why So they use less energy to go as fast as possible Bear in mind they also get their tyres for free We build wheels the hard way BY HAND md gt 2 LJEEEENEI wwwy pro lte net Carbon clincher rims are subject to tyre pressure limits due to the fact they flex and over inflating them will increase the chance of it coming off the rim under heavy braking Not everyone can afford the tyres top pro s ride Don t let famous brand of wheels or tyres tell you that you might feel you are going fast but actually the vibration will wear you down and sap your energy This could only be written by people who have never actually raced as pro and had to pedal tens of thousands of kilometres to get a pay cheque each month SO we recommend you buy th
21. ke be assured that this play is eliminated as soon as you climb aboard your bike Valve extensions We produce valve extensions for all our rims and usually you can find these in the high end bike shops in your country A common complaint on deep section rims is that the rider reports a knocking sound This is usually the valve moving when the wheel rotates There are many solutions to this used by top mechanics all over the world Basically you need to put something like a thin layer of PTFE tape around the valve extension to eliminate the knocking We also recommend not buying tyres with short valves and try to use two valve extensions screwed together on 90 mm deep rims SPOKE TENSIONS Your wheels have been trued and checked by our professional wheel builders All this is done by hand and each wheel has the spoke tension checked 6 times before being de stressed and final tensioned We do not recommend self taught experts to play around with Pro Lite wheels Our service centres are set up to check and identify any work that needs to be done on your wheels The bicycle industry is full of self appointed experts or ex engineers We do not publish our spoke tensions for good reasons if building the perfect wheel was easy then everyone would be doing it authorised Pro Lite service engineers are taught how to replicate the wheel building process we have in our factory If you value your prize possessions then let a trained service engineer take care
22. of them All our spokes are tested before each production run For example let s say we are building 200 sets of Gavia 50 mm tubular wheels That means we need 8800 spokes So we will produce 900 spokes The extra spokes will be batch tested for strength We know that We build wheels the hard way BY HAND md a1 9 1 1715 wwoyvy pro lte net ACI DT and Sapim spokes all snap at around 120 kg of pressure Pro Lite spokes are designed to be loaded to 200 kg of pressure without any problems Certain brands claim that they have tested wheels with higher spoke tensions and it does nothing to improve the ride As we say in the North of England cobblers the reason they say this is because they can t produce wheels that stay together very long using the super high tensions Pro Lite use Also all Pro Lite nipples are soaked in oil for at least two weeks before being used in order to ensure they can withstand the huge pressure exerted on them and also to make sure they bed in when being built and the wheels stay true for thousands of kilometres Pro Lite has many years experience in building wheels for many famous brands The most commonly forgotten item when people ask us to build wheels for them is the rim tape The difference in price between a cheap rim tape and the most expensive is so small it just does not make sense to cut the corner If you had bought a new BMW and did not want to pay for the best motor oil when it came to servicin
23. opposite directions to remove the lock nut off the side cap of non Cassette side Use the allen Key to hold the Axle B Use the wrench to hold the lock nut C Apply force in different directions in order to take off the lock nut of the Cassette Side gt Wrench 17mm Wrench 17mm Allen key 5mm I PRO nuts Allen key 5mm E o Sleeve Alloy Spacer 4 Axle Side cap ed 2 1 0 LUE ENESE Installation Instructions F After you take off the right and left Side cap you can take off the free hub body and the axle Be careful you will find there is one washer fixed on the axle pd 5 LUY LS p Cassette Side Cap Washer no a SHIMANO Freebody Body G After completing the above step you should have all parts as listed po Cassette 4 x Side Cap Washer no a SHIMANO Freebody Body A Attention If you didn t find this washer Bolzano Free hub Please check your free hub body the washer should inside H Take away the washer no a from the axle Use this same washer and insert onto axle from the opposite side Washer no a Washer no a New Location Orginal Location Use this same washer and insert onto axle from the opposite side 01 Sleeve Alloy Spacer Side cap 24247210 LJIG Installation Instructions Bolzano Free hu
24. rface It is critical that the tension used to pre tension the wheel is applied exactly so that after building the reduced friction is correct but also there is no excess play in the hub and bearing surfaces If you decide to strip down your hubs ensure that a qualified mechanic re sets them exactly as before We recommend cleaning the hubs with hot soapy water and not trying to use spray type solvent based cleaners as all these do is break down the grease and damage the seals There are many types of cleaning brushes on the market and a little bit of imagination will let you choose the right one for the job Remember you are looking to clean around the nipples which should be periodically oiled the flange area again which needs to be periodically oiled and the freehub body Don t forget to clean the quick release and re oil it as well as the inside of the hollow axle We build wheels the hard way BY HAND md gt 9 1 1715 wwwy pro lte net Occasionally you might remove the cassette body from the hub and clean out the drive mechanism It is not necessary to remove the cassette for this operation but you can if you wish This mechanism is incredibly robust and well sealed but removing dirt that builds up is often helpful To disassemble the front or rear hub please follow the separate instructions available from the Pro Lite website Complete instructions for hub maintenance are posted on our website www Pro Lite com
