Sutherlands Handbook - 5th Edition

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SUTHERLAND'S
HANDBOOK FOR
BICYCLE MECHANICS
Fifth Edition
Howard Sutherland
Leonard Rubin
John S. Allen
Ed Colaianni
John Porter Hart
SUTHERLAND PUBLICATIONS
Drawings-Susan Feichtmeir, Fredda Cassidy,
Nancy Sutherland, Carlos Chavez, Mark
Schroeder, Carol Loverde, Tim Keenan
Emeryville, California 1990
Library of Congress Cataloging-in-Publication Data
Sutherland, Howard, 1948-
[Handbook for bicycle mechanics]
Sutherland's handbook for bicycle mechanics/floward Sutherland ...
[et al.]; drawings, Susan Feichtmeir ... [et al.]. -5th ed.
p. cm.
Includes index.
ISBN 0-914578-07-3
1. Bicycles-Maintenance and repair-Handbooks, manuals, etc.
I. Title. II. Title: Handbook for bicycle mechanics.
TL430.S95 1990
629.28'772-dc20 90-41793
CIP
Library of Congress Card Number 90-41793
Copyright © 1974, 1976, 1981, 1985, 1990 by Howard Sutherland
Sutherland Publications
Box 9061, Berkeley, California 94709
All Rights Reserved
Introduction
This is the fifth edition of Sutherland's Handbook for Bicycle Mechanics. It is a resource
for people who work in the bicycle industry and for enthusiasts as well. The information
contained in this handbook was gathered from many sources and involved considerable
travel, measuring and study to track down the details that make it valuable. Much of this
data is available nowhere else.
This edition contains many changes that reflect the changes in the bicycle industry.
Indexing is covered thoroughly. Slight adjustments to the derailleurs that used to be made
by the rider while riding now often need to be made in a work stand. The many details that
are important to making indexing work are listed here.
The spoke length section has always been an important part of this handbook. We have
revised and updated this section from top to bottom to make it more thorough and easier to
use. Leonard Rubin redesigned the tools and measurement procedures, and measured
nearly all the 650-plus rims in this edition. (The fourth edition had 243.) I implemented
many of his suggestions for improving this section.
Len also contributed the headset and brake sections and helped with the indexing sections
and many other parts of the book. His commitment to making this book accurate and
complete is greatly appreciated.
I was fortunate to be able to use the beautifully equipped shop at United Bicycle Institute to
research the indexing and spoke length sections. Ron Sutphin and Wayne Martin also
provided much needed encouragement and feedback.
John Barnett of Barnett's Bicycle Institute supplied detailed suggestions for improving the
book and was able to review parts of this edition. His new book, Barnett's Manual
Analysis and Procedures for Bicycle Mechanics, is a valuable companion to this one.
My wife Nancy kept the home fires burning bright. With invaluable attention to detail, she
also managed to proofread and copyedit most of this edition and paste up the entire spoke
length section. I·am grateful for her assistance.
In the previous editions, prepaid reply cards were included to encourage readers to make
suggestions and comments. I tried to incorporate as many suggestions as I could, and I
certainly appreciate all the ideas I received. In this edition, I am again including prepaid
reply cards, and I look forward to hearing from anyone with suggestions for improving the
Handbook. Questions and comments are always welcome.
I suggest you buy two copies of Sutherland's Handbook, one for the shop area and one for
the order desk. You will probably be referring to them often. Many shops buy additional
copies to resell to enthusiasts. Take some time to thumb through the book and become
familiar with what is covered. I know you will find it useful.
June 1990
,...
With thanks to the following people and organizations:
My father, William H. Sutherland

My mother, Betsy Sutherland
and special thanks to my wife, Nancy Linn Sutherland
Virginia Villani Rigida, France Egbert Eghart-Steyr Daimler Puch

Tim Snyder Araya, Japan O. Morad-Sachs, Canada
Silverio Perez Campagnolo, Italy Ay Caramba Burritos
Leigh Moorhouse Wolber, France Karin Koller
Pamela Maes Mavic, France Hillary Male
Greg Middleton FIR, Italy Dan Cole
Larry Browning Alesa, Belgium Howie Cohen
. Olivia Perish Angle Lake Cyclery, Seattle John Porter
Ashland Cycle Sport Jevelot Wayne Campbell
Siskiyou Cyclery Western States Imports Kathy Campbell
Pt. Reyes Bikes Quality Bicycle Imports Beverly Anderson
Rick Comar-Suntour Cycles Peugeot West Fred Willkie
David Berstein & Jeff Sussman-Tioga Gita Sporting Goods, Ltd. Albert Eisentraut
Riteway Products J&B Importers West Jim Bellas
Ariel Trading Company Sachs-Huret, Inc. Todd Wehner
Bicycle Parts Pacific Ashby Avenue Bike Doctor, Berkeley Greg Toleman
Corso Distributing, Inc. Karim Cycles, Berkeley Laura Belkin
Euro Asia Imports Laquieta Caldwell Pete De Fremery
Winkel Wheel Ruby Wiles John Smith
KHS Inc. Skip Gathman Peter Rich
Hi-E Engineering Rick Caldwell Lee Maniscalco
Riggio Imports & Exports The Typesetting Shop Bob Muzzy
Ritchey, U.S.A. John Uthe-Shimano Andrew Ritchie
Sam Patterson-SRAM Corp. (Grip Shift) Chris Allen-SunTour USA Dennis Stone-Stone' s Bicycles, Alameda
Seattle Bicycle Supply Mike DaSilva Kiyoshi Teraska-Kawamura Cycle Co.
Shook-Kingsberry Corp. (American Classic) Dave Wilson-New Zealand Missing Link Bicycle Shop, Berkeley
Ten Speed Drive Imports Bill Homer-Bianchi Berkeley Cycle
Trek Bicycle Corp. (Matrix) Todson, Inc. Velo-Sport, Berkeley
Wilderness Trail Bikes Richard McKown-Sun Metal Products College Avenue Cyclery, Oakland
Marti Sacks-Sun Metal Products Nationwide Cycleparts Supply Ltd. Hank and Frank's Bicycles, Oakland
Michael Teller Sal Corso-Stuyvesant Bicycle Chevy Chase Bicycle Shop
Josh Deetz Jim Merz-Specialized Bicycle Georgetown Cycle Sport
Jeff Tofler-Fisher Mountain Bikes Jack Kelly-Zeus Jones Bicycle, Long Beach
Conrad Oho Lee Katz Los Alamitas Schwinn
Sharp Bicycles, Richmond Bernie Wuthrich-Weinmann Sports, Inc. Schwinn Sales West
Lee Chi The Components Company Safety Cycle Shop
Chang Star Joe Breeze Cycles Peugeot
Naoto Kosugi-Dia-Compe, Inc. Linne Gravestock West Coast Cycle Supply
Kip Byers Don Milberger Gitane Pacific
Wheelsmith Fabrications Peter H. Davis Lawee, Inc.
The Square Wheel, Berkeley James Hargett Linder Euro Imports
Guy-King Cycle Group Steve Brown I. Martin Imports
Performance Bike Shop, San Rafael Brian Grieger Shimano Sales
EI Cerrito Cyclery Chris Lewis H. McIver, Inc.
Richard Goodwin, Mitch Clinton, Tom Ruth Campagnolo, USA
Duke Spinelli, Eric Chavez-Mavic West Phil Wood & Co. Yamaha International Corp.
Glenn Reichwald-Campagnolo USA Bernie Smith Merry Sales
Eli Silberberger-Shimano America Corp. Mike Schwering Schwinn Bicycle Co.
Jeff Gilmore Bicycle Exchange, Cambridge Belleri, Inc.
Brian Williams Bicycle Repair Collective, Cambridge Raleigh Industries of America, Inc.
Doug Milliken Doug Hooten Wilson Bicycle Sales
Pete Mason-Berkeley Cycle Eli Rubin - Berkeley Wheel Works Carlisle Tire and Rubber
Thorsten Schaette International Bicycle Center, Allston, MA National Bicycle Dealers Association
Peter Ubelacker-Magura USA Corporation Frank Berta Ron Kitching's Handbook
A Bicycle Odyssey, Sausalito Gary Fisher Andy Alpine
Sam & Rick's, Oakland Shaw's Lightweight Bicycles, Santa Clara Michael Phillips
Amber Cycle Sports Faber's, San Jose Charles Alpert
Winning Wheels Bicycle Shop, Pacific Grove Carol Loverde The Briarpatch
ZAR, International (FIR) Jane Bernard Fred DeLong
Troxel West Dale Smith
Russ Okawa-Sachs Bicycle Components Louise Lacy and Jerry Mathis-
Mel Pinto Imports Lois Rosner Collins-Phillips Tool Corporation, Escondido, CA
Fat Tire Trading Post, Fairfax Howard Feldenkreis (for producing a custom vernier perimeter tape that
Bontrager Cycles Tom Hignite made possible much more accurate rim
Grafton Performance Aurora Typesetting measurement)
Tye Gribb-Klein Bicycle Corporation Branciforte Bicycles, Santa Cruz
William Clauson-Bikelab (Hiigi) John Temple-Sturmey-Archer and everyone who wrote with suggestions.
Seattle Bicycle Supply Russ Johnson-Shimano
,.. ""'lIIl
CONTENTS
CONTENTS SECTION
HOW TO USE THIS BOOK • Symbols • Class of Fit • Thread 0
Standards • Thread Measuring • Nationality of Parts •
(J)
Standards Evolution • Materials • Cutting Operations • Fits and
Tolerances • Bearings • Hand Tools c::
-J
TRANSMISSION PEDALS· Sizes • Markings • Toe Clip Bolts 1
:c
CRANKS, CHAINWHEELS, CHAIN • Crank Cotters • 2 m
Cotterless Crank Axles • Crank Extractors •
Cotterless Crank Installation • Fit Between Arm and
Axle • Crank Bolts • Chainwheel Interchangeability • Chain
=
r-
;I>
BOTTOM BRACKETS • 3-Piece Cranks • Cup Markings •
Cup Lockrings • Thompson (Thun) •I-Piece Cranks·· Low Profile Cranks •
3
Z
English Cottered Axles • Shell Widths • Cottered Axle Centers • French 0 \I
Cottered Axles • Other Cottered Axles • Cup-Axle Compatibility • Cotterless (J)
Interchangeability • Cotterless Replacement • Cartridge-Bearing Units •
Campagnolo Axle Identification
:c
FREEWHEELS, FIXED GEARS • Ball Sizes • Body Thread Sizes • 4 ;I>
Interchangeability • Body Markings • Hub-Freewheel Spacers • Problems •
Removing Freewheels • Removers • Single-Speed Freewheels • Fixed Gears •
Z
0
=
Freewheel Sprocket Replacement • Freewheel Sprocket Interchangeability
Charts
INDEXING INDEXING • Checklist • About Indexing • Adjustments • Cable Casing and 5 0

Casing Stops • Brazed-on Lever Bosses • Freewheel-Dropout Spacing • Chain 0
Recommendations • Troubleshooting ~
CAMPAGNOLO AND SACHS 6
SHIMANO 7 ."
SUNTOUR 8 0
WHEELS AND
BRAKES
OTHER MAKES
HUBS • Ball Sizes • Cone Wrench Sizes • Front Hub and Axle
Chart • Rear Hub Dimensions • Freewheel Clearance • Chainlines • Rear Hub
9
10
=
..n
=
and Axle Chart • Thread Chasers • Quick Release Units • Var Tool Markings
-<:
SPOKE LENGTH • About the Spoke Length Charts • Large Flange Hubs •
Radial Patterns • Spoke and Nipple Directions • Calculating Spoke Length •
Calculating Rim Correction Factors • Number of Spokes
11
nr-
TIRES • Tire and Rim Types • Rim and Tire Fit • Rim Sections • Tire 12 m
Markings • Measuring Rims' and Tires • Tire Size Charts • Tubular Tire Sizes
~
Valve Hole Sizes
m
CALIPER BRAKES • Side-pull· Center-pull· V-Brakes • Cantilevers • 13 n
Roller-Cams • Miscellaneous Brakes
:c
..enn
HEADSETS, STEMS, HANDLEBARS· Size Standards· Markings· 14
FRAMES AND
FITTINGS Binding • Replacing Stacks • Mixing Parts • Steerer Length • Tips •
;I>
Dimensions • Stem Diameters • Handlebar Diameters Z
FRAME TUBES, FORK ENDS, SEAT POSTS· 15
Diameters • Gear Hangers • Rear Fork End Threads • Replacing Forks •
Seat Posts
APPENDIX • Appendix Contents • Markings and Abbreviations • ISO 16
Standards • Books • Wire Gauge Comparison· Weight Conversions • Tap
Drill Sizes • Spoke Length Formula • Assembly Checklist • Bicycle Parts
in 6 Languages • Length Conversions • Gear Formula • Geared Hub Gear
Ratios • Gear Charts • Index
~
1990 0-1
. . HOW TO USE THIS BOOK
SYMBOLS
These symbols will be used to help you find the information
you are looking for.
o BALLSIZES
~ THREAD SIZES
+ Things to watch for; helpful information
ID The easiest way to identify a part

CL.ASS 0 F FIT
This system of grading will be used to help you choose the
right combination of parts for a job. Because of shortages
of parts and a lack of international standards it .may be
necessary to use a part that doesn't quite fit properly.
Hopefully this "make do"style of bicycle repair won't be
necessary in the future.
Class A Made to fit
Class B Will fit and be serviceable but slight damage
to the parts may result.
Class C Looks like it might work but won't.
THREAD STANDARDS
International Standards British Standard Cycle (B.S.C.),

Organisation (I.S'.O.) American Standard
~
Metric Standard Italian Standard,
Whitworth Standard
0-2 rev. 1985

THREAD MEASURING
EXAMPLE: 9/16"x20 TPI
~ r-rhe first number refers to the nominal diameter of the
~ male part. When actually measured as in figure A, it is
frequently slightly undersize. The second number refers
to the number of threads per inch (TPI) or the number
of millimeters per thread as measured in FigureB with a
thread pitch gauge. Threads must be clean when mea-
suring. Any rocking motion back and forth indicates an
incorrect match.
These numbers do not give you any information about the
standard used in cutting the threads and this is where some
confusion arises.
For instance Italian headsets and English headsets would
seem to be interchangeable with a class A fit.
Italian headset threads 25.4mmx24 TPI
English headset threads 1" x 24 TPI
Since 25.4mm = 1 inch it would seem they were the same.
However, you will notice by comparing the Italian and the
English standard for cutting threads that the angle of the
threads is different. There may be a mismatch, although
slight, to an English fork fitted with an Italian headset or
an Italian fork fitted with an English headset. For this
reason it should be considered a Class B fit.
correct
Figure A
incorrect
Figure B
0-3
,..

NATIONALITY OF PARTS
Parts will be listed as English, French, Italian, Swiss,

(/) u.s. or Austrian to show the standard used in cutting the
u
.... thread or the size of the part. Manufacturers, however, do
z not always use their national standard and different sizes
are used instead. For this reason Raleigh and Schwinn
<
:c will be listed separately. Other exceptions do exist and will
be noted when possible.
u Country of Origin does not necessarily indicate the
UJ national standard for a part. For instance, French bicy-
~ cles exported to the u.s. on a large scale use English
UJ freewheel threads.
~
U COUNTRY STANDARD USED
>
U
Australia English
.... Austria English, Austrian
=
Cd
Belgium
Canada
Denmark
English, some French
English
English
o Englalld
Finland
English*
English
IJ. France French
~ Germany English
o India English
o Italy Italian
=
Q
Japan
Mexico
Netherlands
English, U.S. **
Italian
English
Z Norway English
<
:c Raleigh
Schwinn
English unless listed separately
English unless listed separately
(/) Spain French
Ii' Sweden English
Q Switzerland French unless listed separately
Z United States U.S., English
<
~ *Please note exceptIons under Bottom Brackets and
Cd Headsets.
UJ **Japanese bikes imported to the United States are either
:cE- U.S. standard ,or English standard. Generally, if it has
an Ashtabula (c)ne-piece) crank it is U.S. standard; if it
has a three-piece crank it is English standard.
;J
(/)
0-4 rev. 1985

,..
International Standards and de facto Standards

Bicycle mechanics and shop owners dream of the day
when there are standard sized parts for bicycles. The costs
in duplicated inventory, labor wasted in trial and error,
and customer aggravation at not being able to buy a
seemingly simple part-add up to a lot of frustration and
wasted money.
In fact, there are standards. But there are so many of
them. Back when American bicycles were sold in the
u. S., French bicycles in France, Italian bicycles in Italy
and English bicycles most everywhere else ... national
standards worked most of the time. In the early 1970s,
however, when the demand for high-quality lightweight
bicycles brought bicycles from allover the world to the
U.S., much confusion resulted.
In addition to national standards there are de facto stand-
ards. Sizes for many BMX bikes, for example, are based
on the Schwinn sizes because when BMX first got started,
Schwinn components were the most durable. The market-
place determined the standard. A similar situation exists
for the high-quality multi-speed market. Because Cam-
pagnolo has been used by top riders. for years, a company
making parts for this market has needed to make them
interchangeable with "Campy?' So there is a Campagnolo
standard. Knowledge of what's likely to show up on a
bike is helpful, but the industry needs more than "what's
likely?'
Standards, standards, standards. Why doesn't somebody
come up with one set of standards?
Somebody has. Manufacturers and representatives from
other groups from countries that manufacture bicycles
met in Geneva and over a period of years came up with
standards for the International Standards Organisation or
ISO.
The ISO is an international agency, a meeting ground for
representatives of national standards organizations such
as the U.S: American National Standards Institute. The
ISO attempts to standardize dimensions, markings and
safety requirements to increase compatibility, help inter-
national trade and reduce product hazards. Standards are
introduced slowly to avoid disruptions in trade.
(continued on next page)
1985 0-5
International Standards and de facto Standards (cont.)

The ISO tries to make new, standardized equipment work
as often as possible with existing equipment. For this rea-
son, despite the trend elsewhere toward metric standards,
many of the ISO bicycle standards are based on English
measurements. ISO thread form is slightly different from
English, but parts are still compatible. Axle threads,
wrench flats and the like, which require the use of stand-
ard tools in manufacture or servicing, are metric in the
new ISO standards.
Throughout this edition we have included" the ISO stand-
ards along with the various national standards. In addi-
tion, more detailed specifications are included in the
Appendix.
0-6 1985
,..
MATERIALS
Working on bicycles requires some basic knowledge of

metals and their characteristics. Contrary to the current use
of the word in the bicycle trade, alloy does not mean
aluminum, but rather indicates a mixture of metals. An alloy
is generally a base metal such as steel or aluminum with
relatively small percentages of alloying metals that impart
desired characteristics to the base metal; these include
strength, hardness, wear resistance, machinability, and
corrosion resistance. The characteristics of a metal can be
changed further by heat treating and/or work hardening.
ALUMINUM
Pure aluminum is a soft, weak metal with very good
corrosion resistance. To be used for bicycle parts it is
alloyed with other metals to increase its strength and make it
heat treatable. As this alloying degrades the corrosion
resistance, most aluminum parts are anodized to protect
against corrosion. Generally this coating is clear, although
black and other colors are finding their way into bicycles.
STEEL
The most common steel used on bicycles is carbon steel,
which ranges in carbon content from a few tenths of a
percent in some frame tubes to about one percent in springs.
Generally, the higher the carbon content the stronger the
steel. By adding small amounts of other metals such as
chromium, molybdenum or manganese, much stronger steel
can be produced. These alloys are generally found in higher
quality frame tubes.
Heat Treating
Most steel can be hardened by a variation of two general
techniques: tempering and case hardening.
High carbon steel and many steel and aluminum alloys may
be tempered. In this process the material is heated to a
specific temperature and then quenched to harden it. The
parts are held at another low temperature for an appropriate
length of time to lower the internal stresses and draw back
the hardness to the desired point. This leaves the part
uniformly hard throughout. Case hardening can be used on
low carbon steel, which generally cannot be tempered by the
process of heat treating. Case hardening loads the surface of
the part with a material, usually carbon, that will allow the
surface to become quite hard while leaving the core
unhardened. This is desirable to give a hard-wearing surface
and a nonbrittle body. Case hardening also involves heating
and quenching.
0-7
,...

MATERIALS (cont.)
Work Hardening
(/) Another method of hardening, sometimes unintentional, is
u
.... by work hardening. Bending, pounding or manipulating the
metal causes it to harden. This can be demonstrated by
z putting a sharp bend in a piece of wire and then attempting to
<
:c
straighten it. The bent part obviously has hardened and will
not straighten to its original form. This characteristic makes
it difficult to properly straighten a bent fork blade because
u the bent section is now harder than the unbent section.
L.U
~ Annealing
Annealing is the process of softening metal by heating and
L.U slowly cooling.
...1
U
>- CUTTING OPERATIONS
....
U TOOL STEEL
=
Cd
Cutting tools that are intended to cut steel are made of a
special class of steel called tool steel. Tool steels may be
ou. either high carbon or alloy steel. Alloy steels are generally
called high-speed steel, as they retain their edges at the
temperature generated by high-speed cutting. Carbon steel
tools are less expensive than high-speed steel and are
~
o generally quite adequate for thread-cutting, reaming and
milling when the job is done by hand. The greater cost of
o high-speed steel is justified by increased durability when
=
Q
driven by a power tool. Drill bits for cutting steel should
always be high speed, as they will surely be used with a
power drill. Regardless of the material used, all metal cutting
Z tools have delicate, brittle cutting edges that are easily
<
:c
damaged by misuse. Many more cutting tools are broken
than worn out. Do not throw them together in a box or a
drawer.
(/)
"
Q . . LUBRICATION AND COOLING
Z When using cutting tools, both the tool and the piece to be
<
...1
cut must be properly lubricated and cooled with cutting oil.
Most metal cutting done on bicycles is in steel or aluminum.
Cd For best results in steel, use a high-sulfur base cutting oil
L.U available from hardware stores. It is also adequate for
:c aluminum. Motor oil, bicycle oil, WD 40, or yesterday's
coffee will not do in a pinch! You will dull your tools and do
~ an inferior job unless you use the right cutting oil in the right
::J quantity. Dabbing a little oil somewhere on the tool or work
(/) before cutting is a waste of time. The heat and friction are at
the cutting edges. Keep them flooded with cutting oil
throughout the operation.
0-8
,...

CUTTING OPERATIONS (cont.)
+ SHARPENING
Even under the best conditions cutting tools get dull.
Mechanics throw razor blades away after a few shaves, but
expect a tap to cut steel forever. It will, of course, but only if
you get it resharpened before it gets so dull that it breaks off
in a hole. Quality drills, taps, dies, mills, reamers, and the
like can all be resharpened at a fraction of their replacement
cost! When the tools don't seem to cut as cleanly and
effortlessly as they did when new, look in the Yellow Pages
under "Grinding-Precision and Production." Most large
cities will have at least one shop that can do this type of
work.
DRILLING
Probably the most common metal cutting operation is
drilling. Like other power cutting operations it requires eye
protection and lubrication. The two lips on the end of the
drill do all the cutting and should be kept flooded with
cutting oil. The point between these lips is a small chisel that
does not have a sharp edge and must be forced into the
work. When drilling larger diameter holes you will find it
much faster and easier to drill a pilot hole equal in size to the
chisel edge on the larger drill. All drills, even when properly
sharpened, make a hole larger than the drill bit by a small
percentage. When improperly sharpened, this error may
become quite large and the hole may not be round. Drilling
with a dull bit causes overheating of the work, the bit, the
motor and the operator. The undue friction can cause the
walls of the hole to become work hardened, which may lead
to tap breakage if you attempt to thread the hole.
THREAD CUTTING
It is important that the hole or .shaft size be appropriate for
the tap or die being used. (For tap drill sizes for common
fasteners see Appendix page 16-8). If the tool is required to
remove too much materi'll, it will bind and possibly break. If
too little material is removed, the thread will not be strong
enough. In practice, the thread profile is never as sharp as
the drawing on page 0-4. The strength of a thread is not
improved significantly by exceeding 60% of the theoretical
thread height pictured in the drawing.
Since all the cutting is done by the first few threads of the tap
or die, these edges must be flooded with cutting oil during
the threading operation. Failure to adequately lubricate these
edges will result in rapid dulling of the tool and torn and
ragged threads in the work.
0-9
,...

When threading, the tool should be reversed periodically to

break the chip that is formed by the cutting edge. When
threading a deep, small diameter hole such as the rear axle
adjuster in a dropout, the tap should be backed out
completely and chips removed from the tool to prevent
binding and breaking. When cutting large diameter fine pitch
threads such as bottom brackets and steer tubes, the cutting
tool must be accurately aligned with the work. A die stock
with an accurate guide must be used on steer tubes and a
piloted double tap set must be used on bottom brackets to
assure proper alignment of the bearing races and minimize
tool wear or breakage. It is important to use the proper tap
handle or die stock and rotate evenly with both hands to
prevent side thrust, which may result in broken tools and
ruined work.
THREAD CHASING
Thread chasing is distinct from tapping in that it is not
cutting threads, but is reforming damaged threads. Taps and
dies designed for cutting threads may be used for this
purpose as well as cheaper tools that are adequate only for
chasing. While it may seem to be a much easier job, use care
and flood with cutting oil as in thread cutting. Most bottom
bracket "thread chasers" have little or no pilot, making it
difficult to align the tool with the hole. When chasing right-
hand threaded bottom bracket threads with a pilotless tap,
use a lockring threaded onto the tool to help judge
straightness.
MILLING (FACING) & REAMING

The ends of the head tube and bottom bracket must be cut
accurately so that they are parallel. Facing assures alignment
of the bearing races and freedom from binding. The head
tube must also be reamed so that the pressed bearing races
will fit into the head tube properly. Facing and reaming
operations are done with special cutters made for the job. As
with other cutting operations the tools must be sharp and
well flooded with the proper cutting oil. Generally, the face
of the tube should be milled until the tool is cutting all the
way around the hole.
GRINDING
Grinding may be us,.ed on any steel. It may be used on
hardened steel, as normal cutting tools will not work.
Grinding is a hazardous operation, requiring guards, eye
protection and proper technique. Grinding wheels must be
sharpened and formed with a "wheel dresser" to give good
results. Do not attempt to grind non ferrous metals such as
aluminum or brass! Use a file or power sander for these soft
metals or they will clog the pores of the grinding wheel.
0-10
FILING AND SAWING
These methods of metal cutting have much in common: They
are generally done without lubrication. Always use top
quality files and saw blades; their increased life makes them
well worth the purchase price. Select the proper grade or
teeth per inch for the material to be cut. Use fine teeth close
together for steel or thin material. Use larger teeth further
apart for aluminum or thick material. At least two teeth
should be in contact with the work at all times. Cut away
from your body using a smooth slow stroke. Release
pressure on the back stroke to protect the edges of the teeth.
Files should be cleared of chips after a few strokes to
prevent clogging, which affects speed of cutting and the
quality of the job.
FITS AND TOLERANCES

Parts that are made to be assembled together must be
designed to fit each other. The desired degree of tightness of
the fit and the size of the parts determine the tolerance or
amount of variation permitted on dimensions or surfaces of
the parts. On threaded parts the pitch of the threads and the
length of the engagement must also be considered.
Unfortunately, poor quality control in manufacturing can

alter the results of even the best designs. Many of the
"interchangeable" bicycle parts are so poorly made that to get
a good fit several "identical" parts must be tried. This
shortcoming applies to some of the best known and most
expensive components in the industry. Measuring a sample
of bottom bracket components showed that several of the
major Japanese manufacturers hold very good tolerances,
but they are the exception. It is fortunate that bicycles are
forgiving machines due to their simplicity, flexibility and
light loading. As bicycles become more important as vehicles
for basic transportation, let us hope quality control
improves.
0-11
BEARINGS
BEARING DESIGN
Bearings are used to minimize friction and heating where
various parts rub against each other. The type of bearing
used almost exclusively in bicycles is the ball bearing; it
is very efficient, easy to fit, and inexpensive. Ball bearings
fall into three general classifications which dictate their
design and application: radial bearings which are designed
to be loaded at right angles to the axis of the shaft,
thrust bearings which are designed to be loaded on the
axis of the shaft, and a combined radial and thrust
bearing which will accept some loading on both axes.
The separate cup, cone and ball arrangement used on
most bicycles is of the radial/thrust type. The major load
on bicycle bearings is radial, except for the high thrust
load on the headset lower bearing.
Bicycle bearings are lightly loaded and rotate slowly. This

allows the use of inexpensive, rather crude bearing sur-
faces. Except in very expensive components these sur-
faces are stamped or machined rather than ground true
to a fine finish. Grinding would add more to the cost
than the minimal decrease in friction can justify.
Cartridge or sealed bearings are finding their way into

quality bicycle components. These bearings, commonly
used in industrial applications have the balls captured
between inner and outer races making up a one-piece
unit. (In a normal bicycle bearing the cups and cones
are the races.) These cartridge bearings are very precisely
made and may include felt or plastic seals to hold in
grease and keep out dirt and water. While this type of
bearing is vastly superior, it lacks •one important virtue
that the cup/cone type bearing does have: it will not tole-
rate nearly as much misalignment as the cup/cone bearing
can (and must). The thin flexible axl~ and the narrow
spool of a standard bicycle hub cannot hold cartridge
bearings in alignment. A larger diameter spool is required,
to keep the outer races aligned as the rider imposes both
radial and thrust loads on the hub flanges. Similarly,
the axle inside the hub must be larger in diameter to keep
the inner races precisely lined up. Good design can ac-
complish this without a weight penalty.
0.1'.
+ HOW TO USE THIS BOOK
BEARING MOUNTINGS
A bearing is no better than its mounting.
The smoothness, efficiency, and longevity of bicycle
bearings can usually be improved by refining the mount-
ings found on the average bicycle frame. For general
instructions on reaming, tapping and milling, see section
on cutting operations, above. Procedures for specific
bearings follow.
Hubs
The rear drop-outs and the fork ends are an important
part of the wheel bearing mounting., If the hub is clamped
between non-parallel surfaces, the thin axle will bend
and mis-align the cones. Fork end alignment gauges are
made by Campagnolo, Park and VAR to check and
correct the alignment and spacing of fork ends. (See
Figures 1, 2 and 3.) These tools are a combination gauge
and lever for bending the fork ends into alignment.
Figure 2. Fork ends out of alignment
Figure 1. Fork end alignment

gauges installed
Figure 3. Fork ends aligned
0-13
BEARING MOUNTINGS (cont.)
Head Tube
The head set bearing cups seat in the ends of the head
tube~ The inside of the tube must be accurately reamed
for a press fit and the ends of the tube must be milled
parallel to align the cups. Bicycle Research Products,
Campagnolo, VAR, and Zeus make tools which will do
both of these operations; some head tools also serve as
a press to install the cups. As shown in Figure 4, the head
tool has a T-shaped handle, a flat milling cutter and a
reamer mounted on a threaded rod. The rod is inserted
in the head tube and a centering cone, a spring, and
a star nut are installed at the other end of the tube. The
nut should be tightened to compress the spring about
half way. Flood the work area with cutting oil and rotate
the tool clockwise, looking down on the handle. Do not
reverse direction as this may cause the tool steel cutting
edges to chip. As the tool turns, the reamer will go into
the tube until the milling cutter contacts the tube face
(Figure 5). More spring tension may be needed at this
point. Further rotation will cut the face of the tube at
precisely 90° to its axis. Continue cutting until there is
bright metal all the way around the tube. (It may be neces-
sary to remove the tool to check this.) After one end of
the tube is finished, repeat the procedure for the other
end. After both ends are done, clean the metal chips and
cutting oil from the tube. The tool may be used to press
the cups into the head tube. A centering thrust washer
is installed between the reamer and the bearing cup, as
shown in Figure 6. The centering cone and spring are not
used in this operation. Make sure the cups start straight,
then turn the handle until they are pressed tight against
the tube ends (Figure 7).
flat milling cutter

reamer
---~~~~~=.
---~
centering cone
spring
star nut
Figure 4. Assembly for milling and reaming Figure 5. Milling and reaming head tube
head tube
O.lJ
reamer _
centering thrust washer
bearing cup
star nut
Figure 6. Head cup press assembly Figure 7. Installing head cups with press

Steer Tube
To assure that the threads on top of the steer tube are
aligned with the tube axis, the die cutting them must be
held in a die stock provided with a suitable guide, (Figure
8). The top cone of the head set bearing depends on these
threads for its alignment. Campagnolo, VAR, Zeus
make the proper tools for this job.
Fork Crown
Where the steer tube enters the fork crown the diameter
of the tube and the top of the crown must be machined
to accept the headset bottom cone. This job is best done
on a lathe, but an acceptable 'job may be done with a
crown race cutter as made by Campagnolo, VAR or Zeus
(Figure 9). The tool is slipped over the steer tube and the
spring compressed to apply downward pressure to the
hollow cutter. Using cutt"ing oil rotate cutter clockwise
until it leaves a complete circle of bright metal on the fork
crown. Clean the fork and drive the bearing cone in place
with a hollow slide hammer or a piece of 1" water pipe.
Figure 8. Steer tube thread cutting Figure 9. Fork crown race cutting
0-15
+ HOW TO USE THIS BOOK
Bottom Bracket
The threads and the faces of the bottom bracket shell
are the mount for the crank bearing cups. Even if these
are accurately machined, they will probably be distorted
during the brazing of the frame. Bicycle Research Pro-
ducts, Campagnolo, VAR and Zeus all make a double tap
with an aligning pilot shaft that may be used to correct
or cut these threads. Select the proper taps for the bottom
bracket to be cut. (English and Swiss standards require
left-hand threaded tap on chainwheel side,' right-~and
threaded tap on other side.· French and Italian standards
use right-hand threaded taps on both sides.)
Inspect the inside of the bottom bracket shell to make

certain that none of the frame tubes extend into the path
of the cutters. If they are in the way, they may damage
the taps. Use a file for the slow and tedious job of re-
moving the unwanted tube ends. Install the taps on the
handles and insert the pilot shaft through the bottom
bracket shell and into the hollow handle (Figure 10). Flood
with cutting oil and start both taps into the shell at the
same time (Figure 11). Run the taps in until there are
enough threads to accept the bearing cups. Remove one
tap and replace it with the flat facing mill and aluminum
pilot (Figure 12). Insert the handle onto the protruding
pilot 'shaft until the cutter is against the shell. Using
cutting oil, press in and turn clock-wise (do not reverse)
until the bright metal shows all the way around the end
of the shell (Figure 13). Repeat on the other end of the
shell, changing taps if required. Clean up chips and oil,
incillding the chips hiding in the chain stays, and install
the bottom bracket.
A bottom bracket shell that has stripped or badly damaged

threads may be made as good as new by converting to
Italian standard threading, unless it was already Italian
thread. Remove the old threads using a Bicycle Research
Product Bottom Bracket reamer on one side of the double
tap handle, with a tap matching the threading in the shell
threaded into the other side (Figure 14). Using cutting
oil, push the reamer into the shell while turning it clock-
wise until the old threads are removed. Continue turning
clockwise while pulling the reamer out of the shell.
Without removing the tap, replace the reamer with an
Italian tap and cut new threads.
Leave the Italian tap in the shell and remove the other
tap. Replace this tap with the reamer and repeat the
reaming and threading operations. This fast easy repair
saves a ruined frame for the cost of the bearing cups and
twenty minutes work. The old spindle may be used if
serviceable.
O.lll
In Conclusion
Always keep in mind that a bearing may only function if
it is rigidly and accurately mounted. The more precise
the bearing, the more vulnerable it is to misalignment.
Figure 10. Installing double-sided

tap with aligning shaft
Figure 11. Starting taps
aluminum pilot
facing mill
Figure 12. Milling assembly
Figure 13. Milling bottom bracket

face
Figure 14. Reaming bottom bracket

shell to remove stripped threads
0-17
,..

HAND TOOLS
Screwdrivers, pliers, wrenches, hammers and various special

tools are used in bicycle repair and assembly. The quantity,
quality and profitability of work done in a shop generally
matches what is found on the work bench. A good tool is a
long term investment, but a poor or missing tool continues to
run up expensive labor costs. Screw heads marred by a dull
screwdriver or nuts rounded by an adjustable wrench tell a
customer where not to take his or her bike next time.
For a shop doing repair work on all makes of bicycles many

tools are needed. Consider the tools in the following list as a
basic minimum for a profitable shop.
Wrenches
6mm through 17mm combination 1 each
6mm through 17mm box end 1 each
1/4" through 5/8" combination 1 each
13mm through 17mm cone wrenches 1 each
Pedal Wrench 1
6",8", 12" and 16" adjustable wrenches 1 each
8mm through 15mm socket wrenches 1 each
Metric Allen Set (2mm - 10mm) 1 each
Inch-size Allen Set 1 each
Screwdrivers
1/8" or 3/16" wide blade type 1
1/4" or 5/16" wide blade type 1
Various sizes Phillips-type 3
Pliers
8" Slip Joint 1
7" Diagonal Cutter 1
6" Long Nose 1
12" Channel Lock 1
Cable Cutter 1
SIS Cable Casing Cutter 1
Hammers
1/2 lb Ball-peen 1
1 Ib Rubber Mallet 1
0-18 1990 rev.

.. HOW TO USE THIS BOOK
Miscellaneous
Center Punch 1
Set Pin Punches 1
5" Bench Vise, 50 lbs or more in weight 1 en
6" (15cm) Calipers 1 C
1 ~
6" (15cm) Machinist Scale
6' (2-Meter) Tape 1
1
:cm
=
2.5-Meter Flat Metric Tape
18" Straight Edge 1
Hacksaw 1 r-
Files
Thread Pitch Gauge, Metric and English
1 each
1
>
2
6" Bench Grinder 1
Grinding Wheel Dresser 1
0 ~
Wire Wheel 1 en
3/8" Drill and Bits 1 :c
Special Bicycle Tools >
2
Every type Cluster Tool you can find 1 each
Every type Crank Extractor you can find 1 each 0
Shimano Ball Cup Tool 1 eo
Spoke Wrenches 1 each 0
1/2" and 9/16" left and right Pedal Taps
Bottom Bracket Fixed Cup Remover
1 each
1
0
Bottom Bracket Lock Ring Tool 1 ~
Bottom Bracket Peg Spanner 1 .."
Cotter Pin Press 1 0
Cup Press
Third Hand Brake Tool
Fourth Hand Brake Tool
1
1
1
=
...eo
Chain Wheel Tool 1 n
Axle Thread Chasers
Various special Shimano Tools
1 set
1 each -<
n
Chain Rivot Extractor 1 r-
Dropout Alignment Tool
Shimano Derailleur Hanger
1 m
Alignment Tool 3:
1 m
Wheel Dishing Tool 1 n
Repair Stand 1 :c
Truing Stand 1
>
Phil Spoke Cutter Threader
Sutherland's Handbook
1
1 ...n
2
ONE LAST WORD ABOUT TOOLS: en
Cheap tools are an extravagance no bicycle shop can afford.
rev. 1990 0-19

,...
.';.
, 0-20 1990
PEDALS
PEDAL-CRANK
BALL SIZES: Most pedals use 10 to 15 - 5/32" balls

per bearing or 1/8" balls.
THREAD SIZES
ISO* Primary 1/2" x 20 TPI Right- and left-handed thread
Alternate 9/16" x 20 TPI Right- and left~handed thread
English 9/16" x 20 TPI Right- and left-handed thread
French** 14mm x 1.25mm Right- and left-handed thread
Italian 9/16" x 20 TPI Right- and left-handed thread
U.S.A. 1/2" x 20 TPI Right- and left-handed thread
Italian threads are slighly different than English and are a
tighter fit in English threaded cranks.
* See Appendix for more details on ISO standards.
** Peugeots and some other French bicycles have used
English 9/16 x 20 TPI for the U.S. market since the
mid '70s.
French cranks can easily be tapped to 9/16 x 20.
When. retapping pedal threads start from the back of the
crank arm.
MARKINGS ON WRENCH FLATS
10 Campagnolo,
others Zeus
English, Italian 9/16 x 20 BSC
French 14 x 1.25 no mark
MARKINGS ON CRANK ARMS
10 European Japanese
English 9/16 x 20 no mark
French 14 x 1.25 M14
Italian 9/16 x 20
PEDAL CODES FOR RIGHT- AND LEFT-HANDED
10 THREADS
Right Left
English R L
French D G
Italian D S
Spanish D I
TOE CLIP BOLT-PEDAL
The following use 5mm x 0.8mm threads:
Pedals Toe Clips
Campagnolo Christophe
Lyotard KKT
Olympic Milremo
Pro Ace Verme
Zeus
and most others with threaded holes
rev. 19851-1
CRANKS, CHAINWHEELS, CHAIN
~-- overall length --..-.4
C/)
...
u
Z
thread
size
f
diameter
<C CRANK COTTERS

:c
u National
Tendencies
Diameter Overall
length
Thread size Flat
~
UJ and others without
~ nut
UJ ISO 9.5 (3/8") 43 7.0mm x Imm see Appendix
..1 English 9.5 (3/8") 43 6.7mm x 26 TPI moderate
U French 9.0 40,43 7.0mm x Imm moderate
> German 9.5,common 43 7.0mm x Imm moderate
...
U 9.0 43 1/4" x 26 TPI
=
Cd
Italian
Japanese
9.0,common 43
8.5
9.5
41.5
41.3*
7.0mm x 26 TPI
7.0mm x 26 TPI
6mmx 1.0mm
short steep cut
o Japan Standard
1/4" x 26 TPI also common
~
Peugeot old style 9.0 37.5 6mm x Imm entire length of
~ body cut
o new style 9.0 42 7mm x Imm moderate
o Steyr 9.5 45 1/4" x 26 TPI entire length of
=
Q
Z
Thompson (adult)
(child)
9.5
8.0
42.5
43
1/4" x 26 TPI
1/4" x 26 TPI
body cut
moderate cut
moderate cut
<C Windsor 8.5 41.5 1/4" x 26 TPI short steep cut
:c
C/)
~
Q *S.R. alloy cottered cranks use extra long cotters.

Z
<C + 8.5mm and 9.0mm holes in cranks may be drilled out to accept 9.5mm cotters.
Use a 3/8" drill .
..1
Cd
UJ
:c
r-
:J
C/)
2-0 rev. 1985

COTTERLESS CRANK AXLE BOLTS AND NUTS
~ THREAD SIZES
~ Most including ISO Exceptions
Bolt-type 8mm x 1.0mm Viscount may be 5/16" x 26 TPI or 22 TPI
Nut-type 10mm x 1.25mm Campagnolo Super Record is 10mm x Imm
1985 2-1
o
COTTERLESS CRANK EXTRACTORS
Most extractors have the same external threads (22mm x
Imm). The exceptions are listed below in bold. Even with
extractors that have the same nominal thread size,
manufacturing variations in the extractor and/or the crank do
occur. Keep several tools around; if one tool goes on too
tightly or too loosely, try another that matches the threads
more closely.
Nut-type crank extractors must be used on nut-type axles.
The center bolt on bolt-type extractors cannot be pulled back
enough to engage the threads in a crank mounted on a nut-
type bottom bracket axle.
. . Campagnolo 1990-Record, (C-)Record, Croce d'Aune and
Victory crank arms have left-handed extractor threads. Use
only the built-in extractor (see drawing) or Campagnolo's
special left-threaded extractor.
Do not use the Park tool on pre-1982 Stronglight cranks: the
threads may strip. The Park tool will work where a bolt-
type, nut-type or TA extractor is used.
A Bicycle Research Products crank arm thread-chaser (TC-
8) will restore cross-threaded or slightly damaged crank
threads. It will not work on completely stripped threads. If
the threads are completely stripped use a gear-puller to pull
the crank.
To remove frozen crank dust caps, drill two small holes in Campagnolo's crank
them and use a pin tool. Grease the threads before installing bolt with built-in left-
dust caps. threaded extractor
Crank
Type Bolt or Thread
Axle l Nut Size Extractor Size
1802 bolt-type 14mm bolt-type 22mmx 1mm
nut-type 14mm nut-type 22mmx 1mm
Campagnolo
1990 Record, bolt-type 6mmallen built into dust cap 22mmxlmm
Croce d' Aune, or use special left threaded
(C-)Record, Campagnolo left-
Victory threaded extractor
Super Record nut-type 14mm nut-type 22mmx 1mm
all others bolt-type 15mm bolt-type 22mmx 1mm
Lambert (early) bolt-type 7/8" x 24TPI
2-2 1990
COTTERLESS CRANK EXTRACTORS (cont.)
Crank
Type Bolt or Thread
Axle! Nut Size Extractor Size
SR (Sakae Ringyo) bolt-type 14mm bolt-type 22mmx Imm
nut-type 14mm nut-type 22mmx Imm
Shimano5 bolt-type 14mm bolt-type 22mmx Imm
Specialized bolt-type 15mm bolt-type 22mmx Imm
3
Stronglight
pre-1982 bolt-type 16mm Stronglight - 23.35mm x Imm
pre-1982, Var 22
1982-current bolt-type 14mm bolt-type 22mmx Imm
Sugino nut-type 14mm nut-type 22mmx Imm
bolt-type 15mm bolt-type 22mmx Imm
TA bolt-type 15mm TA, Var408 23mmxlmm
Takagi nut-type 14mm nut-type 22mmx Imm
Viscount bolt-type 15mm bolt-type 22mmx Imm
4
Zeus bolt-type 16mm bolt-type 22mmx Imm
1 See page 2-1 for drawings of axle types.

2 See Appendix for more details on axle standards.
3 Extractors: Pre-1982 Stronglight extractors have a

shoulder at the end of the threads. Do not use a TA tool
(or the TA threads of a Park tool). These tools will screw
into an older model Stronglight crank but will probably
strip the crank threads when you attempt to pull it.
Bolts: For 16mm bolts use a thin-walled socket with an
outside diameter no larger than 22mm. Do not use the
older 16mm bolts with newer cranks that have 22mm
extractor holes. Only a very thin-walled socket or Zeus
extractor will remove them.
4 Use Zeus tool or a very thin-walled socket with outside
diameter no larger than 20.8mm. If you ever get the bolt

out, use a 15mm bolt instead.
5 Shimano Dura-Ace AX, Dura-Ace EX, 600 AX, 600 EX
and Deore used a built-in extractor that didn't work very

well. It is probably best to replace them with a
conventional dust cap and crank arm bolt.
1990 2-3
,...
~~ CRANKS, CHAINWHEELS, CHAIN

~~
~~ INSTALLING COTTERLESS CRANKS
Adjust the chainline by selecting the appropriate parts-

usually the correct length axle (see Bottom Bracket Axles
page 3-10). The cranks mount in one position. Do not
overtighten or leave loose to adjust the position.
Adjust the bottom bracket bearings with the cranks off.
Install the right crank. Check bearing adjustment by
putting side force on the end of the crank. Readjust until
no play is felt. Install left arm.
The axle end and the hole in the crank must be clean and
dry. Do not use oil, grease, or an anti-seize compound.
The tapered square system depends on the crank coming
up firmly on the axle. Any lubrication will cause the arm
to go on too far in tightening or to float on the axle.
Either way the arm will be ruined. Grease or anti-seize
compound may be used on the threads of the crank bolt.
Tighten the crank bolt firmly: 18-20 foot-pounds '(215-
240 inch-pounds). Re-torque the bolt after 100 miles of
riding. This ensures that the crank seats properly on the
axle.
FIT BETWEEN COTTERLESS CRANKS AND AXLES
Axle end and crank hole dimensions vary considerably

due to manufacturing tolerances.
Most axle and crank tapers are very close to 2 degrees,
except for the tapers found on obsolete Japanese (SR Sil-
ver), which are 3 degrees. 3-degree axles are now rare. 3-
degree axle ends are too large to enter the holes of 2-
degree cranks fully. "It must be a 3-degree axle or crank"
is usually not the correct explanation for crank fit prob-
lems.
Except for 3-degree axles, differences in the taper angle of
individual axles due to manufacturing tolerances are
greater than the average differences between brands.
When crank and axle taper angles differ, the axle will
wobble when loosely inserted into the crank as a test.
Except when angle errors are extreme, the crank will seat
itself during initial use, requiring only a few retightenings
of the crank bolt.
Failure to retighten the crank bolt will eventually destroy
the crank.
Most of the difficult crank-fit problems are due to taper
length differences, not angle differences. (See the diagram
on page 2-7.)
2-4 rev. 1985

FIT BETWEEN COTTERLESS CRANKS AND AXLES (cont.)
+ When using the interchangeability charts, tighten the

crank on the axle to check the fit before installing it on
the bike.
Be sure the crank does not come up against the end of
the taper. This happens first near corners of holes. If
crank bottoms out, the square holes do not grip well,
and will come loose or possibly .crack. (See drawing A)
After tightening, remove bolt to check that the end of
the axle is not coming through. If the axle end is flush
or near flush with the face of the crank bolt washer it
sits against (see drawing C), the crank itself may not be
tight enough or will loosen when. ridden. Attempting to
tighten the crank bolt further with this condition present
will shear off the bolt, since it would be tightening against
the axle end itself.
Sometimes you can use a washer between arm and normal
washer. File the hole in an unhardened washer so the
axle end corners can pass through it.
Drawing A Drawing B Drawing C

Incorrect fit Correct fit Incorrect fit
Crank close to "bottoming" Axle end is not flush with Axle end flush, or close to
on end of taper flats. bottom of crank extractor flush, with bottom of
hole and crank arm does not extractor hole.
"bottom" on end of taper flats.
rev. 19852-5
FIT BETWEEN COTTERLESS CRANKS AND AXLES (cont.)
COMBINATIONS THAT DON'T WORK

• TA cranks: crank bolt face comes close to flush with
the ends of many axles.
• Stronglight, Maxy-type and Sugino AT cranks: bot-
tom on the ends of the flat on most axles except
Stronglight, TA, Maxy-type and Phil Wood.
• Maxy-type nut-type axles: stud does not protrude
far enough through extractor hole of many cranks
to engage nut.
• Ofmega and older (indented markings) Avocet axles
and cranks: axle end and crank hole narrower than
others; do not interchange. Zeus also is narrower,
though less so; take care that the axle does not come
flush with extractor hole when installing another
brand of crank on a Zeus axle.
USEFUL COMBINATIONS THAT DO WORK

• Maxy-type axles can be used to place chainline far-
ther from the frame with Stronglight or TA cranks.
You may also grind the end of a bolt-end axle. Bevel the
edges so it doesn't dig into the crank when tightened. Try
the bolt before assembly. You may have to shorten it
slightly.
MISCELLANEOUS ITEMS
If you are using light alloy crank bolts, do not use them
to install the cranks. Use normal steel bolts to tighten and
retighten the arms. Then remove the steel bolts and install
the alloy bolts. Tighten them finger-tight, then just
enough more to tension them.
Always replace the dustcaps. They prevent damage to the
threads. Damaged threads may make it difficult or
impossible to install an extractor. A small amount of
grease on dust cap threads will prevent corrosion.
2-6 1985
CRANK ARM PROFILES
COMPARISON OF HIGH PROFILE AND LOW PROFILE CRANK ARMS
1-'
I I
I I
I I
.. - .,
I I
I I
-'., I
\ I
II
I I
I I
I I
I I
I I
I I
aH-.. ····i-.
',~ ~
I I I
I I I
I I I
I I I
i··i······
I
I
I
I
""1:
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I·'
I II'
I II \
~'
·······1
I
I
I
..-------1
I I
I I
',---,'
High-profile Low-profile
The crank arm on the left is an old-style crank arm. A newer,

low-profile crank arm is on the right. Looking quickly at these
arms it would seem that if you wanted to keep the chainline in
the same position and replace the high profile arm with the low-
profile arm, a much shorter bottom bracket axle would be
needed. The middle drawing shows the two arms superimposed
with chainring position the same for both. The difference, in this
case, turns out to be only 3mm (see the greyed area where the
crank bolt washer would be). This difference varies, of course,
with various models. The point is that sometimes there is not as
dramatic a difference in bottom bracket axles as you would
guess by looking at the crank arms.
2-81990
CHAINWHEEL BOLTS
Bolt head sizes vary more than the thread sizes. Hex o
headed bolts should be tightened and loosened with a
socket or box end wrench that has a face that has been
ground flat.
hole in arm,
~
thread
chainwheel
or spacer
Type A 8x.75 10 use 5mm allen key,
slotted nut
Type B 6xl 8 use slotted nut
TypeC 7xl threaded collar diameter 8.9mm
7xlor
7mm un-
threaded
TypeD 7xl 7xl
threaded
TypeE 5x.80 7 or 8 uses slotted nut or
or 5x.75 4mm allen key
Type A Type Band E Type C TypeD
'21 121
CHAINWHEEl
DIMENSIONS
2-9
CHAINWHEEL INTERCHANGEABILITY
o
3-ARM CHAINWHEELS
Chainwheels listed together are interchangeable
Bolt circle Hole center IMake Model Bolt Hole Min. No
diameters to hole center type size teeth
85 73.5 Sakae (SR) Custom 3 A 10 28
88.9 77 Nicklin N34
(3 Y2 ") Cross N34
Williams C34
95 82.3 Shimano 600,310 A 10 30
106 92 Dague Mundo Calol B 8 32*
Sakae (SR) Apex wi
8mm holes
Sugino Maxy, others
Takagi (3 Tourney
arrows) American Flyer
and others
106 92 Sakae (SR) Apex wi A 10 34
10mm holes
112 97 Takagi (3 1 piece crank D 8
arrows)
116 101 Campagnolo Sport, GrandSport CorD 9 36**
Cinelli
Duprat
Durax
Gnutti
Haubtmann
Magistroni
Nervar
Simplex
Solida
Stronglight
TA, TA Adapter Professional
Ring
Zeus
and others
140 121.2 Campagnolo GrandSport inner B 8 40
*Chainrings come in steel and aluminum; there are dif-
ferent spacers for each. Generally 5mm spacers for
steel and 3.5mm for aluminum.
**Often attaches to spigots (raised bumps) on crank
arms. This bolt circle is often used with a larger
(157mm) bolt circle. Sometimes a piece of metal that
looks like this ~ joins the two circles. Nervar,
Haubtmann, Solida, Zeus, and most others are 78.5mm
between hole centers. Some Italian chainwheels with
this large bolt circle use unevenly spaced holes. Pairs
of holes were spaced 63.4mm apart on ones we
measured.
2-10 rev. 1985
o
CHAINWHEEL INTERCHANGEABILITY
5-ARM CHAINWHEELS
Double chainwheels generally now have a 130mm bolt circle diameter. Triple
chainwheels generally are 110 for the outer and center rings and 74 for the inner ring.
These diameters are listed in bold.
Chainwheels listed together in the same row are interchangeable.
Model name does not necessarily determine the bolt circle. The same name is
sometimes used on cranks with different bolt circles.
Hole
Bolt center
circle to hole Bolt Hole Min.
diameter center Make Model type size teeth
74 43.6 Avocet Touring - inner triple Long A 8, 24
Campagnolo Euclid, Centaur, bolt or 8 x .75 or
Olympus - inner triple A 10
Cook's inner
Cook Bros. inner
Mavic 631 adapter, 637 - inner triple
Ofmega 2000 - inner triple
Sakae (SR) 300 series - inner triple
Shimano All inner triple except
older Deore - see 85mm
Specialized Inner triple
Sugino Inner triple
SunTour Inner triple
Takagi XT - inner triple
80 47 TA Tevano Special 7.2 30
85 50.0 Shimano Older Deore Special 10 26
FC-DE30 - inner triple
Takagi TO AD-TP,.TO ST - inner triple
86 50.6 Sakae (SR) TG series (old 400 series), A 10 28
- inner triple
Solida 1531- inner triple
Stronglight 99, 49, 107 - inner triple
100 - all rings
86 50.6 Edco current - inner triple Special 8 32
90 52.9 Edco old style - inner triple Special 10 32
Mavic old style - inner triple
1990 2-11
o
CHAINWHEEL INTERCHANGEABILITY (cont.)

