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Zinn & the Art of Mountain Bike Maintenance, 5th edition
Text copyright 2010 by Lennard Zinn
Illustrations copyright 2010 by VeloPress
All rights reserved. Printed in the United States of America.
No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by
any means, electronic or photocopy or otherwise, without the prior written permission of the publisher
except in the case of brief quotations within critical articles and reviews.
1830 55th Street
Boulder, Colorado 80301-2700 USA
(303) 440-0601 Fax (303) 444-6788 E-mail [email protected]
Distributed in the United States and Canada by Ingram Publisher Services
A Cataloging-in-Publication record for this book is available from the Library of Congress.
ISBN: 978-1-934030-59-2
For information on purchasing VeloPress books, please call (800) 811-4210 ext. 2169
or visit www.velopress.com.
This book is printed on 100 percent recovered/recycled fiber, 30 percent postconsumer waste,
elemental chlorine free, using soy-based inks.
Cover and interior design by Erin Johnson
Composition by Erin Johnson and Jessica Xavier
Cover photo by Brad Kaminski; bike built by Lennard Zinn
Custom paint job on cover bike by Spectrum Powder Works, Colorado Springs, CO
Title font Sign Production JNL; body text Caecilia Roman
10 11 12 / 11 10 9 8 7 6 5 4 3 2 1
A Tip of the Helmet to . . . ix
Introduction xiii
Chapters 1 Tools 1
2 Basic Stuff: Preride inspection, wheel removal, and general cleaning 15
3 Emergency Repairs: How to get home when something big breaks or you get lost or hurt 33
4 Chains 51
5 Transmission: Front and rear derailleurs, cables, and shifters 71
6 Wheels: Tires, rims and spokes, hubs, cassettes, and freewheels 111
7 Brakes: Cables, levers, and calipers 147
8 Cranksets 195
9 Pedals 225
10 Saddles and Seatposts 243
11 Handlebars, Stems, and Headsets 257
12 Wheelbuilding 291
13 Forks 311
14 Frames 347
Appendixes A Troubleshooting Index 371
B Gear Development 377
C Mountain Bike Fitting 383
D Torque Table 393
Glossary 409
Bibliography 421
Index 423
Illustration Index 433
About the Author and Illustrator 437
C O N T E N T S
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.Copyright 2010 VeloPress All rights reserved
I N T R O D U C T I O N
Peace of mind isnt at all superficial, really. Its the
whole thing. That which produces it is good mainte-
nance; that which disturbs it is poor maintenance.
What we call workability of the machine is just an
objectification of this peace of mind. The ultimate
tests always your own serenity. If you dont have this
when you start and maintain it while youre working,
youre likely to build your personal problems right into
the machine itself.
Robert M. Pirsig,
Zen and the Art of Motorcycle Maintenance
ABOUT THIS BOOKThis book is intended for people who have an
interest in maintaining their own mountain
bikes. I have written it for mountain bike owners
who do not think theyre capable of maintain-
ing their own bikes, as well as for those who do
and who want the how-to details at their finger-
tips. In Zen and the Art of Motorcycle Maintenance,
Robert Pirsig explores the dichotomy between
the purely classical and purely romantic views
of the world, a dichotomy that also applies to
mountain biking. Riding a mountain bike is
generally a romantic experience of emotion,
inspiration, and intuition, even when solving the
complex physics of how to negotiate a technical
section of trail without putting your foot down.
Mountain bike mechanics, however, is a purely
classical structure of underlying form dominated
by reason and physical laws. The two practices
bike riding and bike maintenancefit eloquently
together. Each is designed to function in a par-
ticular way, and to have one without the other
would be missing out on half the fun.
The romantic can appreciate how success at
bike mechanics requires that the procedures be
done with love, without which the care you imag-
ined putting into your mountain bike would be
lost. And even the pure romantic can follow the
simple step-by-step procedures and exploded
diagrams in this book (of which Fig. I.1 is an
extreme example and is the only one not intended
to be simple and clear!) and discover a passion for
spreading new grease on old parts.
Zinn & the Art of Mountain Bike Maintenance is
organized in such a way that you can pick main-
tenance tasks appropriate for you. The repairs in
these pages require no special skills to perform;
anyone can do them. It takes only a willingness
to learn.
Mountain bikes are admirably resilient mach-
ines. You can keep one running a long time just
by changing the tires and occasionally lubricating xiii
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ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE
xiv
the chain. Chapter 2 is about the most minimal
maintenance your bike requires. Even if that is
the only part of this book you end up using, youll
have gotten your moneys worth by avoiding some
unpleasant experiences out on the trail.
This book was originally intended for home
enthusiasts, not shop mechanics. For that reason,
I have not included the long and precise lists of
parts specifications that a shop mechanic might
need. Nonetheless, when combined with a speci-
fication manual, this book can be a useful, easy-
to-follow reference for shop mechanics, too.
WHY DO IT YOURSELF?There are a number of reasons why you would
want to maintain your own mountain bike.
Obviously, if done right, it is a lot cheaper to do
yourself than to pay someone else to do it. This is
certainly an important factor for those riders who
live to ride and have no visible means of support.
Self-maintenance is a necessity for that crew.
As your income goes up and the time available
to maintain your bike goes down, this becomes
less and less true. If youre a well-paid profes-
sional with limited free time, it probably does
not make as much economic sense to maintain
your own bike. Yet you may find that you enjoy
working on your bike for reasons other than
just saving money. Unless you have a mechanic
whom you trust and to whom you take your bike
regularly, you are not likely to find anyone else
who cares as much about your bicycles smooth
operation and cleanliness as you do. You may also
need your bike fixed faster than a local shop can
do during its busy season. And you need to be
able to fix mechanical breakdowns that occur on
the trail.
It is a given: Breakdowns will happen, even
if you have the worlds best mechanic working
on your bike. For this reason, it takes away from
my enjoyment of a ride if I have something on
my bike that I do not understand well enough to
know whether it is likely to last the ride or how to
fix it if it does not.
There is an aspect of bicycle mechanics
that can be extremely enjoyable in and of itself,
almost independent of riding the bike. Bicycles
are the epitome of elegant simplicity. Bicycle
parts, particularly high-end components, are
meant to work well and last a long time. With the
proper attention, they can shine both in appear-
ance and in performance for years to come.
There is real satisfaction in dismantling a filthy
part that is not functioning well, cleaning it up,
lubricating it with fresh grease, and reassembling
it so that it works like new again. Knowing that
I made those parts work so smoothlyand that I
can do it again when they get dirty or wornis
rewarding. I am eager to ride hard to see how
they hold up rather than being reluctant to ride
for fear of breaking something.
Also, if you share my stubborn unwillingness
to throw something out and buy a replacement
simply because it has quit workingbe it a leaky
Waterpik; a torn tent; a duffle bag with a broken
zipper; or an old car, dishwasher, clock, or chain-
saw that is no longer running wellthen this
book is for you. It is satisfying to keep an old piece
of equipment running long past its time, and its a
great learning experience!
There is also something very liberating about
going on a long ride and knowing that you can
fix just about anything that might go wrong with
your bike out on the trail. Armed with this knowl-
edge (which begins with learning to identify the
parts of a mountain bike, shown in Fig. I.2) and
the tools to put it into action, you will have more
confidence to explore new areas and to go farther
than you might have otherwise.
To illustrate, an experience from way back in
1995 comes to mind, when I took a day to ride
the entire 110-mile White Rim Trail loop in Utahs
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.Copyright 2010 VeloPress All rights reserved
xv
INTR
OD
UC
TIO
N
INTRODUCTION
Canyonlands National Park. It is as desolate as
you can imagine out there, and I was completely
alone with the sky, the sun, and the rocks for long
stretches. I had a good mileage base in my legs, so
I knew I was physically capable of doing the ride
during the limited daylight hours of late October.
I had checked, replaced, or adjusted practically
every part of my bike in the days before the ride.
I had also tried out the bike on long rides close to
town. Finally, I added to my saddlebag tool kit a
few tools that I do not ordinarily carry.
I knew that there was very little chance of
anything going wrong with my bike, and with the
tools I had, I could fix almost anything short of a
broken frame on the trail. Armed with this knowl-
edge and experience, I really enjoyed the ride! I
stopped and gawked at almost every breathtak-
ing vista, vertical box canyon, colorful balanced
rock, or windblown arch. I took scenic detours.
I knew that I had a good cushion of safety, so I
could totally immerse myself in the pleasure of
the ride. I had no nagging fear of something going
wrong to dilute the experience.
Confidence in your mechanical ability allows
you to be more courageous about what you will try
on trails. And armed with this confidence youll
be more willing to share your love of the sport
with less experienced riders. Bringing new people
along on rides is a lot more fun if you know that
you can fix their bikes and they wont be stranded
with an old junker that wont roll.
HOW TO USE THIS BOOKSkim through the entire book. Skip the detailed
steps, but look at the exploded diagrams and get
the general flavor of the book and whats inside.
