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2003 Bontrager Service Manual
Recommended tools
Long bearing press
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 freehub
1. Place the axle vise in the
bench vise and clamp the left-
hand end of the axle.
2. Pull sharply with your
fingers to remove the cassette,
with the freehub body attached
(Fig. 1I).
3. Remove the star ratchet,
spacer and spring (under the star
ratchet) from the hub (Fig. 2I).
4. Remove the second star
ratchet and second spring from
the freehub body.
Disassemble the ring nut
1. Clamp the spline tool into
a bench vise (Fig. 3I).
2. Push the right side axle
end into the cylinder. With the
splines engaged, turn the wheel
firmly in an anti-clockwise direc-
tion. The ring nut will be loos-
ened, and the seal between the
hub and freehub body will fall
over the spline tool onto the vise.
3. Thoroughly clean and
inspect all components, includ-
ing inside the hub, with a dry
cloth. If necessary, use a tooth-
brush. If cracks or any other
damage is visible, the parts must
be replaced.
Disassemble the bearings
1. From the right side, tap
the axle out of the hub with the
hammer (Fig. 4I). Remove the
axle from the hub.
2. Slide the left end cap, seal
and bearing off the axle.
3. Turn the axle around and
insert it into the left side of the hub until the axle collar
butts against the bearing. Tap the second bearing out
with the hammer.
4. Thoroughly clean and inspect all components with
a dry cloth. If cracks or any other damage is visible, the
parts must be replaced.
ASSEMBLY
Install the right hand bearing
1. Clamp the spline tool into
a vise.
2. Place the spacer over the
splines (Fig. 5I).
3. Place the bearing onto the
long end of the axle and push
the bearing onto the spline tool
(Fig. 6I).
4. Place the wheel over the
axle, drive side down. Push the
short bearing press over the
other end of the axle. Tap the
bearing into place with the ham-
mer (Fig. 7I).
Install the ring nut
1. Clamp the spline tool into
the vise with only the splines
above the jaws (Fig. 8I).
2. Inspect the ring nut for
cracks or damage. If damaged,
replace it.
3. Place the ring nut with the
recess uppermost over the splines
(Fig. 9I). Place the spacer ring flat
inside the ring nut.
4. Place the wheel, drive side
down, over the spline tool. Insert
the right axle end through the
spline tool. Carefully screw the
ring nut into the hub by turning
the wheel clockwise.
Install the freehub body seal
Important: When installing a new seal, only the right-hand
bearing should be in place. The left-hand bearing must not
be pressed in until after the seal has been installed.
1. Inspect the seal. If the seal
shows signs of wear or damage,
replace it.
2. Clamp the short bearing
press into a vise (Fig. 10I) and
place the wheel, drive side up,
over the tool.
3. Place the seal over the
freehub body seal installation tool
(Fig. 11I) with the ‘V’ facing the
hub.
4. With the seal on the tool,
push them together over the axle.
5. Place the long bearing
press over the axle.
6. Press the seal into the hub by tapping it with the
hammer.
Install the left hand bearing
1. Clamp the spline tool into the bench vise (Fig. 3I).
Pro rear hub
Bontrager Race Lite ATB, Race Lite 29, Race X Lite, Race X Lite Carbon rear wheels, Race Lite Aero
A running change to hubs was made in 2001; the newer hub has a part number embossed in the shell. See exploded dioagrams for differences
Fig. 1I
Fig. 3I
Fig. 6I
Fig. 4I
Bearing
Fig. 7I
Fig. 8I
Fig. 10I
Fig. 5I
Spacer
Fig. 9I
Ring nut
Spacer
Fig. 2I
Spacer
Star
ratchet