Big blue book of bicycle repair : a do-it-yourself bicycle repair guide from Park Tool

Updated with new information, techniques, photos, procedures, and components, the BBB-3 3rd Edition is a complete repair manual created to provide both the novice and veteran mechanic the information needed to perform nearly any repair from trailside repairs to complete overhauls. Written by Park Tool Director of Education, Calvin Jones, the Big Blue Book is the perfect reference guide and step-by-step repair manual for nearly any bike, including road, mountain, bmx, and single-speed. We wrote the book on bicycle repair. New information and topics included in the BBB 3rd Edition: Thru-axle systems Tubeless tire conversion systems 11-speed SRAM® XX1® freehub removal/installation BB30 crankset system PF30 bottom bracket system Specialized® S-Works® cranks Campagnolo® Power TorqueTM systems BB86 and BB92 bottom brackets 11-speed chains 11-speed Campagnolo® chain installation 11-speed derailleurs Shimano® Di2® electronic shifting Campagnolo® EPS® electronic shifting SRAM® Red® derailleur adjustments Shimano® 9000 derailleur adjustments SRAM® and Shimano® clutch type rear derailleurs Tektro® hydraulic brakes Headset standards and SHIS standards Updated torque tables Updated tool tables Table of contents......Page 5 Foreword......Page 11 Introduction......Page 12 1 Basic mechanical skills......Page 13 Threaded Fastener Tension & Torque......Page 14 Lubrication, ThreadLockers, & Cleaners......Page 16 Bearing Systems......Page 17 Repair Stands......Page 18 Home Shop Setup......Page 19 Maintenance Schedule......Page 20 2 Tires & tubes......Page 21 Wheel Removal......Page 22 Removal of Tire & Tube from Rim......Page 24 Hole on the Rim Strip Side of Tube......Page 25 Tire Inspection......Page 26 Inner Tube Repair with Self‐Vulcanizing Patches......Page 27 Tire Liners......Page 28 Inner Tube Valves......Page 29 Tire & Tube Sizing......Page 30 Installation of Tire & Tube on Wheel......Page 31 Wheel Installation......Page 32 Thru-Axle Systems......Page 35 Tubeless Systems......Page 36 Tubeless Conversion Systems......Page 37 Tubular Tires......Page 38 3 Rear sprockets......Page 41 Cassette Sprocket Removal & Installation......Page 42 Freewheel Sprocket Removal & Installation......Page 44 Sprocket Inspection & Cleaning......Page 46 Fixed Gear Sprockets......Page 47 4 Hubs......Page 48 Hub Bearing Service: Adjustable Cup‐and‐Cone Type......Page 49 Disassembly......Page 50 Assembly......Page 51 Hub Adjustment......Page 52 Hub Adjustment: Solid Axle Cup-and-cone......Page 53 Cartridge Bearing Hubs......Page 54 Mavic® Hub (Level 1 Type)......Page 55 5 Wheel truing......Page 58 Wheel Truing Overview......Page 59 Rim Centering (Dish)......Page 60 Truing Procedures......Page 61 Lateral Truing......Page 62 Wheel Centering (Dishing)......Page 63 Spoke Tension......Page 65 Broken & Damaged Spoke Replacement......Page 66 Wheel Wear, Damage, & Repair......Page 67 6 Pedals......Page 68 Pedal Installation......Page 69 Pedal Bearing Service......Page 70 7 Cranksets......Page 71 Crank Types......Page 72 Self-Extracting Crank Systems......Page 73 Three-Piece Cranks: Octalink®, ISIS Drive, Square Spindle, Power SplineTM, and Power DriveTM......Page 74 Two-Piece Compression Slotted Cranks: Shimano® and FSA®......Page 75 Two-Piece Self-Extracting Cranks: Truvativ®, SRAM® GXP®......Page 76 Campagnolo® and Fulcrum® Ultra-Torque® Cranks......Page 77 Campagnolo® Power TorqueTM Cranks......Page 78 Specialized® S-Works® Cranks......Page 79 BB90 and BB95......Page 80 Bottom Bracket Bearing Service for Non-Threaded Shells......Page 81 BB30 Bearings......Page 82 BB30 and PF30 Adaptors for non‐BB30 Cranks......Page 83 BB86, BB90, BB92, BB95 Bearings (Shimano® PF and GXP® PF)......Page 84 Campagnolo® Ultra-Torque® and Fulcrum® Bearings......Page 85 Campagnolo® BB30 Bearing Adaptors......Page 86 Bottom Bracket Bearing Service for Threaded Shells......Page 87 Threaded Cartridge Bottom Brackets: ISIS Drive, Octalink®, and Square Spindle......Page 89 Bottom Bracket Removal......Page 91 Bottom Bracket Adjustment......Page 92 Chainrings......Page 93 Chainring Wear and Damage......Page 94 8 Chains......Page 96 Chain Sizing for Derailleur