When it is time to perform a particular task,
youll know where to find it, and youll have a
basic idea of how to approach it.
Illustrator Todd Telander and I have done our
best to make these pages as understandable as
possible. Exploded diagrams are purposefully
used instead of photographs to show more clearly
how each part goes together. The first time you
go through a procedure, you may find it easier to
have a friend read the instructions out loud as you
perform the steps.
Obviously, some maintenance tasks are more
complicated than others. I am convinced that
anyone with an opposable thumb can perform
virtually any repair on a bike. Still, it pays to spend
some time getting familiar with the really simple
tasks, such as fixing a flat, before throwing your-
self into complex jobs, such as building a wheel.
e LE VEL 1
ee LE VEL 2
eee LE VEL 3
Tasks and tools required are divided into
three levels indicating their complexity or your
proficiency. Level 1 tasks need level 1 tools and
require of you only an eagerness to learn. Level 2
and level 3 tasks also have corresponding tool sets
and are progressively more difficult. All repairs
mentioned in this book are classified as level 1
unless otherwise indicated. Tools are shown in
Chapter 1. The section at the end of Chapter 2,
Performing Mechanical Work: A General Guide
(ii-17), is a must-read; it states general policies
and approaches that apply to all mechanical work.
Each chapter starts with a list of required tools
in the margin. If a section involves a higher level
of work, there will be an icon designating the level
and tools necessary to perform the tasks in that
section. Tasks and illustrations are numbered for
easy reference. Section references use the sym-
bol . For instance, iii-6 means see Section
iii-6 in Chapter 3. Illustrations are referred to as
Figures, for instance, Fig. 3.3.
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ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE
xx
and 650B (27.5-inch) tires and wheels are gaining
favor, particularly for tall riders. Smaller 24-inch
wheels and tires are found on small mountain bikes.
Tire widths and shapes vary and include everything
from studded snow tires to smooth street tires. This
book also covers hybrid bikes (Fig. I.5), which are a
cross between road bikes and mountain bikes.
No matter how a mountain bike is configured,
even those who see themselves as having no
mechanical skills will be able to tackle problems
as they arise if they study the steps necessary
to properly maintain and repair their bike. With
a little bit of practice and a willingness to learn,
your bike will transform itself from a mysterious
contraption seemingly too complicated to tamper
with to a simple, very understandable machine
that can be a genuine delight to work on. Just
allow yourself the opportunity and the dignity to
follow along, rather than deciding in advance that
you will never be able to do this. All you have to
do is follow the instructions and trust yourself.
So, set aside your self-image as someone who
is not mechanically oriented (and any other fac-
tors that may stand in the way of your making
your mountain bike ride like a dream), and lets
start playing with your bike!
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11
expensive), and they ensure that your riding bud-
dies will show up not only to ask your sage advice,
but also to borrow your tools.
And if you really want to go all out and be set
up like a pro (and even have mechanics wanting
to borrow your tools), you can splurge on the set
shown in Figure 1.4. If you loan tools, you might
consider marking your collection to help recover
those items that might otherwise take a long
time finding their way back to your workshop.
It wouldnt hurt writing down the details about
which tool you lent to whom and on what date.
You would be surprised how easy it is to forget
who has one of your seldom-used tools such as
snapring pliers or a metric tap.
i-1LEVEL 1 TOOL KIT
e LE VEL 1Level 1 repairs are the simplest and do not
require a workshop, although it is nice to have a
good space to work. You will need the following
tools (Fig. 1.1A):
Y ou cant do much work on a bike without tools. Still, its not always clear exactly which tools to buy. This chapter clarifies the tools you
should consider owning on the basis of your level
of mechanical experience and interest.
As I mentioned in the Introduction, the main-
tenance and repair procedures in this book are
classified by their degree of difficulty. Nearly all the
repairs in this book are classified as level 1, unless
otherwise indicated. The tools for levels 1, 2, and 3
are pictured and described in the following pages.
Lists of the tools needed in each chapter are shown
in the margin at the beginning of each chapter.
For the uninitiated, there is no need to rush
out and buy a large number of bike-specific tools.
With only a few exceptions, the Level 1 Tool Kit
(Fig. 1.1A) consists of standard metric tools. This
kit is similar to the collection of tools I recom-
mend later in this chapter to carry with you on
rides, though in a more compact and lightweight
form (Figs. 1.56). The Level 2 Tool Kit (Fig. 1.2)
contains several bike-specific tools, allowing you
to do more complex work on the bike. The tools
in the Level 3 Tool Kit (Fig. 1.3) are extensive (and
Behold, we lay a tool here and on the morrow it is gone.
The Book of Mormon
TOOLS
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ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE
2
Tire pump with a gauge and a valve head
to match your bikes tubes (either Presta or
Schrader valvessee Fig. 1.1B; most good pumps
will fit both). A spare rubber valve-seal insert for
the head is a good idea; these wear out.
Standard screwdrivers: small, medium, and
large (one of each).
Phillips-head screwdrivers: one small and one
medium.
Set of three plastic tire levers (Figs. 6.56).
At least two spare tubes of the same size and
valve type as those on your bike.
Container of regular talcum powder. It works
well for coating tubes and the inner casings
of tires. Do not inhale this stuff; its bad for
the lungs.
Patch kit. Choose one that comes with sand-
paper 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,
check that the glue has not dried up, regard-
less of whether the tube has been opened or
not. On rides, you might as well take a little
packet of glueless patches; they dont work as
well as standard patches, but if the glue has
dried up, youll be glad you have them.
One 6-inch adjustable wrench (aka Crescent
wrench).
Pliers: regular and needle-nose.
Set of metric hex keys (aka Allen wrenches
or hex wrenches) that includes 2.5mm, 3mm,
4mm, 5mm, 6mm, 8mm, and 10mm sizes.
Folding sets are available and work nicely to
keep your wrenches organized but are not
strong enough or long enough in the big sizes
(6mm and up); big bolts require more leverage.
I also recommend buying extras of the 4mm,
5mm, 6mm, and 8mm sizes.
Set of metric open-end/box-end wrenches
that includes 7mm, 8mm, 9mm, 10mm, 13mm,
14mm, 15mm, and 17mm sizes.
15mm pedal wrench. This is thinner and lon-
ger than a standard 15mm wrench and thicker
than a cone wrench (Fig. 9.3). Your bikes ped-
als may accept only a 6mm or 8mm hex key
(Fig. 9.4), so you may not need this tool.
Chain tool for disconnecting and reconnecting
chain tool
chain lube
patch kit
spare tube
grease
plenty of rags
modern shock pump
1.1A Level 1 Tool Kit
tire levers
15mm pedal wrench
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CHAPTER 1
3
TOO
LSTO
OLS
chains (Figs. 4.1011). Older chain tools may
be too wide for the narrow chains on newer
bikes; read the Pro Tip in Chapter 4 before
buying one.
Chain-elongation gauge to monitor the condi-
tion of the chain (Figs. 4.56).
spoke wrench
talc
standard and Phillips-head screwdrivers
metric hex keys
metric open-end/box-end wrenches
pliers
6" adjustable wrench
Schrader valve adapterfor old Marzocchi and RockShox forks
rubbing alcohol
tirepump with gauge
Schrader
Presta
rubbingalcohol
noggin
folding metric hex keys
needle-nose pliers
1.1B Valve types
chain-elongation gauge
talcumpowder
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ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE
4
Spoke wrench to match the size of nipples
used on your bikes wheels.
Tube or jar of grease. I recommend using
grease designed specifically for bicycles; how-
ever, standard automotive grease is okay,
except in suspension forks and twist shifters.
Drip bottle or can of chain lubricant (Fig. 4.1).
Please choose a nonaerosol; it is easier to
control, uses less packaging, and wastes less
in overspray.
Rubbing alcohol for cleaning disc-brake pads,
rotors, shocks, and internal parts and for
removing and installing handlebar grips.
A lot of rags!
Other useful items:
If you have an air-sprung suspension fork or
rear shock, you need a shock pump. Get one
with a no-leak head if the front or rear shock
has standard Schrader valves (Fig. 13.10),
and get the adapter you need if your bikes
fork requires either a ball needle or a spe-
cial adapter to insert down inside a sunken
Schrader valve.
i-2LEVEL 2 TOOL KIT
ee LE VEL 2Level 2 repairs are a bit more complex, and I
recommend that you create a well-organized
workspace with a shop bench. Keeping your work-
space organized is probably the best way to make
maintenance and repair easy and quick. You will
need the entire Level 1 Tool Kit (Fig. 1.1A) plus the
following tools (Fig. 1.2):
% Portable bike stand. Be sure that the stand is
sturdy enough to remain stable when youre
really cranking on the wrenches. If for some
reason you cant clamp your bikes seatpost,
you will need a bike stand that holds the bike
by the bottom bracket and the front or rear end
with one wheel out; see the one in Figure 1.4.
portable bike stand
ball-peen hammer
splined pedal-spindle removal tool
Channel-lockpliers
1.2 Level 2 Tool Kit
sound system
duct tape
tire pressure gauge
rubber gloves
snapring pliers
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51
TOOLSchain lubricant
12-inch ruler
chain tool
lots of rags
rubber gloves
OPTIONALchain-elongation
indicator
master link pliers
solvent (citrus based)
self-contained chain cleaner
old water bottle
caliper
pliers
solvent tank
Rohloff cog-wear indicator
4
fancy about it, you can assess the type of condi-
tions in which you ride and choose a lubricant
intended for those conditions. Some lubricants
are dry and pick up less dirt in dry conditions.
