2003

TECHNICAL MANUAL
GEAR HUB SYSTEMS

ENGLISH
 This Technical Manual is
intended for bicycle factories
and qualified bicycles dealers
only!

© Copyright SRAM Corporation 2002

Publ. No. 8034 E
Information may be enhanced
without prior notice.
Released August 2002
SRAM Technical Documentation,
Schweinfurt/Germany

EXA-Drive is a trademark of Campagnolo S.R.L., Italia.

Grilon is a trademark of EMS-Chemie AG, Switzerland.
MAGURA is a trademark of MAGURA GmbH & Co., Germany
HAYES is a trademark of der HAYES BRAKE Inc., U.S.A.
Dacromet is a tradename of Metal Coatings International, U.S.A.
Shimano, HG, IG is a trademark of Shimano Inc., Japan.
CONTENTS
GEAR HUB SYSTEMS

GEAR HUBS AND SHIFTERS

DualDrive 3

Spectro S7 13

Spectro P5 21

CARGO
Spectro P5 Cargo 29

Spectro T3 37

Sparc 45

SPECTRO SYSTEM COMPONENTS

Front Hubs with Drum Brake 53

Two-Axis Brake Levers 56

SmartBar 59

Power Chain 70

SUPPORT

Distributors 78

✆ Who to call / Warranty / Spare Parts 80

Technical Manual 2003 1

2 Technical Manual 2003
 DUALDRIVE
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

• Expanded gear range

• Efficient design
• Stand-still shifting (mode selector)
• Single chainring design
• Sealed system
• Easy wheel removal
• ESP 1:1 actuation ratio technology 182.6
• Improved material use 135
• Outward facing limit screws 67.5
• Low system weight 44.5 4.6
Chainline

33 18 67

Caution:
Not suitable for tandems, trademen’s
delivery bicycles and similar.

Cycle frame:
The strength must be such that with a maxi-
mum braking torque of 250 Nm (2200 in.lbs.)
on the rear wheel no residual deformation
can occur on the rear structure.

DualDrive 27/24 · without brake DualDrive 27/24 · disc brake compatible

Part No.
Brake
—
None
❘ — — ❘—
Interface for Disc brakes
Over Locknut Dim. 135 mm 135 mm
Length 182.6 mm 182,6 mm
Axle

Ends Diameter FG 10.5 FG 10.5

Holes
Hole Diameter
36
2.6 mm
❘ 32 36
2.6 mm
❘ 32
Spoke

Hole Ref. ø 67 mm 67 mm
Flange Dist. to 1/2 OLD 33 mm / 18 mm 33 mm / 18 mm
Totally 576 % (27spd) / 542 % (24spd) ➔
H Totally hub 186 % ➔
U
Ratio

Speed 1 73 % ➔
B Speed 2 100 % ➔
S Speed 3 136 % ➔
Chainline 45 mm 45 mm
Crankset 33 / 38 Teeth ➔
Cogset 9 / 8 Speed, 11-34/32 Teeth ➔
Cogset Compatib. DualDrive 27 / DualDrive 24 ➔
Shifter Compatib. DualDrive 27 / DualDrive 24 ➔
Sealing Extra sealed ➔
Tandem compatib. — —
Disc compatib. — SRAM / Magura / Hayes / Shimano
Weight 970 g 970 g
Hub Shell Aluminum Aluminum
Finish

Shifting device Composite Composite

Technical Manual 2003 3

DUALDRIVE
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

DualDrive 27 DualDrive 24 NEW

NEW
D Speeds 9 8
E Shifter Compatibility DualDrive 27 DualDrive 24

R Cage Length Short, 75 mm Short, 75 mm

Sprocket, max. 34 Teeth 32 Teeth
A Sprocket, min. 11 Teeth 11 Teeth
I Pulleys Exchangeable / Bushing Exchangeable / Bushing

L Direct Mount ● ●
Weight 260 g 220 g
L Upper Knuckle Aluminum Grilon Composite silver
E Lower Knuckle Grilon Composite silver Grilon Composite silver

U Outer Link Aluminum Grilon Composite silver

Design

Inner Link Steel / Zinc coat Steel / Zinc coat

R Outer Cage Forged Aluminum Grilon Composite black
S Inner Cage Grilon Composite black Grilon Composite black
Hanger Bolt Aluminum Steel

DualDrive 27 DualDrive 24
Part No. — —
Largest Cog 34 Teeth 32 Teeth
C Speeds 9 8
A Cogs 11/12/14/16/18/21/24/28/34 11/12/14/16/18/21/26/32

S Spacers Blue Black

Chain compatib. 9spd, HG/IG/PG II comp. 8spd, HG/IG/PG II comp.
S
. Weight 320 g 270 g
Cogs SAPH 440 steel ➔
Design

Screws Steel / Zinc Coat ➔

Finish Matte Nickel Plated Chrome

DualDrive 27 DualDrive 24
Part No. —
❘ 1500 mm ❘ 1600 mm ❘ 1700 mm ❘ 2100 mm
— — — — —
❘ 1500
—
❘— ❘— ❘—
Clickbox Cable
Shifter Type
1400 mm
❘ ❘ ❘
SRS Twistring-Thumbshifter-Combo (2in1)
❘ 1400 mm
❘ ❘ ❘
SRS Twistring-Thumbshifter-Combo (2in1)
❘
mm 1600 mm 1700 mm 2100 mm

Arrangement Handlebar, right Handlebar, right

S Gear Hub DualDrive DualDrive

Com-
pat.

Derailleur DualDrive 9spd DualDrive 8spd

H Gear Indication Der. Window Printed
I Riding Mode Indic. Printed Printed
F Barrel Adj. Gear Hub None None
Barrel Adj. Derailleur Indexing Indexing
T Clamping Diameter 22.3 mm 22.3 mm
E Handlebar, Straight Area Minimum length for shifter = 150 mm Minimum length for shifter = 150 mm
R Cable Routing, Gear Hub Continuous housing (preassembled) Continuous housing (preassembled)
Cable Routing, Der. Open or continuous Open or continuous
S Weight N/A N/A
Cables Stainless steel Stainless steel
Housing Glass filled PA – Silver painted Glass filled PA – Silver painted
Design

Grip Cover Thermoplastic elastomer, Overmolded Thermoplastic elastomer, Overmolded

Clamping Collar Aluminum Aluminum
Clickbox Composite Composite

4 Technical Manual 2003

DUALDRIVE
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

Cable routing
1 DualDrive 27 DualDrive 24
Hub cable Along chainstay only Along chainstay only
1 Derailleur cable Along chainstay only Along chainstay only

3
Cable attachement
see Fig. 1 Cable housing Attachement points Cable stops
5 4 Hub Continuous 1 / 2 / 3 / 4 (see Fig. 1) —
Derailleur Continuous 1 / 2 / 3 / 4 / 5 (see Fig. 1) —
Open — 1 /5 (Fig. 1)

2 CABLE HOUSING FOR DERAILLEUR

Rear cable stop position Rear housing length (only DualDrive 27)

200

180

160

140

120

L (mm)
X
R2 L
100
90 100 110 120 130
X (mm)
R1 90˚ Length X min. 90 mm. Example: Distance X = 100 mm ➔ cable
A X Cable stop below or beside chainstay. housing length L = 140 – 165 mm.

CABLE HOUSING Recommended cranks:

3 15
• Use only new high quality cable and Cyclone:
• DualDrive crank for chainguard, 33 T, Part
com-pressionless cable housing with
end caps. No. CPI-104 (chain guide fork necessary).
• When choosing cable housing lengths, • DualDrive crank for Trekking, 33 T,
14 be sure to allow enough housing for an Part No. CY-100W.
• DualDrive crank for MTB, 33 T,
60

extreme turn of the handlebars in both

13 directions. Part No. CF-100W.
45
32

• Note also, that different stem lengths Truvativ:

25

and cable stop positions effects cable • CR-02-XF-SS or CR-02-XF-SSA

housing length.
DualDrive crank supplier:
DROPOUT Cyclone Precision Inc.
Only flat and no off-set versions. P.O. Box 3-41 · Nantou 540 · Taiwan
Dropout thickness: 7 – 8 mm. Tel.: +886-49-257-829 · Fax: +886-49-257-832
Vertical or horizontal dropout slot. eMail: [email protected]
Dropouts must be parallel. http://www.cpi-cw.com
or Truvativ · http://www.truvativ.com
4 Dropout dimensions: see Fig. 2 and 3.
L X A R1 R2 CHAIN GUIDE FORK
28 6–10 25˚–30˚ 8.5 max 11.5 –13.5 It prevents chain from jumping off front
30 7.5 –10 25˚–30˚ 8.5 max 11.5 –13.5 chainring, is bolted inside the chain
case (1, Fig. 4).
CRANKSET HANDLEBAR
Bicycle without chain case:
Diameter: 22.3 mm.
1 Use a chain guard disc (at the outer
Minimum length of straight area for shifter:
surface of chainring, material no resin)
dA max. 220 mm 150 mm.
Use only standard chainring version (non-
Check the compatibility of intended
shifting teeth).
handlebars and brake levers.
Chainline = 45 mm.

Technical Manual 2003 5

DUALDRIVE
ASSEMBLY

A S S E M B LY H U B A S S E M B LY S H I F T E R
1 1 2 • Lace the wheel as normal. • Slide the shifter (1, Fig. 6) onto the
3 • Place spoke protector disc (1, Fig. 1) on handlebar.
shoulder of hub, fit cassette (2) onto • Rotate the shifter until the barrel
driver profile. Screw lock nut (3) with adjuster (4) is beneath (but out of the
cassette tool (Park Tool FR-5 or SRAM way of) the brake lever.
Part No. 4624 411 010), tightening torque: • Tighten the 3 mm hex clamp bolt (2) to
40 Nm (350 in.lbs.). 1.9 Nm (17 in.lbs.).
• Screw shifting rod (1, Fig. 2) into the hub • Slide the handlebar grip (3) onto the
axle and tighten it with 0.2 Nm (1.8 in.lbs.). handlebar.
• Fit wheel in dropouts.
2 • Place retaining washers (Fig. 2) on both Caution:
sides of the axle – the serrations must • Never use lubricants or solvents to
bear against the dropout. install handlebar grips.
– Version for horizontal dropouts (2): the Handlebar grips provide an axial safety
lug must engage in the dropout slot. function. For this reason, they should be
– Version for vertical dropouts (3): mounted in such a way as to make sure
2
without lug. they do not slip off handlebar.
• Tighten up axle nuts. Tightening • Check that the shifter and brake lever
1 torque 30 – 40 Nm (266 – 350 in.lbs.). function properly and are unobstructed
3 0,2 Nm (realign if necessary).
1,8 in.lbs.
• Never ride without the handlebar grips
A S S E M B LY D E R A I L L E U R this can result in severe injury or death.
3 Advice:
Check the rear derailleur hanger
alignment. A bent rear derailleur hanger INSTALLING CLICKBOX
will result in inaccurate index shifting. • Fit the cable and avoid small radius.
• Attach the rear derailleur to the frame’s • Cable attachment points see Page 5 /
5 mm rear derailleur hanger using a 5 mm hex Fig. 1.
8 – 10 Nm head wrench (Fig. 3). Cable housing must be movable inside
70 – 85 in.lbs. • Check that the b-adjust washer tab attachment.
(b-adjust screw at DualDrive 24) is clear • Place shift lever in uphill riding mode /
of the rear derailleur dropout tab (Fig. 4). gear position “1“ (Fig. 7).
• Tighten the 5 mm hex hanger bolt to • Push Clickbox button down (Fig. 7).
8 – 10 Nm (70 – 85 in.lbs.). • Push on Clickbox to the stop on the hub
axle.
• Press button up.
CHAIN LENGTH • Place thumb shift lever in standard
• Bypassing the rear derailleur, run the
4 chain around the largest cog/chainring
riding mode / gear position “2“ (Fig. 8).
• Match up the marks in the Clickbox
combination (Fig. 5). viewing window by twisting the
– For rear suspension frames, position barrel adjuster (Fig. 8).
the rear suspension for the greatest
chain length required.
DualDrive 24 • Add 4 LINKS or 3 links + Power Link to
this length for proper chain length.
DualDrive 27

(4 Links)

6 1 3

6 Technical Manual 2003

DUALDRIVE
ASSEMBLY

D E R A I L L E U R A D J U S T M E N T Index shifting adjustment:

7 Limit screw adjustment: • Check that the chain and the rear
• View the rear derailleur and pulleys from derailleur are in the smallest cog position.
behind the rear of the bicycle (Fig. 9). • Measure and cut the rear piece of
• Using a small screwdriver, turn the limit cable housing. Make sure that it is not
screw marked ’H’ on the outer link of the too short or long (DualDrive 27: see
derailleur to align the upper guide pulley page 5 for figure and chart).
center with the outboard edge of the • Rotate the twist shifter until the largest
smallest cog – clockwise moves the number and gear indication tab/dash
guide pulley inboard towards the wheel. line up.
• While turning the crank, push the rear • Turn the twist shifter barrel adjuster (4,
derailleur towards the larger cogs by hand. Fig. 6) clockwise fully into the shifter,
• Align the upper guide pulley under the then turn counterclockwise 1 full turn.
largest cog, center to center, by turning • Feed the shifter cable through the rear
the limit screw marked ’L’ on the outer derailleur cable housing, stops and
link – clockwise moves the guide pulley cable guides.
outboard away from the spokes. • Feed the rear derailleur cable through
the rear derailleur-housing stop and
8 Chain gap adjustment:
Chain gap is the distance between the upper
through the cable guide on the fin.
• Pull the cable tight and position it
guide pulley and the cog the chain is riding under the cable anchor washer (Fig. 11).
on. Optimal chain gap is small enough to • Tighten the 5 mm hex cable anchor bolt
allow quick, efficient shifts to and from any to 4 – 5 Nm (35 – 45 in.lbs.).
cog, but large enough to allow smooth • Rapidly shift the chain and derailleur up
shifts to and from the largest cog. and down the cassette several times. If the
cable slips repeat the two former steps.
• Shift chain to the small chain ring. • Shift the chain to the smallest cog.
• While turning the crank, push the rear • While pedaling, move the shifter up one
derailleur inboard by hand to the largest detent.
cog. – If the chain hesitates or does not shift
• Hold the derailleur in this position while to the second cog, increase the cable
making the following adjustment. tension by turning the shifter barrel
• Use a 3 mm hex wrench, turn the b-adjust adjuster counterclockwise.
screw until the chain gap equals – If the chain shifts beyond the second cog,
approximately 6 mm (1/4”) from tip of the decrease the cable tension by turning
9 cog to tip of upper guide pulley (Fig. 10). the shifter barrel adjuster clockwise.
– Turn the b-adjust screw clockwise to • Repeat the two former steps until
increase the chain gap. shifting and cable tension is accurate.
– Turn the b-adjust screw counterclock- • While turning the crank, shift the chain
wise to decrease the chain gap. up and down the cassette and chain
rings several times to ensure that your
Advice: derailleur is indexing smoothly.
Do not use the b-adjust screw to adjust
the rear derailleur to act as a chain-
tensioning device or to prevent chain
suck. This increases the chain gap
causing poor shifting performance.

10
11

6 mm
( 1/ 4" )

5 mm
3 mm 4 – 5 Nm
35 – 45 in.lbs.

Technical Manual 2003 7

DUALDRIVE
MAINTENANCE

11
4 19
3 18
2

1 10 17
9

16
15
8
20
7 14
6 13
5

12

REMOVE WHEEL R E A S S E M B LY H U B
2 • Rotate the twist shifter to the highest see Fig. 1
gear position (speed “8/9“).
Lubrication see “ LUBRICATION GEAR HUB“.
• Place shift lever in uphill riding mode /
• Clamp axle with the two axle flats
gear position “1“ (Fig. 2).
(longer axle thread).
• Push Clickbox button down (Fig. 2).
• Fit shift sleeve (12), bushing (13) with small
• Pull Clickbox off the axle.
diameter first, compression spring (15),
• Screw out shifting rod (20, Fig. 1).
coupling gear clutch (14), and driver (17).
• Dismantle wheel.
• Mount cone (18) and lock nut (19).
Tightening torque 15 – 20 Nm
DISMANTLING HUB (133 – 177 in.lbs.).
see Figure 1 • Clamp other axle end (driver side facing
• Dismantle cassette lock nut with downwards).
cassette tool (Park Tool FR-5 or • Mount ball retainer (16), pawl carrier
SRAM Part No. 4624 411 010). (10) and washer (9).
• Remove cassette and spoke protector • Press pawls against spring force and
disc. mount gear ring (8) with smaller
• Clamp hub with the two axle flats diameter first.
(driverside facing downwards). Rotate gear ring counterclockwise until
• Remove cap (1), unscrew lock nut (2), pawls engage inside the gear ring.
screwed adjusting cone (3) and hub • Fit planetary gear carrier (7) and
3 shell (4). washer (6).
Lubricate the shifting • Dismantle retaining washer (5), remove • Press and rotate planetary gear carrier
joints regularly
washer (6), planetary gear carrier (7) until axle groove is visible.
and gear ring (8). • Mount retaining washer (5).
• Squeeze down pawls and remove pawl • Mount hub shell (4), obligatory with a
carrier (10) with washer (9) and ball re- slight counterclockwise turn.
tainer (16). • Mount adjusting cone (3).
• Clamp other axle end (longer axle • Screw on counternut (2), adjust bearings
thread). to be free of play and tighten with a
• Dismantle lock nut (19) and cone (18). torque of 15 – 20 Nm (133 – 177 in.lbs.).
• Remove driver (17), compression spring • Mount cap (1).
(15), coupling gear clutch (14) and shift • Unclamp hub and mount shifing rod (20)
sleeve (12) with bushing (13). with a torque of 0,2 Nm (1.8 in.lbs.).
When disassembled –
use a waterproof grease Mount spoke protector disc and
cassette.

8 Technical Manual 2003

DUALDRIVE
MAINTENANCE

LUBRICATION CABLE CHANGE

4 GEAR HUB Advice:
2 Hubs are provided with permanent Use only new high quality cable and
lubrication and maintenance-free under compressionless cable housing with
normal conditions. end caps.

Cleaning of parts: Twist shifter (rear derailleur):

• All parts – except the planetary gear • Detach the cable from the derailleur.
carrier and the driver – can be degreased • Cut cable off 15 cm (6") from shifter
in a cleaning bath. barrel adjuster. Discard old cable and
• Planetary gear carrier and driver only cable housing.
1
need to be cleaned on the outside with • Remove screw (1, Fig. 4) and pull open
a brush so as not to degrease the the cable change sleeve (2).
bearings. • Rotate the shifter fully in the cable
release direction (gear position “8/9“).
Lubrication of parts: • Look for cable head entry (3, Fig. 5).
Use only SRAM grease (Part No. 0369 135 201) • Push cable up/out of the shifter and
and standard bicycle oil. discard.
5 • To lubricate the bearing points on • Feed the new cable through the cable
3
the planetary gear sets, position the entry and out the barrel adjuster (4).
planetary gear carrier pawls upside and • Pull cable snug.
apply 2 – 3 drops of oil to the bearing • Install cable change sleeve (2, Fig. 4).
4 bolts – at the same time turning the • Feed the cable through the new cable
planetary gears so that the bearing housing and frame stops.
points are completely wet. Oil axle slot, • Attach cable to the derailleur.
apply a thin coating of grease to the • Adjust indexing per derailleur instruction.
outside.
• Grease the teeth of the axle (fill the Thumb shift lever (gear hub):
gaps). • Place thumb shift lever (5, Fig. 6) in
• Apply grease to gear ring teeth but just uphill riding mode / gear position “1“.
oil the pawls and pawl teeth. • Snap open Clickbox-cover (8, Fig. 7)
• Oil pawl carrier pawls and pawl (no need to move Clickbox from the
6 bearings. axle end).
• Oil cartridge bearing. • Unscrew clamping bolt (9).
• Regrease ball retainers, line ball • Remove the shifter escape hatch (6, Fig. 6).
bearing running tracks with grease. • Remove and discard the old cable.
• Feed the new cable through the cable
Caution: entry (7, Fig. 6), the new calbe housing
Do not use high-pressure water when and pull the cable snug.
cleaning the gear hub (e.g. strong water • Attach the escape hatch.
jets, high-pressure cleaners etc.) – • Pull the cable tight and position it under
if water penetrates it could lead to the cable anchor washer (10, Fig. 7).
5 functional problems. • Tighten the 4 mm hex cable anchor bolt
to 4 – 5 Nm (35 – 45 in.lbs.).
7 • Cut off cable end to 1 – 3 mm.
LUBRICATION • Snap in Clickbox-cover (8).
REAR DERAILLEUR • Place thumb shift lever in standard
6 • Do not use solvants or corrosive riding mode / gear position “2“.
materials to clean the components. • Match up the marks in the Clickbox
• Lubricate the shifting joints regularly viewing window (11, Fig. 7) by turning
(Fig. 3). the barrel adjuster (12).
7 • Grease any cable guides (e.g. beneath
the bottom bracket).

11 12
10

9
8
4 mm
4 – 5 Nm
35 – 45 in.lbs.

Technical Manual 2003 9

DUALDRIVE
MAINTENANCE

TROUBLESHOOTING
Problem Cause Remedy
Hub:
Shifting difficulties Incorrect gear setting Adjust shifting system, oil
control cable, check that cable
stop is fastened correctly.
Pedals are carried forward Bearings set too tight Re-adjust bearing
when freewheeling Loose lock nuts Tighten lock nuts (15 – 20 Nm,
133 – 177 in.lbs.)
Rear frame dropouts non Bend / reorient dropouts
parallel
Derailleur:
Chain jumps from smallest High gear limit screw is not Turn in screw H until the
sprocket to frame dropout. adjusted properly. guide pulley is aligned with
the smallest sprocket.
Difficult or impossible to High gear limit screw is not Unscrew screw H until the
shift chain onto smallest adjusted properly. guide pulley is aligned with
sprocket. the smallest sprocket.
Chain jumps over largest Low gear limit screw is not Turn in screw L until the
sprocket and falls between adjusted properly. guide pulley is aligned with
the spokes and largest the largest sprocket.
sprocket or inner cage Rear derailleur or derailleur Straighten or replace.
plate scrapes on spokes. hanger is bent.
Delayed shifting. Clearance between guide Adjust b-adjust screw by
pulley / sprocket is too large. rotating counterclockwise.
Rough shifting behavior. Clearance between guide Adjust b-adjust screw by
pulley / sprocket is too small. rotating clockwise.
Chain jumps two gears on Shift cable insufficiently Turn barrel adjuster on the
small sprocket tensioned. shifter counterclockwise.
Delayed shifting onto Shift cable insufficiently Turn barrel adjuster on the
larger sprocket tensioned. shifter counterclockwise.
Delayed shifting onto Shift cable is too tight. Turn barrel adjuster on the
smaller sprocket shifter clockwise.
Excessive cable friction, Lubricate or replace cable
pinched or poorly routed and housing. Check for
cable. excessive bending of cable
housing.