5-ARM CHAINWHEELS
Hole
Bolt center
95 55.9 Mavic 635 - inner triple A 10 30
Takagi Tourney touring
(3 Arrows)
95 55.9 Takagi Tourney Standard touring B 8 30
(3 Arrows)
100 59 Campagnolo Triple Special 10 36
Merz Adapter A 10 31
102 60 Avocet Touring Special 10 32
Ofmega 2000
110 64.7 Campagnolo Euclid, Centaur A 10 34
Olympus - middle and outer
Cook's
Cook Bros.
Mavic 637 - middle and outer
Sachs triple cranks - middle and outer
Sakae (SR) 300 series
Shimano triple cranks - middle and outer
Specialized triple cranks - middle and outer
Sugino 110, Maxy, BMX, others
SunTour triple cranks - middle and outer
Takagi XTouter
110 64.7 Sugino steel chainwheels E 7 34
112 65.8 Takagi For I-piece cranks D 6 34
(3 Arrows)
114 67.0 Schwinn For I-piece cranks D 6 39
Approved
Takagi
(3 Arro\\ls)
116 68.2 Campagnolo Victory, Triomphe, Gran Sport A 10 35
118 69.4 Sakae (SR) RG series (old 200 series) A 10 36
118 69.4 Sakae (SR) old 600 series B 8 36
118 69.4 Ofmega A 8 x .75
threaded
119 70.0 Zeus A 10 36
120 70.5 Takagi For BMX 1/8" chain B 8 36
(3 Arrows)
2-12 1990
o
5-ARM CHAINWHEELS
Hole
Bolt center
122 71.7 Edco Touring Outer A 10 38
Nervar some models
Solida 5171,5271
Stronglight 93
Stronglight 49 inner only
Stronglight 105, 104, 103, 101,200
128 75.3 Nervar Sport A 10 38
Nervar Star
130 76.4 Mavic 631 A 10 39
Sachs double cranks
Sakae (SR) current 200 series
Schwinn Le Tour Deluxe
Approved
Shimano double cranks
Shimano Dura-Ace Track
(very old style)
Sugino 130
SunTour double cranks '87 - current
Takagi Tourney Racing SP
(3 Arrows)
Thun Coronado
130 76.4 Schwinn LeTour B 8 39
Approved
Takagi Tourney Racing Standard
(3 Arrows)
135 80 Campagnolo (C)-Record, Record A 10 39
(1985 - current)
Croce D'Aune, Chorus
Athena, Xenon
1990 2-13
o
5-ARM CHAINWHEELS
CIJ
U
.... Hole
Bolt center
Z circle to hole Bolt Hole Min.
<
:cu
diameter
144
center
84.7
Make
Avocet
Model type
A
size
10
teeth
41
Campagnolo Road 1967 - 1984
LIJ Campagnolo Track 1972 - current
~
Edco
Gipiemme
(.IJ Mavic 630
~
u Merz
Mikkelson
Adapter
Adapter
~
u
....
Nervar
Ofmega
2000
=
=
Omas
Sakae (SR) 5LA series (old 100 series)
o Shimano Track 1985 - current
u.. Specialized
Stronglight
Racing
106, 107 ""-
~ Sugino Mighty, others

o SunTour Superbe Track 1987 - current
o Tevano
=
Q
Z
151 88.8 Campagnolo
Campagnolo
Merz
Track pre-1972
Road pre-1967
A 10 44
:c<
Shimano Dura-Ace Track (until 1985)
Sugino Mighty Track (old style)
SunTour Superbe Track - Pre-1987
CIJ Williams
"Q Competicion inner
Zeus
Z
<
~
=
LIJ
:c o
o
E- o o
:::J o 0
CIJ
3-ann 5-pin 5-ann
o o o
2-14 1990
o
5-PIN CHAINWHEELS
Chainwheels listed together are interchangeable
Hole
Bolt center to
circle hole Bolt Hole Min.
50.4 29.6 Many,
including
Cinelli
Duprat
Durax
Gnutti
Huret
Nervar 1004, 1006
Shimano older Deore
Simplex
Solida
Stronglight 49
Sugino Pro Dynamic,
PX, Super Maxy
TA Criterium,
Cyclotouriste
Williams
Zeus
50.8 (2") 29.9 Bullseye
6-BOLT CHAINWHEELS
80 40.0 TA Cyclotouriste E 7.2 26
Lambert middle bolt
116 58.0 TA Randonneur E 7.2 36
143 71.5 Lambert outer bolt circle E 7.2**
152 76.0 TA Criterium E 7.2 43
157 78.5 Nervar
Haubtmann
RFG
Solida
Simplex
Zeus
and others
*This is a common bolt circle used with a 40mm hole in the chainwheel. Bolt sizes are
frequently 5 x .75 or 5 x .80. Hole sizes in aluminum chainwheels are frequently 7 or 8mm
or are threaded for 5mm bolt in steel chainwheels.
**Hole threaded on inner ring.
rev. 1990 2-15

o
CHAIN MEASURING
The first number refers to the pitch or the distance between the
center of one roller and the center of the next roller bearing the
same load (dimension A). The second number refers to the
distance between the inside plates or the smallest space for the
tooth of the .sprocket (dimension B). Nominal and actual sizes
are not exactly the same.
CHAIN
Nominal Size in Inches Nominal Size in Millimeters
Hub Gears and Coaster Brakes 1/2" x 1/8" 12.7x3.170r
12.7 x 3.3
Derailleurs 1/2" x 3/32" 12.7 x 2.38
1/2" x 1/8"* 12.7x3.170r
12.7 X 3.3
Block Chain (now obsolete) 1" x 3/16" 25.4 x 4.76
* Used for 2-, 3- and sometimes 4- and 5-speed freewheels.
o o
L=="====:II-=====::::::;-;:=========--===::::'__~==--=.:=::~:::;--r::::===:::::=--=.=--=:::J ~
~=--=:::~ '--::::==-_==::----:::==--====:::----1 L...---:::=:=--.-:::::::::::;::----r
B C
-2:::=--=:::::'---' ..----:.:::::::::-_c:::=::::-_--:::==---====:::_~r----=:::::=._ _=::::::::.~--i
--t
Narrow Derailleur Chain

Narrow chain has the same internal dimension (B) as regular
1/2" x 3/32" chain. The outside dimension (C) is smaller.
Regular chain is approximately 8.Omm wide while narrow chain
is 7.2 to 7.4mm wide. This difference allows a 7-speed
freewheel to be used in the space of a regular 6-speed freewheel.
Regular width chain cannot be used on narrow 6- and 7-speed

freewheels.
Shimano Uniglide Chain
Shimano Uniglide chain (marked UG) has widened outer plates
and must be cut with a Uniglide chain cutter.
Also see page 5-7 for illustration of bushingless and non-
bushingless chain. See chain recommendations in each
manufacturer's indexing section.
2-16 1990 rev.

BOTTOM BRACKETS
BOTTOM BRACKET CUPS-BOTTOM BRACKET SHELL

3-PIECE CRANKS
o BALL SIZES: 11 - 1/4" balls per side.

Exceptions: Campagnolo used 3/16" balls on,e year in the
mid-1960's. Campagnolo Super Record and (C-)Record
used ball cages with 14 - 3/16" balls. 1990 Record uses
ball cages with 14 - 7/32" balls.
THREAD SIZES: Adjustable Cup Fixed Cup

ISOt 1.375 "x24 TPI right handed thread left handed thread
English 1.370"x24 TPI* right handed thread left handed thread
French** 35mmx1.0mm right handed thread right handed thread
Italian 36mmx24 TPI right handed thread right handed thread
Raleigh*** 1 3/8"x26 TPI r,ight handed thread left handed thread
Swiss 35mmx1.0mm right handed thread right or left handed
thread. ****
*****1.450' 'x26 TPI
Chater Lea right· handed thread left handed thread
t ISO size is compatible with English.
* Phillips bottom bracket cups are described by Raleigh as
being 1 3/8" x 24 TPI Whitworth. This is different from
the British Standard Cycle. See Thread Measuring page
0-3 for a description of thread differences.
** Motobecane uses left threaded (Swiss style) fixed cup on
most bikes. For cottered cranks, if fixed cup has 8 flats
it is left threaded; if it has 2 flats it is right threaded. For
cotterless cranks see page 3-2 for markings on left
threaded cups.
*** Raleigh, Rudge" Humber and brands made by Raleigh
after 1963, except bikes made by Carlton which uses 24
TPI. A Raleigh with 71 or 76mm bottom bracket shell
generally uses 26 TPI. 67 or 68mm shells use. 24 TPI.
**** See page 3-2 for markings on left threaded bottom
bracket cups.
***** Obsolete British size sometimes found on tandems and
others.
Phil Wood & Go. makes mounting rings for their sealed
crankbearings to fit all the bottom bracket threads listed
above including Chater Lea.
When chasing right hand threaded bottom bracket
threads with a pilotless tap, use a lockring threaded
onto the tool to judge straightness.
+ All stripped bottom bracket threads except Italian can be
reamed out and rethreaded to Italian. Use a size K ex-
pansion reamer or a Bicycle Research bottom bracket
reamer.
Viscount bottom brackets can be reamed and tapped to
Italian. Be sure to replace the? aluminum forks. They
break without warning.
rev. 1990 3..1

BOTTOM BRACKETS
BOTTOM BRACKET CUP MARKINGS

FIXED CUP ADJUSTABLE
CUP
CAMPAGNOLO
English 1.370" x 24 TPI 1.370" x 24 TPI
French 35 x 1 35 x 1
Italian 36 x 24F 36 x 24F
Swiss (left thread) 35 x 10
JAPANESE
English 1.37'; x 24T 1.37" x 24T
French 35 x PI 35 x PI
Italian 36 x 24T 36 x 24 T
Swiss (left thread) 35 x PI SI
NERVAR
English 1 ring 2 flats 1 ring 6 sides
French no ring no ring 6 sides
Italian 2 rings 2 flats 2 rings 6 sides
RFG
English CL 4CR
French C C
German GL DR
Italian 2 Flats 4 Pin Holes
Raleigh No Flange
STRONGLIGHT*
English 2 rings 8 sides 6 sides no rings
French 1 ring 8 sides 6 sides no rings
Italian 1 ring 8 sides 4 pin tool holes
or 1 ring 2 flats no rings
Swiss (left thread) no rings 8 sides
TA
English 2 rings 2 rings
French 1 ring 1 ring
Italian no rings no rings
*Stronglight competition all sizes have 2 flats, no rings.
-NOTES-
,....
BOTTOM BRACKETS ~
BOTTOM BRACKET CUP LOCK RINGS
•
MARKINGS ON LOCK RING EDGES
10 NERVAR TA
English ~ English
French ~ French
Italian ~~ Italian
STRONGLIGHT
English 4 or 8 notch*
French 6 notch
Italian 4 or 8 notch*
*Italian lockrings slip over English Bottom Bracket Cups
and English lockrings can't fit over Italian Bottom Bracket
Cups
Thompson (Thun) Bottom Brackets Sets
For Bottom
Bracket Shells 40 x 65, 45 x 65, 30 x 65,
(inside diameter by width) 40 X 70 45 x 70 30 x 70
axle diameter 5/8" (15.8mm) 5/8" (1.5.8mm) 13mm (.511 ")

length 5 1/2" (140mm) .5 1/2" (140mm) 137mm (5 1/4")
ball size 1/4" 5/16" 3/16"
cotter size 3/8" (9.5mm) 3/8" (9.5mm) 8mm
locknut size 26mm (1.02") 26mm (1.02")
Adjustable left side is left threaded. Be sure indentations

in left dust cover line up with slot in cone. Tighten lock-
nut by holding crank arm on other side. Leave cone on
right side in place.
ONE PIECE (ASHTABULA) CRANKS
THREAD SIZES AND BALL RETAINERS
o right threaded
right side
(stationary cone)
left threaded
left side
(agjustable cone)
Retainer Ball number
and size
I USA
Schwinn
15/16 x 24 TPI
15/16 x 28 TPI
7/8 x 24 TPI
7/8 x 28 TPI
66
64
10-5/16
9-5/16
3..3
SUTHERLAND'S HANDBOOK FOR BICYCLE MECHANICS
~
I
~
The following chart was compiled from five different solirces. Numbers are rounded to the nearest ~n~
1/16" or .5mm. There may be minor discrepancies but none that should affect the interchangeability. ZOZ
~~,.".,
~~\i4.i
Please write if you have any problems with this chart.
==.~~
. . Axles on the same line are interchangeable but may not have precisely the same dimensions. n=c oo
=~=
>~
Axles within each center size category are arranged in order of increasing right side. In cases w.here OJ OJ
Z>
this right side is the same they are listed in order of increasing left side.
~~ :::00
Many of the axles listed are no longer being made and are listed only so that replacements can easily >~
=~
:J>~
be made. Hercules, Brampton, Bayliss Wiley and Phillips that have only the old stamping number are
no longer manufactured. Phillips with 7 digit numbers listed, Raleigh, TDC, Japanese JBG and RFG
~
~
~
~O
[T]~
~
axles are still available. ~ ~
(f)
~
= Q
=
.: = =
Qe- = Q -a Q
~
'iJ e Q
Q ~ .=
Q
==
~
Q
Q = =
Q =
Q
Q
=
Q
=
= ""e;
rIJ. <.
.c =
.c
fI}
t =
..,.
f I} ~ ~ Q
=
f I}
~ ~
Q
~
u= ~
Q fI}
Q
:i . .!fl = .!fl Q"
fI}
:§"~
=Q,,-
~
fI}
= .~
fI}
=~
Q.
=
~ .".
~~ Q= :: ~ U
"" ~.
Q
~ ~
J~
~
= == =;
~ ~~
-~
~
:c"C Q
Centers left center Iright total
~
=:
Q ~ ~
= =:=: =:~~~ .c~
~ ~ ~o E-l S-a ~ ~ Q Q"
~ I Notes
1 11/16" (43.Omm) 1 5/16 (34.0) 1 11116" (43.0) 11 5/8" (41.5) 45/8" (117.5) PBA 601 F103 I C16/6 6 20 Miniature cycles
1 15/16" (49.Omm) 11 7/16" (36.5) 11 15/16" (49.0) 11 11/16" (43.0) 15 1/16" (129.0) C16/7 I 7
2 7/16" (62.0mm) 1 7/32 (32.0)

1 7/16 (36.0)
2 7/16 (62.0)
2 7/16 (62.0)
1 3/4 (44.5)
1 3/4 (44.5)
5 7/16 (137.0)
5 5/8 (148.0)
RBA1081 A8
RBAI01 A21
08GC
21GC
I
PBA508
I
3900709
I I
FI04
R16/81 81 A8GR
112
3757
Chopper. rwenty
1 11/16 (43.0) 2 7/16 (62.0) 1 11/16 (43.0) 5 1/2 (142.5) R16/14 14 3 Delivery (Carrier)
Note: all 2 7/16" center axles listed have close to the same right side and vary mostly on the left. They can be interchanged given enough clearance on left.
BOTTOM BRACKETS
I~""'------ overalllength·---------..·1
•
- - -.. .~-
. ~ ~ ~-t-----L-..r
~---.. ..... . . . . . ._ ..r-----......

~ left ---.j- center .1.. right ~
BOTTOM BRACKET SHELL AND COTTERED
AXLE CENTER WIDTHS
This chart lists only tendencies. There are exceptions so
measure to be sure. Axle centers listed are mostly for
cottered axles. Bottom bracket axles are made to be used
with a specific cup thickness. Different cup thicknesses
may cause interchangeability problems.
Cottered Axle
Shell width centers Uses
English (for 2 19/32" - 2 518" 2 1/16" Road and track
Raleigh, see (66-67mm) often (52.5mm)
below) listed as 68mm
French 68mm 54.5 - 56.5mm Road and track
Italian 70mm 56.5 - 58mm Road
65,68,70mm varies Track
Japanese 68mm 52 - 53mm Varies
71mm 55mm
Exceptions:
Cinelli (model 74mm
SC for several
years in the '60's)
Raleigh 2 13/16" (71mm) 2 5/32" Most Raleighs
(55.0mm) except bikes with
24 TPI threads.
3" (76mm) 27/16" Tourist, Chopper,
(62.0mni) Twen~y, others
Thompson 65mm,70mm see page 3-3 3 piece style

(Thun) cranks with press-
in cups and
threaded axles.
COTTERED BOTTOM BRACKET AXLES

AXLE END DIAMETER
Nominal Actual
ISO* 16mm 15.9mm
English 5/8" (15.88mm) 15.75 - 15.80mm
French 16mm 15.9mm
Italian 16mm 15.9mm
*See Appendix for more detail on ISO standards.
rev. 1985 3-5

(.H
I
~
French bottom bracket axles are catalogued by overall length
overall markings
length left center right on axles notes
Gitane-all black
~ ~
130 33 56 41 none ~ 0
~:i
134 35 56 43 none
138 35 56 47 none
:c 0
Motobecane-all black
134 36 55 43 none Original equipment on Motobecane until '74,
8 3:
used with Solida cranks. ~ ~
~ ::0
~ »
136 35 56 45 none Origin.al equipment on Motobecane from '74
until present, used with Solida and Nervar
cranks.
o n
138
> ~
35 56 47 none For Nervar cranks on Gitaneand other French ><m
~ . .~
bikes..
~ (f)
Peugeot~blackends, unpolished middle, polished left and right sides
140 42 5543 none
142 42 55 45 none Original equipment to fit folder
145 43 55 47 none Original equipment to fit V08, AD8, A018,
V018e
RFG-marked RFG
135 37 54 44 13554C
137 37 54 46 13754C
140 40 54 46 140 54C
135 (see note) 68 135 Original equipment on Sutter and other French
bikes. Balls run in grooves on axle, cups are
extra thick and not interchangeable with others.
*Peugeot axles and cups are not interchangeable with others.

BOTIOM BRACKETS
ASSORTED OTHER COTTERED AXLES
mark on overall left center right

axle length
German (not interchangeable with others)

RFG 170 135 36 56 43
Steyr (Puch) none 142* 40 56 46
none 135** 38 56 41
Italian
Magistroni Magistroni 5R 127 33 56 38
Ofmega Made in Italy 137 44 58 35
RFG 136 136 36 57 43
Japanese
(Unknown
brand) No.1 145 41 51 43
S 139 40 53 46
S3 146 42 53 51
U3 143 41 53 49
ST 143 41 54 47
LB 139 35 55 49
ITAZAM 135 35 55 45
57 138 35 57 46
A-8*** 140 33 62 43
*for Clubman and 10 Speeds

**for 1 and 3 speeds
***similar to Raleigh A-8
3-7
BOTTOM BRACKETS
BOTTOM-BRACKET CUP-AXLE COMPATIBILITY
(/) Since bearing race diameters vary, not all conventional

u
.....
-bottom brackets using 1/4" balls are compatible.
z measure here
<
:c
u
tJJ
~
tJJ Axle diameter at base of bearing race
.J Peugeot cottered 15.90 mm .626 inch
U Raleigh cottered 16.40 mm .646 inch
>
U
Japanese cottered 16.45 mm .648 inch
..... Japanese Maxy-type 16.45 mm .648 inch
cc Sugino Mighty 16.50 mm .650 inch
=
Phillips, other British cottered 16.55 mm .652 inch
Stronglight, TA 16.75 mm .659 inch
o Campagnolo, SR Royal, 16.90 mm .665 inch
u. Shimano Dura-Ace,
SunTour Superbe, Zeus
~
o When possible, use cups and axle of the same make and
occ model. When mixing brands and models, test the bearing
fit before installing cups in the bicycle. Smear inside of
cup lightly with grease, installing bearing balls (balls in
Q retainers are more convenient for this purpose). Insert
Z axle and rotate. Remove and note position of ball track
<
:c
on axle.
C/) Ball Track

"
Q
Z Too high
<
.J
cr:
LIJ
:cE- Acceptable
::J
C/)
Too low
1!I,'i
3-8 1985
BOTTOM BRACKETS
,
BOTTOM-BRACKET CUP-AXLE COMPATIBILITY (cont.)
If the bearing track is too high or too low it will accelerate
wear. Especially avoid one track high and the other low,
which will produce a strong "wedging" force on the
races. If one cup is worn out, find a matching replace-
ment or replace both cups with a matched pair.
Cup race diameters tend to follow axle race diameters.
Individual manufacturing variations may affect fit. Typi-
cally, cups as much as 0.25mm (.010 ") oversize and
0.12mm (.005 ") undersize are acceptable. Due to a more
gradual slope of the bearing race surface, Stronglight and
Sugino cups accept a wider range of axle diameters than
others. Sugino Mighty axles will accept a wide range of
cups, even those made for 16.90mm axles.
COMBINATIONS THAT DON'T WORK

• Peugeot cottered axles and cups will not interchange:
Bearing race diameter is much smaller than others.
• Old-type Shimano Dura-Ace axles (BB-7200, BB-7300,
and BB-7500) will not fit through the holes in other
brands of cups. The entire bottom bracket set is inter-
changeable.
• Cups for British cottered axles will not work with many
cotterless axles.
USEFUL COMBINATIONS THAT DO WORK

• 26 TPI Raleigh cups will work with Maxy-type cotter-
less axles.
• Sugino Mighty triple axle will fit in Campagnolo Nuovo
Record cups.
• Maxy-rype axles can be used to place chainline farther
from the frame with Stronglight or TA cranks.
1985 3-9
BOTTOM BRACKETS
BOLT-TYPE COTTERLESS BOTTOM BRACKET
INTERCHANGEABILITY
The following charts are for replacing worn axles, cups,
or complete bottom bracket sets. By comparing the
numbers listed, you will be able to determine the differ-
ences that affect the fit of the parts.
+ This should be regarded as an experimental system
which will work when used with care. Please write and
tell us if you have any problems. We are not and cannot
be responsible for any difficulties arising from the use
of this chart. Manufacturers do occasionally change
specifications without changing model names and num-
bers. Measurements also vary from batch to batch be-
cause of manufacturing tolerances. The parts we mea-
sured may not be representative, but we feel the numbers
here are close enough to be useful.
Center-width factors and axle-end factors are numbers
that are useful only when comparing one listed axle to Bolt-type axle
another.
HOW TO USE THE BOTTOM BRACKET CHARTS
+ 1. Read through completely before starting to disassemble
the bottom bracket and cranks.
2. Examine the bicycle. Determine how much the posi-
tion of the chainwheels can be changed. Will the chain-
wheels rub against the cpainstays if they are moved in?
Will the derailleur work if the chainwheels are farther
out? Estimate in millimeters how much the chain-
wheels can go in or out. Write down your estimate.
3. Note the position of the lockring on the adjustable
cup. How many threads are showing? Write down the
number. Estimate how many more or less threads will
work. Write it down.
4. Disassemble the cranks and bottom bracket set. De-
termine what parts need replacing. Then go to the
correct chart:
A. Replacing Axles Only (see also Bottom Bracket Cup-
Axle Compatibility, page 3-8, and Axle Taper chart,
page 2-7).
B. Replacing Complete Bottom Bracket Set Only (see also
Axle Taper chart, page 2-7).
C. Replacing Cups Only (see Bottom Bracket Cup-Axle
Compatibility, page 3-8).-
Once you understand how to use the charts, it is possible

to use them for other combinations of replacements.
This will, however, increase the possibility that the com-
binations you select will not work.
NOTE: For all charts, a difference of I in the factor
indicates a difference of Imm.
3-10 rev. 1985

BOTTOM BRACKETS
CHART A - REPLACING AXLE ONLY
5. Look up the Axle Center Width Factor for the axle

to be replaced. Note which axles have a similar factor.
Axles with a larger factor will leave more threads for
the adjustable cup lockring. Axles with a smaller fac-
tor will leave less threads. A difference of one in the
factor will make a difference of one thread (1 milli-
meter) on the adjustable cup.
6. Look up the Axle End Factor for the axle to be replaced.
Axles with similar end factors will have similar chainwheel
positions. A larger factor will move the chainwheels away
from the frame. A smaller one will move the chainwheels in
toward the frame.
7. Compare the factors of the axle to be replaced and
the new axle you select. Write down the differences
in the axle center width factors and the axle end
factors.
8. See if the combination you want to try is in either of
the sections "Combinations That Don't Work," pages
3-9 and 2-6).
9. Compare the differences to the estimates you made in
steps 3 and 4.
10. Tighten the crank on the axle before installing it on
the bicycle to check the fit. (See page 2-5.)
Example: Replacing a Nervar 117 with a Stronglight 118.

Comparing the center width factors:
Nervar 117 75.5
Stronglight 118 77.0
The difference of 1.5 indicates 1.5 more threads will show
on the adjustable cup.
Comparing axle factors:
Nervar 117 8.5
Stronglight 118 8.0
The difference of .5 indicates the chainwheels will be
moved in 0.5 millimeters.
CHART B-REPLACING COMPLETE BOT~rOM

BRACKET SET ONLY
(Using same brand and model parts for axle, fixed cup
and adjustable cup)
5. Look up the Center Width Factor of the bottom
bracket set to be replaced. Note which sets have a
similar factor. Sets with a larger factor will be wider
when measured across the outside faces of trie cups.
Axles that have smaller factors will be narrower. This
will affect the number of threads the lockring will
screw onto.
(cont.)
rev. 1985 3-11

BOTTOM BRACKETS
CHART B (cont.)
6. Look up the Axle End Factor for the set to be re-
C/) placed. Choose a set with a similar factor. A larger
....u
factor will move the chainwheels away from the frame.
A smaller factor will move the chainwheels in.
z 7. Compare the factors of the bottom bracket set to be
« replaced and the new set you select. Write down the
:c
u
differences in both the center width factor and the
axle end factors.
8. See if the combination you want to try is in the section
(.U "Combinations That Don't Work," page 2-6.
~ 9. Compare the differences in factors to the estimates
(.U you made in steps 2 and 3.
10. Tighten the crank on the axle before installing it on
~
u the bicycle to check the fit (see paragraph on fit be-
tween crank arms and axle page 2-5).
>
u
.... Example: Replacing an SR (Sakae Ringyo) R68 Complete
=
=:
o
Bottom Bracket Set with a Sugino MW 68.
Comparing the Center Width Factors:
SR (Sakae Ringyo) R68
Sugino MW68
66.5
67.5
u.. The difference of 1.0 indicates one more thread will show
~ with the lockrings removed. Comparing the Axle End
o Factors:
o SR (Sakae Ringyo) R68 7.5
=
Q
Sugino MW68 7.0
The ,difference of 0.5 indicates the chainwheels will be
Z moved 0.5 millimeters closer to the frame.
«
:c CHART C (facing page)-REPLACING FIXED (right)
C/) CUP ONLY
~
Q 5. Look up the Fixed Cup Factor for the cup to be

replaced.
Z
«
~
6. Find a cup with a similar factor to replace it with.
If the factor is larger, the cup will be "thicker," the
=:
(.U
chainwheels will be closer to the frame and more
threads will show on the adjustable cup.
7. Compare the differences in factors to the estimates
:cE- you made in steps 2 and 3.
Example: For English cups replacing a Sugino Mighty
::J cup with a Stronglight cup.
C/)
Sugino Mighty 4.0
Stronglight 2.0
This 2.0 difference will move the chainwheels 2.0mm
away from the frame. It will also make 2 less threads
(2mm) show on the adjustable cup.
3-12 1985
BOTTOM BRACKETS
REPLACING ADJUSTABLE CUPS

Adjustable cups are similar in thickness to fixed cups. A thicker
adjustable cup may be substituted when the center width change
indicates too few threads for the lockring to thread onto. A thinner
cup may be used when the center width change indicates too
many threads are showing (or simply use a thicker lockring if
looks are that important.)
SPACERS FOR FIXED CUPS

Cluster spacers or Sturmey Archer spacers work well to move the
axle end out or make the bottom bracket shell wider. Make sure
you have enough threads for the lockring. This does not work for
Italian bottom brackets.
CHART C-FIXED CUP FACTORS
Lockring
Make English French Italian Thickness
Campagnolo
thin 2.0 2.5 2.5 3.0
thick 4.0 4.5 4.0 3.0
Nervar 2.5 2.5 - 3.0
Ofmega
cadmium plated - - 3.0 2.5-4.0
chrome plated - - 3.0 4.0
Shimano
(old) Dura-Ace* pre-'85 1.5 1.5 1.5 3.5
(new) Dura-Ace after '85 4.0 4.0 4.0 3.0
Stronglight 2.0 1.5 2.0 4.0
SR (Sakae Ringyo) 3.5 3.5 - 3.5
Sugino
Maxy 4.5 4.0 4.5 3.5
Mighty 4.0 4.0 4.0 3.5
SunTour 4.0 4.0 4.0 3.0
Specialized 4.0 - - 3.5
TA 2.5 2.0 3.0 5.0
Tange 1.5 - - 3.5
IDC 3.0 - - 3.5
Zeus - - 2.0 -
*Old Dura-Ace cups had larger holes to accommodate a larger diameter

axle. Not interchangeable with others.
rev. 1990 3-13

(,H.
...
~
I
CHART A I. CHART B COMPLETE BOTTOM BRACKET SET ONLY

AXLE ONLY English French Italian
Center Width Axle End . Center Width Axle End I. Center Width Axle End I· Center Width Axle End
No. on Axle Factor Factor Factor Factor Factor Factor Factor Factor
Avocet
Double (USA-new) 20 74.5 6.. 0 67.5 6.0 68.0 5.5 68.0 5.5
Triple (USA-new) 30 75.5 10.0 68.0 10.0 69.0 9.5 68.5 9.5
Double (old style) 2 77.5 7.5 68.0 6.5 68.0 6.5 70.0 5.5
Triple (old style) 3 77.5 12.0 68.0 11.0 68.0 11.0 70.0 10.0
Campagnolo-to match model to axle measurement see
"Campagnolo Axle Information" on page 3-28 through 3-31.
Balls Shell Center Right Cups*
Super Record, (C-)Record
3/16" 68 52 28 Thick Axles not 67.0 3.5 68.0 3.0 68.5 3.5
3/16" 68 52 29 Thick interchangeable 67.0 4.5 68.0 4.0 68.5 4.5
3/16" 68 52 32 Thick with others 67.0 7.5 68.0 7.0 68.5 7.5
3/16" 68 52 33 Thick 67.0 8.5 68.0 8.0 68.5 8.5
Complete sets are
3/16" 70 54 27 Thick interchangeable; 69.0 5.0 70.0 4.5
I
69.5 4.5
3/16" 70 54 28 Thick see 69.0 6.0 70.0 5.5 69.5 5.5
3/16" 70 54 32 Thick interchangeability 69.0 10.0 70.0 9.5 69.5 9.5
notes, page 3-28.
1990- Record
7/32" 68
7/32" 70
52
54
29
28
Thick
Thick } I 67.0
69.0
4.5
6.0 I 70.0
68.0 4.0
5.5 I 69.5
68.5 4.5
5.5
1/4" Ball Axles

1/4" 68 49.5 31 Thick 70.0 6.5 67.0 4.5 68.0 4.0 68.5 4.5
1/4" 68 49.5 33 Thick 70.0 8.5 67.0 6.5 68.0 6.0 68.5 6.5
1/4" 68 49.5 34 Thick 70.0 9.0 67.0 8.0 68.0 7.5 68.5 8.0
1/4" 68 49.5 35 Thick 70.0 10.0 67.0 9.0 68.0 8.5 68.5 9.0
1/4" 68 49.5 39 Thick 70.0 14.0 67.0 13.0 68.0 12.5 68.5 13.0
1/4" 68 49.5 41 Thick 70.0 16.0 67.0 15.0 68.0 14.5 68.5 15.0
1/4" 68 49.5 45 Thick 70.0 20.0 67.0 19.0 68.0 18.5 68.5 19.0
* Cup thickness with which axle is nonnally supplied
1/4" 70 51.5 30 Thick 72.0
1/4" 70 51.5 31 Thick 72.0
1/4" 70 51.5 32 Thick 72.0
1/4" 70 51.5 33 Thick 72.0
1/4" 70 56.5 26 Thin 77.0

1/4" 70 56.5 27 Thin 77.0
1/4" 70 56.5 29 Thin 77.0
1/4" 70 56.5 30 Thin 77.0
1/4" 70 56.5 31 Thin 77.0
1/4" 70 56.5 34 Thin 77.0
1/4" 70 56.5 35 Thin 77.0
1/4" 70 56.5 38 Thin 77.0
1/4" 70 56.5 40 Thin 77.0
1/4" 70 56.5 44 Thin 77.0
~ 1/4" 74 60.5 30 Thin I 81.0

::0
\0
o
~
* Cup thickness with which axle is nonnally supplied
I
ti: ... ,
S3INYH3=:1W =:I'l3A3IH HOd >lOOHONYH S,ONY'lH=:IHLnS
W
I
~
Q\
::0
\0
.0
CHART A CHART B COMPLETE BOTTOM BRACKET SET ONLY
~
-:- AXLE ONLY English French Italian
Center Width Axle End Center Width Axle End Center Width Axle End Center Width Axle End
Galli
Double 2 74.0 11.0 68.0 9.5 68.0 9.5 70.0 9.5 oo~ 00
Triple 3 74.0 17~0 68.0 15.5 68.0 15.5 70.0 15.5 ~ 0
~ ~
0
Nervar
7.5 69.5 7.5 69.5
~~
~ ~
....,
....,
Single 115 76.0 7.0 - -
Double (5 pin) 117 75.5 8.5 69.0 8.0 69.0 8.0 - -
3:~ 0
Double (3, 5 arm)
Triple
121
126
76.0
76.0
12.0
16.5
69.0
69.0
12.0
16.5
69.0
69.0
12.0
16.5
= tr1 ~
~ ~ ~
Ofmega ~O 00
Children's
Track
60C
68 P
67.5
75.5
12.0
5.0
60.0
68.0
11.0
4.0
60.0
68.0
11.0
4.0
60.0
68.0
10.0
3.0
~.~0 ~
"'0
~
~
70P 77.5 4.0 70.0 3.0 70.0 3.0 70.0 2.0 >"
~3: ()
Double 68 C 75.5 8.5 68.0 7.5 68.0 6.5 68.0 5.5 ~ ~ ~
70C 77.5 7.5 70.0 6.5 70.0 5.5 70.0 4.5 Cl~ ~
Triple 68 Ca 75.5 13.0 68.0 12.0 68.0 11.0 68.0 10.0 =->
e; Cl [T1
....,
70Ca 77.5 12.0 70.0 11.0 70.0 10.0 70.0 9.0 r- ~ (1"\
"'0 tr1 v J
Shimano Dura-Ace (also see Maxy-Type Cotterless Axle Chart for other
Shimano Axles)
= z~
~~
Single (Track) - (old) 68 W 107

70 W 109
1 Axle not
68.0
70.0
2.0
1.5
68.5
70.5
2.0
1.5
68.5
70.0
1.5
1.0
~
tf~
Ntr1
~~
Double - (old) BB-7200 68 W 112 > interchangeable 68.0 6.5 68.5 6.5 68.5 6.0 "'-'Cl
BB-7200 70W 113
Double - (old) BB-7300 (7500) 68 S 107
J . h h
WIt ot ers.
* 70.0
68.0
6.0
2.0
70.5
68.5
6.0
2.0
70~0
68.5
5.5
1.5 >
==
BB-7300 (7500) 70 S 109 70.0 1.5 70.5 1.5 70.0 1.0 Z
C1
tr1
Single (Track) BB-7600 68-S 69.0 8.5 68.0 3.5 68.5 3.5 68.5 3.0 >
~
BB-7600 70-S 71.0 8.0 70.0 3.0 70.5 3.0 70.0 3.5 ~
Double • BB-7400 68 W 112 69.0 11.5 68.0 6.5 68.5 6.5 68.5 6.0 ~
~
BB-7400 70 W 113 71.0 11.0 70.0 6.0 70.5 6.0 70.0 5.5 ~
BB-7400 68-W 69.0 11.5 68.0 6.5 68.5 6.5 68.5 6.0 ~
.--...
BB-7400 70-W 71.0 11.0 70.0 6.0 70.5 6.0 70.0 5.5 ~
o
*Axle is larger in diameter and doesn't fit hole in current Dura-Ace cups. ~
=
~
Axle end is also slightly larger (see page 2-7).

,.-..~
~O
~ ~
CHART A CHART B COMPLETE BOTTOM BRACKET SET ONLY >~
AXLE ONLY English r;:~
French Italian Q ~
~~
= trj
~~
Solida 10
Single (Track) 118.5 77.0 8.0 68.5 8.0 68.5 8.5 70.0 8.0 ~~
Double 122 77.0 12.0 68.5 12.5 68.5 12.5 70.0 12.0 :a~
Triple 125 77.0 15.5 68.5 15.5 68.5 16.0 70'.0 15.5 ~ 0
Mountain, BMX 129 77.0 13.5 68.5 13.5 68.5 14.0 70.0 13.5 ~~
;-~
Specialized (1~
Double 107-68 70.5 4.0 67.5 2.0 67.5 2.0 67.5 2.0 =->
109-70 72.5 4.0 69.5 2.0 69.5 2.0 69.5 2.0 = (1
::1~
Campagnolo double (pre '85)112-68 70.5 8.0 67.5 6.0 67.5 6.0 67.5 6.0 VI trj
69.5 5.0 69.5 -c
Triple
113-70
114.5-68
72.5
70.5
7.0
9.5 67.5 7.5 67.5
5.0
7.5
69.5
67.5
5.0
7.5 = ~
~
(JQ
t-T1
VJ
115.5-70 72.5 8.5 69.5 6.5 69.5 6.5 69.5 6.5 ~ Z 0
Campagnolo, TA triple 119.5-68 70.5 14.5 67.5 12.5 67.5 12.5 67.5 12.5 ~~
Itrj ~
(pre '85) ~~
~1(1
Specialized Mountain triple 120-68 70.5 10.5 67.5 8.5 67.5 8.5 67.5 8.5
Campagnolo, TA triple 120.5-70 72.5 13.5 69.5 11.5 69.5 11.5 69.5 11.5 == 0
(pre '85) ~ 3:
Specialized Mountain triple 125-68
Specialized Mountain triple 127-68
70.5
70.5
13.0
14.0
67.5
67.5
11.0
12.0
67.5
67.5
11.0
12.0
67.5
67.5
11.0
12.0
~ to
Sugino Mountain triple 130-68 70.5 16.0 67.5 14.0 67.5 14.0 67.5 14.0
~ ~
Stronglight
70~0 69~5
s:: n
~ [T]
~
Single (Track) 113 78.0 5.0 5.0 5.0 71.0 5.0
Double (w15 pin cranks) 118 77.0 8.0 69.0 8.0 68.5 8.5 70.0 8.0 ,.-..
Double (w/5 arm cranks) 120 76.0 10.0 68.0 10.0 67.5 10.5 69.0 10.0
121 (Peugeot) 77.0 11.0 68.5 11.0 68.5 11.5 70.0 11.0 8 ~
123 77.0 13.0 68.5 13.5 68.5 13.5 70.0 13.0 ~
'-'"
en
Triple 125 77.0 15.5 68.5 15.5 68.5 16.0 70.0 15.5
126 (Peugeot) 77.0 16.5 68.5 16.5 68.5 17.0 70.0 16.5
(i Tandems 130 77.0 20.0 68.5 20.0 68.5 20.5 70.0 20.0
~
~
Tandem Triple 133 77.0 23.0 68.5 23.0· 68.5 23.5 70.0 23.0
\0
o Mountain Bike 134.5 77.0 15.5 68.5 15.5 68.5 16.0 70.5 15.5
~
I
~
.....:J
SOINVHO:fW :f'OAOIO HOd >lOOOONVH S,ONV'H:fHLnS

(.N
SUTHERLAND'S HANDBOOK FOR BICYCL'E MECHANICS
I
l-'
QC
CHART A CHART B COMPLETE BOTTOM BRACKET SET ONLY
AXLE ONLY English French Italian
No. on Axle F.actor Factor Factor Factor Factor Factor Factor Factor
SR (Sakae Ringyo) Royal (for other SRs see Maxy-TypeCotterless

Axle Chart)
Single
Double
T-68-S
R-68
71.0
71.0
5.0
9.5
66.5
66.5
2.5
7.5
66.5
66.5
3.5
8.0
00
~
~~
0
= 0OJ
R-70 73.0 7.5 68.5 5.5 68.5 6.0 69.5 5.5 !.~ ~
Triple R-68-T 71.0 16.0 66.5 14.0 66.5 14.5 ~ ~ ~
1Il
Sugino75, Mighty (for Sugino Maxy see Maxy-TypeCotterless Axle Chart) ~~ 0

Single (Track) MS-68 or
=..t'fj ~
~ =~
MW-68LP 71.0 4.0 67.5 1.5 68.0 2.0 67.5 1.5 ~ 0 I"T'1
~ ~ VJ
Double (Road) MW-68 or i ~ ~

MT-68LP 71.0 9.5 67.5 7.0 68.0 7.5 67.5 7.0 ~ ~ r-.
MW-70 73.0 7.5 69."5 5.5 70.0 5.5 69.5 5.5 ... = \)
Triple MT-68 71.0 13.5 67.5 11.0 68.0 11.5 69.5 11.0
~~ ~
;- ~ [T]
MT-70 73.0 11.5 69.5 9.5 70.0 9.5 69.5 9.5 .::1 ~ ~
~ .~ (f)
SunTour (see Maxy-type chart for other axles) -o~
~
Superbe, Sprint 68-S 70.0 5.5 67.0 3.5 68.0 3.0 68.5 3.5 (JQ>
~..~
70-S 72.0 6.0 69.0 4.0 70.0 3.5 69.5 4.5
Cyclone-Maxy-Taper (Vx) 68-W 70.0 8.0 67.0 6.0 68.0 5.5 68.5 8.0 tf~
N~
70-W 72.0 9.5 69.0 7.5 70.0 7.0 69.5 7.0 ?~
TA,Tevano
"-"z
~
Single (Track) 314 76.0 6.5 69.5 6.0 69.0 6.5 71.0 5.0 ~
Double 344 76.0 9.5 69.0 9.0 68.5 9.5 70.5 8.0 =c
~
Triple
373
374
75.0
75.5
14.0
16.0
68.5
69.0
13.0
15.0
68.0
68.5
13.5
15.5
70.0
70.5
12.5
14.5 =
>
Z
Zeus .~
Single (Track) 109 x 55P 75.0 0.5 68.0 0.5 68.5 0.0 68.0 0.5 ~
Cronos, New Racer 109 x 57P 77.0 -0.5 70.0 -0.5 70.5 -1.0 70.0 -0.5 >
Double (Road) 114 x55C
114 x 57C
118 x 55C
75.0
77.0
75.0
5.0
4.0
9.0
68.0
70.0
68.0
5.0
4.0
9.0
68.5
70.5
68.5
4.5
3.5
8.5
68.0
70.0
68.0
5.0
4.0
9.0
=
~
~
~
~
118x57C 77.0 8.0 70.0 8.0 70.5 7.5 70.0 8.0 ~
Triple 123 x 55T 75.0 14.0 68.0 14.0 68.5 13.5 68.0 14.0 ~
~
Q
123 x 57T 77.0 13.0 70.0 13.0 70.5 12.5 70.0 13.0
=
~
'-'"
BOTTOM BRACKETS
MAXY-TYPE COTTERLESS AXLES
Stamped numbers and letters are consistent enough
among makers that dimensions can be listed. Left sides
may vary among makers.
TAPER ON AXLE END

Two different tapers have been used on Maxy-type axles:
2 0 and 3 o. They can be distinguished by their different
stampings and numbers. 3 0 axles are quite rare, used
mainly with the out-of-production SR Silver crankset. 3 0
axle ends are too wide to fit far .enough into a 2 0 crank
for the fixing nut to engage the axle-end stud.
CRANK AND AXLE COMPATIBILITY

The square taper of 2 0 Maxy-type axles is similar to that
of Stronglight and TA. Maxy-type axles are longer than
most others; for comparison, see axle-end factor in chart.
The square taper of most other cranks and axles,
including top-of-the-line Japanese, is too narrow and/or
short to be compatible.
BOTTOM-BRACKET CUP C,OMPATIBILITY )
Bearing race diameter is smaller than for most other

spindles except English cottered. Do not interchange cups
Nut-type axle without testing position of bearing track (se~ page 3-'8).
BOTTOM-BRACKET SHELL WIDTH

The single-digit number stamped on the axle frequently
indicates the shell width it is to be used with. 3 is for
68mm bottom-bracket shells and 52mm axle centers. 5 is
used for 71nlm shells and 55mm axle centers. 2 indicates a
50.5mm center.
Cup thickness varies, soitmay be possible to use an axle
with a 55mm center with extra-thin cups in a 68mm
bottom bracket, or an ax'Ie with a 52m.m center with
extra-thick cups in a 71Illm bracket.
MAXY-TYPE AXLE
PLEASE NOTE: There are exceptions and additional This position indicates the approximate
letters in the complete axle chart. right (chainwheel) side axle length.
His 30.5mm.
In this position - A, L & J are 32mm.
D - indicates Bolt Type*. P & N are 35mm.
No mark - indicates Nut Type. Sis 37.5mm.
F - indicates SR polished race Bolt Type.
*-B after marking also indicates Bolt Type;
example: D-3NL = 3NL-B. D -3 N L""
This position indicates the
In this position - approximate left side axle length.
2 indicates 65mm bottom bracket width (50.5mm axle center). S means shorter than original.
3 indicates 68mm bottom bracket width (52mm axle center). L means longer than original.
5 indicates'70mm bottom bracket width (55mm axle center---- Original in this example
Shimano 13olt-Type is listed as 54mm). would be a"D-3N axle.
rev. 1990 3-19

~
N•
= ...==o........•
~
\0
o
~
-c
~
@a])==))B@)J
68mm SHELL WIDTH - 2° Series
-'
Low Sugino
Profile Bolt- Bolt- Old Old Axle
~ 00
Crankset
used with
cranksets
used with
Nut-Type
Marking
Type
Marking
Type
Marking
Mark-
ing**
Shimano
Marking A B C D
End
Factor
>
~
o
Sante D-3K*
68-S**
28
31
52
52
28
30
108
114
4.5
6.5
~
~
~
:lo
~
Double 3H D-3H 3H-B 30.5 52 30.5 113 7.0 ~ 3:
3L,3J D-3L 3J-B 68 W 116 32 .. 52 32 116 8.5 r1
Triple 3A D-3A 3K-B* 32 52 33.5 117.5 10.0
o~ 00
Single 3P D-3P 68 W 119 32 52 35 119 11.5 ~
~ ~
3N D-3~
D-3NL
3N-B 68-W** 32
34.5
52
52
36
36
120
122.5
12.5
12.5
~
~
n
~ ~
Mountain 3NN 3NN-B 36 52 en
~
36 124 12.5
Double
en
3SS D-3SS 3S-B 68 T 121.5 32 52 37.5 121.5 14.0
~S, (3S), 3S2 35 52 37.5 124.5 14.0 >
~ en
Mountain 3Y 37.5 52 37.5 127 14.0 ~
~
D-3T 3T-B 32,' 52 39 123 15.5 en
3TM-B 37.5 52 39 128.5 15.5
Double 3f 35 52 39 126 15.5
R3T 39 52 39 130 15.5
3TR-B 42 52 39 133 15.5,
D-3U 3U-B 68-T 32 52 40.5 124.5 17.0
Triple 3U 35 . 52 40.5 127.5 17.0
Mountain 3X 40.5 52 40.5 133 17.0
3R-B 32, 52 42 126 18.5
Triple ~
3R 35 52 42 129 18.5
Mountain 3TR-B 39 52 42 133 18.5
3RR-B 42 52 42 136 18.5
Mountain 3M 35 52 43.5 130.5 20.0
31e 35 52 45 132 21.5
*Despite similar markings D-3K and 3K-B are not interchangeable.
**Old markings - do not confuse with current Dura-Ace markings.
70mm SHELL WIDTH - 2° Series
Low Sugino ::
Profile Bolt- Bolt- Old Old Axle >
Crankset cranksets Nut-Type Type Type Mark- Shimano End
><
~I
used with used with Marking Marking Marking ing** Marking A B* C D Factor ~
~
Sante D-5K 27 54 27 108 3.5 ~
~
Double 5H D-5H 30.5 55 30.5 115 7.0
C1
5L ·D-5L 5J-B 30.5 55 32 117.5 8.5 o
5LL D-5LL 70W 119 32 55 32 119 8.5 ~
~
Triple 5A D-5A 31 54 32.5 117.5 9.0 ~
5P D-5P 30.5 55 33.5 119 10.0 ~
~
70-W** .32 55 34 121 10.5 ~
00
Single 5N 5N-B 70W 122 32 55 35 122 11.5 00
D-5NL 33.5 55 35 122.5 12.0 >
Double 5SB 32 55 36 123 12.5 ><
~
5SP D-5SP 30.5 55 37.5 121 14.0 ~
00
5SS D-5S 5S-B 70 T 124.5 32 55 37.5 ' 124.5 14.0
5S, (5S) 35 55 37.5 127.5 14.0 ----
~
o co
itt·
70-T 32 55 38.5 125.5 15.0 =
~ a
~
~
Double Sf . Di 5T 5T-B 35 "\'

55 39 129 15.5
D~5U 5U-B 32 55 40.5 127.5 17.0
Triple 5U 35 55 40.5 130.5 17.0 a
5R 35 . 55 42 132 18.5 3:
*Shimano lists bolt-type as having 54mm centers and nut-type as having 55mm center. co
**Old markings - do not confuse with current Dura-Ace markings.
~
65mm SHELL WIDTH - 2° Series n
~
Axle
Nut-Type End ~
(f)
Marking A B C D Facts,r
68S 32 50'.5 32.5 115 9.0
.'
68K 32 50.5 36 118.5 12.5
2S 32 50.5 37.5 120 14.0
~
o 2R 32 50.5 42 124.5 18.5 A B c
~
I
~~ ,
S3IN\f1-l3:JW :J'13A3IH 8.0d >lOOHON\f1-l S,ON\f'18:JI-I~nS

BOTTOM BRACKETS
MEASURING CARTRIDGE-BEARING UNITS

FOR THREADED BOTTOM BRACKETS
Sealed Bottom Brackets with Mounting Rings

(mounting rings not shown)
total length
left length center width right length
(does not include
mounting rings)
I
[ ]
.-
Bottom Brackets with Cartridge Bearings Mounted in Cups
total length
[ ]
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3-22 rev. 1985

Bullseye Rollerbracket
Axles come in 1/4" increments from 4 1/4" to 5-1/2". Chainline is adjustable.
Use with Model Taper Note Length