Some are sticky and therefore less likely to
wash off in wet conditions. Still others claim to
be metal conditioners that actually penetrate
and alter the surface of the metal. One of these,
ProGolds ProLink, gives me longer chain life in all
riding conditions, with daily use, than anything
else I have tried, so thats what I use. Im not say-
ing that there arent other equally good products,
but by recommending one that I know is good,
I can cut down on the e-mails asking me what
chain lube I suggest.
Chain lubes generally come in spray cans and
in squeeze bottles. Sprays should be avoided for
regular maintenance chores because they tend
to spew too much oil over everything, includ-
ing in the air where you can inhale the lube. The
chain needs oil only between contacting parts.
On the outside, a thin film is sufficient to keep
corrosion at bay; more than that will only attract
dirt and gunk without improving the function of
the chain.
A bike chain is a simple series of links connected by rivets. Rollers surround each rivet between the link plates and engage the teeth of the cogs
and chainrings. It is an extremely efficient method
of transmitting mechanical energy from the ped-
als to the rear wheel. In terms of weight, cost, and
efficiency, the bicycle chain has no equal, and
believe mepeople have tried without success to
improve on it for years.
To keep your bike running smoothly, you have
to take care of the chain. It needs to be kept clean
and well lubricated in order to transmit your
energy efficiently and shift smoothly. Chains need
to be replaced frequently to prolong the working
life of other, more expensive, drivetrain compo-
nents because a chain gets longer as its internal
parts wear, thus contacting the gear teeth differ-
ently than intended.
CHAIN SERVICE AND ASSEMBLY
iv-1LUBRICATING THE CHAINWhen lubricating the chain, use a lubricant
intended for bicycle chains. If you want to get
A chain is only as strong as its weakest link.
Anonymous
A sausage is only as good as its last link.
Bluto
CHAINS
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ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE
52
1. Drip a small amount of lubricant across each
roller (Fig. 4.1). Periodically move the chain so
that you can easily access the links you are
working on. To speed the process, turn the
crank slowly while dripping lubricant onto
the chain as it goes by. Yes, this method will
cause you to apply excess lubricant, which
will pick up more dirt. But overlubricating is
far preferable to not lubricating, and if you
wipe and lube the chain after each ride or
two, it wont build up excessive grime.
2. Wipe the chain off lightly with a rag. In wet
conditions, expect to use more lubricant (after
every ride or even during a long, rainy ride).
iv-2CLEANING THE CHAIN BY FREQUENT WIPING AND LUBRICATIONCleaning 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
you do this procedure before every ride, you will
never need to clean the chain with a solvent.
The lubricant softens the old sludge buildup,
which is driven out of the chain when you
ride. Of course, the lubricant also picks up new
dirt and grime, but if you wipe them off before
theyre driven deep into the chain and relubri-
cate the chain frequently, it will stay clean and
supple. Chain cleaning can be performed as fol-
lows with the bike standing on the ground or in
a bike stand:
4.1 Lubing the chain
4.2 Wiping the chain with a rag
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CHAPTER 4
53
CH
AIN
S
1. Grab the chain with a rag. Grasp the lower
length of the chain (between the bottom of
the chainring and the rear-derailleur lower
jockey wheel).
2. Turn the crank backward a number of revo-
lutions. Pull the chain through the rag (Fig.
4.2). Periodically rotate the rag to present a
cleaner section of it to the chain.
3. Lubricate the chain as in iv-1.
To encourage regular care, leave a pair of rub-
ber gloves, a rag, and some chain lube next to your
bike. Then, whenever you return from a ride, put on
the gloves, wipe and lube the chain, and put your
bike away. It takes maybe a minute, your hands
stay clean, and your bike is ready for the next ride.
If you can find time to take a shower after you ride,
you can find time for this. Wipe the chainrings,
cogs, front derailleur, and jockey wheels (Fig. 4.3)
while youre at it, and the entire drivetrain will
always work ideally.
iv-3USING CHAIN-CLEANING UNITSSeveral companies make chain-cleaning units
that scrub the chain with a solvent while it is
on the bike. These chain cleaners are generally
made of clear plastic and have two or three
rotating brushes that scrub the chain as it moves
through the solvent bath (Fig. 4.4). The units offer
the advantage of letting you clean the chain
without removing it from the bike. Regularly
removing the chain shortens any chains life;
moreover, with 9- or 10-speed chains unless you
use a master link, you may find that the chain
breaks under high load, thereby driving your foot,
and perhaps your entire body, into the ground.
Most chain-cleaning units come with a non-
toxic, citrus-based solvent. For your safety, and
other environmental reasons, I strongly recom-
mend that you purchase nontoxic citrus solvents
for the chain-cleaning unit, even if it already
comes with a petroleum-based solvent. If you
recycle used diesel fuel, then go ahead and use it.
In any case, wear gloves and glasses when using
any solvent.
Citrus chain solvents often contain some
lubricants, so they wont dry the chain out. The
combination of lubricant and solvent is why diesel
fuel has had such a following as a chain cleaner.
A really strong solvent without lubricant (acetone,
for example) will displace the oil from inside the
rollers. The solvent will later evaporate, leaving a
4.3 Wiping the jockey wheels with a rag 4.4 Using a solvent-bath chain cleaner
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ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE
54
dry, squeaking chain that is hard to rehabilitate.
The same can happen with a citrus-based solvent
that does not include a lubricant if no lubricant is
separately applied, especially if the chain is not
allowed to dry long enough. The procedure for
using a chain-cleaning unit is straightforward:
1. Remove the top and pour in the solvent up
to the fill line.
2. Place the chain-cleaning unit up against the
bottom of the chain. Reinstall the top so that
the chain runs through it (Fig. 4.4).
3. Turn the bikes crank backward. Run the
chain through the units brushes until it is
clean.
4. Remove the unit from the chain.
5. Lubricate the chain as in iv-1.
6. Let the solvent settle, decant the clear por-
tion, and discard the sludge.
iv-4REMOVING AND CLEANING THE CHAIN
e LE VEL 1You can also clean the chain by removing it from
the bicycle and cleaning it in a solvent. I do not
recommend this procedure unless the chain has
a master link, because repeatedly disassembling
the chain by pushing rivets in and out weakens it.
Mountain bike chains are prone to break-
age 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
chains. A chain that breaks during riding gener-
ally does so when you shift the front derailleur
while pedaling hard. This technique can pry a
link plate open so that the head of a rivet pops
out of the plate, tearing the chain apart. Chain
disassembly and reassembly expand the size of
the rivet hole where you put the chain together,
allowing the rivet to pop out more easily. Shimano
supplies special subpins for reassembly of its
chains that are meant to prevent this problem,
but the chain is still not as strong there as if you
had left the original pin in place.
A hand-opened master link can avoid the
problem of repeatedly opening and reassembling
the chain. Master links are standard on SRAM,
Wippermann, Taya, and KMC chains. An after-
market master link, like Licktons SuperLink, can
also be installed into any chain so long as you
make sure that the master link is the right width.
If you do disassemble the chain (see iv-7
or iv-11 for instructions), you can clean it well,
even without a solvent tank. Just drop the chain
into an old jar or water bottle half filled with sol-
vent. Using an old water bottle or jar allows you
to clean the chain without touching or breathing
the solventsomething to be avoided even when
you are using citrus solvents.
The procedure for cleaning the chain without
using a chain-cleaning unit could not be simpler:
1. Remove the chain from the bike (iv-7 or
iv-11).
2. Drop it in a water bottle or jar.
3. Pour in enough solvent to cover the chain.
4. Shake the bottle vigorously. Keep it low to
the ground in case the top pops off or the jar
breaks.
5. Hang the chain to air-dry.
6. Reassemble it on the bike (see iv-8 to
iv-11).
7. Lubricate it as in iv-1.
Whatever you do, dont leave the chain to
soak for extended periods in citrus-based sol-
vents, because these are water based and will
cause the chain to oxidize (rust), making it move
with more friction and be more prone to break-
age. (Some people believe in having two chains
they rotate on and off the bike, leaving one soak-
ing in solvent while the other one is on the bike.
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CHAPTER 4
55
CH
AIN
S
Although this would work with diesel fuel as the
solvent, it wont work with water-based solvents.
In any case, you gain nothing by soaking the chain
for extended periods, so just dont do it.)
