SRAM Aluminum Road Wheel & Hub Service Manual
Contents
1. 19 REPLACEMENT enre ____ ____ ____ m 19 SRAM SSO AL GOLD AL RACE ____________ ____________ 19 DRAM 527 19 REAR modzzsmm ejcc AERE 20 FRONT CH 21 SAFETY FIRST We care about YOU Please always wear your safety glasses and protective gloves when servicing your wheels Protect yourself Wear your safety gear HOW TO USE THIS SERVICE GUIDE This service guide is sub divided into five independent service sections Rear Hub Service Hub Adjustment amp Verification Rear Hub Front Hub Service Hub Adjustment amp Verification Front Hub and Wheel Lacing amp Spoke Replacement While the Rear Hub Front Hub and Wheel Lacing sections can be completed independently or in tandem it is mandatory that you perform the steps detailed in the Hub Adjustment amp Verification sections for rear and front hubs upon completion of any service Improper preload adjustment caused by over tightening the hub end caps will permanently damage the hub bearing once ridden and will void the warranty You can service your hub while the hub is stil2. Hub bearings 14 15 DISASSEMBLY Use 2 mm hex wrench to loosen but not remove the set screw located on the non drive side end cap 2 Insert 5 mm hex wrench into both end caps Hold the drive side wrench in place and turn the non drive side end cap counter clockwise to remove it Remove the axle by hand from the hub shell 4 Use drift tool and a rubber or plastic mallet to firmly out one of the bearings Turn the hub shell over and repeat this process to remove the other bearing 16 ASSEMBLY TIPS amp TRICKS 00000 If you have a bearing press can simultaneously install both hub shell bearings by using the two Bearing Installation Tools Insert a new bearing into each end of the hub shell Place the large end of each Bearing Installation Tool against each of the bearings Use the bearing press to carefully seat both bearings against the shoulders inside the hub not pictured If you are installing the hub bearings one at a time place a clean rag between the hub shell and the work bench This will protect the finish of the hub shell from damage during the bearing installation process Place the hub shell on a stable flat surface Insert a new bearing into one side of the hub shell Place the small end of the Bearing Installation Tool against the bearing Use a rubber or plastic mallet to gently but firmly tap the bearing into place until it is seated ag
3. movement Control wheel roundnes by tightening loosening the drive side spokes Control wheel trueness by tightening loosening the non drive side spokes Use a bladed spoke adjustment tool to prevent the spokes from twisting during adjustment Continue tightening both drive side and non drive side spokes in 1 8 1 4 turn increments until the final tension has been acheived Refer to the spoke chart for recommended final tension measurements S27 AL Comp spoke nipple S30 AL Gold S30 AL Race S30 AL Sprint spoke nipple washer valve hole non drive side spoke lacing diagram 21 FRONT WHEEL LACING 1 Orient the wheel so that the serial number on the rim is facing up and the hub decal is facing up Insert the threaded end of spoke into the first hole to the left of the rim valve hole Install sooke washer with the curved face of the washer away from the hub S30 only Carefully thread a spoke nipple onto the spoke 1 2 turn Install sooke into one of the spoke slots of the hub flange S30 AL Gold Race Sprint thread the spoke into the rounded end of the spoke nipple so that the rounded end is toward the hub N Repeat this procedure for the remaining 8 spokes on this side of the wheel following the illustrated lacing pattern Carefully turn the wheel over Insert the threaded end of spoke into the first hole to the left of the rim valve hole Install a spoke wa
4. Wheels Spare Parts List in the Service section of www sram com Rear hub Driver body Washer Hub shell Hub bearings End cap DISASSEMBLY Use 2 mm hex wrench to loosen but not remove the set screw located on the non drive side end cap 2 Insert 5 mm hex wrench into both end caps Hold the drive side wrench in place and turn the non drive side end cap counter clockwise to remove it 3 Remove the cassette body assembly by hand from the hub shell Remove the axle by hand from the driver body There is a flat washer that 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 5 Use drift tool and rubber or plastic mallet to firmly out the drive side bearing Repeat this process to remove the non drive side bearing Use your fingers to remove the flat washer from the driver body 7 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 If any of the pawls or leaf springs exhibit signs of wear or damage replace all of them Otherwise remove any grease on the pawls and leaf springs with a clean rag Use your fingers to remove the external lip seal Inspect the external lip seal for signs of damage or wear If there are any signs of da