For uses compare axle 41/4" Universal User adjustable end factors total 3.0 108
lengths to Phil for 41/2" Universal User adjustable end factors total 9.5 114.5
rough equivalents 43/4" Universal User adjustable end factors total 15.5 120.5
5"
5 1/4"
Universal
Universal
User adjustable end factors total
User adjustable end factors total
22.0
28.5
127
133.5
~
5 1/2" Universal User adjustable end factors total 35.5 139.5 ~
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Edco ~.
Installation: Edco bottom brackets are available with English, French and Italian threading. Use standard bottom-bracket ~
tools. Also available is a friction clamp that allows installation in unthreaded or stripped bottom-bracket shells. =
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Left Right a
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Use with Taper
Axle End . Left
Factor Length
Center
Width
Right
Length
Axle End Total
Factor Length
~ o~
Double
Triple
Campagnolo
Campagnolo
6.0
6.0
23
23
67
67
26
30
9.0
13.0
116
120
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FAG
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Model numbers below are preceded with L66BSA for English, L66FRA for French and L66ITA for Italian.
Chainline is not adjustable. Cottered ends are also available.
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Left Right
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Axle End Left Center Right Axle End Total ~~
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Use with Model Taper Factor Length Width Length Factor Length
Double Vl19/23 Maxy-type 8.0 22 73 25.5 11.5 119
EVl19/23 Campagnolo 7.0 22 73 25.5 10.5 120
Triple V127/25 Maxy-type 14.0 27 73 27 14.0 127
to
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o EV127/25 Campagnolo 13.0 27 72 27 13.0 127
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Mavic
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Identification: Old style 600 series had flat conventional lock rings. 610 series have lockrings that mate to a beveled
bottom bracket shell. The bottom bracket shell must be beveled with special Mavic cutting tool 652/653.
610 URD is the current model designation.
Chainline is adjustable. =n
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Left Right
Axle End Left Center Right Axle End Total
~8 ~
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Track 610URD 110 Campagnolo 3.5 16 78 16 3.5 110 ~~ ~
Track 611RD Campagnolo 4.5 17 78 17 4.5 112 n= CO
Double 610URD 114 Campagnolo 6.5 18 78 18 5.5 114 ~~
Double long 610 URD 116 Campagnolo 6.5 18 78 20 7.5 116 ~==
~~
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612RD Campagnolo 6.5 18 78 20 7.5 116 ~~ n
Triple ,610 URD 119 Campagnolo 6.5 18 78 23 10.5 119 =~ ~
Campagnolo 6.5 18 78 25 12.5 121 ?-Z
~
613RD ~~
Triple long 610 URD 123 Campagnolo 7.5 18 78 27 14.5 123 ~
00 (j)
613LRD Campagnolo 8.5 18 78 29 15.5 125
~
Mt. Bike 615RD Campagnolo 16.5 28 78 28 15.5 134 o
Mt. Bike ==
~
Symmetric VTT 616 RD 124
VTT 616 RD 134
Campagnolo
Campagnolo
11.0
16.0
18
23
88
88
18
23
10.5
15.5
124
134 =
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Nadax
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Installation: Use standard bottom-bracket tools. Unlike most others, Nadax sealed units do not allow chainline adjustment. t='
Left Right
Axle End Left Center Right Axle End Total
Campagnolo double #2 Universal 5.5 19.0 76 20.0 8.5 113
Campagnolo triple #3 Universal 8.0 21.5 76 23.5 12.0 119
Phil
All crank bearings are adjustable from side to side. =n
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Installation: Use Phil Wood mounting rings and tool. English, French, Italian, Raleigh and Chater Lea threading is available.
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Cottered axles are also available. S~
All crank bearings can be ordered with custom axle end factors. ~e
(:ompatibility with other brands: Construction is similar to SunTour. Phil mounting rings can be used with SunTour =~
cartridges; however, SunTour mounting rings are too loose for Phil axles. Width of axle center between bearings is different. ~~
Left Right n=
Axle End Left Center Right Axle End Total ~~
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~~
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Track, Campagnolo 'f)~ o
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Low-Profile double #1 Universal 4.5 24 60 24 4.5 108 =~
Campagnolo pre- '85 #2 Universal 5.5 25 60 28 8.5 113
F-Z
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double 00
Campagnolo pre-'85 ~
triple, o OJ
TAdouble, ==
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Stronglight double, = (J
Deore triple,
Mountain bike #3 Universal 8.0 27.5 60 31.5 12.0 119 ~
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TA triple,
Stronglightdouble #4 Universal 8.0 27.5 60 37.5 18.0 125 o en
Tandem crossover #5 Universal 15.5 35 60 35 15.5 130
Mountain bikes, BMX #6 Universal Custom Custom 60 Custom Custom 135
Mountain bikes, BMX #7 Universal Custom Custom 60 Custom Custom 140
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Stronglight
Identification: Dimensions of all Stronglight series are very similar.
600: All steel unit. 700: Aluminum cartridge threaded at ends for lockrings
650: Titanium axle, aluminum cups. Chainline not adjustable. Assembles 701: Same as 701 but full-length threads. Recommended OJ
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like a conventional bottom bracket, except has cartridge bearings.
651: Same as 650 except with steel axle.
for aluminum frames.
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Left Right S~ ~
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Usewith Model Taper
Axle End
Factor
Left
Length
Center
Width
Right
Length
Axle End
Factor
Total
Length =~
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Double 600,650,651,700,701 Stronglight 6.5 19.75 77 21.25 8.0 118 ~~ ~
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Triple 600,650,651,700,701 Stronglight 6.5 19.75 77 27.25 14.0 124 ~~
~ ...
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Sugino =~ ~
Identification: These are cartridge bearing units in individual cups, like the Stronglight 650.BB-SC Series.
F-Z
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[T]
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00 (j)
Left Right ~
Axle Axle End Left Center Right Axle End Total o=c
Use with Marking Taper Factor Length Width Length Factor Length ~
Single Mighty MS Mighty 9.0 16.0 75 18.0 3.5 114.5 =
Double Mighty, Guines
Double Maxy, others
Mountain bike
MW,Guines
SB
RRB
Mighty
Maxy-type
Maxy-type
9.0
10.5
18.5
16.0
16.0
24.0
75
75
75
21.5
26.0
31.0
7.5
14.0
19.0
118.5
129
136
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SunTour
t:=C1
Identification: The "Sealed Bottom Bracket" is a single-unit cartridge 60.5mm long with mounting rings, similar to Phil Wood. SS 0>
series dimensions are identical to SA series, but SS is heavier. The "Direct Sealed Bottom Bracket" uses the same axles, but the ~~
bearings are installed into cups; the central shell is installed when unit is assembled into bicycle. ~~
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Installation: Use SunTour tool #TA-230. Mounting rings or cups are available in English, French and Italian threading. Follow ~S
instructions for installation using lockrings. t:=C1
~~
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"SEALED BOTIOM BRACKET" (Series SA and SS)
~~
Left Right ~>
Axle Axle End Left Center Right Axle End Total ~~
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Use with Marking Model Taper Factor Length Width Length Factor Length r;'.C1
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Track
Double
SPB-TK
SPB-RD
SA-IOO,
SA-110,
SS-100
SS-110
Campagnolo (Superbe)
Campagnolo (Superbe)
3.0
7.5
23.5
28.25
60.5
60.5
23.75
28.25
3.0
7.5
108
117 .aZ
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~
Triple SPB-RD3S SA-120, SS-120 Campagnolo (Superbe) 5.5 26.25 60.5 33.25 13.0 120 rJj
Campagnolo (Superbe) 13.5 34.5 60.5 31.0 10.5 ~

BMX SPB-MX SA-130, SS-130 126 o
Double VX-RD SA-190, SS-190 Maxy-type (Vx) 5.0 24.25 60.5 32.25 13.0 117 ~ OJ
Triple VX-RD3S SA-160, SS-160 Maxy-type (Vx) 10.5 29.75 60.5 35.75 16.5 126 ~ o
BMX
Mountain
VX-MX
VX-MB
SA-140,
SS-150
SS-140 Maxy-type (Vx)
Maxy-type (Vx)
12.0
15.5
31.0
34.75
60.5
60.5
34.5
35.25
15.5
16.5
126
131
==
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"DIRECT SEALED BOTIOM BRACKET" (DS Series) OJ
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Identification: DSBB ("Direct Sealed Bottom Bracket") is a single-diameter cartridge 64mm long, available in English thread only, for BMX and
mountain bike. Do not confuse with SunTour Type A, which has a stepped cartridge 60.5mm long. Cups use lockrings; available in English only.
Installation: Use standard bottom-bracket tool set.
»
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~
Left Right [T1
Axle End Left Center Right Axle End Total ~
Length (f)
Use with Axle Marking Model Taper Factor Width Length Factor Length
BMX DSBB-VX-MX DS-200, DS-210 Maxy-type (Vx) 12.0 29.25 64.0 32.75 15.5 126
Mountain DSBB-VX-MB DS-220~ DS-230 Maxy-type (Vx) 16.5 33.5 64.0 33.5 16.5 131
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1.0
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BOTTOM BRACKETS
•
CAMPAGNOLO BOTTOM BRACKET IDENTIFICATION
MARKINGS
Number in this position Letters in this position
indicates bottom bracket indicate intended use:
shell width in mm. SS - Road
" P - Track
" / SP - Road or Track
68-88-120- Road axles (marked SS) with a
X3 3-digit number here are pre-1978.
X3 indicates the axle ~ The 3-digit number was used
was intended for to indicate ideal rear hub width,
triple chainwheels. 120 in this example. This number
lasted longer for track axles.
When identifying Campagnolo Bottom Brackets it is best to use all the available
evidence. Start with the marking on the axle. There are many different axles with
the same marking, so next identify the ball sizes it is used with. Most axles use
1/4" balls. Axles with a Imm step between the bearing surface and the main shaft
use 3/16" or 7/32" balls. Next measure the axle center to determine if it normally is
used with thick cups or thinner cups (see column B). Then, if needed, measure the
right side, the left side and the overall length to confirm you have an exact match.
In the tables under cups, rifled refers to the spiral grooves in the hole
INTERCHANGING CAMPAGNOLO BOTTOM BRACKET PARTS

Ball sizes cannot be interchanged. Each axle is designed for a specific ball size
and cup size and cannot be mixed.
Interchanging Complete Bottom Bracket Sets (Axle, Cups and Ball
Cages)
Generally, complete bottom bracket sets with the same overall length of axle and
marked with the same shell width can be interchanged without moving the
chainline.
Examples: The following complete bottom bracket sets are interchangeable:
68-SS Chorus length Illmm
68-SS Croce d'Aune length Illmm
68-SS (C-)Record length Illmm
Interchanging Bottom Bracket Axles only
Generally bottom bracket axles that use the same ball size and have the same
length, and same center size can be interchanged without moving the chainline.
Example: The following bottom bracket axles are interchangeable:
68-P-120 (old) Record Track length I09mm
68-SS Victory length 109mm
Moving the chainline:
Substituting a 68-SS Chorus axle at Illmm for a 68-SS Victory axle at I09mm
will move the chainline out Imm. Studying the charts carefully and noting the
similarities of the dimensions will show many other substitutions that are possible
when moving the chainline is permissible or needed.
Interchanging Cups
Super Record cups interchange with (C-)Record (pre-1990 with 3/16" bearings) cups
Croce d' Aune cups interchange with Nuovo Record cups. Chorus cups
interchange with Athena, Triomphe, (old) Record and Gran Sport cups. Thick,
sealed cups for mountain bikes are the same thickness for spacing purposes as
thick, rifled hole cups.
3-28 1990
BOTTOM BRACKETS
CAMPAGNOLO BOTTOM BRACKET DIMENSIONS

Pre-1978 Bottom Brackets (If the marking +1.0-+1.5 appears in
addition to the other markings see 1978 axles note below.)
Super Record with 3/16" balls

No.-size
Balls Marking Chain-
/cage on Axle A B C D Cups wheels Models
14-3/16" 65-P-110 25 54.0 25 104 thin* Track Super Record
14-3/16" 68-SS-120 29 52.0 32 112 thick, rifled* Double Super Record

14-3/16" 70-SS-120 29 54.0 30 113 thick, rifled* Double Super Record
* Aluminum with steel insert
1/4" Ball Axles

11-1/4" 65-P-110 26 51.5 26 104 thin Track (old) Record
11-1/4" 68-SS-120 29 49.5 33 112 thick, rifled* Double Nuovo Record

11-1/4" 68-SS-120 27 54.5 30 112 thin Double (old) Record, Gran Sport
11-1/4" 68-SS-120 27 54.5 35 117 thin Triple (old) Record, Gran Sport
X3
11-1/4" 70-SS-120 30 51.5 31 113 thick, rifled* Double Nuovo Record

11-1/4" 70-SS-120 27 56.5 35 118 thin Triple (old) Record, Gran Sport
X3
1978 Axles
In 1978, Campagnolo double and triple crank arms and axles were modified. Track
cranks and axles were not changed. The double and triple axles were lengthened
1.0mm on the left and 1.5mm on the right. The axle markings in 1978 were the
pre-1978 markings with +1.0-+1.5 added. What is now marked 68-SS was
marked 68-88-120+1.0-+1.5. These long, confusing markings lasted about a year
and were replaced by the markings 68-88, 70-S8, 68-88 X3 and 70-,88 X3 for
the corresponding axles. The letter Z found on many pre-1978 axles was dropped
in 1978. To identify the crank arms, look at the collar around the axle hole on the
back of the arm. The pre-1978 style has a raised collar 5-6mm wide and 2mm
high. The 1978 and later crank arms collars were 10mm wide and 3mm high.
1979 thru current Bottom Brackets
Changes: In 1978 road axles for double chainwheels became 1.0mm longer on the
left side and 1.5mm longer on the right than the corresponding pre-1978 axles. The
rear hub width marking on the axle was dropped for road hubs.
In 1985 the 109 axles were lengthened to 111 by adding 1mm to each side.
1990 3-29
...
BOTTOM BRACKETS
•
CAMPAGNOLO BOTTOM BRACKET DIMENSIONS (cont.)
1979 thru current Bottom Brackets
Super Record, (C-)Record and (1990 - current) Record
These axles have a Imm step between the bearing surface and the main axle shaft.
No.-size
Balls Marking Chain-
/cage on Axle A B C D Cups wheels Models
14-3/16" 65-SP 30 49.5 30 109 thick, rifled * 1 or 2 (C-)Record
14-3/16" 68-SP 28 52.0 28 109 thick, rifled * 1 or 2 (C-)Record (same as 109mm 68-SS)
14-3/16" 68-SS 28 52.0 28 109 thick, rifled * 1 or 2 (C-)Record (same as 109mm 68-SP)
14-3/16" 68-SS 30 52.0 33 114.5 thick, rifled * Double Super Record Road
14-3/16" 70-SP 27 54.0 27 109 thick, rifled * 1 or 2 (C-)Record (same as 109mm 70-SS)
14-3/16" 70-SS 27 54.0 27 109 thick, rifled * 1 or 2 (C-)Record (same as 109mm 70-SP)
14-3/16" 70-SS 30 54.0 32 115.5 thick, rifled * Double Super Record Road
14-7/32" 68-SP 29 52.0 29 111 thick, rifled * 1 or 2 (1990-current) Record

14-7/32" 70-SP 28 54.0 28 111 thick, rifled * 1 or 2 (1990-current) Record
* Aluminum with steel insert
D
1< - _.....-r---4--------~--____.
!
IS<D
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.....____-
r=- - - + - - + - - - - ~-~---- - - - - - . - . . . + - - - + - - ----r--t:::::::::..::.~-
C:><:D ~
A -: : B ::-~ C
3-30 1990
BOTTOM BRACKETS
CAMPAGNOLO BOTTOM BRACKET DIMENSIONS (cont.)

1979 thru current Bottom Brackets (cont.) (/)
1/4" Ball Axles
Parenthesis around the marking sometimes indicates the axle is for use with thick cups such
c::
~
as the Croce d'Aune and therefore has a narrower center than the axles used with thin cups.
:c
No.-size m
Balls
/cage
11-1/4"
Marking on Axle
68-SS
A
27
B
54.5
C
27
D
109
Cups
thin
Chain-
wheels
Double
Models
Victory
=
r-
>
11-1/4" 68-SS 27 54.5 30 112 thin 2 or 3 Triomphe double, Victory triple
:z
11-1/4"
11-1/4"
11-1/4"
68-SS or 68-SS A
68-SS or 68-SS B
68-SS or 68-SS G*
31
28
30
49.5
54.5
54.5
31
28
111
111
114
thick, rifled**
thin
Double
Double
Croce d'Aune
Chorus o"
30 thin Double Athena - black (/)
11-1/4" 68-SS G* 31 54.5 31 116 thin Double Athena - black (current)
11-1/4" 68-SS F 31 54.5 31 116 thin Double Xenon - black :c
11-1/4"
11-1/4"
68-SS FI
68-SS
33
31
49.5
49.5
33
34
117.5
114.5
thick**
thick, rifled**
Double
Double
Xenon - black
Nuovo Record >
:z
11-1/4" 68-SS 28 54.5 32 114.5 thin Double (old) Record, Gran Sport
o
11-1/4"
11-1/4"
68-SS X3
68-SS X3
28
30
54.5
54.5
35
38
117.5 thin
123 thin
Triple
Triple
(old) Record - grey
Gran Sport - black =
o
11-1/4"
11-1/4"
68-SS X3-M
68-SS X3-M
41
41
49.5
49.5
41
45
132
136
with
with
seal**
seal**
Triple
Triple
Euclid 132 (with center bulge)
Euclid 136 (with center bulge) o
11-1/4" 68-SS X3-M SPE 45 49.5 45 140 with seal** Triple Euclid 140 (with center bulge) ~
11-1/4" 68-SS X3-S 35 49.5 35 124 with seal** Triple Centaur 124 - black
'TJ
11-1/4" 68-SS X3-S SPE 39 49.5 39 132 with seal** Triple Centaur 132 - black
o
=
11-1/4" 68-SS X30 35 49.5 35 124 with seal** Triple Olympus 124 - black
11-1/4" 68-SS X30 SPE 39 49.5 39 132 with seal** Triple Olympus 132 - black
11-1/4"
11-1/4"
11-1/4"
70-SS
70-SS
70-SS or 70-SS A
26
27
30
56.5
56.5
51.5
26
29
30
109
113
111
thin
thin
thick, rifled **
Double
2 or 3
Double
Victory
Triomphe double, Victory triple
Croce d'Aune
=
...
n
nr--<
11-1/4" 70-SS or 70-SS B 27 56.5 27 111 thin Double Chorus
11-1/4" 70-SS or 70-SS G 29 56.5 29 114 thin Double Athena - black
11-1/4" 70-SS F 30 56.5 30 116 thin Double Xenon - black
11-1/4"
11-1/4"
70-SS FI
70-SS
32
31
51.5
51.5
32
33
117.5
115.5
thick**
thick, rifled**
Double
Double
Xenon - black
Nuovo Record
m
11-1/4" 70-SS 28 56.5 31 115.5 thin Double (old) Record, Gran Sport 3:
70-SS X3 29 56.5 37 122 thin Triple (old) Record - grey m
11-1/4"
11-1/4" 70-SS X3 30 56.5 38 124 thin Triple Gran Sport - black n
11-1/4" 70-8S X3-M 40 51.5 40 132 with seal** Triple Euclid 132 (with center bulge) :c
11-1/4" 70-SS X3-M 40 51.5 44 136 with seal** Triple Euclid 136 (with center bulge) >
11-1/4"
11-1/4"
11-1/4"
70-SS X3-M SPE
70-5S X3-S
70-SS X3-S SPE
44
34
38
51.5
51.5
51.5
44
34
38
140
124
132
with seal**
with seal**
with seal**
Triple
Triple
Triple
Euclid 140 (with center bulge)
Centaur 124 - black
Centaur 132 - black
...
:z
n
11-1/4" 70-SS X30 34 51.5 34 124 with seal** Triple Olympus 124 - black (/)
11-1/4" 70-SS X30 SPE 38 51.5 38 132 with seal** Triple Olympus 132 - black
*68-S5 G was first produced as 114mm then 116mm.
**For spacing purposes thick, rifled hole cups, cups with a seal and thick
Xenon cups are the same thickness.
1990 3-31
BOTTOM BRACKETS
•
1990 rev.
FREEWHEELS 0
MULTI-SPEED FREEWHEEL-HUB SHELL
O
~.
BALL SIZES 1/8"
· freewheelballs IS
CountIng · a waste of time. It is better to use
one or two too few balls than too many.
THREAD SIZES
ISO* 1.375" x 24 TPI (34.92 mm x 1.058 mm)
English 1.370" x 24 TPI (34.80 mm x 1.058 mm)
French 34.7 mmx 1 mm (1.366" x 25.4 TPI)
Italian 35 mm x 24 TPI (1.378" x 1.058 mm)
Country of manufacture does not indicate thread dimensions.
Most freewheels imported into 'this country have English
threads. English, Japanese and USA bicycles generally come
with English threaded freewheels. French bicycles generally
come with French threaded freewheels; however, recent
Peugeots and some others use English threaded freewheels.
Italian bicycles generally use Italian thread.ed freewheels.
Stop and measure before forcing a freewheel.
A check with a thread pitch gauge will separate French from
Italian and English threads. English and Italian hub threads
can be distinguished by measuring with a vernier caliper. A 2"
micrometer, however, is the preferred tool. This method may
.. not work on some hubs.
FREEWHEEL INTERCHANGEABILITY
ISO
Hub
English
Hub
French
Hub
Italian
Hub
ISO Freewheel A A c** A
English Freewheel A A c** B***
French Freewheel c** c** A c**
Italian Freewheel A B*** c** A
Class of Fit
A Made to fit.
B Will fit and be serviceable but will damage threads slightly.
C Looks like it might work but won't.
*See Appendix for ~more details on ISO standards.
**Difference in thread pitch makes this combination
unacceptable.
***This combination works, but avoid changing back and
forth betweeOn Italian and English freewheels. Not for
strong or heavy riders.
rev. 19854-1
o FREEWHEELS
ID MARKINGS ON FREEWHEEL BODIES

Markings on freewheel bodies are only found on more recent models.
Atom
English rectangular punch mark on back of body
French no mark
1\laeda
English no mark
French M stamped in inner ring of body on outside
Maillard-see Atom
Normandy-see Atom
Regina
Old Marking
English F.I. stamped in back
French F.F. stamped in back
Italian nothing stamped in back
Current Marking
ISO 3 grooves in back
English 1 groove in back
French 2 grooves in back
Italian no grooves in back
Zeus
English B stamped in back
French M stamped in back
ID MARKINGS ON HUBS
Campagnolo
Old Marking-between spoke hole flange and freewheel threading
English 1 groove
French no groove
Italian no groove
Current Marking
marked with thread size
Ofmega-marking between spoke hole flange and freewheel
threading
English 1 groove
French 2 grooves
Italian no grooves
Zeus
English B.S.C. stamped on center shaft of the hub
French nothing stamped on center shaft of the hub
4-2 rev. J985

FREEWHEEL SPACERS
FREEWHEELS G
Campagnolo 1, 1.5, 2mm
Sturmey Archer HMW127 1/16" (1.6mm)
Raleigh 1/32" (.8mm), 1/8" (3.2mm)
Cyclo (French) 1.2, 1.7mm
MOUNTING FREEWHEELS
FACTORS TO CONSIDER
1. Hole in freewheel has to be large enough to fit over

locknuts of hub.
2. Before you put it on, make sure you can get it off.
See "Problems to Avoid."
3. Match the threads with the hub.
4. Be aware of any chainline changes. Note the offset
differences on the freewheel back. Also see hub section
page 10-5.
5. Check outside clearance, especially clusters with out-
side chainguard. Will they clear seat stay, chain stay
and derailleur mounting bolt?
6. Be sure faces of freewheel and hub that butt together
-are compatible, i.e. Regina Scalare (close ratio) has
recessed face that may not butt properly on some hubs.
7. Is a new chain necessary?
+ PROBLEMS TO AVOID
Don't use an old style Shimano splined' freewheel on
Campagnolo, Shimano Dura Ace or similar hub. It comes
off only after removing axle from other side.
Mount splined Atom, Zeus, or Regina to a Campagnolo
or similar hub only if you have a Phil tool.
Before installing a freewheel on a sealed bearing hub, be
sure you can get it off. Atom-type splined freewheels
can only be removed with a Phil remover or by disassembly.
Old style Shimano splined freewheels must be disas-
sembled to be removed from Phil, Hi-E, Weyless, and oth-
er sealed bearing hubs.
Always remove the freewheel before cutting the spokes
out of a wheel.
12mm tandem axles are too big for the holes in many
freewheel pullers. Current Bicycle Research tools have
clearance for 12mm axles.
4-3
G FREEWHEELS
REMOVING FREEWHEELS
FACTORS TO CONSIDER
Fit for notch tools
1. Tool must be in good shape.
2. Dogs must closely fit notches.
3. Tool must butt against body, not bottom of notch.
4. Tool must be properly located against body or axle
or both, to ensure the dogs stay properly engaged when
force is applied.
5. Tool must be secured with quick release or axle nut
to break freewheels loose.
6. With remover clamped in a vise, press down at rim
while turning to remove.
Dogs that are too long prevent the rim from seating on
the body. This allows the remover to rock and the dogs
to climb up and strip the body.
If stripped, chisel off the chewed-up part on a Regina
notched-type freewheel. Often it will chip off square.
Then start again.
Current Bicycle Research tools all have clearance for
I2mm tandem axles.
FREEWHEEL REMOVING TOOLS

Combinations of freewheels and pullers are listed as
"A", "B", or "B-". An "A" fit is probably the most
successful combination and, if properly secured and lo-
cated, won't result in any damage to the freewheel or
tool. With a "B" fit there is some chance of damage to
the freewheel and tool. A "B-" fit is more likely to
damage both tool and freewheel; but if you have to re-
move freewheel to throw it out, it might be worth it.
,Not all combinations that work are listed. If you try
others, be sure to follow the recommendations listed
under' 'Factors to Consider."
If all else fails, you can remove a freewheel by dismantling
it. Exceptions to this are the old style Winner.
MARKINGS ON VAR TOOLS WITH QUICK

RELEASE THREADS
See page 10-10.
4-4
TOOLS FOR REMOVING MULTI-SPEED FREEWHEELS
FREEWHEELS G
Make of Freewheel Class of Fit-Tool Notes
Atom - splined A Atom (splined) With Phil Tool, removing axle
Bicycle Research spacers is not necessary. Be sure tool
CT-1 Atom is well seated. Keep a sawed-off one
Phil Tool for hubs that don't allow tool to seat
Var 407,401 fully.
Zeus (splined)
Regina 805032 Atom-style splined removers are not
all the same size due to tolerances.
Keep several around to match
different freewheels. Too loose a fit
or one that doesn't go in all the way
can cause trouble.
-notched B Var 186
VarOl
B- Bicycle Research
CT-1 Regina
Caimi-Everest-Simplex B Bicycle Research
CT-1 Regina
Campagnolo 704
Kingsbridge 101
Shimano Dura-Ace
(new style)
B- Cyclo (English)
Kingsbridge 100
Shimano Dura-Ace
(old style)
Var 186
Var 188
VarOl
Campagnolo A Campagnolo 0520/40
Kingsbridge 115
Var404
Bicycle Research CT-9
Cyclo (English) A Cyclo (English) French and English Cyclos are
Kingsbridge 100 completely different.
Cyclo (French) A Cyclo (French) DR.64 French Cyclo tools will fit over the
B Kingsbridge 100 large locknuts found on New Star
Var 188 hubs. English and French Cyclos are
completely different.
Cyclo-Pans (French) A Use tool that comes SunTour tool can be modified to
with the freewheel work by filing the outside of the
DR.68, DR.P dogs.
Maeda -See SunTour
1990 4-5
FREEWHEELS
TOOLS FOR REMOVING MULTISPEED FREEWHEELS (cont.)
Maillard, Sachs
-splined Aris see Shimano splined after
(1990) 1985 (UG)
-notched Aris, A Maillard 409,410 & 411 411 has a special skewer.
700 Kingsbridge 110
Var413
B- Shimano Dura-Ace
(old style)
Var 186
-splined (old) See Atom (splined)
-large diameter A Var 412 large diameter
hole with 6-s10ts remover with 6 bumps
-Helicomatic A Maillard 415 wrench Remove ring with special wrench,
Var 524 wrench then pull freewheel off.
Merveille A EldiBGM Threads that mate with the hub go
Var 187 B straight through. You will have to
B- Regina single-speed remove the two smallest sprockets
remover before using the Eldi tool. Var 01 may
Var01 have to be filed slightly to match.
Milremo-splined See Atom splined
-Pans See Cyclo Pans
-2 notch See Atom notched
Normandy A Bicycle Research
CT-3 Normandy
Maillard 408
Var405
Regina - splined A Regina 805032
Phil Atom Tool
Var401
See also Atom splined
-notched A Bicycle Research Campagnolo adaptor (704/1) for 13-
CT-1 Regina tooth cogs and 6 speeds lacks the ring
Kingsbridge 101 that prevents sideways slippage. The
Shimano Dura-Ace Campagnolo remover #1 remover can
(new style) be modified to fit a freewheel with 13
B Kingsbridge 100 teeth by grinding off the outside dogs.
This modification means you can't
B- Cyclo (English) tum the remover block over when it
(some) becomes. worn or use it for single
Var01 speed sprockets. New Bicycle
Var 186 Research fits 12-tooth Regina.
Var 188
Sachs-Huret See Maillard
4-6 1990
FREEWHEELS 0
Schwinn Approved See Atom splined or Shimano Pre-'85 splined'for small-diameter
internal splined cogs.
See Normandy for large-diameter intemal-splined cogs.
See SunTour or Atom for notched cogs.
Shimano Splined Freewheels
Pre-1985 A Bicycle Research Tool outside diameter 20.1 mm.
-old style CT-4 Shimano Shimano old style splined freewheel
splined Shimano TL-FW20 will not fit on a Shimano Dura-Ace
A Type (A type) hub. A 17-mm hex locknut will just
Var411 fit through the splines in an old-style
splined freewheel.
After 1985 A Bicycle Research Tool outside diameter 22.6 mm.
-new style CT-6 Shimano Removing axle spacers is not
splined CT-6MB necessary.
BType Shimano TL-FW30
(B type-UG) Bicycle Research CT-6MB is a
Uniglide MF-1500 Var414 heavy duty version for mountain
MF-1600 bike and tandem use. Nuts and
600 EX MF-6208 spacers must be removed to use it.
Sante MF-5000
Dura-Ace MF-7400
(no name) MF-Z012
Shimano Notched Freewheels

-Dura-Ace B Shimano Dura-Ace Very old style has flush surface
very old style (very old style) (threaded flange doesn't protrude
B- Var 186 above the freewheel's adjusting
cone).
-Dura-Ace A Bicycle Research On old-style freewheels the threaded
old style, CT-l Regina flange protrudes above adjusting
600 Kingsbridge 101 cone face. Shimano Dura-Ace very
See also 600 EX Shimano TL-FWI0 old and old-style freewheel tools are
MF-7160 B Cyclo (English) not interchangeable; be sure to use
MF-6160 Kingsbridge 100 the correct one. Tighten the tool
MF-6150 Var 188 down extra snug. Old style has ring
to locate tool on body. Very old
style tool has two dogs.
-600 EX See above tools for Remove black ring with a pin tool,
(with black ring Dura-Ace old style, 600 then use tools listed for Dura-Ace
inside smallest old style, 600. To avoid removing
sprocket) ring use Bicycle Research CT-600
MF-6207 carefully.
1990 4-7
FREEWHEELS

Shimano Freehub
-Freehub A Shimano Freehub Tool works like a gear puller. For
for pressed on removal tool pressed-on Freehub-typeJ body
freewheel body (TL-FH30) found on 600AX, AX, 600 EX 7-
speed.
-Freehub A Shimano Freehub Bolt-like tool
Dura-Ace, (TL-FW10)
Dura-Ace EX
-Freehub A 10mm hex wrench
freewheel body
held on with
10mm hex bolt
-Freehub on Not removable
steel hub shell
-Hyperglide A Shimano TL-HG15
sprocket locknut Bicycle Research
CT-6 Shimano
Shimano Other
-Automatic A Shimano Automatic Freewheel must be partly dismantled
before removal.
Reassembly is easy.
-FF System A Shimano A type Remove outer locknut anti spacers to
Friction gain access to splines.
Freewheel
Simplex See Caimi-Everest-Simplex
SunTour (Maeda) A Bicycle Research Bicycle Research has reinforced
Winner, Winner- CT-10 dogs.
Pro, and ex SunTour TA-320
-4 notch
-MicroLite A SunTour MicroLite (6 dog)
6 notch
Perfect Pro A Bicycle Research Bicycle Research or Kingsbridge
Compe, 8.8.8. CT-7 SunTour tool can be used without temoving
and NewWinner Kingsbridge 111 locknuts and without quidk release to
-2 notch SunTour (2 dog) hold it in place. Use vice and press
Var706 down at rim while turning. SunTour
B Cyclo (English) tool will not fit on 6 or 7-speed
-some freewheels. (2 notch)
-4 notch (old) B- Maillard 700
Var413
A SunTour (4 dog) (old)
4-8 1990
FREEWHEELS

IDC -3 or 4 notch A Bicycle Research
CT-5 TDC
IDC
Var402
-4 notch A Bicycle Research
CT-5 TDC
IDC
Var402
B Var 01
Var 186
Zeus 2000 A Bicycle Research
CT-2Atom
Phil Tool
Var 401
Var407
Zeus (splined)
1990 4-9
FREEWHEELS
SPROCKET REMOVAL
Modem freewheels have splined inner sprockets held in
place by threaded outer ones. This allows easy removal of
all sprockets, even with the freewheel in place. Removing
the sprockets from an older, all threaded freewheel body is
different. One or two of the larger sprockets are left-
threaded and remove from the inside; the rest are right
threaded and remove from the outside. Do not attempt to
hold the bare freewheel body when removing the last
threaded sprocket. Instead, thread on two sprockets and
lock them against each other (like cone and locknut), not
against the freewheel body shoulder. Use this pair of
sprockets to hold the freewheel while loosening the last
sprocket.
SPROCKET REPLACEMENT
It is usual to replace worn sprockets when installing a new
chain because the new chain does not run smoothly on
sprockets which have worn to the old chain's longer links.
Often only the two outer sprockets need to be replaced.
INTERCHANGEABILITY CHARTS
The charts on the following pages cover sprocket inter-
changeability for the freewheel models listed below:
Model Page Model Page

ARIS 4-12 Shimano
Atom Freewheel 4-12
77 4-12 Shimano
Threaded 4-16 Non-Hyperglide Freehub
Campagnolo 4-17 Cassettes 4-20
Cyclo 4-29 Shimano
Everest 4-17 Hyperglide Sprocket Groups 4-22
G. Caimi 4-17 SunTour
Maillard 600, 700, Helicomatic 4-12 New Winner, Winner-S, Perfect,
Normandy 4-18 Pro-Compe, Microlite 4-24
Regina SunTour
Syncro 90, CX, BX 4-14 Accushift, Winner,
Extra, Scalare, 3-speed 4-14 Winner Pro, a 4-26
Sachs-Huret, ·Orbit, ARIS 4-12 SunTour
Schwinn Interchange New Winner-
Model F2, F3, J 4-18 Winner/Winner Pro 4-28
Model F 4-16 TD Cross 4-16
4·10 1990 rev.

FREEWHEELS
FREEWHEEL SPROCKET INTERCHANGEABILITY (cont.)
How to Use the Interchangeability Charts

Horizontal rows represent freewheel models and vertical
columns represent sprocket positions (1 inside to 7
outside).
Sprockets inside each outlined box are interchangeable
by an arrow crossing a heavy line + .

with one another. One-way interchangeability is indicated
Restricted
interchangeability is indicated by a dotted arrow •• ~
(if one-way) or by a dotted line ----- (if two-way) and is
explained in a lettered footnote.
For each sprocket listed, the manner in which it attaches to
the cluster is indicated. Also indicated is any provision a
sprocket may have to hold the next smaller sprocket. The
following symbols are used:
To accept next-
To attach to cluster smaller sprocket,
Symbol sprocket has: sprocket has:
Splines
Inside threads
(left-handed)
Inside threads
(right-handed)
Outside threads
(right-handed)
Inside threads Inside threads,
)$"'$"'$( (right-handed) same diameter
Inside threads Inside threads,
)5'.!!!! (right-handed) lesser diameter
- Outside threads Inside threads
tOOttt
'.!!!! (right-handed)
_ Inside threads Outside threads
'5 $$231 (right-handed)
Arrow indicates the direction of sprocket removal.
Note that splined and right-threaded sprockets always
come off to the right (outside) of the cluster, left-
threaded sprockets come off to the left (inside).
1990 4-11
FREEWHEELS
MAILLARD, ATOM 77, SACHS-HURET
FREEWHEEL SPROCKET INTERCHANGEABILITY
(outside)
..
(inside) Sprocket Positions
Freewheel 1 2 345 6 7
Maillard 600 SH 15-30,32T A
Helicomatic IMal
5-speed
~
-
Maillard 600 SH 14-20T
Helicomatic IMHI
6-speed narrow
Maillard 700 SH ISHAI 14-18T 13-15T 12,13T

Helicomatic ISHB\ ISHDI ISHEI
7-speed narrow
~
-
"tttt~$$O$( ~
-
SHC body
Maillard 700 SH
- 13-
-
Helicomatic SHF
6-speed narrow -
..
"tOOt~$$$$'
SHCbody
Atom 77 B 19-22,24,26,28, 17- 15-
-
5-sprocket body 32,34T
--.
6-speed narrow F
Atom 77 B
~ 14-
6-sprocket body
6-speed narrow
Maillard 700 Course 17-26, 28, 30T 14-18T 13-16T

6-speed regular IMAI 15-23T MC MC
MMbody IMBl G G
~
Maillard 700 Course ~ 14-16T
5-speed regular IMDI
MMbody A
Sachs-Huret Orbit 24T 17, 19,21T

-----t---
15TE 13T
6-Speed D
~ ~ -
~ --.
Maillard 700 Compact

6-speed narrow
CC body
Maillard 700 Compact

7-speed narrow
IMAI
..
-
16-21 T
IMRI
~
15-23T
IMBI
..-
14-18T
IMSI
13-16T
MT
12-16T
MT
CCbody G G
..- ..-
... ... ... ... • ...
ARIS ~17-26,28,30,32T 11' 16-21T 1'15-18T ~14-17T IT 13-16T IT 12-14T
7-Speed narrow IAYI tGyl IBYI IHYI IIY I ILYI
CC body H
~ ~ ~
--+
~
-
.. ..
; ,.--------
ARIS 16-21T :" ICYI15T 14-17T 13-16T
6-Speed regular IBYI : IBY116-18T IDyl IEYI
I
~
CSbody H I
I
I
- -
4-12 1990
FREEWHEELS
MAILLARD, ATOM 77, SACHS-HURET
Notes:
en
A. Maillard 700 5th-position sprocket has a wide inner flange and may be used c:::
on a 600 SH 5-speed directly; it is too wide for use on a SH 6-speed. 600 SH ~
6-speed outer sprockets Ref. MH require Maillard spacer Ref. 2261 when :c
used on a SH 5-speed. Some Maillard 700s have a body 5 sprockets wide, m
B.
with an outer sprocket pair and a 13T minimum. Others have a body 6
sprockets wide, with all sprockets threaded on and a 14T minimum.
The Atom 77 freewheels listed here are narrow 6-speeds. All sprockets of 6-
sprocket body Atom 77 attach directly onto body. The 6th-position sprocket
=
r-
»
of 5-sprocket body Atom 77 attaches to 5th-position sprocket. The 5- :2
sprocket body Atom 77 can be built up as a 7-speed using Maillard SHB, o"
D.
SHD and SHE sprockets in 5th, 6th and 7th position.
Sachs Orbit inner sprocket is dished and so not interchangeable with others. en
E. 14, 15T Maillard 700 sprocket's inner flange is not high enough to secure
:c
F.
neighboring lugged sprocket on Orbit.
Also interchanges with 3-lug sprockets on Normandy; Schwinn Approved
Models F2, F3 and J; Shimano MF 1501, A-type and B-type. See page 4-18.
»
:2
G. Sprockets are sold as a pair but can be separated. o
H. ARIS sprockets can be used in place of the corresponding Maillard 700
sprockets. Maillard 700 sprockets cannot be used on ARIS freewheels if
indexing is to be used.
=
o
o
~
."
MAILLARD SPROCKET SPACERS o
Freewheel
Model Body Speeds & Spacing Spacer I.D. O.D.
Thick-
ness =
=
....
Helicomatic SHC 6-, 7-speed narrow 2263 silver steel 45.5mm 50mm 3.0mm
n
or black plastic 45.5mm 50mm 3.0mm
-<:
700 Course MM 5-, 6-speed regular 2160 red 50mm 56.5mm 3.6mm
n
2163 red 44mm 54mm 3.65mm r-
700 Compact CC 6-, 7-speed narrqw 2141 green 50mm 56.5mm 3.0mm m
ARIS CS 6-speed regular 3564 white (A) 50mm 56.5mm 3.45mm
3:
CS 6--speed regular 3583 white (B) 44mm 53mm 3.45mm
m
CC 7-speed narrow 3569 black (F) 50mm 56.5mm 2.95mm
n
:c
»
:2
....
n
en
1990 4-13
FREEWHEELS
REGINA SPROCKET SPACERS
(inside) Sprocket Positions (outside)

Freewheel 1 2 3 4 5 6 7 8
Syncro 90-S
8-speed [!g] [!g] [1Q] [lQ] [iQ] none none
Syncro 90-S
7-speed [!Q] [!Q] [1Q] [!Q] none none
shorter 7-sp Sync. body
Syncro 90-S
7-speed narrow [!Q] [!Q] [1Q] [lQ] [lQ] none
longer 7-sp Sync. body
Syncro 90-S
6-speed narrow [!Q] [!Q] [1Q] [!Q] none
Syncro 90
6-speed regular [ig] [ig] [K§] ~ none
Syncro 90
5-speed regular [ig] [ig] ~ none
L..-.--
ex-s
6-speed narrow [!Q] ~ none [g none
ex-s
America A [!g] [MA none [1Q] none none
7-speed narrow [gJ lMJ []I]
ex
America B [jg] ~B none none none
6-speed regular [ill ~
BX
6-speed regular [R!J [R!J ~ none none
BX
5-speed regular [R!J [R!J ~ none
ex
5-speed regular [ig] ~ none none
REGINA SPACER DIMENSIONS

Spacer I.D O.D. Thickness
Kl, Sl 49mm 53mm 3.65mm
K2, S2 49mm 52mm 3.0mm
K3, S3 41mm 45.5mm 3.0mm
K4, S4 46.5mm 51.5mm 1.65mm beveled
K5, S5 46.5mm 51.5mm 0.8mm
K6 41mm 52mm 3.85mm beveled
K7 41mm 52mm 3.3mm beveled
K8 41mm 4.5mm 3.5mm
1990 4-15
CROSS~
FREEWHEELS
O
. Q.
Freewheel Body
T.D. REGINA THREADED and AlOM THREADED
Notes
1 2 345 6
T.D. Cross 20,22-24 18-22,24T 14-17T
28T A
~ ~
Regina-threaded
3.. Speed B
Regina Sprockets
4-Speed
14-18T top
Regina Sprockets
5-Speed
Any outer sprocket combination in the shaded area can
13-17T top
be mounted on any of the above four freewheel bodies.
Manufacturer's series designations are circled. Atom Sprockets
5-Speed
Identifying Regina Freewheels DT top
Regina Extra and Scalare have all positions threaded;

inner .sprockets unscrew clockwise to the inside. Extra
body has flush hub mounting; Scalare has back of body
slightly recessed around hole for hub. Regina Sprockets
Regina ex (regular), BX (regular) and CX-S (narrow- 5-Speed
spaced) freewheels are labeled on the lockrings. 14-18T top
Regina Futura Cassette Freewheels have sprockets that Atom Sprockets

are not individually replaceable. 5-Speed
14-16T top
Notes
A. T.D. Cross #1 sprocket is dished and is not interchangeable with the others, although the spline
configuration is the same.
B. Regina 3-speed uses the same sprockets ca.S other Regina freewheels.
c. (Dand @ have the same threads butCDis 4.5mm thick with beveled flange while @) is 3.5
mm thick with squared flange.
D. New..style@(threaded __ . as shown) is clearly not interchangeable with old..style®
threaded ~ .Old-style@is no longer available (see note M for its use on Scalare body).
E. Note that Regina Scalare is the only all-position threaded body that will accept a 1ST sprocket
in the 3rd position.
K. Regina(Dand Atom ® sprockets here are interchangeable with SchwinnF2 and F3, and with
Normandy outer sprockets. See page 4..18
M. Old-style Scalare fre~wheels do not use the Regina and Atom outerc0tnbinati?ns shown, but
haveCDin place Of@.o.. a.nd.Old.. -stYle®.9
.• ,. in Placeof@, making a(D@Q)old@(2)five-speed
instead of the currentU)@@) @(f).
N. Atom 12, 13T with 34.8 mm 0.0. thread also fits Regina CX-S and Maillard Helicomatic 7..
speed.
A~ 1':;' ..",,,,, 100<

FREEWHEELS
CAMPAGNOLO
Freewheel Body Sprocket Positions

(inside) (outside)
1 2 3 4 5 6 7
Campagnolo 17..28T 16..27T 14..23T 13.. 18T 12.. 16T
6-Speed @ ® @ ® @
~
~ ~
Campagnolo 16..23T 15.. 22T 14·21T
7-Speed
Notes: Spacer C is used between sprockets and ® <®

e For the 7-speed an addi-
tional. spacer is needed betwee~.s....rockets 3 and4eE... ar.I.Ymodels combined sprock-
ets @ and ® into sprocket ~. If a 16-tooth sprocket was used in the second
position, this required spacer C2 to be used between @ and @> .
G. CAIMI, EVEREST and SIMPLEX

Freewheel Body Sprocket Position

(inside) (outside)
1 2 3 4 5 6
G. Cairni } 17-26,28,30T 15-21 T 14-18T
Everest 5-Speed
Simplex
G. Caimi } 14-16T 13,14T

Everest 6-Speed
Simplex
rev. 1985 4·17

FREEWHEELS
SHIMANO, NORMANDY AND SCHWINN APPROVED Models F2, F3 and J
Freewheel (inside) Sprocket Positions (outside)

1 2 345 6 7
Normandy 19-22,24,26,28,30,32T 17T 14T
Schwinn Approved K
Model F2, F3 ~ Interchangeable with
~
Atom 77. (See page 4-12.)
Shimano MF-1501, 19-24,26-28, 32, 34T 17T 14,15T
Schwinn Approved ~ ~
Modell
•
Shimano Uniglide
MF1500, MF1510
18-24, 26,28, 32, 34T
(1.8mm thick)
•
15-20T
H
.~ 14, 15T
5-speed G G
~
Shimano Uniglide
MF 1600
6-speed G
Shimano A-type 18T

..
16T 14T
Model FC-300 ~ ~
I
Shimano B-type 17T 15T 13T

Model FC-300 ~
J
Shimano 600 MF-6140 16-26,28,30, 15-20T 13-17T

MF-6151, 6207
5-speed
31, 32, 34T ~
N
~
-
Shimano Dura-Ace (old)
MF-7150
5-speed
Shimano 600 MF-6160

MF-6161, 6207
6-speed
Shimano Dura-Ace (old)
MF-7160
6-speed A
,~ ,~
Shimano
Uniglide MF-Z012 17-24,26,2~,30,32,34T 14-20T 13-16T
600 VO MF..6208 16-26,28, 30, 32,34T 14-20T C
Dura-Ace MF-7400 16-26,28T 14-22T
6-speed c c
Shimano
Vniglide MF-Z012
5-speed
Shimano
Dura-Ace MF-7400 16-26,28T 14-22 13-16 12-14
14-20
Sante MF-5000
7-speed
16-26,28T
--
)JSSSSSSSS(
4·181990
FREEWHEELS
SHIMANO, NORMANDY AND SCHWINN APPROVED Models F2, F3 and J
FREEWHEEL SPROCKET INTERCHANGEABILITY (cont.)
Notes:
A.
Sprockets above the dotted line are 3-dog type; sprockets below the
dotted line are sawtooth-splined type except 30, 32 and 34T. 3-dog
sprockets will fit on sawtooth splines of cassette bodies in positions
1, 2,and 3, but sawtooth-splined sprockets will not fit 3-dog bodies.
C. Sprockets with built-in spacers are marked 6S for 6-speed and 7S for
7-speed.
G. Shimano Uniglide freewheel body lockring is level with outer rim.
Splined sprockets are thinner and will not lock in place if used on other
similar Shimano freewheels.
H. Shimano Uniglide outer sprockets may be used on other similar
Shimano freewheels if a spacer like the one behind the 4th sprocket is
used to the inside ofeach sprocket. The 16T sprocket requires a special
beveled spacer (a bevel may be ground on the standard spacer) to
prevent chain interference.
/. Note that Shimano A-type FC-300 has two threaded diameters and
one splined diameter.
J. Note that Shimano B-type has outer sprocket threaded into face of
body.
K. Schwinn Approved models F2~nd F3 outer sprocket has special
threads to accept high~ear chain guard; it is otherwise interchange-
able with the Regina (2) and the Atom @.
SHIMANO FREEWHEEL SPROCKET SPACERS

1 2 3 4 5 6 7
Shimano
Uniglide MF-2012 A A B C none
600UG MF-6208
Dura-Ace MF-7400
6-speed
Shimano
Uniglide MF-2012 A A B none
5-speed X X
Shimano
Dura-Ace MF-7400 7A 7A 7B 7C none none
Sante MF-5000 X X X
6-speed
x. Use this spacer if not built-in to next smaller cog.
SPACER DIMENSIONS
Spacer I.D. O.D. Thickness
A 49.5mm 53mm 3.65mm
B 42.5mm 53mm 3.65mm beveled
C 42.5mm 47-48mm 3.65mm
7A 49.5mm 53.5mm 3.1mm
7B 43mm 53.5mm 3.1mm
7C 43mm 47-48mm 3.1mm
1990 4-19
FREEWHEELS
SHIMANO NON-HYPERGLIDE FREEHUB SPROCKET INTERCHANGEABILITY

Freewheel 1 2 3 4 5 6 7 8
Dura-Ace A 14-26,28T Marked: Marked:
~
CS-7400-8 INDEX INDEX
8-speed 75 or 7-8S 75 or 7-85
12-14T
Dura-Ace 13-15T
CS-7400-7 wi built-
7-speed insnacer
Sante CS-5000 14-26,28,30,32,34T E

----
D
~- +---------~
-
Marked: 6S
600 Ultegra 78 or 7-8S
CS-6400-7 12-16T
7-speed ~
.. - .......... - -.. ;............. --+- ............. ...-1
Dura-Ace A 13T Marked: 6S

CS-7400-6 Marked: or no mark
6-speed, 5-sp. B 13 INDEX 12-18T
65 ~
600 EX F D,E No mark

CS-6400-6 wi built- 13-16T
CS-6208-6 in spacer ~
Standard CS-1000
6-speed
A. Includes AX, EX and "New" Dura-Ace.

B. Dura-Ace AX and EX 5-speed has same outer 2 sprockets as 6-speed with
one less inner sprocket.
C. Dura-Ace threaded-on cogs (champagne colored) are not interchange-
able with others.
D. Cog without built-in spacer can be used here when combined with proper
spacer.
E. To mount as a cassette, sprockets used in sprocket position 5 on a 6-speed
or 7-speed must have threaded sprocket through-bolt holes.
F. Standard spline sprockets are interchangeable with Dura-Ace and others,
but do not have the high-performance tooth profile.
SPROCKET THROUGH BOLTS

Number of
Sprockets
Model Joined Length
Dura-Ace not used
Sante, 600, Standard 7-speed 5 21.5mm
600, Standard 5 23.0mm
Hyperglide 7-speed 5 23.0mm
Group Mark (1989)
B,D,C
Hyperglide 7-speed 6 28.5mm
Group Mark (1990)
E, F, G, H, I, J, K
4·20 1990
FREEWHEELS
SHIMANO NON·HYPERGLIDE FREEHUB SPROCKET SPACERS
(inside) Sprocket Positions

Sprockets 1 2 3 4 5 6 7
Dura-Ace A Aluminum Aluminum Aluminum Aluminum Aluminum none none
CS-7400-8 Silver Silver Silver Silver Silver
8-speed Spacer B, Spacer B Spacer B Spacer B Spacer B
3.0mm 3.0mm 3.0mm 3.0mm 3.0mm
Dura-Ace Steel~ Steel~ Steel~ Steel~ none none
CS-7400-7 Silver Silver Silver Silver
7-speed Spacer B Spacer B Spacer B Spacer B
3.1mmJ 3.1mmJ 3.1mmJ 3.1mmJ
Sante CS-5000 Resin- Resin- Resin- Resin- Resin- none
600 Ultegra Dark Grey Dark Grey Dark Grey Dark Grey Dark Grey
CS-6400-7 mark: 7S mark: 7S mark: 7S mark: 7S mark: 7S
7-speed Spacer B Spacer B Spacer B Spacer B 2nd position
3.15mm 3.15mm 3.15mm 3.15mm Spacer A
3.3mmH
Dura-Ace A Steel-Grey Steel-Grey Steel-Grey none none
CS-7400-6 Spacer B Spacer B Spacer B
6-speed, 5-speed 3.65mmK 3.65mmK 3.65mmK
600 EX Resin-Light Resin-Light Resin-Light Resin-Light Steel with

CS-6400-6 Grey Grey Grey Grey spline cuts
CS-6208-6 Spacer B Spacer B Spacer B Spacer B
Standard CS-IOOO 3.7mm 3.7mm 3.7mm 3.7mmH H
6-speed
H. None if sprocket has built-in washer.

