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10
11
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CONTENTS
A Tip of the Helmet to . . .
Introduction
ix
xiii
Chapters
1
Tools
15
33
Chains
51
71
111
147
Cranksets
195
Pedals
225
10
243
11
257
12
Wheelbuilding
291
13
Forks
311
14
Frames
347
Appendixes
A
Troubleshooting Index
371
Gear Development
377
383
Torque Table
393
Glossary
409
Bibliography
421
Index
423
Illustration Index
433
437
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
INTRODUCTION
to learn.
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
xiii
xiv
WHY DO IT YOURSELF?
your own bike. Yet you may find that you enjoy
the trail.
alone with the sky, the sun, and the rocks for long
xv
e LEVEL 1
e e LEVEL 2
e e e LEVEL 3
INTRODUCTION
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
I NT R O D UC TI O N
xx
TOOLS
i-1
e LEVEL 1
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
1.1A
chain tool
tire levers
grease
Patch kit. Choose one that comes with sandpaper instead of a metal scratcher and patches
with soft orange rubber backing to the black
rubber (Fig. 6.11). At least every year and a half,
chain lube
check that the glue has not dried up, regardless of whether the tube has been opened or
spare tube
plenty of rags
patch kit
3
chain-elongation gauge
spoke wrench
noggin
standard and Phillipshead screwdrivers
tire
pump
with
gauge
talcum
powder
rubbing
alcohol
pliers
talc
rubbing alcohol
metric hex
keys
folding metric
hex keys
1.1B
chains (Figs. 4.1011). Older chain tools may
Valve types
Presta
Schrader
CHAPTER 1
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
T O O LS
1.2
ball-peen hammer
grease designed specifically for bicycles; however, standard automotive grease is okay,
except in suspension forks and twist shifters.
portable bike
stand
Channel-lock
pliers
snapring
pliers
i-2
LEVEL 2 TOOL KIT
e e L E V EL 2
Level 2 repairs are a bit more complex, and I
recommend that you create a well-organized
workspace with a shop bench. Keeping your workspace organized is probably the best way to make
rubber gloves
duct tape
tire pressure
gauge
sound system
CHAINS
A chain is only as strong as its weakest link.
Anonymous
A sausage is only as good as its last link.
TOOLS
Bluto
chain lubricant
12-inch ruler
chain tool
lots of rags
rubber gloves
OPTIONAL
chain-elongation
indicator
master link pliers
solvent (citrus
based)
self-contained chain
cleaner
caliper
pliers
solvent tank
Rohloff cog-wear
indicator
ing in the air where you can inhale the lube. The
chain needs oil only between contacting parts.
iv-1
the chain.
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
51
52
4.1
iv-2
CLEANING THE CHAIN BY FREQUENT
WIPING AND LUBRICATION
Cleaning the chain can be accomplished in
a number of ways. The simplest method to
maintain a chain is to wipe it down frequently,
lubricate it, and then wipe off the excess lube. If
1. Drip a small amount of lubricant across each
a bike stand:
4.2
4.3
4.4
53
jockey wheel).
the gloves, wipe and lube the chain, and put your
stay clean, and your bike is ready for the next ride.
any solvent.
Citrus chain solvents often contain some
CHAPTER 4
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
C H AI NS
iv-3
54
clean.
iv-4
REMOVING AND CLEANING THE CHAIN
e L E V EL 1
breaks.
Mountain bike chains are prone to breakage because of the conditions in which they are
used, but chain breakage is even more of an issue
because of the narrow width of 9- and 10-speed
iv-11).
55
iv-6
e LEVEL 1
a. Chain-elongation gauges
iv-5
REPLACING THE CHAIN
LE VE L 1
chain roller, and let the long tooth drop into the
the problem. A new chain will not mesh properly with deformed teeth, and it is likely to skip
whenever you pedal hard. So before all of that
extra wear and tear hits your pocketbook, get in
the habit of checking the chain on a regular basis
4.5
CHAPTER 4
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
C H AI NS
198
square on the end (Figs. 8.1, 8.18, 8.2123) and fit into
Installation
e LEVEL 1
bearing.
spacer
spindle
right
bearing
cup
spacer
spindle cover
with O-rings
left crankarm
(Attention: left-hand thread!)