10 Technical Manual 2003

DUALDRIVE
MAINTENANCE

Technical Manual 2003 11

12 Technical Manual 2003
 SPECTRO S7
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

• Comfort Action Shifting

• Improved Ergonomics
• Optimal Gear Ratio
• Spectro Design
• Matte Chrome Finish
• Reliable Brake Performance
• Most Efficient Hub In Its Class

L Version with Coaster Brake

OLD
Caution: HR
• Spectro S7 hubs are not suitable for C
1/2 OLD D DS
tandems, trademen’s delivery bicycles E
and similar. min. 13.5
7
• Use always 2 retaining washers.
Alternatively assemble both retaining
washers on the left axle end (Fig. 5).
T

Cycle frame:
• Dropouts must be parallel.
• Slot width at rear dropout max. 10,5 mm.
• The strength must be such that with a maxi-
mum braking torque of 250 Nm (2200 in.lbs.)
on the rear wheel no residual deformation 0
can occur on the rear structure.
F2 F1 Ø 7.3 10
R
A 2 max A 1 max

Spectro S7 with coaster brake Spectro S7 with drum brake Spectro S7 without brake
Type MH 7215 MH 7225 MH 7205

Over Locknut Dim., OLD

Brake Coaster
130 mm
Drum
135 mm
„D“ ❘ „NL“ None
130 mm
Length, L 183.4 mm 188.5 mm 183.4 mm
Axle

Ends Diameter, T FG 10.5 FG 10.5 FG 10.5

Dropout Width Dim. A1 max. = 12.5 mm / A2 max. = 12 mm A1 max. = 12.5 mm / A2 max. = 12.2 mm A1 max. = 12.5 mm / A2 max. = 10 mm
Holes 36 36 36
Hole Diameter, DS 3.0 mm 2.9 mm 3.0 mm
Spoke

Hole Ref. ø, HR 75 mm 89 mm 75 mm
Flange Dist. to 1/2 OLD F1 = 33 mm / F2 = 34 mm F1 = 34.8 mm / F2 = 35.7 mm F1 = 33 mm / F2 = 34 mm

H Totally 303 % ➔ ➔
Speed 1 57 % ➔ ➔
U
Gear Hub Ratio

Speed 2 68 % ➔ ➔
B Speed 3 81 % ➔ ➔
S Speed 4 100 % ➔ ➔
Speed 5 124 % ➔ ➔
Speed 6 148 % ➔ ➔
Speed 7 174 % ➔ ➔
1/
2" x 1/8" or 1/2" x 3/32" 1/
2" x 1/8" or 1/2" x 3/32" 1/
Usable Dimensions 2" x 1/8" or 1/2" x 3/32"
Chain

Line, C/D/E 54 / 51 / 48 mm 55.5 / 52.5 / 49.5 mm 54 / 51 / 48 mm

Ratio 24", 26", 28"= 1.83 – 1.90 / 20"= 1.83 – 2.00 ➔ ➔
Shifter Compatib. Spectro Grip 7 ➔ ➔
Clickbox Compatib. Clickbox S7 ➔ ➔
Tandem Compatib. — — —
Weight 1714 g 1737 g 1556 g
Hub Shell Material Steel Aluminum Steel
Finish

Finish Matt Chrome Plated Clear Coat Matt Chrome Plated

Technical Manual 2003 13

SPECTRO S7
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

Spectro Grip 7
S Part No. —
❘— ❘— ❘— ❘— ❘— ❘— ❘—
H Shifter Type Twist Shifter

I Cable
Gear Indication
1450 mm
Window
❘ 1550 mm ❘ 1650 mm ❘ 1750 mm ❘ 1850 mm ❘ 1950 mm ❘ 2050 mm ❘ 2150 mm
F Clamping Diameter 22.3 mm
T Handlebar, Straight Area Minimum length for shifter = 150 mm

E Weight 89g
Housing Glass filled PA
R
Design

Grip PP
S Grip Cover Thermoplastic elastomer, Overmolded
Clamping Collar Aluminum

SPECTRO S7
ASSEMBLY
A S S E M B LY H U B • Fit retaining washers (1, Fig. 4) on both
1 1 2 • Lace the wheel as normal. See spoke axle ends. The serrations must bear
length table. against the dropout and the lug must
• Place the dust cap (1, Fig. 1) and engage in the dropout slot.
sprocket (2) on the driver. In case of exceeding the dimension A 1
• Push sprocket circlip (3, Fig. 2) onto the max. = 12.5 mm (see Page 13), e.g. by thick
cone of tool sleeve (4). Place tool sleeve dropouts, both retaining washers should
with large diameter on the driver. be assembled on the left axle end (Fig. 5).
• Push the spring end of sliding sleeve (5) • On the sprocket side fit the protective
of the tool over the tool sleeve. Thrust bracket (1, Fig. 6) directly below the
2 4 3 5
sliding sleeve in direction (6), this forces
circlip into the recess of the driver.
fixing nut. Tightening torque on acorn or
hex nuts 30 – 40 Nm (266 – 350 in.lbs.).
• Remove tool and check that the circlip is • Mount the brake lever using a suitable
6 seated correctly. frame clamp (2, Fig. 4 resp. Fig. 10).
• Turn dust cap (7, Fig. 3) until the three Caution:
Mounting Tool
lugs (8) are between the three beads (9) Mount the brake lever between the two
Part No. 0582 104 000 on the sprocket (10). straps of the frame clamp.
• Position dust cap and push towards The clamp must be seated on the frame
sprocket until it is felt to lock into place. without play.
• Placing the wheel in the rear frame. Use a self-locking nut! Tightening
3 • Mount the chain. torque: 2 – 3 Nm (18 – 27 in.lbs.).
8 7

9 Spoke length table:

Tire Size Cross Length MH 7215/7205 Length MH 7225
47–406 20" x 1.75 x 2 3x 181 mm 179 mm
10 37–490 22" x 1 3 / 8 3x 225 mm 222 mm
47–507 24" x 1.75 x 2 3x 232 mm 229 mm
37–540 24" x 1 3 / 8 3x 251 mm 248 mm
47–559 26" x 1.75 x 2 3x 259 mm 256 mm
4 5 37–590 26" x 1 3 / 8 3x 275 mm 272 mm
47–622 28" x 1.75 3x 289 mm 286 mm
37–622 28" x 1 3 / 8 x 1 5 / 8 3x 289 mm 286 mm
28–622 28" x 1 1 / 8 3x 289 mm 286 mm
32–622 28" x 1 5 / 8 x 1 1 / 4 3x 289 mm 286 mm
28–630 27" x 1 1 / 4 fifty 3x 294 mm 291 mm
1 32–630 27" x 1 1 / 4 3x 294 mm 291 mm
2
Spoke lengths are approximate values. They must be checked through lacing attempts
and adjusted accordingly.

14 Technical Manual 2003

SPECTRO S7
ASSEMBLY

Advice: • Turn locating sleeve on the axle until the

6 • If a different protective bracket (1, Fig. 6) guiding rib (4) is facing roughly upwards.
is used the thickness of the attachment • Place shifter in gear position “1“.
plate must be max. 3 mm. • Push on Clickbox (2, Fig. 6) to the stop on
• Do not use additional washers. the hub axle. The guiding rib (4, Fig. 9) of
• At least the beginning of the axle thread the locating sleeve thereby engages in
must be visible in front of the axle nut. the slot on the housing. In the end position
tighten up the knurled bolt (3, Fig. 6) by
hand (0,3 Nm / 2,7 in.lbs.).
1 A S S E M B LY S H I F T E R S
3 2 Advice:
• Contrary to the old shifter version the ADJUSTMENT
shifter cable of the new version runs • Be sure to reset rotational shifter from
above the brake lever. Maybe you need 5th. to 4th gear.
7 4 50 mm more cable length. • Match up the marks in the Clickbox
5 • When choosing cable housing lengths, viewing window (4, Fig. 7) by turning
be sure to allow enough housing for an the adjusting screw (5).
extreme turn of the handlebars in both
directions.
3 2 • Note also, that different stem lengths CONNECTING DRUM BRAKE
1 Caution:
and handlebar positions effects cable
housing length. Only use brake levers with a cable
• Slide shifter (1, Fig. 7) onto handlebar. moving distance of at least 15 mm and a
• Mount fixed grip (2) onto end of handlebar. minimum leverage of 3.8.
• Slide shifter against fixed grip, adjust • Fit cable stop (1, Fig. 10) with adjusting
shifter on handlebar and tighten with bolt (2) and nut (3) and insert into the slot
bolt (3) with a torque of 1.5 Nm (13 in.lbs.). on the brake anchor plate.
8 • Turn adjusting bolt down by approx. 2/3
and route the brake cable from the
Caution:
2 1
• Never use lubricants or solvents to brake handle.
install fixed grips. • Push lower brake cable end through
Fixed grips provide an axial safety adjusting bolt (2) and insert lower cable
function. For this reason, they should be housing end into adjusting bolt.
mounted in such a way as to make sure • Thread brake cable end (4) into
they do not slip off handlebar. fork unit (5).
• Check that the shifter and brake lever • Tighten screw (6) slightly.
function properly and are unobstructed • Attach fork unit to brake lever (7).
(realign if necessary). • Pull brake cable end taut with pliers
• Never ride without the fixed grips. The so that fork unit can still be attached and
9 7 turning grip may loosen from housing removed (important for changing wheel).
and slip off handlebar – this can result • Tighten screw (6).
in severe injury or death.
6 Caution:
4 • When fitting the cable avoid small radius. For NL version drum brake hub with
Attach the cable 3 times to the down special lever (8), only use original NL
tube (1, Fig. 8). brake cable (fork unit (5) is not suitable).
2
1 • Last attachment point is on the lower
3 rear wheel fork (2, Fig. 8) immediately
5
behind the chain wheel. ADJUSTMENT DRUM BRAKE
Cable housing must be movable inside • Unscrew adjusting screw (2, Fig. 10)
10 attachment. until the brake pads drag lightly.
• Actuate the hand brake lever forcefully
2 several times and then, if necessary,
3
1 INSTALLING CLICKBOX turn the adjusting screw further in just
• Insert shift rod (1, Fig. 9) in shift tube (2) until the wheel starts spinning freely.
4 6
(oil parts lightly) and then push into axle • Lock hex nut (3).
bore as far as the stop. Turn slot (6) in
5
shift tube to a position where it is easily
visible.
7
• Push locating sleeve (3) with guiding rib
(4) to the front onto the hub axle – making
sure that the internal lug (5) is guided in
the slot (6) of the shift tube until it can be
8 felt – and heard – to engage.

Technical Manual 2003 15

SPECTRO S7
MAINTENANCE

8
7
1 31
32

CH
S
30
SA

6 29

28
5
27
4
3 26
20 25
19
18 24
2 23
22 41 42
17 21
1
16
15
40

39
14
13 38
12
11
10
37
35 36
9
34

33

REMOVE WHEEL • Remove cover (26), spring (25) and

2 • Place shifter in gear position “1“. cover (24).
• Dismantle retaining washer (23).
• Loosen the knurled screw and pull the
Spectro S7 mounting aid Clickbox off the axle. • Remove thrust washer (22) and plastic
Part No. 65 0324 103 000 profile washer (21).
• Disengage the location sleeve and pull it off.
Remove shift rod/tube out of the axle bore. • Unscrew grub screw (16) (Caution: It is
• Remove wheel. subject to spring pressure) – and dis-
mantle the long compression spring (17)
DISMANTLING HUB guide pin (18), thrust block (19) and the
see Fig. 1 short compression spring (20).

• Remove circlip (38), sprocket (37) and

R E A S S E M B LY H U B
X dust cap (36) as normal.
see Fig. 1
• Withdraw locating sleeve (42) (latched)
• Take out shift rod/tube (40/41). Lubrication see “MAINTENANCE /
• Clamp hub by the axle between aluminum LUBRICATION“.
jaws with sprocket side facing downwards. • Insert into the axle (on the side with the
• Unscrew both locknuts (1). internal thread):
• Remove lever cone (2) ball retainer (3) • Short compression spring (20).
and brake shell (4). • Thrust block (19) – it is the same both sides.
• Withdraw hub sleeve (5) upwards. • Guide rod (18) – it is the same both sides.
• Unscrew brake cone (6) from flat thread. • Long compression spring (17).
• Take out retaining washer (7) and thrust • Compress spring and fit grub screw (16).
washer (8). • Clamp axle, end for clickbox facing
3 • Remove planetary gear carrier (9), upwards.
washer (10) compression spring (11) and • Fit plastic profile washer (21) with its
the three sun gears (12, 13, 14). large diameter upwards.
• Clamp other axle end. • Fit thrust washer (22) and retaining
• Unscrew fixed cone (35). washer (23).
• Remove driver (34), compression spring • Locate cover (24), compression spring (25)
(32) with cover (31), large compression with 7 turns, cover (26, insides to the
spring (30), ball retainer (33), gear ring (29) spring).
and coupling gear (28). • Compress spring and position thrust
• Compress spring (25) and remove thrust block (27) – it is the same both sides –
block (27). centrally in the axle.

16 Technical Manual 2003

SPECTRO S7
MAINTENANCE

• Clamp other axle end. CABLE CHANGE

4 • Fit large sun gear (14), with deflector Dismantling shifter cable:
2 bevels upwards. • Place shifter in gear position “1“.
3
• Position medium sun gear (13), with • Do not remove the Clickbox from the axle
1
deflector bevels upwards. end.
• Fit small sun gear (12) – with recesses in • Unscrew the adjusting screw (1, Fig. 4)
front, thrust block engages in the slots. completely. Unscrew the cover screw (2),
• Position smallest compression spring (11). brush aside the adjusting screw (1) and
• Fit 1 mm thick washer (10). remove the cover (3).
• Fit planetary gear carrier (9). • Withdraw shifter cable and clamping
• Place the mounting aid(Fig. 2) on the bolt (1, Fig. 5) upwards, loosen clamp
planetary gear carrier such that the and pull clamping piece from the cable.
markings (X) on the 3 small planet gears • Slightly lift the grip cover (Fig. 6), push
and the mounting aid match up. the cable out and discard.
• Turn planetary gear carrier and at the
5 same time push it downwards over the Assembly shifter cable:
sun gears. • Route new cable through shifter housing
1 • Fit thrust washer (8) and retaining and pull cable to seat cable head
washer (7) in the undercut. completely into cable recess.
Only now remove the mounting aid. Feed the cable through the new cable
housing and adjusting screw.
Advice: • Position clamping bolt (1, Fig. 7) at a
2 If the gears are not accurately assembled distance of 90 mm, tighten up with
the hub may feel tight in use. This may 1.5 Nm (13 in.lbs.) and cut off cable ends
lead to gear wheel damage during travel. to 2 – 3 mm. For positioning the clamping
bolt use adjust gauge (Fig. 8). (Part. No.
• Reclamp axle (Clickbox end facing 65 0324 107 000)
upwards) • Locate clamping bolt (1, Fig. 5) and place
• Fit coupling gear (28) with carrier plate shifter cable around the carrier cylinder
downwards
6 • Push ring gear (29) over the coupling gear.
(counter-clockwise winding).
• Position the cover (3, Fig. 4) and tighten
• Locate large spring (30). up with the cover screw (2).
• Fit largest ball retainer (33) with balls Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.).
underneath. Screw in the adjusting screw (1)
• Fit cover (31, inside to the spring). completely.
• Assemble the compression spring (32)
with 12 turns. Advice:
• Position driver (34) – push it down – and • If you want to remove the Clickbox from
screw on fixed cone (35) to the stop, the axle end for changing the cable, do
tightening torque 20 Nm (177 in.lbs.). as follows:
• Clamp other axle end. – Place shifter in gear position “1“.
• Screw brake cone (6) onto the flat thread. – Loosen the knurled screw and pull the
• Assemble hub shell – with a slight Clickbox off the axle.
counter-clockwise movement. – Now it’s essential to push the end (1,
In case the hub shell jams, position the Fig. 8) of the adjust gauge completey
7 plastic ring (Fig. 3) correctly.
• Insert brake shell (4, Fig. 1) – retaining
into the Clickbox and tighten up the
knurled bolt (so that you maintain the
lugs upwards, thereby the friction spring initial tension of the spring inside the
2 +1 mm 90 ±0,5 mm on the brake cone must engage in the Clickbox).
slot on the brake shell. – Change cable as per description above.
• Locate ball retainer (3) (balls underneath), • If you remove the Clickbox from the
position lever cone (2), thereby turn it axle and change the cable without
clockwise until the retaining lugs engage. using the end of the adjust gauge, then
1 • Screw on locknuts (1), adjust bearing you will lose the initial tension of the
so that there is no play and lock nuts spring inside the Clickbox. In this case
together with 15 – 20 Nm you must assemble the cable by placing
(133 – 177in.lbs.). it around the carrier cylinder with an
8 additional winding (Fig. 5).
Advice:
Dismantling and reassembly of hub types
MH 7205 / MH 7225 should be carried out
in the same way. Differences: Instead of
brake shell/cone a click-and-pawl carrier
is installed on the planetary gear carrier
here. Without flat thread – fixed with a re-
taining washer.
1

Technical Manual 2003 17

SPECTRO S7
MAINTENANCE

EXCHANGEABILITY ADJUSTMENT
9 SHIFTER / CLICKBOX • Be sure to reset rotational shifter from
Produced till 1998 (Fig. 9): 5th. to 4th gear.
Dont’t combine with newer versions! • Match up the marks in the Clickbox
viewing window (Fig. 12) by turning
TILL 1998

Produced till end 2002 and as of 2003 (Fig. 10):

the adjusting screw (1).
Combine shifter and Clickbox only accor-
ding to Fig. 10.
Distance of the clamping bolt:
Each Clickbox version needs its specific
distance of the clamping bolt:
• Till 1998: Distance 68,5 mm
Don’t combine with newer versions!
• Till end 2002: Distance 89 mm
• As of 2003: Distance 90 mm

10 REPLACEMENT BY A
NEW CLICKBOX (AS OF
2003)
• Place shifter in gear position “1“.
TILL END 2002

• Loosen the knurled screw and pull the

Clickbox off the axle.
• Unscrew the adjusting screw (1, Fig. 12)
completely. Unscrew the cover screw (2),
brush aside the adjusting screw (1) and
remove the cover (3).
• Push the end (1, Fig. 11) of the adjust
!
ay gauge (Part. No. 65 0324 107 000) com-
t w pletely into the Clickbox and tighten up
t ha
n ly the knurled bolt (so you maintain the
n eo initial tension of the spring inside the
m bi Clickbox).
co
• Withdraw shifter cable and clamping
bolt (1, Fig. 5) upwards.
AS OF 2003

• Locate clamping bolt (1, Fig. 5) in the

new Clickboxh and place shifter cable
around the carrier cylinder (counter-
clockwise winding).
Advice:
If you remove the Clickbox from the
axle and change the cable without
using the end of the adjust gauge, then
11 you will lose the initial tension of the
spring inside the Clickbox. In this case
you must assemble the cable by placing
it around the carrier cylinder with an
additional winding (Fig. 5).
• Position the cover (3, Fig. 12) and tighten
up with the cover screw (2).
Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.).
Screw in the adjusting screw (1)
1 completely.
• Loosen the knurled screw on the Click-
box and pull the adjust gauge off.
• Push on Clickbox on the hub axle.
12 Tighten up the knurled bolt by hand.
2
3
1

18 Technical Manual 2003

SPECTRO S7
MAINTENANCE

DRUM BRAKE • Oil the inside of the sun gears, grease

13 Install brake anchor plate (or exchange it): the outside teeth (fill the gaps in the
• Place thrust washer (8, Fig. 13) over the teeth).
axle on the adjusting cone and fit • Oil outside teeth and carrier plate on
2
3 complete brake anchor plate. Position the coupling gear and lightly grease the
1
washer (9) distance sleeve (10) and borehole from right and left.
4 6 screw on locknut (11). • Do not apply grease to ring gear but just
• Push brake lever (7) to the stop and hold oil the pawl pockets.
5 it there to center the brake jaws in the • Grease the brake cone in the borehole
8 brake drum – tighten up locknut with a and the friction spring.
torque of 15 – 20 Nm (133 – 177 in.lbs.). • Spread grease on the inside and outside
9 7 of the brake shell.
10 ADJUSTMENT DRUM BRAKE • Fill lever cone with grease reserves for
11
• Unscrew adjusting screw (2, Fig. 13) brakes
until the brake pads drag lightly. • Regrease ball retainer, line ball bearing
• Actuate the hand brake lever forcefully running tracks with grease.
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock hex nut (3).

Caution:
Check that all the brake system
components are functioning properly!

MAINTENANCE /
LUBRICATION
Caution:
The Spectro hubs are provided with
permanent lubrication and under normal
conditions is maintenance-free. If the
coaster brake is loaded excessively its
effect can be too strong, the hub may lock.
In such a case the brake shell should be
lubricated with a special grease (Part No.
0369 135 201). Renew brake shell, when
rhombic pattern is worn out.