J. Steel-Silver 78 Spacer B may be used in place of Resin-Dark Grey 7S
Spacer B if sprocket through-bolts are not used.
K. Steel-Grey 6S Spacer B may be used in place ofResin-Light Grey Spacer
B if sprocket through-bolts are not used.
SHIMANO FREEHUB SPACER DIMENSIONS

Thick-
Spacer I.D. O.D. ness
8-speed 34.5mm 42mm 3.0mm
7-speed B 34.5mm 38.5mm 3.1mm*
narrow A 34.5mm 38.5mm 3.3mm
6-speed B 34.5mm 42mm 3.65mm
regular A 34.5mm 42mm 1.0mm
*Resin spacers are listed as 3.15mm, steel as 3.1
1990 4-21
G FREEWHEELS
HYPERGLIDE SPROCKET GROUPS

C1) Hyperglide .sprockets must all have the same group mark for optimum shifting.
u
.....
Please note the exceptions below. Other Shimano cassette sprockets can be used
but performance will decrease. Hyperglide sprockets will not fit on non-
hyperglide free hub bodies.
Z
<I:
:c 1989
Group
1990
Group
u Model No. Mark Mark Combination
UJ 8-speed CS-7401 S 12, 13, 14, 15 ,16, 17, 19, 21 T
:E T 13, 14, 15, 16, 17, 19, 21, 23T
UJ 7-speed CS-HG90 chrome J 13, 14, 15, 16, 17, 19, 21T
..1
U CS-HG70 silver I 13, 14, 15, 17, 19, 21, 23T
>
U
CS-HG50 brown H 13, 15, 17, 19, 21, 23, 26T
..... B E 12, 14, 16, 18, 21, 24, 28T
=
=:
C
D
G
F
13, 15, 17,20,23,26,30T
14, 16, 18,21,24,28,32T
ou. K 13,15, 17,20,24,29,34T
~
o 1989 GROUP MARK vs. 1990 GROUP MARK
o 1989 Group. Mark cassettes use 23mm through bolts that screw in to the 5th
=
Q
sprocket from the inside. This requires a 3.3mm spacer (A) that has indents to
clear the ends of the bolts. The lockring is 7mm thick and requires a lockring
spacer.
Z 1990 Group Mark cassettes use 28.5mm bolts that screw into the 6th sprocket
from the inside. This requires a 3.3mm spacer (Hyperglide A) that has holes for
<I: the through bolts. The lockring is 5mm thick and has no lockring spacer.
:c 1989-90 GROUP MARK INTERCHANGEABILITY
C1)
~
If no through bolts are used and the outside sprocket of the 1990 group is used
Q with the adjacent spacer, the following sprocket interchangeability is possible:
Z B group sprockets interchange with E group sprockets.
<I: D group sprockets interchange with F group sprockets.
..1 C group sprockets interchange with G group sprockets.
=:UJ
:c
f-
::J
C1)
4-22 1990
FREEWHEELS
SHIMANO NON·HYPERGLIDE FREEHUB SPROCKET SPACERS
(inside) Sprocket Positions (outside) (Ij

Sprockets 1 2 3 4 5 6 7 8 c::~
Dura-Ace A
CS-7400-8
8-speed
Aluminum
Silver
Spacer B,
Aluminum
Silver
SpacerB
Aluminum
Silver
SpacerB
Aluminum
Silver
SpacerB
Aluminum
Silver
SpacerB
none none
:cm
=
3.0mm 3.Omm 3.0mm 3.0mm 3.0mm
Dura-Ace
CS-7400-7
Steel-
Silver
Steel-
Silver
Steel-
Silver
Steel-
Silver
none none
r-
7-speed SpacerB SpacerB Spacer B SpacerB ;I>
3.1mmJ 3.1mmJ 3.1mmJ 3.1mmJ :2
Sante CS-5000
600 Ultegra
Resin-
Dark Grey
Resin-
Dark Grey
Resin-
Dark Grey
Resin-
Dark Grey
Resin-
Dark Grey
none o ~
CS-6400-7 mark: 7S mark: 7S mark: 7S mark: 7S mark: 7S (Ij

7-speed SpacerB
3.15mm
SpacerB
3.15mm
SpacerB
3.15mm
SpacerB
3.15mm
2nd position
Spacer A :c;I>
3.3mmH
Dura-Ace A Steel-Grey Steel-Grey Steel-Grey none none :2
CS-7400-6 SpacerB SpacerB SpacerB
o
6-speed, 5-speed
600 EX
3.65mmK
Resin-Light
3.65mmK
Resin-Light
3.65mmK
Resin-Light Resin-Light Steel with

=
o
CS-6400-6 Grey Grey Grey Grey spline cuts o
CS-6208-6
Standard CS-1000
SpacerB
3.7mm
SpacerB
3.7mm
SpacerB
3.7mm
SpacerB
3.7mmH H
~
6-speed ."
o
H. None if sprocket has built-in washer.
J. Steel-Silver 7S Spacer B may be used in place of Resin-Dark Grey 7S
Spacer B if sprocket through-bolts are not used.
=
=
.....
K. Steel-Grey6S Spacer B may be used in place ofResin-Light Grey Spacer
B if sprocket through-bolts are not used. n
<
nr-
SHIMANO FREEHUB SPACER DIMENSIONS
Thick-
m
Spacer I.D. O.D. ness 3:
8-speed 34.5mm 42mm 3.0mm m
7-speed B 34.5mm 38.5mm 3.1mm* n
narrow
6-speed B
A 34.5mm
34.5mm 42mm
38.5mm
3.65mm
3.3mm
:c;I>
regular A 34.5mm 42mm 1.0mm
*Resin spacers are listed as 3.15mm, steel as 3.1 :2
.....
n
(Ij
1990 4-21
,..
FREEWHEELS
HYPERGLIDE SPROCKET INTERCHANGEABILITY

fI) Hyperglide sprockets are marked with a group mark. Interchangeability is limited
u
....
to the combinations listed below. Other non-Hyperglide Shimano cassette
sprockets can be used but shifting performance will decrease. Hyperglide
z sprockets will not fit on non-hyperglide free hub bodies.
<
:c
8-speed Dura-Ace
Model No. CS-7401
u 1989 1990
Group Group Sprocket Combinations
I.IJ Mark Mark Sprockets listed together in bold vertical boxes are interchangeable.
:E
I.IJ
S 12 13 14 15 16 17 19 J2il
~
T 13 14 15 16 17 19 l.::J 23
U
>
U
'-speed Models
.... CS-HG90 chrome
=
CS-HG70 silver
CS-HG50 brown
Cd Sprocket Combinations
o 1989 1990 Sprockets listed together in bold vertical boxes ·are interchangeable.
Group Group Groups of sprockets listed together in light horizontal boxes are interchangeable only
~ Mark Mark as a group and only with the adjoining group.
~
o
~ ~
~
B 12 14 16 18 21 28
o E 12 14 16
-18 21 24 28
=
~ - ~
Q F 14 16 18 21 28
Z D 14 16
-18 -21 24 28 32
:c<
~ ~ ~
C 13 15 17 20
fI)
~
G
~
13
-15
-17 -20 23 26 30
Q
Z
<
K 13 15 17 20
- 24 29 34
---- -
H 13 15 17 19 21 23 26
~
Cd
I.IJ
I
J
[ili]
13 14
15
15 16
17
-----
17 -
19
19
21
21
- 23
:cE-
1989 GROUP MARK vs. 1990 GROUP MARK
::J 1989 Group Mark cassettes use 23mm through bolts that screw into the 5th
fI) sprocket from the inside. This requires a 3.3mm spacer (A) that has indents or
holes to clear the ends of the bolts. The lockring is 7mm thick and requires a
lockring· spacer.
1990 Group Mark cassettes use 28.5mm through bolts that screw into the 6th
sprocket from the inside. This requires a 3.3mm spacer (Hyperglide A) that has
holes for the bolts. The lockring is 5mm thick and has no lockring spacer.
4-22 1990
FREEWHEELS 0
HYPERGLIDE SPACERS AND LOCKRINGS
123 4 5 6 7 8
Hyperglide Alrnninum Almninum Alrnninum Alrnninum Alrnninum none none 5mm
8-Speed Silver Silver Silver Silver Silver thick
CS-7401 SpacerB SpacerB SpacerB SpacerB SpacerB lockring
3.0mm 3.0mm 3.0mm 3.0mm 3.0mm
Hyperglide Resin- Resin- Resin- Resin- A none 5mm
7- Speed dark grey dark grey dark grey dark grey Y thick
Group Mark (1990) mark 7S mark 7S mark 7S mark 7S 3.3mm lockring
E spacerB spacerB spacerB spacerB
orD orD orD orD
3.15mm 3.15mm 3.15mm 3.15mm
Hyperglide Resin- Resin- Resin- Resin- A Spacer 5mm
7-Speed dark grey dark grey dark grey dark grey Y lIE thick
Group Mark (1990) mark 7S mark 7S mark 7S mark 7S 3.3mm 0300 lockring
F, G, H, I, J, K spacerB spacerB spacerB spacerB
orD orD orD orD
3.15mm 3.15mm 3.15mm 3.15mm
Hyperglide Resin- Resin- Resin- Resin- C or A none 7mm
7-Speed dark grey dark grey dark grey dark grey Z thick
Group Mark (1989) mark 7S mark 7S mark 7S mark·7S 3.3mm lockring
B,D,C spacerB spacerB spacerB spacerB with
orD orD orD orD spacer
3.15mm 3.15mm 3.15mm 3.15mm X
X. 7mm thick Iockring must be used with Iockring spacer or lockring will bind on freehub.
Y. Hyperglide A spacer has holes for through bolts. If no through bolts are used, non-Hyperglide
3.3mm spacer may be used.
z. Spacer C used on B, D, and C Groups has indention for ends of through bolts.
1990 4-23
FREEWHEELS
SUNTOUR SPROCKET INTERCHANGEABILITY
Freewheel Body 1 234 5 6 7
SD, Perfect 17-22,24,26T I4-I8T
C/') 3-Speed Note: In SunTour
u
..... Y8" chain
literature, sprocket
positions are numbered
z SD, Perfect from Ion the
«
:c
4-Speed outside.
Pro-Compe PC-5000, 16-28,30,32,34,38T 14-20T

u Perfect PT-5000, AG H
UJ 5-Speed
'!ill'
~ Perfect PN.. 6000 B
6.. Speed regular (for
UJ use on Fujis and others)
.:I
I'.'"p!!£!\X"
.
U Pro.. Compe PC-6000 13,14T
>
U
6-Speed regular 1.4. ·16T
..... ...........
=
=:
Perfect PS-6000, PS6S
6-Speed regular
~--------------~---------~-_JL ~~,
13,14T
A
8'
o
~
Perfect US-6500
6-Speed ultra (narrow)
16-28,
30,32T G
• E
16T
F
:G
~ .....- _--................
G .•. i4T·····
..-
~ ......
o New Winner NW.. 7000, l&
~19-24T
IS-2IT 115-19~:
I~Ll ---+ IAUI
[k]13-1ST [[]12,13T
o Microlite LF-7000 X
7-Speed ultra (narrow) 17,18T ~
F,D : F,D:.
::~ -"m~Uttt ~
=
Q
New Winner NW-6500,
MicroBte LF.. 6000 X
lAY I
[BJ
r-------
·:ffi
I
~ 1M] ~3 14T
:]]] ,
~ ~'!!!!'
-
Z 6-Speed ultra (narrow) IARI15.19'1'AfU5-17T
«
:c New Winner NW-6000
I
I
I
I
H 14-16T
(8J
13,14T
rID
6-Speed regular yu-iii'
~
, ,~
I
C/)
~
,
I
I '~~ .............
New Winner NW-5000 16T I 14T
Q 5-Speed regular (YJ
I
I (R]
I
Z J
«
.:I
Winner-S
6-Speed regular
16-20T 13-1ST
=: Winner-S
UJ 5-Speed regular IS-20T
:c Notes
~ A. Interchangeable with Shimano Dura-Ace and 600 at the inside to secure Ultra winners splined sprock-
;:J outer sprockets. ets.
C/') B. For use on Fuji and other bicycles with 124 mm E. Some sprockets have half-circle shaped dogs and
over locknut hubs. Since this freewheel is slightly must be filed to fit freewheels below the dashed
narrower, it may not work with some brands of line.
standard chain. x. Letters in boxes are SunTour's series designations.
C. Mounting 5-speed sprocket here leaves outer ball Boxes where the first of at least two letters is an A
race exposed. designate a Microlite sprocket or a spacer. Microlite
D. When moving a sprocket to the right across the aluminum sprockets are interchangeable with the
dashed line, a bevel must be ground on the right New Winner steel sprockets, except splined AA
side of the teeth. Sprockets moved to the left will fit sprockets that have eight dogs and do not fit onto
regular width Winner, but must have a high flange the steel body for sprockets with four dogs.
4.24 TPv.19R5
SUNTOUR SPACERS
Freewheel Body (inside)
S:~k~~o~~EELS 0; (outside)
7
SD, Perfect
3.. Speed
SD, Perfect
4-Speed
Pro-Compe PC.. 5000,

Perfect PT-5000, AG
S.. Speed
Perfect PN-6000
6-Speed regular (for
use on,Pujis, others)
Pro-Compe PC-6000
6-Speed regular
Perfect PS.. 6000, PS6S

6-Speed regular
Perfect US.. 6500

New Winner NW-7000,

Microlite LF-7000 none
New Winner NW-6S00,
Microlite LF-6000
6-Speed ultra (narrow
New Winner NW-6000

6.. Speed regular
New Winner NW-SOOO

5..Speed regular
Winner-S
6-Speed regular
Winner-S
S.. Speed regular
Notes (cont.)
F. 15T steel sprocket requires beveled spacer I. Where thin shims are used in addition to standard
#15004514. @acerj' they must be replaced exactly as they were.
G. Ultra 16T and 14T sprockets have a narrow built-in 1': .• UTP' spacer is.for use only with Microlite sprockets.
spacer and fit only Ultra, New Winner and Micro-
lite bodies.
H. 15T Sprocket requires beveled spacer
#15004511 or #15004515.
rev. 1985 4-25

FREEWHEELS
SUNTOUR ACCUSHIFT FREEWHEEL SPROCKET

INTERCHANGEABILITY
Winner and WinnerPro 7-, 6-, and 5-speed freewheels are built on the
same body.
a 7-, 6-, and 5-speed bodies are all different. 7-speed bodies have the
threaded portion protrude 4.2mm from freewheel face. 6-speed bodies
have the threaded portion protrude 2mm. 5-speed bodies have a flush face.
Sprockets are stamped with the sprocket letter and number of teeth. The
stamped side should be facing the next largest sprocket.
Note: In SunTour literature, sprocket positions are numbered from 1 on
the outside.
...-
Freewheel 1 2 345 6 7
I
Winner FW-WTIO-S7U 18-26, 28, 17T 16-23T 15-22T 13-16T 12-14T

Winner WT-7000 30, 32,34T 1~ '5' : 'W
a
::;'- R1
WinnerProWP-7000
~
:[g15-17T
~
...-
lLJ
7-speed Ultra (narrow) [£] 14T [ill
Winner FW-WTIO-S6U [A] [ill 15-22T A 13-15T
Winner WT-6500
WinnerProWP-6500
...
I
I
6-speed Ultra (narrow) I

I [[]
Winner FW-WTIO-S6R 15-22T 14-16L 13-15T
Winner WT-6000 )J"':'$$$1
WinnerProWP-6000 [KJ- [ID-
6-speed regular
-----------
Winner FW-WTIO-S5R [y] 16T 15-23T :-[ID15~22T- 13-15T
Winner WT-5000 with [g 15-17T
WinnerProWP-5000 built-in [Q] 14T
a
a
5-speed regular
FW-ALOO-S7U
FW-ALOO-K7U
7-speed Ultra (narrow)
19-26,28,
30, 32, 34T
spacer
-----------
17-24T
B
---------
16-24T 15-24T
~
[g15-17T
...-
13T
a FW-ALOO-SR6
6-speed regular
18-26,28,
30, 32,34T
15-23T
~
[g15-17T
[i5J 14T
...-
[H] 14T
13-16T
[Q]
[]
a FW-ALOO-SR5 18-26~ 28, 15-23T [g 15-17T 13-16T

5-speed regular 30, 32, 34T [Q] 14T
A. If next smaller sprocket has more than 13T, then OOlsprockets can be
used in this position.
B. If next smaller sprocket is[§ 13T use [g or [Q] sprocket in this
position.
If next smaller sprocket isrnl14T or rnl15T us~ sprocket is this
position.
4-26 1990
FREEWHEELS
SUNTOUR ACCUSHIFT FREEWHEEL SPACERS
Model 1 2 345 6 7
Winner FWWT10-S7U
Winner WT-7000 IUBDI IUCBI IUCFI IUCFIM none none
Winner ProWP-7000
Winner FW-WT10-S6U
Winner WT-6500 IUBD/ IUCB/ l!E:] IUCFIM none
Winner ProWP-6500
Winner FW-WT10-S6R
Winner WT-6000 ~ ~ ~ ~ none
Winner ProWP-6000
6-speed regular
1-----------
-----------
Winner FW-WT10-S5R I
I
Winner WT-5000 IBDlo ICBI llcBIR ISBlp

Winner ProWP-5000 1
1
IRBI
I
5-speed regular I
1
a FW-ALOO-S7U 54mmOD
a FW-ALOO-K7U IUBD/ 44mmID IUCFI /uCFI IUCFIN none
7-speed Ultra (narrow) 2.8mm
thick
a FW-ALOO-SR6 IBDI 54mmOD 54mmOD 48mmOD none
6-speed regular 44mmID 44mmID 44mmID 44mmID
3.6mm 3.6mm 3.6mm 3.6mm
thick thick S thickR thick R
a FW-ALOO-SR5 IBDlo 54mmOD 48mmOD none
5-speed regular 44mmID 44mmID 44mmID
3.6mm 3.6mm 3.6mm
thick thickR thickR
M. No spacer needed if [fJ 14T is next smaller sprocket.

N. No spacer needed if [H]14T is next smaller sprocket.
O. No spacer needed if [y]16T is next smaller sprocket.
P. Spacer ISB Iis used if next larger sprocket is 'l,[m sprocket
Spacer IRD lis used if the next larger sprocketis a [g or ill] sprocket.
R. No spacer needed if ill] 14T is next smaller sprocket.
S. Usel CBI if next smaller sprocket is 15T.
2.7.
3.55mm
2.85.
-n-
4.5mm
2.2mm
1990 4-27
o FREEWHEELS
SUNTOUR NON-ACCUSHIFT FREEWHEEL SPROCKET INTERCHANGEABILITY
Innermost Outermost
New Winner and Winner/ WinnerPro Splined Middle Threaded
Interchangeability
Sprockets Sprockets Sprockets
7-speed Ultra (narrow) Winner! WinnerPro [A] C
Ne'w Winner
6-speed Ultra (narrow) Winner! WinnerPro [AJ C []J
New Winner
6-speed Regular Winner! WinnerPro [AJ C [K]lliJ
New Winner
5-speed Regular Winner! WinnerPro [AJ C [ID
New Winner
c. Middle sprocket positions on early (and only early) Winner/ WinnerPro

bodies were threaded and grooved for threaded or splined freewheel cogs.
Current bodies are not threaded and will only accept splined Winner/
WinnerPro cogs. Threaded New Winner cogs can be used in the middle
positions of the early Winner/ WinnerPro bodies only if New Winner
spacers are used. The resulting freewheels are not Accushift compatible.
4-28 1990
FREEWHEELS 0
CYCLO FREEWHEEL SPROCKET INTERCHANGEABILITY
Freewheel Body Sprocket Positions

(inside) (outside)
1 2 345 6 7
Cyclo 15-28, 30T 14T A
3-Speed not
yg" Chain removeable
Cyclo 14T A
4-Speed not
removeable
Cyclo 64, 72, 14T A

Competition not
5-Speed removeable
Cyclo 64, 72 14T A 13T

Competition 13T top not
5-Speed removeable tiiit
....--......-j...-............ 1IIIIIIlI. '"~-_ ...
Cyclo 64,
Competition
14T A "'
not
6-Speed removeable
Cyclo Pans 15~28, 30T 13-18T

5-Speed P68
Cyclo Pans
'llit'
6-Speed
Cyclo Pans B
6-Speed narrow
Cyclo Pans 14-16T~

7-Speed narrow
Cyclo, Type B 16-20T 14-16T

(Made in England) c
"""
............
"""
............
Notes
A. This sprocket is part of the freewheel body and is not removeable. Inner
sprockets are left-threaded and unscrew towards the inside.
B. For correct spacing on 6-speed turn outside sprocket over.
C. Type B Cyclo is made in England and is unrelated to the French Cyclo models
listed above it. AU sprockets unscrew to the outside. To remove #5, loosen the
others, lock #2 and #3 together (like cone and locknut) and loosen #5.
rev.19854-29
o FREEWHEELS, FIXED GEARS
SINGLE-SPEED FREEWHEEL THREADS

Most single-speed freewheels use the same threads as multi-
speed freewheels (see page 4-1). Exceptions are as follows.
French Juvenile 32 mm x 1.0 mm
SunTour mini size 30 mm x 1.0 mm
TOOLS FOR REMOVING SINGLE-SPEED FREEWHEELS
Make of Freewheel Class of Fit-Tool

Atom-Maillard A Var412
Var 413 for French Juvenile
Cyclo (French) A DR.SD
103 & 303
Everest A Campagnolo #1
Merveille A Var 187 Linden
B Eldi
Regina
Regina A Regina
B Campagnolo #1 (may need a bit of grinding)
Eldi
Shimano -standard A Shimano Single and Freehub A removal tool
DX -4 notch A Kingsbridge 120
SunTour EZ OFF
SunTour (standard) A SunTour Single freewheel removal tool
Kingsbridge 120
EZ OFF-4 notch A SunTour EZ OFF 4 dog tool
IDC B Eldi
Regina
FIXED GEAR-HUB SHELL

Fixed gear hubs have a left-threaded lockring to secure sprocket. Thread sizes
of fixed gear sprockets are the same as those used for freewheels.
Thread sizes of lockrings may vary from maker to maker. Amaker will
usually use one lockring size for all hubs, even though the sprocket thread is
different. This is true of Campagnolo and Zeus.
Sprocket Lockring Threads

Campagnolo 1.32" x 24 TPI left-threaded
English 1.29" x 24 TPI left-threaded
French 33 mm x 1.0 mm left-threaded
4-30 1990 rev.

INDEXING
Items to INDEXING CHECKLIST Page numbers to find

check first more information
New Tune Re- Cam- Sachs Shi- Sun
Bike* up pair pagnolo mano Tour
Component Compatibility
t/ o Levers compatible with derailleurs. 6-3 6-8 7-2 8-2
t/ o Levers compatible with freewheel spacing. 6-3 6-8 7-2 7-2
t/ o Derailleur compatible with freewheel minimum and 6-4 6-8 7-5 8-5
maximum teeth with given rear dropout.
t/ o Chain compatible with derailleur and freewheel. 6-1 6-7 7-1 8-1
t/ o Correct space for freewheel plus dropout thickness. 5-7 5-7 5-7 5-7
t/ o Brazed-on lever bosses must be correct dimensions. 5-6 5..6 5-6 5-6
t/ o For large diameter down tubes (larger than 28.6mm)
use flat lever stop instead of radiused one.
Cable and Casing
t/ o Cable is correct diameter and smooth to touch. 15-4 I 5-4 LB:J 5-4
t/ t/ t/ o Cable casing seated, "stretched" and lubricated.
t/
t/
t/
o
o
o
Casing is compatible.
Casing ends cleanly cut, capped using correct caps.
Cable routing is smooth with no killks or sharp bends.
ltB.4.5-4
5-5 5-5 BE.
5-54 ...• 5-4
5-5
Route is not inside frame. ,l
t/ o Cable casing is correct length to eliminate binding at

cable stops and derailleur.
t/ t/ o Cable stops are tight on frame.
t/ t/ o Cable is on correct side of derailleur anchor bolt.
t/ t/ t/ o Cable anchor bolt is tight.
Levers
t/ t/ t/ o Lever clamp is tight.
t/ t/ t/ o Selection ring set for desired function. @D__Ci 8-2
t/ t/ t/ o Lever not too tight or too loose.
t/ t/ o Check lever for wear causing too much free play.
t/ t/ o Campagnolo lever insert correct.
Derailleur
t/ t/ t/ o Derailleur is mounted securely to drop out.
t/ t/ o Check derailleur and guide pulley for wear.
t/ o Guide and tension pulleys not reversed. Cl_·_CBIJ 5-13 1
Chain
t/ t/ o Check chain for wear.
t/ o ~i~~~~~r Pro, Regina CS-X or Regina SAR chain right El D 5-13 I
Freewheel
t/ t/ o Check cogs for wear.
t/ t/ o Check bearings for wear and looseness.
t/ t/ o Freewheel cogs installed correctly front to back on 1
4- 14 1.
4- 12 ~44.:2202
.• · . •. 4-.2..61.
body and correct spacers used in assembly. "' ~ .
* Correctly spec'd
,COpy THIS PAGE.
19905·1
,..
INDEXING
•• ••••
®
(/) ABOUT INDEX SHIFTING
....u Index shifting requires more attention to more details when adjusting and
z repairing than non-index shifting. A chattering rear derailleur in a non-
indexing system is taken care of by moving the lever slightly. In an
<
:cu indexing system that same symptom may need to be fixed in a repair stand.
There are about ten different components that determine how well an
indexing system works. In each one of these components there is a little
UJ play, a little room for wear and an allowance for slight misadjustment. This
~ play, wear and misadjustment allowance can add up and keep the system
UJ from working. Hopefully, the system is designed so that a little play here is
~ canceled out by a little wear there, and the system works well for a lot of
miles.
U
>
U
Indexing systems are designed as a whole with levers, cable, cable casing,
.... cable casing end caps, derailleurs, dropouts, derailleur hangers, hubs,
=
=:
freewheels, and chain all matched carefully to produce a complete system.
Interchangeability between systems is not practical. Our measurements of
various systems indicate you cannot mix manufacturers' components.
o
u.
Within SunTour there is a lot of interchangeability and within Shimano there
is a lot (see tables for exceptions), but between the two there isn't any
consistent interchangeability.
~
o In an ideal index system the derailleur guide pulley is close to centered
under each freewheel cog when each shift is completed. Upshifting and
o checking each cog, then downshifting and checking each cog is 12, 14 , 18
=
Q
or more checks. Some less than ideal combinations of components will shift
in the repair stand and maybe work for a couple of weeks of riding, but then
be nothing but trouble after wearing in a little. Thoroughly checking sys-
Z tems, although time consuming, is the only way to spot potential problems.
<
:c The information in this section is derived largely from manufacturers'
(/) information and our experience. There are a lot of factors that are common
to all systems and some that are unique to each brand. This section is
"Q divided up to reflect that.
Z Problems
<
~ Assuming the components are compatible, cable and cable casing are the
=: components to check first. See the checklist on the previous page for a
detailed list of cable and cable casing-related items to check.
UJ
:c~ Next check the chain for wear and compatibility. Many times a change of
chain can remedy the problem. See chain page and each manufacturer's
::J page for chain recommendations.
(/)
Systematically going through the checklist on the previous page should nail
down any problems. If it doesn't, go to the troubleshooting section,
beginning page 5-8.
5-2 1990
INDEXING
INDEXING ADJUSTMENT
(for Campagnolo see page 6-2 for additional setup tips.)
Frame 1. Align the fork ends with a fork end gauge set.
Adjustments 2. Align the gear hanger with gear hanger adjustment tool.
Derailleur 3. Attach derailleur to hanger.

Adjustments 4. Set shift lever to friction mode, if possible.
5. Adjust high gear and low gear adjusting screws.
Adjust the guide pulley so it is centered under the smallest cog with
the high gear adjusting screw. Then adjust the guide pulley so it is
centered under the largest cog with the low gear adjusting screw.
6. Check chain length.
Put chain on largest chainwheel and smallest freewheel cog. Guide
pulley and tension pulley centerline should be close to right angles to
the ground. Check the large chainwheel and large freewheel
combination to be sure there is enough chain. Check the small
chainwheel and small cog combination to be sure the derailleur can
handle the chain length.
7. Stress the cable.
Be sure the casing ends are seated and the cable end is seated in the
lever.
8. Check cable smoothness.
A slight movement of the lever should move the derailleur a slight
amount. See Cable and Cable Casing, page 5~4.
9. Adjust derailleur angle for guide pulley clearance.
(Some derailleurs don't have this adjustment screw. Some SunTour
derailleurs rely on the Dff attachment. See SunTour Derailleur
Capacity Chart.) Unscrew the angle adjusting screw until it doesn't
affect the angle of the derailleur. Shift to the largest cog and then off.
If it hesitates coming off, tum the angle adjusting screw in until the
chain shifts off the largest cog. T~e guide pulley should be as close as
possible to the sprocket without making excess noise when back
pedaling.
10. Set shift lever to indexing mode, if it is not already.
11. Adjust cable tension.
Shift to the second smallest cog. Tighten the cable with the adjusting
barrel until it is slightly too tight. Then tum the crank and loosen the
cable until the symptoms are eliminated. Continue through all the
cogs making adjustments as needed.
12. Shift through all the gears.
Run through all.the gear combinations with the smallest and largest
chainwheels and readjust as needed. See Indexing Checklist
(page 5-1) and Indexing Troubleshooting Chart (pages 5-8 through
5-13) as needed.
1990 5-3
INDEXING
•• ••••
®
CABLE, CABLE CASING AND CASING CAPS
C/)
u
.... Cable, cable casing and casing caps are a critical part of successful
z index systems. Keep in mind the following:
:c<
u
CABLE
• Use high quality 1.2mm cable that is smooth to the touch. The exceptions
U.l are Shimano Dura-Ace systems, which use 1.5mm braided cables. It is
~ best to measure cables since the finish can make the cable appear fatter or
thinner.
U.l • SunTour recommends using 1.2mm cable for all its indexing systems.
~ • Using larger or smaller diameter cable changes the amount of derailleur
U movement and is not recommended. (Thick Campagnolo derailleur cables
> change the amount of derailleur movement and should be avoided.)
....
U
=
Cd
CABLE CASING
• Use Shimano SIS or SunTour Accushift casing. (Accushift casing is
ou.. better than casing marked SunTour Index.)
• Do not use ordinary wound or lined cable casing.
• Casing ends must be cleanly cut and/or ground smooth with a grinder or
~
o file. Shimano cable cutter TL-CTIO is recommended.
• Cable casing must be correct length to eliminate binding at stops and
o derailleur. Casing should curve without abrupt or compound bends.
=
Q
• Internal routing of cables is not recommended; it causes too many tight
bends.
Z
<
:c
CASING CAPS
• Use casing caps on casing ends. Be sure casing caps closely fit the
.C/) casing, the derailleur, and the cable casing stops on the frame. Shimano
and SunTour make several different casing caps.
Q
Z
<
~
Cd
U.l
:c~
::>
C/)
5-4 1990
INDEXING •
•• •
• •
CABLE CASING CAPS
(I)
Cable Casing Casing Stop
c:::
~
:cm
-for Campagnolo and
=
r-'
)-
other derailleurs 2:
o"
(I)
:c)-
2:
o
t=
o
o
~
."
o
=
t=
....
n
-<
n
r-'
m
3:
m
n
:c)-
S\N1OIR IJ: '.1 ::#3
....2:
n
(I)
1990 5-5
INDEXING
BRAZED-ON SHIFT LEVER BOSSES

C/)
u
.....
THREAD SIZES
Campagnolo 5mm x 32TPI*
z Sachs-Huret 5mmxO.8mm*
:c<
SunTour 5mmx 0.8mm*
Shimano 4.5mm x 0.75mm
u * 5mm x 32TPI and 5mm x 0.8mm are so close they are interchangeable.
U.l
:E MARKINGS
U.l Shimano lever fixing bolts with 5mm x O.8mm threads are marked M5.
~ Shimano lever fixing bolts with 4.5mm x 0.75 threads are unmarked.
U
> !
I E
I
I
U
..... V1
I
1
I
I
cc
I I
I I
I
I
I
I
A: 9mm
a:: I
I B: 5.85mm
o
U.
c: 4.5mm
D: 5mm
~ E: 12mm
o
occ
Q Campagnolo Type Boss (sometimes referred to as Italian)
Z
<
:c
C/)
~
Q Shimano A Type Boss

Z Shimano levers designed for Campagnolo type bosses can be
<
~
mounted to Shimano A-Type bosses using Shimano Conversion
Kit (680 9858) for M4.5 lever boss.
a::
U.l
:c~
:J Shimano B Type Boss
C/)
5-6 1990
INDEXING
FREEWHEEL-DROPOUT SPACING
This chart is based on a normal dropout thickness (dimension C) of 6.5mm*.
Dimension B is the handiest since a quick check can be made with the wheel
and freewheel mounted in the bicycle.
Freewheel A B
Campagnolo 7-speed narrow sp~ced 36.0 9.5-11.5
6-speed regular spaced 36.0 9.5 - 11.5
Shimano Dura-Ace 8-speed spaced 40.5 10.0 - 11.5
7-speed narrow spaced 36.0 - 36.5 10.5 - 12.0
6-speed regular spaced 34.5 - 36.0 11.5 - 14.0
Shimano Other 7-speed narrow spaced 36.5 - 38.0 11.0 - 13.0
6 speed regular spaced 35.0 - 37.0 12.0 - 14.5
SunTour 7-speed narrow spaced 36.5 11.5 - 13.5
*Shimano recommends that the dropout be 7.5mm plus or minus 0.5mm

thick. Dropouts are often closer to 6.5 mm.
When dimension B is too great, add a spacer between the freewheel and the
hub. Be sure to check the clearance between the frame and the chain when
the chain is on the smallest cog.
Extra thick dropouts on aluminum frames may cause dimension B to go
over the recommended amount. This can cause difficulty shifting the largest
cogs as the derailleur swings to its inside limits.
CHAIN RECOMMENDATIONS
Bushingless chain has the ability to twist
more than chain with bushings. Some
Chain with Bushing
systems work best with a chain that will twist
and some with a chain that resists twist. Be
sure to follow the recommendations in each
manufacturer's section.
Chain without Bushing
1990 5-7
INDEXING
TROUBLESHOOTING CHART
....~ Shift Lever-Brazed-on Bosses

Trouble Cause Remedy
Z
~ Lever doesn't fit or is too Brazed-on boss dimensions Carefully remove paint and chrome.
: loose. incorrect.
Check dimensions of boss. Oversize dimensions
u can be carefully filed down. Undersize boss may be
'-U unusable.
~ Lever movement is too tight Lever friction adjusting Loosen lever friction adjusting screw slightly.
'-U or selector is difficult to tum. screw is too tight.
~
U Lever boss is too large for Check lever boss flat dimensions.
> lever.
....
U Boss hole not centered. Replace boss.
= Lever friction adjusting screw Lever boss threading is not Grind a small amount off the end of the friction
o=
won't tighten enough. deep enough. screw. Note: Grind as little as possible.
u.. Braze or glue in lever boss

threading.
Clean threads using correct tap. See lever boss
dimensions.
~
o Spacer or washer missing. Check assembly against exploded drawing in
o catalog.
=
Q
Z
Boss is too long.
Flats are not deep enough.

Carefully grind a little off the end of the boss.
Carefully file the flats deeper.
~ Index selector doesn't work. Lever boss flats Replace boss.
: perpendicular to down tube.

SunTour: If flats are installed exactly 90° to down
C/) tube the lever will shift ultra freewheels when
~
indicating "RE," and will shift regular spaced
Q freewheels when on "UL." Some SunTour clamp
Z mount lever flats are 90° to the down tube. The
~ levers attached to these clamps can be used when
~
=
'-U
: SunTour: Using clamp
the lever bosses are perpendicular to the down tube.
GPX levers don't engage the flats and can be used.
See above note.

~ mount levers on brazed-on
:J bosses.
C/)
Lever stop does not fit down Down tube diameter is Replace radiused lever stop with flat lever stop.
tube. greater than 28.6mm.
5-8 1990
INDEXING
TROUBLESHOOTING CHART (cont.)

Shift Lever-All Mountings
Index selector doesn't work. Mode selector is set between Check that the mode selector is lined up correctly
functions. with desired function.
Lever movement too tight or Lever friction adjusting Loosen lever friction adjusting screw slightly.
selector is difficult to tum. screw is too tight.
Lever doesn't index with 7- Lever not designed for 7- Check lever compatibility chart for correct lever.
speed freewheel. speed freewheels.
Campagnolo: Incorrect Check Campagnolo lever chart for correct insert.

insert.
SunTour: IPC or IFC lever Set selector ring to "UL."

selector ring set to "RE." Also see SunTour note on previous page under
"Index selector doesn't work."
Lever doesn't index with 5- Lever not designed for Check lever compatibility chart for correct lever.
or 6-speed freewheel. regular spaced freewheels.
Campagnolo: Incorrect Check Campagnolo lever chart for correct insert.

insert.
SunTour: Selector ring set Set selector ring to "RE" or index.

to "UL," "power" or friction.
SunTour: a-3000 lever or a-3000 lever must be used Match components.

a- 3000 derailleur doesn't with a-3000 derailleur.
index.
1990 5-9
INDEXING
~ TROUBLESHOOTING CHART (cont.)

~ Derailleur
Z Trouble Cause Remedy
~
:t Rear derailleur doesn't move Cable not tight enough. Tighten cable with derailleur adjusting barrel.
U far enough to shift on to
UJ large cogs.
~ OR chain skips cogs when

UJ shifting to larger cogs.
~ OR slight clatter after
U shifting to larger cog.
>
U Shift to largest cog hesitant. Low limit adjustment screw Loosen low limit adjusting screw.
~
needs loosening.
CC
c:: Shifts from large to small Cable too tight. Loosen cable with derailleur cable adjusting barrel
ou. cogs hesitant.
OR chain skips cogs when

or cable anchor bolt.
shifting from large to

~
o smaller cogs.
oCC OR grinding noise after

shifting to smaller cog.
Q Shifts to smallest cog High limit adjusting screw Loosen high limit adjusting screw.
Z hesitant. too tight.
~ Chain will not shift off or is Rear derailleurs guide pulley Check the derailleur capacity. If it should be able to
:t hesitant to shift off the too close to largest freewheel handle the largest cog, tum the angle adjusting
'"Z
~
Q
largest cog (chain is noisy
when the crank is turned
backwards).
cog. Either the angle
adjustment screw is
incorrectly adjusted or the
screw in to rotate the guide pulley away from the
freewheel.
SunT.~ur: For derailleurs without adjusting screw
largest cog exceeds the
~ derailleur capacity.
check Drr block for correct installation. See
~ Derailleur Capacity Chart.
c::UJ Random misshifts. The casing end is not capped Cap the casing end with the correct cap. SunTour
:t Hard to tum the rear

at the derailleur. has 5 different ones to match different
combinations of cables and stops. Shimano has 3.
E-- derailleur adjusting barrel.
:J
'"
5-10 1990
INDEXING
Other Symptoms
Indexing gradually Cable was not stretched Stretch cable and check seating and readjust.
deteriorates. and/or casing not seated
before adjustment.
Cable anchor bolt loose. Tighten cable anchor bolt.
Freewheel not fully Tighten freewheel and sprockets.

tightened on hub, or
freewheel sprockets not fully
tightened on freewheel body.
Derailleur mounting bolt Tighten mounting bolt.

loose.
Wom out freewheel or chain. Replace.
Consistent misshifts - Cable casing ends not cut Grind or cut cable ends flat, eliminate cable
Misses only certain cogs flat adding spring to system binding.
(other than the smallest and or cable binds.
largest).
Shift lever selector ring set Set selector ring for freewheel being used.
incorrectly.
Incompatible freewheel. Replace with compatible freewheel.
Derailleurs high gear limit Set lever to "friction" or "power setting." Readjust
screw out of adjustment. high gear limit screw so guide pulley is directly
under smallest sprocket. Screw adjusting barrel in
all the way and re-tension cable.
Dropout misaligned. Straighten dropout, readjust derailleur and re-

tension cable.
Freewheel sprockets face the Check cable and casing routing for binding before
wrong way, or are single blaming freewheel spacing. 'If needed install correct
bevel instead of double, or sprockets and spacers in correct positions.
spacers are incorrect.
Hub-freewheel-dropout See component section for correct spacing.

spacing incorrect.
continued next page
1990 5-11
INDEXING
TROUBLE SHOOTING CHART (cont.)

Other Symptoms (cont.)
Consistent misshifts (cant.) Cable too stiff or too large Use correct cable.
Misses only certain cogs in diameter.
(other than the smallest and
largest).
Cable not stiff enough or Use correct cable.

too small in diameter.
Campagnolo See notes in Campagnolo section.
Works on one chainring Bad chainline. Adjust chainline.

but not another
Dirty derailleur. Clean derailleur.
Incorrect chain length. Adjust chain length. See page 5-3, #6.
Random Misshifts Cable not sliding freely. Points to check:
1. Quality 1.2mm cable, correct cable casing and

correct cable ends.
2. Cable casing ends cut flat.
3. Cable stops and levers are secured tightly to

frame.
4. Cable and casing free from dirt and properly

lubricated. Lining is no substitute for lubrication.
5. Casing may be too long or short causing

binding.
6. Bottom bracket cable guide causes binding. If

lubrication improves performance it will probably
be temporary. Replace guide with clamp-on type.
7. Cable is attached on correct side of anchor bolt.
8. Internal cable housing can cause binding. Check

by moving the shift lever a slight amount. The
derailleur must move a corresponding amount,
continued next page otherwise re-route the cable.
5-12 1990
INDEXING

Other Symptoms (cont.)
Random Misshifts (cont.) Chain and/or freewheel dirty, Clean and lubricate or replace with new compatible
rusty or worn. chain. If trouble persists replace freewheel with
new compatible freewheel.
Chain is not compatible. Check chart and install correct chain.
Chain is incorrect length. Add or subtract chain.

SunTour: Shift into high gear. Add or subtract
links until dot on pulley cage lines up with mark
on derailleur body.
SunTour Pro, Regina Turn right side up.

CX-S or Regina 50
Regina CX-S must also have silver-colored plate
Anniversario chain
facing out.
installed upside down or
inside out. Regina 50 Anniversario must have black plate
facing in.
Derailleur dirty or worn. Clean or replace. Check guide pulley.
Derailleurs guide and tension Shimano: Guide pulley (marked Centeron or

pulleys are reversed. Ceramic Bushing) can move side to side. Tension
has no side-to-side play.
SunTour: Guide pulley( marked "G" has square
tooth profile. Tension pulley (marked "T") has a
pointed tooth profile.
Random Misshifts- Rear dropout misaligned. Straighten rear dropouts.

Unusually noisy drive
train.
1990 5-13
,.
••• INDEXING
•• •
®
1990 rev.
INDEXING •••
•••
®
CAMPAGNOLO SYNCRO AND SYNCRO II
Design Elements
• Several different inserts are available for the levers to allow
for different derailleurs and freewheels spacing.
.. Works best with Campagnolo Approved Regina 90 S
Freewheel and Regina 50 Anniversario chain.
• Levers require the rider toovershift slightly when shifting
onto larger sprockets.
Campagnolo's shift lever inserts allow the'same levers to be
used for different freewheel spacings and a variety of
different derailleurs with very different geometries,
Overshift is required to ,complete a shift onto a larger ,cog.
Overshift pushes the chain past the cog centerline to shift.
The lever is then released, which allows the guide pulley to
fytum to a position where it is centered under the cog.
CbainRecommendations
A high quality chain with bushings is fe.commended. Regina
5-0 Anniversario chain works best.
About the Derailleur Capacity ·Cha.rts

The numbers listed in the derailleur capacity charts have been
cO,mpiled from Campagnolo's liter;ature. We have found
some .of these to be optimistic. Dr()poutgeometry~
,cbainwheel sizes, hub position,chflin~tay geometry an.d
other factors may increase or decrease a given derailleur's
c·ap~city.
Max~Chainwheel Difference == Largest chainwheel minus

the smallest
Total Cap,acity =Largest freewheel sprocket minus smallest,
plus the Max Chainwheel Difference.
Max. Freewheel Teeth =Largest freewheel sprocket
Blank spaces indicate no listing in the manufacturer's
literature.
1990 6·1
,.
••• INDEXING
•• •
®
CAMPAGNOLOSYNCROIILEVERS
Syncro II levers use different inserts to vary the amount of cable
pulled between detents. The inserts are the same for Syncro and
Syncro II.
Campagnolo literature has shown many more combinations than are
listed here. The ones listed here represent the best combinations.
Please be sure to follow the Syncro II Setup Tips listed below.
To change to friction mode, note lever position (gear) then pull
knurled washer (#10) away from frame and tum the washer
clockwise 90°. To go from friction mode to Syncro mode position
the lever in the same gear as it was when the lever was changed
from Syncro to friction. Then tum the washer 90° counterclockwise.
Syncro II Setup Tips in addition to all the indexing adjustment

instructions on page 5-3:
1. Use what seems like too much grease when assembling each part
of the lever.
2. Check that the release bush (part 5) matches perfectly with the
flats on the boss. File the flats slightly to improve the match, if it
can be done without making the clearance excessive.
3. The friction D-ring (part 6) should feel loose. Tighten the D-ring
as.you would on a friction lever then back it off 1/2 to 1 full tum.
You may want to Pllt a drop of Loctite on the threads.
4. Pre-bend the cable. Insert the cable into the lever with the head
fully seated. Wrap the cable around the lever 90° to the way it
normally goes and pull tight. This will put a bend in the·cable that
will help it to settle quickly.
6-2 1990
INDEXING
CAMPAGNOLO SYNCRO LEVER INSERTS (I)

Model Categories Shift Lever Inserts Derailleur Freewheel c::
~
'-speed • Blue-no mark Athena
Xenon
Campagnolo Approved
Regina 90-S 7-speed** :c
m
• Green-stamped A7
• Black-stamped B7
Chorus-"A" mode
Chorus-"B" mode
Euclid
Centaur
Shimano SIS 7-speed
=
r-
;I>
• Gray-no mark Croce D'Aune :2
6-speed • Yellow-stamped "C"* Athena
Xenon
Regina regular spaced 6-
speed
o"
(I)
Chorus-"A" mode Shimano SIS 6-speed
• Red-stamped A6
• White-stamped B6 Chorus-"B" mode
Euclid
:c;I>
Centaur
:2
* A yellow insert without a "C" stamped in it was also o
**
produced. The notches in it, however, are spaced
differently.
Marked with the C in a diamond trademark inside the
=
o
threaded portion that mates with the hub. o
~
-n
o
=
The insert silhouettes are the same size as
the actual inserts. By placing the insert on the
silhouettes you can identify which one is which
even if the paint has been dissolved.
=
....
n
<
n
r-
~ ~ m
I I I I 3:
~ ~ m
n
Blue Green Black Grey :c;I>
:2
....
~ ~
n
(I)
• I I I
'-' ~
Yellow Red White
1990 6-3
INDEXING
REAR DERAILLEURS
CAMPAGNOLO INDEXING DERAILLEUR CAPACITY

Please see notes "About Derailleurs Capacity Charts"
on page 6-1.
Note: When using Shimano SIS cable casing, Campagnolo

derailleurs require an end cap that steps down to 5.3mm.
When using Accushift cable casing use the 5mm end cap.
CAMPAGNOLO INDEXING REAR DERAILLEURS
Maximum
Freewheel
Teeth
Total Dropout
Model Model No. Capacity L=24
• Record ("C.. Record") (1990 model) N/A 27T 28T
• Croce D'Aune (original)
Short Cage BOlO-SM 33T 30T
Long Cage BOlO-LG 30T 28T
(1990 model) N/A 27T 28T
• Chorus
Short Cage COlO--SM
"A" setting 25T 27T*
"B" setting 33T 32T
Long Cage COlO-LO
"A" setting 35T 30T*
"B" setting 37T 32T
• Athena DOlO 30T 30T
• Xenon FOlO 30T 30T
• Centaur
Short Cage QOlO-SM 32T 30T
Medium Cage QOlO-MD 38T 32T
Long Cage QOlO-LG 44T 32T
• Euclid
Short Cage MOlO-SM 32T 30T
Medium Cage MOlO-MD 38T 32T
Long Cage . MOlO-LO 44T 32T
• Olympus
Medium Cage ZOIO-MD 38T 32T
Long Cage ZOlO-LG 44T 32T
*We recommend a maximum freewheel of 19T in the "A" setting.
6-4 1990
NON-INDEXING
REAR DERAILLEURS
CAMPAGNOLO NON-INDEXING REAR DERAILLEURS

Maximum
Freewheel
Teeth
Dropout
Model Model No. L=24mm
• Gran Turismo 2270 36T
• Gran Sport (short cage) 3500 26T
• Gran Sport GT (long cage) 3550 32T
• Nuovo Record 1020lA 26T

• Rally 3450 36T
• Record ("e-Record") (original) 28T

• Super Record 4001 28T
• Triomphe Corsa (short cage) OOIO-SM 28T

• Triomphe Leisure (long cage) OOIO·LG 32T
• Valentino Extra 2170 26T
• Velox 2250 26T

• Victory Corsa (short cage) GOIO-SM 28T
• Victory Leisure (long cage) GOIO-LG 32T
• 980 0102068 26T
1990 6-5
FRONT DERAILLEURS
CAMPAGNOLO FRONT DERAILLEURS

Max. Clamp Diameter
Half-Stepl Chainring or Braze-On
Model Model No. Alpine Difference* (BID)
• Athena, Chorus, Croce D' Aune C021 half-step 18T B/G
C022 half~step 18T 28.5
• Centaur M022 alpine 26T 28.6

• Centaur, Euclid M023 alpine 26T 28-33 (adjustable)
M024 alpine 26T 35-36
• Chorus C023 half-step 18T 28-33 (adjustable)

• Gran Sport 3600 half-step lIT 28.5
• Nuovo Record 1050 half-step lIT 28.5
• Olympus Z022 alpine 26T 28.6

Z021 alpine 26T B/G
• Nuovo Record 1052/NT half-step 18T 28.5

1021/00 half-step 18T B/G
• Record ("C-Record") A021 half-step 18T B/G

A022 half-step 18T 28.5, 29.5**
• Super Record 1022/00 half-step lIT 28.5

1023/00 half-step lIT B/O
• Triomphe-Corsa 0022 half-step 18T 28.5

• Triomphe-Leisure 0022-LX alpine 23T 28.5
• Valentino 2050 half-step 28.5

• Nuovo Valentino 0104008 half-step lIT 28.5
• Victory-Corsa 0022 half-step lIT 28.5

0021 half-step lIT B/G
• Victory-Leisure 0022-LX alpine 23T 28.5
0021-LX alpine 23T B/G
• Xenon F022 half-step 18T 28.5

F021 half-step 18T B/O
• 980 0104012 half-step lIT 28.5

• 990 0104013 alpine 23T 28.5
* Max. chainring difference listed is for round chainrings as opposed to oval chainrings.
** Limited production run for carbon fiber seat tubes.
6-6 1990
,..
INDEXING
••••••
®
SACHS-HURET ARIS
Design Elements
• Overshift built into lever. Overshift is about 2mm of cable travel.
• Floating guide pulley
• Grooved and pinched freewheel teeth.
• Systems are supplied with Sedisport bushingless chains, although
we recommend a chain with bushings.
Sachs-Huret uses overshift built into the lever like SunTour only
more so (overshift of 2mm of cable travel for Sachs-Huret vs. Imm
for SunTour). This pushes the chain centerline past the cog
centerline to complete the shift. The guide pulley then settles into a
position where it is centered under the cog.
Like the Shimano system,.Sachs-Huret also has a floating guide
pulley. This allows the guide pulley to center itself under the
sprocket when it is not perfectly aligned.
The grooved and pinched freewheel teeth are not as "active" as the
Shimano twist teeth but work well when combined with overshift of
the shift levers.
Chain Recommendations
Bushingless chain is usually supplied with these systems. We have
found, however, that a chain with bushings that has less side flex
and twist works better.
Sedisport Pro and ATB Chain

Because the Sedisport Pro and ATB chains have mushroomed over
pins to help it withstand side thrust, Sachs recommends special care
when removing the chain. These two chains have a special dimpled
connecting pin that is located by a single black chain side plate. Push
the pin on the dimpled end when removal is needed. Push on the
mushroomed non-dimpled end when installing.
About the Derailleur Capacity Charts