After removing the chain, allow the solvent
in the bottle or jar to settle for a few days so that
you can decant the clear stuff and use it again. Ill
say this throughout the book: Use a citrus-based
solvent. It is not only safer for the environment;
it is also gentler on your skin and less harmful
to breathe. Wear rubber gloves when working
with any solvent, and use a respirator meant for
volatile organic compounds if you are not using
a citrus-based solvent. There is no sense in fixing
your bike to go faster if you end up becoming a
slow, sickly bike rider.
iv-5REPLACING THE CHAIN
e LE VEL 1As the rollers, pins, and plates wear out, the
chain lengthens. That, in turn, hastens the wear
and tear on other drivetrain parts. An elongated
chain concentrates the load on each individual
gear tooth, rather than distributing it over all of
the teeth that the chain is wrapped around, and
as a result the gear teeth become hook-shaped
and the tooth valleys become wider. If such wear
has already occurred, a new chain will not solve
the problem. A new chain will not mesh prop-
erly 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
(iv-6) and replacing it as needed.
How long it takes for the chain to wear out
will vary, depending on chain type, maintenance,
riding conditions, and strength and weight of the
rider. Figure on replacing the chain every 500 to
1,000 miles, especially for bikes ridden in dirty
conditions by a large rider. Lighter riders riding
mostly on paved roads can often extend replace-
ment time to more than 2,000 miles.
iv-6CHECKING FOR CHAIN ELONGATION
e LE VEL 1a. Chain-elongation gaugesThe simplest accurate method for checking chain
elongation is to use a gauge. Make sure you check a
number of spots on the chain; youll find variation.
The Rohloff gauge (Fig. 4.5) is simple, quick,
and reliable. Its a go/no-go gauge. Brace the hook
end against a chain roller, and if the opposing
curved tooth falls completely into the chain so
that the length of the tools body contacts it, the
chain is shot. If the chain is still in good shape, the
curved tooth will not go all of the way in. The tooth
marked S is for checking a chain running strictly
on steel rear cogs, and the tooth marked A is for
checking aluminum and titanium cogs, but I use
just the A side. I find that if the A edge comes down
to the chain and I replace it right then, I get almost
infinite life out of my chainrings and cogs, even
titanium ones. Thats worth it to me.
The ProGold chain gauge (Fig. 4.6) is also quick
and accurate. Brace the hooked end against a
chain roller, and let the long tooth drop into the
4.5 Checking chain wear with the Rohloff gauge. If the curved tooth with the S (steel cogs) falls completely into the chain, replace the chain (A is for aluminum cogs).
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ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE
198
Square taper, Octalink, and ISIS are three
different bottom-bracket and crankarm interface
standards. Square-taper bottom-bracket spindles are
square on the end (Figs. 8.1, 8.18, 8.2123) and fit into
a square hole in the crankarm. The spindle ends are
tapered (at a 2-degree angle) to tighten into the crank
as the arm is pushed into the spindle. ISIS (Fig. 8.19)
and Shimano Octalink (Fig. 8.20) are both oversized
hollow spindles (aka pipe spindles) with longitudinal
splines on the ends.
3. Unscrew the crank pullers (Fig. 8.6) center
push bolt so that its tip is flush with the
face of the tool. Make sure the flat end of
the push bolt is the right size for the bottom
bracket; the push bolt end is much smaller
for a square-taper spindle than for an ISIS or
a Shimano Octalink splined spindle.
4. Thread the crank puller into the hole in the
crankarm. Be sure that you thread it in (by
hand) as far as it can go; otherwise, you will
not engage sufficient crank threads when you
tighten the push bolt, and you will damage
the threads. Future crank removal depends
on those threads being in good condition.
5. Tighten the push bolt clockwise (Fig. 8.6)
until the crankarm pulls off the spindle. Use
a socket wrench or the included handle.
6. Unscrew the puller from the crankarm.
Installationa. Integrated-spindle cranks with two pinch
bolts on the left arm
e LE VEL 11. Grease the spindle tip and the bore of each
bearing.
2. Push the spindle (which is attached to the
right crankarm) in through the bearings from
the drive side.
3. Slide the left arm onto the end of the spindle.
Check that the crank is at 180 degrees from
the right arm.
8.5 Removing and installing a Shimano 20072010 XTR FC-M970 crankset
left bearing cupspacer
spindle
washer adjusting nut
left crankarm
washer retainer
bolt
bolt
right bearing cup
right crankarm TL-FC35
crankarmremoval tool
TL-FC17adjusting nut tool
spacerspindle cover with O-rings
(Attention: left-hand thread!)
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423
I N D E X
Adjustable cups, 207, 215, 216, 221, 409
Air compressors, 11, 122, 154Air pressure, 318, 320, 326327Air-sleeves, servicing, 353, 354, 355Alignment tool, 10Antiseize compound, 28, 200Antitwist tool, 9Automatic transmission uid (ATF),
336, 337Axle-clamp tool, 10 Axle nuts, 15, 20Axles, 30, 212, 299, 409
checking, 19cleaning, 130removing, 129replacing, 235securing, 2324through-, 2022, 23, 128
Ball bearings, 142, 174, 203, 204, 207, 218, 231, 234, 358, 359, 360, 361, 409
angular-contact, 272, 277, 278, 279, 281
ceramic, 136, 217, 219cleaning, 130131, 133, 221, 237,
277, 280loose, 278, 279lubricating, 131, 132, 281, 286orienting, 218219, 278overtightening, 272press-in, 211, 279replacing, 130, 131, 217220, 277,
280, 282, 359360sealed, 416standard, 280steel, 136, 217See also Cartridge bearings
Bar ends, 153, 154, 287, 409installing, 9596, 255, 257position of, 390391replacing, 9596, 257, 258
Barrel adjusters, 77, 78, 88, 89, 90, 92, 93, 149, 151, 152, 153, 154,
166, 409BBT-39 tool, 200, 212Bearing cups, 207, 211, 212, 409Bearing pullers, 211, 219220Bearing removers, 11Belt drives, 6466, 101Bike dimensions, 385Bike tting, 383391, 385393Bike stands, 4, 9Blankets, 14, 48Body measurements, 385388Bosses, 176, 180, 181, 183, 186, 188,
191, 194, 309brake, 148, 150, 345, 348, 410cantilever, 148, 311, 312, 313, 348,
350, 351, 411disc-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, 212full-carbon, 204tapping, 350unthreaded, 203
Bottom-bracket tools, 6 Bottom brackets, 65, 102, 108, 109,
110, 191, 195, 198, 203216, 231, 345, 388, 409
adjusting, 201, 222, 223BB30: 220BB86: 204, 205, 206BB90: 204, 206BB92: 204206, 210211, 220BB95: 204206, 210211, 219
cartridge, 212213, 216, 220221, 223225
cup-and-cone, 213216, 221, 222, 223
eccentric, 58, 66external-bearing, 203, 205, 206,
209210height, 384, 386, 410
installing, 83, 208216, 221integrated-spindle, 216, 217ISIS, 198, 213ISO, 206noise in, 221224overhauling, 109, 216221, 223PF24: 205, 210211, 220PF30: 204, 220Shimano, 207, 209, 213, 215square-taper, 198, 203, 208threaded, 206207, 217220, 350threadless, 204, 210212, 219
Box-cutter knife, 6Brake boosters, 189, 194, 410Brake hoses, 46, 164, 166, 173
installing, 189Brake levers, 96, 152155, 177, 184,
255positioning, 152154removing, 96, 152154, 258shift cables and, 88squeezing, 15, 163
Brake pads, 23, 42, 126, 164, 174, 299, 410
adjusting, 151, 177, 180, 181, 188189, 193
checking, 15, 156cleaning, 156cottered, 155, 156, 157disc, 155157offset of, 177178, 182removing, 166, 171replacing, 166, 179180, 181, 191,