Cleaning of parts:
• All parts – except for the planetary gear
carrier – can be degreased in a cleaning
TROUBLESHOOTING
bath. Problem Cause Remedy
• The planetary gear carrier only needs to Shifting Damaged Replace
be cleaned on the outside with a brush difficulties control cable control cable
so as not to degrease the planetary gear Incorrect Adjust shift.
bearing. gear setting system
To much ad- Beginning of
Caution: ditional axle axle thread
Do not use high-pressure water when attachments must be visi-
cleaning the gear hub (e.g. strong water between hub ble in front of
jets, high-pressure cleaners etc.) – and axle nut the axle nut
if water penetrates it could lead to Pedals are Bearings Re-adjust
functional problems. carried set too tight bearings
forward Loose Tighten
Lubrication of parts: when free- lock nuts lock nuts
• To lubricate the bearing points on wheeling (15 – 20 Nm)
the planetary gear sets, position the Chain is over- Reduce
planetary gear carrier on its crown and tensioned chain tension
apply 2 – 3 drops of oil to the bearing
Hub locks Brake shell Wash out
bolts – at the same time turning the has run dry hub sleeve,
when
planetary gears so that the bearing braking repolish and
points are completely wet. Oil axle (coaster relubricate
through the axle bore and axle slot, brake) brake cylin-
apply a thin coating of grease to the der, renew
outside. brake shell

Technical Manual 2003 19

20 Technical Manual 2003
 SPECTRO P5
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

• Comfort Action Shifting

• Improved Ergonomics
• Optimal Gear Ratio
• Spectro Design
• Matte Chrome Finish
• Reliable Brake Performance
• Most Efficient Hub In Its Class

Version Spectro P5 Cargo: L Version with coaster brake

see page 29.
OLD
C
TK
Caution: 1/2 OLD D
• Spectro P5 hubs are not suitable for E DS
tandems, trademen’s delivery bicycles min. 13.5
7
and similar.
• Use always 2 retaining washers.
Alternatively assemble both retaining
washers on the left axle end (Fig. 5).
T

Cycle frame:
• Dropouts must be parallel.
• Slot width at rear dropout max. 10,5 mm.
• The strength must be such that with a maxi-
mum braking torque of 250 Nm (2200 in.lbs.) 0
on the rear wheel no residual deformation
F2 F1 Ø 7.3 10
R
can occur on the rear structure. A 2 max. A 1 max.

Spectro P5 with coaster brake Spectro P5 with drum brake Spectro P5 without brake
Type MH 5215 MH 5225 MH 5205

Over Locknut Dim., OLD

Brake Coaster
122 mm
Drum
126 mm
„D“ ❘ „NL“ ❘ „NL“ None
122 mm
Length, L 175 mm 179 mm 175 mm

❘ FG 10.5 toothed cone

Axle

Ends Diameter, T FG 10.5 FG 10.5 FG 10.5

Dropout Width Dim. A1 max. = 12.5 mm / A2 max. = 11.5 mm A1 max. = 12.5 mm / A2 max. = 12.5 mm A1 max. = 12.5 mm / A2 max. = 10.5 mm
Holes 36 36 36
Hole Diameter, DS 3.0 mm 2.9 mm 3.0 mm
Spoke

Hole Ref. ø, HR 75 mm 89 mm 75 mm

H Flange Dist. to 1/2 OLD F1 = 28.5 mm / F2 = 29.5 mm F1 = 30.5 mm / F2 = 29.5 mm F1 = 29 mm / F2 = 29 mm

Totally 251 % ➔ ➔
U
Gear Hub Ratio

Speed 1 63 % ➔ ➔
B Speed 2 78 % ➔ ➔
S Speed 3 100 % ➔ ➔
Speed 4 128 % ➔ ➔
Speed 5 158 % ➔ ➔
Usable Dimensions 1
/2" x 1/8" or 1/2" x 3/32" 1
/2" x 1/8" or 1/2" x 3/32" 1
/2" x 1/8" or 1/2" x 3/32"
Chain

Line, C/D/E 49 / 45.5 / 43 mm 51.5 / 48.5 / 45.5 mm 49 / 45.5 / 43 mm

Ratio 24", 26", 28"= 1.8 – 1.9 / 20"= 1.8 – 2.0 ➔ ➔
Shifter Compatib. Spectro Grip 5 ➔ ➔
Clickbox Compatib. Clickbox P5 ➔ ➔
Tandem Compatib. — — —
Weight 1495 g 1536 g 1330 g
Hub Shell Material Steel Aluminum Steel
Finish

Finish Matt Chrome Plated Clear Coat ❘ ❘

Clear Coat Black Painted Matt Chrome Plated

Technical Manual 2003 21

SPECTRO P5
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

Spectro Grip 5
S
H
Part No.
Shifter Type
—
Twist Shifter
❘— ❘— ❘— ❘— ❘— ❘— ❘—
I Cable
Gear Indication
1450 mm
Window
❘ 1550 mm ❘ 1650 mm ❘ 1750 mm ❘ 1850 mm ❘ 1950 mm ❘ 2150 mm ❘ 2350 mm
F Clamping Diameter 22.3 mm
T Handlebar, Straight Area Minimum length for shifter = 150 mm

E Weight 89g
Housing Glass filled PA
R
Design

Grip PP
S Grip Cover Thermoplastic elastomer, Overmolded
Clamping Collar Aluminum

SPECTRO P5
ASSEMBLY
A S S E M B LY H U B • Fit retaining washers (1, Fig. 4) on both
1 1 2 • Lace the wheel as normal. See spoke axle ends. The serrations must bear
length table. against the dropout and the lug must
• Place the dust cap (1, Fig. 1) and engage in the dropout slot.
sprocket (2) on the driver. In case of exceeding the dimension A 1
• Push sprocket circlip (3, Fig. 2) onto the max. = 12.5 mm (see Page 21), e.g. by thick
cone of tool sleeve (4). Place tool sleeve dropouts, both retaining washers should
with large diameter on the driver. be assembled on the left axle end (Fig. 5).
• Push the spring end of sliding sleeve (5) • On the sprocket side fit the protective
of the tool over the tool sleeve. Thrust bracket (1, Fig. 6) directly below the
2 4 3 5
sliding sleeve in direction (6), this forces
circlip into the recess of the driver.
fixing nut. Tightening torque on acorn or
hex nuts 30 – 40 Nm (266 – 350 in.lbs.).
• Remove tool and check that the circlip is • Mount the brake lever using a suitable
6 seated correctly. frame clamp (2, Fig. 4 resp. Fig. 10).
• Turn dust cap (7, Fig. 3) until the three Caution:
lugs (8) are between the three beads (9) Mount the brake lever between the two
Mounting Tool
on the sprocket (10). straps of the frame clamp.
Part No. 0582 104 000
• Position dust cap and push towards The clamp must be seated on the frame
sprocket until it is felt to lock into place. without play.
• Placing the wheel in the rear frame. Use a self-locking nut! Tightening
3 • Mount the chain. torque: 2 – 3 Nm (18 – 27 in.lbs.).
8 7

9 Spoke length table:

Tire Size Cross Length MH 5215/5205 Length MH 5225
47–406 20" x 1.75 x 2 3x 181 mm 179 mm
10 37–490 22" x 1 3 / 8 3x 225 mm 222 mm
47–507 24" x 1.75 x 2 3x 232 mm 229 mm
37–540 24" x 1 3 / 8 3x 251 mm 248 mm
47–559 26" x 1.75 x 2 3x 259 mm 256 mm
4 5 37–590 26" x 1 3 / 8 3x 275 mm 272 mm
47–622 28" x 1.75 3x 289 mm 286 mm
37–622 28" x 1 3 / 8 x 1 5 / 8 3x 289 mm 286 mm
28–622 28" x 1 1 / 8 3x 289 mm 286 mm
32–622 28" x 1 5 / 8 x 1 1 / 4 3x 289 mm 286 mm
28–630 27" x 1 1 / 4 fifty 3x 294 mm 291 mm
1 32–630 27" x 1 1 / 4 3x 294 mm 291 mm
2
Spoke lengths are approximate values. They must be checked through lacing attempts
and adjusted accordingly.

22 Technical Manual 2003

SPECTRO P5
ASSEMBLY

Advice: • Push locating sleeve (3) with guiding rib

6 • If a different protective bracket (1, Fig. 6) (4) to the front onto the hub axle – making
is used the thickness of the attachment sure that the internal lug (5) is guided in
plate must be max. 3 mm. the slot (6) of the shift tube until it can be
• Do not use additional washers. felt – and heard – to engage.
• At least the beginning of the axle thread • Turn locating sleeve on the axle until the
must be visible in front of the axle nut. guiding rib (4) is facing roughly upwards.
• Place shifter in gear position “2“.
• Push on Clickbox (2, Fig. 6) to the stop on
1 A S S E M B LY S H I F T E R S the hub axle. The guiding rib (4, Fig. 9) of
3 2 Advice: the locating sleeve thereby engages in
• Contrary to the old shifter version the the slot on the housing. In the end position
shifter cable of the new version runs tighten up the knurled bolt (3, Fig. 6) by
above the brake lever. Maybe you need hand (0,3 Nm / 2,7 in.lbs.).
7 4 50 mm more cable length.
5 • When choosing cable housing lengths,
be sure to allow enough housing for an ADJUSTMENT
extreme turn of the handlebars in both • Be sure to reset rotational shifter from
directions. 4th. to 3th gear.
3 2 • Note also, that different stem lengths • Match up the marks in the Clickbox
1
and handlebar positions effects cable viewing window (4, Fig. 7) by turning
housing length. the adjusting screw (5).
• Slide shifter (1, Fig. 7) onto handlebar.
• Mount fixed grip (2) onto end of handlebar.
• Slide shifter against fixed grip, adjust CONNECTING DRUM BRAKE
shifter on handlebar and tighten with Caution:
bolt (3) with a torque of 1.5 Nm (13 in.lbs.). Only use brake levers with a cable
8 moving distance of at least 15 mm and a
minimum leverage of 3.8.
Caution:
2 1
• Never use lubricants or solvents to • Fit cable stop (1, Fig. 10) with adjusting
install fixed grips. bolt (2) and nut (3) and insert into the slot
Fixed grips provide an axial safety on the brake anchor plate.
function. For this reason, they should be • Turn adjusting bolt down by approx. 2/3
mounted in such a way as to make sure and route the brake cable from the
they do not slip off handlebar. brake handle.
• Check that the shifter and brake lever • Push lower brake cable end through
function properly and are unobstructed adjusting bolt (2) and insert lower cable
(realign if necessary). housing end into adjusting bolt.
• Never ride without the fixed grips. The • Thread brake cable end (4) into
9 7 turning grip may loosen from housing fork unit (5).
and slip off handlebar – this can result • Tighten screw (6) slightly.
in severe injury or death. • Attach fork unit to brake lever (7).
6 • Pull brake cable end taut with pliers
4 • When fitting the cable avoid small radius. so that fork unit can still be attached and
Attach the cable 3 times to the down removed (important for changing wheel).
2 tube (1, Fig. 8). • Tighten screw (6).
1 • Last attachment point is on the lower
3 rear wheel fork (2, Fig. 8) immediately Caution:
5
behind the chain wheel. For NL version drum brake hub with
Cable housing must be movable inside special lever (8), only use original NL
10 attachment. brake cable (fork unit (5) is not suitable).

2
3
1 INSTALLING CLICKBOX ADJUSTMENT DRUM BRAKE
• Insert shift rod (1, Fig. 9) in shift tube (2) • Unscrew adjusting screw (2, Fig. 10)
4 6
(oil parts lightly) and then push into axle until the brake pads drag lightly.
bore as far as the stop. If the shifting rod • Actuate the hand brake lever forcefully
5
is sticking up out of the axle end: apply several times and then, if necessary,
slight pressure on the shift rod with its turn the adjusting screw further in just
7
threaded section and screw inwards in until the wheel starts spinning freely.
a clockwise direction until it can again • Lock hex nut (3).
be moved axially (valid for older hub
versions). Turn slot (6) in shift tube to a
8 position where it is easily visible.

Technical Manual 2003 23

SPECTRO P5
MAINTENANCE

1 8
7

5 29
28
4
27
3
2

1 26
17 25
24
16 23 39
15 22 41
21 38
14 20
19
18
40
13 37
36
35
12
11
10 34
32 33
9
31
30

2
REMOVE WHEEL • Take out thrust block (24), (to do this
Spectro P5 mounting aid • Place shifter in gear position “2“. compress the spring). Remove spring
Part No. 5024 300 000 • Loosen the knurled screw and pull the (22) and the two covers (23/21).
Clickbox off the axle. • Dismantle retaining washer (20), washer
• Disengage the location sleeve and pull it (19), conical compression spring (18),
off. Remove shift rod/tube, if necessary and the large sun gear (12). Clamp other
pull shift rod outwards and unscrew in a axle end (thrust block visible).
counter-clockwise direction. • Unscrew grub screw (14) – Dismantle
• Remove wheel. spring (15), guide bolt (16) and thrust
block (17).
X DISMANTLING HUB • Remove small sun sun gear (11).
see Fig. 1
R E A S S E M B LY H U B
• Remove circlip (35), sprocket (34) and
see Fig. 1
dust cap (33).
• Clamp hub with sprocket side facing Lubrication see “MAINTENANCE /
downwards with the two axle flats. LUBRICATION“.
• Unscrew the two locknuts (1). • Clamp axle with internal thread up-
• Remove lever cone (2), ball retainer (3) wards.
and brake shell (4). • Position small sun gear (11) with crown
• Withdraw hub sleeve (5) upwards. gears to the front.
• Unscrew brake cone (6) from flat thread. • Position thrust block (17) in the slotted
3 • Remove retaining washer (7), thrust hole (is laterally guided when the sun
washer (8). gear is screwed in).
• Remove planetary gear carrier (9) and • Locate bolt (16), then spring (15) in the
thrust washer (10). axle and screw in grub screw (14) until
• Clamp other axle end. it is flush with the axle.
• Unscrew fixed cone (32). • Reclamp axle. Fit large sun gear (12) (it
• Remove driver (31), compression spring is the same both sides). Position conical
(29), large compression spring (27) and ball compression spring (18), with the large
retainer (30). – Withdraw gear ring (26) diameter first. Press spring together and
and coupling gear (25) and then remove fit washer (19) and retaining washer (20).
cover (28) from the coupling gear.

24 Technical Manual 2003

SPECTRO P5
MAINTENANCE

• Assemble cover (21), compression CABLE CHANGE

4 spring with 7 turns (22) and the second Dismantling shifter cable:
2 cover (23, insides to the spring). • Place shifter in gear position “2“.
3
• Compress spring and position thrust • Do not remove the Clickbox from the axle
1
block (24) (it is the same both sides) in end.
the center of the slotted hole. • Unscrew the adjusting screw (1, Fig. 4)
• Position coupling gear (25) with carrier completely. Unscrew the cover screw (2),
plate facing downwards. brush aside the adjusting screw (1) and
• Fit cover (28, inside to the spring) for remove the cover (3).
compression spring. • Withdraw shifter cable and clamping
• Position gear ring (26) over the teeth of bolt (1, Fig. 5) upwards, loosen clamp
the coupling gear. and pull clamping piece from the cable.
• Place ball retainer (30), with balls below • Slightly lift the grip cover (Fig. 6), push
on the gear ring. the cable out and discard.
• Position large compression spring (27)
5 on gear ring. Assembly shifter cable:
• Mount compression spring with 13 turns • Route new cable through shifter housing
1 (29) on the axle. (Is supported in the and pull cable to seat cable head
coupling wheel by the cover). completely into cable recess.
• Locate driver (31), press it down and Feed the cable through the new cable
screw on fixed cone (32) as far as the housing and adjusting screw.
stop. Tightening torque 20 Nm. (Then • Position clamping bolt (1, Fig. 7) at a
2 reclamp hub.) distance of 80 mm, tighten up with
• Push on thrust washer (10) and fit 1.5 Nm (13 in.lbs.) and cut off cable ends
planetary gear carrier (9). In doing this: to 2 – 3 mm. For positioning the clamping
Position mounting aid (Fig. 2) on the bolt use adjust gauge (Fig. 8). (Part. No.
planetary gear carrier so that the (X) 65 0324 107 000)
markings on the threeplanetary gears • Locate clamping bolt (1, Fig. 5) and place
match with the mounting aid. shifter cable around the carrier cylinder
• Insert planetary gear carrier, place
6 thrust washer (8) on it and mount
(counter-clockwise winding).
• Position the cover (3, Fig. 4) and tighten
retaining washer (7) in recess. up with the cover screw (2).
Only now remove the mounting aid. Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.).
Screw in the adjusting screw (1)
Advice: completely.
If the gears are not accurately installed
the hub may be tight to move. Advice:
This could lead to damage to the gear- • If you want to remove the Clickbox from
wheels in operation. the axle end for changing the cable, do
as follows:
• Screw brake cone (6) onto flat threads. – Place shifter in gear position “2“.
• Mount hub sleeve (5), with a slight – Loosen the knurled screw and pull the
counter-clockwise turn. Clickbox off the axle.
In case the hub shell jams, position the – Now it’s essential to push the end (1,
plastic ring (Fig. 3) correctly. Fig. 8) of the adjust gauge completey
7 • Locate brake shell (4, Fig. 1) – with retai-
ning lugs uppermost –, then the friction
into the Clickbox and tighten up the
knurled bolt (so that you maintain the
spring on the brake cone must engage initial tension of the spring inside the
2 +1 mm 80 ±0,5 mm with the slot on the brake shell. Clickbox).
• Insert ball retainer (3) – with balls below. – Change cable as per description above.
• Position lever cone (2) – in doing this • If you remove the Clickbox from the
turn it clockwise until the retaining axle and change the cable without
lugs engage. using the end of the adjust gauge, then
1 • Screw on counternuts (1), adjust bearings you will lose the initial tension of the
to be free of play and tighten lock nuts. spring inside the Clickbox. In this case
Tightening torque 15 – 20 Nm you must assemble the cable by placing
(133 – 177in.lbs.). it around the carrier cylinder with an
8 additional winding (Fig. 5).
Advice:
The dismantly and reassembly of the hub
types MH 5205 / MH 5225 should be
carried out in the same way. Differences:
Instead of brake shell/cone a click-and-
pawl carrier is installed on the planetary
gear carrier here. Without flat thread –
fixed with a retaining washer.
1

Technical Manual 2003 25

SPECTRO P5
MAINTENANCE

EXCHANGEABILITY ADJUSTMENT
9 SHIFTER / CLICKBOX • Be sure to reset rotational shifter from
Produced till 1998 (Fig. 9): 4th. to 3th gear.
Dont’t combine with newer versions! • Match up the marks in the Clickbox
viewing window (Fig. 12) by turning
TILL 1998

Produced till end 2002 and as of 2003 (Fig. 10):

the adjusting screw (1).
Combine shifter and Clickbox only accor-
ding to Fig. 10.
Distance of the clamping bolt:
Each Clickbox version needs its specific
distance of the clamping bolt:
• Till 1998: Distance 68,5 mm
Don’t combine with newer versions!
• Till end 2002: Distance 83 mm
• As of 2003: Distance 80 mm

10 REPLACEMENT BY A
NEW CLICKBOX (AS OF
2003)
• Place shifter in gear position “2“.
TILL END 2002

• Loosen the knurled screw and pull the

Clickbox off the axle.
• Unscrew the adjusting screw (1, Fig. 12)
completely. Unscrew the cover screw (2),
brush aside the adjusting screw (1) and
remove the cover (3).
• Push the end (1, Fig. 11) of the adjust
!
ay gauge (Part. No. 65 0324 107 000) com-
t w pletely into the Clickbox and tighten up
t ha
n ly the knurled bolt (so you maintain the
n eo initial tension of the spring inside the
m bi Clickbox).
co
• Withdraw shifter cable and clamping
bolt (1, Fig. 5) upwards.
AS OF 2003

• Locate clamping bolt (1, Fig. 5) in the

new Clickboxh and place shifter cable
around the carrier cylinder (counter-
clockwise winding).
Advice:
If you remove the Clickbox from the
axle and change the cable without
using the end of the adjust gauge, then
11 you will lose the initial tension of the
spring inside the Clickbox. In this case
you must assemble the cable by placing
it around the carrier cylinder with an
additional winding (Fig. 5).
• Position the cover (3, Fig. 12) and tighten
up with the cover screw (2).
Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.).
Screw in the adjusting screw (1)
1 completely.
• Loosen the knurled screw on the Click-
box and pull the adjust gauge off.
• Push on Clickbox on the hub axle.
12 Tighten up the knurled bolt by hand.
2
3
1

26 Technical Manual 2003

SPECTRO P5
MAINTENANCE

DRUM BRAKE Lubrication of parts:

13 Install brake anchor plate (or exchange it): • To lubricate the bearing points on
• Place thrust washer (8, Fig. 13) over the the planetary gear sets, position the
axle on the adjusting cone and fit planetary gear carrier on its crown and
2
3 complete brake anchor plate. Position apply 2 – 3 drops of oil to the bearing
1
washer (9) distance sleeve (10) and bolts – at the same time turning the
4 6 screw on locknut (11). planetary gears so that the bearing
• Push brake lever (7) to the stop and hold points are completely wet. Oil axle
5 it there to center the brake jaws in the through the axle bore and axle slot,
8 brake drum – tighten up locknut with a apply a thin coating of grease to the
torque of 15 – 20 Nm (133 – 177 in.lbs.). outside.
9 7 • Oil the inside of the sun gears, grease
10 the outside teeth (fill the gaps in the
11
ADJUSTMENT DRUM BRAKE teeth).
• Unscrew adjusting screw (2, Fig. 13) • Oil outside teeth and carrier plate on
until the brake pads drag lightly. the coupling gear and lightly grease the
• Actuate the hand brake lever forcefully borehole from right and left.
several times and then, if necessary, • Do not apply grease to ring gear but just
turn the adjusting screw further in just oil the pawl pockets.
until the wheel starts spinning freely. • Grease the brake cone in the borehole
• Lock hex nut (3). and the friction spring.
• Spread grease on the inside and outside
Caution: of the brake shell.
Check that all the brake system • Fill lever cone with grease reserves for
components are functioning properly! brakes.
• Regrease ball retainer, line ball bearing
running tracks with grease.
MAINTENANCE /
LUBRICATION Advice:
Caution: The Spectro P5 hubs complete with
The Spectro hubs are provided with shifting component have been modified in
permanent lubrication and under normal such a way that the shifting forces are
conditions is maintenance-free. If the considerably lower than was previously
coaster brake is loaded excessively its the case.
effect can be too strong, the hub may lock. The new shifting component (shifter /
In such a case the brake shell should be Clickbox) is shown in Fig. 7, Page 23.
lubricated with a special grease (Part No. Indentification of the new hubs: red grub
0369 135 201). Renew brake shell, when screw (14, Fig. 1, Page 24) in the left axle
rhombic pattern is worn out. end and new spring (15) in the axle.
In order to achieve the maximum
Cleaning of parts: reduction in shifting forces with a
TROUBLESHOOTING • All parts – except for the planetary gear combination of new shifting component /
Problem Cause Remedy carrier – can be degreased in a cleaning old hub, the new spring (15) and the red
Shifting Damaged Replace bath. grub screw (14) should be installed in the
difficulties control cable control cable • The planetary gear carrier only needs to hub axle (see describtion “DISMANTLING/
Incorrect Adjust shift. be cleaned on the outside with a brush REASSEMBLY HUB“).
gear setting system so as not to degrease the planetary gear
To much ad- Beginning of bearing.
ditional axle axle thread
attachments must be visi- Caution:
between hub ble in front of Do not use high-pressure water when
and axle nut the axle nut cleaning the gear hub (e.g. strong water
Pedals are Bearings Re-adjust jets, high-pressure cleaners etc.) –
carried set too tight bearings if water penetrates it could lead to
forward Loose Tighten functional problems.
when free- lock nuts lock nuts
wheeling (15 – 20 Nm)
Chain is over- Reduce
tensioned chain tension
Hub locks Brake shell Wash out
when has run dry hub sleeve,
braking repolish and
(coaster relubricate
brake) brake cylin-
der, renew
brake shell

Technical Manual 2003 27

28 Technical Manual 2003
 SPECTRO P5 CARGO
TECHNICAL DATA / ASSEMBLY REQUIREMENTS CARGO

Caution:
The Spectro P5 Cargo is suitable for
tandems, trademen’s delivery bicycles
and similar. An additional external rear
brake is necessary due to the high load.

