Technical Manual // Zakk
Contents
1. a year When used under extreme conditions heavy rain mud transport in the rain etc the free wheel should be serviced more often Regular maintenance of the hub helps to ensure a longer life and optimum running performance for years In the case of exposure to water under excessive pressure e g high pressure cleaners water may penetrate into the hub This may damage the hub Do not use any sol vents or detergents IMPORTANT e Before every use check the function of your rear wheel hub Make sure that the freewheel and enga gement connection function impeccably Should there be any mal function the rear wheel hub must not be used In such a case the problem must be repaired be fore use If you are not in a position to repair the hub contact a professional bike mechanic e We strongly recommend that you have your wheels built by an experienced specialist Proper wheel buil ding is the best way to ensure that your wheels will last and be problem free e New hubs have a higher rolling resistance than used hubs because the grease in the freewheel has not yet INSTRUCTIONS been evenly distributed and the seals have not yet been bedded in e Radial lacing on our hubs is not recommended as it may lead to impermissible deformations on the hub flange Flange breakage is not covered under the war ranty in this case e Disregarding these instructions will limit the func tion of the freewheel and can lead to injury or oth2. in the hub as it was before Now proceed similar to step 5 to push out the disc brake side bea ring using the hammer on the bolt Slide the bearing off the axle and remove the bolt Make sure you have removed the locking ring REMOVING AXLE AND BEARINGS gt gt gt WWW LAST BIKES COM STEP 1 We recommend to use new bearings whenever they have been removed Removing the bearings can da mage the bearings You may not notice the damage instantly but the life span will be short Better replace them now Insert the axle and slide on both bearings STEP 2 Use both bearing tools to set the bearings Close the vice until you feel the bearings bottoming out Over tightening will harm the axle Install the remaining parts according to the instruc tions given in the chapter installing the driver INSTALLING AXLE AND BEARINGS WWW LAST BIKES COM
3. 3 TECHNICAL MANUAL ZAKK PRODUCT VERSIONS V1 1 REVISION 3 gt gt gt WWW LAST BIKES COM Gast INSTRUCTIONS Please read the entire users quide and technical ma nual before using the hubs or before carrying out any kind of maintenance work This manual is intended for retailers with the appropri ate skills and knowledge It details the principle design features of the product and also provides instructions as to maintenance and repair work Please take special care to use only proper tools in order to undertake the work detailed in this manual In the event of improper servicing of the hubs the manufacturer has the right to refuse any warranty Due to continual improvements that are made to our products itis possible that the product you have recei ved differs slightly from the models described in this manual For the newest version of the service manual or for miscellaneous questions please consult the of ficial representative for the country in which you resi de or consult our website www last bikes com Please give special attention to the following notice which is listed under the title bellow CAUTION In the case of non compliance with these instructions the function of the product will be im paired which may lead to injuries with serious conse quences and the loss of the product warranty 23 MAINTENANCE OF THE HUBS Maintenance of the rear and front hubs must be carri ed out at least once
4. 4 000162 000202 000206 000205 000212 000213 000214 000215 000165 SPARE PART KITS Art No driver assembly 11 T gold Zakk V1 V1 1 000151 driver assembly 12 T gold Zakk V1 V1 1 000153 driver assembly 14 T gold Zakk V1 V1 1 000154 bolts 1 and cups 2 M10 black Zakk V1 V1 1 000166 All driver assemblies include driver 6 pawls 2 springs 2 dri ver bearings driver seal and locking ring gt gt gt WWW LAST BIKES COM 2 DIMENSIONS M10xP1 5 WWW LAST BIKES COM REQUIRED TOOLS 8 mm allen wrench grip shown or 24 mm spanner vice not shown or second grip 24 mm spanner spacer for disassemly Art No 000337 The grip must have flat parallel faces If you do not have the spacer for disassembly you may use a tube with 12 mm diameter 1 mm wall thickness and 10 mm length Do not use tubes with diameter greater than 12 mm STEP 1 Remove both bolts and install the spacer for disassem bly using one of the bolts on the driver side REMOVING THE DRIVER Clamp the disc side end cap of the hub using it s fla tened faces with the vice Tighten the bolt with up to 20 Nm gt gt gt WWW LAST BIKES COM STEP 3 Use the grip to turn the end cap counter clockwise Ty pically the end cap is tightened firmly When turning the end cap for removal