The numbers listed in the derailleur capacity charts have been
compiled from Sachs-Huret's literature. The capacities listed are for
"normal conditions." Dropout geometry, chainwheel sizes, hub
position, chainstay geometry and other factors may increase or
decrease a given derailleur's capacity.
Total Capacity = Largest freewheel sprocket minus smallest, plus

the front gear difference.
Max. Chainwheel Difference = Largest chainwheel minus the
smallest
Blank spaces indicate no listing in the manufacturer's literature.
1990 6-7
INDEXING
REAR DERAILLEURS
SACHS·HURET INDEXED RIGHT SHIFT LEVERS
Derailleurs on same or next line correspond cosmetically. Shift levers in the same box work with
any of the derailleurs in the adjacent box
Model Shift
Categories Models Lever Derailleur Freewheel
7- & 6- • New Success MA 85.5* AR 47.2 D Sachs-Maillard
speed • New Success Touring AR47.2 T ARIS
• Rival Sport MA 82.4*, MA 82.7 P AR 41.3 D 7-speed narrow
• Rival Touring AR41.3 T or 6-speed
regular
6-speed • Rival ATB MA 82.8 G AR 41.4 T Sachs-Maillard
RGS 5- or 6-
I'-----~~~-----'-t---~~~~~~-__+__~~~~~~~"_'__+__~~~~
speed regular
6- & 5- • Rider IS MA 88.30, MA 88.33 AR 46.2 w/spoke guard
speed
• Elysee (with MA 93.1 G AR 49.1 D Sachs-Maillard
"Positron-type" cable) ARIS
• Explorer MA90 AR48 Sachs-Maillard
Explorer
* E following these numbers stands for frame mount. G stands for handlebar mount.
SACHS·HURET INDEXED REAR DERAILLEUR CAPACITY

Please see notes, "About the Derailleur Capacity Charts," on page 6-7.
Maximum
Freewheel
Maximum
Model Model Chainwheel Total Dropout
Categories Models No. Difference Capacity L= 24 L= 28
,- & 6- • New Success AR 47.2 D 16T 28T 26T 28T
speed • New Success Touring AR 47.2 T 26T 40T 30T 32T
• Rival Sport AR 41.3 D 16T 28T 26T 28T
• Rival Touring AR 41.3 T 26T 40T 30T 32T
6-speed • Rival ATB AR 41.4 T 26T 40T 34T
6- & 5- • Rider AR 46.2 43T 34T
speed
• Elysee (with AR 49.1 D 16T 28T 30T 32T
"Positron-type" cable) _
• Explorer AR 48 28T 28
6-8 1990
NON-INDEXING
REAR DERAILLEURS
SACHS-HURET NON-INDEXING REAR DERAILLEURS

Maximum Freewheel
Teeth
Total Dropout
Model Model No. Capacity L=24mm L=28mm
• Jubilee AR44/2 31T 28T
• Jubilee-long cage 2253 40T 28T
• Success 2470 31T 28T

• New Success 47/2 30T 30T
• New Success-long cage AR 47/3 42T 36T
• Duopar 40/3 34T 36T

2648 H 36T 36T
2648 GC 36T 38T
• DuoparEco 2690 H 36T 36T

2690 GC 36T 38T
• Pilot 2900-00 H 30T 28T

AR 45/2 30T 30T
• Rival 41/2 28T 36T

• Rival-long cage AR 41/3 42T 36T
2850-00 30T 28T
• Rider AR 46/2 28T 32T

• Rider-long cage AR 46/3 43T 36T
-Eco AR 30/2 31T 28T

• Eco-Iong cage AR 30/3 38T 28T
• Eco-S AR 31/2 31T 28T
1990 6-9
FRONT DERAILLEURS
(/) SACHS-HURET FRONT DERAILLEURS

u
..... Half-Stepl
Max. Clamp Diameter
Chainwheel or
z Model Model No. Alpine Difference* Braze-On (B/O)
«
:c • Jubilee AV66/2 half-step 16T 28-28.6
u
'-IJ" • Success AV975 half-step 16T 28-28.6
• New Success AV 67/3 alpine 26T 28-28.6, 29, 30
.~ • New Success, Pilot AV 67/2 half-step 16T 28-28.6, 29, 30
• New Success ARIS AV66.5 D half-step 16T 28-29
'-IJ AV 66.6 D half-step 16T B/a
~
AV66.5T alpine 26T 28-29
U
>
U
AV66.6T alpine 26T B/a
..... 28-28.6, 29, 30

= • Hi Stepper (Duopar) AV67/3s half-step 16T
a: • Rival AV62/2 half-step 16T 28-29, 30

o
u..
AV62/2
AV 62/3
alpine
half-step
26T
16T
28-29, 30
B/a
~ AV62.2D half-step 16T 28-29, 30

o • Rival Sport ARIS
AV62.2 T alpine 26T 28-29, 30
o AV62.3 D half-step 16T B/a
=
Q • Rival ATB ARIS AV41.4T alpine 26T 28-29, 30
Z
<I:: • Eco S AV60/2 half-step 16T 28-29, 30
:c • Rider, Eco, Commander
• Rider, Eco
AV69/2
AV 69/3
half-step
alpine
16T
26T
28-29, 30
28-29, 30
(/) AV62.4D half-step 16T 28-29
~ • Rider Sport ARIS
Q
Z • Club ** half-step
half-step
16T
16T
28-28.6, 25.4
28-28.6, 25.4
<I:: • Club AS **
~ *Subtract 4 teeth when using oval chainrings
a:'-IJ **Model number not available.
:c
~
:J
(/)
6-10 1990
INDEXING
SHIMANO SIS
Design Elements
• Twisted teeth "active" freewheel.
• Floating guide pulley.
Shimano's "active" freewheel helps guide the chain to complete the shift
The floating guide pulley centers itself under each' cog without having the
pulley cage perfectly lined up. '
Bushingless chain works best, although the sy~tem is Plore tolerant of a
variety of chains than other systems.
Freewheel Chain
Hyperglide narrow CN-M732'
CN~MT62
CN-90-70-50
7-speed & 8.-speed nan-.ow Shimano narrow
non.. Hyperg}ide for road bikes $edispo!t narrow *
6-speed regular spaced Shimano UG reg,ular chain
Shimana narrow
Sedisport narrow*
* For Sedisp'0rt Pro andAT8 chains see chain recommendation~ at t~e
begin~ing of the Sachs.-:,Huret section.
Hyp~rglide fre,ewheels require the lJ,seof special Hyperglide chain with
mushroomed-over pins that c~n help it withstand side thrust Shimano
recommends using'only a Uniglide chain'cutter. When breakin'g the chain
push a single pin all the way out When rejoining the chain use the special
HG pin to replace. After pin is inserted break off remaining end with pliers.
When cutting Uniglicie chain withplier-type cutters Shim(ino recommends
installing their Var adapter for Varpliers or their Hpzan adapters f<?f Hozan
pliers.
The numbers listed in the derailleur capacity charts have been compiled from
Shimano's literature. The capacities listed are, for "normal conditions."
Dropout geometry, chainwheel sizes, hub position, chainstay geometry and
other factors may increase or decrease a given derailleur's capacity.
Max. Chainwheel Difference:: Largest chainwheel-minus t4e smallest
Total' Capacity ;:;: Largest freewheel sprocket minus smallest, plus
the Max. Chainwheer~Difference
Max. Freewheel Teeth ::Largest freewheel ~procket
1990
INDEXING
SHIMANO SIS LEVERS

+ Dura-Ace levers will not work with standard SIS derailleurs and standard SIS levers will
not work with Dura-Ace derailleurs.
Freehubl Rear
Model Categories SIS Type Lever Models Freewheel Derailleur
Dura-Ace 8-speed Dura-Ace • Dura-Ace 8-speed, FH-7402 Dura-Ace RD-7402
Integrated-8 SL-7402
Dura-Ace 7-speed Dura-Ace • Dura-Ace 7-speed Shimano Dura-Ace RD-7401
SL-7401 7-speed SIS
Dura-Ace 6-speed Dura-Ace • Dura-Ace 6-speed Shimano Dura-Ace RD-7400
SL-7400 6-speed SIS
Standard 7-speed Standard • Sante Shimano Any SIS rear

Lightweights • 600 Ultegra *(7-speed) 7-speed SIS derailleur except
(down tube and sten1 • 105, 105SC 7-speed Dura-Ace
mount) • Sport LX 7-speed
• RX 100 7-Speed
• Exage 500EX, 400EX, 300 EX
• Deore XTII, XT, II 7-speed
• Deore DX
ATB (handlebar Standard • Mountain-LX 7-speed
mount) • DeoreLX
• Exage 500LX, 400LX, 300LX
• 200GS 7-speed
Standard 6-speed Standard • 600 Ultegra *(6-speed) Shimano Any SIS rear
Lightweights • 600 EX 6-speed 6-speed SIS derailleur except
(down tube and stem • 105 6-speed Dura-Ace
mount) • L Components 6-speed
• Exage Sport 6-speed
• Exage Action 6-speed
• Deore XT 6-speed
• Deore 6-speed
• Exage Motion 6-speed
ATB (handlebar Standard • Exage Mountain 6-speed
mount) • Exage Trail 6-speed
• Exage Country 6-speed
• 200GS 6 speed
* The 600 Ultegra SL-6400 lever can be modified for 6- or 7-speed use. For 6-speed, insert
adapter into cable groove.
7-2 1990'
INDEXING
SHIMANO RAPIDFIRE LEVERS

One Push Max. Steps*
Right Lever Left Lever
Model for Rear for Front
Derailleur Derailleur
• DeoreXT 6 steps 2 steps
• DeoreDX
• DeoreLX 3 steps 1 steps
• Exage
• 200 GS
* Starting from smallest rear cog or smallest front chainring,
the number of steps one push will move the chain.
SHIMANO SIS DROPOUT DIMENSIONS

The following are the recommended dimensions for optimum
shifting performance and the Shimano dropouts that meet these
dimensions.
L e X Dropout Model
24mm 30,-335 0
4-12mm Shimano-EF FE-EF20
26mm 30~35° 6-12mm Shimano-SF FE-SF20
28mm 25~30° 6-12mm
29mm 25~30° 6-12mm Shimano-SFR FE-SF21
Shimano-SFRW FE-SF22
30mm 25~30° 7.5-12mm
1990 7-3
INDEXING
REAR DERAILLEURS
SHIMANO SIS REAR DERAILLEUR CAPACITIES-SHIMANO DROPOUTS
Derailleurs listed here are SIS compatible. Some derailleurs with identical names are
not SIS compatible. Carefully check model numbers· stamped in the back of the
body.
Dura-Ace levers will not work with standard derailleurs and standard levers will not
work with Dura-Ace derailleurs.
Max.
Model Max. Freewheel
No. Chain- Teeth
stamped wheel Total Dropout Dropout
in back SIS Differ- Capa- EF SF
Model Categories of body Type ence city L=24 L=26
Dura-Ace 8-, 7- & 6-Speed RD-7402 Dura-Ace 14T 26T 26T
(also see page 7-8 for older RD-7401, Dura-Ace 13T 26T 26T
non-indexing model numbers) RD-7400
Standard 6-& 7-Speed

• 600 Ultegra RD-6400 Standard 14T 26T 28T
• 600 EX* RD-6208 13T 28T 28T
• Sante RD-5000 13T 24T 24T

RD-5001 13T 24T 24T
• Sante-Medium Cage (LS) RD-5001 13T 28T 23T 28T
* Also see page 7-7 for older models.
Pulley Center
( to
Pulley Center
Rear derailleur cage viewed from the back.
7-4 1990
INDEXING ••••
REAR DERAILLEURS· ® •
SHIMANO SIS REAR DERAILLEUR CAPACITIES-SHIMANO DROPOUTS (cont.)
The capacity for the derailleurs listed on this page can bedetennined by the pulley
center to pulley center length. See the table at the bottom of the page.
Model No. Model No.
stamped in stamped in
back of back of
Model Categories body Model' Categories body
Standard 6-& 7-Speed
• 105 SC RD-1055 • Exage 500LX RD-M500
• 105 RD-1051 • Exage 400LX RD-M400
RD-1050 • Exage 300LX RD-M300
• (Exage) Sport LX RD-A452 • Exage .Sport RD-A450

• (Exage) Mountain LX RD-M452 • Exage Action RD-A350
• Exage Motion RD-A250
• Deore RD-MT62
RD-MT60 • Exage Mountain RD-M450
• Exage Trail RD-M350
• DeoreXT RD-M735 • Exage Country RD-M250
RD-M732
RD-M730 • 200 GS RD-M200
• DeoreDX RD-M650 • L (Light Action) RD-L554

• DeoreLX RD-M550 Note: Models L532, RD-L532
• RX100 RD-A550 L523 and L525 are SIS RD-L523
compatible only in the SS RD-L525
• Exage 500EX RD-A500 (short cage) m~del.
• Exage 400EX RD~A400
• Exage 300EX RD-A300 • (marked SIS, as are other RD-L541
models)
continued next column
Max. Freewheel Teeth

Max. Drop-
Pulley Chain- Drop- Drop- out
Cage Length Center to wheel Total out out SFR,
Designation Pulley SIS Differ- Capa- EF SF SFRW
Example: RD-452-SGS Center Type ence city L=24 L=26 L=29
SS or no designation 56mm Standard 13T 28T 28T
GS 75mm 20T 34T* 26T 30T
SGS 8(5.5mm 20T 38T 28T 32T
* 1990 Shimano Service Handbook lists GS Total Capacity as 36T
1990 7-5
INDEXING
REAR DERAILLEURS
C/') SHIMANO SIS REAR DERAILLEUR CAPACITIES (cont.)
...Z
U Please see notes, "About the Derailleur Capacity Charts," on page 7-1.
Max.
Chain
~ Model No. wheel Total Max.
:cu Model Categories
stamped in back
of body
SIS
Type
Differ- Capa-
ence city
Freewheel
Teeth
UJ Standard 6-Speed that
:E can fit PR20 dropout
UJ • (marked SIS, as are other RD-M531 Standard 36T 30T*
....) models)
u Standard 6-Speed with
> gear hanger
...u • (marked Shimano SIS,
as are other models)
RD-R552-SS
RD-R552-GS
Standard 13T
20T
28T
36T
28T
30T
= RD-TY20-SS 13T 28T 24-28T
=
o
u. Standard 5-Speed with
gear hanger
RD-TY20-GS 20T 34T 30T
~ • (marked Shimano SIS, RD-R552-SS Standard 28T 28T

o
o
as are other models) RD-R552-SGS
* Using Shimano fork end SF or PR20
36T 30T
=
Q
Z
SHIMANO OLDER NON-SIS INDEXING REAR DERAILLEURS
These derailleurs must be used with Shimano's corresponding levers for indexing to
~ work. The Positron must be used with the corresponding lever and push-pull cable.
:c Model No.
stamped in
Max.
Chainwheel Total
Max.
Freewheel
C/')
~ Model Categories back of body Difference Capacity Teeth
Q Dura-Ace AX RD-7300 13T 26T 24T
Z 600 AX RD-6300 13T 28T 28T
~ AdamasAX RD-ADI0 13T 28T 28T
....)
Positron DG-I00 13T 34T 34T
:c=
Positron AX RD-AXI0 13T 28T 28T
UJ Positron-FH* RD-PFI0* 13T 28T 28T*
Positron-FH (medium cage)* RD-PF20* 13T 32T 32T*
~ Positron-FH 400* RD-PF40* 13T 28T 28T*
::J Positron-FH EM* RD-PF30* 13T 32T 32T*
C/')
Positron-II* RD-P210* 13T 28T 28T*
Positron-111* RD-P312* 13T 28T 28T*
Positron-400* RD-P240* 13T 28T 28T*
* For use only with Shimano Front-Freewheeling setup.
7-6 1990
NON-INDEXING
REAR DERAILLEURS
SHIMANO NON-INDEXING REAR DERAILLEURS
Please see notes, "About the Derailleur Capacity ChartS," on page 7-1. C/)
Derailleurs that have cage length designations as part of the model number measure as
c::
~
follows:
Cage Length Designation Pulley Center to
:c
tTl
Example: RD-L513-SGS Cage Size Pulley Center :=
r-
SS Short Cage 56mm
GS Long Cage 75mm )-
SGS Super Long Cage 86.5mm :2
o,.
For many of these derailleurs no dropout dimension (L) was given in Shimano's C/)
literature. Generally the short cage derailleurs use a 24mm dropout while the longer cage
derailleurs need a 26mm or longer dropout. We have noted where Shimano makes a
:c
)-
specific recommendation.
:2
Model No. Max. Max.
o
Model
stamped in back Chainwheel
of body Difference
Total Freewheel
Capacity Teeth =
o
• Deore (medium cage)
(long cage)
RD-DE10
RD-DE20
20T
20T
30T
34T
30T
34T o
• Deore XT (w/Superplate) RD-M700-SP 40T* 34T ~
• DeoreXT RD-M700 22T 40T 34T ."
• 600 RD-6100 13T 13T 28T o
• 600 (long cage) RD-6101 13T 13T 34T :=
• 600 AX
• 600 EX**
RD-6300
RD-6200
RD-6207
13T
13T
13T
28T
28T
28T
28T
28T
28T
=
....
n
• 600 EX (long cage) RD-6210
RD-6207-GS
13T
13T
34T
34T
34T
34T <
n
• 105 RD-A105 13T 28T 28T r-
RD-A105-GS 13T 34T 34T tTl
• L (Light Action)
The Light Action
RD-L512
RD-L513
3:
tTl
derailleurs listed in the RD-L514
n
next column have the
capacities listed according
RD-L522
RD-L523 :c
)-
to the cage lengths RD-L525
SS- Short Cage

RD-L532
28T 28T . .
:2
....
GS- Long Cage
SGS- Super Long Cage
34T
40T
34T
34T
n
C/)
* 42T with dropout that has a 29mm L dimension.
** Also see page 7-4 for newer model.
1990 7-7
NON-INDEXING
REAR DERAILLEURS
(/') SHIMANO NON-INDEXING REAR DERAILLEURS (cont.)
U
.... Model No. Max. Max.
stamped in Chainwheel Total Freewheel
Z Model back of body Difference Capacity Teeth
<C
:c ·Z
The Z derailleurs listed in
RD-Z501
RD-Z503
U the next column have their RD-Z505
L.IJ capacities listed according to
~ cage lengths
L.IJ SS- Short cage 30T 28T
~ GS- Long cage 34T 34T
U SGS- Super Long Cage 40T 34T
>-
....
U
= Older Models (alphabetically)
=
o
LI.
• AL-II
• Altus-LT
• Altus-LT (long cage)
RD-ALII
RD-ATI2
RD-AT22
22T
13T
13T
40T
28T**
34T
34T
28T**
34T
• Altus-ST RD-ATII 13T 28T** 28T**
~ • Altus-ST (long cage) RD-AT21 13T 34T 34T
o • Crane DB-IOO 13T 28T 28T
o • Crane-GS DB-IIO 13T 34T 34T
=
Q
• Dura-Ace**
• Dura-Ace EX
RD-7100
RD-7200
13T
13T
26T
26T
26T
26T
Z • Eagle-II RD-EGIO
RD-LK-I0
13T
13T
34T
34T
34T
34T
<C • Lark II
:c • Lark-Mini
• RS
RD-LK20
RD-RSll,
13T
13T
28T
34T
28T
34T
(/') RD-RSI2 13T 34T 34T
~
Q • Sky Lark RD-SLIO 13T 34T 34T

• Titlist RD-TLIO 13T 28T 28T
Z • Titlist-GS RD-TLll 13T 34T 34T
<C • Tourney RD-TNIO 13T 28T 28T
~
:ci-=
• Tourney-GS (long cage) RD-TNII 13T 34T 34T
• Tourney RD-TYIO-SS 13T 30T 30T
(.IJ • Tourney-GS (long cage) RD-TYIO-GS 13T 34T 34T
• 500 DC-IOO 13T 28T 28T
• 500-GS DC-IIO 13T 34T 34T
;:) • 400 DC-400 13T 28T 28T
(/') • 400-GS DC-410 13T 34T 34T
• 400 FF RD-40IF 13T 34T 34T
* Add 2 teeth with a dropout that has a 29mm L dimension.
** Also see page 7-4 for newer models
7-8 1990
FRONT DERAILLEURS
SHIMANO FRONT DERAILLEUR CAPACITIES

"Half Step" refers to a gearing setup with chainwheels that are close
enough in tooth number to make a front shift that is roughly half that
of a rear shift (% increase or decrease in gear inches). In common
setups, this is a chainwheel difference of 4 or 5 teeth. This setup
requires a front derailleur whose inner and outer cages are close in
height (matching the closeness of the diameters of the chainwheels).
"Alpine" (sometimes called "Crossover") refers to a gearing setup

featuring chainwheels that are typically 10-12 teeth apart. This
makes for distinct ranges of gears (one for each chainwheel), as
opposed to the evenly dispersed front and rear shifts found with a
"Half-Step" setup. "Alpine" derailleurs have inside and outside
plates that differ considerably in height, thus allowing the chain to
be guided over the large shifts between chainwheels.
SHIMANO INDEXING FRONT DERAILLEURS

Indexing front derailleurs must use their corresponding shift levers.
Chainwheel
Difference Half-Stepl Clamp Diameter
Model Model No. Min. Max. Alpine or Braze-On (B/O)
• Exage Sport FD-A450* 3T 14T half-step 28.0-28.6, BfO
FD-A451
FD-A350*
FD-A351
• Exage Mountain** FD-M450* 20T*** alpine 28.0-28.6, 31.8, 34.9, BfO
FD-M451
* Narrow chains cannot be used with these derailleurs. Shimano recommends only the regular
width UG chain.
** Shimano recommends that this derailleur only be used with under-the-bottom bracket cable
routing.
*** 24T when used in the friction mode.
1990 7-9
FRONT DERAILLEURS
SHIMANO NON-INDEXING FRONT DERAILLEURS
C/') Also see next page for older models
U Half-Stepl Capacity Clamp Diameter or

..... Model Model No. Alpine Min. Max.* Braze-On (B/O)
Z
«
x:
• Dura-Ace
• Deore DX
FD-7403
FD-M650
half-step
alpine
15T
26T
28.0-28.6, BIG
28.0-28.6
28.0-28.6, 31.8, 34.9
u • Deore LX FD-M550 alpine 26T
L.IJ • DeoreXT FD-M700 alpine 8T 22T 28.6
~ FD-M730-HS
FD-M730-AL
half-step
alpine
5T
8T
26T
26T
28.0, 28.6, 31.8
28.0, 28.6, 31.8
UJ FD-M735 alpine 26T 28.0-28.6, 31.8, 34.9
~
U • Deore XT II FD-M732-HS half-step 5T 24T 28.0, 28.6, 31.8
>
U
FD-M732-AL alpine 8T 24T 28.0, 28.6, 31.8
..... • Sante FD-5000 half-step 14T 28.6, BIG
=
ce:
o
• 600 Ultegra
• 600 EX
• 105
FD-6400
FD-6207
FD-1050
half-step
half-step
half-step
3T
3T
3T
14T
18T
14T
28.0-28.6, BIG
28.6, BIG
28.0-28.6, BIG
half-step 14T 28.0-28.6, BIG
u.. FD-1055
14T 28.0-28.6
·Z FD-Z254 half-step
~ 28.0-28.6
o FD-Z255
FD-Z260
alpine
llalf-step
22T
14T 28.0-28.6
o FD-Z261 alpine 22T 28.0-28.6
=
Q • Mountain LX FD-M452-HS
FD-M452-AL
half-step
alpine
5T
8T
26T
26T
28.0, 28.6
28.0, 28.6
Z FD-A452 half-step 14T 28.0-28.6, BIG
«
x:
• Sport LX
• RX-100 FD-A550 half-step 14T 28.0-28.6, BIG
• Exage 300 EX FD-A300 half-step 14T 28.0-28.6
C/') • Exage 400 EX FD-A400 half-step 14T 28.0-28.6, BIG
.-.
Q • Exage 500 EX FD-A500 half-step 14T 28.0-28.6, BIG
14T 28.0-28.6
Z • Exage 300 LX FD-M300 half-step
«
~
• Exage 400 LX
• Exage 500 LX
FD-M400
FD-M500
alpine
alpine
26T
26T
28.0-28.6, 31.8, 34.9
28.0-28.6, 31.8, 34.9
ce: • Exage Country FD-M250 alpine 8T 22T 28.0-28.6
UJ • Exage Motion FD-A250 half-step 17T 28.0-28.6
x:
(-t
• Exage Trail FD-M350
FD-M351
alpine
alpine
22T
22T
28.0-28.6, 29.0, 31.8, 34.9
28.0-28.6, 29.0, 31.8, 34.9
:J • 200 GS FD-M200 alpip.e 22T 28.0-28.6
C/') • (no name) FD-AX50 half-step 3T 14T 28.0-28.6
• (no name) FD-AX55 alpine 8T 22T 25.4, 28.6
• (no name) FD-TY20 half-step 14T 28.0-28.6
• (no name) FD-TY25 alpine 22T 28.0-28.6
* Shimano recommends subtracting 4 teeth from max. capacity for Biopace. Subtract 2 teeth for
Biopace HP.
7-10 1990
FRONT DERAILLEURS
SHIMANO NON-INDEXING FRONT DERAILLEURS
Older Models (Pre-' 85) alphabetically
Half-Step/ Capacity Clamp Diameter or
Model Model No. Alpine Min. Max.* Braze-On (B/O)
• AdamasAX FD-AD10 half-step 14T 28.6
• Altus FD-AL11 alpine 8T 22T 28.6, 25.4
• Altus FD-AT11 half-step 14T 28.6, 25.4
• Altus-LT FD-AT12 half-step 14T 28.6, 25.4
• Altus-ST FD-AT-11 half-step 14T 28.6, 25.4
• Deore FD-DE10 alpine 20T 28.6
• Deore FD-MT60-HS half-step 5T 26T 28.0, 28.6, 31.8
FD-MT60-AL alpine 8T 26T 28.0, 28.6, 31.8
• Deore II FD-MT62-HS half-step 5T 24T 28.0, 28.6, 31.8
FD-MT62-AL alpine 8T 24T 28.0, 28.6, 31.8
• Dura-Ace EA-100 half-step 16T 28.6
FD-7100 half-step 16T 28.6
• Dura-Ace EX FD-7200 half-step 14T 28.0-28.6, BfO
• Dura-Ace AX FD-7300 half-step 14T 28.0-28.6, BfO
• New Dura-Ace FD-7400 half-step 15T 28.0-28.6, BfO
·FE FD-FE11 half-step 3T 14T 28.6, 25.4

FD-FE12
• Positron-III FD-P311 half-step 14T 28.6
FD-P312
• Positron AX FD-AX10 half-step 14T 28.6, 25.4
• Thunder Bird-II ED-300 half-step 16T 28.6
• Titlist EB-200 half-step 14T 28.6
• 400 EC-400 half-step 14T 25.4, 28.6

• 500 EC-500 half-step 14T 25.4, 28.6
• 600 FD-6100 half-step 14T 28.6

• 600 EX FD-6200 half-step 14T 28.6
• 600 AX FD-6300 half-step 14T 28.6
·z FD-Z202 half-step 14T 28.6
FD-Z204-HS half-step 3T 18T 28.6
FD-Z204-AL alpine 6T 27T 28.6
FD-Z206-HS half-step 3T 18T 28.6,31.8
FD-Z206-AL alpine 6T 27T 28.6, 31.8
* Shimano recommends subtracting 4 teeth from max. capacity for Biopace. Subtract 2 teeth for
Biopace HP.
1990 7-11
,..
FRONT DERAILLEURS
7-12 1990
INDEXING
SUNTOUR ACCUSHIFT AND ACCUSHIFTPLUS

Design Elements
• Overshift built into shift levers
• System has less built-in "play" than others.
SunTour Accushift is very different from Shimano SIS.
Overshift is built into the levers (overshift of Imm of cable travel). This pushes
the chain centerline past the cog centerline to complete the shift. The guide
pulley then settles back into a position where it is centered under the cog.
The guide pulley lines up exactly under each freewheel cog without as much
"play" as other systems.
• AccushiftPlus chain and Sedis ATB* chain·are recommended for
AccushiftPlus and Accushift systems. Do not use other bushingless chains
such as Sedisport.
• Also recommended for Accushift (pre-1990) systems are the chains with
bushings listed below.
Freewheel Chain
AccushiftPlus 7-speed Ultra AccushiftPlus
Sedis ATB*
AccushiftPlus 6-/5-speed Regular Space AccushiftPlus
Sedis ATB*
Accushift 7-speed Ultra AccushiftPlus
Sedis ATB*
SunTonr Superbe Pro, Pro, Cyclone, GPX
Accushift 6-/5-speed Regular Space AccushiftPlus
Sedis ATB*
SunTonr Superbe Pro, Pro, Cyclone, GPX
HKK",Z"
DID Lanner
*See Sedisport chain notes in the Sachs-Huret section when using Sedis chain.

The numbers listed in the derailleur capacity charts have been compiled from
SunTour's literature. The capacities listed are for "normal conditions."
Dropout geometry, chainwheel sizes, hub position, chainstay geometry and
other factors may increase or decrease a given derailleur's capacity.
Max. Chainwheel Difference =Largest chainwheel minus the smallest
Total Capacity =Largest freewheel sprocket minus smallest, plus
the Max. Chainwheel Difference.
Max. Freewheel Teeth = Largest freewheel sprocket
19908-1
INDEXING
SUNTOUR ACCUSHIFTPLUS AND ACCUSHIFT LEVERS

Accushift down tube clamp-on index shifters have lever post flats that are often perpendicular to
the down tube while the braze-ons have lever post flats are normally parallel to the down tube. If
you run across braze-ons that are mounted with the flats perpendicular you can use levers from a
clamp-on set. Another solution is to use GPX levers that are keyed to the large square portion of
the braze-on rather than the post flat.
Lever Model Categories-Some model names are listed more

than once since levers changed from year to year or they come in 7-
speed narrow and 6-speed/ 5-speed models. Freewheel Derailleur
IPC-Indexed Power Control Use with any Use with any

3-mode ring marked: SunTour rear
RE for indexing 6- and 5-speed regular spaced SunTour freewheel that can Accushift
freewheel. be removed with derailleur
P ("power")-for ratcheted non-indexing shifting. the four-notch except
UL for indexing 7-speed narrow-spaced SunTour freewheel. remover (Winner, a-3000.
Winner Pro,
• Superbe Pro SunTour Alpha or
• Sprint 9000 Ultra7 freewheels)
except Ultra6.
AccushiftPlus (4 mode) Index Control
4-mode ring marked:
7 for indexing 7-speed narrow spaced SunTour freewheels.
7F for friction with clicks-shifting 7-speed narrow SunTour
freewheels.
6 for indexing 6 speed regular spaced SunTour freewheels.
6F for friction with clicks-shifting 6-speed regular-spaced
SunTour freewheels.
·GPX
• Radius
IFC-Indexed Friction Control
3-mode ring marked:
RE for indexing 6- and 5-speed regular-spaced SunTour
freewheel.
F (friction) for non-indexing shifting.
UL for indexing 7-speed narrow spaced SunTour freewheel.
·GPX
AccushiftPlus (2 mode) Index Control Use with any Use with any
7-speed SunTour narrow rear
2-mode ring marked: spaced (not Accushift
7 for indexing 7-speed narrow-spaced SunTour freewheels. regular) freewheel derailleur
7F for friction with clicks-shifting 7-speed narrow SunTour that can be except
freewheels. removed with the a-3000.
four-notch
• Bar-End Control • XCD, XCD Express remover (Winner
·VX • X-I Croma, X-I Pro, Winner)
• XC-Pro, XC-Pro Express • XCE, XCM, XCT except Ultra6.
• XC-Comp • FT, FT Express
8-2 1990
INDEXING
SUNTOUR ACCUSHIFTPLUS AND ACCUSHIFT LEVERS (cont.)
Lever Model Categories Freewheel Derailleur

IFC-Indexed Friction Control Use with any Use with any
7-Speed SunTour narrow- rear
Accushift 7-Index-Friction regular) freewheel derailleur
that can be except
• Bar-Con • XCD-6000 removed with the a-3000.
• Edge-4050 • XCE-4500 four-notch
• XC-9000 remover (Winner
Pro, Winner)
except Ultra6.
AccushiftPlus (2 mode) Index Control Use with any Use with any
6-/5-speed SunTour regular- rear
6 for indexing 6-speed regular spaced SunTour freewheels. narrow) freewheel derailleur
6F for friction with clicks-shifting 6-speed regular-spaced that can be except
SunTour freewheels. removed with the a-3000.
four-notch
• Bar-End Control • XCD, XCD Express remover (Winner,
·VX • X-I Croma, X-I SunTour a).
• AC-2000, 1000 • XCE, XCM, XCT
• XC-Pro, XC-Pro Express • FT, FT Express
·XC-Comp
IFC-Indexed Friction Control
6-/5-speed
2-mode ring marked:
Accushift-Index-Friction
• Cyclone-7000 • XC-9000
• Ole • XC-Sport-7000 Brake
• Bar-Con • XCD-6000, 4050
• a-5000 , 4050, 3040, • XCE-4500
2000, 1500 • XCM-3040
IC-Indexed Control
6-speed
I-mode-Index mode only
All derailleurs except a-3000
• Scrambler II
IC-Indexed Control Use with
6-speed a-3000 rear
I-mode-Index mode only derailleurs
a-3000 only only.
• a-3000
1990 8-3
•••• INDEXING
• •
SUNTOUR DROPOUT RECOMMENDATIONS
The following are the recommended dimensions for optimum shifting performance
and some of the SunTour dropouts that meet these dimensions.
L 8 X Dropout Model
24mm 30-35° 3-7mm Superbe-Pro EF-230
ideal-35° SunTour-a DO-ALAI
DO-ALAO
DO-ALB I
DO-ALB0
26mm 30-35° 3-7mm Superbe-Pro EF-160
ideal-35°
28mm 30-35° 3-7mm SunTour-GS EF-IOI
ideal-30° EF-170
EF-180
SunTour-GT EP-IOI
EF-200
EF-140
30mm 30-35° 3-7mm SunTour-SD EF-12I
ideal,~30° (vertical) EF-210
EF-220
8-4 1990
REAR DERAILLEURS· @ •
SUNTOUR ACCUSHIFT & ACCUSHIFT PLUS REAR DERAILLEUR CAPACITY
. . with Angle Adjusting Scr~w On Derailleur
Lightweight Models Model No. ATB Models Model No.

• Superbe Pro RD-SBOO • XC-Pro RD-XPOO
• Sprint 9000 RD-SPIO • XC 9000 RD-XCOO
·GPX RD-GPOO • XC-Comp RD-XC20
• Radius RD-RAOO • XC Sport 7000 RD-XSOO
• Ole RD-OLOO ·XCD RD-XDIO
• Cyclone 7000 RD-CLIO • X-I Chroma RD-CROO
• Edge RD-EDOO • X-I RD-XIOO
• Blaze RD-BEOO ·XCE RD-XEOO
·YX RD-YXOO, YXIO ·XCM RD-XMOO
• a-5000 RD-5000 ·XCT RD-XTOO, XTIO
• a-3000 RD-2000 • AC-2000 RD-A200
• AC-IOOO RD-AIOO
• a-1500 RD-1500
• Scrambler II RD-SRIO
Cage Length Pulley Max. Maximum Freewheel Teeth

Designation Center To Chain- Total
Example: Pulley wheel Capa- Dropout Dropout Dropout
RD-XMOO-GX Center difference city L=24 L=26 L=28
SS-Superbe Pro,
Sprint, and GPX 47.5mm I2T 26T 26T 26T 28T
SS others 56.5mm 12T 2ST 26T 28T 28T
GT 80mm I9T 34T 28T 30T 32T
GX 85mm 2IT 40T 28T 30T 32T
Pulley Center
-( to
Pulley Center
Rear derailleur cage viewed from the back.
1990 8-5
INDEXING
REAR DERAILLEURS
C/)
u
....
SUNTOUR ACCUSHIFT REAR DERAILLEUR CAPACITIES
. . with D/T attachments (1988, 1989 models only)
z
«
:cu
The capacities for the derailleurs on this page can be detennined by measuring the length between
pulley centers. See the tables below.
Models Model No. Models Model No.
UJ • XC 9010 RD-XC10 • XCD 4050 RD-4050
~ • XCD 6000 RD-XDOO

RD-ED45
• Blaze 3040 RD-BE45
RD-3040
• Edge 4050 • a-3040
(.IJ RD-XM34
• a-4050 RD-4050 ·XCM3040
~
u • XCE4050 RD-XE45 • a-3000 RD-3000
>
u with SunTour, Campagnolo and Tange Dropouts NR stands for not recommended
.... Max. 6-Speed Regular Spacing- 7-Speed Narrow Spacing-
=
Cd
Cage
Desig-
Pulley
Center
to Pulley
Chain-
wheel Total
Differ- Capac-
Maximum Freewheel Teeth
Dropout Dropout Dropout

Dropout Dropout
or.J.. nation
SS
Center
56.5mm
ence
12T
ity
28T
L=24
26TA
L=26
26T
L=28
28T
L=24
26TA,G
L=30 or less
NR
32TD,F,H
~ GX 85mm 20T 40T 28TC 28T 32TH 28TD
o
o with Shimano Dropouts NR stands for not recommended
=
Q Pulley
Max.
Chain-
6-Speed Regular Spacing-
7-Speed Narrow Spacing-
Z Cage Center wheel Total Dropout Dropout Dropout Dropout Dropout Dropout
«
:c
Desig-
nation
to Pulley
Center
Differ- Capac-
ence ity
EF
L=24
UF, SF
L=26
SFR
L=28
EF
L=24
UF, SF SFR
L=26 L=28
SS 56mm 12T 28T 26TB 28TC NR 26TB 28TC NR

..
C/)
GX 85mm 20T 40T 26TI 30TJ 32TK 26TD 30TD,F 32TD,F,K
Q
Z A. For 26T freewheels add Dff attachment with 2mm end facing forward.
«
~
B. For 24T freewheels add Dff attachment with 2mm end facing forward.
C.
For 26T freewheels add Dff attachment with 4mm end facing forward.
, fro~t
2mm 4mm
Cd For 28T freewheels add Dff attachment with 4mm end facing forward. ~I ..;.ear
UJ D. Smallest three cogs must be 13, 15 and 17T.

:cf- E.
F.
Largest cog must be 28T.
Largest cog must be 28, 30, or 32T.
G. Largest cog must be 24 or 26T.
:::J H. For 32T freewheels add Dff attachment with 4mm end facing forward.
C/) /. For 26T freewheels add Dff attachment with 4mm end facing forward.
J. For 28T freewheels add Dff attachment with 2mm end facing forward.
K. For 30T freewheels add Dff attachment with 2mm end facing forward.
For 32T freewheels add Dff attachment with 4mm end facing forward. D/T Attachment
8-6 1990
REAR DERAILLEURS· ® •
SUNTOUR NON-ACCUSHIFT INDEXING REAR DERAILLEURS

Max.
Max. Freewheel
Chainwheel Total Teeth
Model Model No. Difference Capacity L=26
• Mighty Click* RD-2700 13T 22T 30T
• Mighty Click-GT* RD-2800 13T 34T 34T
* Early indexing system; required Mighty Click levers.
1990 8-7
NON-INDEXING
REAR DERAILLEURS
SUNTOUR NON-INDEXING REAR DERAILLEURS
Max. Chainwheel Differ./ Total Capacity/ Max. Freewh.

Dropout Dropout Dropout Dropout
Model Model No. L=24mm L=26mm L=28mm L=30mm
- Sprint RD-7000
- SYX-GT RD-7400 14T/32T/32T
- SYX-SS RD-7300 12T/26T/28T
- AT-1000 RD-AT1 O-GX 20T/40T/32T

- RT-1000 RD-RT10-SS 14T/28T/28T
- Seven-GT RD-SNOO-GT */34T/28T */34T/30T

- Seven-SS RD-SNOO-SS */30T/28T
- Honor-GT RD-HOOO-GT */32T/34T

- Honor-SS RD-1100 11T/ 28T/ 30T
Older Models (Pre-87) alphabetically

Max. Chainwheel Differ./ Total Capacity/ Max. Freewh.
- Allegro RD-AEOO 11T/ 28T/ 26T 11T/ 28T/ 28T
RD-AEOO-GX 19T/39T/28T 19T/39T/30T 19T/39T/32T
-AGTech RD-5000 10T/34T/37T

- AG Tech-GTL RD-5600 19T/40T/37T
(extra long cage)
-AR RD-4200 15T/ 28T/ 26T

- AR-GT (long cage) RD-4400 13T/34T/34T
-ARX RD-4300 14T/28T/26T
- ARX (long cage) RD-4500 13T/32T/32T
- BL (short cage) RD-3200 13T/ 24T/ 24T
- BL-S RD-3600 17T/30T/26T
(medium cage!)
- BL-GT (long cage) RD-3300 13T/34T/34T
* Maximum chainwheel difference not listed in SunTour literature.
8-8 1990
NON-INDEXING
REAR DERAILLEURS
SUNTOUR NON-INDEXING REAR DERAILLEURS (cont.)
-Older Models (Pre-1987) alphabetically (cont.)
Max. Chainwheel Differ. / Total Capacity / Max. Freewh.
• Cyclone RD-6000 13T/ 24T/ 25T 14T/28T/26T
RD-6200 13T/ 24T/ 25T 14T/30T/28T
RD-6800 13T/ 24T/ 25T 17T/34T/30T
RD-1700 13T/ 24T/ 25T
• Cyclone GT RD-1800 17T/32T/34T

• Cyclone Mark II RD-3500 14T/28T/26T
• Cyclone Mark II-GT RD-3700 12T/34T/34T
(long cage)
·GT RD-1200 15T/36T/34T

• LePree-S RD-6100 14T/30T/28T
• LePree-GT RD-6700 17T/34T/30T
• MounTech RD-4900 13T/34T/34T
• MounTech-GTL RD-5500 19T/40T/34T
• Seven RD-1900 13T/26T/26T

• Seven-GT RD-2000 11T/ 32T/ 34T
• Skitter* RD-1000 12T/28T/30T
• Superbe Pro RD-3100 10T/20T/23T

RD-5200 11T/ 25T/ 26T
• Superbe RD-2100 10T/20T/23T

RD-5300 I1T/22T/23T
• Superbe Tech-S RD-4700 15T/ 28T/ 26T

(short cage)
• Superbe Tech-L RD-4800 13T/ 34T/ 34T
(long cage)
• Superbe Tech-GTL RD-5400 19T/40T/34T
(extra long cage)
• Trimec RD-4600 13T/ 28T/ 28T

• Trimec RD-6400 17T/30T/26T
·XC RD-6300 17T/38T/34T
·YX RD-2200 11T/ 24T/ 26T

• YX-GT RD-2400 13T/34T/34T
• YX-S RD-2500 15T/28T/26T
·YGT RD-1500 18T/ 34T/ 30T

• Volante RD-2600 10T/21T/24T
(short cage)
• Yolante-S RD-4100 15T/30T/28T
(long cage!)
* Low normal derailleur---cable pull shifts to smaller freewheel cog.
19908-9
FRONT DERAILLEURS
SUNTOUR INDEXING FRONT DERAILLEURS
"Half Step" refers to a gearing setup with chainwheels that are

close enough in tooth number to make a front shift that is
roughly half that of a rear shift (% increase or decrease in gear
inches). In common setups, this is a chainwheel difference of 4
or 5 teeth. This setup requires a front derailleur whose inner and
outer cages are close in height (matching the closeness of the
diameters of the chainwheels).
"Alpine" (sometimes called "Crossover") refers to a gearing

setup featuring chainwheels that are typically 10 to 12 teeth
apart. This makes for distinct ranges of gears (one for each
chainwheel), as opposed to the evenly dispersed front and rear
shifts found with a "Half-Step" setup. "Alpine" derailleurs have
inside and outside plates that differ considerably in height, thus
allowing the chain to be guided over the large shifts between
chainwheels.
SUNTOUR ACCUSHIFT INDEXING FRONT DERAILLEURS

Half-Step/ Capacity Clamp
Model Model No. Alpine Min. Max. Diameter
• XCE4051* FD-XE46-GX alpine 24T 28.6
• Scrambler* FD-4200 half-step 22T 28.6
SUNTOUR NON-ACCUSHIFT INDEXING FRONT DERAILLEURSt

• Mighty Click 10** FD-1800 half-step 18T 28.6
• Trimec FD-3600 alpine 24T 28.6
SUNTOUR "TOP-PULL" FRONT DERAILLEURtt

• Top Pull FD-TPOO-GX alpine 6f 124T 28.6, 31.8
* Requires matching model indexing shift lever.
** "Top normal" derailleur (cable pull produces shift to smaller chainring).
t Early indexing systems; required matching shift levers.
tt Cable is routed down to derailleur from above-requires appropriate braze-ons on frame.
,8-10 1990
FRONT DERAILLEURS
SUNTOUR FRONT DERAILLEURS

Lightweight Models
Chainwheel Clamp
Half-Stepl Difference Diameter
Model Model No. Alpine Min. Max. or Braze-On (B/O)
• Superbe Pro FD-SBOO-SS half-step If 16T 28.6,28.0,31.8, BfO
• Sprint 9000 FD-3900-SS half-step If 18T 28.6
• Sprint FD-SPOO-SSB half-step If 18T 28.6
• Cyclone 7000 FD-CL10-SS half-step If 18T 28.6, BfO
• GPX FD-GPOO-SS half-step If 16T 28.6, BfO

• Ole FD-OLOO-SS half-step If 18T 28.6, BfO
• Radius FD-RAOO-SS half-step If 16T 28.6, 31.8, BfO
• a-5000 F'D-5000-SS half-step If 18T 28.6, BfO

FD-5000-GT alpine 6f 22T 28.6
FD-5000-GX alpine 6f 24T 28.6
• Edge FD-EDOO-SS half-step If 18T 28.6, 31.8

• Edge 4050 FD-ED45-SS half-step If 18T 28.6, BfO
• a-4050 FD-4050-SS half-step If 18T 28.6, BfO
• Blaze FD-BEOO-SS half-step If 18T 28.6, 31.8

• Blaze 3040 FD-BE34-SS half-step If 18T 28.6
• a-3040 FD-3040-SS alpine 6f 24T 28.6, BfO
• a-3000 FD-3000-SS half-step If 18T 28.6

·SYX FD-4300 half-step If 18T 28.6
·YX FD-YXOO-SS half-step If 18T 28.6, 31.8
• AC-2000 FD-A200-SS half-step If 18T 28.6

• AC-1000 FD-RTI0-SS half-step If 18T 28.6, 31.8

FD-AT1 O-GX alpine 6f 24T 28.6
• RT-1000 FD-RTI0-SS half-step If 18T 28.6

• Allegro FD-AEOO half-step If 16T 28.6
• Seven FD-SNOO half-step If 18T 28.6
• Spirt FD-I000 half-step If 18T 28.6
1990 8-11
FRONT DERAILLEURS
en SUNTOUR FRONT DERAILLEURS (cont.)