Tolerable stress: L Version with Coaster Brake

Axle load: max. 120 kilograms OLD
Torque/driver body: max. 85 Nm (750 in.lbs.), C
HR
no continuous stress. 1/2 OLD D
E DS
min. 13.5
Identification Spectro P5 Cargo: 7
Yellow grub screw inside the axle end.
T

0
F2 F1 Ø 7.3 10
R
Version Spectro P5 for normal bikes: A 2 max. A 1 max.
see page 21.
Cycle frame:
Caution: • Dropouts must be parallel.
Use always 2 retaining washers. • Slot width at rear dropout max. 10,5 mm.
Alternatively assemble both retaining • The strength must be such that with a maximum braking torque of 250 Nm (2200 in.lbs.) on the rear wheel no
washers on the left axle end (Fig. 5). residual deformation can occur on the rear structure.

Spectro P5 Cargo with coaster brake Spectro P5 with drum brake

Typ MH 5215 Cargo MH 5225 Cargo
Brake Coaster Drum „D“
Over Locknut Dim., OLD 122 mm 126 mm
Length, L 175 mm 179 mm
Axle

Ends Diameter, T FG 10.5 toothed cone FG 10.5

Dropout Width Dim. A1 max. = 12.5 mm / A2 max. = 11.5 mm A1 max. = 12.5 mm / A2 max. = 12.5 mm
Holes 36 36
Hole Diameter, DS 3.0 mm 2.9 mm
Spoke

Hole Ref. ø, HR 75 mm 89 mm

H Flange Dist. to 1/2 OLD F1 = 28.5 mm / F2 = 29.5 mm F1 = 30.5 mm / F2 = 29.5 mm

Totally 224 % ➔
U
Gear Hub Ratio

Speed 1 67 % ➔
B Speed 2 78 % ➔
S Speed 3 100 % ➔
Speed 4 128 % ➔
Speed 5 150 % ➔
Usable Dimensions 1
/2" x 1/8" or 1/2" x 3/32" 1
/2" x 1/8" or 1/2" x 3/32"
Chain

Line, C/D/E 49 / 45.5 / 43 mm 51.5 / 48.5 / 45.5 mm

Ratio 24", 26", 28"= 1.8 – 1.9 / 20"= 1.8 – 2.0 ➔
Shifter Compatib. Spectro Grip 5 ➔
Clickbox Compatib. Clickbox P5 ➔
Tandem Compatib. Yes Yes
Weight 1495 g 1536 g
Hub Shell Material Steel Aluminum
Finish

Finish Matt Chrome Plated Clear Coat

Technical Manual 2003 29

SPECTRO P5 CARGO
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

Spectro Grip 5
S
H
Part No.
Shifter Type
—
Twist Shifter
❘— ❘— ❘— ❘— ❘— ❘— ❘—
I Cable
Gear Indication
1450 mm
Window
❘ 1550 mm ❘ 1650 mm ❘ 1750 mm ❘ 1850 mm ❘ 1950 mm ❘ 2150 mm ❘ 2350 mm
F Clamping Diameter 22.3 mm
T Handlebar, Straight Area Minimum length for shifter = 150 mm

E Weight 89g
Housing Glass filled PA
R
Design

Grip PP
S Grip Cover Thermoplastic elastomer, Overmolded
Clamping Collar Aluminum

SPECTRO P5 CARGO
ASSEMBLY
A S S E M B LY H U B • Fit retaining washers (1, Fig. 4) on both
1 1 2 • Lace the wheel as normal. See spoke axle ends. The serrations must bear
length table. against the dropout and the lug must
• Place the dust cap (1, Fig. 1) and engage in the dropout slot.
sprocket (2) on the driver. In case of exceeding the dimension A 1
• Push sprocket circlip (3, Fig. 2) onto the max. = 12.5 mm (see Page 29), e.g. by thick
cone of tool sleeve (4). Place tool sleeve dropouts, both retaining washers should
with large diameter on the driver. be assembled on the left axle end (Fig. 5).
• Push the spring end of sliding sleeve (5) • On the sprocket side fit the protective
of the tool over the tool sleeve. Thrust bracket (1, Fig. 6) directly below the
2 4 3 5
sliding sleeve in direction (6), this forces
circlip into the recess of the driver.
fixing nut. Tightening torque on acorn or
hex nuts 30 – 40 Nm (266 – 350 in.lbs.).
• Remove tool and check that the circlip is • Mount the brake lever using a suitable
6 seated correctly. frame clamp (2, Fig. 4 resp. Fig. 10).
• Turn dust cap (7, Fig. 3) until the three Caution:
lugs (8) are between the three beads (9) Mount the brake lever between the two
Mounting Tool
on the sprocket (10). straps of the frame clamp.
Part No. 0582 104 000
• Position dust cap and push towards The clamp must be seated on the frame
sprocket until it is felt to lock into place. without play.
• Placing the wheel in the rear frame. Use a self-locking nut! Tightening
3 • Mount the chain. torque: 2 – 3 Nm (18 – 27 in.lbs.).
8 7

9 Spoke length table:

Tire Size Cross Length MH 5215 Length MH 5225
47–406 20" x 1.75 x 2 3x 181 mm 179 mm
10 37–490 22" x 1 3 / 8 3x 225 mm 222 mm
47–507 24" x 1.75 x 2 3x 232 mm 229 mm
37–540 24" x 1 3 / 8 3x 251 mm 248 mm
47–559 26" x 1.75 x 2 3x 259 mm 256 mm
4 5 37–590 26" x 1 3 / 8 3x 275 mm 272 mm
47–622 28" x 1.75 3x 289 mm 286 mm
37–622 28" x 1 3 / 8 x 1 5 / 8 3x 289 mm 286 mm
28–622 28" x 1 1 / 8 3x 289 mm 286 mm
32–622 28" x 1 5 / 8 x 1 1 / 4 3x 289 mm 286 mm
28–630 27" x 1 1 / 4 fifty 3x 294 mm 291 mm
1 32–630 27" x 1 1 / 4 3x 294 mm 291 mm
2
Spoke lengths are approximate values. They must be checked through lacing attempts
and adjusted accordingly.

30 Technical Manual 2003

SPECTRO P5 CARGO
ASSEMBLY CARGO

Advice: • Push locating sleeve (3) with guiding rib

6 • If a different protective bracket (1, Fig. 6) (4) to the front onto the hub axle – making
is used the thickness of the attachment sure that the internal lug (5) is guided in
plate must be max. 3 mm. the slot (6) of the shift tube until it can be
• Do not use additional washers. felt – and heard – to engage.
• At least the beginning of the axle thread • Turn locating sleeve on the axle until the
must be visible in front of the axle nut. guiding rib (4) is facing roughly upwards.
• Place shifter in gear position “2“.
• Push on Clickbox (2, Fig. 6) to the stop on
1 A S S E M B LY S H I F T E R S the hub axle. The guiding rib (4, Fig. 9) of
3 2 Advice: the locating sleeve thereby engages in
• Contrary to the old shifter version the the slot on the housing. In the end position
shifter cable of the new version runs tighten up the knurled bolt (3, Fig. 6) by
above the brake lever. Maybe you need hand (0,3 Nm / 2,7 in.lbs.).
7 4 50 mm more cable length.
5 • When choosing cable housing lengths,
be sure to allow enough housing for an ADJUSTMENT
extreme turn of the handlebars in both • Be sure to reset rotational shifter from
directions. 4th. to 3th gear.
3 2 • Note also, that different stem lengths • Match up the marks in the Clickbox
1
and handlebar positions effects cable viewing window (4, Fig. 7) by turning
housing length. the adjusting screw (5).
• Slide shifter (1, Fig. 7) onto handlebar.
• Mount fixed grip (2) onto end of handlebar.
• Slide shifter against fixed grip, adjust CONNECTING DRUM BRAKE
shifter on handlebar and tighten with Caution:
bolt (3) with a torque of 1.5 Nm (13 in.lbs.). Only use brake levers with a cable
8 moving distance of at least 15 mm and a
minimum leverage of 3.8.
Caution:
2 1
• Never use lubricants or solvents to • Fit cable stop (1, Fig. 10) with adjusting
install fixed grips. bolt (2) and nut (3) and insert into the slot
Fixed grips provide an axial safety on the brake anchor plate.
function. For this reason, they should be • Turn adjusting bolt down by approx. 2/3
mounted in such a way as to make sure and route the brake cable from the
they do not slip off handlebar. brake handle.
• Check that the shifter and brake lever • Push lower brake cable end through
function properly and are unobstructed adjusting bolt (2) and insert lower cable
(realign if necessary). housing end into adjusting bolt.
• Never ride without the fixed grips. The • Thread brake cable end (4) into
9 7 turning grip may loosen from housing fork unit (5).
and slip off handlebar – this can result • Tighten screw (6) slightly.
in severe injury or death. • Attach fork unit to brake lever (7).
6 • Pull brake cable end taut with pliers
4 • When fitting the cable avoid small radius. so that fork unit can still be attached and
Attach the cable 3 times to the down removed (important for changing wheel).
2 tube (1, Fig. 8). • Tighten screw (6).
1 • Last attachment point is on the lower
3 rear wheel fork (2, Fig. 8) immediately
5
behind the chain wheel. ADJUSTMENT DRUM BRAKE
Cable housing must be movable inside • Unscrew adjusting screw (2, Fig. 10)
10 attachment. until the brake pads drag lightly.
• Actuate the hand brake lever forcefully
2 several times and then, if necessary,
3
1 INSTALLING CLICKBOX turn the adjusting screw further in just
• Insert shift rod (1, Fig. 9) in shift tube (2) until the wheel starts spinning freely.
4 6
(oil parts lightly) and then push into axle • Lock hex nut (3).
bore as far as the stop. If the shifting rod
5
is sticking up out of the axle end: apply
slight pressure on the shift rod with its
7
threaded section and screw inwards in
a clockwise direction until it can again
be moved axially (valid for older hub
versions). Turn slot (6) in shift tube to a
8 position where it is easily visible.

Technical Manual 2003 31

SPECTRO P5 CARGO
MAINTENANCE

1 8
7

5 29
28
4
27
3
2

1 26
17 25
24
16 23 39
15 22 41
21 38
14 20
19
18
40
13 37
36
35
12
11
10 34
32 33
9
31
30

2
REMOVE WHEEL • Take out thrust block (24), (to do this
• Place shifter in gear position “2“. compress the spring). Remove spring
Spectro P5 mounting aid • Loosen the knurled screw and pull the (22) and the two covers (23/21).
Part No. 5024 300 000 Clickbox off the axle. • Dismantle retaining washer (20), washer
• Disengage the location sleeve and pull it (19), conical compression spring (18),
off. Remove shift rod/tube, if necessary and the large sun gear (12). Clamp other
pull shift rod outwards and unscrew in a axle end (thrust block visible).
counter-clockwise direction. • Unscrew grub screw (14) – Dismantle
• Remove wheel. spring (15), guide bolt (16) and thrust
block (17).
DISMANTLING HUB • Remove small sun sun gear (11).
X see Fig. 1
R E A S S E M B LY H U B
• Remove circlip (35), sprocket (34) and
see Fig. 1
dust cap (33).
• Clamp hub with sprocket side facing Lubrication see “ MAINTENANCE /
downwards with the two axle flats. LUBRICATION“.
• Unscrew the two locknuts (1). • Clamp axle with internal thread up-
• Remove lever cone (2), ball retainer (3) wards.
and brake shell (4). • Position small sun gear (11) with crown
• Withdraw hub sleeve (5) upwards. gears to the front.
• Unscrew brake cone (6) from flat thread. • Position thrust block (17) in the slotted
• Remove retaining washer (7), thrust hole (is laterally guided when the sun
washer (8). gear is screwed in).
• Remove planetary gear carrier (9) and • Locate bolt (16), then spring (15) in the
thrust washer (10). axle and screw in grub screw (14) until
• Clamp other axle end. it is flush with the axle.
• Unscrew fixed cone (32). • Reclamp axle. Fit large sun gear (12) (it
• Remove driver (31), compression spring is the same both sides). Position conical
(29), large compression spring (27) and ball compression spring (18), with the large
retainer (30). – Withdraw gear ring (26) diameter first. Press spring together and
and coupling gear (25) and then remove fit washer (19) and retaining washer (20).
cover (28) from the coupling gear.

32 Technical Manual 2003

SPECTRO P5 CARGO
MAINTENANCE CARGO

• Assemble cover (21), compression CABLE CHANGE

4 spring with 7 turns (22) and the second Dismantling shifter cable:
2 cover (23, insides to the spring). • Place shifter in gear position “2“.
3
• Compress spring and position thrust • Do not remove the Clickbox from the axle
1
block (24) (it is the same both sides) in end.
the center of the slotted hole. • Unscrew the adjusting screw (1, Fig. 4)
• Position coupling gear (25) with carrier completely. Unscrew the cover screw (2),
plate facing downwards. brush aside the adjusting screw (1) and
• Fit cover (28, inside to the spring) for remove the cover (3).
compression spring. • Withdraw shifter cable and clamping
• Position gear ring (26) over the teeth of bolt (1, Fig. 5) upwards, loosen clamp
the coupling gear. and pull clamping piece from the cable.
• Place ball retainer (30), with balls below • Slightly lift the grip cover (Fig. 6), push
on the gear ring. the cable out and discard.
• Position large compression spring (27)
5 on gear ring. Assembly shifter cable:
• Mount compression spring with 13 turns • Route new cable through shifter housing
1 (29) on the axle. (Is supported in the and pull cable to seat cable head
coupling wheel by the cover). completely into cable recess.
• Locate driver (31), press it down and Feed the cable through the new cable
screw on fixed cone (32) as far as the housing and adjusting screw.
stop. Tightening torque 20 Nm. (Then • Position clamping bolt (1, Fig. 7) at a
2 reclamp hub.) distance of 80 mm, tighten up with
• Push on thrust washer (10) and fit 1.5 Nm (13 in.lbs.) and cut off cable ends
planetary gear carrier (9). In doing this: to 2 – 3 mm. For positioning the clamping
Position mounting aid (Fig. 2) on the bolt use adjust gauge (Fig. 8). (Part. No.
planetary gear carrier so that the (X) 65 0324 107 000)
markings on the threeplanetary gears • Locate clamping bolt (1, Fig. 5) and place
match with the mounting aid. shifter cable around the carrier cylinder
• Insert planetary gear carrier, place
6 thrust washer (8) on it and mount
(counter-clockwise winding).
• Position the cover (3, Fig. 4) and tighten
retaining washer (7) in recess. up with the cover screw (2).
Only now remove the mounting aid. Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.).
Screw in the adjusting screw (1)
Advice: completely.
If the gears are not accurately installed
the hub may be tight to move. Advice:
This could lead to damage to the gear- • If you want to remove the Clickbox from
wheels in operation. the axle end for changing the cable, do
as follows:
• Screw brake cone (6) onto flat threads. – Place shifter in gear position “2“.
• Mount hub sleeve (5), with a slight – Loosen the knurled screw and pull the
counter-clockwise turn. Clickbox off the axle.
• Locate brake shell (4, Fig. 1) – with – Now it’s essential to push the end (1,
retaining lugs uppermost –, then the Fig. 8) of the adjust gauge completey
7 friction spring on the brake cone must
engage with the slot on the brake shell.
into the Clickbox and tighten up the
knurled bolt (so that you maintain the
• Insert ball retainer (3) – with balls below. initial tension of the spring inside the
2 +1 mm 80 ±0,5 mm • Position lever cone (2) – in doing this Clickbox).
turn it clockwise until the retaining – Change cable as per description above.
lugs engage. • If you remove the Clickbox from the
• Screw on counternuts (1), adjust bearings axle and change the cable without
to be free of play and tighten lock nuts. using the end of the adjust gauge, then
1 Tightening torque 15 – 20 Nm you will lose the initial tension of the
(133 – 177in.lbs.). spring inside the Clickbox. In this case
you must assemble the cable by placing
Advice: it around the carrier cylinder with an
8 The dismantly and reassembly of the hub additional winding (Fig. 5).
type MH 5225 should be carried out in the
same way. Differences: Instead of brake
shell/cone a click-and-pawl carrier is
installed on the planetary gear carrier
here. Without flat thread – fixed with a
retaining washer.

Technical Manual 2003 33

SPECTRO P5 CARGO
MAINTENANCE

EXCHANGEABILITY ADJUSTMENT
9 SHIFTER / CLICKBOX • Be sure to reset rotational shifter from
Produced till 1998 (Fig. 9): 4th. to 3th gear.
Dont’t combine with newer versions! • Match up the marks in the Clickbox
viewing window (Fig. 12) by turning
TILL 1998

Produced till end 2002 and as of 2003 (Fig. 10):

the adjusting screw (1).
Combine shifter and Clickbox only accor-
ding to Fig. 10.
Distance of the clamping bolt:
Each Clickbox version needs its specific
distance of the clamping bolt:
• Till 1998: Distance 68,5 mm
Don’t combine with newer versions!
• Till end 2002: Distance 83 mm
• As of 2003: Distance 80 mm

10 REPLACEMENT BY A
NEW CLICKBOX (AS OF
2003)
• Place shifter in gear position “2“.
TILL END 2002

• Loosen the knurled screw and pull the

Clickbox off the axle.
• Unscrew the adjusting screw (1, Fig. 12)
completely. Unscrew the cover screw (2),
brush aside the adjusting screw (1) and
remove the cover (3).
• Push the end (1, Fig. 11) of the adjust
!
ay gauge (Part. No. 65 0324 107 000) com-
t w pletely into the Clickbox and tighten up
t ha
n ly the knurled bolt (so you maintain the
n eo initial tension of the spring inside the
m bi Clickbox).
co
• Withdraw shifter cable and clamping
bolt (1, Fig. 5) upwards.
AS OF 2003

• Locate clamping bolt (1, Fig. 5) in the

new Clickboxh and place shifter cable
around the carrier cylinder (counter-
clockwise winding).
Advice:
If you remove the Clickbox from the
axle and change the cable without
using the end of the adjust gauge, then
11 you will lose the initial tension of the
spring inside the Clickbox. In this case
you must assemble the cable by placing
it around the carrier cylinder with an
additional winding (Fig. 5).
• Position the cover (3, Fig. 12) and tighten
up with the cover screw (2).
Torque 0.35 – 0.45 Nm (3.1 – 4.0 in.lbs.).
Screw in the adjusting screw (1)
1 completely.
• Loosen the knurled screw on the Click-
box and pull the adjust gauge off.
• Push on Clickbox on the hub axle.
12 Tighten up the knurled bolt by hand.
2
3
1

34 Technical Manual 2003

SPECTRO P5 CARGO
MAINTENANCE CARGO

DRUM BRAKE Lubrication of parts:

13 Install brake anchor plate (or exchange it): • To lubricate the bearing points on
• Place thrust washer (8, Fig. 13) over the the planetary gear sets, position the
2 axle on the adjusting cone and fit planetary gear carrier on its crown and
3
1 complete brake anchor plate. Position apply 2 – 3 drops of oil to the bearing
washer (9) distance sleeve (10) and bolts – at the same time turning the
4 6
screw on locknut (11). planetary gears so that the bearing
• Push brake lever (7) to the stop and hold points are completely wet. Oil axle
5 through the axle bore and axle slot,
8 it there to center the brake jaws in the
brake drum – tighten up locknut with a apply a thin coating of grease to the
torque of 15 – 20 Nm (133 – 177 in.lbs.). outside.
9 7
10 • Oil the inside of the sun gears, grease
11 the outside teeth (fill the gaps in the
ADJUSTMENT DRUM BRAKE teeth).
• Unscrew adjusting screw (2, Fig. 13) • Oil outside teeth and carrier plate on
until the brake pads drag lightly. the coupling gear and lightly grease the
• Actuate the hand brake lever forcefully borehole from right and left.
several times and then, if necessary, • Do not apply grease to ring gear but just
turn the adjusting screw further in just oil the pawl pockets.
until the wheel starts spinning freely. • Grease the brake cone in the borehole
• Lock hex nut (3). and the friction spring.
• Spread grease on the inside and outside
Caution: of the brake shell.
Check that all the brake system • Fill lever cone with grease reserves for
components are functioning properly! brakes.
• Regrease ball retainer, line ball bearing
running tracks with grease.
MAINTENANCE /
LUBRICATION
Caution:
The Spectro hubs are provided with
permanent lubrication and under normal
conditions is maintenance-free. If the
coaster brake is loaded excessively its
effect can be too strong, the hub may lock.
In such a case the brake shell should be
lubricated with a special grease (Part No.
0369 135 201). Renew brake shell, when
rhombic pattern is worn out.