5. eased wear and improper function after a certain period of use or instantane ously INSTALLING THE DRIVER gt gt gt WWW LAST BIKES COM REQUIRED TOOLS 8 mm allen wrench grip shown or 24 mm spanner vice not shown or second grip 24 mm spanner plastic hammer grip for locking rings tool set for setting the bearings Art No 000338 eventually spacer for disassemly Art No 000337 The grip must have flat parallel faces If you do not have the spacer for disassembly you may use a tube with 12 mm diameter 1 mm wall thickness and 10 mm length Do not use tubes with diameter greater than 12 mm STEP 1 Remove the bolts and cups Clamp the driver side end cap with the vice using the end cap s flat faces Open the disc side end cap with the grip by turning it counter clockwise If you are lucky the disc brake side end cap will get loose In this case remove the end cap completely Proceed to step 4 If you re not lucky proceed with step 2 STEP 2 Tighten the end cap with 35 Nm To do so keep the hub clamped in the vice and use the grip Install the spacer for disassembly using one of the bolts on the disc brake side Clamp the driver side end cap of the hub using it s flatened faces with the vice Tighten the bolt with up to 20 Nm gt gt gt WWW LAST BIKES COM STEP 3 Use the grip to turn the end cap counter clockwise Ty pically the end cap is tightened firmly When turning the end cap
6. er severe consequences and the loss of the product warranty WARRANTY TERMS Please visit our website for the latest version of the warranty terms gt gt gt WWW LAST BIKES COM G aAsT INSTALLING THE WHEEL HUB For proper operation the wheel must be securely fixed with the bolts to the dropouts of the frame Therefore tighten the bolts with the given torque using a torque wrench CAUTION Excessively tightened bolts may cause the hub structure to be damaged REMARK If the wheels is moved by chain forces use a chainten sioner to avoid this Max 35 Nm TORQUE 23 INSTALLATION MAx 35 Nm TORQUE gt gt gt WWW LAST BIKES COM 1 2 3 4 5 6 7 7 8 9 DESCRIPTION bolt DIN 912 M10x30 12 9 Zakk V1 V1 1 cup for Mio bolt black Zakk V1 V1 1 end cap left black Zakk V1 1 locking ring Zakk V1 V2 bearing 6902 2RS driver left hub body Zakk V1 V2 dimensions 28 x 15 x 7mm axle Zakk V1 1 hub body with ratchet 32 hole bl Zakk V1 V1 1 hub body with ratchet 36 hole bl Zakk V1 V1 1 bearing 6002 2RS right body Zakk V1 V2 dimensions 32 x15 x9 mm spacer for axle Zakk V1 V1 1 spring Zakk V1 V2 pawl Zakk V1 V1 1 seal for driver Zakk V1 V1 1 driver only 11T gold Zakk V1 V1 1 driver only 12T gold Zakk V1 V1 1 driver only 14T gold Zakk V1 V1 1 end cap right black Zakk V1 1 1 Art No 000335 000336 000189 000200 000161 000190 000203 00020
7. for removal with the grip it is important that the reaction moment is split The reaction mo ment must be splitted onto the vice and the bolt allen key To achieve this press against the allen key while turning the end cap with the grip The force on the al len key must be smaller than the force on the grip The force on the allen key should be about half of the force you use on the grip The disc brake side end cap should get loose now If this is not the case try to push more against the allen key while turning the end cap Before doing so tighten the end caps again with 35 Nm STEP 4 In case you have a complete wheel sit down and place the wheel on you legs If you have a single hub use the vice Open it up sothe hub flange can be placed on the faces of the vice Do not clamp the hub To protect the disc brake flange surface place a cloth or rubber fabric between hub and vice Use the plastic hammer to push out the axle driver and bearing towards the drive side Do not use a metal hammer otherwise the threaded axle may get har med Make sure that axle and bearing have space to be pushed out STEP 5 Remove the locking ring on the disc brake side using a locking ring grip gt gt gt WWW LAST BIKES COM STEP 6 Clamp the axle on it s flat face using the vice Open the end cap turning counter clockwise Remove the end cap completely and slide driver spacer and bea ring off the axle STEP 7 Place the axle
8. with the grip it is important that the reaction moment is split The reaction mo ment must be splitted onto the vice and the bolt allen key To achieve this press against the allen key while turning the end cap with the grip The force on the al len key must be smaller than the force on the grip The force on the allen key should be about half of the force you use on the grip gt gt STEP 4 Remove the bolt and the tool while the hub stays clamped in the vice REMOVING THE DRIVER STEP 5 Remove the drive side end cap Pull the driver off the axle gt gt gt WWW LAST BIKES COM Make sure the straight tip A of the spring points clock wise when looking on the side of the freewheel which includes the pawls The orientation of the bent spring tip B can differ from the illustration on the right It is only important that the straight tip A is oriented clockwsie as described above and illustrated in the fi gure Use light grease on the freewheel mechanism Push the spacer and afterwards the driver on the axle When the driver does not move further rotate the dri ver counter clockwise against the hub and push gent ly This will allow the pawls to set into the ratchet of the hub Fit the drive side end cap and tighten it with 35 Nm Use light grease for the freewhell mechanism CAUTION The orientation of the spring is important for the performance of the free wheel system Wrong installation will lead to incr
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