raceface x-type kit - real world cycling, · pdf filepictorial installation manual enduro®...

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• Enduro® Outboard Bearing Replacement Kit• Bottom Bracket Bearing Puller/Press Tool• 8mm Allen wrench• 10mm Allen wrench• Outboard bearing cup tool (Park BBT-9 or similar) • Rubber-faced mallet • “Pocket” screw driver (very small, flat blade)• Silicone grease or anti-seize compound• Torque wrench

enduro fork seals .com

REAL WORLD CYCLING

©2006 Real World Cycling/enduroforkseals.com All rights reserved.

PICTORIAL INSTALLATION MANUAL

ENDURO® OUTBOARD BOTTOM BRACKET REBUILD KIT

RECOMMENDED TOOLS AND SUPPLIES

INSTRUCTIONS FOR THERACE FACE® X-TYPE BEARING SYSTEM

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1) Loosen the right side crank arm and spider assembly using an 8mm Allen wrench (turn counter-clockwise).

2) Remove right crank arm and spider assembly.


REAL WORLD CYCLING


NOTE: The 8mm wrench will pass straight through the 10mm hex in the extractor cap, which is to be left in place.

PICTORIAL INSTRUCTIONS

RACE FACE® X-Type

NOTE: REMOVE YOUR BICYCLE CHAIN BEFORE BEGINNING

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3) Remove left crank arm and spindle assem-bly.

a) Remove all the drive side spacers, making a note of them for re-assembly.



REAL WORLD CYCLING PICTORIAL INSTRUCTIONS

RACE FACE® X-Type

3a

b) Use a rubber mallet to “start” the spindle if it won’t pull out by hand.

c) Set the left crank arm and spindle assembly aside.

3b

3c

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4) Remove the left, or non-drive side bearing cup.

Make a note of the spacers for re-assembly.


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6) Place a large screwdriver into the “V” opening of the puller and use it as a “T” handle to pull the dust cap off. Repeat for the other side.

6) Place a large screwdriver into the “V” opening of the puller and use it as a “T” handle to pull the dust cap off. Repeat for the other side.


RACE FACE® X-Type

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5) Remove the DRIVE (right) side cup.

a) Turn the bottom bracket cup wrench clockwise.


REAL WORLD CYCLING


b) Set the inner sleeve and the spacers aside (take note of the spacers for proper re-assembly).


RACE FACE® X-Type

5a

5b

6©2006 Real World Cycling/enduroforkseals.com

All rights reserved.



RACE FACE® X-Type

6) Set one of the bearing cups down on a fl at surface and insert the Collet from the Bearing Puller/Press Tool.

Insert the collet narrow-end-fi rst. The rub-ber ring holding the collet halves together is not necessary. Particularly when removing bearings from the Race Face cups, it will be easier to expand the collet with the rubber ring removed.

7) Start the collet expander into the collet.

“COLLET EXPANDER”“COLLET EXPANDER”

“COLLET”

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REAL WORLD CYCLING



RACE FACE® X-Type

8) Apply pressure to the Collet Ex-pander until it “seats” between the collet halves.

If you encounter diffi culty in getting the expander to seat between the collet halves, lift the cup off of the fl at surface and push on the expander until it fully seats as shown.

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9) Set the bearing cup (with collet and expander) into the Cup Holder.


REAL WORLD CYCLING



RACE FACE® X-Type

10) Press out the bearing and plastic cap by inserting the Bolt and using an 8mm Allen wrench to turn it clockwise until you hear and feel the bearing “drop out” of the cup.

“CUPHOLDER”

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11) Lift the cup off of the Collet Expander.


REAL WORLD CYCLING



RACE FACE® X-Type

12) Unthread the Bolt from the Cup Holder and remove the old bearing and plas-tic cap.

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13) Remove the sealing ring from the outer circumference of the bearing cup.

( If not removed, this ring will interfere with the new sealing system)

14) Place one of the bearings from the Enduro® Kit onto the 24mm side of the Bearing Guide.

(The other side of the Guide is for installing OE bear-ings)


RACE FACE® X-Type

“BEARING GUIDE”“BEARING GUIDE”

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15) Place the Bearing Guide into the Cup Holder.

16) Place the bearing cup on top of the new bearing.


REAL WORLD CYCLING



RACE FACE® X-Type

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17) Place the Support into the threaded end of the bearing cup.


REAL WORLD CYCLING


18) Insert the Bolt and turn it clockwise with the 8mm Allen wrench until it “bottoms.”

Then, remove the bolt and take out the bearing cup.


RACE FACE® X-Type

“SUPPORT”

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REAL WORLD CYCLING



RACE FACE® X-Type

“BEFORE”

“AFTER”

19) The bearing will not yet be fully seated in the cup. To accomplish this, place the old bearing in the Guide and repeat the pressing process as shown in “A-E” below:

B

C

D

A

E

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RACE FACE® X-Type


20) Re-install the left (non-drive side) cup and spacer(s).

a) Apply anti-seize compound to the cup threads.

b) Replace original spacer(s).

c) Start the cup into the frame by hand. The left side threads in normal-ly (clockwise).

d) Use a proper BB Cup Tool d) Use a proper BB Cup Tool to tighten the cup fi rmly in to tighten the cup fi rmly in place.

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RACE FACE® X-Type


21) Re-install the right (drive side) cup and spacer(s).

Remember:1) Apply anti-seize to the cup threads.2) Replace the proper number of spacers.3) Install the inner sleeve!

Remember that the drive side cup has reverse, or left-hand threads. Tighten by turning counter-clock-wise.