192, 193rims and, 4041spacing, 149, 158, 166toeing in, 183, 191, 193194worn, 148, 150, 193
Brake reach, adjusting, 154155Brakes, 23, 24, 152, 154, 170171,
173, 183, 185, 186, 410bleeding, 168170checking, 15, 16, 22curved-face, 183cylindrical-arm, 183
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ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE
424
cylindrical-clamp, 182disconnecting, 328, 331feel of, 184Hayes, 157, 159, 168170, 173hub, 414linkage, 148, 190, 194mounting, 162-163opening, 4041options for, 147148releasing, 1617, 23, 148, 150rim, 16, 149, 150, 301rubbing, 370Shimano, 8889, 95, 167, 185troubleshooting with, 192194See also Cantilever brakes; Disc
brakes; Hydraulic brakes; Roller-cam brakes; U-brakes; V-brakes
Braking, 291, 322chattering/vibration when, 183,
369, 372, 374, 375problems with, 369370
Brushes, 24, 26Buckets, 24Bushings, 180, 181, 211, 231, 234,
330, 334, 335, 353, 354, 355, 356, 358, 361, 410
replacing, 359360
Cable cutters, 6, 86Cable stops, 348, 410Cable 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, 4546clamping, 4041Gore-Tex, 86, 94, 95, 178installing, 22, 74, 9293, 94, 150loose, 4041, 85lubricating, 30, 9495, 107, 149,
150maintaining, 103, 149, 152, 192replacing, 30, 85, 8792, 149, 150,
152shift, 80, 85, 88, 8990Shimano, 8990sticky, 68, 107tying, 43worn, 151, 193
Calipers, 11, 41, 150, 156, 163, 170, 313, 410
cleaning, 171173disc-brake, 31, 161, 162, 173174
hydraulic, 156, 171173measuring, 415mounting, 161162overhauling, 173174postmount, 163
Cantilever brakes, 16, 22, 31, 41, 147148, 149, 150, 151, 175180, 411
curved-face, 183overhauling, 180187sidepull, 417
Cantilevers, 147, 148, 150, 151, 152, 194, 417
Carbon-grip compound, 9Cartridge bearings, 103, 133136,
208, 219, 231, 276, 279, 280, 286, 358, 359, 411
angular-contact, 277, 278, 281cleaning, 133134lubricating, 31See also Ball bearings
Cartridge-removal tool, 340Cartridges, 208, 352
air ination, 35Centering, 126, 178179, 301303Chain cleaners, 26, 5354Chain elongation, checking for,
5556, 67, 69Chain-elongation gauges, 3, 5556,
69Chain gap, 7879Chain keepers, 7Chain length, determining, 5759, 73Chain links, 411
loosening, 67replacing, 38, 56, 60spacing between, 66spare, 13tight/stiff, 66, 67twisted, 3638
Chain retention devices, 100101Chain stops, 110Chain suck, 6667, 107, 201, 370, 411Chain tensioner, 101Chain tools, 23, 12, 33, 38, 42, 56,
59, 61, 62Chain whips, 6, 7, 138, 139, 140, 141,
142, 411Chainlines, 85, 107108, 224, 411
measuring, 108110Chainring bolts, 195, 201, 202, 222Chainring-cassette removal tools, 6Chainring-nut tools, 6, 202, 411Chainrings, 27, 37, 4245, 51, 53, 55,
57, 58, 60, 64, 65, 195, 197202,
216, 411bent, 201chainstays and, 223225cleaning, 26, 66, 200inner, 109, 223inspecting, 66, 200201installing, 66, 202jammed chains and, 36loose, 221maintaining, 200middle, 10spindles and, 209worn, 200
Chains, 411assembling, 5152broken, 38, 54, 56, 57, 59cleaning, 2627, 5255, 66connecting, 57, 5961dropping, 110, 370jammed, 15, 3638, 370lubricating, 4, 13, 2526, 27, 30,
5154, 66, 67, 74, 105, 254maintaining, 152measuring, 140removing, 27, 44, 45, 5457, 63replacing, 55, 62, 67, 68, 74, 150Shimano, 26, 56, 59, 6061, 62skipping, 67, 107, 370slapping, 370, 372squeaking, 67SRAM, 54, 56, 61, 62troubleshooting, 6669with twisted link, 3738wiping, 25, 26, 27, 30, 5253, 67Wippermann, 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, 67chainrings and, 223225jammed chains and, 36
Circlips, 208, 211, 212, 220, 313, 327, 336
Clamps, 58, 81, 82, 83, 254, 255, 276cylindrical, 182saddle, 245, 246seatpost, 31, 46, 253, 254split, 153See also Stem clampsCleats, 226, 230adjusting, 227229, 240installing, 227229loose, 239240
Clunking noises, problems with, 222223, 372
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INDEX
425
Cog-wear indicator gauge, 11Cogs, 51, 55, 58, 64, 73, 74, 75, 77,
78, 79, 108, 111, 127, 137146, 209, 411
cassette, 138141checking, 6768cleaning, 26, 53, 138, 139, 140removing, 68, 102, 138, 139, 140,
145146replacing, 68, 139, 140, 141worn, 67, 139, 140
Compression, 316, 357, 358, 361Compression damping, 321322,
362, 365, 366, 411adjusting, 316, 323, 325, 364
Compression rings, 273, 276, 278Concentric-pivot systems, 43, 65,
102Cones, 6, 127, 128133, 213216,
221, 222, 223, 236, 237, 409, 411Crank bolts, 195, 197, 199, 200, 222,
411Crank extraction tools, 197Crank pullers, 6, 195, 198Crankarms, 84, 195, 197202, 210,
211, 216, 217, 221, 225, 226, 227, 244, 363, 385, 411
length/determining, 388loose, 222223removing/installing, 202, 212,
215, 218Cranks
custom, 388hard-to-turn, 223integrated-spindle, 195, 197,
198199, 203, 204, 205length, 390, 411removing/installing, 195, 197200Shimano, 197, 199, 202, 207square taper, 197, 199troubleshooting, 221224
Cranksets, 195, 210, 412BB30: 204, 219external-bearing, 207lubricating, 31three-piece, 197, 199, 203, 204,
207209Truvativ, 209, 210, 218, 219two-piece, 203, 207
Creaking noises, 372bottom bracket, 221222crank, 221222handlebar, 287pedaling, 207, 239240seatpost, 254
Crowfoot sockets, 11, 412Crown-race punches, 285Crown-race removers, 11, 283, 284Cup removal tools, 7Cups, 412
adjustable, 207, 215, 216, 221, 409bearing, 207, 211, 212, 409bottom bracket, 30, 83, 213, 217,
223, 350xed, 214, 413
Damping, 318, 357, 412adjusting, 325326, 327, 334changing oil and, 336338,
355356compression, 316, 321322, 323,
325, 362, 364, 365, 366, 411hydraulic, 262, 309310, 314preload, 363364pressurizing, 358rebound, 318, 320321, 323, 325,
361, 362, 364, 365, 366, 416Damping adjusters, 326, 327, 334,
365Damping systems, 325, 336338Derailleur cages, 42, 68, 84, 107Derailleur-hanger alignment tools,
11, 68, 349Derailleurs, 23, 27, 47, 57, 7180,
8085, 209, 412adjusting, 68, 71, 7480, 8385,
200bent, 43, 68, 107bottom-pull/top-pull, 82broken, 71, 103bypassing, 44cables and, 82, 85, 9294 chain length and, 57disassembling, 88, 106down-swing, 81E-type, 81, 8283, 209, 213, 223installing, 7374, 8283lubricating, 30, 105maintaining, 26, 53, 103106positioning, 83, 84, 107repairing, 4244replacing, 69, 79, 105, 106Shimano, 45, 46, 71, 73, 7475,
76, 77, 79, 8283, 84, 87, 88, 92, 106, 107, 213
spokes and, 370, 372SRAM, 78, 82, 87, 106, 107top-swing, 81, 224troubleshooting, 107110worn, 67, 107
Disc-brake pads, checking/replac-ing, 155157
Disc brakes, 17, 22, 31, 147, 148, 152, 155164, 166175, 192, 412
adjusting, 158164, 166cable-actuated, 155installing, 158164, 166overhauling, 171174
Dishing, 301303, 349, 367, 412Dishing tools, 7, 301, 302, 412Drills, 11Drivetrains, 60, 65, 74, 101, 107, 292,
412cleaning, 2426wear/tear on, 55
Dropout-alignment tools, 11, 341343, 342, 344, 367368
Dropout Saver, 351Dropouts, 18, 20, 23, 24, 65, 66, 71,
73, 78, 102, 109, 128, 309, 311, 349, 412
aligning, 68, 342343, 344, 366aluminum/titanium, 368bent, 80, 312, 344bolt-on, 367inspecting, 348sliding, 58spacing, 341, 342thickness of, 351
Duct tape, 14Dust caps, 144, 199, 200, 236, 237,
239, 412Dust covers, 143, 237
Easy-outs, 354, 412Elastomers, 249, 262, 309, 311, 314,
315, 318, 319, 324326, 327, 331, 361, 412
End caps, 86, 152, 410, 412
Fasteners, torque for, 396407 (table)
Feeler gauges, 11Files, 6Firmly tightened, 29, 395Foot pounds (ft-lbs), Newton-
meters and, 397Fork braces, 311, 315Fork-crown race punch, 7Fork-crown race remover, 283Fork-crown races, 281, 282284,
285286Fork crowns, 309, 310, 311, 312, 313,
315, 413clamping, 268