5. retains the end cap and helps to prevent unintentional adjustment Do not force or over tighten the set screw this could cause it to deform or strip the threads Before mounting your wheel on the bike you will need to verify that your hub is properly adjusted 3 Use your hands to check for a small but noticeable amount of axial side to side play in the end caps This axial play is necessary and correct when the wheel is not mounted on the bike 4 Mount your wheel onto the bike and secure the quick release according the manufacturer s instructions Securing the release provides the final preload to the hub bearings 18 5 Hold the bike so that the wheel is the ground Rotate and hold the wheel so that the valve stem is at 90 degrees Let go of the wheel The wheel should rotate freely If the wheel does not rotate freely the end caps are too tight Repeat the hub adjustment procedures until the wheel rotates freely Set the bike back on the ground Side load the rim back and forth with your hand and check for play at the rim There should not be any noticeable play If excessive play is observed the end caps are not tight enough Repeat the hub adjustment procedures and reduce the amount you loosen the non drive side end cap by small increments until the wheel still rotates freely and the rim does not have any noticeable play 19 WHEEL BUILD 8 SPOKE REPLACEMENT This portion of the service guid
6. 10 kgf 1030 N 98 N Meses o AL Gold 150 15 kgf 1471 N 147 N Drive side 10 AL 150 15 kgf 1471 N 147 AL Sprint 130 15 kgf 1275 147 AL Gold 85 15 kgf 833 147 Non drive side 10 1 cross AL 85 15 kgf 833 N 147 N AL Sprint 65 15 kgf 637 N 147 N SRAM S27 AL COMP Use Sapim CX replacement spokes with S27 AL Comp wheels Front Wheel Rear Wheel Spoke Count Spoke Length Lacing Pattern Final Spoke Tension bew 278 mm Radial 105 10 kgf 1030 N 98 N Mese O 9 Front Wheel gt a 4 20 REAR WHEEL LACING N Start on the drive side of the wheel Orient the wheel so that the serial number on the rim is facing down and the cassette driver body of the rear hub is facing up Insert the threaded end of spoke 0 into the first hole to the left of the rim valve hole Install a sooke washer with the curved face of the washer away from the hub S30 only Carefully thread a spoke nipple onto the spoke 1 2 turn Install the head of spoke into one of the spoke slots of the drive side hub flange I P o N 00 o S30 AL Gold Race Sprint thread the spoke into the rounded end of the spoke nipple so that the rounded end is toward the hub Repeat this procedure for the remaining 9 drive side spokes following the illustrated drive side lacing pattern Carefully turn the wheel over
7. SRAM Aluminum Road Wheel amp Hub Service Manual S50 AL Gold Race Sprint 527 AL Comp SRAM LLC WARRANTY EXTENT OF LIMITED WARRANTY 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 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 Cincluding provinces in Canada may a Preclude the disclaimers and limitations of this warranty 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 limita tions LIMITATIONS OF LIABILITY To the extent allowed by local l
8. ainst the shoulder inside the hub shell Turn the hub shell over and repeat this process to install the other new bearing Insert the axle through the hub shell assembly 3 Insert a 5 mm hex wrench into the drive side end cap Hold the wrench in place and gently thread the non drive side end cap by hand onto the axle until it bottoms out and stops turning To complete your hub service move onto the Wheel Lacing amp Spoke Replacement section if necessary then complete the mandatory Hub Adjustment and Verification Front Hub section 17 ADJUSTMENT 8 VERIFICATION FRONT HUB QYCAUTION Proper hub adjustment is the most critical adjustment you will need to make to your wheels It will allow you to achieve maximum efficiency and performance from the high precision bearings in your wheels Improper preload adjustment caused by over tightening the hub end caps will permanently damage the hub bearing once ridden and will void the warranty Make sure you have completed Step 3 of the Assembly procedures for Front Hubs prior to adjusting your hubs Align the O zero degree gradient mark on the non drive side end cap to a fixed point on the hub Hold the drive side end cap in place and loosen the non drive side end cap by rotating it counter clockwise to the 120 degree gradient mark 2 Use 2 mm hex wrench to tighten the end set screw until it bottoms out The set screw