U All-Terrain Models
.... Chainwheel Clamp
Z Half-Step/ Difference Diameter
<C Model Model No. Alpine Min. Max. or Braze-On (B/O)
:c • XC Pro FD-XPOO-GX alpine 6f 24T 28.6, 31.8, 35.0
U • XC Comp FD-XCI0-GX alpine 6f 24T 28.6, 31.8, 35.0
UJ • XC 9000 FD-XCOO-GX alpine 6f 24T 28.6,28.0
~ • XC Sport 7000 FD-XSOO-GT alpine 6f 22T 28.6

FD-XSOO-GX alpine 6f 22T 28.6
l.U
.~ 28.6, 31.8, 35.0
·XCD FD-XDI0-GX alpine 6f 24T
U • XCD 6000 FD-XDOO-GX alpine 6f 24T 28.6,31.8, BIG
>-
U
FD-XSOO-GX alpine 6f 24T 28.6, 31.8, BIG
.... • XC 6000 FD-XSOO-GT alpine 4T 22T 28.6, 31.8, BIG
=
=: • a-5000 FD-5000-GT
FD-5000-GX
alpine
alpine
4T
6f
22T
24T
28.6
28.6
ou.. 24T
• XCD 4050 FD-4050-GX alpine 6f 28.6,;31.8,B/G
~. • XCE4050 FD-XE45-GX alpine 6f 24T 28.6
o • XCE4051 FD-XE46-GX alpine 6T 24T 28.6
o
=
Q
• a-3040
·XCM 3040
FD-3040-GX
FD~3000-GX
FD-XM34-GX
alpine
alpine
alpine
6f
6f
6T
24T
24T
24T
28.6
28.6
28.6
Z • X-I FD-XI00-GX alpine 6f 24T 28.6, 31.8, 35.0
<C • X-I Chroma FD-CROOGX alpine 6f 24T 28.6, 31.8, 35.0
:c
en
~
·XCE
• a-3000
FD-XEOO-GX
FD-3000-GT
alpine
alpine
6f
6f
24T
22T
28.6, 31.8, 35.0
28.6
Q ·XCM FD-XMOO-GX alpine 6f 24T 28.6, 31.8
Z ·XCT FD-XTOO-GX alpine 6f 24T 28.6, 31.8
<C
~ • a-2000 FD-2000-GX alpine 6f 24T 28.6
=:UJ • AC-2000 FD-A200-GX
FD-1500-GX
alpine
alpine
6f
6f
24T
24T
28.6
28.6
• a-1500
:c • AT 1000 FD-AT10-GX alpine 6f 24T 28.6
E- • AC 1000 FD-ATOO-GX alpine 4T 22T 28.6
:::J • Scrambler FD-4200 half-step If 22T 28.6
C/)
8-12 1990
FRONT DERAILLEURS
C/)
SUNTOUR FRONT DERAILLEURS (cont.)
Older Models (Pre-1987) .,c:
Half-Step/
Chainwheel
Capaci~y Clamp
:cm
Model
- Superbe Pro
- Superbe
Model No.
FD-2000
FD-3000
Alpine
half-step
half-step
Min.
2T
Max.
14T
18T
Diameter
28.6
28.6
=
r-
>
- Superbe FD-1500 half-step 2T 18T 28.6
2
- AGTech FD-2800 alpine 6f 26T 28.6 o
-AR FD-2500 half-step 2T 18T 28.6 C/)"
-ARX
-BL
FD-2600
FD-1900
half-step
half-step
2T
2T
18T
18T
28.6
28.6 :c
- Compe-Y * FD-1100 half-step 2T 18T 28.6 >
2
- Cyclone FD-1300 half-step 2T 18T 28.6,28.0 o
- Cyclone Mark-II FD-2300
FD-2400
half-step
half-step
2T
2T
18T
18T
28.6
28.6
='
o
o
- Le Pree FD-3400 half-step 2T 18T 28.6 ~
- MounTech FD-2700 alpine 6T, 26T 28.6
zr 16T 28.6 ."
-NSL* FD-1700 half-step
o
=
- Seven FD-1400 half-step 2T 18T 28.6
- Trimec
-YX
FD-2900
FD-1600
half-step
half-step
2T
2T
18T
18T
28.6
28.6 ='
.....
-XC FD-3500 alpine 6T 22T 28.6 n
..(
*Top normal derailleur--cable pull shifts to smaller chainwheel.
n
r-
m
:s:
m
n
:c
>
z
.....
n
C/)
1990 8-13
,..
FRONT DERAILLEURS
8-14 1990
INDEXING
GRIP SHIFT REAR DERAILLEUR COMPATIBILITY*

Grip Shift
Model No.
Make Model For 6-Speed For '-Speed For S-Speed
Campagnolo Chorus "A" R310
Athena R330
Sachs-Huret New Success R510 R515
Rival R520 R525
Shimano Dura-Ace RII0 R115 R118
Other SIS Models R120 R125
SunTour Superbe Pro R210 R215
Sprint 9000
GPX
Cyclone 7000 (6-spd. only)
XC Pro
XCComp -
XCD
GRIP SHIFT FRONT DERAILLEUR COMPATIBILITY*

Double/Triple Grip Shift
Make Model Chainwheels Model No.
Campagnolo Chorus, Athena, Croce D'Aune Double F3IO,F330
Sachs-Huret New Success Double F5IO, F515
Rival Double F520,F525
Shimano Dura-Ace Double FIIO, FII5, FII8
Other Current Models Double FI20, FI25
Triple FI20T, FI25T
SunTour Superbe Pro
Sprint 9000
GPX Double F2IO,F215
Cyclone 7000 Triple F2IOT, F215T
XC Pro
XCComp
XCD
*All specifications presume freewheels or cranksets specified by derailleur
manufacturer for each model.
1990 9-}
INDEXING
C/) GRIP SHIFT MODEL IDENTIFICATION

u
..... Direction of Rotation
z Model Fits Handlebar for Cable-Pull *
«
:cu
Name
CAT-II
Diameter
23.9 -'24.4 mm
Front
Counter-
Rear
Clockwise
Distinguishing Features
Knurled plastic, closed on one end l
clockwise
DB2 (Supplied) Counter- Clockwise Knurled plastic, closed on one end2
UJ clockwise
~ CX 22.2 - 22.6 mm clockwise Counter- Knurled plastic, open on both ends
clockwise
UJ
~ PRO-CAT- I 23.9 - 24.4 mm Counter- Clockwise Foam grip, closed on one end
U clockwise
>
U
PRO-CX 22.2 - 22.6 mm 3 or
23.9 - 24.4 mm 3
Counter-
clockwise
Clockwise Foam grip, open on both ends 3
.....
=
Cd
PRO-CX 22.2 - 22.6 mm4
*as viewed from end of handlebar

Counter-
clockwise
Clockwise Foam grip, open on both ends 4
o
~
1. Requires drilling handlebars.
2. Same as CAT-1, except supplied with pre-drilled handlebar.
3. For use with aero bars; comes with a removable shim to accommodate both sizes.
~ 4. For use with mountain bars; the clamp is designed to provide extra clearance for brake lever clamps.
o
o
=
Q
Model number location
Z
«
:c
C/)
~
Q
Z
«
~
Cd
UJ
:c~
:J
C/)
9-2 1990
REAR DERAILLEURS • •
MAVIC INDEXING
Design Elements
• One set of levers (821) is used to index both 6- and 7-speeds. The
cable routing through the derailleur is adjustable for narrow or
regular spaced freewheels.
• The derailleur guide pulley is a non-floating design and overshift is
built into the lever.
Sedis ATB chain or other high quality bushingless chain.
Freewheel Recommendations
Mavic says Shimano or Aris freewheels work best. Do not use
SunTour.
MAVIC INDEXING LEVER (821)

On the derailleur between the cable anchor bolt and the cable
adjusting barrel is a small arm with a hole in it. Route the cable
through the hole for regular spaced freewheels. Route the cable
behind the arm for narrow spacing.
MAVIC INDEXING REAR DERAILLEURS

Max.
Total Freewheel
Model Capacity Teeth
• 840 (short cage) 30T 28T
• 841 (longcage) 32T 30T
• 845 (ATB) 44T 32T
1990 9-3
NON-INDEXING
REAR DERAILLEURS
MAVle NON-INDEXING REAR DERAILLEURS

Max.
Total Freewheel
Model Capacity Teeth
• 801 36T 32T
• 803 36T 32T
• 851 36T 32T
• 853 36T 32T
FRONT DERAILLEURS
MAVIC FRONT DERAILLEURS

Max.
Half-Step/ Chainring Clamp Diameter
Model Alpine Difference or Braze-On (B/O)
• 810 Half-Step 20T 28.0
• 811 Half-Step 20T French Style Bla
• 812 Half-Step 20T Italian Style Bla
• 813 Alpine 26T 28.0
• 830 Alpine 26T 28.0

• 831 Alpine 26T French Style Bla
• 832 Alpine 26T Italian Style B/O
• 860 Half-Step 20T 28.0

• 861 Half-Step 20T French Style Bla
• 862 Half-Step 20T Italian Style Bla
• 863 Alpine 26T 28.0
• 870 'Alpine 26T 28.0

• 871 Alpine 20T French Style BIG
• 872 Alpine 26T Italian Style BIG
• 875 Alpine 26T 28.0
9-4 1990
NON-INDEXING
REAR DERAILLEURS
SIMPLEX REAR DERAILLEURS
Max.
Model Total Freewheel
Model No. Capacity Size
• Alpha TIP 10074 30T 24T or 30T (adjusting screw)
• Criterium (with 30T 30T
dimpled cage)
• Criterium AR 637 NI 34T 34T
• LJ 1000 T 30T 30T
• LJ 4000 CP/SP 5578 26T 26T
• LJ Super 615 30T 30T
• Maxi (Prestige) 39T 36T
• Prestige 637
(see SX lOOT)
• Prestige AR 637 NI 34T 34T
• Prestige AR 637 P 34T 34T
• S 001 TIP 10039 30T 30T
• S 061 TIP 30T 30T
• SJ 810 GTIP 39T 36T
• SLJ 5500 CP/SP 5550 26T 26T
• SLJ 5500 GT/SP 5554 39T 36T
• SLJ 5500 T/SP 5551 30T 30T
• SLJ 6600 GT/SP 5552 39T 36T
• SLJ 6600 T/SP 5553 22T 24T
• SLJ A 5000 T 30T 30T
• SLJ A 5000GT 39T 36T
• SLJ AR 615 NI 36T 34T
• SO 1 TIP 10043 30T 30T
• SX 1 TIP 30T 24T or 30T (adjusting screw)
• SX 100 T 637-P 30T 30T
• SX400GT 40T 36T
• SX 410 GTIP 39T 36T
• SX 410 TIP 30T 30T
• SX 440 GT/SP 10165 40T 34T
• SX 440 T/SP 10125 30T 30T
• SX 610 GTIP 38T 36T
• SX 610 TIP 28T 28T
• SX 630 GT/SPMB 38T 34T
• SX 630 T/SP 28T 28T
• SX 640 GT/SP 10235 38T 32T
• SX 640 T/SP 10185 28T 28T
·SX810GT 39T 36T
• SX 810 T 30T 30T
1990 9-5
FRONT DERAILLEURS
SIMPLEX FRONT DERAILLEURS

Model Half-Step/ Capacity Clamp Diameter
Model No. Alpine Min. Max. orBraze-On (B/O)
• SJA 103 MB alpine 24T 28.0-28.6
• SJA 102 half-step 14T 28.0-28.6
• SJA 103 alpine 24T 28.0-28.6
• SJA 222 half-step 14T French-style BIG
• SJA 223 10650 alpine 24T French-style B/O
• SJA 302 10535 half-step 14T 28.0-28.6
• SJA 303 10594 alpine 24T 28.0-28.6
• SLJ A 422 half-step 14T French-style B/O
• SLJ A 423 10710 alpine 24T French-style BIG
• SLJ A 522 4983 half-step 14T 28.0-28.6
• SLJ A 523 4998 alpine 24T 28.0--28.6
• SLJ A 622 10785 half-step 14T Italian-style B/G
• SX A 32 10500 half-step 14T 28.0--28.6, 25.4
• SXA 33 10510 alpine 24T 28.0-28.6, 25.4
9-6 rev. 1990

HUBS
HUBS-HUB AXLES
FRONT HUBS
o BALL SIZES: Most front hubs use 10 - 3/16" balls per side
except the following:
ACS Pre-1983
ACS 1983--current
9 - 5/64" balls per side
9 - 1 /4" balls per side
Campagnolo 9 - 7/32" balls per side-NuovoRecord,
Super Record, Record*
10 - 3/16"balls per side-Grand Sport,
Victory, Chorus, Croce D'Aune,
and others
Maillard Spidel 9 - 7/32" balls per side
NQrmandy Competition (old style with shallow cut cone)
Sunshine Pro-Am 11 -3/16" balls per side
Superbe 11 - 3/16" balls per side
Zeus Gran Sport 9 - 7/32" balls per side
* Record marked S.U. on center of hub shell uses 9 - 7/32".
Record not marked S.U. on center of hub shell uses 10 - 3/16".
USA RETAINERS
No. of balls Diameter of
Retainer per retainers balls Manufacturer
23 8 1/4" Bendix Heavy Duty
42 10 1/4" Bendix Trailer Hub
10 5 1/4" Excel Mark vn
5 7 3/16" Excel Mark 60
10 5 1/4" Monark Silver King
13 7 1/4" Musselman
5 7 3/16" New Departure
3201A 7 Schwinn
5 Skived 7 3/16" Schwinn Union
5 7 3/16" Schwinn Union
4962H Union Heavy
13 7 1/4" Westfield
REAR HUBS-MULTI-SPEED FREEWHEEL
o BALL SIZES: 9 - 1/4" balls,per side except the following:

ACS Pre-19831
ACS 1983-current
Maillard Helicomatic
13 - 5/32" balls p~r side
Schwinn Disc Brake 12 - 3/16" balls per side
Suntour Cassette Hubs 12 - 3/16" balls per side
Right-hand hub cones tend to rotate and tighten toward the center,
eventually cracking the hub shell.. Tighten the right cone and locknut
firmly against each other and make adjustments on the left side.
When installing Phillips or Raleigh, hubs with fixed cones that butt
against a shoulder on the axle, be sure the fixed cone is on the right and
the adjusting cone with flats is on the left.
On Schwinn front hubs without cone locknuts, be sure the cone
lockwasher is on the right side.
rev. 1990 10-1

HUBS
CONE WRENCH SIZE GUIDE
Compiled by Francis Bollag of Kingsbridge Cycle Supply.

Used with permission.
HUB FRONT REAR

Cone Locknut Cone Locknut
Atom 13 16* 15 16*
Campagnolo
Record Track 13 17* 14 18*
Record Road 13 16* 14 14
Tipo 13 16* 14 17*
Maillard
Helicomatic 13 16* 13 16*
Most Others 13 16* 15 16*
Normandy
Luxe Compo 13 16* 14 18*
Shimano
Dura Ace 13 13 14 14
3-Speed 15 17*
Specialized 13 17* 13 17*
Sturmey-Archer 16 15*
Sunshine 13 17* 15 17*
SunTour
Superbe Track 13 17 14 17
Superbe Pro 13 14 13 14
Superbe (Old) 13 13 14 14
Road Vx 14 17* 15 17*
*Hex locknut, standard wrench may be used.
Many manufacturers regularly substitute cones and locknuts

based on parts availability and whim.
10-2 rev. 1985

HUBS
FRONT HUB AND AXLE DIMENSIONS
In addition to the Ilational tendencies listed below many makers

produce hubs for their top-quality lines with over locknut dimensions
similar to Campagnolo' s.
Note: 9.5mm is very close to 3/8". The same is true of 8mm and 5/16".
~
Over Axle
FRONT Thread Locknuts Length
ISO Solid 8mmx Imm 100± Imm (primary)
91 ± Imm (secondary)
ISO Hollow (and 9mmx Imm 100± Imm (primary)
BMX solid) 91 ± Imm (secondary)
ENGLISH
Solid 5/16" x 26 TPI too many variations
Dynohub 3/8" x 26 TPI*
FRENCH
Solid 8mmx 1.0mm 96mm 132mm
(or 26 TPI)
Hollow 9mrnx 1.0mm 96mm 105mm
(or 26 TPI)
ITALIAN
Solid 8mmx26TPI 102mm 135mm
Hollow 9mm x 26 TPI 102mm Illmm
JAPANESE
Solid 5/16" x 26 TPI 89, 93mm 130mm
3/8" x 26 TPl* 96mm 133mm
9mm x 1.0mm (JIS) 100mm 108mm
Hollow 9mm x 26 TPI 96mm 104mm
9mm x 1.0mm (JIS) 100mm 108mm
USA
Solid 5/16" x 24TPI, too many variations
3/8" x 24TPI*
CAMPAGNOLO
Solid-Nuovo Tipo 8mm x 26 TPI 100mm 132mm
Solid-Track 9mm x 26 TPI 100mm 139mm
Hollow 9mm x 26 TPI 100mm 108mm
JOU YU (Joy Tech)
Solid 8mmx26TPI 140mm
Hollow 9mm x 26 TPI 110mm
BMX-Solid 93, 96mm
Mountain Bike 96,lOOmm
(Top Quality)
*flatted to 5/16"(8mm)
rev. 1990 10-3

HUBS
REAR HUB DIMENSIONS
National Tendencies
There are many exceptions, so measure if in doubt. Make up
for differences by adding, removing or relocating washers and
spacers. If axle length won't allow the change, squeeze or
spread the dropouts. Align the dropouts with the proper tool
after altering the width. Never use the action a quick release
unit to squeeze the dropouts together.
To Measure Dimension A
Hold a piece of square bar (a square-shank screwdriver
for approximate measure) against the locknut and axle so
that it's perpendicular to the axle, then measure the dis-
tance between the face the freewheel butts against and the
bar.
Axle Spacers
Kingsbridge Cycle Supply makes axle spacers 1, 3 and 5
mm thick.
~A
over locknut dimension

axle length
10-4 reV. 1985

HUBS
FREEWHEEL CLEARANCE
Freewheel Width
(Sprocket Face to Minimum
Sprocket Face) Dimension A
Regular Spacing
5 speeds 25 29
6 speeds 31 35
Narrow Spacing
6 speeds 27 31
7 speeds 32 36
8 speeds 36.5 40.5
Frames whose end of the right stays are flattened must be

used with Campagnolo and other similar hubs with a min-
imum Dimension A. This is so the chain clears easily and
the wheel carl be removed.
CHAINLINES
Front chainline refers to the distance from the bicycle

centerline to chain\.vheel midpoint. Rear chainline is the
bicycle centerline to sprocket midpoint. Front and rear
chainlines rarely match in practice. Chainwheels are fre-
quently moved out to avoid having the chain rub on the
outside chainwheel when the gears are in a small chain-
wheel and small sprocket combination. Also, sometimes
the frame will be built with the right fork end out further
than the left.
chain line
-~
·~t
- - - - - - center line - - - - - . - -
1990 rev. 10-5

HUBS
REAR HUB AND AXLE DIMENSIONS
REAR
ISO Solid
I Thread
9.0mm x 1.0mm
Over
Locknuts
Axle
Length
Dimen-
sion A
Chain-
line
ISO Hollow 10mm x 1.0mm

ISO Single freewheel, 110mm 21mm
Coaster brake
ISO 3-, 4-speed freewheel, 117mm 28mm
Hub gear
ISO 4-, 5-speed freewheel 122mm 34mm
ISO 5-, 7-speed freewheel 126mm 36mm
ENGLISH~Solid 3/8" x 26 TPI many variations
FRENCH-Sport
Solid 9.5mm x 1.0mm 122mm 160mm 34mm
(or 26 TPI) 1241nm 162mm 36mm
126mm 165mm 36mm
130mm 168mm 36mm
Hollow 9.5mm x 1.0mm 122mm 133mm 34mm 39.5mm
(or 26 TPI) 124mm 135mm 36mm 40mm
126mm 137mm 36mm varies
ITALlAN-Sport
Solid 9.5mm x 26 TPI 122mm 155mm 34mm
Hollow 9.5mm x 26 TPI 122mlTI 132mm 34mm
126mm* 136mm 36mm*
JAPANESE-Sport
Solid 3/8" x 26 TPI, 124mm* 169mm 36mm* 43.5mm
10mm x Imm (JIS) 126mm 169mm 36mm varies
Hollow 3/8" x 26 TPI, 120mm 128mm 31mm 42mm
10mm x Imm (JIS) 124mm 132mm 34mm
126mm* 136mm 36mm*t 43.5mm
135mm 145mm varies varies
USA-Solid 3/8" x 24TPI
CAMPAGNOLO
Solid-Nuovo Tipo 9.5mm x 26 TPI 120mm 155mm 29mm
Solid-Track 10mm x 26 TPI 110mm 149mm 21.5mm 40mm
120mm 159mm 24mm 42.5mm
Hollow 10mm x 26 TPI 121mm** 129, 132mm 30mm** 43.5mm
125mm 134mm 35mm
126mm 136mm 36mm
130mm 140mm 36, 37mm
JOU YU (Joy Tech)
Solid 9.5mm x 26 TPI
Hollow 10mm x 26 TPI
BMX 109mm 21mm
110mm
Mountain Bike 126mm 37mm
130mm 37mm
* Before ISO standards were adopted many were 125mm with 35mm freewheel space.
t These hubs may also come with a 31 or 33mm Dimension A to accommodate derailleurs (mostly higher
priced) that will not sweep the 36mm.
** This hub is often listed as 120 over the locknuts with a 29mm dimension A.
10-6 rev. 1990

HUBS
CARTRIDGE BEARINGS
Cartridge bearings are used extensively in industry and it would seem logical
just to pop a standard bearing in a bicycle hub to get the advantage of its
seal. Unfortunately, these bearings are designed to be mounted with more
precision than can be achieved in a conventional hub. For long bearing life,
the inner and outer bearing races must be aligned precisely and stay aligned.
Flex or bending under load make this impossible with the 8 to lOmm hub
axles used on all except Phil hubs. Except in extremely muddy conditions,
this misalignment results in bearing life even shorter than that of unmain-
tained cup and cone bearings.
Figure A shows a bearing mounted in a bicycle hub. Note that the load
pushes down in the center of the raceways and there is a slight gap at the
top, exaggerated for clarity in the drawing. This gap is essential if the bear-
ing is to function smoothly; it can be felt at the rim of a built-up wheel as a
trace of side-play. Trying to eliminate this side-play by pushing one of the
bearing raceways to the side will ruin the bearing quickly (see Figure B).
Hub
Enlarged View
slight gap • hub shell

outer raceway
inner raceway
axle shoulder
Figure A. Properly Aligned Cartridge Bearing
Figure B. Misaligned Cartridge Bearing
To work effectively, the outer raceway must be pressed securely into the hub
shell and the inner raceway must be held securely between shoulders on the
axle and tightened locknuts. At the same time, the inner and outer raceways
must be aligned so that tIle balls run in the center of the raceways. Always
use an exact replacement axle since an axle with shoulders too far apart or
too close together (Figure B) will cause rapid bearing failure. All parts must
be clean so that debris does not cause misalignment of the raceways.
1985 10-7
HUBS
CARTRIDGE BEARINGS (cont.)
Axles must be straight to keep the inner raceways properly aligned. A bent
axle will cause rapid wear. Tightening a hub with a straight axle into fork
ends that are not aligned (see page 0-13) will bend the axle enough to cause
misalignment of the raceways.
CARTRIDGE BEARING SIZES
Most cartridge bearings are marked with SKF numbers. All the bearings we
measured were metric except Cook Bros., which were inch sizes and there-
fore not interchangeable with the others.
The markings usually consist of a brand name and a number followed by
letters. Some common brand markings are NTN, WTW, NACHI and KSK.
The numbers indicate the standard size. The letters following the number
indicate the type of seal used. Seals are not standard.
The following sizes are common:
inside outside inside outside
nunmber dianmeter dianmeter nunmber dianmeter diameter
6000 10mm 26mm 6200 10mm 30mm
6001 12mm 28mm 6201 12mm 32mm
6002 15mm 32mm 6202 15mm 35mm
6003 17mm 35mm 6203 17mm 40mm
CARTRIDGE-BEARING HUBS (except Phil*)-

ASSEMBLY AND DISASSEMBLY
o DISASSEMBLY I
Be sure you want to replace the bearings, as
removal will ruin good bearings. Note the arrange-
ment of the locknuts and washers so they can be
replaced in the same order. Note also whether the
unthreaded portion of the axle extends past the
cartridge. Remove the locknuts from both sides of
the hub.
G) DISASSEMBLY I
For hubs with shoulders on the axles Use soft jaws to
Using soft jaws, supportthe hub shell (but not the protect hub finish
bearing or axle) between the open jaws of a vise
(see Figure C). Thread an axle nut o-n the axle to
protect the threads. Gently tap on the end of the
axle with a soft hammer until the cartridge on the
opposite side comes loose.
For hubs without shoulders on the axles
Remove axle. Squeeze the ends of a SunTour bear- Figure C. Removing bearings from
ing remover together and insert it through the hole hubs with shoulders on the axle.
in the inner raceway of the bearing. Insert an old
10-8 1985
CARTRIDGE-BEARING HUBS
HUBS
DISASSEMBLY AND ASSEMBLY (cont.)
axle in the other side of the hub. Gently tap on the
end of the axle with a soft hammer until the car-
tridge on the opposite side comes loose.
G:) DISASSEMBLY I
Remove the loose bearing. Repeat to remove the
remaining cartridge.
_ASSEMBLyl
Hammering on cartridge bearings will ruin them.
cartridge bearing
Insert the axle in the hub. Place one cartridge on
hub shell
each side. Then place a dished cartridge-bearing
installation washer on each end (see Figure D). Be
sure to use a washer of proper size that contacts
the outer race only. Applying force on the il1ner
race will damage the bearing. If an unthreaded
Figure D. Use of cartridge-bearing portion of the axle extends past the cartridge,
installa~~on washers additional washers or spacers may be necessary. If
used, they should slip freely over the unthreaded
portion of the axle. Hand-tighten axle nuts on
each end of the axle and align the installation
washers over the cartridges.
GASSEMBLy!
Hold the assembly in a vise by one of the axle
nuts. Tighten the other axle nut to squeeze the car-
tridges into place. Observe progress closely, mak-
ing sure the cartridges go in straight.
GASSEMBLYI
For hubs with shoulders on the axles
Loosen one axle nut and add an extra axle nut to
it. Lock them together. Working against the two
locked-together nuts, loosen the nut on the other
end. Then unlock and remove the remaining two
nuts. Remove the installation washers and replace
the various locknuts and washers in their original
order.
For hubs without shoulders on the axles
Loosen and remove the axle nuts. Remove the
installation washers and replace the various lock-
nuts and washers in their original order.
* For Phil hubs replace the axle and bearings as a
unit using the kit and instructions supplied by Phil
Wood and Co.
1985 10-9
HUBS
THREAD CHASER MARKINGS
Bicycle Research
type size marking notes

TC-l 8mm x 26 TPI small (1/2") hex, no groove
TC-2 9.5mm x 26 TPI large (9/16") hex, no groove
TC-3 5/16" x 24 TPI small (1/2") hex, 1 groove Also fits X caliber
skateboard trucks
TC-4 3/8" x 24 TPI large (9/16") hex, 1 groove
TC-5 "5/16" x 26 TPI small (1/2") hex, 2 grooves
TC-6 7.5mm small (1/2") hex, 3 grooves Fits Chicago
skateboard trucks
-
TC-7 '3/8" x 26 TPI large (9/16") hex, 2 grooves ManyBMX,
some skates
QUICK RELEASE UNITS
Atom 5mmxO.90mm
Brev. Stop 5mm x 0.80mm
Campagnolo 5mm xO.80mm
Gnutti 5mmxO.80mm
Milremo 5mmxO.90mm
Normandy 5mmxO.90mm
Pelissier 5mmxO.90mm
Schwinn Approved
(made in France) 5mm x 0.90mm
Shimano 5mm x O.80mm
Simplex Old Style* 5mm x 0.75mm
Simplex New Style* 5mm x O.80mm
Weyless .25" x28 TPI
Zeus 5mm x 0.80mm
*Simplex old style has plastic wing nut; Simplex new style
is all metal.
MARKINGS ON VAR FREEWHEEL REMOVERS
Models 186 and 188
mark quick release fits quick

thread size release units
BA 5mmx .90mm Atom, Normandy, others
BC 5mmx .80mm Campagnolo, others
BS 5mm x .75mm Old Style Simplex
Locking sleeves for the Var 01 freewheel tool are marked

as follows:
9.5 to indicate 9.5mm x 1.00mm
5.90 to indicate 5mm x 0.90mm
5.80 to indicate 5mmxO.80mm
5.75 to indicate 5mm x 0.75mni
10-10
,..
SPOKE LENGTHS 1
ABOUT THE SPOKE LENGTH CHARTS
Using the tables in this section will give you spoke lengths that
are accurate to within plus or minus 1.5 mm. This is as
accurate as is needed for most wheels. Also keep in mind that
we have occasionally measured variations in rim diameters of
more than 2mm, even in high quality name brand rims. For
wheels that are smaller than 20" many more factors come into
play, and these tables will be less accurate and should only be
considered a starting point for some trial-and-error wheel
building. We have also listed rim and hub dimensions for the
Wheelsmith and other computer programs in separate shaded
columns. When using the Wheelsmith calculator or other
programs you will only need to use the tables in Steps 1 and 3.
Spoke and Nipple Differences

Spoke lengths are calculated to come to the bottom of the slot
of a Union, DT or Wheelsmith spoke nipple. Measure the
spokes you use; compare your nleasurement with the
measurement printed on the box they came in. You may need
to make your own adjustments to the final lengths to get more
consistently accurate results.
Hub Spoke Holes and Spoke Diameter

Heavy gauge spokes combined with large hub spoke holes
generally use the same lengths as normal size spokes. The
effect of the larger hole is canceled out by the larger nipple
used. Using a regular gauge spoke in a larger hub hole will
mean a shorter spoke is needed. The amount shorter is usually
small (less than 0.5mm) but can combine with other factors to
result in a spoke that is too long.
LARGE FLANGE HUBS

When building wheels with large flange hubs, check the angle
Spokes are the nipple enters the rim. Breakage will occur if the spoke
measured nipple is stressed at this point. Rims are sometimes dimpled to
from the make up for this. Some nipples will work at a greater angle
inside of from perpendicular than others. Try it in a spoke hole to see.
the bend Problems usually happen when using drum brakes or other
to the end. e~tra large flange hubs and a 3 or 4 cross pattern. Other
problems can happyn when combining a large flange hub with
a 20- or 24-inch rim. The solution is to use a 2- or 1- cross
pattern. Please note the section on radial patterns on page 11-2
when using 2-or 1- cross patterns.
rev. 1990 11-1

r SPOKE LENGTHS
RADIAL PATTERNS
The spoke length tables work most easily with tangent or
close-to-tangent spoke patterns like 4-cross or 3-cross. (See
drawings below.) The fewer crosses the wheel is built with the
more exactly the hub diameter has to match the hub diameter
categories in Step 1. Radially built wheels must match the
diameter category exactly for accurate results. For radial
wheels note the difference between the hub diameter category
listed and the actual hub diameter, then subtract or add Imm
from the final spoke length for every 2mm difference.
Example: Radial spoking pattern with Phil hubs. Phil all-alloy front
hub has a 42mm flange diameter (spoke hole center to spoke hole
center). This is 2.5mm smaller than the 44.5mm category. Since the
hub is 2.5mm smaller add 1.25mm to the final spoke length to get an
accurate length for a radial wheel. In practice, adding Imm is
accurate enough.
Rim
Radial Spoke
Tangent Spokes--=---......
like a 4 cross/36 spoke
pattern The hub diameter makes an
important difference in spoke length
with a radial wheel-5mm this
illustration.
Spokes at a tangent to the hub

are nearly identical in length; hub 48mm Hub (to spoke hole centers)
diameter is not as important.
58mm Hub (to spoke hole centers)
11-2 rev. 1990

SPOKE LENGTHS 1
SPOKE AND NIPPLE DIMENSIONS
Wire diameter below refers to the diameter before the threads
are rolled on. The major diameter usually referred to in thread
sizes will be larger than the wire diameter.
Sizes listed in the same column are roughly the same size.
ISO
Wire Diameter (mm) x TPI 1.5* 1.8x56 2.0x56 2.3x56 2.6x56
Wire Diameter (inches) x TPI .059* .071x56 .079x56 .091x56 .102x56
Nipple Flats (mm) 3.3 3.3 3.8 4.5
Nipple Diameter (mm) 4.0 4.0 4.5 5.5
English
Gauge (SWG) 17* 16* 15 14 13 12
Wire Diameter (inches) x TPI .056* .064* .072x56 .080x56 .092x56 .104x56
French
Gauge (JP) 10* 11* 12 13 14 15 16
Wire Diameter (mm)
x mm per thread 1.5* 1.6* 1.8x.4 2x.4 2.2x.45 2.4x.45 2.7x.55
Wire Diameter (inches) x TPI .059* .063* .071x63.5 .079x63.5 .087x56.4 .094x56.4 .106x46.2
Nipple Flats (mm) 3.2 3.2 3.2 3.7 4.0
Nipple Diameter (mm) 4.0 4.0 4.0 4.5 5.0
Japanese
Wire Diameter and TPI-see ISO
Nipple Flats (mm) 3.4 3.4 3.6 3.9
Nipple Diameter (mm) 4.0 4.0 4.3 4.6
USA
Gauge (US Steel Wire Gauge) 15 14 13 12
Wire Diameter x TPI .072* .080x56 .092* .106x56
Nipple Flats (mm) 3.3 3.9
Nipple Diameter (mm) 3.7 4.57
*These measurements are for the narrower butted portion of the spoke where there aren't any threads.
Note that as the wire gets larger, French gauge numbers go up

while English and USA gauge numbers go down. The gauge
numbers cross right where cycle spokes are. This is one reason
the ISO standards for spokes are being adopted allover the
world.
To distinguish a spoke with a 56 TPI thread, a 28 TPI thread

gauge may be used. It will fit nicely in every other thread.
rev.1990 11-3
r SPOKE LENGTHS
CALCULATING SPOKE LENGTH
1st step of 3 steps
Determine which hub diameter Example One: Shimano Dura-Ace Small Flange
category the hub fits into. Front measures 38mm. It fits the 40mm hub
diameter category. Adjustments will be made in
. the next step, if necessary
Sample hubs are listed for each
category. Be sure to measure Example Two: Mavic 500 Small Flange Rear is
since there are many more 44.8mm so it fits in the 44.5mm hub diameter
models than listed here. category
HUB DIAMETER
Hub diameters are measured

from spoke hole center to
spoke hole center.
The information in the shaded area to the right of the flange

diameter column is for use with electronic spoke calculators or
computer programs. It is also useful for making adjustments to
spoke lengths for unusual hubs.
When using an electronic spoke-length calculator such as

Wheelsmith's or a computer program you will need the information
only in the first and third steps.
2nd Step
27",28" and 700C rims go to page 11-14 16" and 400 rims go to page 11-60
26", 700D and 650 rims go to page 11-30 14" rims go to page 11-62
24", 22 ", 600 and 550 rims go to page 11-40 12" rims go to page 11-64
20" rims go to page 11-50 10" rims go to page 11-65
18" rims go to page 11-58
11-4 rev. 1990

SPOKE LENGTHS 1
1st step of 3 steps (cont.) C/)
c:~
:c
m
:=
r-
»
:2
o ~
C/)
:c
»
:2
o
34rnrn HUB DIAMETER
Generally: Fair to good quality
=
o
Small Flange Front Hubs o
~
."
Make Model
Front/
Rear
Flange
Diameter o
:=
Maillard
Mavic
Sealed Mechanism
CX580
front
front
34
34
.n..
=
Phil Wheelchair
Dinky front 35
<
n
Straddle Mount Dinky front 35 r-
Sturmey Archer front 33
m
3:
SunTour XCD-6000 front 36 m
n
:c
»
...
:2
n
C/)
rev. 1990 11-5

~SPOKE LENGTHS
CI) 1st step of 3 steps (cant.)

U
..... 40mm HUB DIAMETER
Z Generally: Good to high quality
<I:: Small Flange Front Hubs
:c
U
UJ Front/ Flange
Make Model Rear Diameter
~
UJ Arai 8000 front 40
...l
Campagnolo Chorus front 39
U C-Record front
U
> Athena front
39
39
.....
=
=:
GT
Hi-E
BMX front
front
40
39
0 Mavic 500, 550,R.D. front 40
~
Sulky (500 R.D.) front 40
~
0 Profile BMX front 38
0 Revcore BMX front 41
=
Q Shimano BMX
600 Ultegra
front
front
38
38
Z DeoreXT front 38
<I:: Dura-Ace front 38
:c Integrated-8515
CI) Specialized Sealed-Bearing front 39

Ii'
Q SunTour XC-9000 front 39

IZ GPX
Sprint
front
front
39
39
<I:: Superbe Pro front 39
...l
=: Suzue BMX Sealed Bearings front 38
UJ
:c
~
;:>
CI)
11-6 rev. 1990,

SPOKE LENGTHS 1
1st step of 3 steps (cont.)
44.5mm HUB DIAMETER

Generally: Small Flange Rear Hubs
Flange
Front/ Dia-
Make Model Rear meter
ACS BMX Z Hub front 44
American S front 42
Classic rear 43
Bullseye BMX front 42.5

BMX rear 42.5
Road 126 rear 42.5
Mountain 130 rear 42.5
Campagnolo Athena rear 44

C-Record rear 44.5
Chorus rear 44
GT BMX rear 46
Mavic 500, 550, R.D. rear 45
570 Track rear 45
M.R.C. 570 (Z hub) rear 45
rev. 1990 11-7

r SPOKE LENGTHS
44.5mm HUB DIAMETER (cont.)
Flange
Front/ Dia-
Phil Bicycle hubs (see 48mm for rear and brake hubs
all-alloy-BMX front 42
all-alloy-BMX front 42
all-alloy-road front 42
all-alloy-road front 42
Wheelchair hub 42
(also see 34mm for Dinky hub)
Profile BMX rear 44.5
Shimano BMX Freehub - DX rear 44.5

BMXFreehub rear 45.5
105 rear 45
8-spd Dura-Ace
integrated 8515 rear 44
7-spd Dura-Ace rear 44
Deore X1 II rear 45
6-spd DeoreXT rear 45
Specialized BMX front 43

Sealed Bearing rear 44.5
SunTour GPX (see 48mm Hubs)

Sprint rear 44
Superbe Pro rear 44.5
XC-9000 rear 45
XCD-6000 rear 45
XCD-9000 rear 45
Suzue BMX Sealed rear 44

Bearings
11-8 rev. 1990

SPOKE LENGTHS 1
48rnrn HUB DIAMETER
Generally: Medium Flange and Coaster Brakes
Flange
Front/ Dia-
Bendix Coaster -70 rear 51
Cook Bros. front 52
F&S Coaster
Torpedo-Komet rear 50
Komet Super G rear 50
Sachs Jet rear 50
GT BMX rear 46
Phil Rear all-alloy

(left/right side)
120 -5-Speed rear 42/48
125-Low Dish 5-Spd rear 42/48
125-6/7-Speed . rear 42/48
130-6/7-Speed rear 42/48
130-8-Speed
135-8-Speed
Brake hubs all-alloy

(left/right side)
100 front 48/42
108 front 48/42
120-5-Speed rear 48
125-6/7-Speed rear 48
140-Symmetric 6/7-Spd rear 48
140-Regular 6/7-Spd rear 48
with Steel Center
100 front 48
108 front 48
120-5-Speed rear 48
rev.1990 11-9
r SPOKE LENGTHS
48mm HUB DIAMETER (cant.)
Flange
Front/ Dia-
Revcore BMX rear 46.5
Shimano D-Type Coaster rear 51
Specialized BMX rear 46
Sunshine BMX Sealed Bearing front 52
SunTour BMX Coaster rear 51.5

BMX Free Coaster rear 51.5
GPX rear 46.5
Wilderness front 46.5

Trails front 47
58mm HUB DIAMETER

Generally: Internally Geared 3 Speeds
and F & S 2- and 3-Speeds
Flange
Front/ Dia-
Bullseye BMX-Large Flange front 53.5

BMX-Large Flange rear 54
F & S(Sachs)
Komet Super D rear 55
Torpedo Duomatic rear 58
Torpedo 3-Speed S
(Coaster Brake) rear 58
Torpedo 3-Speed rear 58
Shimano Coaster Brake

Type A rear 56
,Type B rear 56
11-10 rev. 1990 J

SPOKE LENGTHS'
1st step of 3 steps
58mm HUB DIAMETER (cont.)
Flange
Front/ Dia-
Shimano 3-Speed
(cont.) Cartridge rear 59
F rear 59
3-Speed Coaster Brake
3SC rear 59
3CC rear 59.5
Sturmey Coaster Brake SC.1 rear 53
Wilderness 126 rear 59

Trails 131 rear 59
136 rear 59
141 rear 59
63mm HUB DIAMETER

Generally: Fair to good quality
Large Flange Front and Rear
Flange
Front/ Dia-
A. C. S. R.L. Hub rear 62.5

-Free Coaster
Joy Tech BMX front 62

BMX rear 62
Sansin AE-15A front 62.5
Sunshine BMX front 61.5
SunTour BMX front 63

Dual Freehub rear 62
Suzue Freestyle front 63

rear 63
Tandem front 63
rear 63
rev.1990 II-II
r SPOKE LENGTHS
C/) 1st step of 3 steps (cont.)

U
..... 67mm HUB DIAMETER
Z Generally: Quality Large Flange
« Front and Rear Hubs
X Flange
U Front/ Dia-
~ Make Model Rear meter
~
Hi-E 121 rear 67
~ 127 rear 67
.J 130 rear 67
U 131 rear 67
>
U Sachs Orbit 10100 rear 67
..... Orbit 12100 rear 67
~
Sturmey AW,S5 rear 65
CC S3C rear 65
0
~ SunTour 3-Speed rear 65
Track front 67.5
~ rear 67.5
0
0
~
Q 90mm HUB DIAMETER
Z Generally: Aluminum Shell
« Drum Brakes
X Flange
C/) Front/ Dia-
~
Q
Z Bendix 2-Speed Rear 80
«.J Sachs Galaxie HT 5320 Rear 87
Galaxie HT 6320 Rear 87
CC
~
X
E-
:.:J
C/)
11-12 rev. 1990

Flange
Front/ Dia-
Sturmey AW Dyno Hub rear 112
127mm HUB DIAMETER

Maxicar Tandem Hubs
rev.1990 11-13
r27", 700C SPOKE LENGTHS
CALCULATING SPOKE LENGTH (cont.)
27",28" and 700C Rims (700D see 26")
2nd step of 3 steps
Count the number of holes in the hub and 27" Example One (cont.): Shimano Dura-
decide on a spoking pattern, i.e., 4-cross, 3- Ace front hub with 32 holes. Look at the
cross, (4X, 3X) etc. Find the length listed for 40mm hub diameter table. For a 3X
wheel write down the length 308mm.
that combination in the hub diameter category
selected in step 1. Write down the length. For 27" Example Two (cont.): Mavic 500
the right rear of multi-speed freewheel hubs rear hub with 36 holes. On the 44.5mm
subtract 2mm. (See below for details.) table a 3X wheel indicates a length of
Adjustments will also be needed for hubs that 305mm for the left side. For the right side
are different from the specifications below. use 303mm.
TIle tables on the facing page will give you a length for a
630mm diameter rim. Step 3 will adjust these lengths for the
exact rim you have.
3rd step-go to page 11-16

The following hub dimensions were used for the tables on the
opposite page. They are the approximate dimensions for road
bike front hubs and the left rear of a road bike rear hub.
Hub center to flange center-35mm
Spoke hole diameter-2.6mm
Spoke seating and stretch-O.4mm
Differences in Hubs
Many hubs differ from the hub dimensions listed above so
adjustments may need to be made as follows:
Hub center to flange center-a 27" Example Three: A front track hub with a 45mm hub
Imm difference will make a center to flange center is 10mm wider than the
O.lmm difference in final spoke dimensions these tables are based on. Multiplying
10mm by O.lmm you get Imm. Add Imm to the final
length.
spoke length.
Spoke hole size-a O.2mm difference will make a O.lmm

difference in the final spoke length. In practice this is usually
not enough difference to matter.
Right Rear Hub Spoke Length

Most right rear road hubs require a shorter spoke. How much These combinations have
shorter varies. Many hubs have a hub center to flange center the same spoke length:
on the right rear of 20mm. This is a 15mm difference from
16 hole IX = 32 hole 2X
the tables. Using the guidelines for differences in hub center
20 hole 2X =40 hole 4X
to flange dimensions, subtract 1.5mm for the right rear 24 hole 2X =48 hole 4X
spokes. This is usually rounded up to 2mm.
11-14 rev. 1990

,... ,.,
SPOKE LENGTHS 27" , 700CIJ

27",28" and 700C Rims (cont.) (700D see 26")
2nd step of 3 ~teps (cont.)
34mm Hub Diameter 40mm Hub Diameter
5X 4X 3X 2X IX radial 5X 4X 3X 2X IX radial
48 - - - - - - 48 311 306 302 298* 296* 295*
40 310 306 302* 299* 298* 40 310 304 299* 296* 295*
36 313 307 302* 299* 298* 36 312 306 300* 297* 295*
32 309 304 300* 298* 32 308 302 297* 295*
28 312 305 300* 298* 28 311 303 297* 295*
24 307 301* 298*
44.5mm Hub Diameter 48mm Hub Diameter

48 310 305 300 296* 294* 293* 48 310 304 299 295* 292* 291*
40 309 303 298* 294* 293* 40 309 302 296* 293* 291*
36 312 305 299* 295* 293* 36 312 304 297* 293* 291*
32 307 300 295* 293* 32 307 299 293* 291*
28 311 302 295* 293* 28 311 301 294* 291*

48 309 302 296 291* 288* 286* 48 309 301 294 289* 285* 284*
40 308 299 292* 288* 286* 40 307 298 291* 286* 284*
36 312 302 294* 288* 286* 36 311 301 292* 286* 284*
32 305 296 289* 286* 32 305 294 287* 284*
28 310 298 290* 286* 28 310 297 287* 284*

48 308 300 293 287* 283* 282* 48 307 295 285 277* 272* 271*
40 307 297 289* 284* 282* 40 304 291 280* 273* 271*
36 311 300 291* 284* 282* 36 311 295 282* 274* 271*
32 304 293 285* 282* 32 301 285 274* 271*
28 310 296 286* 282* 28 308 290 276* 271*

48 293 282 272* 266* 264* 48 289 274 263* 255* 252*
40 288 276* 267* 264* 40 283 267* 256* 252*
36 293 278* 268* 264* 36 289 270* 257* 252*
32 299 282 269* 264* 32 297 274 258* 252*
* Hubs using these combinations must match the hub diameter category exactly for
accurate results. See drawings and text page 11-2.
.... ~
rev.1990 11-15
r27", 700C CALCULATING SPOKE LENGTH (cont.)
SPOKE LENGTHS

3rd step of 3 steps
Find the rim in the tables 27" Example One (cont.): Dura-Ace front hub with an
Araya SS-40 27x 1-1/8 rim. Rim Correction Factor for
below. Subtract the rim this rim is -6. The length from step 2 is 308. 308 minus 6
correction factor from the is 302. 302 is the final length.
number you came up with
in step 2. The answer is 27" Example Two (cont): Mavic rear hub with a Mavic
the final length of the 700C Open 4 CD rim. The rim correction factor for this
spoke you need. rim is -13. The lengths from step 2 are 305 for the left
side and 303 for the right. 305 minus 13 is 292 and 303
minus 13 is 290. 292 and 290 are the final lengths.
Identifying Rims
Rims are grouped in descending order by bead seat
diameters. ISO rim markings are used in these tables Rim with Rim with
to help distinguish the various models of rims. For single eyelet double eyelet
an explanation of these markings see page 12-3.
The rim cross section drawings are not exact
representations of each rim.
Unless noted otherwise, rims listed do not have
eyelets or dimples. '
635mm Bead Seat Diameter

(28 x 1-1/2)
Outside rim diameter approximately 649mm Rim
Correc-
ISO Designation/ tion
Make Material Distinguishing Features Model Factor
Araya steel ~ 24-635 Modell -2
Sturmey-Archer steel ~ 25-635 F -2
U 24-635 EA4 -3

(27 x 1-1/4, 27 x 1-1/8, 27 x 1)
Correc-
Akront alloy U 13-630 50 -5
Ambrosio alloy
~ 14-630 with single eyelets Elite -5
~
14-630 with aero rim washers Aero Elite -9
Alesa-see Weinmann (use old ref. numbers)
11-16 rev. 1990 ~

SPOKE LENGTHS 27'"
3rd step of 3 steps (cont.) C/)
c:
630mm Bead Seat Diameter (cont.) ~
(27 x 1-1/4, 27 x 1-1/8, 27 x 1)
::m
Make Material
ISO Designation/
Distinguishing Features Model
Corree-
tion
Factor
=
r-
>
Z
Araya alloy
~ 13-630 with double eyelets
14-630 with double eyelets
20A
SS-40
-6
-6
0 ~
~
14-630 with aero rim washers Aero lW (ADX-IW) -8 C/)
16-630 Aero 2W (ADX-2W) -10
::
U 14-630
16-630
17-630
SS-45
16A(5)
18
-5
-4
-3
>
Z
17-630 SP-30 -4 0
~
19-630
20-630
16A(3)
15
-3
-4
=
0
0
Araya steel
V 16-630 Aero 4W (ADX-4W) -6
~
U 16.5-630 5H -3
~
20-630 5 -3
0
CMC
Femco
steel
steel
U
U
18-630
18-630 5
-4
-3
=
.n..
=
Fiamme alloy
~ 14-630 with single eyelets 80-Elan -5
~ 18-630 71-Sport -2
-<
n
~
r-
Marzorati MP alloy 18-630 -3
m
Matrix alloy
~ 13-630 with single eyelets Titan -6
~
U 17-630 with eyelets Titan T -4 m
n
~ 12-630 ISOC -12
::
>
~
...
Mavic alloy 13-630 with single eyelets MA -6
13-630 with double eyelets MA 40, MA 2 -6 Z
13-630 with single eyelets Module E -5
13-630 with double eyelets Module E2 -4

n
C/)
13-630 with double eyelets G40 -6
15-630 with single eyelets Module 3 -6
15-630 with double eyelets Module 3D Argent -6

19-630 with double eyelets Module 4 -6
rev.1990 11-17
~27" SPOKE LENGTHS
C/) 3rd step of 3 steps (cont.)
U
..... 630mm Bead Seat Diameter (cont.)
Z (27 x 1-1/4, 27 x 1-1/8, 27 x 1)
~ Outside rim diameter approximately 641mm Rim
X ISO Designation/
Corree-
U Make Material Distinguishing Features Model
tion
Factor
UJ
~ Milremo-see Wolber
UJ Mistral-see Sun Metal

.J
U M.O. Mfg. steel U 20-630 -3
>
U
Nisi alloy ~!J 20-630 Sport-Toro-Strettisimo -5
.....
~
Rigida alloy 13-630 with single eyelets AL 13/20 -6
~ 13-630 with single eyelets Rush -6
=
0
u..
Rigida steel U
16-630 with single eyelets
17-630
21-630
AL 16/22
Deco 30
Deco 35
-4
-4
-4
~
~
Saturae alloy 14-630 with double eyelets HC19 -4
0 (Specialized) 15-630 with double eyelets C20 -4
0 U 16-630 with eyelets e22 -4

~
Q Schwinn steel U 20-630 S-6 -5
Z Sturmey-Archer steel U 20-630 EA25.0 -4

~ 20-630 K25.0 -2
X
~
Sun Metal alloy 13-630 with single eyelets Mistral M13 -6
C/) 13-630 with single eyelets Mistral M13L -6
fI\
13-630 Levanter L13 -6
Q 16-630 C16 -6
Z
~ tj 14-630 Mistral M14A -8
.J
a::UJ U 17-630 with eyelets
17-630
20-630 with eyelets
Mistral M17
Levanter L17
Mistral M20
-5
-5
-5
X 20-630
25-630 with eyelets
Levanter L20
Mistral M25
-5
-5
~
::J Sun Metal steel U 18-630 Style L -3
C/)
11-18 rev. 1990

SPOKE LENGTHS 27'"
3rd step of 3 steps (cont.)
630mm Bead Seat Diameter (cont.)
(27 x 1-1/4, 27 x 1-1/8, 27 x 1)
Corree-
Ukai-see similar Araya models
Weinmann alloy 13-630 with single eyelets (613) -7

(old ref. no. in 8 13-630 with double eyelets 2313 (913 SQR) -7
parentheses) 14-630 with single eyelets (513 S) -5
17-630 with double eyelets 2317 (917 SQR) -7
14-630 (514/AI24) -2
W 16-630 (516/AI29) -3
16-630 with eyelets (516/AI29) -2
W 15-630 2215 (415X) -2
16-630 2115 (716,416, 116) -4

U 16-630 with eyelets 2115 (716,416, 116) -3
16-630 with dimples 2115 (716,416, 116) -5
17-630 (256) -2
Wolber/Super
Champion
alloy
8 14-630
14-630
with
with
single eyelets
double eyelets
Gentleman 81
Gentleman GTA2
-5
-4
14-630 with double eyelets Gentleman GTX -4
14-630 with double eyelets T430 Alpine -4
U 17-630 with eyelets

17-630 with eyelets
Modele 58
Modele 59
-4
-4
rev.1990 11-19
~700C SPOKE LENGTHS
CI) 3rd step of 3 steps (cont.)
U
..... Unless noted otherwise, rims listed do not have eyelets or dimples.
Z 622mm Bead Seat Diameter
<C
r.: (700C, 28 x 1-5/8 x 1-3/8)
Outside diameter approximately 634mm Rim
U Corree-
'-IJ ISO Designation/ tion
~
'-IJ Akront alloy

U 13-622 50 -9
....J Ambrosio alloy 13-622 with double eyelets Elite Prisma -11
U ~ 14-622 with single eyelets Elite -8
;>- 14-622 with single eyelets ~uper Elite -7
U
.....
14-622 with double eyelets Elite City 22 -8
tQ ~ 14-622 with rim washers Aero Elite -12
a:: Alesa-also see alloy 17-622 with double eyelets 9017 -11
0 Weinmann for ~ 17-622 with single eyelets 6017 -11
IJ. rims not listed
stainless 17-622 with dimples 817 -7
~
here (use
old ref. nos.) steel
U 20-622 with dimples 820 -8
0 822 -9
0 tV 22-622 with dimples
tQ Araya alloy 14-622 20A -10

Q ~ 14-622 with double eyelets 20A -9
14-622 with double eyelets SS-40 -9
Z 14-622 with double eyelets VX-400 -8
<C 14-622 CTL-370 -10
r.: 14-622 with aero washers Aero lW (ADX-IW) -12
CI) ~ 16-622 Aero 2W (ADX-2W) -14
" 14-622 CT-19 -9
Q
Z U 14-622
16-622
SS-45
16A(5)
-8
-8
<C 16-622 SP-20 -8
....J
a:: 17-622
17-622
18
SP-30
-7
-8
'-IJ
r.:
f-
19-622 16A(3) -7
~ 20-622 15 -8
:J Araya steel
CI)
U 17-622 5H -7
11-20 rev. 1990

SPOKE LENGTHS
700C'
3rd step of 3 steps (cont.) CIJ
c:
(700C, 28 x 1-5/8 x 1-3/8)
:crr1
Make Material
ISO Designation/
Corree-
tion
Factor =
r-
).
Campagnolo alloy
(8J 13-622 with single eyelets
Gamma Strada
Lambda Strada
-9
-8
Z
13-622 with double eyelets Omega Strada -8 0 '-'
13-622 with double eyelets Omicron Strada -8

CIJ
Ypsilon Strada
Delta XL Strada
-8
-8
:c).
14-622 with double eyelets Omega XL Strada -8 Z
13-622 Lambda Strada V -15
0
Pt:J 13-622 Omega Strada V -16 t=
13-622 Ypsilon Strada V -16 0
Fiamme alloy (8J 14-622 with single eyelets 80 - Elan -9 0
~
~ 18-622 71 - Sport -6
~
Fir alloy (8J 13-622 with double eyelets EL20 -8 0
ES 35
EL45
-8
-7
=
t=
.....
EU90
EA50
-8
-10 n
nr--<
14-622 with double eyelets EA60 -10
Galli alloy
Pt:J 13-622 with aero rim washers Aero Pro -9
Matrix alloy 13-622 with single eyelets Titan -9 rr1

(8J 13-622 with single eyelets
Titan-II
Titan S
-10
-9
3:
rr1
12-622 ISOC -16 n
Pt:J 13-622 ISO C-II -14
:c).
17-622 with eyelets Titan T -8
U Z
.....
nCIJ
rev.1990 11-21
r700C SPOKE LENGTHS
en 3rd step of 3 steps (cant.)
...
U
Z 622mm Bead Seat Diameter (cont.)
«
:c
(700C, 28 x 1-5/8 x 1-3/8)
Corree-
U ISO Designation/ tion
'-U Make Material Distinguishing Features Model Factor
~ Mavic alloy 13-622 with single eyelets G40 -8

~ 13-622 with single eyelets MA -9
'-U 13-622 with double eyelets MA2 -9
~
U 13-622 with double eyelets MA40 -9
>
U
ModuleE
Module E2
-8
-8
....
=
CC
0
15-622 with single eyelet

Module 3
Module 3D Argent
Module 4
-10
-9
-9
U.
~
~ 13-622 with single eyelets 190 FB Rim Tech
(Velo Tech)
-9
13-622 with double eyelets Open 4 CD -13

0
0 Milremo-see Wolber
=
Q
Z
Mistral-see Sun Metal
Nisi alloy 12-622 with double eyelets HRB-22 -8

~
«
:c 11-622 with single eyelets Mixer -9
~ 12-622 with single eyelets Mixer -9
en
~
12-622 with double eyelets Contenter -9
Q Rigida alloy 13-622 with double eyelets Score -9

Z ~ 13-622 with double eyelets SX 100 -10
«
~

AL 13/20
Aero
-10
-13
CC ~ 13-622 with double eyelets HLC 2000 -12
'-U 13-622 with single eyelets Rush -10
:c ~ 16-622 with eyelets AL 16/22 -8

~
;:) Rigida steel U 17-622 Deco 30 -8
en 21-622 Deco 35 -8
11-22 rev. 1990

SPOKE LENGTHS 700C'
(700C, 28 x 1-5/8 x 1-3/8)
Corree-
Ritchie alloy
~ 17-622 Vantage Comp -10
Saturae alloy 14-622 with double eyelets HC19 -8

(Specialized) ~ 15-622 with double eyelets C20 -8
U 16-622 with single eyelets C22 -8
Saavedra alloy
~ 13-622 with aero rim washers Featherweight -9
Super Champion-see Wolber
~ 13-622 with single eyelets Mistral M13L -11
13-622 Levanter L13 -10
~ 14-622 Mistral M14A -12
17-622 with eyelets Mistral M17 -9

U 17-622 Levanter L17 -9

U 25-622 with eyelets Mistral M25 -9
Sun Metal steel U 18-622 steel Style L -3
Ukai-see similar Araya models
rev.1990 11-23
r 700C SPOKE LENGTHS
t;J) 3rd step of 3 steps (cont.)
U
Z (700C, 28 x 1-5/8 x 1-3/8)
~ Outside diameter approximately 634mm Rim
:c ISO Designation/
Corree-
tion
U Make Material Distinguishing Features Model Factor
UJ (613)
Weinmann alloy 13-622 with single eyelets -11
~ (old ref. no. in ~ 13-622 with double eyelets 2313 (913 SQR) -11
14-622 with single eyelets (513S)
UJ parentheses) -9
....J 14-622 with single eyelets 571S -9
U 17-622 with single eyelets 2317 (617 SQR) -11
>
U
17-622 with double eyelets (917 SQR) -11
.....
CC ~ 13-622 9013 -11
Cd U 14-622 with eyelets (414) -7

0 16-622 2115 (716,416, 116) -8
u.. 16-622 with eyelets
16-622 with dimples
2115 (716, 416, 116)
2115 (716,416, 116)
-7
-9
~
-8
0 20-622 drilled for .120/12g spokes (720)
22-622 (722,122) -9
0
CC M 14-622
14-622 with eyelets
(514/A124)
(514/A124)
-7
-6
Q 15-622 with eyelets (515X) -5
Z
~ 16-622 (516/A129) -7
:c 16-622 with eyelets

19-622
(516/A129)
(419X)
-6
-7
I
t;J)
" W 15-622 with eyelets 2215 (415X) -6
Q stainless 20-622 with dimples (801) -8
Z Weinmann
(old ref. no. in steel
U
~ parentheses) 22-622 with dimples (811) -9
....J VJ 22-622 with dimples (811R) -8
Cd
UJ
:cl--
::J
t;J)
11-24 rev. 1990

SPOKE LENGTHS
700C 1
3rd step of 3 steps (cant.)
(700C, 28 x 1-5/8 x 1-3/8)
Correc
Wolber/Super alloy 14-622 with single eyelets Gentleman 81 -9

Champion 14-622 with double eyelets Gentleman GTA2 -8
14-622 with double eyelets Gentleman GTX -8
14-622 with double eyelets T430 Alpine -8

14-622 TX Profil -14
17-622 with eyelets Modele 58 -8

17-622 with eyelets Modele 59 -8
xx-622 Mixte -8
rev.1990 11-25
r700C SPOKE LENGTHS
(/) 3rd step of 3 steps (cont.)
u
.... 700C Sew-ups
Z Outside diameter approximately 634mm Rim
<C Correc-
:c ISO Designation/ tion
u Make Distinguishing Features Model Factor
UJ Akront 20 Tubular
~ Ambrosio 20 with double eyelets
UJ 20 with double eyelets
~ 20 with double eyelets
U
>-
U
21 with double eyelets
.... 22 with double eyelets
==
19 with aero w -13
:
o
u..
Alesa -7
-7
-6
~
o Araya Tita-Ace
R-50
-6
-6
o 16B Gold -6
=
Q
Z
16B Red
Pro Staff 340
Pro Staff 400
-6
-5
-5
<C 17.5 with single eyelets Aero 5 (ADX-5) -9

:c 19 with aero rim washers
19
Aero
Aero
1
4
(ADX-l)
(ADX..4)
-11
-10
..(/) 21 with aero rim washers Aero 2 (ADX-2) -12
Q 18t -2
Z tRim requires special nipples and washers. Due to extra length of nipples, spokes could be up to 4mm shorter than
<C listed here. Rims are drilled for specific lacings. Small holes are drilled in the tire bed near the valve hole to indicate
~ lacing pattern. Two holes indicates radial both sides. One hole indicates radial one side and crossed the other side.
a:: No hole indicates crossed pattern on both sides.
UJ
:c
~
:J
(/)
11-26 rev. 1990

SPOKE LENGTHS
7ooc1
700C Sew~ups (cont.)
Correc-
Make Distinguishing Features Model Factor
Campagnolo 20 with double eyelets Delta XL Strada -7

20 with double eyelets Lambda Strada -7
20 with double eyelets Omega Strada -7


20 with double eyelet -7

20 with double eye -7
20 with double ey -7
-7
-7
-7
Fir Alkor -7
Sirus -6
Isidis -6
Quasar -6
Pulsar -6
with double eyelets Speedy (Track) -6

o with double eyelets Ergal (Yellow Label) -6
21 with double eyelets Red Label -6
21 with double eyelets Ergal-Iride -6

21 with double eyelets Hard Silver -7
21 with double eyelets Master -6
21 with double eyelets RCX -7

21 with double eyelets Super Corsa -7
rev.1990 11 ~27
r700C SPOKE LENGTHS
U
.... 700C Sew-ups (cont.)
Z Outside diameter approximately 634mm Rim
~ Correc-
:c Make
ISO Designation/
tion
Factor
U
L.U Galli
t:JJ 20 with single eyelets Criterium
~ 20
20
with
with
single
single
eyelets
eyelets
Paris-Roubaix
Servizio Corse
L.U 20 with single eyelets Top Pro
~
U Gimondi t:JJ 21.5 with double eyelets
>
U
.... Hi-E t:JJ 21 with special nipples
=
CC
Matrix
V 18.5 with square washers
18.5 without rim washers
0 Mavic t:JJ 18 with double eyel -7

u.. 20 with double e
20 with double eye
-7
-7
~
0 .280
euSSC
-7
-7
0 Argent 12 SSC -7
=
Q Argent 8
Argent 10
-7
-7
Z aRlO -7
~
:c .5
ouble eyelets
double eyelets
Montlhery Pro
Montlhery Legere
Montlhery Route
-7
-7
-8
C/)
~
Q 21.5 with double eyelets

22 with single eyelets
Paris Roubaix SSC
Speciale Sport
-7
-8
Z 22 with double eyelets Argent 7 -7
~
~ 22 with double eyelets OR7 -7
CC 19 with single eyelets Mach2CD -14
L.U V
:c~ 19 with double eyelets
18.5 with double eyelets
Mach2CD2
CXP 25**
-13
-6
:J t:JJ 20 with single eyelets Piste (Track) -6

C/)
** Requires nipple with hex heads. Spoke length can be upto 3mm shorter than listed.
11-28 rev. 1990

SPOKE LENGTHS 700CI)
3rd step of 3 steps (cout.) en
c:
700C Sew-ups (cont.) ~
Corree-
:cm
Make
Nisi
t:JJ
ISO Designation/
19
Model
Pista Speciale (Track)

tion
Factor
-5
=
r-
>
19 with double eyelets Sludi Mod 290 -6
19 with double eyelets Sludi Mod 320 -6 2
0
AN-85
Countach en"
20 with double eyelets Solidal
:c
21 with double eyelets >
2
0
V
Rigida
t:JJ
21.5 with double eyelets

21.5 with double eyel
-9
-8
=
0
21.5 with single eyele -8 0
~
Saturae, -6
Satume
t:JJ ."
0
Saavedra -10
=
=
...
Sun Metal Mistral M17 A -9 n
nr--<
Mistral M19A -13
Wein m
904 Professional
Carrera "AS"
-7
-6 :s:m
Wolber/ 20 with double eyelets Aspin/Aspen -7 n
Super Cham 20
20
with
with
double
double
eyelets
eyelets
Medaille d'Or
Aubisque
-7
-7 :c
20 with double eyelets Competition -7 >
20
17.5
with double eyelets Arc-en-ciel
Profil 18
-7
-10
...n
2
V 19 Profil 20 -14
en
rev.1990 11-29
r26" SPOKE LENGTHS
26", 700D and 650 Rims
2nd step of 3 steps
decide on a spoking pattem, i.e., 4-cross, 3- Ace front hub with 32 holes. Look at the
cross (4X, 3X) etc. Find the length listed for 40mm hub diameter table. For a 3X wheel
write down the length 293mm.
selected in Step 1. Write down the length. For 26" Example Two (cont.): Mavic 500 rear
the right rear of multi-speed freewheel hubs hub with 36 holes. On the 44.5mm table a
subtract 2mm. (See below for details.) 3X wheel indicates a length of 290mm for
Adjustments will also be needed for hubs that the left side. For the right side use 288mm.
are different from the specifications below.
The tables on the facing page will give you a length for a 600mm
diameter rim. Step 3 will adjust these lengths for the exact rim you
have.

opposite page. They are the approximate dimensions for road bike
front hubs and the left rear of a road bike rear hub.