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fork legs and, 316, 327328Fork legs, 40, 309, 311, 315, 325damaged, 313fork crowns and, 316removing, 327328telescoping, 310
Fork rake, 309, 413Fork travel, 319
changing, 323, 338-339measuring, 315317
Forks, 16, 18, 115, 289, 310, 317, 413air-sprung, 312, 326327alignment of, 312, 313, 314, 318,
341344aluminum, 314, 343carbon-ber, 314, 343coil-spring, 311, 319, 324326, 327double-crown, 327, 328, 330failure of, 311, 312headset installation and, 284285high-end, 321, 331inspecting, 311313, 313314linkage, 312, 314lubricating, 31, 314maintaining, 313314, 314315Manitou, 34, 159, 331movement of, 321, 322overhauling, 314, 330331,
334336rebound damping and, 321removing, 277, 280, 282, 330331,
341rigid, 309, 313314, 344RockShox, 326, 327, 328, 337,
338339, 340, 357SID, 326, 327, 337single-crown, 327, 328steel, 341, 344stuck stems in, 287suspension, 20, 31, 46, 128, 189,
263, 282, 284, 309, 310, 313, 314, 314315, 317324, 330, 384, 386
telescoping, 310, 312, 314threaded, 265266, 267, 312titanium, 314, 343triple-clamp, 327328, 330tuning, 314, 315, 317327upside-down, 419
Frame sizebody measurements and,
385388correct, 384385nding, 383, 386387
Frames, 31, 208, 212, 289, 413
alignment of, 366368carbon, 347, 348cleaning, 348designing, 345, 347diamond, 345, 412headset installation and, 284285suspension, 101102, 347, 358
361, 368, 386, 389, 390types of, 249, 347
Freehubs, 78, 134, 137146, 413disassembling, 144lubricating, 142146overhauling, 111removing, 144, 146seized, 47solvents and, 142, 144
Freewheel removers, 7, 141Freewheels, 127, 137146, 413
lubricating, 30, 146maintaining, 111replacing, 68, 111, 141seized, 47
Front triangles, 345, 347, 349, 413
Gauges, 56, 57, 68Gear development, 375381
for 26-inch wheels, 376378 (table)
for 29-inch wheels, 381383 (table)
Gloves, 13, 55Grease, 4, 13, 137, 201
molybdenum disulde, 94nonlithium, 6, 92, 97, 335silicone-based, 6Slick Honey, 251, 335, 355, 357,
359Teon, 92, 97
Grease guns, 6, 136, 142Grip Shifts, 29, 78, 94, 95, 107, 258,
413long/short, 97, 98overhauling, 9192replacing, 9697
Grips, 111, 255, 266installing, 9596, 257258removing, 9596, 153, 257, 258trimming, 258
Hacksaw, 6Hammers
ball-peen, 6, 7soft, 7
Handlebar height, 385, 388, 389390adjusting, 266, 392
Handlebar position, 242, 244, 263, 266, 388391
Handlebar reach, 384385, 388, 390Handlebar slips, 286287Handlebars, 251, 255, 257, 258260,
273, 315, 325, 413broken, 47, 260, 287carbon, 154, 260, 393drop, 384385installing, 258259knees and, 383, 384maintaining, 16, 259260overtightened, 259, 393replacing, 258, 259260, 266riser, 255, 391saddles and, 390troubleshooting, 286287twisting, 259, 266, 267types of, 260, 266undertightened, 393
Hangers, 13, 43, 69, 78, 80, 366, 410, 412
alignment of, 349350bent, 68, 107, 349350brake-cable, 271, 281derailleur, 348, 349350, 351straddle-cable, 184
Head angles, 309, 413Head tubes, 277, 278, 282, 284, 286,
367, 388, 413measuring, 268, 270
Headlights, 14Headset cups, 286
removing, 276, 282Headset presses, 7, 11, 285286Headset rockets, 282Headsets, 255, 263, 270286, 312,
313, 413adjusting, 265, 268, 272276, 279,
282, 286, 287cartridge-bearing, 272cupless, 268, 277, 278, 282installing, 284286integrated, 270, 271, 274, 278,
284, 414loose-ball, 278, 281loosening, 274275overhauling, 276282overtightening, 275pitted, 275, 287press-in internal with lipped
cups, 268replacing, 281, 282284, 287semi-integrated, 270threaded, 273276, 279282, 418
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.Copyright 2010 VeloPress All rights reserved
INDEX
427
threadless, 269, 270272, 276279, 285, 387, 390
tight, 272273, 274275, 287traditional, 168, 270troubleshooting, 286287
Hex keys, 12, 29, 47, 414metric, 2, 7, 20, 40, 41, 42
HG-IG check tool, 68, 139Hose cutters, 11Housing, 76, 77, 82, 89, 90, 92, 148
152, 185, 193, 273, 410cutting, 11, 86, 153friction and, 150index-shift, 86installing, 74, 87lower-knuckle, 79lubricating, 30, 85, 9495, 151, 152replacing, 30, 152sticky, 68Teon-lined, 150, 151
Hubs, 102, 103, 127137, 231, 306, 414
assembling, 131132cartridge-bearing, 127, 128,
132136cup-and-cone, 127, 128133DT Swiss, 28, 125, 133, 134, 142,
145front, 127, 292Grease Guard, 136137high-end, 128, 136internal-gear, 101103lubricating, 131132overhauling, 111, 127136replacing/ipping, 141142sealed-bearing, 127, 128wheelbuilding and, 289, 291, 292,
299Hydraulic brakes, 42, 99, 107, 148,
150, 158, 166173, 187190, 192, 193, 194, 414
bleeding, 31, 166, 168, 170, 171, 189190
disconnecting, 328replacing pads on, 189
Hydraulic uid, 158, 166, 167, 169, 170, 171, 172, 173, 194
Hydraulic oil, 325
Inertial valves, 322, 325, 327, 365, 414
adjusting, 323, 364Inner legs, 310, 314, 327, 334, 335,
336, 337, 339, 414installing, 328, 330
Inner tubes, 114, 122, 123, 251nding leaks in, 115116inating, 35, 36installing, 36, 118120patching, 36, 116removing, 111112spare, 2, 1213, 3435tying knots in, 35
International Organization for Standardization (ISO), 117, 159
Interrupted-seat-tube congura-tions, 387, 388
Jockey wheels, 27, 43, 58, 59, 68, 73, 74, 78, 80, 414
bolts, 106cartridge-bearing, 104105lost, 4445maintaining, 68, 103105wiping, 26, 53
Knee clearance, 384
Lacing, 289, 294, 296, 297299, 306checking, 299, 307radial, 304305three-cross, 304305
Leaksnding, 115116sealing, 122, 123, 124
Leverage, 154155, 166, 176, 177, 414Levers, 89, 90, 150, 170, 173
lockout, 362, 364Shimano, 8788, 99100, 107, 155split-clamp, 153SRAM, 87, 95, 97, 155See also Brake levers; Quick-
release levers; Tire leversLicktons SuperLink, 61Limit screws, 73, 107
adjusting, 46, 71, 74, 7576, 78, 84, 85
Locknuts, 58, 133, 145, 146, 149, 152, 237, 271, 273, 275, 281, 414
loosening, 128129, 132, 151, 274removing, 236, 280tightening, 132
Lockouts, 316, 362, 364, 414Lockring tools, 6, 160Lockrings, 78, 140, 160, 207, 213,
224, 414adjustable-cup, 223removing, 139, 221tightening, 215216
Loctite, 28, 68, 77, 136, 212, 222,
231, 313Lubrication, 3031, 128, 330
ball bearing, 31, 131, 132, 281, 286cable, 30, 9495, 107, 149, 150chain, 4, 13, 2526, 27, 30, 5154,
66, 67, 74, 105, 254crankset, 31derailleur, 30, 105fork, 31, 314freehub, 142146freewheel, 30, 146housing, 30, 85, 9495, 151, 152hub, 131132pedal, 31, 239240piston, 173, 190quill, 281saddle, 31seatpost, 31, 254, 266, 348shifters, 30wheel, 30
Magnet, 7Master cylinders, 173, 415Master links, 13, 33, 42, 54, 57,
5960, 61, 6364, 67, 69, 415Matches, 14, 48Money, 14
patching sidewalls with, 36Morningstar Drumstix tool, 175Morningstar Freehub Buddy, 7, 142,
143, 144Morningstar Freehub Soup, 142,
143, 144Morningstar Rotors on Center (ROC)
dial-indicator tool, 10, 174175Mounting bolts, 69, 105, 192, 415Mounts
broken, 348disc-brake, 309, 351IS, 159, 313ISCG, 101
Multitools, 12, 38
Needle bearings, 279, 280, 415Newton-meters (N-m), foot-pounds
and, 397Nipples, 124, 127, 290, 292, 293, 294,
307308, 415tightening/loosening, 125, 299,
300, 301, 302, 303types of, 126, 291, 308
O-rings, 144, 158, 164, 172, 337, 354, 355, 357, 362363
Off-center rims (OCR), 292, 293, 308
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.Copyright 2010 VeloPress All rights reserved
ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE
428
Outer legs, 310, 312, 315, 323, 328, 330, 334, 415
Oversteering, 319, 322, 324Overtightening, 259, 272, 275, 393
Pad spacers, 12, 190Pad swing, 182Pad-to-rim adjustment, 176178,
187, 189, 192Pad twist, 182Parts washer, 7Patch glue, 116Patch kits, 2, 12, 3435, 36, 116Patches, 35, 36