right
crankarm
bolt
TL-FC35
crankarm
removal
tool
TL-FC17
adjusting
nut tool
bolt
washer retainer
washer
adjusting nut
INDEX
166, 409
BBT-39 tool, 200, 212
Bearing cups, 207, 211, 212, 409
Bearing pullers, 211, 219220
Bearing removers, 11
Belt drives, 6466, 101
Bike dimensions, 385
Bike tting, 383391, 385393
Bike stands, 4, 9
Blankets, 14, 48
Body measurements, 385388
Bosses, 176, 180, 181, 183, 186, 188,
191, 194, 309
brake, 148, 150, 345, 348, 410
cantilever, 148, 311, 312, 313, 348,
350, 351, 411
disc-brake, 312, 313, 350, 351
Bottom-bracket cups, 30, 83, 213,
217, 223, 350
Bottom-bracket shells, 11, 58, 66, 81,
83, 207, 208, 209, 210, 212, 213,
214, 215, 216, 220, 222, 223,
252, 352, 387, 410
cleaning, 211, 212
full-carbon, 204
tapping, 350
unthreaded, 203
Bottom-bracket tools, 6
Bottom brackets, 65, 102, 108, 109,
110, 191, 195, 198, 203216, 231,
345, 388, 409
adjusting, 201, 222, 223
BB30: 220
BB86: 204, 205, 206
BB90: 204, 206
BB92: 204206, 210211, 220
BB95: 204206, 210211, 219
cartridge, 212213, 216, 220221,
223225
cup-and-cone, 213216, 221, 222,
223
eccentric, 58, 66
external-bearing, 203, 205, 206,
209210
height, 384, 386, 410
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
423
424
cylindrical-clamp, 182
disconnecting, 328, 331
feel of, 184
Hayes, 157, 159, 168170, 173
hub, 414
linkage, 148, 190, 194
mounting, 162-163
opening, 4041
options for, 147148
releasing, 1617, 23, 148, 150
rim, 16, 149, 150, 301
rubbing, 370
Shimano, 8889, 95, 167, 185
troubleshooting with, 192194
See also Cantilever brakes; Disc
brakes; Hydraulic brakes;
Roller-cam brakes; U-brakes;
V-brakes
Braking, 291, 322
chattering/vibration when, 183,
369, 372, 374, 375
problems with, 369370
Brushes, 24, 26
Buckets, 24
Bushings, 180, 181, 211, 231, 234,
330, 334, 335, 353, 354, 355,
356, 358, 361, 410
replacing, 359360
Cable cutters, 6, 86
Cable stops, 348, 410
Cable tension, 72, 7678, 107
adjusting, 71, 74, 85, 148149, 151,
152, 186, 230231, 396
Cables, 76, 97, 148154, 178, 185,
190, 251, 311, 410
broken, 4546
clamping, 4041
Gore-Tex, 86, 94, 95, 178
installing, 22, 74, 9293, 94, 150
loose, 4041, 85
lubricating, 30, 9495, 107, 149,
150
maintaining, 103, 149, 152, 192
replacing, 30, 85, 8792, 149, 150,
152
shift, 80, 85, 88, 8990
Shimano, 8990
sticky, 68, 107
tying, 43
worn, 151, 193
Calipers, 11, 41, 150, 156, 163, 170,
313, 410
cleaning, 171173
disc-brake, 31, 161, 162, 173174
216, 411
bent, 201
chainstays and, 223225
cleaning, 26, 66, 200
inner, 109, 223
inspecting, 66, 200201
installing, 66, 202
jammed chains and, 36
loose, 221
maintaining, 200
middle, 10
spindles and, 209
worn, 200
Chains, 411
assembling, 5152
broken, 38, 54, 56, 57, 59
cleaning, 2627, 5255, 66
connecting, 57, 5961
dropping, 110, 370
jammed, 15, 3638, 370
lubricating, 4, 13, 2526, 27, 30,
5154, 66, 67, 74, 105, 254
maintaining, 152
measuring, 140
removing, 27, 44, 45, 5457, 63
replacing, 55, 62, 67, 68, 74, 150
Shimano, 26, 56, 59, 6061, 62
skipping, 67, 107, 370
slapping, 370, 372
squeaking, 67
SRAM, 54, 56, 61, 62
troubleshooting, 6669
with twisted link, 3738
wiping, 25, 26, 27, 30, 5253, 67
Wippermann, 37, 54, 56, 62, 67, 69
Chainstays, 23, 40, 43, 65, 66, 74,
81, 102, 103, 109, 159, 213, 349,
361, 367, 411
chain suck and, 67
chainrings and, 223225
jammed chains and, 36
Circlips, 208, 211, 212, 220, 313, 327,
336
Clamps, 58, 81, 82, 83, 254, 255, 276
cylindrical, 182
saddle, 245, 246
seatpost, 31, 46, 253, 254
split, 153
See also Stem clamps
Cleats, 226, 230
adjusting, 227229, 240