Spoke hole diameter-2.6rnm
Differences in Hubs
O.lmm difference in final spoke dimensions these tables are based on. Multiplying
length.
spoke length.
Spoke hole size-a O.2mm difference will make a O.lmm difference

in the final spoke length. In practice this is usually not enough
difference to matter.
Right Rear Hub Spoke Length

Most right rear road hubs require a shorter spoke. How much These combinations have
shorter varies. Many hubs have a hub center to flange center the same spoke length:
on the right rear of 20mm. This is a 15mm difference from the
tables. Using the guidelines for differences in hub center to 16 hole IX = 32 hole 2X
flange dimensions, subtract 1.5mm for the right rear spokes. 20 hole 2X =40 hole 4X
24 hole 2X = 48 hole 4X
This is usually rounded up to 2mm.
11·30 rev. 1990

,.. ""'lIl
SPOKE LENGTHS 26'"

26", 700D and 650 Rims (cont.)
2nd step of 3 steps (cont.)
48 - - - - - - 48 296 291 287 283* 281* 280*
40 296 291 287* 284* 283* 40 295 289 285* 282* 280*
36 298 292 288* 285* 283* 36 298 291 285* 282* 280*
32 294 289 285* 283* 32 293 287 282* 280*
28 297 290 285* 283* 28 297 288 283* 280*
24 292 286* 283*
44.5mnl Hub Diameter 48mm Hub Diameter

48 295 290 285 281* 279* 278* 48 295 289 284 280* 277* 277*
40 294 288 283* 279* 278* 40 294 287 281* 278* 277*
36 297 290 284* 280* 278* 36 297 289 283* 278* 277*
32 293 285 280* 278* 32 292 284 278* 277*
28 296 287 281* 278* 28 296 286 279* 277*
58mm Hub Diameter 63mm·Hub Diameter

48 294 287 281 276* 273* 272* 48 294 286 279 274* 270* 269*
40 293 284 278* 273* 272* 40 292 283 276* 271* 269*
36 297 287 279* 273* 272* 36 297 286 277* 27t* 269*
32 291 281 274* 272* 32 290 279 272* 269*
28 295 283 275* 272* 28 295 282 273* 269*

48 294 285 278 272* 268* 267* 48 292 281 271 263* 257* 256*
40 292 282 274* 269* 267* 40 290 276 266* 258* 256*
36 296 285 276 269* 267* 36 296 281 268* 259* 256*
32 289 278 270* 267* 32 286 271 260* 256*
28 295 281 271* 267* 28 294 275 261* 256*

48 278 267 258* 252* 250* 48 274 260 248* 240* 237*
40 274 261* 252* 250* 40 268 252* 241* 237*
36 278 263* 253* 250* 36 274 255* 242* 237*
32 285 267 254* 250* 32 282 260 243* 237*
* Hubs using these combinations must match the hub diameter category exactly for
.... ~
rev.1990 11-31
r26" SPOKE LENGTHS
26", 700D and 650 Rims (cont.)
3rd step of 3 steps
Araya 26 x 1-1/2 RM-20 rim. The rim correction factor
below. Subtract the rim for this rim is -27. The length from step 2 is 293. 293
correction factor from the minus 27 is 266. 266 is the final length.
in step 2. The answer is 26" Example Two (cont): Mavic rear hub with a Mavic
the final length of the 26 x 1-1/2 Rando M4 rim. The rim correction factor for
this rim is -25. The lengths from step 2 are 290 for the
spoke you need.
left side and 288 for the right. 290 minus.25 is 265 and
288 minus 25 is 263.265 and 263 are the final lengths.
Identifying Rims
Rims are grouped in descending order by bead seat
diameters. ISO rim markings are used in these tables Rim with Rim with
to help distinguish the various models of rims. For single eyelet double eyelet
an explanation of these markings see page 12-3.
The rim cross section drawings are not exact
representations of each rim.
Unless noted otherwise, rims listed do not have
eyelets or dimples.

(26 x 1-1/4 EA1)
Outside rim diameter approximately 609mm
Please note: 26 x 1-3/8 is a more common size.

Rim
Correc-
Araya alloy U 19-597 16A(3) -5
steel U 16-597 5H -5
Rigida steel U 17-597 Deco 30 -6

20-597 Deco 35 -5
Schwinn steel U 20-597 S-6 (26xl-1/4) -5
~ 22-597 S-5 (26x1-3/8) -8
Sturmey steel U 20-597 EA23.5 -5
Weinmann
(old ref. no. in
alloy U 16-597 2115 (716, 416, 116) -5
parentheses)
11-32 rev. ]990

CALCULATING 'SPOKE LENGTH (cont.)
SPOKE LENGTHS 26" 1
26" 700D and 650 Rims (cont.)
3rd step of 3 steps (cont.) ~
c:
590mm Bead Seat Diameter ~
(26 x 1-3/8 EA3, 650A) :t
Outside rim diameter approximately 602mm Rim m
Make Material
ISO Designation/
Model
Corree-
tion
Factor =
r-
)-
2
Ambrosio alloy ~ 20-590 -8 0 ~
~
Araya alloy U 16-590 16A(5) -9
17-590 18 -8
:t
~ 20-590 15 -9 )-
2
Araya steel U 20-590 5 -9
0
CMC steel U 18-590 -9 ca
Femco steel U 18-590 5 -6
0
0
Mavic alloy
~ 13-590 with double eyelets Module E2 -9 ~
19-590 with double eyelets Module 4 -11 ~
0
...nca=
M.O. Mfg. steel U 20-590 -8
Raleigh steel tV 22-590 R23.0 -11

21-590 Deco 35 -8
<
n
Schwinn-see 597mm Bead Seat
r-
Sturmey Archer steel U 20-590 EA 23.0 -9 rn
tV 24-590 R23.0 -10 3:
m
Sun Metal alloy U 20-590 with single eyelets Mistral M20 -10 n
Sun Metal steel U 21-590 Style K -10 :t
)-
Ukai-see similar Araya model
Weinmann
(old ref. no. in
alloy
U 16-590
2115 (716,416, 116)
(A125)
-9
-8
...n2
parentheses) 20-590 2119 (120) -9 ~
20-590 (420, 420R) -10
Weinmann stainless U 20-590 with dimples (801R) -10
rev.1990 11-33
r 26" SPOKE LENGTHS
(/) 3rd step of 3 steps (cont.)
....U
Z 584mm Bead Seat Diameter
(650B, 26 x 1-1/2)
<C
:cU Outside rim diameter approximately 599mm
ISO Designation/
Rim
Corree-
tion
L.U Make Material Distinguishing Features Model Factor
~ Alesa-see Weinmann (use old ref. numbers)
UJ Araya alloy ~ 20-584 15 -12
~
U ~ 20-584 ADX-8W -14
>- Mavic alloy
~
....U 15-584 with double eyelets Module 3 ArgentD -14
=
Cd Rigida alloy
~

Module 4
AL 15/21
-14
-14
0 ~ 16-584 with single eyelets AL 16/22 -12
U.
~ U 21-584 steel Deco 35 -12
0 Wolber/Super alloy U 17-584 with eyelets Modele 58 -12

0 Champion
=
Q 587mm Bead Seat Diameter
also UB 600x19
Z (700D)
<C
:c Outside rim diameter approximately 600mm
ISO Designation/
Rim
Corree-
tion
(/) Distinguishing Features Model Factor
~ Make Material
Q Araya alloy ~ 19-584 RM20 -13
Z
<C 571mm Bead Seat Diameter
~ (26 x 1-3/4, 650C)
Cd Outside rim diameter approximately 585mm Rim
L.U Corree-
:c
~~ Make Material
ISO Designation/
tion
Factor
::J Mavic alloy

~ 13-571 with single eyelets Open 4 CD -23
(/)
Schwinn steel U 25-571 S-7 -19
11-34 rev. 1990

SPOKE LENGTHS 26'"
26" 700D and 650 Rims (cant.)
also HB 575x20, HB 575x25
(26 x 1.50, 26 x 1.75, 26 x 2.125)
Correc-
A.C.S. plastic 23-559 Z-Rim -26
Alesa-also see alloy 21-559 with double eyelets 9021 ..26

Weinmann for 21 . . 559 with single eyelets 6021 . . 27
rims not listed 21 .. 559 with single eyelets 621 -26
here (use old ref.
numbers) 17-559 417 -25
21-559 421 -25
Ambrosio alloy 19..559 with double eyelets Compact -27

21-559 Ontario deLuxe -28
24-559 with double eyelets Performance -26
20-559 with single eyelets Montana -27

20-559 Ontario -27
25-559 Endrick -25
30-559 California -27
~ 26..559 Benelux 32 -24
Araya alloy \LJl 17-559 RM-17 -26

~ 19-559 with ridges at edges RM-20 -25
of brake surface
20-559 VP-20 ..26
25..559 with ridges at edges RM-25 -27
of brake surface
y 20-559 XA.. 1 -29'
19-559 7S ..26
U 20-559 with dimples RX-7 ..26
20-559 with dimples 7X(N) -26
22..559 Mp.. 22 -26

25..559 with dimples 7X,7C -27
Araya steel '--J 25-559 7A -26
rev. 1990 ,11-35

~26" SPOKE LENGTHS
C/') 3rd step of 3 steps (cont.)
U
Z also HB 575x20, HB 575x25
~ (26 x 1.50, 26 x 1.75, 26 x 2.125)
:c Outside rim diameter approximately 575mm Rim
U ISO Designation/
Corree-
tion
[.IJ
~
[.IJ
Bontrager alloy
~ 13-559 with double eyelets
MA40
Module 3 CD
-25
-25
.J
U U 17-559 with eyelets 58 -24
>
U
Campagnolo alloy
~
13-559 with double eyelets Beta -25
..... 14-559 with double eyelets Alpha XL -24
ec ~ 19-559 with double eyelets Kappa -26

a: 23-559 with double eyelets Zeta -27
0 CMC steel
LJ 24-559 -27
~ 25-559 -26
~ Deetz alloy 13-559 with single eyelets HD19 -26

0 ~ 13-559 with double eyelets D19 -26
0 Fir alloy
~ 13-559 with double eyelets ES35 -25
ec
Q U 19-559 MS24 -27
Z ~ 19-559 MS26 -26

~ 22-559 with double eyelets MS29 -27
:c Femco alloy
~ 25-559 with dimples A7 -27
..C/') steel LJ 30-559 OB -26
Q
Z Kin-Lin alloy
~ 26-559 21AL -27
~
.J Mavic alloy
~ 13-559 with double eyelets MA2 -25
a:
[.IJ ~ 17-559 with single eyelets
M231 CD
RandoM4
-26
-25
:c 20-559 with double eyelets
M261 CD
RandoM5
-26
-26
~
::J
C/') V 18-559 with double eyelets
22.5-559 with double eyelets
22.5-559 with double eyelets
EnergyM7
Paris Dakar
OxygenM6
-32
-29
-29
Matrix alloy
~ 18-559 Single Track -29
t:) 12-559 Iso C -33
11-36 rev. 1990 s

SPOKE LENGTHS 26'"
3rd step of 3 steps (cont.) t:rJ
C
also HB 575x20, HB 575x25 :r:
m
=
(26 x 1.50, 26 x 1.75, 26 x 2.125)
Correc- t-
ISO Designation/ tion )-
Z
Nisi alloy
~ 26-559 with double eyelets Zigguart -29
0,.
V 20-559 with single eyelets Dart -28 t:rJ
M.O. Mfg. steel '--J 25-559 -26 :r:
)-
Rigida alloy
~
18-559
18-559
with
with
single eyelets
double eyelets
Laser 40
Laser 400
-28
-27
Z
20-559 with single eyelets Rally 30 -28 0
20-559 with double eyelets Rally 300 -27 ca
20-559
20-559
with
with
single eyelets
double eyelets
CTX50
CTX 500
-31
-30
0
0
~
25-559 with dimples AL 25/32 -26 ~
25-559 with single eyelets AL 25/32 -26
.."
Rigida steel
'--J 25-559 U 25/34 -25 0
Ritchie alloy
~
25-559 with dimples
17-559
19-559
U 28/37
Vantage Camp
Vantage Expert
-26
-26
-28
=
ca
.....
n
~ 20-559 Vantage Sport -26
<
n
Saavedra alloy
V 20-559 All Terrain
Aerodynamic
-34
t-
Saturae alloy 20-559 with single eyelets X28, HX28 -28
m
(Specialized) ~ 25-559 with single eyelets X32, HX32 -26 ~
m
~ 17-559 with single eyelets X22, HX22 -23
n
Schwinn steel l.-1J 25-559 S-2 -26 :r:
)-
Specialized alloy ~ GX23 -27
~
17-559
19-559 X26 -26 Z
.....
n
t:rJ
rev.1990 11-37
r26" SPOKE LENGTHS
also DB 575x20, HB 575x25
(26 x 1.50, 26 x 1.75, 26 x 2.125)
Corree..
Sun Metal alloy (8J 13-559 M13L -26
~~~~~~~~~~~~~~~~~~~
~ 14-559 Mistral M14A -28

~~~~~~~~~~~~~~~~~~~
~ i~~;;~
C16 -26
Chinook (C20) -27

20-559 Levanter L20 -26
25-559 Style I -25
LJ 25~559 Style J -24
~ 25-559 Levanter L25 -25
Sun Metal steel

LJ 25~559
27~559
Style M
Style N
-26
-25
Weinmann
(old ref.no.
alloy
~ 20-559 with double eyelets 2421 (921) -26
in parentheses)
~ 20-559
20-559
2219 (120)
(420)
-25
-25
22-559 (122B) -26
25-559 with eyelets 525/431 -26
25-559 with dimples 525/431 -26
~ 22-559 with eyelets (522X) -24

25~559 with eyelets 2225 (425X) -24
25-559 with eyelets 2225-1 (525X) -23
Wolber/ alloy 14-559 AT 15 -25

Super Champion 16-559 AT 18 -25
~ 19-559 AT 20 -27
~ 27-559 Canyon -26
11-38 rev. 1990

SPOKE LENGTHS 26" ~
26" and 650 Sew-ups
Please note there are 5 different 26" sew-up categories listed here! See 24" sew-ups for 25" rim. Rim
Correc-
Width in mml tion
26" Sew-ups (650)-597mm Outside Diameter
Nisi 19 with rim washers
Weinmann 26 950 Cycloball
26" Sew-ups (650)-594mm Outside Diameter
Mavic 18.5 with double eyelets

26" Sew-ups-584mm Outside Diameter
Nisi -20
Fiamme Speedy -16
ProfH 18 -21
Profil 20 -25
Turbo -21
M17A -20
M19A -24
Assos 16t 16mm x 26" -15
tRim requires special nipples and washers. Due to extra length of nipples spokes could be up to 4mm shorter than
listed here. Rims are drilled for specific lacings. Small holes are drilled in the tire bed near the valve hole to
indicate lacing pattern. Two holes indicates radial both sides. One hole indicates radial one side and crossed the
other side. No hole indicates crossed pattern on both sides.
rev. 1990" 11-39

r24", 22" SPOKE LENGTHS
24", 22", 600 and 550 Rims
2nd step of 3 steps
decide on a spoking pattern, i.e., 4-cross, 3- Ace front hub with 32 holes. Look at the
cross (4X, 3X) etc. Find the length listed for 40mm hub diameter table. For a 3X wheel
that combination in the hub diameter category write down the length 264mm.
selected in step 1. Write down the length. For
24" Example Two (cont.): Mavic 500 rear
the right rear of multi-speed freewheel hubs
hub with 36 holes. On the 44.Smm table a
subtract 2mm. (See below for details.) 3X wheel indicates a length of 260mm for
Adjustments will also be needed for hubs that the left side. For the right side use 258mm.
are different from the specifications below.
The tables on the facing page will give you a length for a 540mm
diameter rim. Step 3 will adjust these lengths for the exact rim you
have.

opposite page. They are the approximate dimensions for road bike
front hubs and the left rear of a road bike rear hub.

Differences in Hubs
dimensions these tables are based on. Multiplying
O.lmm difference in final spoke
length. spoke length.
Spoke hole size-a O.2mm difference will make a O.Imm difference

in the final spoke length. In practice this is usually not enough
difference to matter.
Right Rear Hub Spoke Length These combinations have

Most right rear road hubs require a shorter spoke. How much the same spoke length:
shorter varies. Many hubs have a hub center to flange center 16 hole IX = 32 hole 2X
on the right rear of 20mm. This is a 15mm difference from the 20 hole IX = 40 hole 2X
tables. Using the guidelines for differences in hub center to 20 hole 2X =40 hole 4X
flange dimensions, subtract 1.5mm for the right rear spokes. 24 hole IX =48 hole 2X
24 hole 2X =48 hole 4X
This is usually rounded up to 2mm.
11-40 rev. 1990

,.. """'Ill
SPOKE LENGTHS
24" , 22" 1
24",22",600 and 550 Rims (cont.)
4X 3X 2X IX radial 4X 3X 2X IX radial
40 266 261 257* 255* 254* 40 265 259 255* 252* 251*
36 268 263 258* 255* 254* 36 268 261 256* 252* 251*
32 265 259 255* 254* 32 264 257 252* 251*
28 267 260 255* 254* 28 267 259 253* 251*
24 263 256* 254* 24 261 254* 251*

40 265 258 253* 250* 249* 40 264 257 252* 248* 247*
36 268 260 254* 250* 249* 36 267 259 253* 248* 247*
32 263 255 250* 249* 32 262 254 249* 247*
28 267 257 251* 249* 28 266 256 249* 247*
24 260 252* 249* 24 259 250* 247*

40 263 255 248* 243* 242* 40 263 253 246* 241* 239*
36 267 257 249* 244* 242* 36 267 256 247* 241* 239*
32 261 251 244* 242* 32 260 249 242* 239*
28 266 254 245* 242* 28 265 252 243* 239*
24 257 246* 242* 24 256 244* 239*

40 262 252 244* 239* 237* 40 260 247 236* 229* 226*
36 267 256 246* 240* 237* 36 266 251 238* 229* 226*
32 260 248 240* 237* 32 257 241 230* 226*
28 265 251 241* 237* 28 264 245 231* 226*
24 256 242* 237* 24 251 233* 226*

40 - 244 231* 223* 220* 40 - 239 223* 212* 208*
36 - 249 234* 224* 220* 36 - 245 226* 213* 208*
32 256 237 225* 220* 32 253 230 214* 208*
28 264 242 226* 220* 28 264 237 216* 208*
24 249 228* 220* 24 245 218* 208*
*Hubs using these combinations must match the hub diameter category exactly for
.... ~
rev.1990 11-41
24",22",600 and 550 Rims (cont.)
3rd step of 3 steps
Araya 24 x 1-1/4 20A rim. The rim correction factor for
below. Subtract the rim this rim is -3. The length from step 2 is 264. 264 minus 3
correction factor from the is 261. 261 is the final length.
number Y9u came up with
in step 2. The answer is 24" Example Two (cont): Mavic rear hub with a Sun
the final length of the Metal 24 x 1-3/8 Mistral M17. The rim correction
factor for this rim is -5. The lengths from step 2 are 260
spoke you need.
for the left side and 258 for the right. 260 minus 5 is 255
and 258 minus 5 is 253. 255 and 253 are the final lengths.
Identifying Rims
Rims are grouped in descending order by bead seat diameters. ISO rim
markings are used in these tables to help distinguish the various models of
rims. For an explanation of these markings see page 12 -3 .
The rim cross section drawings are not exact representations of each rim.
Unless noted otherwise, rims listed do not have eyelets or dimples.
Be sure to measure the outside rim diameter before building a wheel
to confirm that you have the correct category of rim. Unlike 27 x 1-1/4
and 27 x 1-1/8 rims which have the same bead seat diameter, 24 x 1-
1/4 and 24 x 1-1/8 do not have the same bead seat diameter.
546 and 547mm Bead Seat Diameter

(24 x 1-1/4)
Corree-
Araya alloy (bdJ 13-546 with double eyelets 20A -3
U 16-546 16A(5) -1
Femco steel U 18-547 5 0
Schwinn steel U 20-546 S-6 (24x 1-1/4) -1
~ 22-546 S-5 (24xl-3/8) -4
Sun Metal alloy U 20-547 Levanter L20 -1
steel LJ 14-547 No. 912323 0
Weinmann
(old ref. no.
alloy
~ 20-546 2119 (120K) -2
in parentheses)
~ 21-546 (801) 0
11-42 rev. 1990

SPOKE LENGTHS
24",22" 1
24",22",600 and 550 Rims (cont.)
3rd step of 3 steps (cant.)
HB 557 x 17
(24 x 1.25, 24 x 1.375)
Correc-
Sun Metal steel '--J HB 557 x 17 Style H o

(600A) also see 541mm bead seat below
Correc-
Fiamme alloy 17-541 71-Sport (Yellow Label)-1
Nisi alloy 21-541 Sport-Toro-Stretto -2

13-541 with single eyelets Mistral M13L -6
14-541 Mistral M14A -8
Rigida steel 17-541 steel Deco 30 -4
Wolber/Super alloy 15-541 with single eyelets Gentleman -4

Champion
rev.1990 11-43
r 24", 22" SPOKE LENGTHS
24",22",600 and 550 Rims (cont.)
(24 x 1-3/8) also see 541 bead seat above
Correc-
Ambrosio (8J 14-540 with single eyelets Elite -5
Araya alloy ~ 20-540 15 -4
steel U 20-540 5 -4
CMC steel U 18-540 -4
Raleigh steel ~ 22-540 R21.0 -7

20-540 Deco 35 -4
Schwinn-see 546mm Bead Seat Diameter
Sturmey Archer steel U 20-540 EA 21.0 -4
Sun Metal alloy U 18-540 with eyelets

20-540 with eyelets
Mistral M17
Mistral M20
-5
-5
20-540 Laventer L20 -5
steel U 20-540 Style K -5
Weinmann
(old ref. no. in
alloy
~ 20-540 2119 (120K, 720K) -5
parentheses)
11-44 rev. 1990 '

SPOKE LENGTHS
24", 22" 1
24",22",600 and 550 Rims (cont.)
(24 x 1-3/4)
Correc-
Schwinn steel U 25-521 S-7 -15

(24 x 1-1/8)
Correc-
Araya alloy 20A -15
SS-45 -14
Sun Metal alloy Mistral M14A -18
Mistral M13 -16
rev.1990 11-45
24",22",600 and 550 Rims (cont.)
....
U
Z also labeled HB 524x20, HB 524x25
<
:c
(24 x 1.50, 24 x 1.75, 24 x 2.125)
U ISO Designation/
Correc-
tion
L.IJ Make Material Distinguishing Features Model Factor
~
L.IJ A.C.S. plastic ~ 25-507 Z-Rim -20
~ Ambrosio alloy ~ 26-507 Benelux 32 -20
U
;>- Araya alloy
~
20-507 with ridges at edges RM-20 -22
25-507 with ridges at edges RM-25 -22
U
....
cg V 20-507 with dimples Aero 7W (ADX-7W) -28
Cd ~
20-507 with dimples
25-507 with dimples
7X(N)
7X
-23
-22
0
U. steel '-J 25-507 7A -21
~
0
Kin-Lin alloy
~ 24-507 with dimples 21AL -23
0 Rigida alloy
~ 25-507 with dimples AL 25/32 -22
cg
Q
steel
'-J 25-507
28-507 with dimples
U 25/34
U 28/37
-19
-19
Z
< Saturae
(Specialized)
alloy
~ 20-507 with single eyelets X28 -23
:c Schwinn t...JJ 25-507 S-2 -22

C/)
~
~
Sun Metal alloy 20-507 Chinook (C20) -23
Q
Z ~ 25-507 Mistral M25 -21
<
~
25-507 Levanter L25 -21
Cd '-J 24-507 TypeJ -21
L.IJ steel '-J 25-507 steel TypeM -21

:c 27-507 steel TypeN -21
~ Ukai-see similar Araya model

;:)
C/)
11-46 rev. 1990

SPOKE LENGTHS
24", 22" 1
24",22",600 and 550 Rims (cont.)
also labeled UB 524x20, HB 524x25
(24 x 1.50, 24 x 1.75, 24 x 2.125)
Correc-
Weinmann alloy 25-507 525/431 -21

(old ref. no. in U 25-507 with dimples 525/431 -24
parentheses)
25-507 2225 (525X) -21
~ 25-507 with eyelets 2225 (525X) -20
~ 35-507 with dimples S35 -23
rev.1990 11-47
rl24", 22" SPOKE LENGTHS
24",22",600 and 550 Rims (cont.)
U
..... 501mm Bead Seat Diameter
Z (22 x 1-3/8)
~ Outside rim diameter approximately 514mm Rim
x: ISO Designation/
Corree-
tion
U Make Material Distinguishing Features Model Factor
L.tJ
~ Araya alloy ~ 20-501 15 -23
L.tJ steel U 20-501 5 -23

...J
U Sun Metal alloy
U 18-501 Levanter L17 -24
>
U
20-501 Lavanter L20 -25
..... '--J 15-501 steel No. 912213 -24
=
a:
Weinmann
(old ref. no.
in parentheses)
alloy
~ 20-501 2119 (120K) -24
0
~
~ (550A)
0 Outside rim diameter approximately 502mm Rim
Corree-
0
=
Q
Make
Gitane OEM
Material
steel U
ISO Designation/
20-490
Model
tion
Factor
-28
Z
~ Rigida steel U 17-490 Deco 30 -28
x: 457mm Bead Seat Diameter
C/)
~
Q (22 x 1.50, 22 x 1.75, 22 x 2.125)
Z Outside rim diameter approximately 473mm Rim
~ ISO Designation/
Corree-
tion
...J
a: Make Material Distinguishing Features Model Factor
L.tJ Araya steel '--J 25-457 7A -47

x:r- CMC steel '--J 24-457 -46
;:)
C/)
11-48 rev. 1990~

SPOKE LENGTHS
24", 22" 11
24",22",600 and 550 Rims (cont.)
25", 24", 22" and 600 Sew-Ups
Please note there are 4 different sew-up rim diameters listed here: one 25", three 24" and one 22". Rim
Correc-
Width in mml tion
25" Sew-ups-554mm Outside diameter
Saavedra 19 with aero rim washers Turbo -5
24" (600) Sew-ups-534mm Outside diameter
Araya
V 19
Mavic t:j 18.5 with double eyelets

22
V -18
Wolber/Super 17.5 -14

Champion V
Fiamme Speedy -12

Red Label -12
Sun Metal Mistral M17A -15

Mistral M19A -19
Turbo -16
16t 16mm x 24" -11
22" Sew-ups-483mm Outside diameter
Fiamme without eyelets or washers 22" -37
tRim requires special nipples and washers. Due to extra length of nipples, spokes could be up to 4mm shorter than
listed here. Rims are drilled for specific lacings. Small holes are drilled in the tire bed near the valve hole to indicate
lacing pattern. Two holes indicates radial both sides. One hole indicates radial one side and crossed the other side.
No hole indicates crossed pattern on both sides.
rev.1990 11-49
r20" SPOKE LENGTHS
20" and 500 Rims
2nd step of 3 steps
Count the number of holes in the hub and 20" Example One: GT BMX front hub
decide On a spoking pattern, I.e., 4.. cross, 3.. with 32 holes. Look at the 40mm hub
cross (4X, 3X) etc. Find the length listed for diameter table. For a 3X wheel 221mm. is
the listed length. Add Imm for the front
hub. Write down 222mm.
selected in Step 1. Write down the length.
Front hubs flanges are often farther apart and 11
20 Example Two: GT BMX rear hub
generally need a Imm longer spoke. (See with 36 holes. On the 44.5mm table a 3X
below for details.) Adjustments will also be wheel indicates a length of 215mm.
needed for hubs that are different from the
specifications below.
The tables on the facing page .will give you a length for a 450mm
diameter rim. Step 3 will adjust these lengths for the exact rim
you have.
3rd step-·._.go to page 11 . . 52
opposite page. They are the approximate dimensions for a rear
BMX hub or coaster brake.
Hub center to flange center.........28mm

Spoke hole diameter~2.6mm
Spoke seating and stretch.. . . . . O.4mm
Differences in Hubs
Hub center to flange center---a 20" Example One (cont.): OT BMX front hub with a
Imm difference will make a 35mm hub center to flange center is 7mm wider than
O.12mm difference in final spoke the dimensions these tables are based on. Multiplying
7mm by O.12mm you get 0.84mm. Add Imm to the
length.
spoke length.
Spoke hole size--a O.2mm difference will make a O.lmm These combinations have
difference in the final spoke length. In practice this is the same spoke length:
usually not enough difference to matter. 16 hole IX == 32 hole 2X
20 hole IX := 40 hole 2X
20 hole 2X ::: 40 hole 4X
24 hole IX == 48 hole 2X
24 hole 2X= 48 hole 4X
II· 5 0 rev. 1990

,...

SPOKE LENGTHS 20" 1
20" and 500 Rims (cont.)
36 223 217 212* 209* 208* 40 222 216 210* 207* 205*
32 219 213* 210* 208* 36 218 211 * 207* 205*
28 222 215 210* 208* 32 221 213 207* 205*
24 217 211 * 208* 28 216 208* 205*
20 220 212* 208* 24 220 209* 205*

40 219 213 208* 204* 203* 40 219 212 206* 203* 201 *
36 222 215 209* 204* 203* 36 222 214 207* 203* 201 *
32 218 210 205* 203* 32 217 209 203* 201 *
28 221 212 205* 203* 28 221 211 204* 201 *
24 215 206* 203* 24 214 205* 201 *

40 218 209 202* 198* 196* 40 217 208 201 * 196* 194*
36 222 212 204* 198* 196* 36 222 211 202* 196* 194*
32 216 206 199* 196* 32 215 204 197* 194*
28 220 208 200* 196* 28 220 207 197* 194*
24 212 201 * 196* 24 211 199* 194*
67 mm Hub Diameter 90mm Hub Diameter

4X 3X 2X IX radial 3X 2X IX radial
40 217 207 199* 194* 192* 40 202 191 * 183* 180*
36 222 210 201 * 194* 192* 36 206 193* 184* 180*
32 215 203 195* 192* 32 212 196 185* 180*
28 220 206 196* 192* 28 200 186* 180*
24 210 197* 192* 24 206 188* 180*
102.5mm Hub Diameter

3X 2X IX radial
40 199 186* 177* 174*
36 204 189* 178* 174*
32 211 193 179* 174*
28 197 181 * 174* *Hubs using these combinations must match the hub diameter category
24 204 183* 174* exactly for accurate results. See drawings and text page 11 ..2.
rev.1990 11.. 51
r20" SPOKE LENGTHS
3rd step of 3 steps
Find the rim in the tables 20" Example One (cont.): GT BMX front hub with an
Araya 7X(N) rim. The rim correction factor for this rim is
below. Subtract the rim -27. The length from step 2 is 222.222 minus 27 is 195. 195
correction factor from the is the final length.
in step 2. The answer is 20" Example Two (cont): GT BMX rear hub with a Sun
the final length of the Metal 20xl.75 Mistral M17. The rim correction factor for
spoke you need. this rim is -27. The length from step 2 is 215.215 minus 27
is 188. 188 is the final length.
Identifying Rims
Rims are grouped in descending order by bead seat diameters. ISO rim
markings are used in these tables to help distinguish the various models of
rims. For an explanation of these markings see page 12-3.
The rim cross section drawings are not exact representations of each rim.
Unless noted otherwise, rims listed do not have eyelets or dimples.

(20 x 1-3/8, 20 x 1-1/4, 20 x 1-1/8)
Corree-
Araya alloy
~ 14-451 with aero washers Aero lW (ADX-IW) -7
~ 14-451 with double eyelets 20A -5
~ 20-451 with dimples 15 -5
Araya steel U 20-451 5 -3
Dunlop steel ~ 21-451 E.5.J. -3
Raleigh steel tV 20-451 R 18.0 -6
11-52 rev. 1990,

SPOKE LENGTHS 20" ,
24" 500 Rims (cont.)
3rd step of 3 steps (cant.) C/)
c:
(20 x 1-3/8, 20 x 1-1/4, 20 x 1-1/8) :t
Outside rim diameter approximately 463mm Rim rn
Make Material
ISO Designation/
Corree-
tion
Factor
=
r-
>
Schwinn steel U 20-451 S-6 (20x1-1/4) -3 2
~ 22-451 S-5 (20xl-3/8) -6 0.,.
C/)
Schurmann steel U 20-451 -3
:t
Sturmey steel ~ 20-451 EB 18.0 -3
>
2
Sun Metal alloy 13-451 Mistral M13L -5
8J 13-451 Mistral M13 -5 0
U 18-451
20-451 with eyelets
20-451
Levanter L17
Mistral M20
Levanter L20
-4
-5
-4
=
0
0
~
Sun Metal steel \--.J 14-451 No 911914 -4
IIT1
Ukai-also alloy
~ 21-451 16A-1 -4
0
see similar
Araya models
U =
=
13-451 Racer Z-2 -6
~
....
14-451 -7
n
Weinmann
(old ref. no. in
alloy
~ 21-451 (A101) -2 -<
n
parentheses)
~ 21-451 2119 (120K) -4 r-
rrt
(500A)
:s:
rn
Outside rim diameter approximately 452mm Rim n
ISO Designation/
Corree-
tion :t
Make Material Distinguishing Features Model Factor >
Rigida steel U 17-440 Deco 30 -9 ....2
n
C/)
rev.1990 11-53
r20" SPOKE LENGTHS
20"and500 Rims (cont.)
also HB 422x20, HB422x25
(20 x 1.50, 20 x 1.75, 20 x 2.125)
Correc-
A.C.S. plastic ~ 25-406 Z-Rim ..27
alloy ~ 25-406 RL..Edge ..25
Ambrosio alloy 26-406 Benelux 32 -25
Araya alloy
v 20-406 with dimples Aero 7W (ADX-7W) ..33
V 20..406 XA.. 1 ..30
20-406 with dimples 7X(N) ~7

L2J 25..406 with dimples 7X ..28
25.. 406 with dimples 7C ~8
25-406 with dimples and ridges 7L -27
and edges of brake surface
Araya steel
'---J 25-406 7A ..27
'---J 25.. 406 with dimples 17(4) ..29
R ... ·51.· 25..406 17(1) ..27