9. aw except for the obligations specifically set forth in this warranty statement in no event shall SRAM or its third party supplies be liable for direct indirect special incidental or consequential damages LIMITATIONS OF WARRANTY This warranty does not apply to products that have been incorrectly installed and or adjusted according to the respective SRAM technical installation manual The SRAM installation manuals can be found online at www sram com www rockshox com www avidbike com www truvativ com or www zipp com This warranty does not apply to damage to the product caused by 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 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 Dust seals Brake sleeves Bottomout pads Bushings Brake pads Bearings Air sealing o rings Chains Bearing races Glide rings Sorocket
10. d Verification Rear Hub section 12 ADJUSTMENT amp VERIFICATION REAR HUB QYCAUTION Proper hub adjustment is the most critical adjustment you will need to make to your wheels It will allow you to achieve maximum efficiency and performance from the high precision bearings in your wheels Improper preload adjustment caused by over tightening the hub end caps will permanently damage the hub bearings once ridden and will void the warranty Make sure you have completed Step 11 of the Assembly procedures for Rear Hubs prior to adjusting your hubs Align the O zero degree gradient mark on the non drive side end cap to a fixed point on the hub Hold the drive side end cap in place and loosen the non drive side end cap by rotating it counter clockwise to the 120 degree gradient mark 2 Use 2 mm hex wrench to tighten the end set screw until it bottoms out The set screw retains the end cap and helps to prevent unintentional adjustment Do not force or over tighten the set screw this could cause it to deform or strip the threads Before mounting your wheel on the bike you will need to verify that your hub is properly adjusted 3 Use your hands to check for a small but noticeable amount of axial side to side play in the end caps This axial play is necessary and correct when the wheel is not mounted on the bike 4 Mount your wheel onto the bike and secure the quick releas
11. e according the manufacturer s instructions Securing the quick release provides the final preload to the hub bearings 15 5 Hold the bike so that the wheel is the ground Rotate and hold the wheel so that the valve stem is at 90 degrees Let go of the wheel The wheel should rotate freely If the wheel does not rotate freely the end caps are too tight Repeat the hub adjustment procedures until the wheel rotates freely Perform the hub adjustment verification without the cassette or chain installed they will interfere with the free rotation of the wheel Set the bike back on the ground Side load the rim back and forth with your hand and check for play at the rim There should not be any noticeable play If excessive play is observed the end caps are not tight enough Repeat the hub adjustment procedures and reduce the amount you loosen the non drive side end cap by small increments until the wheel still rotates freely and the rim does not have any noticeable play FRONT HUB SERVICE TOOLS NEEDED FOR SERVICE Safety glasses Grease Grease brush SRAM bearing installation tools see diagram Gloves 2 5 mm hex wrenches Drift tool Rubber or plastic mallet EN SRAM Bearing Installation Tools REPLACEMENT PARTS Hub bearings For part numbers please refer to the SRAM Wheels Spare Parts List in the Service section of www sram com Front Hub Hub shell End cap