installing, 227229
loose, 239240
Clunking noises, problems with,
222223, 372
INDEX
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
425
426
231, 313
Lubrication, 3031, 128, 330
ball bearing, 31, 131, 132, 281, 286
cable, 30, 9495, 107, 149, 150
chain, 4, 13, 2526, 27, 30, 5154,
66, 67, 74, 105, 254
crankset, 31
derailleur, 30, 105
fork, 31, 314
freehub, 142146
freewheel, 30, 146
housing, 30, 85, 9495, 151, 152
hub, 131132
pedal, 31, 239240
piston, 173, 190
quill, 281
saddle, 31
seatpost, 31, 254, 266, 348
shifters, 30
wheel, 30
Magnet, 7
Master cylinders, 173, 415
Master links, 13, 33, 42, 54, 57,
5960, 61, 6364, 67, 69, 415
Matches, 14, 48
Money, 14
patching sidewalls with, 36
Morningstar Drumstix tool, 175
Morningstar Freehub Buddy, 7, 142,
143, 144
Morningstar Freehub Soup, 142,
143, 144
Morningstar Rotors on Center (ROC)
dial-indicator tool, 10, 174175
Mounting bolts, 69, 105, 192, 415
Mounts
broken, 348
disc-brake, 309, 351
IS, 159, 313
ISCG, 101
Multitools, 12, 38
Needle bearings, 279, 280, 415
Newton-meters (N-m), foot-pounds
and, 397
Nipples, 124, 127, 290, 292, 293, 294,
307308, 415
tightening/loosening, 125, 299,
300, 301, 302, 303
types of, 126, 291, 308
O-rings, 144, 158, 164, 172, 337, 354,
355, 357, 362363
Off-center rims (OCR), 292, 293, 308
INDEX
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
427
428
415
Pistons, 166, 337, 338, 356, 358
cleaning, 172173
disc-brake, 157158
lubricating, 173
pushing back, 157158
Pivot bolts, 415
Pivots, 154, 155, 194, 312, 313, 415
bushing, 31
derailleur, 69, 79
loose, 107
lubricating, 152, 190
maintaining, 106, 358359
overhauling, 105
Pliers, 2, 14, 37
Channel-lock, 6
master-link, 7, 63, 64
snapring, 6
Vise-Grip, 63
Postmounts, 159, 161, 163, 309, 313,
351
PowerLink, 61, 63, 64
Preload, 319, 322, 324, 362, 363
Preload adjusters, 331, 362,
363364
Press t systems, 204, 205, 220
ProGold ProLink, lubricating with,
51, 67
Pulling, problems with, 369
Pumps, 2, 12, 35, 124
oor, 120
shock, 4, 12, 326
Punctures, 15, 16
xing, 3436
preventing, 3334
snakebite, 34, 35, 120, 124
Quick-release (QR), 416
Quick-release (QR) levers, 148, 188
Quick-release (QR) seatpost binders, 248, 388
Quick-release (QR) skewers, 20, 22,
34, 45, 139, 142, 342
checking, 15
installing, 132
opening, 1718
removing, 128, 141
tightening, 19
Quills, 265, 416
lubricating, 281
Race Face, 197, 199, 210, 416
Races, 127, 136, 409, 416
fork-crown, 281, 282284,
285286
Rags, 4
Rattling noises, 287
Really tight, 30, 396
Reamers, 11
Rear triangles, 43, 65, 102, 342, 345,
416
Rebound damping, 318, 320321,
361, 362, 364, 416
adjusting, 321, 323, 325, 365, 366
Release tension adjustment, 227,
229231, 240, 371
Ride height. SeeSag
Rim strips, 35, 118, 121
Rims, 16, 121, 149, 150, 416
bent, 41, 111
brake pads and, 4041
cleaning, 192193, 303
deep-section, 112
disc-brake, 301
drilling, 308
examining, 120
off-center, 292, 293, 308
replacing, 291
scraping, 125, 299, 300
spokes and, 124127
tubeless, 293
wheelbuilding and, 289, 292, 294
Roller-cam brakes, 17, 150, 190,
191192, 194, 416
Rotors, 127, 304
bent, 175
bolting, 160161
cleaning, 193
installing/removing, 159161
splined, 159, 160, 161
truing, 4142, 174175
Rubbing alcohol, 4, 257
Rubbing noises, problems with, 373
Saddle height, 240, 243, 248, 388
Saddle position, 242, 244, 246, 247,
253, 388389
Saddles, 391, 416
adjusting, 243
choosing, 241242
clamping, 245
handlebars and, 390
installing, 245246, 247248
lubricating, 31
maintaining, 242
shape/design of, 242