25. s md gt 2 LJEEEENEI wwy pro lte net Spoke Replacement 1 Assuming you have a broken spoke on the rear drive side we will explain how to replace the broken spoke 2 Bear in mind that we do not encourage people who are not highly trained and familiar with wheel building to try this 3 If you have any doubt please organise to have your wheels repaired or serviced by the Pro Lite service centre in your country 4 Pro lite wheels are built using the finest Swedish stainless steel to produce the strongest spokes used to build wheels anywhere in the world o The tension is extremely high compared to other wheels and can only be attained by using the correct Pro Lite tools and a DT owiss spoke tension gauge 6 Using the attached drawing let s assume spoke number one is broken 7 Remove the wheel and the cassette and quick release system 8 Place the wheel in a wheel jig 9 Directly opposite spoke number 1 is spoke 14 De tension this by 1 turn only 10 Then detension spoke 15 and then spoke 13 by one turn only 11 Then repeat in the following order 16 12 17 11 18 10 19 9 20 8 21 7 22 6 23 5 24 4 3 2 12 Repeat the whole process until the spokes begin to feel loose enough to move by hand but not fully dis assembled from the nipple 13 Insert the new spoke and ensure the thread and nipple is well oiled first 14 Apply heavy grade oil to all the nipples and leave to soak for at least 10 minutes 15 Systematically start to tension
26. sure onto the bearings if over tightened As a rule of thumb we suggest you tighten the quick release so that it leaves small mark on your hand when tightening it The bearings are easily capable of handling the pressure you exert on them but we do know that you will slightly pre load the bearings if you over tighten the quick release You are also erasing the extra benefits you gain with the use of the EZO bearings inside the hubs Over tightening a quick release can also strip the threads rendering it useless and could also be dangerous if the threads strip whilst riding BRAKE PADS for Carbon rims Your carbon Pro Lite clincher rims are moulded with our Basalt patented braking surface http en wikipedia org wiki Basalt_fiber This means you have the only safe carbon clinchers in the world that you can inflate tyres to 10 bars 150 psi and still be safe When the brakes are applied the pads generate a huge amount of heat and this can vary a lot depending on the composition of the material used In 2006 we tested every available brake pad we could get our hands on We then rode down an 8km hill in Taichung with the brakes on at speeds up to 85kmh Each set of pads was ridden three times The results were simply amazing We destroyed over 60 rims in 3 days testing other supplier s pads So we are confident when we say don t use other pads use genuine Pro Lite pads we know why we are telling you this We build wheels the hard way BY HAND
27. tight as the measuring stud 3g of the dial gauge 3 can block in the clamping body 3f 1 Supporting arm 2 Lever arm 3 Dial gauge 3a Clock face 3b Main pointer 3c Setting ring 3d Pointer mm graduation 3e mm graduation 3f Clamping body 3g Measuring stud 3h Head to be lifted 4 Compression spring 5 Stop 6 Stop screw dial gauge 7 Groove and locking screw 8 Stud support fixed 9 Stud support moveable 10 Bearing Pivot 3 Make sure that the big pointer 3b on the clock face is exactly on zero If this is not the case the setting ring 3c has to be adjusted until the big pointer 3b is exactly on zero This zeroing out has to be realized before each measurement Normally step 2 can be left out 1 z Poe Spoke Tensiometer Now the tensiometer is ready for use Compress the lever arm 2 so that it touches the supporting arm 1 and clamp the spoke between the studs by lining the spoke up along the spoke line on the tensiometer picture 1 Release the lever arm 2 as showed on picture 2 Hold the tensiometer parallel to the hub axle It is very important with bladed spokes that you hold the tensiometer at a right angle to the spoke without twisting do not apply any additional torque Note that the middle stud support 9 10 pivot is fixed in the middle of the spoke With butted spokes the stud supports 8 9 must absolutely lie within the butted section and not in a transition The dial gauge 3 shows the
28. ttle Make sure you pre stretch the tyre Simply hook it over your foot and uses two hands and pull it hard towards you you will feel it stretch Work your way around the tyre twice Before fitting to the rim do this one more time If storing new tyres then try and get some old rims to pre stretch them onto and inflate them to about 40 psi to keep the shape You don t need to stretch the tyre so hard you will hear the fabric ripping work up to a good pressure and the tyre will become the right size for easy fitting Once ready to fit install with the valve first and work the tyre onto the rim in one direction back to the valve Once fitted you will find usually the valve is not straight simply pinch the tyre and lift it along working your way around the rim so that you end up with the valve at 90 degrees to the tyre Make sure the rim tape on the base of the tyre sits neat all the way round as this will be a good guide to making sure the tyre sits straight and runs straight Once fitted inflate to about 40 psi and adjust to make sure when you spin the wheel the tyre is running straight Adjust by pinching and re positioning Leave overnight before fully inflating When you come to change the tyre the process becomes easier as you have a base layer of glue to help you so a quick layer of glue and you can then fit your pre stretched tyre and away you go We build wheels the hard way BY HAND md gt 9 1 1715 wwwy pro lte net
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