12. e covers general wheel build and spoke replacement As there are many different methods for spoke tensioning the following information provides the final sooke tension you should achieve using your preferred method for spoke tensioning TOOLS NEEDED FOR SERVICE Safety glasses Spoke wrench Park Tool 5 15 for internal spoke nipples Loctite 577 Spoke wrench for 0127 3 23 mm external spoke nipples Bladed spoke adjustment tool ex Park Tool BSH 4 Tensiometer with tension conversion chart Truing stand Lightly coat the threads of the replacement spokes with Loctite 577 During the wheel build process pre stress the wheel by lightly squeezing pairs of spokes to ensure the spokes seat properly in both the hub and the rim SRAM wheels use both radial and 1 cross spoke lacing patterns For 1 cross lacing patterns the spokes that point rearward should be installed on the bottom so they sit against the hub shell The spokes that point forward should be install on the top 1 cross lacing pattern REPLACEMENT PARTS For part numbers please refer to the SRAM Wheels Spare Parts List in the Service section of www sram com SRAM 30 AL GOLD AL RACE amp AL SPRINT Use Sapim replacement spokes with 530 AL Gold and S30 AL Race wheels Use CX Sprint replacement spokes with S30 AL Sprint wheels Spoke Count Spoke Length Lacing Pattern Final Spoke Tension Radial 105
13. ered trademarks of others GEN OO00000003216 TABLE OF CONTENTS SRAM S30 AL GOLD RACE SPRINT 527 AL COMP nnmnnn nnmnnn 5 __________ __ ______________ 5 5424 4118 2512244 6 M 6 TOOLS NEEDED QU ellc 6 REPLACEMENT PART ce OVS FA SE dili e 7 Pr 5 h A E A A T AE E E E E N 9 HUB ADJUSTMENT amp VERIFICATION REAR 12 FRONT HUB SERVIC E qnn nnn n R M 14 TOE OR SERVIRE S itum eee eee EUM eer 14 BREPLESCBENMENT FART 14 8 15 ee Re ae ee eee 16 HUB ADJUSTMENT amp VERIFICATION FRONT 17 WHEEL BUILD SPORE 55
14. l in the wheel However if your spokes rim are damaged you can remove the from the wheel which will make servicing your hub easier Use a spoke 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 SRAM S30 AL GOLD RACE SPRINT amp S27 AL COMP HUB TECHNICAL DATA Hub Shell Material Black Diamond Ti carbide coating with gold white labels 530 AL Gold co Black Diamond Ti carbide coating with red white labels 530 AL Race Black anodized polished S30 AL Sprint Black anodized sandblasted S27 Comp Bearno 2RS ceramic cartridge bearing 2 front 4 rear S30 AL Gold 2RS cartridge bearing 2 front 4 rear S30 AL Race Sprint 530 AL Comp Axle Oversized Aluminum Freewheel Body Aluminum Freewheel pP Mechan m 3 pawls with 3 individual leaf springs M m SRAM and Shimano 8 9 and 10 speeds Compatibilty p p Lacing Front lacing radial Rear lacing radial DS x1 NDS Spoke Count Front 18 Rear 20 REAR HUB SERVICE TOOLS NEEDED FOR SERVICE Safety glasses Grease Grease brush SRAM bearing installation tools see diagram Gloves 2 5 mm hex wrenches Drift tool Rubber or plastic mallet SRAM Bearing Installation Tools REPLACEMENT PARTS Hub bearings Driver body leaf springs Driver body Driver body seal Driver body pawls For part numbers please refer to the SRAM
15. mage or wear replace it Otherwise remove any grease on the external lip seal with a clean rag ASSEMBLY Press the external lip seal with the smooth side facing the driver body over the leaf spring and pawl carrier The external lip seal must be fully seated against the thin shoulder of the driver body 2 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 3 Insert the pawls into the pawl slots You may need use a pick 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 Apply a light coat of grease to the leaf springs and pawls 10 Insert the axle through the driver body Slide the flat washer over the axle until it rests on the leaf spring and pawl carrier If you have a bearing press you can simultaneously install both hub shell bearings by using the two Bearing Installation Tools Insert a new bearing into each end of the hub shell Place the large end of each Bearing Installation Tool against each of the bearings Use the bearing press to carefully seat both bearings against the shoulders inside the hub not pictured If you are installing the hub bearings one at a time place a clean rag between the hub shell and the work bench This will protect