troubleshooting problems with,
253254
Sag, 315, 319, 324, 361, 366, 416
measuring, 316317, 318
setting, 362363
Saw guide, 263
Scraping noises, problems with, 373
Screwdrivers, 12, 42, 43, 45, 46
bent-shaft spoke-nipple, 10
Phillips-head, 2
Sealants, 9, 16, 34, 35, 120, 122124,
417
aerosol, 123
glycol-based, 122, 123
latex-based, 122
tubeless tires and, 121, 123124
Seals, 173, 178, 216, 217, 328, 330,
356, 357, 359
bearing, 136, 277
cleaning, 354355
installing, 278, 281
quad, 355
removing, 218, 355
square, 158, 355
Seat bags, 33, 42
Seat tubes, 45, 80, 82, 248, 249, 254,
367, 416
length of, 386, 387
Seatpost clamps, 31, 46, 253
lubricating, 254
Seatposts, 241, 243, 384, 389, 417
adjusting, 249251
aluminum, 245, 252, 253, 254
broken, 47
carbon, 245, 251252
Crank Brothers, 249, 250, 251, 388
extensions, 244
GravityDropper, 249, 250, 251, 388
height-adjustable, 249251, 388
installing, 246, 248249
lubricating, 31, 254, 348
maintaining, 244245
Maverick, 249, 250, 251
position of, 244, 250
removing, 46, 244, 248, 251253
single-bolt, 246
stuck, 251253
suspension, 244245, 249, 254
troubleshooting problems with,
253254
two-bolt, 246, 247
Seatstays, 23, 65, 349, 367, 417
Setscrews, 29, 79, 98, 106, 133, 185,
186, 191, 248, 331, 349
Shifters, 92, 95103, 255
adjusting, 7480, 8385
derailleurs and, 107
dual-lever trigger, 152
friction, 413
internal, 339340
removing, 129
Spacing, 66, 149, 166, 341, 342, 344,
349
brake pad, 158
crank-to-frame, 224
pad-to-rotor, 163
problems/remedying, 7778
Spanners, 417
pin, 7, 29, 215, 216, 221, 415
toothed-lockring, 29
Spiders, 102, 201, 417
Spindle removal tool, 6
Spindles, 109, 210, 227
bottom-bracket, 66, 203, 209,
211212, 223
chainrings and, 209
installing, 212
integrated, 195, 197, 198199, 203,
204, 205, 216, 217
pedal, 6, 227
splined, 207
square-taper, 207
upgrading, 239
Splines, 29, 140, 141, 160, 207, 417
Spoke calculator, 290, 291
Spoke-prep compound, 291
Spoke tension, 10, 124, 292, 301
reducing, 308
Spoke-tension gauge, 10
Spokes, 76, 290, 417
adjusting, 39, 40, 127, 299, 300,
301, 302, 303
broken, 3940, 41, 124, 126127
converging parallel, 299
crossing, 299, 307
derailleurs hitting, 370
rst set of, 293294, 305
fourth set of, 297299, 306
Kevlar, 40
lacing, 289, 294, 296, 297299
length of, 290
prestressing, 302, 303
pulling, 293, 303, 308
radial, 308
replacing, 3840, 126127, 291
rims and, 124127
second set of, 294295, 305306
spare, 13, 40
thickness, 290, 307308
third set of, 296297, 306
twisted, 125
weaving, 126127
Spoking patterns, 308
one-cross, 289, 291, 306307
INDEX
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
429
430
Wire, 14
Wrenches
adjustable, 2, 37, 113
Allen, 29, 409
cone, 6, 128, 132
crowfoot, 11, 412
xed-cup, 223
headset, 6, 14, 274
metric, 2, 20
open-end/box-end, 2, 12, 29
pedal, 13-14, 226
socket, 6, 29, 417
soft, 7
splined, 7, 9, 29
spoke, 4, 7, 13, 39, 40, 41, 124,
291, 299
torque, 7, 20, 200, 210, 229, 312,
393394, 419
Torx, 6, 12, 29, 42, 201, 202, 419
Y-, 9
INDEX
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
431
Zinn has been writing for VeloNews since 1989 and is the magazines senior technical writer. Other books
by Zinn are Zinn & the Art of Road Bike Maintenance (VeloPress, 3rd ed. 2009), Zinn & the Art of Triathlon Bikes
(VeloPress, 2007), Zinns Cycling Primer (VeloPress, 2004), Mountain Bike Performance Handbook (MBI, 1998),
and Mountain Bike Owners Manual (VeloPress, 1998).
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.
Copyright 2010 VeloPress All rights reserved