Cleaning of parts: TROUBLESHOOTING

• All parts – except for the planetary gear Problem Cause Remedy
carrier – can be degreased in a cleaning
Shifting Damaged Replace
bath.
difficulties control cable control cable
• The planetary gear carrier only needs to
be cleaned on the outside with a brush Incorrect Adjust shift.
gear setting system
so as not to degrease the planetary gear
bearing. To much ad- Beginning of
ditional axle axle thread
Caution: attachments must be visi-
between hub ble in front of
Do not use high-pressure water when
and axle nut the axle nut
cleaning the gear hub (e.g. strong water
jets, high-pressure cleaners etc.) – Pedals are Bearings Re-adjust
if water penetrates it could lead to carried set too tight bearings
forward Loose Tighten
functional problems.
when free- lock nuts lock nuts
wheeling (15 – 20 Nm)
Chain is over- Reduce
tensioned chain tension
Hub locks Brake shell Wash out
when has run dry hub sleeve,
braking repolish and
(coaster relubricate
brake) brake cylin-
der, renew
brake shell

Technical Manual 2003 35

36 Technical Manual 2003
 SPECTRO T3
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

• Easy Adjust
• Superior Quality
L Version with Coaster Brake HR
• Matte Chrome Finish
OLD
• Most Efficient Hub In Its Class
C DS
1/2 OLD D
E
Caution:
Spectro T3 hubs are not suitable for
tandems, trademen’s delivery bicycles
and similar.

Cycle frame:
T

• Dropouts must be parallel.

Ø 7.3
• Slot width at rear dropout max. 10,5 mm.
• The strength must be such that with a maxi-
mum braking torque of 250 Nm (2200 in.lbs.)
on the rear wheel no residual deformation
0
can occur on the rear structure. F2 F1 10
R

Spectro T3 with coaster brake Spectro T3 with drum brake Spectro T3 without brake
Type MH 3115 MH 3125 MH 3105

Over Locknut Dim., OLD

Brake Coaster
118 mm
Drum „D“
118 mm
❘ „NL“ None
117 mm
Length, L 152 / 164 mm 164 mm 152 mm ❘ 164 mm
Axle

Ends Diameter, T FG 10.5 FG 10.5 FG 10.5

Holes
Hole Diameter, DS
36
3.0 mm
❘ 28 36
2.8 mm
36
3.0 mm
Spoke

H Hole Ref. ø, HR 58 mm 89 mm 58 mm

U Flange Dist. to 1/2 OLD F1 = 24.5 mm / F2 = 25.5 mm F1 = 25.5 mm / F2 = 32.5 mm F1 = 24.5 mm / F2 = 25.5 mm
Chain Gear Hub Ratio

Totally 186 % ➔ ➔
B Speed 1 73 % ➔ ➔
S Speed 2 100 % ➔ ➔
Speed 3 136 % ➔ ➔
Line, C/D/E 44.5 / 41.5 / 38.5 mm 44.5 / 41.5 / 38.5 mm 44 / 41 / 38 mm
Ratio 24", 26", 28"= 2.0 – 2.4 / 20"= 2.0 – 2.5 ➔ ➔
Shifter Compatib. Spectro Grip 3 / Spectro Bandix 3 ➔
Tandem Compatib. — — —
Weight 1182 g 1270 g 911 g
Hub Shell Material Steel Aluminum Steel
Finish

Finish Matt Chrome Plated Silver Painted Matt Chrome Plated

Spectro Grip 3 (for adults) Spectro Bandix 3 (for kids) NEW

NEW

S
Part No.
Shifter Type
—
Twist Shifter
❘ —
Twist Shifter
—

H Cable
❘
ø 1.2 mm 2174 mm 2500 mm ø 1.2 mm 2174 mm

I Comp. Cable Housing Capped, Compressionless with Resin Liner inside

Gear Indication Printed Printed
F Barrel Adjuster Indexing Indexing
T Clamping Diameter 22.3 mm 22.3 mm

E Handlebar, Straight Area Minimum length for shifter = 145 mm Minimum length for shifter = 125 mm
Weight 58 g 58 g
R Housing PA PA
S
Design

Grip PA PA
Grip Cover Thermoplastic elastomer Thermoplastic elastomer
Clamping Collar Aluminum Aluminum

Technical Manual 2003 37

SPECTRO T3
ASSEMBLY

1 2 A S S E M B LY H U B Advice:
1 • Lace the wheel as normal. See spoke The Spectro T3 hubs have been modified
length table. for the series launch of the new
• Place the dust cap (1, Fig. 1) and deflection pulley.
sprocket (2) on the driver. Identification: yellow counter nut on
• Push sprocket circlip (3, Fig. 2) onto the the driving end of the axle and modified
cone of tool sleeve (4). Place tool sleeve compression spring (22 resp. 14, Fig. 1 /
with large diameter on the driver. Page 40)
• Push the spring end of sliding sleeve (5) In order to prevent malfunctions, these
2 4 3 5 of the tool over the tool sleeve. Thrust modified hubs may no longer be combined
sliding sleeve in direction (6), this forces with the chain guide nut.
6 circlip into the recess of the driver. The deflection pulley can also be used for
• Remove tool and check that the circlip is the previous hub version (silver-coloured
seated correctly. counter nut on the axle). In order to
Mounting Tool
Part No. 0582 104 000 • Turn dust cap (7, Fig. 3) until the three achieve the maximum reduction in
lugs (8) are between the three beads (9) shifting forces with this
on the sprocket (10). combination, the new, modified compres-
3 8 7 • Position dust cap and push towards sion spring should be installed (descripti-
on see „REASSEMBLY HUB“).
sprocket until it is felt to lock into place.
9 • Screw tension chain (2, Fig. 5) into the
axle end. Caution:
• Placing the wheel in the rear frame. • Only install additional axle attachments
• Mount the chain. (e.g. struts) between nut and retaining
10 • After positioning the wheel in the rear washer.
fork fit non-turn washer (1, Fig. 4) to the • Cable stop bracket: dimensions
outside of the dropout (hub side opposite see Fig. 9.
the sprocket). The serrations must bear • Axle end must protrude by min. 1 mm
4 against the dropout and the lug must to max. 4 mm beyond the nut (1, Fig. 5).
engage in the dropout slot.
• Tighten up special type axle nut (1, Fig. 5) • Mount the brake lever using a suitable
and axle nut at other axle end. Tightening frame clamp (2, Fig. 4 resp. Fig 10).
torque 30 – 40 Nm (266 – 350 in.lbs.). Caution:
• Guide tension chain (2) trough Mount the brake lever between the two
deflection pulley (3). straps of the frame clamp.
1 The clamp must be seated on the frame
• Position deflection pulley at axle nut and
2 push until it is felt to lock into place. without play.
Turn deflection pulley until the yellow Use a self-locking nut! Tightening
area is at the top (4, Fig. 6). torque: 2 – 3 Nm (18 – 27 in.lbs.).
5

Spoke length table:

Tire Size Cross Length MH 3115/3105 Length MH 3125
1
28 / 36 Holes 28 / 36 Holes 36 Holes
2 47–406 20" x 1.75 x 2 2x/3x 182 mm / 184 mm —
37–490 22" x 1 3 / 8 — /3x — / 228 mm —
3 47–507 24" x 1.75 x 2 2x/3x 234 mm / 235 mm —
37–540 24" x 1 3 / 8 — /3x — / 254 mm —
47–559 26" x 1.75 x 2 2x/3x 258 mm / 262 mm 253 mm
37–590 26" x 1 3 / 8 — /3x — / 254 mm 273 mm
6 47–622 28" x 1.75 2x/3x 289 mm / 292 mm 285 mm
28–622 28" x 1 1 / 8 — /3x — / 292 mm 285 mm
32–622 28" x 1 5 / 8 x 1 1 / 4 — /3x — / 292 mm 285 mm
37–622 28" x 1 3 / 8 x 1 5 / 8 — /3x — / 292 mm 285 mm
28–630 27" x 1 1 / 4 fifty — /3x — / 297 mm 287 mm
32–630 27" x 1 1 / 4 — /3x — / 297 mm 287 mm
4
Spoke lengths are approximate values. They must be checked through lacing attempts
and adjusted accordingly.

38 Technical Manual 2003

SPECTRO T3
ASSEMBLY

A S S E M B LY S H I F T E R S ADJUSTMENT
7 • Slide shifter (1, Fig. 7) onto handlebar. • Place the shifter in gear position "3".
1 • Add thrust washer (2). Move the crank to check that the gear
• Mount fixed grip (3) onto end is engaged.
of handlebar. • To make the adjustment, the cable must
• Without applying pressure, slide shifter be taut in third gear to be able to transfer
3
against fixed grip, adjust shifter on a shift movement directly to the hub.
handlebar and tighten with bolt (4). Allen • Push locating sleeve (2, Fig. 8) onto the
2
key 2.5 Nm, torque 1,7 Nm (15 in.lbs.) small pull rod (3) until the control cable
4 • Not recommended for use on thin walled is taut. Make sure that you don’t pull the
2.5 mm aluminum handlebars such as Hyperlite © indicator chain out of the deflection
1.7 Nm type handlebars. pulley (4).
15 in.lbs.
Caution: Check:
• Never use lubricants or solvents to • Place shifter in gear position "1" while
8 install fixed grips.
Fixed grips provide an axial safety
moving the crank.
• Setting too loose: In gear position "1" the
function. For this reason, they should be tension chain can be pulled out of the
mounted in such a way as to make sure deflection pulley by hand.
they do not slip off handlebar. • Setting too tight: It is difficult to place
• Check that the shifter and brake lever the shift lever in gear position "1".
function properly and are unobstructed • If required, readjust the shift mechanism
(realign if necessary). (in third gear).
5 • Never ride without the fixed grips. The
4 turning grip may loosen from housing
and slip off handlebar – this can result CONNECTING DRUM BRAKE
1 in severe injury or death. Caution:
3 2
Only use brake levers with a cable
moving distance of at least 15 mm and a
INSTALLING CABLE minimum leverage of 3.8.
• When fitting the cable avoid small radius. • Fit cable stop (1, Fig. 10) with adjusting
9 Use only compressionless cable housings bolt (2) and nut (3) and insert into the slot
with resin liner inside and capped. on the brake anchor plate.
• Screw the cable stop clamp and cable • Turn adjusting bolt down by approx. 2/3
min.
13 mm pully clamp on the down tube or seat tube. and route the brake cable from the
max. 30° • Secure the lubricated shift cable at brake handle.
equidistant intervals on the frame • Push lower brake cable end through
(in case of continuous cable housing). adjusting bolt (2) and insert lower cable
• Feed the shifter cable into the locating housing end into adjusting bolt.
min. 12 mm sleeve (5, Fig. 8), fix at the appropriate • Thread brake cable end (4) into
min. 90 mm length (cable stop bracket: see Fig. 9) fork unit (5).
using the clamping bolt (1). • Tighten screw (6) slightly.
Allan key 2.5 mm, tightening torque • Attach fork unit to brake lever (7).
1.5 Nm (13 in.lbs.). Shorten any cable • Pull brake cable end taut with pliers
which is sticking out. so that fork unit can still be attached and
• Connect to the hub: push locating sleeve removed (important for changing wheel).
10 (2, Fig. 8) loosely onto small pull rod (3). • Tighten screw (6).

Caution:
2 For NL version drum brake hub with
3 special lever (8), only use original NL
1
brake cable (fork unit (5) is not suitable).
4 6

ADJUSTMENT DRUM BRAKE

5 • Unscrew adjusting screw (2, Fig. 10)
until the brake pads drag lightly.
7 • Actuate the hand brake lever forcefully
several times and then, if necessary,
turn the adjusting screw further in just
until the wheel starts spinning freely.
• Lock hex nut (3).

Technical Manual 2003 39

SPECTRO T3
MAINTENANCE

1 Coaster brake / MH 3115

REMOVE WHEEL
• Apply fingertip pressure onto the metal
key of locating sleeve to release it from
14 the pull rod.
13 • Remove deflection pulley.
11 • Screw off both axle nuts and remove
5
retaining washers.
4 • Remove wheel.
3
12
2 10 DISMANTLING HUB
1 see Fig. 1
9 23 • Unscrew indicator chain (23), remove
8 22 circlip (21), sprocket (20), dust cap (19)
7 20 21
6 and clamp axle (10) on the driver side.
19 • Unlock hexagonal nuts (1) and unscrew.
• Remove brake arm (2), ball retainer (3)
18 and brake sleeve (4) and remove hub
17
16 shell (5).
• Remove safety washer (7), thrust washer
(8) and then the planet carrier (9)
complete with brake cone (6). Unscrew
the brake cone from the planet carrier.
• Clamp other axle end.
a x
• Loosen the lock nut (22) and fixed cone
2 Without brake / MH 3105
b (18) and remove.
• Remove driver (17), compression springs
c (14 and 13) and ball retainer (16).
• Push the sliding key (12) through the
large bore in the coupling wheel of the
ring gear (11) – the bore and thrust block
3
must be aligned.
d
e • Remove the gear ring (11) from the axle.

Advice:
The dismantly and reassembly of the hubs
with drum brake and without brake
1 should be carried out in the same way
(Fig. 2 / 3).

Differences
• There is no brake sleeve (4) and brake
cone (6).
• The planet carriers (a) have a cylindrical
shaft instead of a flat thread, which hou-
ses a pawl carrier (b) held by a safety
washer instead of the brake cone.
3 Drum brake / MH 3125 • Further differences: instead of a lever
x
a cone (2) for type MH 3115, an adjusting
b cone (d) with dust cap (e) for type
MH 3105 and a small adjusting cone (D)
c and corresponding ball retainer (f) for
type MH 3125 are fitted.

f
D

40 Technical Manual 2003

SPECTRO T3
MAINTENANCE

R E A S S E M B LY H U B CABLE CHANGE
4 see Fig. 1 / 2 / 3 Dismantling shifter cable:
• Use only new cable and compression-
Lubrication see “ MAINTENANCE / less cable housing
LUBRICATION“. • Detach the cable from the internal hub.
Ø 1,1 mm • Clamp the hub axle (10) with the slot for • Remove the cable housing. Cut the cable
thrust block upwards), fit ring gear (11) off 15 cm (6") from the shifter barrel
and align the large bore in the coupling adjuster. Discard the old cable and cable
wheel with the slot. Position the radius housing.
of the sliding key (12) facing downwards • Line up the ‘3’ gear number mark with
and turn the coupling wheel slightly. the indicator mark.
• Fit the compression springs (13 and 14). • From the edge, pull open the cable
• Place ball retainer with balls in (16) on change hatch (Fig. 6).
ring gear (11), mount driver (17), fit fixed • Remove and discard the rest of the old
cone and lock with hexagonal nut (22), cable.
tightening torque 15 – 20 Nm
(133 – 177 in.lbs). Assembly shifter cable:
• Turn hub over and slide on planet carrier • Feed the new cable through the shifter.
5 (9) – thrust washer (X) must first be fitted • Feed the cable through the new cable
for types MH 3105/3125. (For type MH housing and stops.
3115, this washer is already integrated in • Feed the shifter cable into the locating
the planet carrier). Mount thrust washer sleeve (5, Fig. 7), fix at the appropriate
Ø 1,4 mm
(8) and place safety washer (7) in the length using the clamping bolt (1). Allan
recess of the axle. key 2.5 mm, tightening torque 1.5 Nm
• Screw brake cone (6, type MH 3111) onto (13 in.lbs.). Shorten any cable which is
the flat thread – for types MH 3105/3125 sticking out.
mount pawl carrier (b) and secure in • Connect to the hub: push locating sleeve
place using safety washer (c). (2, Fig. 7) loosely onto small pull rod (3).
• Fit hub shell (5) – turning it counter-
clockwise slightly to get past the stop ADJUSTMENT
notches – until the shell runs cleanly • Place the shifter in gear position "3".
onto the ball retainer. Move the crank to check that the gear
• For type MH 3115, insert the brake slee- is engaged.
ve (4) so that the spring end of the fric- • To make the adjustment, the cable must
tion spring on the brake cone (6) sits in be taut in third gear to be able to transfer
6 one of the two slots on the brake sleeve. a shift movement directly to the hub.
Insert the ball retainer and fit the lever • Push locating sleeve (2, Fig. 7) onto the
cone – move the lever cone lightly until small pull rod (3) until the control cable
the lugs on the brake lever catch in the is taut. Make sure that you don’t pull the
grooves on the adjusting cone. indicator chain out of the deflection
• Adjust the hub clearance by screwing on pulley (4).
hexagonal nut (1) until the hub shell runs
free of play but not under tension. Lock Check:
with a second nut to a tightening torque • Place shifter in gear position "1" while
of 15 – 20 Nm (133 – 177 in.lbs.). moving the crank.
• For type MH 3105 insert ball retainer (3), • Setting too loose: In gear position "1" the
mount adjusting cone (d) with dust cap tension chain can be pulled out of the
(e) and hexagonal nuts (1). Adjust the deflection pulley by hand.
hub clearance as for type MH 3115. • Setting too tight: It is difficult to place
• For type MH 3125, the ball retainer (f) the shift lever in gear position "1".
7 and dust cap (pressed in) normally • If required, readjust the shift mechanism
remain in the hub shell. The hub (in third gear).
clearance is set with adjusting cone (D)
as for type MH 3115.

1
3 2

Technical Manual 2003 41

SPECTRO T3
MAINTENANCE

DRUM BRAKE Cleaning of parts:

8 Instal brake anchor plate (or exchange it): • All parts – except for the planetary gear
• Place thrust washer (8, Fig. 8) over the carrier – can be degreased in a cleaning
axle on the adjusting cone and fit bath.
2
3 complete brake anchor plate. Position • The planetary gear carrier only needs to
1
washer (9) distance sleeve (10) and be cleaned on the outside with a brush
4 6 screw on locknut (11). so as not to degrease the planetary gear
• Push brake lever (7) to the stop and hold bearing.
5 it there to center the brake jaws in the
8 brake drum – tighten up locknut with a Lubrication of parts:
torque of 15 – 20 Nm (133 – 177 in.lbs.). • To lubricate the bearing points on
9 7 the planetary gear sets, position the
10 planetary gear carrier on its crown and
11
ADJUSTMENT DRUM BRAKE apply 2 – 3 drops of oil to the bearing
• Unscrew adjusting screw (2, Fig. 8) until bolts – at the same time turning the
the brake pads drag lightly. planetary gears so that the bearing
• Actuate the hand brake lever forcefully points are completely wet. Oil axle
several times and then, if necessary, through the axle bore and axle slot,
turn the adjusting screw further in just apply a thin coating of grease to the
until the wheel starts spinning freely. outside.
• Lock hex nut (3). • Oil the inside of the sun gears, grease
the outside teeth (fill the gaps in the
Caution: teeth).
Check that all the brake system • Oil outside teeth and carrier plate on
components are functioning properly! the coupling gear and lightly grease the
borehole from right and left.
• Do not apply grease to ring gear but just
MAINTENANCE / oil the pawl pockets.
LUBRICATION • Grease the brake cone in the borehole
Coaster Brake: and the friction spring.
Improved braking in third gear after • Spread grease on the inside and outside
production date CW 38/96 of the brake shell.
• In case of repair, older hub models (Fig. 4) • Fill lever cone with grease reserves for
can be converted with a repair set (Fig. 5). brakes.
It is important that all three parts are • Regrease ball retainer, line ball bearing
replaced at the same time – new, running tracks with grease.
reinforced compression springs, planet
carrier with 4 lugs and ring gear with Caution:
4 lugs on the driving plate. Do not use high-pressure water when
cleaning the gear hub (e.g. strong water
A change at the new or converted hubs: jets, high-pressure cleaners etc.) –
• When braking in third gear, the indicator if water penetrates it could lead to
chain moves out of the deflection pulley functional problems.
by approx. one chain link – after braking,
the tension chain returns immediately to
its normal position.

Caution:
The Spectro hubs are provided with
permanent lubrication and are maintenance-
free under normal conditions. For type
MH 3115, however, particularly high
loading of the coaster brake can cause
to overcompensate. In this case, apply
special grease (Part No. 0369 135 201) to
the brake sleeve or replace it.
Renew brake shell, when rhombic pattern
is worn out.

42 Technical Manual 2003

SPECTRO T3
MAINTENANCE

TROUBLESHOOTING
Problem Cause Remedy
Shifting difficulties Incorrect gear setting Adjust shifting system, oil
control cable, check that cable
stop is fastened correctly.
Pedals are carried forward Bearings set too tight Re-adjust bearing
when freewheeling Loose lock nuts Tighten lock nuts (15 – 20 Nm)
Chain is overtensioned Reduce chain tension
Ccoaster brake:
Hub locks when braking Brake shell has run dry Wash out hub sleeve, re-
polish and relubricate brake
cylinder, renew brake shell
Pedals yield slowly during Brake cone / brake sleeve Replace brake cone and brake
braking (does not impair sleeve
safety).

Technical Manual 2003 43

44 Technical Manual 2003
 SPARC
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

190 205
135 33.5 194
40 55 40

16 25

2.7

30°
185

8.6
Caution:
Not suitable for tandems, tradesmen’s
12.5 67.5 49.5 delivery bicycles and similar.

Sparc hub NEW

NEW S Sparc Shifter
Version Europe 28" Europe 20" USA 26" H Part. No. —
❘— ❘—
Econ Mode 18 km/h 18 km/h 14 mph I Shifter Type Twist Shifter
Electric Drive V max.