applying, 116118Pedal overlap, 385, 415Pedal platforms, 317, 321, 322, 325,
362Pedaling, 308, 311, 317, 322
creaking with, 207, 375knee/joint pain while, 240resistance while, 58, 371stance, 415
Pedals, 235, 415cage-type, 225cartridge-bearing, 238239clip-in, 225, 226, 227231,234,
236, 240, 371, 411clunking by, 371Crank Brothers, 228, 229, 230,
234, 238, 239at, 225installing, 226227, 239Look, 228, 229, 230, 231, 232233,
234, 235, 238loose-bearing, 31, 236237, lubricating, 31, 239240Onza, 230231, 238 overhauling, 231232, 234239play in, 223, 371release tension for, 227, 229231,
371removing, 226227Ritchey, 232, 235, 238, 239Scott, 235Shimano, 231, 232, 234, 235Speedplay, 229, 231, 234, 235, 240Time, 228, 229, 230, 231, 232, 234,
235, 238, 239, 240troubleshooting, 239240
Pedros Green Fizz, 24Pedros Ice, 31Pedros Syn Lube, 30Phil Wood Tenacious Oil, 145Pin spanners, 7, 29, 215, 216, 221,
415Pistons, 166, 337, 338, 356, 358
cleaning, 172173disc-brake, 157158lubricating, 173pushing back, 157158
Pivot bolts, 415Pivots, 154, 155, 194, 312, 313, 415
bushing, 31derailleur, 69, 79loose, 107lubricating, 152, 190maintaining, 106, 358359overhauling, 105
Pliers, 2, 14, 37Channel-lock, 6master-link, 7, 63, 64snapring, 6Vise-Grip, 63
Postmounts, 159, 161, 163, 309, 313, 351
PowerLink, 61, 63, 64Preload, 319, 322, 324, 362, 363Preload adjusters, 331, 362,
363364Press t systems, 204, 205, 220ProGold ProLink, lubricating with,
51, 67Pulling, problems with, 369Pumps, 2, 12, 35, 124
oor, 120shock, 4, 12, 326
Punctures, 15, 16xing, 3436preventing, 3334snakebite, 34, 35, 120, 124
Quick-release (QR), 416Quick-release (QR) levers, 148, 188Quick-release (QR) seatpost bind-
ers, 248, 388Quick-release (QR) skewers, 20, 22,
34, 45, 139, 142, 342checking, 15installing, 132opening, 1718removing, 128, 141tightening, 19
Quills, 265, 416lubricating, 281
Race Face, 197, 199, 210, 416Races, 127, 136, 409, 416
fork-crown, 281, 282284, 285286
Rags, 4Rattling noises, 287Really tight, 30, 396Reamers, 11Rear triangles, 43, 65, 102, 342, 345,
416Rebound damping, 318, 320321,
361, 362, 364, 416adjusting, 321, 323, 325, 365, 366
Release tension adjustment, 227, 229231, 240, 371
Ride height. SeeSagRim strips, 35, 118, 121Rims, 16, 121, 149, 150, 416
bent, 41, 111brake pads and, 4041cleaning, 192193, 303deep-section, 112disc-brake, 301drilling, 308examining, 120off-center, 292, 293, 308replacing, 291scraping, 125, 299, 300spokes and, 124127tubeless, 293wheelbuilding and, 289, 292, 294
Roller-cam brakes, 17, 150, 190, 191192, 194, 416
Rotors, 127, 304bent, 175bolting, 160161cleaning, 193installing/removing, 159161splined, 159, 160, 161truing, 4142, 174175
Rubbing alcohol, 4, 257Rubbing noises, problems with, 373
Saddle height, 240, 243, 248, 388Saddle position, 242, 244, 246, 247,
253, 388389Saddles, 391, 416
adjusting, 243choosing, 241242clamping, 245handlebars and, 390installing, 245246, 247248lubricating, 31maintaining, 242shape/design of, 242troubleshooting problems with,
253254Sag, 315, 319, 324, 361, 366, 416
measuring, 316317, 318
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.Copyright 2010 VeloPress All rights reserved
INDEX
429
setting, 362363Saw guide, 263Scraping noises, problems with, 373Screwdrivers, 12, 42, 43, 45, 46
bent-shaft spoke-nipple, 10 Phillips-head, 2
Sealants, 9, 16, 34, 35, 120, 122124, 417
aerosol, 123glycol-based, 122, 123latex-based, 122tubeless tires and, 121, 123124
Seals, 173, 178, 216, 217, 328, 330, 356, 357, 359
bearing, 136, 277cleaning, 354355installing, 278, 281quad, 355removing, 218, 355square, 158, 355
Seat bags, 33, 42Seat tubes, 45, 80, 82, 248, 249, 254,
367, 416length of, 386, 387
Seatpost clamps, 31, 46, 253lubricating, 254
Seatposts, 241, 243, 384, 389, 417adjusting, 249251aluminum, 245, 252, 253, 254broken, 47carbon, 245, 251252Crank Brothers, 249, 250, 251, 388extensions, 244GravityDropper, 249, 250, 251, 388height-adjustable, 249251, 388installing, 246, 248249lubricating, 31, 254, 348maintaining, 244245Maverick, 249, 250, 251position of, 244, 250removing, 46, 244, 248, 251253single-bolt, 246stuck, 251253suspension, 244245, 249, 254troubleshooting problems with,
253254two-bolt, 246, 247
Seatstays, 23, 65, 349, 367, 417Setscrews, 29, 79, 98, 106, 133, 185,
186, 191, 248, 331, 349Shifters, 92, 95103, 255
adjusting, 7480, 8385derailleurs and, 107dual-lever trigger, 152friction, 413
indexed, 7678, 414lubricating, 30maintaining, 97103removing, 258replacing, 9091, 96Shimano, 77, 88, 96, 177, 416SRAM, 9091, 95, 107thumb, 8788, 97, 100, 418troubleshooting, 107110twist, 9091, 9697, 98, 99, 103,
153, 154, 419Shifting, 371
adjusting, 73checking, 16optimizing, 78, 95ramps, 200
Shimano Pedaling Dynamics (SPD), 226
Shimmying, 369Shims, 78, 82, 163, 356, 417Shocks, 310, 356, 358, 363
air, 361, 362coil spring, 361deating, 353downhill courses and, 365366elastomer, 361, 362inspecting, 348349installing, 355maintaining, 352, 353removing, 353354saddle, 241
Shoes, 225, 228Shop, well-stocked, 911Shuddering, while braking, 183Sidewalls, 114
patching, 36, 121, 122, 124Skewers, 133, 135, 417
bolt-on, 18, 20quick-release, 15, 1718, 19, 20,
22, 34, 45, 128, 132, 139, 141, 142, 342
tightening, 19, 20Slick Honey grease, 251, 335, 355,
357, 359Slime, 34, 417Snug, 29, 395Solvents, 130
citrus, 53, 54, 55, 105, 135, 221, 277, 280
freehubs and, 142, 144using, 2627, 54
Spacers, 128, 132, 157, 159, 213, 263, 265, 274, 276, 278, 279, 315, 323, 417
adding, 209
internal, 339340 removing, 129
Spacing, 66, 149, 166, 341, 342, 344, 349
brake pad, 158crank-to-frame, 224pad-to-rotor, 163problems/remedying, 7778
Spanners, 417pin, 7, 29, 215, 216, 221, 415toothed-lockring, 29
Spiders, 102, 201, 417Spindle removal tool, 6Spindles, 109, 210, 227
bottom-bracket, 66, 203, 209, 211212, 223
chainrings and, 209installing, 212integrated, 195, 197, 198199, 203,
204, 205, 216, 217pedal, 6, 227splined, 207square-taper, 207upgrading, 239
Splines, 29, 140, 141, 160, 207, 417Spoke calculator, 290, 291Spoke-prep compound, 291Spoke tension, 10, 124, 292, 301
reducing, 308Spoke-tension gauge, 10Spokes, 76, 290, 417
adjusting, 39, 40, 127, 299, 300, 301, 302, 303
broken, 3940, 41, 124, 126127converging parallel, 299crossing, 299, 307derailleurs hitting, 370rst set of, 293294, 305fourth set of, 297299, 306Kevlar, 40lacing, 289, 294, 296, 297299 length of, 290prestressing, 302, 303pulling, 293, 303, 308radial, 308replacing, 3840, 126127, 291rims and, 124127second set of, 294295, 305306spare, 13, 40thickness, 290, 307308third set of, 296297, 306twisted, 125weaving, 126127
Spoking patterns, 308one-cross, 289, 291, 306307
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.Copyright 2010 VeloPress All rights reserved
ZINN & THE ART OF MOUNTAIN BIKE MAINTENANCE
430
radial, 291, 293, 303305three-cross, 289, 291, 297, 304
306, 418two-cross, 289, 291, 306307
Spring preload, 318, 319, 324, 363, 417
Spring rate, 318, 319, 320, 324, 362, 365
adjusting, 108, 323, 366Spring tension, 178179, 191
adjusting, 185186Springs, 230, 356, 365, 366, 417
air, 251, 314, 324coil, 314, 315, 319, 320, 324325,
331increasing tension of, 66negative, 326, 327, 363positive, 326removing, 315316soft, 318stiff, 318
Squeaking noises, 372, 373with saddles, 254
Squealing noises, 373with breaking, 157, 373
Stand-over height, 345, 383, 384, 386, 387, 418
Stans No Tubes tubeless system, 120121, 418
Star-nut installation tools, 7, 274Star nuts, 263, 264, 274, 279, 418Steering