16. s Pawls Rubber moving parts Cassettes Transmission gears rings Shifter and brake cables Spokes shock mounting and outer Free hubs hardware and main seals Handlebar grips Aero bar pads Upper tubes stanchions Shifter grips Corrosion Stripped threads bolts Jockey wheels Tools Caluminium titanium Disc brake rotors magnesium or steel Wheel braking surfaces 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 SRAM wheels carbon and AL have a 100 kg 220 lbs rider weight limit Copyright SRAM LLC 2010 This document includes trademarks and registered trademarks of SRAM LLC designated by the symbols and respectively For exploded diagram and part number information please refer to the Spare Parts Catalog available on our website at www sram com For order information please contact your local SRAM distributor or dealer Information contained in this document is subject to change at any time without prior notice Your product s appearance may differ from the pictures diagrams contained in this document Product names used in this document may be trademarks or regist
17. sher S30 only Carefully thread a spoke nipple onto the spoke 1 2 turn Install spoke into the hub flange spoke slot closest to the 12 o clock position e 9 Repeat this procedure for the remaining 9 spokes Refer to the spoke lacing diagram for the proper spoke installation pattern NI Install the wheel into a truing stand Use a spoke wrench to turn each of the spokes in 1 2 turn increments to increase spoke tension Continually check for roundness vertical movement and trueness side to side movement 00 Continue tightening both drive side and non drive side spokes in 1 8 1 4 turn increments until the final tension has been acheived Refer to the spoke chart for recommended final tension measurements 527 AL Comp spoke nipple 530 AL Gold 530 AL Race 550 AL Sprint spoke nipple valve hole radial lacing pattern www sram com GEN OO00000003216
18. so that the cassette driver body is facing down Insert the threaded end of spoke into the second hole to the right of the rim valve hole Install a sooke washer S30 only Install a sooke washer S30 only Carefully thread a spoke nipple onto the spoke 1 2 turn Install sooke into the hub flange spoke slot closest to the 3 o clock position that angles toward the valve hole Insert the threaded end of spoke 2 into the fourth hole to the right of the rim valve hole Carefully thread a spoke nipple onto the spoke 1 2 turn Install spoke 2 into the hub flange spoke slot closest to the 12 o clock position that angles to the right Repeat this procedure for the remaining 8 non drive side spokes Refer to the spoke lacing diagram for the proper spoke installation pattern Use a spoke wrench to turn each of the the drive side spokes in 1 2 turn increments until the drive side spoke tension is at approximately 30 40 of the final value S30 AL Gold 45 60 kgf 441 588 N S30 AL Race 45 60 kgf 441 588 N S30 AL Sprint 39 52 kgf 382 510 N S27 AL Comp 39 52 kgf 382 510 N Install the wheel into a truing stand and check for roundness Tighten or loosen the drive side spokes until the wheel is round Install the wheel into a truing stand Use a spoke wrench to turn each of the spokes in 1 2 turn increments to increase non drive side spoke tension Continually check for roundness vertical movement and trueness side to side
19. the finish of the hub shell from damage during the bearing installation process 7 Place the hub shell drive side down on a stable flat surface Insert a new bearing into the non drive side hub shell Place the large end of the Bearing Installation Tool against the bearing Use a rubber or plastic mallet to gently but firmly tap the bearing into place until it is seated against the shoulder inside the hub shell Install the non drive side bearing first 11 Turn the hub shell over so that the non drive side is down Insert a new bearing into the drive side hub shell Place the large end of the Bearing Installation Tool against the bearing Use a rubber or plastic mallet to gently but firmly tap the bearing into place until it is seated against the shoulder inside the hub shell Evenly apply a small amount of grease approximately 1 gram or an amount roughly the size of a pea to the driver body rachet ring Insert the cassette body assembly through the drive side of the hub shell Use your fingers to compress the pawls in order to fully seat and engage the pawls with the driver body ratchet ring Insert a 5 mm hex wrench into the drive side end cap Hold the wrench in place and gently thread the non drive side end cap by hand onto the axle until it bottoms out and stops turning To complete your hub service move onto the Wheel Lacing amp Spoke Replacement section if necessary then complete the mandatory Hub Adjustment an
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