Speed Mode
Engine Type
24 km/h
2 x 12V DC engines
24 km/h 18 mph
F Cable
Gear Indication
1500 mm
Window
❘ 1600 mm ❘ 1700 mm
Power 2 x 100 W max.
T Clamping Diameter 22.3 mm
Assist Type Pedal controlled
E Handlebar, Straight Area Minimum length = 150 mm
Assist Ratio Econ / Speed
R Weight 70 g
Brake None
Over Locknut Dim. 135 mm
Length 190 mm
R Sparc Remote Control Unit

❘ —1600 mm ❘ —1700 mm ❘ —1800 mm ❘ —2200 mm

Axle

Ends Diameter FG 10.5 E Part. No. —

H Holes 36 M
.
Cable 1500 mm ❘ ❘ ❘ ❘
U Mode Selector Off / Econ / Speed
Spoke

Hole Diameter 2.9 mm

B Hole Reference ø 194 mm C Mode Indication Printed

Totally 249 % O Clamping Diameter 22.3 mm

N
.
Cable Connection 3.5 mm stereo jack
Gear Hub Ratio

Speed 1 63 %
Weight 45 g
Speed 2 78 %
Speed 3 100 %
Speed 4 128 % Sparc Battery Box
Speed 5 158 % B Part No. — — — — —
Usable Dimension 1/
2" x /8" or /2" x /32"
1 1 3
A Cable 650 mm 750 mm 850 mm 1400 mm 1950 mm
.
Chain

Line 49.5 mm (only off-set sprockets) Battery 12V / 7Ah lead battery
Ratio 1.7 – 1.9 2.3 – 2.6 1.8 – 2.6 B Charger 12V / 1.5A 12V / 2.0A
Shifter Compatib. Sparc Shifter O Charging time 4 hours 45 minutes 3 hours 30 minutes
Frame Compatib. Dropouts max. 7 mm / OLD 135 mm X Luggage carrier comp. Struts: ø 8 mm / dist. 68 mm center to center / parallel
Weight 2500 g Weight 3000 g

Technical Manual 2003 45

SPARC
ASSEMBLY

LACING THE WHEEL A S S E M B LY S H I F T E R

1 1 2 Version Europe 28" / USA 26": • Slide shifter (1, Fig. 6) onto handlebar.
1-cross only. • Add 2 thrust washers (2).
All spoke heads must be positioned at the • Mount fixed grip (3) onto end of handlebar.
outside of the spoke flange. • Without applying pressure, slide shifter
Spoke tension about 1000 N recommended. against fixed grip.
• Adjust shifter on handlebar and
Version Europa 20": tighten with bolt (4) with a torque of
• 1-cross: 1.5 Nm (13 in.lbs.).
Use only rim „Rigida 20x406 59 (L 01 12 E)“
2 4 3 5
(or contact SRAM).
All spoke heads must be positioned at the
Caution:
• Never use lubricants or solvents to
outside of the spoke flange. install fixed grips.
6 Spoke tension about 1000 N recommended. Fixed grips provide an axial safety
• Radial lacing: function. For this reason, they should be
No restrictions. mounted in such a way as to make sure
Mounting Tool
Part No. 0582 104 000 Spoke tension about 1000 N recommended. they do not slip off handlebar.
• Check that the shifter and brake lever
function properly and are unobstructed
A S S E M B LY H U B (realign if necessary).
3 • Place the dust cap (1, Fig. 1) and • Never ride without the fixed grips. The
8 7 sprocket (2) on the driver. Toothing close turning grip may loosen from housing
to the hub (only sprocket version off-set). and slip off handlebar – this can result
9 • Push sprocket circlip (3, Fig. 2) onto the in severe injury or death.
cone of tool sleeve (4). Place tool sleeve
with large diameter on the driver. • When fitting the cable (1, Fig. 7) avoid
• Push the spring end of sliding sleeve (5) small radius.
10 of the tool over the tool sleeve. Thrust • Last attachment point is on the lower
sliding sleeve in direction (6), this forces rear wheel fork (2, Fig. 7) immediately
circlip into the recess of the driver. behind the chain wheel.
• Remove tool and check that the circlip is Cable housing must be movable inside
4 seated correctly. attachment.
• Turn dust cap (7, Fig. 3) until the three
lugs (8) are between the three beads (9)
on the sprocket (10). INSTALLING CLICK BOX
• Position dust cap and push towards • Insert shift rod (1, Fig. 8) in shift tube (2)
sprocket until it is felt to lock into place. (oil parts lightly) and then push into axle
• Placing the wheel in the rear frame. bore as far as the stop. Turn slot (6) in
Advice: shift tube to a position where it is easily
1 Dropouts must be parallel. visible.
• Mount the chain. • Push locating sleeve (3) with guiding rib
• Fit non-turn washer (1, Fig. 4) to the (4) to the front onto the hub axle – making
5 outside of the dropouts. The serrations
must bear against the dropout and the
sure that the internal lug (5) is guided in
the slot (6) of the shift tube until it can be
lug must engage in the dropout slot. felt – and heard – to engage.
• On the sprocket side fit the protective • Turn locating sleeve on the axle (7) until the
bracket (1, Fig. 5) directly below the guiding rib (4) is facing roughly upwards.
axle nut. Tightening torque on acorn or • Place shifter in gear position “2“.
hex nuts 30 – 40 Nm (266 – 350 in.lbs.). • Push on clickbox (2, Fig. 5) to the stop on
the axle. The guiding rib (4, Fig. 8) of the
Advice: locating sleeve thereby engages in the
1
• If a different protective bracket is used slot on the housing. In the end position
2
3 the thickness of the attachment plate tighten up the knurled bolt (3, Fig. 5) by
must be max. 3 mm. hand (0,3 Nm / 2,7 in.lbs.).
• Do not use additional washers.
• At least the beginning of the axle thread
6 must be visible in front of the axle nut. ADJUSTMENT HUB
1
• Be sure to reset rotational shifter from
4th. to 3rd gear.
5 • Match up the arrow marks in the
6 Clickbox viewing window (5, Fig. 6)
by turning the adjusting screw (6).
2 3
4

46 Technical Manual 2003

SPARC
ASSEMBLY

A S S E M B LY B AT T E R Y B O X A S S E M B LY R E M O T E
7 • Pull both quick releases outward and CONTROL UNIT
turn them to the „open“ position (Fig. 9). • Slide remote control unit (1, Fig. 10) onto
1 • Position battery box onto luggage handlebar.
2 3 carrier struts (3, Fig. 7). • Mount brake lever (2) and fixed grip (3).
• Push quick releases inwards and turn • Adjust remote control unit on handlebar
them to the „closed“ position. and tighten the bolt (4) with a torque of
• Slide plug of battery cable in the slot of 1.5 Nm (13 in.lbs.).
the battery box until it snaps in. • Slide plug of remote control cable in the
• Attach cable along the frame or luggage slot (5) of the remote control unit until it
carrier strut. snaps in.
Advice: • Attach cable along the frame.
Last attachment point of the cable at the Advice:
rear fork: approx. 8 cm away from the Last attachment point of the cable at the
axle end. rear fork: approx. 8 cm away from the
Do not jam the cable between frame axle end.
and rear hub and keep it away from the Do not jam the cable between frame
rotating hub shell. and rear hub.
8 • Slide plug in the slot on the hub until it Make a cable loop between plug and
snaps in. cable attachment point to avoid tensile
7
load.
Advice: • Slide the plug straightly in the slot on the
Closed elements such as brazed-on eye hub until it snaps in.
6 bolts are not suitable because plug will Angular installation may damage the
4 not pass through. slot.

Check:
2
S T O R I N G T H E B AT T E RY Switch remote control to „Speed“ position
1 If you intend to not use your bicycle for a and rotate the rear wheel.
3
5 while, e.g. during the winter, the battery box At least 2 green and 1 red LED must gleam.
should be stored fully charged in a dry and If not, assemble plugs again completely.
cool place. If not, assemble plugs again completely /
We recommend to recharge the battery right.
9 once a month. Recharge the battery at
least every 6 months.

closed open

10

2
3
1

5
1
4

Technical Manual 2003 47

SPARC
MAINTENANCE
10
7
1 9
8

32
31
30

4 41
6 29
28
5 27

26
39
25
3
24
2 23 38
1 22
21 40
20 36
19
18
17
16
37
15
34 35
14

33
13
12
11

REMOVE WHEEL DISMANTLING GEAR HUB

2 • Pull the remote control cable plug off see Fig. 1
the hub.
Sparc mounting aid • Apply fingertip pressure onto the tap and • Remove circlip (35), sprocket (34) and
Part No. 3024 001 000 pull battery cable plug off the hub. dust cap (33).
• Loosen the knurled screw (40, Fig. 1) and • Clamp hub with the two axle flats
pull the Clickbox off the axle. sprocket side facing downwards.
• Disengage the locating sleeve and pull it • Remove electric drive (4).
off. Remove shift rod/tube (37/36), pull • Unscrew the locknuts (1+2).
shift rod out of the axle bore. • Remove plate (6) with washer (5).
• Remove wheel. • Remove hub shell (7).
• Remove circlip (8) and washer (9).
X
ELECTRIC DRIVE • Remove planetary gear carrier (10) and
Remove: circlip (11).
• Unscrew resin nut (3, Fig. 1). • Clamp other axle end.
• Remove electric drive (4). • Unscrew fixed cone (32).
• Remove driver (31), compression spring
Caution: (29), large compression spring (27) and
Do not disassemble and do not lubricate ball retainer (30). – Withdraw gear ring
the electric drive. (26) and coupling gear (25) and remove
cover (28) from the coupling gear.
Reassembly: • Take out thrust block (24), (to do this
• Position electric drive onto hub. compress the spring). Remove spring (22)
• While rotating the electric drive push it and the two covers (23/21).
inside until the two small inside pins • Dismantle retaining washer (20), washer
engage in corresponding small holes (41). (19), conical compression spring (18),
Check: The thread must be visible at and the large sun gear (13).
least 8 mm. • Clamp other axle end.
• Screw on resin nut (3) with a torque of • Unscrew grey grub screw (14) – dis-
3 – 5 Nm (27 – 44 in.lbs.). mantle spring (15), guide bolt (16) and
thrust block (17).
• Remove small sun gear (12).

48 Technical Manual 2003

SPARC
MAINTENANCE

R E A S S E M B LY H U B • Mount hub shell (7), with a slight

3 4 see Fig. 1 counterclockwise turn.
3 • Fit plate (6) and washer (5).
Lubrication see “ LUBRICATION GEAR HUB“, • Screw on counternuts (2+1), tightening
2 next page. torque 15 – 20 Nm (133 – 177 in.lbs.).
• Clamp axle with small internal thread • Reassemble electric drive.
upwards.
1
• Position small sun gear (12) with crown CABLE CHANGE
gears to the front. Dismantling shifter cable:
• Position thrust block (17) in the slotted • Place shifter in gear position “2“.
hole (is laterally guided when the sun • Loosen clamping bolt (1, Fig. 3) on the
gear is mounted). shifter and slide the complete shifter
• Locate bolt (16), then spring (15) in the inwards towards the middle of handle-
axle and screw in grey grub screw (14) bar 20 mm or more. (It may be necessary
until it is flush with the axle end. to loosen and move the brake lever.)
• Clamp other axle end. Fit large sun gear • Separate housing (2) from turning grip (3).
(13). Position conical compression • Unscrew bolt (1, Fig. 4), remove cap (2).
4 spring (18), with the large diameter first. • Withdraw shifter cable and clamping
Compress spring and fit washer (19) and bolt (1, Fig. 6) upwards, loosen clamp
2 retaining washer (20). and pull clamping piece from the cable.
4 • Assemble cover (21), compression • Remove the old cable (4, Fig. 3).
1 spring with 7 turns (22) and the second
cover (23, insides to the spring). Assembly shifter cable:
5 • Route new cable through shifter housing
• Compress spring and position thrust
block (24) (it is the same both sides) in and pull cable to seat cable head
the center of the slotted hole. completely into cable recess.
• Position coupling gear (25) with carrier • Reassemble shifter by aligning four
plate facing downwards. tabs on shifter housing with matching
• Fit cover (28, inside to the spring) for recesses on turning grip and snap
compression spring. together (Fig. 3).
• Position gear ring (26) over the teeth of • Feed the cable through the new cable
the coupling gear. housing and adjusting screw.
• Place ball retainer (30), with balls below • Position clamping bolt (1, Fig. 5) at a
on the gear ring. distance of 83 mm, tighten up with
• Position large compression spring (27) 1.5 Nm (13 in.lbs.) and cut off cable ends
on gear ring. to 2 – 3 mm.
5 • Mount compression spring with 13 turns • Locate clamping bolt (1, Fig. 6) (srew
(29) on the axle. (Is supported in the head not visible) and place shifter cable
coupling wheel by the cover.) around the carrier cylinder (counter-
• Locate driver (31), press it down and clockwise winding).
2 +1 mm 83 ±0,5 mm
screw on fixed cone (32). Tightening • Insert the square nut of the adjusting
torque 20 Nm. bolt (2) in the housing and completely
• Clamp other axle end. screw in the knurled bolt.
• Push on thrust washer (11) and fit • Position cap (2, Fig.4) and tighten up
5 mm planetary gear carrier (10). In doing this: with bolt.
1 Position mounting aid (Fig. 2) on the
planetary gear carrier so that the (X) Advice:
markings on the three planetary gears To set the clamping bolt / adjusting
match with the mounting aid. screw distance a setting piece can be
• Insert planetary gear carrier, place used (Part No. 65 0324 105 001).
thrust washer (9) and mount circlip (8) in
6 recess. ADJUSTMENT
• Be sure to reset rotational shifter from
Remove the mounting aid.
4th. to 3rd gear.
Advice: • Match up the arrow marks in the
1
If the gears are not accurately installed Click Box viewing window (4, Fig. 4)
the hub may be tight to move. by turning the adjusting screw (5).
This could lead to damage to the gear-
wheels in operation.

Technical Manual 2003 49

SPARC
MAINTENANCE

LUBRICATION GEAR HUB BATTERY CHANGE

7 Cleaning of parts: Disassembly:
• All parts – except for the planetary gear • Apply fingertip pressure onto the tap and
carrier – can be degreased in a cleaning pull battery cable plug off the battery
bath. box.
• The planetary gear carrier only needs to • Turn quick releases to the „open“
be cleaned on the outside with a brush position (Fig. 7) and pull them outward.
so as not to degrease the planetary gear • Take off battery box from luggage
bearing. carrier.
• Unscrew the 4 bottom screws (slotted
Lubrication of parts: screwdriver / Torx T10) and take off
Use only SRAM grease (Ref. No. 0369 135 201) battery box cover.
closed open
and standard bicycle oil. • Hang out stirrup (3, Fig. 8).
• To lubricate the bearing points on • Take out battery and pull off plugs (1+2).
the planetary gear sets, position the Advice:
planetary gear carrier on its crown and Do not pull off any plug from card modul.
apply 2 – 3 drops of oil to the bearing
bolts – at the same time turning the Reassembly:
8 planetary gears so that the bearing • Connect plugs to new battery:
points are completely wet. – black cable: Negative Pole (1, Fig. 8)
• Oil axle through the axle bore and axle – red cable: Positive Pole (2)
slot, apply a thin coating of grease to the and put battery inside.
2 outside. • Assemble stirrup (3) (bulge downward).
1
• Oil the inside of the sun gears, grease • Mount battery box cover by the 4 screws.
the outside teeth (fill the gaps in the • Pull both Quick Releases outward and
teeth). turn them to the „open“ position (Fig. 7).
• Oil outside teeth and carrier plate on • Position battery box onto luggage
the coupling gear and lightly grease the carrier struts.
borehole from right and left. • Push Quick Releases inwards and turn
• Do not apply grease to ring gear but just them to the „closed“ position.
3
oil the pawl pockets. • Slide plug of battery cable in the slot of
• Regrease ball retainer, line ball bearing the battery box until it snaps in.
4
running tracks with grease.
Advice:
Advice: Use only batteries as specified.
Do not use high-pressure water when
cleaning (e.g. strong water jets, high-
pressure cleaners etc.) – if water
penetrates it could lead to functional
problems.

50 Technical Manual 2003

SPARC
MAINTENANCE

C H A R G I N G T H E B A T T E R Y • Do not use in rooms (garages) with an • The battery must never be burned. Risk
• Insert the plug of the charger into the explosion risk. of explosion!
socket of the battery box. • Do not dismantle the charging unit and • The battery must be disposed of accor-
• Insert the charger into an electric mains battery box yourself. ding to the waste disposal regulations.
socket. Incorrect assembly can lead to • Only ever use the Sparc charging unit
electric shock or fire. with the Sparc battery.
The LED will glow red during charging, • The charging unit should not get into • In the USA only use the ”USA charging
changing to green when the battery is fully the hands of children. unit”.
recharged. • Charging should only be carried out in
A trickle charge prevents self-discharge of sufficiently well ventilated areas.
the battery. • When not in use always withdraw the
Therefore, the charger can be permanent- mains plug for the charging unit from S T O R I N G T H E B AT T E RY
ly connected to the battery. the socket (do not pull on the charging If you intend to not use your bicycle for a
unit’s cable). while, e.g. during the winter, the battery box
Advice: • Regularly check the cable and protect it should be stored fully charged in a dry and
• We recommend to recharge the battery from sharp edges. If it is damaged have cool place.
once a month. it renewed immediately by a specialist We recommend to recharge the battery
• The battery should only be operated or workshop. once a month. Recharge the battery at
charged in a temperature range of +5°C • Protect the unit from oil, grease, least every 6 months.
to +40°C. aggressive cleaning agents and paint
thinners since they can destroy the
Caution: housing.
• Only charge the battery in the operating • If it falls, from a bench for example, the REMOTE CONTROL UNIT
position. unit must immediately be given a safety Do not disassemble the remote control
• Recharge the battery at least every 6 check by a specialist workshop. This is unit.
months. also necessary if contact pins become
• Only use in dry internal areas. loose.

TROUBLESHOOTING
Problem Cause Remedy
Gear hub:
Shifting difficulties Damaged control cable Replace control cable
Incorrect gear setting Adjust shifting system
To much additional axle Beginning of axle thread
attachments between hub must be visible in front of
and axle nut the axle nut
Pedals are carried forward Bearings set too tight Readjust bearings
when freewheeling Loose lock nuts Tighten lock nuts
(15 – 20 Nm)
Chain is overtensioned Reduce chain tension
Electric system:
Electric drive does not work Remote control in position OFF Switch to ECON or SPEED
Remote control defect Replace remote control
Plugs not engaged Slide all plugs completely
in slots
Cable defect Replace defect cables
Battery discharged Charch battery
Battery inside not connected Connect battery inside
Battery defect Replace battery
Fuse blasted Replace fuse (4, Fig. 8) in
battery box (25 A)
Electric drive defect Replace electric drive
Electric drive emits Foreign body in electric Take out foreign body
unusual noise drive
Electric drive defect Replace electric drive

Technical Manual 2003 51

52 Technical Manual 2003
 SPECTRO VT 5000 / VT 3000
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

• Reliable Brake Performance In All Weather Conditions Typ VT 5000

• Practically Maintenance Free 21,5

14
• Sealed Cartridge Bearing

9,5

Version D

158
M9x1

Front fork:
The strength must be such that with a
maximum torque of 300 Nm (2700 in.lbs.)
on the wheel no residual deformation can
occur on the front fork.

Warning:
• There is a risk of accident if unsuitable
forks are used!
• Not suitable for tandem use. 100
• Wheel size: only 24"/26"/28" wheels are
suitable for use. 136
Version NL

VT 5000 VT 3000

D
Part No.
Brake anchor plate
—
Version D
—
Version NL
—
Version D
❘— —
Version NL
❘—
R Over Locknut Dim. 100 mm 100 mm 100 mm 100 mm
Length 135 mm 135mm 135 mm 135 mm
U Type Solid Solid Solid Solid
Axle

M Material Steel Steel Steel Steel

Ends Diameter M9x1 M9x1 M9x1 M9x1
B Holes 36 36 36 36
Spoke

R Hole Diameter 2.9 mm 2.9 mm 3 / 3.3 mm 3 / 3.3 mm

Hole Reference ø 89 mm 89 mm 86 mm 86 mm
A Bearing Cartridge Cartridge Cartridge Cartridge
K Sealing Lip Seal Lip Seal Lip Seal Lip Seal
E Weight 750 g 750 g 770 g 770 g
Hub Shell Material Aluminum Aluminum / galvananized Steel
Finish

➔
Finish Clear Coat ➔ ❘
Aluminum/Silver Silver Silver
❘ Black

Technical Manual 2003 53

SPECTRO VT 5000 / VT 3000
ASSEMBLY

6 FITTING WHEEL IN ADJUSTMENT DRUM BRAKE

1 3
FRONT FORK • Unscrew adjusting screw (8, Fig. 1) until
• Lace the wheel as normal. the brake pads drag lightly.
5 • Placing the wheel in front fork. The • Actuate the hand brake lever forcefully
brake lever (1, Fig. 1) goes on the left several times and then, if necessary,
side viewed from behind the rear of the turn the adjusting screw further so that
bicycle. Guide the top end of brake the brake once again brushes the wheel
2 anchor plate (2) into the brazing part of as it turns.
the fork if fitted. If there is no brazing • Lock hex nut (9)
part, use VT pipe clamp (3).
• Slide washers or snap rings onto axle Caution:
10 ends. Check that all the brake system
• Fit axle nuts (4) with wrench 15 mm, components are functioning properly!
torque 30 – 40 Nm (266 – 350 in.lbs.).
• Tighten screw connections on VT pipe
1 clamp (5/6), torque approx. 3 Nm (27 in.lbs.). OPERATION
4
Caution: To get used to the new brake, operate the
The clamp must be seated on the fork brake lever carefully to acquire a feel for
with no play. the drum brake’s deceleration.