Bikes......Page 97 Chain Removal......Page 99 Shimano® and FSA® Chains with Connecting Rivet......Page 100 Campagnolo® 10-Speed Chain......Page 101 Setting or Peening of 11-Speed Coupling Rivet......Page 102 Chain with Reusable Rivets......Page 103 Tight Link Repair......Page 104 Chain Tension: Two-Sprocket Bikes......Page 105 Tandem Crank Synchronizing......Page 106 Chain Wear and Damage......Page 107 Chain Lubrication......Page 108 9 Derailleur systems......Page 109 Cable System......Page 110 Cable Housing Length and Routing......Page 111 Shift Levers......Page 112 Flat Bar Trigger Shifters......Page 113 Above-the-Bar Shifters......Page 114 Drop Bar Integral Brake/Shift Levers......Page 115 Front Derailleur......Page 116 Height Adjustment......Page 118 Rotational Adjustment......Page 119 L-Limit Screw......Page 120 H-Limit screw......Page 121 Shimano® Front Derailleur FD-9000......Page 122 Shimano® FD-9000 Front Derailleur Adjustment......Page 123 Derailleur Capacity and Maximum Sprocket Size......Page 124 Limit Screw Adjustment......Page 125 L-Limit Screw......Page 126 Index Adjustment......Page 127 Chainline......Page 129 Derailleur Hanger Alignment & Repair......Page 130 Derailleur Wear & Service......Page 132 Shifters......Page 133 Di2® Battery......Page 134 Front Derailleur......Page 135 Rear Derailleur......Page 136 Campagnolo® EPS® Derailleurs: Super Record®, Record®, and Athena®......Page 137 EPS® Rear Derailleur Adjustment......Page 138 EPS® Front Derailleur Adjustment......Page 139 EPS® Derailleur Ride-Setting......Page 140 Troubleshooting......Page 141 10 Internal gear systems......Page 142 SRAM® DualDriveTM......Page 143 SRAM® I-Motion® 9......Page 144 Shimano® Nexus Inter-7®, Nexus Inter‐8®, & Alfine® Hubs......Page 145 11 Caliper disc brake systems......Page 147 Brake Pads......Page 148 Disc Brake Rotors......Page 149 Hydraulic Disc Calipers......Page 150 Hydraulic Brake Caliper Alignment......Page 151 Brake Pad Removal and Replacement......Page 152 Brake Bleeding......Page 153 Magura® Hydraulic Caliper Brakes......Page 154 Hayes® Hydraulic Caliper Brakes......Page 155 Avid® Hydraulic Caliper Brakes......Page 156 Tektro® Hydraulic Caliper Brakes......Page 159 Mechanical Disc Brake Systems......Page 160 Caliper Pad Alignment and Clearance......Page 161 Avid® Mechanical Disc Brakes......Page 162 12 Caliper rim brake systems......Page 165 Drop Bar Brake Levers......Page 166 Cable System......Page 167 Cable Housing Length......Page 168 Caliper Rim Brakes......Page 169 Brake Pad Alignment......Page 170 Pad Toe......Page 171 Linear-Pull Caliper Adjustment......Page 172 Cantilever Caliper Adjustment......Page 173 Dual-Pivot Caliper Adjustment......Page 176 Side-Pull Caliper Adjustment......Page 177 13 Handlebars, stems, saddles, & seatposts......Page 178 Bar Grips......Page 179 Clip-On and Aero Handlebars......Page 180 Quill Stems......Page 181 Threadless Stems......Page 182 Saddles......Page 183 Seatposts......Page 184 14 Headsets......Page 187 Headset Types......Page 188 Headset Service......Page 189 Threadless Headset Service......Page 190 Threaded Headset Service......Page 192 Threaded Headset Adjustment......Page 193 Pressed Headset Removal......Page 194 Pressed Headset Installation......Page 195 Fork Steering Column Sizing......Page 196 Threadless Steering Columns......Page 197 Star Nut and Compression Plug Installation......Page 198 Threaded Steering Columns......Page 199 15 Frame & fork......Page 200 Chain Stay......Page 201 Steel......Page 202 Carbon Fiber......Page 203 16 Suspension......Page 204 Air (Gas) Springs......Page 205 Suspension Linkages......Page 206 Tire Contact......Page 207 17 On-ride repair......Page 208 Chain Suck......Page 209 Crank Falling Off......Page 210 Bent Saddle or Seat Post......Page 211 18 Reference Materials......Page 212 A Tool List......Page 213 B Glossary......Page 215 C Torque Recommendations......Page 220 Torque Conversion Scale......Page 224 D Headset Standards......Page 225 E Bike Map......Page 226 A complete and concise manual for any mechanical procedure you choose to tackle when repairing your bicycle. Road or mountain, recumbent or kids bike, whatever you ride, this manual gives you a well-rounded look at its mechanics.