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2003 Bontrager Service Manual
Recommended tools
Comp bearing press, front hub
Short bearing press
17mm cone wrench
Multi-purpose grease
Bench vise
Axle vise
Hammer, soft faced
Thin-bladed slot screwdriver
DISASSEMBLY
Hub parts and names are referenced on next page.
Disassemble the hub
1. Tap the axle (either end)
with the hammer until the axle
is flush with the surface of the
end cap.
2. Remove the opposite end
cap (Fig. 1K).
3. Tap the axle end without
the end cap with the hammer
(Fig. 2K) and remove the axle.
4. Slide the end cap, seal, and
bearing from the axle (Fig. 3K).
5. Re-insert the axle through
the hub and tap out the second
bearing.
Clean and inspect the parts
Thoroughly clean and
inspect all components with a
dry cloth. If cracks or any other
damage is visible, replace the
part.
ASSEMBLY
1. Place the Comp bearing
press on the workbench or other
solid surface. Push a new bear-
ing onto the axle, and push the
axle into the bearing press (Fig.
4K).
2. Place the hub over the
axle.
3. Place the second Comp
bearing press over the axle. Tap
the upper bearing press with the
hammer (Fig. 5K) to press the
bearing into the hub.
4. Remove the upper bearing
press.
5. Pull the axle out about
10mm (3/8in). Press the second
bearing over the axle (Fig. 6K).
6. Place the second bear-
ing press over the axle. Tap the
upper bearing press with the
hammer (Fig. 7K) to press the
second bearing into the hub.
Check the bearing installation be spinning the axle. It
should rotate freely without irregular friction.
7. Lightly grease the surface
of both bearings.
8. Pull the V-seal off the end
cap (Fig. 8K). Clean it thoroughly
with a cloth, lightly grease it,
and reinstall it on the end cap
with the open ‘V’ facing the hub.
9. Position the completed end cap over the axle, and
press into place with your fingers.
After completing assembly of the hub, check its function by spinning the axle with your fingers. It
should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is
eliminated when the wheel is installed with the quick release properly closed.
Comp front hub
Bontrager Race Modified, Race Modified Disc front wheel, 2003 Race Lite ATB, Race Lite ATB Disc front
wheel
Fig. 2K
Fig. 3K
Fig. 1K
End cap
Fig. 5K
Fig. 4K
Bearing
Bearing
press
Fig. 6K
Fig. 7K
Fig. 8K
End cap
V-seal