axis, 309, 418stiff, 372systems, 111, 255
Steering-tube overlap, 263, 278Steering tubes, 267, 268, 270, 271,
273, 275, 276, 278, 279, 280, 281, 283, 284285, 309, 310, 311, 418
carbon, 263, 264, 274clamping, 282cutting, 285fork alignment and, 341, 342343,
344lubricating, 266stripped threads on, 313stuck stems in, 287threaded, 260, 312, 313threadless, 260, 262265, 312
Stem bolts, 265, 282, 287Stem clamps, 259, 262, 263, 265,
268, 270, 279, 287, 312spreading, 267tightening, 274
Stem length, 263, 285, 388, 390, 418Stem wedges, 265, 270Stems, 255, 260, 262268, 273, 275,
278, 285, 418adjusting, 262266, 268, 385broken, 266checking, 16clamp-type, 262, 267front-opening, 258installing, 262266quill-type, 265, 281, 416removing, 260, 262, 265, 266268,
280stuck, 266268, 287suspension, 262torque on, 393troubleshooting, 286287
Stopscrews, 45, 80Straddle cables, 190191, 418
adjusting, 184185Subpins, 57, 59, 60, 61Suspension, 111
aligning, 343cables and, 150fork, 20, 31, 46, 128, 189, 263, 282,
284, 309, 310, 313, 314315, 317324, 330, 384, 386
frame, 101102, 347, 358361, 368, 386, 389, 390
maintaining, 249problems with, 372rear, 43, 47, 81, 108, 128, 147, 318,
347, 361365seatpost, 244245, 249, 254stem, 262tuning, 361365
Swingarms, 23, 82, 347, 348349, 351, 358, 363, 367, 418
Syringes, 7, 171, 189, 190, 338
Talcum powder, 2, 118Tension gauge, 66Third Eye Chain Watcher, 110Threadlock compound, 201, 293,
313, 330, 394Threads
xing damaged, 350prepping/tightening, 2728
Through-axles, 2022, 23, 128quick-release, 20, 21removing/installing wheels with,
20Thumb shifters, 97, 100, 418
replacing cable in, 8788Tight, 29, 395
Tightness, 2930, 393Tire beads, 114, 115, 119, 120, 121,
418Tire inators, 13, 267Tire levers, 2, 12, 114, 158, 418Tire pressure, 6, 16, 120, 318Tires
checking, 16, 118deating, 113, 116, 120, 123, 124diameter of, 375at, 15, 16, 3334, 112, 372, 374inating, 113, 120, 122, 124installing, 36, 118121removing, 111112, 114, 115, 342size of, 117standard, 120121, 122tubeless, 34, 111, 114, 115, 116,
120121, 122, 123124Toeclips, 225Toeing in, 183, 191, 193194Tool kits
Level 1: 14, 14Level 2: 1, 4, 6Level 3: 1, 7, 9
Tools, 1, 31, 54, 90, 163, 223, 417carrying/while riding, 1114, 33,
48Enduro, 218, 219Mavic, 216Phil Wood, 218Shimano, 61, 62, 199, 285terminology of, 72
Top tubes, 387, 388, 419Torque, 199, 200, 419
for fasteners, 396407 (table)measuring, 393, 395recommendations on, 397setting, 394tightening, 2930, 395
Triple-clamp forks, 327328, 330Truing, 41, 124, 127, 303
lateral, 125, 299301radial, 301side-to-side, 301
Truing stands, 7, 124, 126, 299, 300, 301, 302
Tubes. See Inner tubesTubing cutters, 11Twist shifters, 9091, 9697, 98, 99,
103, 153, 154, 419
U-brakes, 16, 22, 148, 190191, 194, 419
Understeering, 322, 324Undertightening, 393
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.Copyright 2010 VeloPress All rights reserved
INDEX
431
V-brakes, 16, 17, 22, 31, 147, 148, 149, 152, 154, 155, 183, 190, 194, 419
adjusting, 176179installing, 176179overhauling, 175180parallel-push, 178, 179
Valve core removers, 7, 357, 358Valve cores, 113, 123, 356, 357Valve extenders, 112, 113Valve stems, 113, 114, 115, 119, 120Valves, 115, 120
broken, 35Presta, 34, 45, 112, 113, 114, 115,
118, 121, 123, 415Schrader, 4, 34, 112, 115, 251, 320,
326, 327, 353, 416Vibrations, braking and, 369Vise, 6, 7Vise grip, 6Vise whips, 7, 138, 139, 141, 142, 419
Wheel-retention devices, 21, 419Wheelbuilding, 40, 289290, 303,
307308custom, 289disc-brake, 291front, 291, 293, 294rear, 291, 293
Wheels, 343bent, 3841, 369for big riders, 307308centering, 301303disc-brake, 291, 292, 294, 303,
305306heavy-duty, 289lubricating, 30prestressing, 302removing/installing, 16, 1724,
111, 115, 128, 133, 150, 163, 166, 341, 342, 367
straightening, 3841truing, 40, 124126, 299301
Wire, 14Wrenches
adjustable, 2, 37, 113Allen, 29, 409cone, 6, 128, 132crowfoot, 11, 412xed-cup, 223headset, 6, 14, 274metric, 2, 20open-end/box-end, 2, 12, 29pedal, 13-14, 226socket, 6, 29, 417soft, 7splined, 7, 9, 29spoke, 4, 7, 13, 39, 40, 41, 124,
291, 299torque, 7, 20, 200, 210, 229, 312,
393394, 419Torx, 6, 12, 29, 42, 201, 202, 419Y-, 9
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.Copyright 2010 VeloPress All rights reserved
About the author
Lennard Zinn is a bike racer, frame builder, and technical writer. He grew up cycling, skiing, whitewater
rafting, and kayakingas well as tinkering with mechanical devicesin Los Alamos, New Mexico. After
receiving his physics degree from Colorado College, he became a member of the U.S. Olympic Development
Cycling Team. He went on to work in Tom Ritcheys frame-building shop and has been producing custom
mountain, road, and triathlon frames, as well as custom cranks and stems, at Zinn Cycles since 1982
(www.zinncycles.com).
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).
ABOUT THE ILLUSTRATORTodd Telander is a former mechanic and bike racer who devotes most of his time these days to artis-
tic endeavors. He attended the University of California at Santa Cruz, and while earning degrees in
Environmental Studies and Biology, he completed a graduate-level program in scientific illustration.
He has since studied fine art in several western states and was awarded an artists residency at Rocky
Mountain National Park. In addition to drawing bike parts, he paints and draws wildlife and landscapes
for publishers, museums, design companies, and individuals. You can see more examples of his work on
his website, www.toddtelander.com.
Sample from Zinn & the Art of Mountain Bike Maintenance, 5th Ed.Copyright 2010 VeloPress All rights reserved
Also available from VeloPress
Zinn & the Art of Road Bike Maintenance3rd EditionLennard Zinn applies his prodigious powers of mechanical expertise to the art and science of road bike repair. Newcomers and experienced mechanics alike will benefit from the books hundreds of illustrations (including exploded views of how components go together), its step-by-step instructions for basic and advanced repair, and Zinns practical, time-saving maintenance tips. Covers new and old bikes alike.
440 pages $24.95ISBN 978-1-934030-42-4
Zinn & the Art of Triathlon BikesAerodynamics, Bike Fit, Speed Tuning, and MaintenanceMore than a repair manual, Zinn & the Art of Triathlon Bikes presents proven techniques to wring more speed from todays triathlon bicycles. With clear advice on bike fit and comfort, getting aero, tuning for speed, and choosing wisely among equipment upgrades, the tips in this book virtually guarantee faster bike splits. Of course, Zinn includes comprehensive maintenance and repair instructions too, accompanied by more than 300 illustrations and step-by-step directions to ensure trouble-free rides.
352 pages $24.95ISBN 978-1-931382-97-7
Zinns Cycling PrimerMaintenance Tips & Skill Building for CyclistsDrawing upon the research of cycling experts around the world, Zinns Cycling Primer is a one-stop guide for improving your riding skills. Covering all aspects of road and mountain cycling, Lennard Zinn shows you how to improve your bike fit and bike handling skills, as well as your training and recovery, injury prevention, core strength, and nutrition. Zinn also includes step-by-step instructions for basic road and mountain bike maintenance, repair, and upgrades.
232 pages $24.95ISBN 978-1-931382-43-4
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