You will notice that the Enduro® BB system does not use plastic shims for the spindle. The inner race of our bearings has a smaller ID that directly contacts the spindle. This allows room for larger ball bearings, improving strength and stiffness.

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RACE FACE® X-Type


22) Place a seal on the spindle and slide it up to the left crank arm spacers. Orient the seal so that the silicone side will face away from the bearing.

23) Lubricate the spin-dle with grease and in-sert it through the bear-ings (starting with the left cup!).

If your bike’s bottom bracket faces are parallel and the bear-ings are properly seated, the spindle should line up with the opposite bearing and come through with very little effort. If you encounter some resis-tance, be sure the spindle is lined up and then tap the left crank arm with the heel of your hand to help it through.

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RACE FACE® X-Type


24) Place the other seal over the end of the spindle and slide it up to the bearing.

25) Replace the original spacers.

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RACE FACE® X-Type


26) For easier drive-side installation, remove the crank extraction cap from the crank arm. Turn the cap clockwise with a 10mm Allen wrench to loosen.

With the crank extractor cap removed, the crank bolt can be removed.

“EXTRACTOR CAP”

“CRANK BOLT”

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RACE FACE® X-Type


27) Lubricate the spindle splines and crank bolt threads.

28) Aline the splines and start the drive side assembly onto the spindle.

29) Start the crank bolt by hand (it threads in clockwise).

30) Tighten the crank bolt until the splines “bottom out.” Final torque should be 30 Foot Pounds (NOT Inch Pounds). NOTE: IF YOU NOTICE ANY UNUSUAL TIGHTNESS, OR IF THERE IS TOO MUCH PLAY, PLEASE SEE THE FAC-TORY TROUBLE-SHOOTING GUIDE ON PAGE 21.

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RACE FACE® X-Type

31) Lube the threads of the extractor cap and thread it into the crank arm. Remember it has left-hand threads, so turn counter-clockwise.

32) Tighten the ex-tractor cap by turning it counter-clockwise with a 10mm Allen wrench. Maximum torque is 160 Inch Pounds. Remember that the purpose of this cap is just to make the crank bolt self-extract-ing. It is not helping to keep the crank arm attached, so not much torque is required.

Replace the chain and go ride!

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RACE FACE® X-Type

CONDITION:

ASSEMBLY “TOO TIGHT”

• Excessive Ro- tational Friction (beyond reason- able amount of initial seal drag)

• Bearing Side- Loading Apparent

CAUSE:

• BB shell width too wide (out of tolerance)

• BB shell not faced or milled correctly to remove all paint

• BB shell threads mis- aligned

• Extra chainline spacer is mistakenly added.

• Assembly tolerance stack-up on all parts

FIX:

1) Ensure BB shell threads are chased cleanly and that BB shell is faced (after painting).

2) Ensure BB shell width is within tolerance. If too wide, face-mill BB shell down until it is within required spec.

3) If #1 and #2 above are correct, proceed to on the of the following options:

OPTION 1:- Remove assembly from bike.- Remove 1 x 1mm chainline spacer (preferably from non-drive side so chainline isn’t affected).- Re-install remaining spacers and re-install assembly into bike as per installation instructions #5 and #6 above.

OPTION 2:- Remove assembly from bike.- Remove all spacers and seals from LH (non-drive) side of spindle assembly.- Remove 3.5mm Quad-Ring preload elastomer from recess in LH crank and replace with supplied 2.5mm pre-load elastomer (flat shape, black rubber) into recess in LH crank.- Re-install spacers and re-install assembly into bike as per installation instructions #5 and #6 above.

CONDITION:

ASSEMBLY “TOO LOOSE”

• Excessive side to side “Play” is noticable in the BB spindle / cup assembly when grabbing opposing ends of crank arms and rock- ing back and forth laterally.

• (Note: a small amount of detect- able movement is normal and ac- ceptable.)

• Generally the assembly rotates very freely with little or no detect- able rotational friction or drag.

CAUSE:

• BB shell width too narrow (out of tolerance)

• BB shell not faced or milled correctly to remove all paint

• BB shell threads mis- aligned

• Required chainline spacer or spacer seal is missing from installed assembly

• Assembly tolerance stack-up on all parts

FIX:

1) Ensure BB shell threads are chased cleanly and that BB shell is faced (After painting).

2) Ensure BB shell width is within tolerance. If too narrow, proceed to step #3.

3) If #1 and #2 above are correct, proceed as follows: - Remove assembly from bike. - Add supplied extra 1mm spacer seal (black) to non-drive side of assembly (so chainline isn’t affected). - Re-install assembly into bike as per installation instructions # 5 and # 6 above.

4) If assembly is “loose” with optional 2.5mm pre-load elastomer installed, proceed as follows: - Remove assembly from bike. - Remove all spacers and seals from LH (non-drive) side of spindle assembly. - Remove 2.5mm preload elastomer from recess in LH crank and replace with supplied 3.5mm Quad-Ring pre-load elastomer into recess in LH crank. - Re-install spacers and re-install assembly into bike as per installation instructions #5 and #6 above.

RACE FACE® FACTORY TROUBLE-SHOOTING GUIDE

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RACE FACE® X-Type


Outboard Bottom Bracket Bearing Puller/Pressby Sonny’s Bike Tools

Outboard Bottom Bracket Bearing Replacement Kitby Enduro Bearings

These great procucts available at:

www.enduroforkseals.com

raceface x-type kit - real world cycling, · pdf filepictorial installation manual enduro®...

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