8 Caution:
9
7 CONNECTING DRUM BRAKE • If the bicycle is left standing for long
11 Caution: periods, surface rust in the brake drum
13
Only use brake levers with a cable may increase braking effect. For this
moving distance of at least 15 mm and a reason, start by braking gently a few
12
minimum leverage of 3.8. times the next time the bicycle is used
• Fit cable stop (7, Fig. 1) with adjusting to remove the surface rust. This will
bolt (8) and nut (9) and insert into the slot prevent the brake from aggressive
on the brake anchor plate (10). braking.
2 • Turn adjusting bolt down by approx. 2/3 • On long, steep downhill stretches, also
and route the brake cable from the use the second brake (rear wheel)
brake handle. alternately to prevent the brakes from
• Push lower brake cable end through heating up excessively.
adjusting bolt. • Do not touch hub after cycling – risk of
• Insert lower cable housing end into burning!
adjusting bolt.
• Thread brake cable end (11) into fork
unit (12).
• Tighten screw (13) slightly.
• Attach fork unit to brake lever (1).
• Pull brake cable end taut with pliers
so that fork unit can still be attached and
1 removed (important for changing wheel).
• Tighten screw (13).
• For NL version drum brake hub with
special lever (1, Fig. 2), only use original
NL brake cable (fork unit (12, Fig. 1) is
not suitable)

54 Technical Manual 2003

SPECTRO VT 5000 / VT 3000
MAINTENANCE

MAINTENANCE Advice: Caution:

• Bearings is sufficiently lubricated and • Do not use high-pressure water when The brake anchor plate must be replaced
essentially maintenance-free. cleaning the hub (e.g. strong water jets, if oil or other substances containing
• Cable housing without inner tube: high-pressure cleaners etc.) – if water grease get into the brake pads. Oily brake
lubricate regularly. penetrates the unit it could lead to pads reduce braking effect and cause the
functional problems. brake to fail completely. This may result
• Do not rinse hub with benzine, petroleum in accidents with extremely serious
etc. as this could produce impurities in injuries.
the brake pads.

Technical Manual 2003 55

 TWO-AXIS BRAKE LEVER
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

Caution:
Two-Axis
SRAM Brake Levers are designed for use
Part No. — — with linear-pull brakes. Do not use SRAM
T Brake Lever Left Right Brake Levers with conventional cantilever
brakes (those with arms measuring less
Lever Size 4 Finger
W Brake Compatibility i-Brake / Linear Pull
➔
➔
than 76 mm and utilizing a non-linear
straddle cable). Use of SRAM Brake
O Leverage Adjust Single Position ➔ Levers with conventional cantilever
- Cable Pull 28 mm ➔ brakesets, drum brakes or roller brakes
A Pivot Bushing I-Glide ➔
will result in faulty braking performance.

X Reach Adjust Yes Yes

I Barrel Adjuster Ergonomic Indexing Ergonomic Indexing

Clamping Diameter 22.3 mm 22.3 mm
S

76 – 108 mm
Weight 155 g 155 g
Design

Housing Grilon Composite ➔

Lever Forged Aluminum ➔
Designed for use with Do not use conventional
linear-pull brakes. cantilever brakes.

CABLE HOUSING
• Use only new brake cable and cable
housing.
• When choosing cable housing lengths,
be sure to allow enough housing for an
extreme turn of the handlebars in both
directions.
• Note also, that different stem lengths
and cable stop positions effects cable
housing length.

56 Technical Manual 2003

TWO-AXIS BRAKE LEVER
ASSEMBLY / MAINTENANCE

B R A K E L E V E R A N AT O M Y INSTALLATION REACH ADJUSTMENT

• When sliding the brake lever onto the Using a 2 mm hex wrench (Fig. 3):
clamp bolt
handlebar, allow enough room for the • Turn the reach adjustment screw clock-
clamp shifter, the handlebar grip, and the bar end. wise to bring the lever closer to the
• Using a 3 mm hex wrench, tighten the handlebars.
clamp bolt to 3.4 Nm (30 in.lbs.) (Fig. 1). • Turn the screw counterclockwise to
lever Be careful not to over tighten! move the lever further away.
• Line up the barrel adjuster and the brake
lever housing cable slots. Caution:
• Pull on the lever and push the brake After any adjustment to the reach always
cable head through the opening in the check the brake cable tension to ensure
reach adjustment brake lever housing (Fig. 2).
screw
proper brake system performance.
barrel adjuster • Install the brake cable head into the Readjust the cable tension if necessary.
cable socket in the lever.
• Set up the brakes and brake pads per
brake instructions.
• Actuate each brake lever 5 – 10 times.

Caution:
1 Check that all the brake system
3 mm
components are functioning properly!
3.4 Nm
30 in.lbs.

2 mm

Technical Manual 2003 57

58 Technical Manual 2002
 SMARTBAR
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

• New Style
• ErgoFit – allows for height, reach, and
rise adjustment
• ErgoFunction – improved control,
enhanced ergonomics and safety
• Upgradeable – full suite of integrated
accessories

SmartBar Quill Stem

Part No. — — — — — — — —
Q Stem diameter 1“ ● ● ● ●
U Stem diameter 1 1/8“ ● ● ● ●
I Brake Compatibility 2:1 (linear pull) leverage only ➔ ➔ ➔ ➔ ➔ ➔
L Rear, 9spd ESP ● ● ● ●
L
Shifter

Rear, 8spd ESP ● ● ● ●

Front, Micro Adjust ● ● ● ●
Front, Index ● ● ● ●

SmartBar Clamp-On Stem

Part No. — — — — — — — —
C Stem diameter 1“ ● ● ● ●
L Stem diameter 1 1/8“ ● ● ● ●
A Brake Compatibility 2:1 (linear pull) leverage only ➔ ➔ ➔ ➔ ➔ ➔
M Rear, 9spd ESP ● ● ● ●
P
Shifter

Rear, 8spd ESP ● ● ● ●

Front, Micro Adjust ● ● ● ●
Front, Index ● ● ● ●

Technical Manual 2002 59

 SMARTBAR
ASSEMBLY ERGOFIT STEM (QUILL STEM)

Caution: • Rotate the elastomer quill cover upward

1 The SmartBar requires a knowledgeable to allow access to the 6 mm hex wedge
and trained bicycle mechanic for proper bolt (Fig. 3).
installation and adjustment.
• Tighten the 6 mm hex wedge bolt to
To ensure rider safety, all stem adjust-
20 – 30 Nm (177 – 270 in.lbs).
ments should be made by a trained
mechanic using a calibrated torque
Caution:
wrench to verify required tightening
• Always check that the stem cannot slip
torque.
up/down or rotate in/on the steerer tube
when the handlebars are turned.
• Lightly grease the outside of the stem
• If the handlebars can be turned
quill tube below the MINIMUM
so that the stem does not line up with
INSERTION mark before assembly.
the front wheel, check and re-tighten
the hex wedge bolt.
• Slide the stem into the steerer tube of the
• Re-tighten and check again for proper
front fork making sure that it is inserted
attachment and operation!
past the ”MINIMUM INSERTION” mark
on the stem quill (Fig. 1).

• Align the SmartBar assembly so that

the stem centerline is in line with the
centerline of the front wheel (Fig. 2).
2

6 mm
20 – 30 Nm
177 – 270 in.lbs.

60 Technical Manual 2002

SMARTBAR
ASSEMBLY ERGOFIT STEM (CLAMP-ON STEM)

Caution: • Rotate the elastomer quill cover upward

4 The SmartBar requires a knowledgeable to allow installation of the headset top
and trained bicycle mechanic for proper cap and access to the two 5 mm hex
installation and adjustment. clamp bolts (Fig. 6).
To ensure rider safety, all stem adjust-
ments should be made by a trained Advice:
mechanic using a calibrated torque Adjust the headset bearings and top cap
wrench to verify required tightening tension following the headset manufactu-
torque. rers’ recommendations.

• Make sure that there is at least 37 mm of • Tighten the two 5 mm hex clamp bolts to
threadless steerer tube above the head- 15 – 20 Nm (133 – 177 in.lbs) (Fig. 6).
set (and spacers) for clamping the stem.
Caution:
Advice: • Always check that the stem cannot slip
Use several headset spacers between the up/down or rotate in/on the steerer tube
headset and stem to allow for more height when the handlebars are turned.
adjustment. • If the handlebars can be turned so that
the stem does not line up with the front
• Slide the stem over the steerer tube of wheel, check and re-tighten the hex
the front fork (Fig. 4). clamp bolts.
• Re-tighten and check again for proper
• Make sure that the top of the stem clamp attachment and operation!
is no more than 5 mm above the top of the
5 steerer tube (Fig. 6).

• Align the SmartBar assembly so that

the stem centerline is in line with the
centerline of the front wheel (Fig. 5).

6
5 mm
max.

5 mm
15 – 20 Nm
133 – 177 in.lbs.

Technical Manual 2002 61

SMARTBAR
ADJUSTMENT ERGOFIT STEM (REACH ADJUSTMENT)

The ErgoFit stem has two rotating adjust- • Tighten the 6 mm hex front
7 ment bolts and a ”Flip-Flop” design that adjustment bolt to 35 – 40 Nm (310 – 350
allow for a very wide range of adjust- in.lbs) (Fig. 7).
ments.
• Tighten the 6 mm hex rear
adjustment bolt to 35 – 40 Nm
FORE-AFT POSITION
(310 – 350 in.lbs).
• To fine-tune the fore-aft
position of the handgrips adjust the Ergo-
Caution:
Fit rotation adjustments (Fig. 7).
• Always check that the stem rotation
• Loosen the two 6 mm hex adjustment adjustments cannot be rotated up or
bolts just enough that the links can be down after tightening.
rotated freely. • If the handlebars can be moved up or
down or rotated forward or backward
• Rotate the main structure and links
after tightening the adjustment bolts,
forward and down or backward and up
check and re-tighten both the adjust-
until the desired fore-aft position is
ment bolts making sure that they are in
achieved. Choose any one of the locking
one of the locking positions.
positions that are evenly spaced in
6 mm • Re-tighten and check again for proper
6 mm 15-degree increments (Fig. 8).
35 – 40 Nm attachment and operation!
35 – 40 Nm 310 – 350 in.lbs. • Tighten the 6 mm hex rear adjustment
310 – 350 in.lbs.
bolt just enough to hold the desired
position.
• Rotate the main structure and grips so
that lower flat section of the main
structure is nearly level with the ground
8 and the gear indicators are clearly
visible from the riding position. Locking
positions are evenly spaced in
15-degree increments (Fig. 9).

62 Technical Manual 2002

SMARTBAR
ADJUSTMENT ERGOFIT STEM (REACH ADJUSTMENT)

FLIP-FLOP POSITION • Tighten the 6 mm hex rear adjustment

10 • To make a large change to the fore-aft bolt to 35 – 40 Nm (310 – 350 in.lbs).
position adjust the ”Flip-Flop” position
• Align the SmartBar assembly so that
to long or short adjustment (Fig. 10):
the stem centerline is in line with the
• Loosen the 6 mm hex wedge bolt or the centerline of the front wheel (Fig. 2 /
two 5 mm hex clamp bolts to allow the Fig. 5).
stem to rotate freely on the steerer tube
• Quill stem: Tighten the 6 mm hex wedge
(Fig. 3 / Fig. 6).
bolt to 20 – 30 Nm (177 – 270 in.lbs) (Fig. 3).
• Loosen the two 6 mm hex
• Clamp-On stem: Tighten the two 5 mm
g adjustment bolts just enough that the
l on hex clamp bolts to 15 – 20 Nm (133 – 177
links can be rotated freely (Fig. 11).
in.lbs) (Fig. 6).
• Loosen the 6 mm hex rear adjustment
bolt and remove the bolt completely. Caution:
• Always check that the stem rotation
Advice:
adjustments cannot be rotated up or
You will have to support the main
down after tightening.
structure while you make this change.
• If the handlebars can be moved up or
• Change the Flip-Flop stem quill or stem down or rotated forward or backward
clamp 180 degrees to the desired short after tightening the
or long position. adjustment bolts, check and re-tighten
both the adjustment bolts making sure
• Re-insert the 6 mm hex rear adjustment
that they are in one of the locking
bolt and tighten just enough to hold the
positions.
desired position.
• Re-tighten and check again for proper
• Follow the prior instructions to fine-tune attachment and operation!
r t the fore-aft position.
s ho
• Tighten the 6 mm hex front adjustment
bolt to 35 – 40 Nm (310 – 350 in.lbs).

11

6 mm
6 mm 35 – 40 Nm
35 – 40 Nm 310 – 350 in.lbs.
310 – 350 in.lbs.

Technical Manual 2002 63

SMARTBAR
ADJUSTMENT ERGOFIT STEM (HEIGHT ADJUSTMENT)

To fine tune the up-down position of the Caution:

12 handgrips of a quillstem SmartBar adjust • Always check that the stem cannot slip
the stem up or down on the steerer tube. up/ down or rotate in/on the steerer
tube when the handlebars are turned.
• Loosen the 6 mm hex wedge bolt (Fig. 12).
• If the handlebars can be turned so that
• Move the stem to the desired position up the stem does not line up with the front
6 mm or down making sure that it is inserted wheel, check and re-tighten the hex
20 – 30 Nm past the ”MINIMUM INSERTION” mark wedge bolt or hex clamp bolts.
177 – 270 in.lbs. on the stem quill (Fig. 13). • Re-tighten and check again for proper
attachment and operation!
• Align the SmartBar assembly so that
the stem centerline is in line with the
centerline of the front wheel (Fig. 14).
• Tighten the 6 mm hex wedge bolt to
20 – 30 Nm (177 – 270 in.lbs) (Fig. 12).

13

14

64 Technical Manual 2002

SMARTBAR
ADJUSTMENT CONTROL POD

Verify that the rotational position of the Caution:

15 brake levers is desired as assembled. • Do NOT rotate the control pod assembly
outside of the allowed adjustment range
If no position change is required: of 20 – 60 degrees down from horizontal
• Insert a 5 mm hex wrench into the hole (Fig. 17)!
in the end of the handgrip. Tighten the • Rotating the pods beyond their allowed
5 mm hex bolt to 6 Nm (53 in.lbs) (Fig. 15). adjustment range will damage the gear
indication cables and function.
If a different position is desired:
• Insert a 5 mm hex wrench into the hole
• The pods can be adjusted in increments
in the end of the handgrip (Fig. 15).
of 10 degrees within the range of
Loosen the bolt five complete turns. This
20 – 60 degrees down from horizontal.
is enough to allow the control pod to be
5 mm pulled a few millimeters away from the • Once desired position is determined
6 Nm main structure without disassembly of the tighten the 5 mm hex bolt to 6 Nm
53 in.lbs. control pod unit. (53 in.lbs) (Fig. 15).
Caution:
Do NOT disassemble the control pod!
The gear indication cables are set at the
factory, and improper disassembly will
16 damage the gear indication cables and
function.

mm • Pull the control pod slightly away

max. 3 – 5
(3 – 5 mm) from the main structure and
rotate to the desired position (Fig. 16).

17

20°

20–60°

Technical Manual 2002 65

SMARTBAR
ASSEMBLY BRAKE CABLE / BRAKE COMPATIBILITY

• Line up the barrel adjuster with the slot Caution:

18 in the underside of the control pod All SmartBars are equipped to actuate
housing. two brakes with 2:1 (linear pull) leverage
only.
• Pull on the brake lever and push the
cable head through the opening in the
brake lever housing (Fig. 18).
Use only new cable and housing.
• Install the cable head into the cable
socket in the brake lever (Fig. 19).
• Set up the brakes and brake pads per
brake instructions.
• Actuate each brake lever 5 – 10 times
and ensure proper operation.

19

SMARTBAR
BRAKE LEVER REACH ADJUSTMENT

Using a 2 mm hex wrench.

20 • Turn the reach adjustment screw clock-
wise to bring the lever closer to the
handgrip (Fig. 20).
• Turn the screw counterclockwise to
move the lever further away.
• Actuate each brake lever 5 – 10 times
and ensure proper operation.

Caution:
• Do NOT force the screw past its normal
stop!
• After any adjustment to the reach
always check the brake cable tension
to ensure proper brake system
performance.
• Readjust the cable tension if necessary.

66 Technical Manual 2002

SMARTBAR
ASSEMBLY SHIFTER CABLE INSTALLATION

24spd and 27spd ESP systems 7 Speed Spectro Gearhubsystems

21 • Feed the cable through the cable • The cable, housing and Clickbox are
housing and stops. pre-assembled at the factory.
2 1
• Attach the cable to the derailleur. Advice:
Use only new cable and housing. When fitting the cable
avoid small radius.
• Adjust indexing per derailleur
instructions. • See figure for cable
attachment points (1, Fig. 21).

• Last attachment point is on the

lower rear wheel fork (2, Fig. 21)
immediately behind the chain wheel.

Advice:
Cable housing must be
movable inside attachment.

• CLICKBOX INSTALLATION AND

ADJUSTMENT per Technical Manual /
Spectro S7.

SMARTBAR
ADJUSTMENT GEAR INDICATION

Caution: • While holding the lockring stationary

22 Do NOT disassemble the gear indication turn the clear gear indication dome until
display! the middle gear number is exactly lined
up with the gear indicator needle.
The gear indicators and cables are set at
the factory and improper disassembly will • Use the three protruding tabs on the
damage the gear indication and its clear gear indication dome to turn the
function. In the event of external damage dome and the gear display beneath it
or adjustment problems not solved by the while holding the lockring stationary
following procedures, please call technical (Fig. 22).
service for detailed repair instructions.

• Check all gears are shifting well, shift

the derailleur or internal gear hub into
Protruding the middle gear:
tabs Lockring Gear 4 = middle gear for 7spd
internal hub
Gear 4 = 4th largest sprocket on
8spd cassette
Gear 5 = 5th largest sprocket on
9spd cassette
Gear 2 = middle chainring for
front derailleurs with
triple chainrings (left
side gear indication).

Technical Manual 2002 67

SMARTBAR
GRIP REPLACEMENT

S TAT I O N A R Y G R I P : TWIST GRIP:

23 Removal Removal
• Rotate the shifter fully in the cable • Remove stationary grip, see left.
release direction. (Gear “1” on the front
shifter, gear “1” on the Spectro 7spd • Pull the spacer tube straight off the
shifter, gear “8” on the 8spd shifter, and SmartBar (Fig. 24).
gear “9” on the 9spd shifter).
• Next, while pressing the control pod
Caution: housing toward the center of the
Do NOT disassemble the control pod! handlebar, slowly pull the twist grip
straight off, taking care to keep the coil
• The gear indication cables are set at the spring from falling out.
5 mm factory, and improper disassembly will
6 Nm damage the gear indication cables and Replacement
53 in.lbs.
function. • Slide new twist grip over SmartBar.

• Insert a 5 mm hex wrench into the hole • Slide the spacer tube back onto the
in the end of the handgrip (Fig. 23). SmartBar and part way through the new
grip, making sure that the flange is on
24 • While pressing the twist grip toward the the outboard side toward the stationary
center of the handlebar, unscrew the grip (Fig. 24).
bolt completely until the stationary grip
can be pulled straight off (Fig. 24). • Replace rear end of coil spring onto
spring tab of new grip (Fig. 25).
Replacement
Stationary • Align the flat keyed feature on the new • While sliding the grip towards the
grip stationary grip assembly with the flat housing, align the free end of the spring
Twist keyed feature on the end of the Smart- into the spring cavity in the spool
grip
Bar and push the grip assembly onto the (already in the housing).
Flat Spacer
SmartBar until it makes contact with the
keyed tube spacer tube (Fig. 24). • Push the spacer tube all the way into the
feature grip assembly.
• Tighten the 5 mm hex bolt to 6 Nm
(53 in.lbs) (Fig. 23). • Rotate grip forward slightly compressing
the coil spring and push the grip towards
the housing until there is no gap
25 between the housing and grip.

• Align the flat keyed feature on the

stationary grip assembly with the flat
keyed feature on the end of the Smart-
Bar and push the grip assembly onto the
SmartBar until it makes contact with the
spacer tube (Fig. 24).

• Tighten the 5 mm hex bolt to 6 Nm

(53 in.lbs) (Fig. 23).

68 Technical Manual 2002

SMARTBAR
CABLE CHANGE / CLEANING

24SPD & 27SPD ESP SYSTEMS Replacement

26 Removal
• Feed the new cable through the cable
entry and out the barrel adjuster.
1 • Detach the cable from the derailleur.
• Pull the cable snug to seat cable head in
• Cut cable off 15 cm (6”) from shifter the shifter.
arrel adjuster. Discard old cable and
housing. • Replace the cable change hatch.

• From the top edge pull open the cable • Feed the cable through the new cable
change hatch (1, Fig. 26). housing and adjusting barrel.

• Rotate the shifter fully in the cable • Position clamping bolt at a distance of
release direction. (Gear “1” on the front 90 mm, tighten to 1.5 Nm (13 in.lbs.) and
shifter, gear “8” on the 8spd shifter, and cut off cable end to 2 – 3 mm (Fig. 29).
gear “9” on the 9spd shifter.)
• Locate clamping bolt (5, Fig. 28) (screw
27 • Look for cable head and push cable up /
out of the shifter and discard (Fig. 26).
head not visible) and place shifter cable
around carrier cylinder (counter-clock-
wise winding).
3 Replacement
4
• Feed the new cable through the cable • Position cap (4, Fig. 27) and tighten
2
entry and out the barrel adjuster. Be with bolt (3), torque 0.35 – 0.45 Nm
sure to thread the cable through the (3.1– 4.0 in.lbs.).
small hole in the spool.
• Screw the barrel adjuster (2) completely
• Pull the cable snug to seat the cable onto the clickbox.
head in the shifter.
• CLICKBOX INSTALLATION AND
• Replace the cable change hatch. ADJUSTMENT per Technical Manual
Gear Hub Systems / Spectro S7.
• Feed the cable through the new cable
housing and frame stops.

• Attach the cable to the derailleur.

28
• Adjust indexing per derailleur
5 instructions.

7 SPEED SPECTRO
GEARHUBSYSTEMS
Removal
• Rotate the shifter fully in the cable
release direction. Gear position “1”.

• Do not remove the Clickbox from the axle

end.

• Unscrew the barrel adjuster (2, Fig. 27)

29 completely.

• Unscrew bolt (3, Fig. 27), remove cap (4).

• Withdraw shifter cable and clamping

2 +1 mm 90 ±0,5 mm CLEANING
bolt (5, Fig. 28) upwards, loosen clamp
• Clean all parts with soapy water only.
and pull clamping piece from the cable.
• It is recommended that you clean the
bike in a upright position, this allows the
• From the top edge pull open the cable
water to drain out correctly.
change hatch (1, Fig. 26)
• After cleaning, if moisture does impair
the clarity of the gear indication lens
• Look for cable head and push cable up /
cap it is not recommended to remove the
out of the shifter and discard.
lens, instead leave your bike in a warm
dry room, until the moisture disappears
from the lens.

Technical Manual 2002 69

POWER CHAINS
TECHNICAL DATA / ASSEMBLY REQUIREMENTS

PC 99 Holow Pin1 PC 89R Holow Pin1 PC 69 PC 59 PC 49

P Part No. — — — — — —

O Application MTB Road MTB MTB MTB

Compatibility Front HG / EXA-Drive HG / EXA-Drive HG / EXA-Drive HG / EXA-Drive HG / EXA-Drive
W Compatibility Rear HG / EXA-Drive HG / EXA-Drive HG / EXA-Drive HG / EXA-Drive HG / EXA-Drive
E Max. No. of sprockets 9 only 9 only 9 only 9 only 9 only

R Dimension 1
/2" x 11/128" 1
/2" x 11/128" 1
/2" x 11/128" 1
/2" x 11/128" 1
/2" x 11/128"
Length 6.8 mm 6.35 mm 6.8 mm 6.15 mm 6.8 mm 6.8 mm 6.8 mm

C Riveting Cross Step Cylindrical Step Cylindrical Step Step Step

Pin

Chrome Hardened Yes Yes Yes Yes Yes

H Push Power 2000 N / 450 lbs. 1500 N / 340 lbs. 1500 N / 340 lbs. 1500 N / 340 lbs. 1500 N / 340 lbs.
A Min. Tensile Strength 9000 N / 2023 lbs. 9000 N / 2023 lbs. 9000 N / 2023 lbs. 9000 N / 2023 lbs. 9000 N / 2023 lbs.

I Weight (114 links) 297 g 284 g 290 g 271 g 297 g 297 g 297 g
External Pin Plate Silver / Nickel Plated Silver / Nickel Plated Silver / Nickel Plated Silver / Nickel Plated Grey / Polished
N
Design

Internal Pin Plate Silver / Nickel Plated Silver / Nickel Plated Silver / Nickel Plated Grey / Polished Grey / Polished
S Weight Reduced Yes Yes Yes
Connecting Method Power Link Gold Power Link Gold or Pin1 Power Link Gold or Pin Power Link Gold or Pin Power Link Gold or Pin
1 Caution: Holow Pin chain connecting method: with Power Link Gold only

PC 68 PC 58 PC 48 PC 38 Saltshaker PC 38
P Part No. — — — — —
O Application MTB MTB MTB MTB MTB

W Compatibility Front HG / IG / PG / EXA-Drive HG / IG / PG / EXA-Drive HG / IG / PG / EXA-Drive HG / IG / EXA-Drive HG / IG / EXA-Drive

Compatibility Rear HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive HG/HG-I/IG/PG/EXA-Drive
E Max. No. of sprockets max. 8 max. 8 max. 8 max. 8 max. 8
R Dimension 1
/2" x 3/32" 1
/2" x 3/32" 1
/2" x 3/32" 1
/2" x 3/32" 1
/2" x 3/32"
Length 7.1 mm 7.1 mm 7.1 mm 6.9 mm 6.9 mm
C Riveting Cross Step Step Step Step Step
H
Pin

Chrome Hardened Yes Yes Yes

A Push Power 2000 N / 450 lbs. 1500 N / 340 lbs. 1500 N / 340 lbs. 1100 N / 350 lbs. 1100 N / 350 lbs.

I Min. Tensile Strength

Weight (114 links)
9000 N / 2023 lbs.
307 g
9000 N / 2023 lbs.
307 g
9000 N / 2023 lbs.
307 g
9000 N / 2023 lbs.
300 g
9000 N / 2023 lbs.
300 g
N External Pin Plate Silver / Nickel Plated Silver / Nickel Plated Grey / Polished Grey / Dacromet Grey / Polished
Design

S Internal Pin Plate Silver / Nickel Plated Grey / Polished Grey / Polished Grey / Dacromet Brown / Annealed
Connecting Method Power Link Silver Power Link Silver or Pin Power Link Silver or Pin Power Link Grey or Pin Power Link Grey or Pin

P PC 10 Saltshaker PC 10 PC 7X PC 1 Saltshaker PC 1 Ni PC 1

O Part No.
Application
—
MTB
—
MTB
—
BMX / Track
—
Gear Hubs
—
Gear Hubs
—

W Compatibility Front HG HG Single Single Single Single

E Compatibility Rear HG HG Single Single Single Single

R Max. No. of sprockets max. 7

1/
max. 7 1 1 1 1
2" x
3/
32"
1/
2" x
3/
32"
1/
2" x
1/
8"
1/
2" x
1/
8"
1/
2" x
1/
8"
1/
2" x
1/
Dimension 8"

C Length 6.9 mm 6.9 mm 8.1 mm 7.8 mm 7.8 mm 7.8 mm

H Step Step Step Step Step Step

Pin

Riveting
Push Power 1000 N / 225 lbs. 1000 N / 225 lbs. 1500 N / 340 lbs. 800 N / 180 lbs. 800 N / 180 lbs.
A Min. Tensile Strength 9000 N / 2023 lbs. 9000 N / 2023 lbs. 11000 N / 2500 lbs. 9000 N / 2023 lbs. 9000 N / 2023 lbs.
I Weight (114 links) 300 g 300 g 345 g 330 g 330 g 330 g
N External Pin Plate Grey / Dacromet Brown / Annealed Gold / Gold Plated Grey / Dacromet Silver / Brown /
Design

Internal Pin Plate Grey / Dacromet Brown / Annealed Grey / Polished Grey / Dacromet Nickel Plated Annealed
S Connecting Method Power Link Grey or Pin Power Link Grey or Pin 3 pcs. Connecting Link Snap Lock or Pin Snap Lock, 3pcs Link or Pin

70 Technical Manual 2003

POWER CHAINS
ASSEMBLY / MAINTENANCE

1
/ 2 " x 3/ 32 " A N D 1 / 2 " x 11 / 128 " P C 1 1 /2 " x 1 /8 "
1 (DERAILLEURS / SINGLE (SINGLE AND MULTI-
AND MULTI-SPEED HUBS) SPEED HUBS)

+ Chain length:
• Shorten chain to the length specified by
Closing chain with Snap Lock:
• Fit the shortened chain, bring the ends
(2 Links) the derailleur manufacturer. together and connect with the Snap Lock.
SRAM derailleurs: Place the outer plate on one pin (Fig. 6).
• Place chain over largest front chain- • Gently flex the chain until the outside
2 wheel and largest rear sprocket and add connector plate snaps into position over
2 links or 1 link + Power Link (Fig. 1). the second pin (Fig. 7).
• For rear suspension frame, position the
rear suspension for the greatest chain Caution:
length required. • Make sure plate is fully seated in the
pin channel and plates are parallel to
each other.
Closing standard version with clamping pin: • If movement of the connector plate is
• Fit chain, bring the two ends together noticed a new Snap Lock must be used.
and press pin (Fig. 2) through with • Always use a new Snap Lock when
3 assembly tool. The pin must extend by
the same amount at both outer plates. It
fitting a new chain. Failure to shorten
the chain properly or to lock it exactly
must be possible to move the connecting into place may cause damage to the
link slightly. chain and eventually total chain failure,
• The use of the SRAM assembly plier material damage or the rider to fall off
(Part No. 00 2799 980 001) is recommen- his bicycle resulting in injury.
ded for PC 68, PC 58 and PC 48.

4 P C 7 X 1 /2 " x 1 /8 "
Power Link connecting links: (BMX / TRACK)
Caution:
• Use only as specified, to avoid material Closing chain:
damage or the rider to fall off his bicycle • Fit the shortened chain, bring the two
resulting in injury. ends together and connect with the
• Use only Power Link Gold for closing chain lock. The chain lock consists of an
5 Holow Pin chain versions (no pin). outer plate with pins (1, Fig. 8), an outer
plate (2) and a retaining spring (3).
Power Link Grey grey coloured • Insert outer plate with pins (1) into the
for PC 38, PC 10 chain ends, attach outer plate (2) and
Power Link Silver silver coloured press chain lock together (1+2).
for PC 68, PC 58, PC 48 • Attach retaining spring (3) with the
6 Power Link Gold gold coloured
for PC 99, PC 89R,
closed end of the retaining ring pointing
in the direction of chain travel (Fig. 9).
PC 69, PC 59, PC 49 • Slide retaining spring in the direction
of arrow (4, Fig. 9) to engage it in the
Closing: grooves in the pins.
• Fit chain, bring the ends together and
7 insert both halves of the Power Link into
the chain ends. (Fig. 3) MAINTENANCE
• Press both halves of the Power Link • Regular lubrication will extend the
together (Fig. 4) and lock in place by chain's service life.
pulling the chain apart. (Fig. 5) • Apply oil to the chain rollers and allow
to work in.
Opening: • Clean dirty chains before oiling. Do not
8 1 • Press both plates of the Power Link use any grease-dissolving or acidic
together (Fig. 4) while sliding the chain agents. Cleaning agent must be rinsed
ends together (unlock). Remove the two off after a few minutes with water.
halves of the link from the chain ends. Apply oil after chain is completely dried.
2 3
Caution:
Always use a new Power Link when
9 fitting a new chain. Failure to shorten the
chain properly or to lock it exactly into
4 place may cause damage to the chain and
eventually total chain failure, material
damage or the rider to fall off his bicycle
resulting in injury.

Technical Manual 2003 71

NOTICES

72 Technical Manual 2003

NOTICES

Technical Manual 2003 73

NOTICES

74 Technical Manual 2003

NOTICES

Technical Manual 2003 75

NOTICES

76 Technical Manual 2003

NOTICES

Technical Manual 2003 77

SUPPORT
DISTRIBUTORS

GERMANY
USA EUROPE Epple Zweirad GmbH
Mittereschweg 1
Action Bicycle USA The Merry Sales Company 87700 Memmingen
217 Washington Ave - A 1415 San Mateo Ave Ph: +49 8331 751411
Carlstadt, NJ 07072 San Francisco, CA 94080 AUSTRIA Fx: +49 8331 751450
Ph: 1.800.284.2453 Ph: 1.800.245.9959 KTM Fahrrad GmbH e-mail: [email protected]
Ph: 201.804.9090 Ph: 650.871.8870 Harlochnerstrasse 13
www.actionbicycleusa.com www.merrysales.com Hermann Hartje KG
5230 Mattighofen
Deichstrasse 120-122
Bicycle Tech International Olympic Cycle Supply Ph: +43 7742 4091 0
27318 Hoya/Weser
3201B Richards Lane 5711 W Douglas Ave FX: +43 7742 4091 72
Ph: +49 4251 811 240
Sante Fe, NM 87505 Milwaukee, WI 53218 e-mail: [email protected]
Fx: +49 4251 811 249
Ph: 1.800.558.8324 Ph: 1.800.236.8380 e-mail: [email protected]
Ph: 505.473.0011 Ph: 414.461.8380 BELGIUM www.hartje.de
www.bti-usa.com www.olympicsupplycompany.com Transmission S.A. SRAM Hotline: 0180-3772633
Boulevard du Centenaire 4
DownEast Bicycle Specialists Quality Bicycle Products
1325 Dion-Valmont
Porter Road 6400 West 105th St GREECE
Ph: +32 10 24 46 46
Fryeburg, ME 04037 Bloomington, MN 55438 Gatsoulis Imports
FX: +32 10 24 47 77
Ph: 1.800.242.1043 Ph: 1.800.346.0004 8 Thessalonikis Street
Ph: 207.935.4242 Ph: 952.941.9391 14342 New Filadelfia-Athens
www.debike.com www.qbp.com CZECH REPUBLIC Ph: +30 1 251 2779
Vokolek Import Fx: +30 1 253 3960
Giant Bicycle, Inc. Raleigh Bicycle Co., USA Sezimova 12
3287 Old Conejo Rd 22710 72nd Ave S 146 00 Praha 10
New Bury Park ,CA 91320 Kent, WA 98032 HUNGARY
Ph: +420 2 41 74 07 12
Ph: 1.800 US GIANT Ph: 1.800.222.5527 Biker Kft.
Fx: +420 2 41 74 23 93
Ph: 805.267.4600 Ph: 253.395.1100 Gyepsor u.1
e-mail: [email protected]
www.giant-bicycle.com www.raleighusa.com 1211 Budapest
www.vokolek-import.cz
Ph: +36 1 278 10 20
G. Joannou Seattle Bike Supply Zitny Fx: +36 1 278 10 23
151 Ludlow Ave 7620 South 192nd Ceskobratrske Nam. 133 e-mail: [email protected]
Northvale, NJ 07647 Kent, WA 98032 29301 Mlada Boleslav www.biker.hu
Ph: 201.768.9050 Ph: 1.800.955.2453 Ph: +420 326 722214
www.jamisbikes.com Ph: 425.251.1516 Fx: +420 326722214 ICELAND
www.redlinebicycles.com Örninn Hjól HF
Hans Johnsen Company
8901 Chancellor Row Security Bicycle DENMARK Ceskobratrske Nam. 133
Dallas, TX 75248 32 Intersection St Dan Agentur ApS IS-108 Reykjavik
Ph: 1.800.879.1515 Hempstead, NY 11550 Stationsvej 77 Ph: +354 5889890
Ph: 214.879.1550 Ph: 1.800.645.2990 5792 Årslev Fx: +354 5889896
www.hjc.com Ph: 516.485.6100 Ph: +45 65 99 24 11 e-mail: [email protected]
Fx: +45 65 99 28 42 www.orninn.is
The Hawley Company Sinclair Imports e-mail: [email protected]
One Hawley Drive 2775 Highway 40
Lexington, SC 29074 Verdi, NV 89439
I TA LY
ESTONIA A.M.G. s.r.l.
Ph: 1.800.822.1980 Ph: 1.800.654.8052
Balti Autoosade AS Via Piave 10
Ph: 803.359.3492 Ph: 702.345.0600
Mustamäe tee 18A 23871 Lomagna (Como)
www.hawleyusa.com www.sinclairimports.com
10617 Tallinn Ph: +39 039 5301167
J&B Importers, Inc. Trek Bicycle Corporation Ph: +372 6 200 600 Fx: +39 039 9220270
11925 S W 128th St 801 W Madison St Fx: +372 6 200 699
Miami, FL 33116 Waterloo, WI 53594
L AT V I A
Ph: 1.800.666.5000 Ph: 1.800.369.8735 FINLAND Veloserviss Ltd
Ph: 305.238.1866 Ph: 920.478.2191 J. Syväranta Oy 111 Brivbas Str
www.jbimporters.com www.trekbikes.com Nervanderinkatu 1005 Riga
KHS Inc. United Bicycle Parts 5E 47 / PL 64 Ph: +371 750 1292
2840 East Harcourt 691 Washington St F-00101 Helsinki Fx: +371 750 1298
Rancho Dominguez, CA 90221 Ashland, OR 97520 Ph: +358 9 434 2030 e-mail: [email protected]
Ph: 1.800.347.7854 Ph: 1.800.482.1984 Fx: +358 9 493 890
Ph: 310.632.7173 Ph: 541.488.1984 NETHERLANDS
www.bicyclesusa.com www.ubike.com FRANCE Koch Kleeberg B.V.
Lexco Wilson Bicycle Sales SAVOYE SA Dukdalfweg 25
2738 W Belmont 31157 Wiegman Rd Rue de I’industrie 1332 BJ Almere
Chicago, IL 60618 Hayward, CA 94544 01470 Serrières de Briord Ph: +31 36 5320504
Ph: 1.800.626.6556 Ph: 1.800.877.0077 Ph: 33 474 36 13 77 Fx: +31 36 5322548
Ph: 773.588.8890 Ph: 510.471.7520 Fx: 33 474 36 15 14 e-mail: [email protected]
www.wilsonbike.com e-mail: [email protected] www.koch-kleeberg.nl

78 Technical Manual 2003

SUPPORT
DISTRIBUTORS ✆
Vertex Cycle Systems BV SWEDEN
Delfweg 12 Vartex AB CARRIBEAN
2211 VM Noordwijkerhout Batterivägen 14
Ph: +31 252 340611 43232 Varberg X-Trimulti Sports
Fx: +31 252 345030 Ph: +46 340 64 60 00 530 Ponce De Leon Avenue
www.vertexcs.nl Fx: +46 340 61 11 90 San Juan
e-mail: [email protected] Puerto Rico 00901-2304
N O R WAY www.vartex.se Ph: +787 289 8122
Stians Sport A.S. Fx: +787 289 8773
Disenåveien 26 SWITZERLAND
2100 Skarnes Amsler & CO AG
Ph: +47 6296 6020 Lindenstraße 16 JAPAN
Fx: +47 6296 6021 8245 Feuerthalen
e-mail: [email protected] Ph: +41 52 647 36 36 Kawashima Cycle Supply Corp.
www.merida.no Fx: +41 52 647 36 66 No. 4-2-4 Kushiya-Cho Nigashi,
SRAM Hotline: +47 62 96 70 20 e-mail: [email protected] Sakai, Osaka 590-0944
www.amsler.ch Ph: +81 722 38 6126
POLAND SRAM Hotline: +41 52 647 36 36 Fx: +81 722 21 4379
HARFA-HARRYSON Henryk Charucki
Ul. Ks. Witolda 48 UNITED KINGDOM
50-203 Wroclaw, Fisher Outdoor Leisure Plc KOREA
Ph: +48 713721570 Unit 8/9 Brick Knoll Park
Fx: +48 713278092 Ashley Road Industrial Estate Highland Sports, Ltd.
e-mail: [email protected] Ashley Road 1006, Deechi-3 Dong, Kangnem-Ku
www.harfa-harryson.com.pl St. Albans, Hertfordshire Seoul
AL1 5UG Ph: +822 553 2667
PORTUGAL Fx: +44 1727 798345 Fx: +822 553 2669
Ciclo Coimbres Fx: +44 8009 807129
Parca Manuel Da Silva Reis 122
4400 Vila Nova de Gaia NEW ZEALAND
Ph: +351 23 79 4461 AUSTRALIA
Fx: +351 23 06 163 Cycle Supplies
Groupe Sportif Pty. Ltd. 17A Brockworth Pl Ricarton
RUSSIA 20 Harker Street Christchurch, 0000
TRIATLON ‘Velomir’ Burwood Ph: +64 3 332 3622
Lusinovskaya Ul 53/12 Victoria 3125 Fx: +64 3 332 3243
113096 Moscow Ph: +03 9888 9882
Ph: +7 095 237-8463 FX: +03 9888 9902
Fx: +7 095237-8463
PHILLIPINES
SLOVAKIA
BRAZIL
VeloCity-DaDa
EXCELIA s.r.o. 2195 Leverizza St. Unit #i
Pedal Power Brazil
Trencianska 764/409 Cartimar, Pasay City
R. Gomes de Carvalho S41
018 51 Nova Dubnica Ph: +632 832 2352
Sao Paulo SP
Ph: +421 827 430034 Fx: +632 820 2626
04547 002
Fx: +421 827 430034 e-mail: [email protected]
Ph: +5511 38467720
FX: +5511 38456377
SLOVENIA
Proloco Trade d.o.o.
Britof 96A CANADA SINGAPORE
4000 Kranj Boon Bike Supply
Ph: +386 4 280 2000 Kempter Marketing (KMI)
488 Changi Road
Fx: +386 4 280 2022 1271 St. Louis
Singapore 419898
e-mail: [email protected] St. Lazare, PQ J7T1Z9
Ph: +65 242 8488
Ph: 450.424.4600
Fx: +65 242 8488
S PA I N Fx: 450.424.5828
Casa Masferrer, s.a. www.kmi.ca
Pol. Ind. Congost. Avenida
San Julian s/n Norco Products Limited SOUTH AFRICA
E-08400 Granollers (Barcelona) 1465 Kebet Way
Ph: +34 9 3846 6051 Port Coquitlam, BC V3C6L3 Cape Cycle Systems (PTY) LTD.
Fx: +34 9 3846 5356 Ph: 1.800.521.9088 10/12 Argo Road, Wetton
e-mail: [email protected] Ph: 604.552.2930 7780 Cape Town
www.casamasferrer.com Fx: 604.552.2931 Ph: +27 21 761 3528
www.norco.com Fx: +27 21 761 5914

Technical Manual 2003 79

SUPPORT
WHO TO CALL / SRAM WARRANTY / SPARE PARTS ✆
WHO TO CALL NORTH AMERICA
In warranty cases or need of Dealer Helpdesk Number:
technical support help, please
contact the appropriate locations.
(800)-346-2928

EUROPE
Please contact your local distributor.

WARRANTY
1. SRAM settles warranty claims accor- 3. Warranty claims are only valid upon this warranty shall not cover damages
ding to the legal EU regulations effective presentation of a proper proof of caused by the use of parts of different
as of 01.01.2002, alternatively according purchase. manufacturers or otherwise which are
to the legal regulations of the respective 4. Parts subject to normal wear and tear not compatible or suitable resp. not
country. (for example brake sleeves, brake pads, authorized by SRAM for use with SRAM
2. Any other warranty claims not included chains, sprockets, shifter cables, components.
in this statement are void. This handlebar grips etc.) and damage which 5. If a defect is discovered, please contact
especially includes any disassembly or is caused by improper use, specifically the dealer where the bicycle or the
assembly costs (for instance by the caused by disregard for our assembly SRAM component in question was
dealer), which shall not be covered by and operating instructions, shall not be purchased.
SRAM. covered by this warranty. Furthermore,

SPARE PARTS SRAM ORIGINAL PARTS

You can find an extensive spare parts Caution:
program in SRAM’s Spare Parts List Installation of parts and accessories not originally intended
Model Year 2003 · Publ. Number 8503. could result in less than optimal performance and/or injury.

80 Technical Manual 2003

www.sram.com

WORLD HEADQUARTERS
Chicago, Illinois U.S.A.
SRAM Corporation
1333 North Kingsbury, 4th floor
Chicago, Illinois 60622
phone: +1-312-664-8800
fax: +1-312-664-8826

EUROPEAN HEADQUARTERS
Amersfoort, The Netherlands
SRAM Europe
Basicweg 12-D
3821 BR Amersfoort
The Netherlands
phone: +31-33-450-6060
fax: +31-33-457-0200

ASIAN HEADQUARTERS
Taichung, Taiwan
SRAM Taiwan
No. 1598-8 Chung Shan Road
Shen Kang Hsiang, Taichung
County 429
Taiwan R.O.C.
phone: +886-4-2561-3678
fax: +886-4-2561-3686