~ 30..406 17(2) ..27
30-406 with dimples 17(3) ..29
CMC steel '---J 25..406 -26
Femco alloy A7 ..26
steel '---J 25..406 7NF-27

~~~----,--.",-...~~.....---,-..,,,,,..-------...,..,...-------...,--..--...,....,...,..,,,,..-------,,,,..-------~..,...-.,,..--.,,,,..-------------,,,,..--------
'---J 25..406 7A -27

.......,...----------------""..-------""..-------""..---------------,,,,,..-------------,,,,..-------------------...,.,...,.,..,~,,,,..-------=----------,,,,..-------------~
'---J 30..406 with dimples ..31
Kin Lin steel .'---J 30-406 with dimples ..31
M.D. Mfg. steel '--J 25-406 -28
Mavic alloy ~ 19-406 with double eyelets TTM4, TTM4CD -28
Peregrine alloy ~ 24406 HP 48 -29
Rigida alloy L2J 25-406 with dimples AL 25/32 ..29
Ritchie alloy ~ 17-406 Vantage Camp -29
II-54 rev. 1990 _

SPOKE LENGTHS 20" ,
24" 500 Rims (cont.)
406mm Bead Seat Diameter (cont~)
also HB 422x20, DB 422x2S
(20 x 1.50, 20 x 1~75, 20 x 2.125)
Correc-
ISO Designation! tion
Saavedra alloy 20-406 BMX Aerodynamic -35
Sun Metal alloy 18-406 with eyelets Mistral M17 -27


25-406 Style I ,..27
20-406 Chinook (C20) -29

20-406 with double eyelets M13L -27
Sun Metal steel

LJ 25-406
27-406
Style M
Style N
-27
-27
Super Champion~see Wolber
Ukai~see similar Araya model
Weinmann 25-406 525/431 -27

(old ref. numbers 25-406 with eyelets 525/431 -26
in parentheses) 25-406 with dimples 525/431 -27
25-406 2225 (525X) -26

25-406 with eyelets 2225 (525X) -25
Wolber/Super ~ 27-406 with eyelets Canyon -28

Champion

(20 x 1-3/4)
Correc~
Araya steel U 24-419 -21
Schwinn steel S-7 -21
rev.1990 II-55
r20" SPOKE LENGTHS
20"and 500 Rims (cont.)
400mm Bead Seat Diameter (see also 18 x 1-3/8)
(20 x 2)
Correc-
Sturmey steel U 29-400 FA 16.0 -26
20" Sew-ups
Please Note: There are two different rim diameters listed here.
Rim
Correc-
Width in mm/ tion
20" Sew-ups--433mm Outside Diameter
Araya V 21 with aero washers -22
Nisi -17
Sun Metal Mistral M19A -24
20" Sew-ups--430mm Outside
Saavedra Turbo -22
11-56 rev. 1990'

,..
SPOKE LENGTHS 20" 1

-NOTES-
rev.1990 11-57
,..
r18" SPOKE LENGTHS

18" and 17" Rims
C/)
u 2nd step of 3 steps
....
z Use the directions for 20" rims. These tables should be
<
:c
considered as a start for some trial-and-error wheel
building~ Smaller wheels have too many variables to be
These combinations have
the same spoke length:
16 hole IX == 32 hole 2X
accounted for in tables like these. Interlacing spokes is
u not recommended for these size wheels.
20 hole IX::;: 40 hole 2X
UJ
:E 3rd step-··--···go to facing page.
UJ
....1 The following hub dimensions were used for the tables on this
U page.
>- Rim diameter-.---400mm
....U Hub center to flange center~28mm
=
a::
o
Spoke hole diameter~2.6mm
Spoke seating and stretch---.-O~4mm
Differences in Hubs-Hub center to flange center~a 1mm
difference will make a 0.15mm difference in spoke length.
~
~ 34mm Hub Diameter 40mm Hub Diameter 44.5mm Hub Diameter
o 2X IX radial 2X IX radial 2X IX radial
o 28 191 186* 185* 28 190 184* 182* 28 188 182* 179*
=
Q
24
20
194
197
187*
188*
185*
185*
24
20
192
196
185*
186*
182*
182*
24
20
191
196
183*
184*
179*
179*
Z 16 190 185* 16 188 182* 16 187 179*
<I: 12 194 185* 12 192 182* 12 191 179*
:c 48mm Hub Diameter 58mm Hub Diameter 63mm Hub Diameter
C/)
~ 2X IX radial 2X IX radial 2X IX radial
Q 28 188 180* 178* 28 185 176* 173* 28 184 174* 170*
Z 24 191 181* 178* 24 189 177* 173* 24 188 175* 170*
<I: 20 195 183* 178* 20 194 179* 173* 20 194 177* 170*
....1 16 185 178* 16 182 173* 16 181 170*
Cd 12 191 178* 12 189 173* 12 188 170*
UJ
:c 67mm Hub Diameter 90mm Hub Diameter
~ 2X IX radial IX radial
:::J 28 183 172* 168* 28 163* 157*
C/)
24 187 174* 168* 24 165* 157*
20 194 176* 168* 20 168 157*
16 180 168* 16 157*
12 187 168* 12 157*
* Hubs using these combinations must match the hub diameter category exactly for accurate results. See
drawings and text page 11-2~
...
11-58 rev. 1990
CALCULATING SPOKE LENGTHS (cont.)
SPOKE LENGTHS 18" 1
18" and 17" Rims (cont.)
3rd step of 3 steps
(18 x 1-3/8)
Correc-
Araya steel ~ 20-400 5 -4
Sturmey Archer steel ~ 20-400 -4

(17 x 1-1/4)
Correc-
Make Material Distinguishing ~"eatures Model Factor
Milremo alloy early Alex Moulton -18
Mis tral--- alloy Alex Moulton -18

(English-not
Sun Metal)
Sun Metal alloy ~ 13-369 with eyelets Mistral M13L -21

also HB 371x20, DB 371x25
(18 x 1.75)
Correc-
Araya steel '--J 25-355 7A -28
Ukai steel '--J 25-355 with dimples -30
18" Sew-Ups
Please Note: There are tWQ different rim diameters listed here.
18" Sew ups-382mm Outside Diameter

Fiamme alloy (t:::JJ 21mm width Bambino -17
18" Sew ups---380mm Outside Diameter

Sun Metal alloy V 19mm width Mistral M19A -25
rev.1990 11-59
,... ......
rr 16" SPOKE LENGTHS

16" and 400 Rims
2nd step of 3 steps
Use the directions for 20" rims These tables should be
These combinations have
considered as a start for some trial-and-error wheel the same spoke length:
building. Smaller wheels have too many variables to be 16 hole IX = 32 hole 2X
accounted for in tables like these. Interlacing spokes is 20 hole IX = 40 hole 2X
not recommended for these size wheels.
3rd step-go to facing page.

The following hub dimensions were used for the tables on this
page.
Rim diameter-350mm
Spoke seating and stretch-0.4mm
Differences in Hubs-,-Hub center to flange center-a Imm
34mm Hub Diameter 40mm Hub Diameter 44.5mm Hub Diameter

2X IX radial 2X IX radial 2X IX radial
28 167 162* 160* 28 165 159* 157* 28 164 157* 155*
24 169 163* 160* 24 168 160* 157* 24 167 158* 155*
20 172 164* 160* 20 172 161* 157* 20 171 160* 155*
16 165 160* 16 164 157* 16 162 155*
12 169 160* 12 168 157* 12 167 155*
48mm Hub Diameter 58mm Hub Diameter 63mm Hub Diameter

28 163 156* 153* 28 161 152* 148* 28 159 150* 146*
24 166 157* 153* 24 164 153* 148* 24 164 151* 146*
20 171 158* 153* 20 170 155* 148* 20 170 153* 146*
16 161 153* 16 158 148* 16 157 146*
12 166 153* 12 164 148* 12 164 146*

2X IX radial 2X IX radial
28 158 148* 144* 28 153 139* 133*
24 163 149* 144* 24 160 141* 133*
20 170 152* 144* 20 169 144* 133*
16 155 144* 16 149 133*
12 163 144* 12 160 133*
* Hubs using these combinations must match the hub diameter category exactly for accurate results. See
drawings and text page 11-2.
.... ...4
11-60 rev. 1990

SPOKE LENGTHS 16" 1
3rd step of 3 steps en
c:
~
(16 x 1-3/8) :c
Outside rim diameter approximately 363mm Rim m
Make Material
ISO Designation/
Corree-
tion
Factor
=
r-
)-
Araya steel U 20-349 5 -5 2
0
Sturmey Archer steel U 20-349 -5
en"
:c
)-
steel '---J 20-349 No. 941613 -6
2
Weinmann alloy
~ 21-349 2119 (120K) -5
0
ea
(400A) 0
Outside rim diameter approximately 353mm 0
Weinmann alloy ~ 21-340 (AI0l) -8 ~
."
305mm Bead Seat Diameter 0
...nea=
(16 x 1.75)
Corree-
Make Material
ISO Designation/
tion
Factor -<
n
Araya alloy
~ 25-305 7X -29 r-
steel 25-305 -28
m
'---J 25-305 with dimples -29 3:
m
CMC steel '---J 25-305 -27
n
Femco steel '---J 25-305 7A -28 :c
;J>
Schwinn
Sun Metal
steel
steel
t....1J
'---J
25-305 steel
25-305
27-305
Style M
Style N
-28
-28
-28
...
:2
n
Ct:
Ukai steel t....1J 25-305 -28
16" Sew-ups-331mm Outside Diameter

Sun Metal alloy 17mm width Mistral M17A -20
tJ 19mm width Mistral M19A -23
rev.1990 11-61
,..
~ 14" SPOKE LENGTHS

CALCULATING SPOKE LENGTH' (cont.)
14" Rims
2nd step of 3 steps
Use the directions for 20" rims These tables should be
considered as a start for some trial.. and-error wheel building.
Smaller wheels have too many variables to be accounted for in
tables like these. Interlacing spokes is not recommended for
these size wheels.
3rd step-,'-'"go to facing page.

The following hub dimensions were used
for the tables on this page.
Rim diameter----300mm
Hub center to flange center.. . . . . 28mm
Spoke hole diameter----2.6mm
Spoke seating and stretch----0.4mm
Differences in Hubs-Hub center to flange center------a 1mm
34mm Hub Diameter 40mm Hub Diameter 44.5mm Hub Diameter

28 141 136* 134* 28 140 133* 131* 28 138 132* 129*
24 143 137* 134* 24 142 134* 131* 24 141 132* 129*
20 147 138* 134* 20 146 136* 131* 20 146 134* 129*
16 140 134* 16 138 131* 16 136 129*
12 143 134* 12 142 131* 12 141 129*
48mm Hub Diameter 58mm Hub Diameter 63mm Hub Diameter

28 137 130* 127* 28 135 126* 122* 28 134 124* 120*
24 141 131* 127* 24 139 127* 122* 24 138 125* 120*
20 145 133* 127* 20 145 129* 122* 20 144 127* 120*
16 135 127* 16 132 122* 16 131 120*
12 141 127* 12 139 122* 12 138 120*
67mm Hub Diameter

2X IX radial
28 133 122* 118*
24 138 124* 118*
20 144 126* 118*
16 130 118*
12 138 118*
*Hubs using these combinations must match the hub diameter category exactly
for accurate results. See drawings and text page 11 . . 2.
11..62 teV.1990
SPOKE LENGTHS 14'"
14" Rims (cont.)
3rd step of 3 steps
(14 x 1·3/8)
Correc-
Sturmey Archer steel U 20-298 -5
Ukai U 20-298 -5

also DB 270x20, UB 270x25
(14 x 1.75)
Correc-
Araya steel
LJ 20-253 with dimples
25-253
17 (5)
7A
-29
-28
Ukai steel LJ 25-253 with dimples
14" Sew-ups-····270mm Outside Diameter

Sun Metal alloy .LT£.LU.... .L"-4..L M19A
rev.1990 11·63
12" SPOKE LENGTHS
12" Rims
en 2nd step of 3 steps
U
..... Use the directions for 20" rims. These tables The following dimensions were used
Z should be considered as a start for some trial for the rim tables below:
<
:c
and error wheel building. Smaller wheels
have too many variables to be accounted for
Rim Diameter-250mm
Hub Center to flange center-28mm
u
[.JJ
in tables like these. Interlacing spokes is not
recommended for these size wheels.
Spoke hole diameter-6mm
Spoke seating and stretch-0.4
~ Differences in Hubs-Hub center to flange center-a Imm difference will make a 0.22mm
difference in spoke length.
[.JJ
....l 34mm Hub Diameter 40mm Hub Diameter 44.5mm Hub Diameter 48mm Hub
U IX radial IX radial IX radial IX radial
>
U 20 113* 110* 20 111* 107* 20 110* 105* 20 108* 103*
..... 16 115* 110* 16 114* 107* 16 112* 105* 16 111* 103*
=
=:
12 119 110* 12 118 107* 12 117 105* 12 117* 103
oU. 58mm Hub Diameter

IX radial
63mm Hub Diameter
IX radial
67mm Hub Diameter
IX radial
20 105* 98* 20 103* 96* 20 102* 94*
~
o 16 108* 98* 16 107* 96* 16 106* 94*
o 12 115 98* 12 114 96* 12 114 94*
=
Q
*Hubs using these combinations must match the hub diameter category. See drawings and text
page 11-2.
Z
<
:c
12" Rims
3nd step of 3 steps
en
~
Q 203mm Bead Seat Diameter

Z (12-1/2 x 2-1/4)
<
....l
Correc-
=:
[.JJ
Make Material
ISO Designation/
tion
Factor
:c CMC steel LJ 24-203 -28
E- Sun Metal alloy LJ 24-203 Style J -25

:J
en steel LJ 24-203 Style M -27
11-64 rev. 1990

SPOKE LENGTHS 10"
10" Rims
2nd step of 3 steps
Use the directions for 20" rims. These tables The following dimensions were used
should be considered as a start for some trial for the table below:
and error wheel building. Smaller wheels have Rim Diameter-200mm
too many variables to pe accounted for in Hub Center to flange center-28mm
tables like these. Crossed patterns not Spoke hole diameter-2.6mm
recommended for 10". Radial lengths are the Spoke seating and stretch-0.4
same no matter how many spokes are used.
Differences in Hubs-Hub center to flange

center-a 1mm difference will make
approximately 0.3mm difference in spoke
length.
Radial Pattern-Hubs must match the hub diameter category exactly. See
drawings and text page 11-2.
34mm Hub-87* 58mm Hub-75*
40mm Hub-84* 63mm Hub-73*
44.5mm Hub-82* 67mm Hub-71 *
48mm Hub-80*
10" Rims
3rd step of 3 steps
(10 x 1-5/8)
Correc-
Marzorati alloy V 25-194 Mini Westwood -9
HB 168x20
(10 x 1.5)
Outside rim diameter 168mm Rim
Correc-
Araya steel LJ HB 168x20 with dimples 17(5) -30
rev.1990 11-65
SPOKE LENGTHS
CALCULATING RIM CORRECTION FACTORS

CI)
....u
Z Measure the inside diameter of the rim with a tape
measure. To be sure rim is round, measure in several
<C A
:c places. This dimension will be called A.
u(.IJ
:E
(.IJ
1
~
u Measure the spoke nipple from the bottom of the slot to the
>
u
end. This dimension will be called B.
....
=
=:
ou..
~
o
o
=
Q Place a spoke nipple in the rim and measure the part that
extends beyond the rim. This dimension will be called C.
Z
<C
:c
CI)
~
Q
Z
<C
~ The theoretical rim radius the charts are based on will be
=:
(.IJ
called D.
:c D =315
300
for
for
27"
26"
rims
rims
175
150
for
for
16"
14"
rims
rims
E- 270 for 24" rims 125 for 12" rims
:J 225 for 20" rims 100 for 10" rims
CI)
200 for 18" rims
The formula to find the correction factor for a rim not

listed on the chart is:
(A
\'
+2 2(J3~C»).
- D-
·
CorrectIon Factor
11-66
SPOKES LENGTHS 1
NUMBER OF SPOKES
Figure A 32 spokes Figure B 40 spokes
32,36 AND 40 SPOKE WHEELS

10 32 and 40 spoke wheels have similar spoke patterns as
illustrated in figures A and B. With practice they can be
easily told apart by looking at the distance between spokes
at the rim.
36 spoke wheels have a pattern as illustrated in figure C.
20,24, AND 28 SPOKE WHEELS

24 spoke wheels have a pattern similar to 32 and 40 spoke
wheels.
20 and 28 have a pattern similar to 36 spoke wheels.
Figure C 36 spokes
11-67
r SPOKE LENGTHS
...
11-68
TIRES
TIRE AND RIM TYPES

The most common types of tires are wired-on, hooked-
beadl and sew-up. Bot4 wired-on and hooked-bead tires
have a wire embedded in the rubber at the inside edge of
the tire. Wired-on rims have straight sides. The bead seat
Tire width of a wired-on tire is where the edge of the tire meets the
rim. Air pressure in the tube keeps the bead of the tire
pressed outward. Without air pressure the bead can slip
into the well in the center of the rirI1 allowing it to come
off over the edge on another part of the rim.
Hooked-bead tires have a protruding bead that fits
around the hooked edge of the rim to hold the tire in
place. These rim cross sections are illustrated on the fol-
t
lowing page.
Rim width Sew-up tires, also known as tubulars or sprints, have the
inner tube sewn in. Sew-up rims lack flanges; the tire is
held to the dished face of the rim by air pressure and a
special adhesive.
TIRE AND RIM FIT

Type. In the past each rim type fit only the corresponding
tire type. Now the distinctions are blurring. Many higher-
pressure rims come with a ridge on the inside edge of the
rim flange which is similar to though smaller than the
hooked edge of a hooked-edge rim. Many folding tires
must be mounted on rims with these bumps to prevent
stretching of the flexible, plastic bead material.
Width. Tires with an 1802 Section Width 3 of between 1.45
and 2.00 times the rim width (measured· in millimeters
between the inside -of the flanges) should fit well.
Hooked-edge rims hold tires with a section width of up to
2.25 times the rim width. Never use an inner tube that is
too narrow for the tire in which it is installed: it may
work at first but it will soon split at the seams.
lTrue clincher tires, tires held on by a pronounced bead

and a rubber flap under the inner tube, are now obsolete
in most parts of the world. Many people still use the term
clincher to refer to the wired-on and hooked-bead tires
that have replaced them.
2The former European Tire and Rim Technical Organiza-
tion (ETRTO) markings have been adopted by the ISO.
3180 Section Width is approximately equal to the distance
between the beads, measured over the tread in millime-
ters, divided by 2.5. See Measuring Rims and Tires, page
12-5.
rev. 1985 12-1

TIRES
TIRE AND RIM FIT (cont.)
Diameter. Bead and bead seat diameter are much more
important dimensions than outside diameter because they
determine tire/rim fit. (Unfortunately, most tires are still
marked with the nominal outside diameter. Since tires
with equal outside diameters may differ slightly in bead
diameter, they may not fit the same rim.) To ensure
proper fit, tire bead diameter must be very close to rim
bead seat diameter-in general, within 1 mm. If the tire is
too large it will blow off the rim when inflated; if too
small, the beads will pull down below the bead seat-if
the tire can be mounted at all.
RIM AND TIRE WIDTH

The following rim widths are recommended for use with
the tire sections to the right. Rim width is measured
between the flanges.
Rim Width Tire Section
(inside flanges) British ISO French
12 to 15mm 3/4 20 20
13 to 15mm 7/8 22 22
13 to 18mm 1 25 25
14 to 20mm 1 1/8 28 28
15 to 21mm 1 1/4 32 32
16 to 23mm 1 3/8 37 35
17 to 24mm 1 1/2 40 ~8
20 to 29mm 1 5/8 44 42
23 to 31mm 1 3/4 47 45
24 to 33mm 2 54 50
27 to 35.6mm 2 1/8 57 54
30.5 to 41mm 2 1/4 62 57
12-2 rev. 1985

TIRES
TIRE AND·RIM MARKINGS

ISO Tire Markings. The ISO tire size designations are the
only accepted international standard. Many tires carry
them in addition to the more familiar markings. For
wired-on tires the ISO tire markings consist of two num-
bers as follows:
37 - 622"
ISO Tire Section/ bead diameter
Width in mm in mm
Hooked-bead tires mayor may not use the HB designa-
tion (see ISO rim markings below).
ISO Rim Markings. For wired-on rims the ISO rim desig-
nations also consist of two numbers:
13 - 622
ISO Rim Width/ 'bead seat diameter
between flanges in mm
inmm
For hooked-bead rims the ISO has designated HB num-
bers although the above markings for wired-on rims are
also seen. HB numbers are as follows:
HB 575 x 25
HB for Hooked~tsideIdiamet~insidewidth
Bead of the rim in mm
inmm
HB numbers are only found on hooked-bead rims.
British. Tires are marked in inches with two or three

numbers as follows:
28 x 15/ 8 x 13/ 8 (ISO 37-622)
nominal/ I
standard " actual
outside width width
diameter
Tires designed for standard rim SIzes carry only two
numbers:
26 x 13/ 4 (ISO 44-571)
nomin'l \idth
outside
diameter
J6 x 1. 75 (ISO 44-559)
nominal ~idth
outside
diameter
rev. 1985 12-3

l TIRES
~
TIRE SIZE CHART (Headings)
Common Tire Markings (American, English, French, etc.)

If width number is replaced by a dash (-), a range of widths
is available in the same bead seat size.
ISO Size Designation

Tire Section in mm, followed by bead seat diameter in
mm. For HB numbers see page 12- 3. When a range of
widths is available, it is shown with the standard width in
bold face: 32-340 to 37-340.
Bead Seat Circumference

3.14 times bead seat diameter.
Brake Radius
Subtract this value from the distance between brake bolt
hole and axle center to obtain brake reach.
Rim Outside Diameter (assuming normal flange height)

Actual value for a particular rim may be as much as 5mm
less, especially with narrower rims.
Tire Outside Radius

Use this value to calculate tire to fork clearance. Radius of
standard width tires is in boldface.
12-6 1985
TIRES [( I
U
MEASURING RIMS AND TIRES
ISO measurements are in millimeters. Measure rims and

tires as described below.
Rims. Rim width is the distance between the inside of the
flanges, which can be measured directly. To measure the
bead seat diameter, first obtain the flange height and the
outside flange diameter. The flange height is the distance
from the bead seat to the top of the flange. The outside
diameter can be measured directly on a bare rim or with a
dishing tool. Measure in several places and take an
average.
If necessary, the outside flange diameter can be calculated
from the rim circumference. Measure the circumference by
marking a spot on the rim with a piece of tape and rolling
the rim exactly one full turn along a flat surface. The
distance of travel is the rim circumference. Calculate the
bead seat circumference as follows:
rim outside rIm 3.14
diameter
= circumference
rim bead seat rim outside 2 x flange

diameter diameter height
Tires. ISO Section Width can be approximated as fol-

lows:
ISO Distance between
Section - beads measured over 2.5
Width the tread in mm
For proper fit, ISO Tire Section Width should be between
1.4 and 2.0 times rim width (up to 2.25 times for hooked-
bead tires and rims).
The most accurate way to determine the bead diameter is
to measure a rim that the tire fits. Rim bead seat diameter
is usually within 2mm of tire bead diameter. If no such rim
is available, use the following technique to measure the
bead circumference and calculate the bead diameter. Lay
the tire on a flat surface and expand a 1/4 " wide flat steel
tape inside the bead. If the tire will not lie flat against the
tape, make up a long strip of thin cardboard, using 1" strips
taped together, and measure that. Calculate the bead
diameter as follows:
bead bead
3.14
diameter circumference
The results will tend to be low, perhaps as much as 3mm
due to the difficulty of holding the tape against the bead .
...
1985 12-5
TIRES
TIRE AND RIM MARKINGS (cont.)

Common fraction in width designation indicates wired-on
type, decimal fraction indicates hooked-bead type.
Note that 26 x 13/ 4 and 26 x 1.75 are different type tires and
are not interchangeable.
Sch'rvinn and Canadian. Schwinn tire markings are the

same as the British markings described above with the
following exceptions (also noted in the tire size chart):
Schwinn British ISO
26 x 13/ g 26 x 11/ 4 32-597
24 x lYH 24 x 1Y4 32-546
These two Schwinn sizes are not interchangeable with the
British sizes having identical markings.
Vredestein-Paragon (Netherlands). Markings are in inches,

similar to those of the British system, except that when
there are three numbers, the last two are reversed
compared to the British markings. British and Vredestein-
Paragon tires in nominal sizes of 24" or less are not
interchangeable.
/28 x Irs x 1% ,(ISO 37~622)
nominal actual st}ndard
outside width width
diameter
French. Markings are in millimeters as follows:

700 x 35, C~ (ISO 37-622)
nominal/ nominal width code
outside (sometimes
diameter omitted)
In the French system, two tires have the same bead seat
diameter if the first 'numbers and the final letters match.
Italian, German, Swedish, and the like. Many manufac-

turers mark their tires in in9hes although actual sizes are
often different from true British sizes. Look for an ISO
designation or measure the tire as described below.
TIRES
CLASSIC RIM CROSS SECTIONS*
HOOKED-BEAD OR HOOKED-EDGE RIMS

30mm 33.Smm 3S.8mm
"Lightweight" "Middleweight" "Balloon"

1.375 1.75 2.125
WIRED-ON RIMS
38.1mm
Narrow Westwood Westwood Endrick Westrick

EType FType EA Type R Type
(Schwinn S-6 is (Schwinn S-5 is
similar in shape similar in shape
to this type) to this type)
E Type NarrowWestwood F Type Standard Westwood
EA Type Endrick Pattern K Type Special Lightweight
EB Type Narrow Junior R Type Westrick Raleigh
Westwood Pattern
SCHWINN RIMS
35.4mm 35.8mm
Schwinn S-6 see British Endrick
Schwinn S-5 see British Westrick
Schwinn S-7 Schwinn S-2

("M iddleweight") ("Balloon")
*Modern rims vary so much they defy neat classification.
rev. 1985 12-7

SUTHERLAND'S HANDBO·OK FOR BICYCLE MECHANICS
~r
•
,
QC
TIRES
TIRE AND RIM SIZE CHARTS
~ Indicates sizes that may not be interchangeable with other sizes with identical or similar markings. Use ISO markings to positively identify tire.
ISO Tire Vredestein*(V) Approx

Marking Swedish (S) Bead Tire
Bead (Width- North German (G) Seat Rim Out-
Seat Beadseat American Schwinn British Standard Circum- Brake Outside side
Diameter Diameter Sizes Rim I British Rim French Italian Unidentified (SU) ference Radius Diameter Radius
647 32-647 28xl~ I EA2 700 I 700x32 (V) 2032 323 659 358
642 37-642 to 28xl% I F5 700A '.1 28xl% I 28xl% (V), (S) 2016 321 654 361-
44-642 EA4 28xl%x1yg. 700x35A 700x35A (V) 368
E4 ~28xlY2 (8)
28xlY2xl% (8)
635 28-635 to I ~28xl~ ~28xl~ I FlO 700B I 700B I 28x-xlY1 (V) 1994 317 649 348-
40-635 to F25.0 ~28xlY2 700B (V) 360
44-635 FA25.0 ~28xlY2 (G)
~28xl~ (8)
631 32-631 ~27xl~ (8) 1982 315 643 350
630 20-630 to >27xl~ 27xl% K2 ~27xlY4 ~27xl!-4 ~27xl!-4 (G) 1978 315 642 338-
30-630 ~27xl!4 K25.0 348
27xlyg EA25.0
27xl
623 44-623 ~28xl% (S) 1958 312 636 359
622 20-622 to ~ 700C 28xl~ I F.13 700C 700C 28x-x1* (V) 1955 311 634 334-
47-622 ~28xlY2 - 28x1~ E7 28xl~x- 28xl3i ~28x-xl~ (V) 361
(Canada) EA6 28xl!-4 (G)
28xl% (G)
~28xl~ (G)
622 44-622 28xl.75 28xl.75 (V), (G) 1955 311 634 361
609 40-609 27xl~ 1913 I 304 622 347
32x650
607 40-607 27xl~ 1906 303 619 346
599 32-599 to 26xl.375 1880 300 611 331-
37-599 26xl.25 334
HB 611x20
597 32-597 to 1 ~26xl}8 - .1 S-6 26xl~ I E.A.l 650 26xl}.i (V) 1876 298 609 333-
37-597 (Schwinn) S-5 E.l 650x32 (V) 338
K.l
EA23.5
590 28-590 t o l ~26xl% ~26xl% I E.A.3 650A I 26xl}8 26xl}8 (V) 1854 295 602 335-
37-590 to E.3 26xl}8 26x1Y2X1}8 (V) 338
40-590 F.4 26xl}8xlY4 26xlygA (G)
EA23.0 26xlY1 (G)
R23.0 650A(V)
E23.0
585 40-585 to ~26xl~ (S) 1837 292 600 335-
47-585 26xl-% 342
Transit (S)
584 32-584 to ~26xlY21 5-4 26xlYl I F9 650B .~26xlY2 26x-xlY2 (V), (5)1 1835 292 599 327-
40-584 to 650B 26xl.~ 26xl~ 650B (V) 335-
47-584 26xl}8 (G) 342
26xl}8xlY2 fG), (S)
571 40-571 to ~26x 1% 'IS-7 ~26xl% .1 F.12 650C 26xl~ 26xl34 (V) 1 1794 286 585 333-
44-571 to 26xlY2- 26x2xl* F.22.5 25xl~ 650x45C (V) 336
47-571 (Canada) 650x45C 26x2 (G)
I. 561 62-561 26x2.25 (S) 1764 281 576 346
559 44-559 to 1
.• 26xl.501 S-2 26xl.75x2 26x2 26x2.00(V) 1755 279 573 321-
54-559 • ~26xl.7S 650x50 650x50 (V) 330
26x2.125 26xl.75 (G)
HB 575x25 26x2.00 (G)
26x2xl%(G)
650x45 (G)
HB560x20 24xl.375, 560 316-
24xl.25 313
547 32-547 to .1 24xl Y4 . 1 S-6 24-1~ 24xlY2 1715 273 559 308-
37-547 ~24xl}8 S-5 beaded (G) 313
(Schwinn)
541 32-541 to 600A 24xl}8xlY4 (V) 1700 271 554 305-
37-541 ~24xl}8xlY4 310
~ I * BSR on a Vredestein tire stands for British Standard Rim.
::0
\0
o
~
N
~, ~
SOINVHO:lW:I'lOAOIH HOd >lOOH<INVH S,<INV'lH:lHLClS

~ ,..
N ......
I
=
~
TIRES
TIRE AND RIM SIZE CHARTS (cont.)
~ PJ
~ Indicates sizes that may not be interchangeable with other sizes with identical or similar markings. Use ISO markings to positively identify tire.
ISO Tire Vredestein *(V) Approx
Diameter Diameter Sizes Rim British Rim French Italian Unidentified (SU) ference Radius Diameter Radius
540 32-540 to 24x1}8 ~24xl% E.5 24x1}8 24x1}8x1Y2 (V) 1695 269 552 304-
37-540 F.3 600x35A 24x1}8A (G) 309
EA21.0 600x35A (V)
F21.0 24x1Y2x1}8 (S)
R21.0 24x1}8 (S)
534 40-534 ~24xlY2 F8 600B 24x1Y2 (V) 1676 267 548 310
24x1Y2 600x38B (V)
531 40-531 ~24xlY2 (S) 1667 265 545 308
24x1~x1Y2 (S)
521 47-521 ~24x1}4 S-7 24xl~ 1635 260 532 310
508 32-508 22xl~ (V) 1595 254 520 289
550x32 (V)
507 44-507 to ~24xl.75 S-2 600x45 24x1.75x2 24x2x1}4 (V) 1592 253 523 295-
54-507 24x2.125 304
HB 524x25
503 50-503 24x2 1579 251 518 304
Transport (S)
501 32-501 to ~22x-l% E.6 22x1;4 1575 250 514 283-
37-501 to F.2 550x32A 290
47-501 EA19.5
498 32-498 to ~22xl% (G) 1563 249 510 284-
37-498 22x1}8x1;4 (S) 289
490 32-490 to 550A 22xl%A (SU) 1539 245 502 280-
37-490 ~22x l}8x 10i 22x1;4 (G) 285
489 32-489 to 22x1}8 ~22xl% (V) 1535 244 501 279-
37-489 550A 550A (V) 284
484 40-484 to 550B ~22xl!;2 (G) 1520 242 499 285-
44-484 22xl}8xlY2 (S) 289
482 40-482 ~22xlY2 (V) 1515 241 497 284
550B (V)
470 47-470 550C 22xl~ 1475 235 482 285
457 44-457 to 22xl.75 1435 228 473 270-
54-457 22x2.125 279
HB 473x25
451 32-451 to 20xl% S-5 ~20xl% E.5J 20xl~ 20x1}8BSR (V) 1416 225 463 260-
37-451 20xl~ S-6 EA18.0 500x35A 265
R18.0
EB18.0
HB 459x25 20xl.375, 458 266-
20xl.25 262
440 28-440 to 500A 1382 220 452 251-
37-440 to ~20xl%xl~ 260-
40-440 263
438 37-438 20xl}8 ~20xl% (V) 1375 219 450 259
500x35A (V)
432 40-432 20xlY2 (V) 1356 216 446 259
500x38B (V)
428 40-428 to 20xl}8xl!;2 20x2 (S) 1345 214 442 257-
54-428 271
419 47-419 ~20xl% S-7 20x-l~ 1314 209 431 259
406 44-406 to ~20xl.75 S-2 20xl.75x2 20x2xl~ (V) 1274 203 422 244-
54-406 20x2.125 500x50 500x50 (V) 253
HB 422x25 500x45 20xl.75x2 (S)
20x2.00 (G)
400 37-400 to ~18xl% E.4J 450x28 18xl}i 18xl}8BSR (V) 1257 200 412 240-
54-400 18xl!;2 F.4J 450x37 450x32A 20x2xl~ (S) 257
18xl~ FA 16.0 450x55
20x2
~
~
~
390 37-390 to ~450A 1225 195 403 235-
1.0
o 40-390 18xl%xl}i 238
~
N
~
I * BSR on a Vredestein tire stands for British Standard Rim.
~
.... ....1
S~INYH~3W 3'~A~IO HOd >lOOOONYH S,ONY'H3HLnS

~
"..
~ ~
I
~
~
(( TIRES
U
~
TIRE AND RIM SIZE CHARTS (cont.)
Indicates sizes that may not be interchangeable with other sizes with identical or similar markings. Use ISO markings to positively identify tire.
ISO Tire Vredestein*(V) Approx
Diameter Diameter Sizes Rim British Rim French Italian Unidentified (SU) ference Radius Diameter Radius
387 37-387 ~18x1}8 18xl% (V) 1216 193 400 233
450x38A (V)
381 40-381 18xl~ (V) 1196 190 395 233
450x38B (V)
369 32-369 ~17x1~t ~16x1~ (SU) 1169 184 382 219
357 32-357 ~17xl~ (S) 1122 179 371 214
355 44-355 to 18xl.75 450x45 18x2x1% (V) 1115 177 371 219-
54-355 18x2.125 18x1.75 (G) 228
HB 371x25 18x2 (G)
349 32-349 to ~16xl% ~16xl% E.3J ~16x1~ 1097 174 362 209-
37-349 EA14.0 400x32A 214
EB14.0
340 32-340 to ~400A 1069 170 353 205-
37-340 to ~16x1}8x1~ 210-
44-340 217
339 37-339 ~16x1}8 ~16xl% (V) 1065 169 352 209
400x35A (V)
337 37-337 ~16x1}8A (SU) 1058 168 350 208
335 37-335 ~16x1}8 (Polish) 1052 167 347 207
330 40-330 16xl~ (V) 1036 165 344 208
400x38B (V)
317 44-317 16x1% S-7 16xl~ 996 158 329 205
3U5 44-305 to 16xl.75 16x2x1% (V) 957 152 321 194-
57-305 16x2.125 16x2 (V) 203
16x1.75x2 (S)
298 32-298 to ~14xl% ~14xl% E.2J 14x1~ 14x1}8BSR (V) 937 149 310 184-
37-298 to F.2J 350x32A 14x1}8 (S) 189-
44-298 EA11.7 14x1}8 196
288 32-288 to 350A 904 144 300 179-
37-288 to ~14x1}8x1~ 184-
44-288 191
286 37-286 ~14x1}8 14xl% (V) 897 143 298 183
350x35A (V)
279 40-279 14x1Y2 14xlY2 (V) 877 139 294 182
350x38B (V)
253 44-253 to 14xl.75 795 126 269 168-
54-253 14x2.125 177
HB 270x25
248 32-248 to ~12xl% 12x1}8 779 123 260 158-
37-248 to 12x1~ 163
44-248 300x32A
12x1}8
239 32-239 300A 751 119 251 154-
37-239 to ~12x1}8x1~ 159-
57-239 179
235 37-235 ~12xl% (V) 738 117 247 157
300x35A (V)
229 40-229 12xlY2 (V) 718 114 243 157
300x38B (V)
222 47-222 11x1% llxl~ (V) 698 111 234 161
203 62-203 12Y2x2~ 12Y2x2~ 320x57 12Y2x1.75 12Y2x2~ (V), (S) 638 101 217 166
12Y2x2~
194 32-194 to 10x1~ 10x1}8 (SU) 609 97 209 132-

44-194 144
137 32-137 8x1~ 8xl~ (G) 425 67 148 102
wheel chair
110 54-110 8Y2x2yg 8Y2x2 (V) 346 56 126 113
~ 94 47-94 200x47 7xl~ (G) 295 47 108 97
~
\0
o
~
* BSR on a Vredestein tire stands for British Standard Rim.
N t Original (old) Moulton mark 16 x 1~.
I
~ .... .....
~
S3INVH33W 3'l3A3IO HOd >IOOOONVH S,ONV'lH3H.lnS

TIRES
TIRE INFLATION
PSI: Pounds per square inch
ATM: Atmospheres (Bar, Atii)
Kg/Cm 2 : Kilograms per square
centimeter
SEW-UP (TUBULAR) SIZES

PSI ATM Kg/Cm 2
For outside rim diameter comparisons see Spoke Length tables.
Sew-up wheels in 28-inch (700C) and 26-inch (650)B sizes 9
130
interchange with corresponding wired-on wheels without 9
adjusting brake shoe position. 8.5
Sew-up wheels in nominal sizes 24 inches and under have 120 8.5
much smaller rim and tire diameter than wired-on tires of the 8
same inch sizes. Wired-on tires of the same inch size may not 8
fit under the fork crown of a frame made for sew-ups; to avoid 110 7.5
a low bottom bracket and long brake reach, it is often best to 7.5
use the next larger sew-up size when substituting small sew-
7
ups for wired-on tires. 100 7
6.5
6.5
VALVE HOLE SIZES 90
6
Presta 6.8mm 6
Dunlop (Woods) 8.3mm 5.5
Schrader 9.0mrn 80
5.5
5
70 5
4.5
4.5
60 4
4
50 3.5
3.5
3 3
40
2.5 2.5
30 2 2
1.5 1.5
20
1 1
10
0.5 0.5
o 0 0
12-12 rev. 1985

CALIPER BRAKES
SIDE-PULL BRAKE DIMENSIONS
A B
/r--i I ~ - -,
(I I I I
\ I I I I
'--l. __:
:- - - '
When selecting a brake, choose one so that the brake shoes are close
to the center of the slot. Fitting a brake at the highest or lowest limits
may cause problems as the pads wear or the mounting bolt is
adjusted.
These figures are taken from the manufacturers' catalogs.
Dimensions listed in bold apply to the group of brakes directly

below the bold listing.
Left- or
Right- Center
Make & Model Side of
Model Number Cable Slot A B
ACS
. - 860 R 77.5 70 85
CAMPAGNOLO
New Short Reach 45.7 40 51.5
• Chorus C500 L
• Athena D500 L
• Xenon F500 L
Old Short Reach 47 42 52
• Gran Sport 117 L
• Record (pre-'85) 2040/1 L
• Super Record 4061/1 L
• Triomphe 915/102 L
• Victory 415/001 L
Normal Reach 52 47 57
• Record (pre-'85) 2040 L
• Super Record 4061 L
rev. 1990 13-1

CALIPER BRAKES
SIDE-PULL BRAKE DIMENSIONS (cont.)
Left- or
Right- Center
DIA-COMPE
Also marked Gran-Compe,
Aero-Compe, Royal-Compe
Ultra Short Reach
• Aero-Compe AC300G L 40 37 43
• Aero Gran-Compe AGC300/BL L 40 37 43
• BRS 500 BA50, BA50K L 41 38 44
Short Reach
· - 400N, QS400N L 43 38 48
• BRS 300 BA35 L 44 39 49
• Royal Compe II RCI1400 L 44 39 49
• Royal Gran Compe RGC400 L 44 39 49
• BRS 300 BA35 L 44 39 49
• BRS 400 BA45 L 44 39 49
• a-5000 a-5000 400 L 45 39 51
• a II a 11-400 L 45 39 51
• 016400 OLE400 L 45 39 51
• New Gran-Compe NGC400 L 45 40 50
• BRS 500 BA55, BA55K L 45 42 48
• BRS Radius BA25 L 46 40 52
• BRS Blaze BA08 L 46 40 52
• BR.S Edge BA10 L 46 40 52
• BRS 200 BA20 L 46 40 52
Normal Reach
· - 500,500N,
QS500N, GX500N
R 50 43 57
• a-5000 a-5000 500 L 51 45 57

• a II a 11-500 L 51 45 57
• VX BA07 L 51 45 57
• DC Series 505, 506, 505Q, L 51 45 57
506Q
• 016500 OLE500 L 51 45 57
• BRS 300 BA37 L 52 47 57
• BRS 400 BA47 L 52 47 57
• Royal Compe II RCI1500 L 52 47 57
• Gran-Compe GC500 L 52 47 57
(marked DC 500)
• Aero-Compe AC500 L 53 48.5 57.5
Long Reach
· - 630 R 56.5 49 64
·• Aero-Compe
- 730
AC800
R
L
62
67.5
53
63
71
72
···
- 810 R 70 61 79
- 890 R 78 68 88
- 1003 R 82.5 73 92
·· -
-
1020
1080
R
R
82
93
73
81
91
105
rev. 1990 13-3

CALIPER BRAKES
SIDE-PULL BRAKE DIMENSIONS
A B
r - - -: 1--;-\
1 1 1 1/
.... __ ~ r- J -
adjusted.

Left- or
Right- Center
ACS
. - 860 R 77.5 70 85
CAMPAGNOLO
New Short Reach 45.7 40 51.5
• Chorus C500 L
• Athena D500 L
• Xenon F500 L
Old Short Reach 47 42 52
• Record (pre- '85) 2040/1 L
• Super Record 4061/1 L
• Victory 415/001 L
• Record (pre- '85) 2040 L
• Super Record 4061 L
rev. 1990 13-1

D CALIPER BRAKES
Left- or
Right- Center
CHANG STAR
Also marked Royal Star,
C-Star, Star, or C&T
Short Reach
· -
• Pro-Star 400
N400
P400
L
L
44
44
39
39
49
49
Normal Reach
• Pro-Star 500 P500 R 50 43 57
• (marked C&T) CT500 R 50 43 57
• Gran Star 500 GS 500-160 L 52 47 57
Long Reach
• Pro-Star 500 P630AG R 56.5 48 65
• (marked C&T) CT630 R 56.5 49 64
··
- N630 R 56.5 49 64
- N730A, N730S R 62 53 71
BMX & Freestyle
· - 810A, N810S,
890MX
R 69.5 61 78
···
- N810A R 70 61 79
- MX900A R 75 66 84
- MX910A L 75 66 84
·· -
-
890A, N890A
FS981
R
R
77
77
68
67
86
87
· - FS980 R 77 67 87
·· -
-
1020A
P1020A
R
R
82
82
73
72
91
92
·· -
-
MX1000A
MX1010A
R
L
82.5
82.5
73
73
92
92
CLB
· - 1080A R 93 81 105
Ultra Short Reach

• Space Line L 42.5 38 47
• Promo L 42.5 38 47
• Compact L 42.5 38 47
Normal Reach
• Competition L 51.5 46 57
• Professional 3842 L 52.5 48 57
• GL 47.60 L 53.5 47 60
Long Reach
• GL 48.65 L 56.5 48 65
• GL 55.75 L 65 55 75
• GL 63.85 L 74 63 85
13-2 1990 rev.

CALIPER BRAKES
Left- or
Right- Center
DIA-COMPE
Aero-Compe, Royal-Compe
Ultra Short Reach
• Aero-Compe AC300G L 40 37 43
• Aero Gran-Compe AGC300/BL L 40 37 43
• BRS 500 BA50, BA50K L 41 38 44
Short Reach
· - 400N, QS400N L 43 38 48
• BRS 300 BA35 L 44 39 49

• Royal Compe II RCII400 L 44 39 49
• BRS 300 BA35 L 44 39 49
• BRS 400 BA45 L 44 39 49
• a-5000 a-5000 400 L 45 39 51
• a II a 11-400 L 45 39 51
• 016400 OLE400 L 45 39 51
• BRS 500 BA55, BA55K L 45 42 48
• BRS Radius BA25 L 46 40 52

• BR.S Edge BA10 L 46 40 52
• BRS 200 BA20 L 46 40 52
Normal Reach
· - 500,500N,
QS500N, GX500N
R 50 43 57
• a-5000 a-5000 500 L 51 45 57

• a II a 11-500 L 51 45 57
• VX BA07 L 51 45 57
• DC Series 505, 506, 505Q, L 51 45 57
506Q
• 016500 OLE500 L 51 45 57
• BRS 300 BA37 L 52 47 57
• BRS 400 BA47 L 52 47 57
• Royal Compe II RCII500 L 52 47 57
• Gran-Compe GC500 L 52 47 57
(marked DC 500)
• Aero-Compe AC500 L 53 48.5 57.5
Long Reach
·· -
-
630
730
R
R
56.5
62
49
53
64
71
• Aero-Compe AC800 L 67.5 63 72
···
- 810 R 70 61 79
- 890 R 78 68 88
- 1003 R 82.5 73 92
·· -
-
1020
1080
R
R
82
93
73
81
91
105
rev. 1990 13-3

CALIPER BRAKES
Left- or
Right- Center
DIA-COMPE (cont.)
BMX & Freestyle
• MX MX900, MX903 R 75 66 84
MX MX901 L 75 66 84
• Trial (marked MX) 903 R 75 66 84
• FX FS880 R 77 68 86
FX (marked MX) FS880L R 77 68 86
• Bulldog FS884 R 77 68 86
• Nippon FS883, FS883L R 77 68 86
• MX MX883 R 77 68 86
MX MX884 L 77 68 86
MX (marked Bulldog) MX884Q R 77 68 86
• MX MX1000 R 82.5 73 92
• Trial (marked MX) 1003 R 82.5 73 92
LEE CHI
·· -
-
LC400AG
600AG
L
L
48
52
43
47
53
57
·
MAFAC
- 896A R 77 68 86
·· -
-
LS-2, LC-L
LC-GL
L
L
50
52.5
44
45
56
60
MAVIC
Short Reach 45 42 48
• Route 410 L
• Pro 420 L
• Super Pro 430,440 L
Normal Reach
• Route 410 L 50 46 54
MODOLO
Short Reach
• X-Setra L 45 40 50
• X-Tenos L 45 40 50
• X-Eras L 45 40 50
• Q-Even L 45 40 50
• Q-Exe L 45 40 50
• Equipe L 46 40 52
• Flash L 46 40 52
• Master Pro L 46 40 52
• Professional L 46 40 52
• Speedy L 46 40 52
Normal Reach
• Corsa L 50 43 57
• Q-Exe L 50 43 57
• Speedy L 50 43 57
• Sporting L 50 43 57
• Flash L 52 46 58
• Professional L 52 46 58
Long Reach
• Sporting L 56.5 49 64
• Corsa L 57 49 65
• T-EIT L 66 57 75
13-4 1990 rev.

CALIPER BRAKES
Left- or
Right- Center
SHIMANO
• Dura-Ace BR-7200 L
Dura-Ace BR-7400 L
Dura-Ace BR-7402 L
• 600 Ultegra BR-6400-49 L
• 600 EX BR-6207-49 L
600 EX BR-6208-49 L
• 600 BR-6200-49 R
• Sante BR-5000 L
• 105 BR-1050-49 L
105* BR-1055 L
• RX100* BR-A550 L
• Exage* BR-A500 L
• Exage Sport BR-A450-49 L
• Exage Action BR-A350-49 L
• Exage Motion BR-A250-49 L
• Light Action BR-L490 L
Normal Reach
• Z BR-Z570 L 50 43 57
• Dura-Ace BR-72l0 L 52 47 57
• 600 Ultegra BR-6400-57 L
• 600 EX BR-6207-57 L
600 EX BR-6208-57 L
• 600 BR-6200-57 R
600 BR-62l0 L
• 105 BR-l050-57 L
105* BR-l055 L
105 BR-Zl05 L
• RXlOO* BR-A550 L
•
Exage* BR-A500 L
•
Exage Sport BR-A450-57 L
•
Exage Action BR-A350-57 L
•
Exage Motion BR-A250-57 L
•
Light Action BR-L570 L
•
Z BR-Z570 L
Normal & Long Reach
• Z BR-Z640 L 56.5 49 64
Z BR-Z720 R 63 54 72
• Tourney BR-TS30 R
Tourney BR-TS60 R
Tourney BR-TS40 R
Tourney BR-TSlO R
Tourney BR-TS40 R 70- 61 79
Tourney BR-TSlO R
• Z BR-Z790 R
• DX BR-MXlO R 79 70 88
• Tourney BR-MX20 R
Tourney BR-TS40 R
* Super SLR models must only be used with the matching levers that have stiffer
return springs.
rev. 1990 13-5

CALIPER BRAKES
Left-or
Right- Center
SUNTOUR
Also see DIA-COMPE
• GPX BA-GPOO L
• Superbe Pro BA-SBOO-S L
• Sprint BA-SPOO L
• Sprint 9000 BA-SP10 L
• Cyclone 7000 CB-7100 L
• Superbe Pro BA-SBOO-N L
• Cyclone 7000 CB-8100 L
UNIVERSAL
Ultra Short Reach
• Mod. CX 97 L 40.5 39 42
Short Reach
• Mod. 77 99/B L 45 40 50
• Mod. 68 102 L 47.5 41 54
• Mod. 77 front 99/N L 48 42 54
Normal Reach
• Mod. 51 front 100 L 50.5 45 56
• Mod. 125 125 L 51 46 56
• Mod. CX 98 L 52.5 46 59
WEINMANN
Short Reach
• 490 SQ L 47 41 52.5
• Carrera 400 L 47 41 52.5
Normal Reach
• Alpha LT 570 L 50 43 57
• NDC 577 R 50 43 57
• 590 SQ L 52 47 57
• Carrera 600 L 53 46 60
• 605 L 53 46 60
Long Reach
• Alpha LT 720 L 62 53 71
Alpha TR 721 R 62 53 71
• Junior 730 R 62 53 71
• NDC 727 R 62 53 71
NDC 728 R 62 53 71
• SBS 200 712* R 62 53 71
• Symetric 763 R 64 52 76
• PBS 300 714 R 66.5 62 71
• Junior 810 R 70 61 79
• Alpha TR 801 R 70 61 79
• NDC 808 R 70 61 79
• SBS 200 792* R 70 61 79
• PBS 300 804 R 76 71 80
• Junior 890 R 78 69 87
• Symetric 943 R 81 68 94
• Junior 1020 R 83.5 74.5 92.5
• Symetric 923 R 83.5 75 92
* Hybrid of side- and center-pull designs.
13-6 1990 rev.

CALIPER BRAKES
CENTER-PULL BRAKE DIMENSIONS
---0
(J
--~
I I
I :
--1
adjusted.

Center
Make & Model of
Model Number Slot A B
CHANG STAR
• 610A 56 49 63
• 750A 69 60 78
CLB
Normal Reach
• CLB 2 Front 53.5 48.5 58.5
• Racer Special 54 47 61
Long Reach
• CLB 1/48.65 56.5 48 65
• CLB 2 Rear 57 52 62
• Racer 73 60 51 69
• Racer 62 55 69
• CLB 1/55.77 66 55 77
• CLB 1/63.85 74 63 85
• Half-Balloon 81 71 91
Racer
DIA-COMPE
Royal-Compe
• New Gran-Compe NGC450 48.5 42 55
• Gran-Compe marked GC510 50 43 57
"Gran-Compe DC 510"
• -(current production) 610 54 47 61
• -(early production) 610 56 49 63
• Gran-Compe marked GC700 61.5 52 71
"Gran-Compe DC 700"
. - 750 69 60 78
rev. 1990 13-7

(] CALIPER BRAKES
CENTER-PULL BRAKE DIMENSIONS (cont.)

Center
Make & Model Of
MAFAC
Short Reach
• GT GTOA 43 38 48
• Competition GL CnOA 44 39 49
• GT GTIA 48 43 53
• Competition GL CnlA 49 44 54
Normal Reach
• 2000 MOA 50.5 43 58
• Racer RO 50.5 43 58
• S SO 51.5 44 59
• GT GT2A 53 48 58
• Competition GL Cn2A 54 49 59
• 2000 MIA 55.5 48 63
• Racer Rl 55.5 48 63
Long Reach
• S SI 56.5 49 64
• Competition GL Cn3A 58.5 51 66
• 2000 M2A 60.5 53 68
• Racer R2 60.5 53 68
• S S2 61.5 54 69
• 2000 M3A 65 55 75
• Racer R3 65 55 75
• S S3 66 56 76
• Raid Rd 72.5 65 80
SHIMANO
• Tourney BR-TCI0, 30 54.5 47 62
BR-TCI0, 30 66 57 75
UNIVERSAL
• Mod. 61 front N.I05 54.5 49 60
Mod. 61 rear N.I06 64 56 72
• Sport front N.I08 64 56 72
Sport rear N.I09 64 56 72
WEINMANN
.-
• Vainqueur 610
CP 633
55
55.5
49
48.5
61
63
.-
• Vainqueur 750
CP 753
66
66
57
57
75
75
13-8 1990 rev.

CALIPER BRAKES
"DELTA" BRAKE DIMENSIONS

Center
Make & Model of
CAMPAGNOLO
• Croce D'Aune B500 44 39 49
• Record (1990) A500D 47 38 56
MODOLO
• Kronos CP4 45 42 48
WEINMANN
• Delta; Delta Pro 48 41 55
• Delta II 576, 576-02, 49 41 57
576-06
"U" BRAKES DIMENSIONS- Centerpull brakes with braze-on mounting studs for use with
mountain bikes. All the brakes listed here have adjustable toe-in and reach.
Center ~traddle- Spring
Make & Model of Cable Shoe Tension
Model Number Slot A* B* Heads Type** Wrench
CAMPAGNOLO - U brake models 1 39 33 45 single nut 3mm allen
DIA-COMPE
1
• XCE BA-XEOO 39.5 33 46 single nut 13mm
• XCE-4050 1 BA-XE45-C 39.5 33 46 single nut
• Advantage AD 990 38.5 35 42 single stud 13 & 19mm 2
LEE CHI
• - (alloy) 737A 39 32 45 single stud None
IRD (Interlock Racing Designs)
3
• Rotary 38.5 35 40 double stud 3/4"
• Progressive 38.5 35 40 double stud 3/4"
SCOTT U.S.A.
• Pedersen SE 40 34 46 single stud None
SHIMANO
• Deore XT II I BR-M733 39 34 44 single nut 2mm allen
• Exage Mountain (plastic) 1 BR-M451 41.5 35 48 single nut 2mm allen
l
• DeoreXT BR-M731 42.5 37 48 single nut 2mm allen
SUNTOUR See DIA-COMPE
* If conical washers are used the brakes were measured with conical washers "squared." A wider range of adjustment
can be made by tilting the conical washer stack.
** See Cantilevers Brakes for Shoe Type drawings.
1. Adjustments made with conical brake shoe washers. Be sure to use shoes with conical washers.
2. Adjusting nuts are 19mm with additional 13mm flats that can also be used.
3. Refer to manufacturers' instructions for setup and adjustments.
rev. 1990 13-9

CALIPER BRAKES
ROLLER-CAM BRAKES
o
o
The cam plate in a roller-cam brake has a series of ramps the rollers
move along. The angle of the ramps determines the amount of
movement and pressure at the brake pads.
When viewed turned on its side, the cam begins with a steep ramp
that moves the pads rapidly towards the rim. The next ramp is
shallower, producing greater leverage while moving the pad a
smaller amount.
Adjust the brake so that when the pads contact the rim, the rollers
are just past the crest of the steep ramp and are beginning to move
along the shallow ramp.
Roller position Roller position

of brake when when pads
is released. contact the rim.
The roller hides the crest so it is difficult to see during setup. Mark
the cam with a line perpendicular to the shallow ramp, starting just
past the crest. The line should point to the center of the roller when
the pads contact the rim. Check to see that the rollers do not come
near the reverse curve at the end of the cam plate.
Adjustments
For minor adjustments adjust the cable and/or the distance between
the shoe and the caliper arm. For larger adjustments, if the brake has
two roller position holes, try the other position. If the rollers aren't
even close to the right position, try a different cam plate. Wilderness
Trail Bikes and SunTour offer narrow and wide cam plates.
13-10 1990 rev.

CALIPER BRAKES
ROLLER-CAM BRAKE DIMENSIONS
Adjust-
Center ibility Spring Roller Mounting
Make & Model of Toe-In (T) Tension Posi- Stud
Model Number Range A B Reach (R) Wrench tions Diameter
ODYSSEY
• Pitbull 83 73 93 R - 1 -
SHIMANO
• Dura-Ace AX BR-7300 front 45 39 51 R - 1 -
rear 48 42 54 R - 1 -
• 600 AX BR-6300 front 45.5 40 51 R - 1 -
rear 47.5 42 53 R - 1 -
• 600 AX BR-6310 front, rear 45.5 40 51 R - 1 -
SUNTOUR
• XC Power CB-6000 39 - - T 19mm2 1 8.9mm
• XC Sport CB-6600 39 35 43 T,R 17mm 2 8.9mm
• XC 9000 BA-XCOO 39 35 43 T,R 13mm 2 8.9mm
• XCD 6000 BA-XDOO 39 35.5 42.5 T,R none 2 8.9mm
• XCD 4050 BA-4050 39 35.5 42.5 T,R none 2 8.9mm
WTB
(Wilderness
Trail Bikes)
• Speedmaster 40 38 42 R 5/8,,3 2 8.9mm
• Compact 36 34 38 R 5/8,,3 2 8.9mm
Speedmaster
• Mini-Cam l 40 26 36 Tl,R 5/8"3 2 5/16"-7.9mm
• Potts/ 40 38 42 R 5/8,,3 2 3/8"-9.5mm
Cunningham
2. Use SunTour 16/19mm wrench TA-210. Early versions used 15mm wrench.
3. A 16mm wrench comes close.
rev. 1990 13-11

CALIPER BRAKES
CANTILEVER BRAKES
CANTILEVER BRAKES
Careful mounting and servicing of cantilever brakes is essential to
prevent the brake shoes from slipping past the rim and into the spokes.
Pad-Rim Position
As the pads of a cantilever brake wear they will contact the rim closer and closer
to the inner edge of the rim (away from the tire). Adjust the pads close to the
outside edge of the rim (close to the tire). This is the opposite of the way center-
pull brakes wear.
Pad-Rim Clearance
Check for easy release of the straddle cable for easy wheel removal.
Shoe-Caliper Arm Position
Position pads as close to the the caliper arm as possible. This reduces flex and
the amount the brake sticks out to the side.
Spring Tension
Adjust spring tension so that both pads contact the rim at the same time. If this
requires more than a little adjustment check the following: wheels not straight in
the dropout, incorrect wheel dish, uneven pad wear, uneven pad installation,
dirty or unlubricated pivots, asymmetric braze-on location, spring ends in
different holes on multiple-hole studs.
Pivot Studs
Some studs are made by swaging the cylinder to a sheet metal box. The builder
must then braze both the cylinder to the stud and the stud to the fork. The
swaged joint can come loose if the cyclinder is not brazed to the stud.
Some bicycle manufacturers have been known to run as much as 0.4mm
(.010") oversize on the O.D. of the pivot stud. This may not pose a problem for
inexpensive brake arms, as they typically have a loose fit anyway. High-quality
arms are likely to bind, or not even mount. Consequently, it is sometimes
necessary to use a machinist's reamer to increase the I.D. of the arm bushing,
or try a different brake arm.
Before assuming that the stud diameter is oversize, make sure that it isn't
simply flared at the end, due to overtightening of the mounting bolt, in which
case it is only necessary to lightly file the flared section down to the original
O.D.
13-12 1990 rev.
CALIPER BRAKES
CANTILEVER BRAKES (cont.)
Factors that affect cantilever brake fit:

1. Distance between brake pivots.
2. Parallel pivot orientation. Use vernier caliper to check that pivots are
parallel.
3. Rim diameter
4. Rim Width
5. Fork-end axle slot position position relative to brake pivot
6. Width of tire relative to width of rim. (For example narrow rims with
fat tires require different setup to ensure pad does not contact tire.
Sometimes this necessitates a lower profile shoe, longer straddle-
cable length, etc.)
7. Spring-to-pivot stud compatibility (some brakes do not have enough
spring tension on older, single-hole studs.)
BRAKE SHOEjPAD TYPES
~~
Nut Type
~
Bolt Type
rev. 1990 13-13

CALIPER BRAKES
CANTILEVER BRAKE DIMENSIONS
Pivot to Adjust-
Center brake shoe Straddle- ability Spring
Make & Model of clamp bolt Cable Shoe Toe-In (T) Tension
Model Number Reach hole* Heads Type Reach (R) Adjustment
CAMPAGNOLO
• Standard models 24 21-27 single stud T,IR 3mm allen
• Compact models 26 20-32 single nut T,R 2.5mm allen
CHANG STAR
Also marked Star and
Pro Star
·
• (plastic)
880A
-
24
26
21-27
21-31
double
single
stud
nut
T,R
T1,R
None
None
· 882A 27 26-28 single stud T,R None
·
DIA-COMPE
885AC 29 24-34 single nut T1,R None
Also marked Gran-Compe

· - 960 23 23 double stud T,R None
· -
• New Gran-Compe
981
NGC982
24.5
24.5
22-27
23-26
single
single
stud
stud
T,R
T,R
None
None
· -
• Colbar
983
984
24.5
25
23-26
20-30
single
single
stud
nut
T,R
T1,R
None
13 & 19mm2
·
•
-
XCE (alloy)
986
CT-XEOO
25.5
25.5
21-30
21-30
single
single
stud
nut
T,R
T,lR
13mm
15mm
• XCE (plastic) 26.5 21-32 single nut T1,R None
• XCM (alloy) CT-XMOO 25.5 21-30 single nut T1'R ISmm
• XCM (plastic) 26.5 21-32 single nut T1,R None
• XCT (plastic) CT-XTI00 25.5 21-30 single nut T1,R 15mm
• X-I CT-XI00 25.5 21-30 single nut T1,R 15mm
• X-I Chroma CT-CROO 25.5 21-30 single nut T1,R 15mm
GRAFTON
• Speed Controllers 23 20-26 double3 stud T,R .050" allen
(earlier production)
(later production) 25.5 22-29 double3 nut T1,R .050" allen
IRD (Interlock Racing
Designs)
• Switchback4 Type I 23 20-25 none stud T none
Switchback4 Type II 23 20-25 none stud T 11/16"
LEE CHI
• - (steel) 706S 25 20-30 single nut T allen
··
-
- 700A
706A
25.5
26
23-28
21-31
double
single
stud
bolt
T,R
T1,R
None
None
MAFAC
• Criterium K 25 25 single5 stud None
* If conical washers are used the brakes were measured with the stack of conical washers "squared." Wider
adjustment can be made by tilting the conical washer stack.
2. Adjusting nuts are 19mm, and have an additional set of 13mm flats. Either wrench size can be used.
3. A barrel fitting with a set screw is supplied so that a single cable can be used.
4. See manufacturer's setup and adjustment instructions.
5. Head of straddle cable is 3.8mm (similar to a derailleur cable) and sits in a spool shaped, 5.4mm
ferrule.
13-14 1990 rev.

CALIPER BRAKES
CANTILEVER BRAKE DIMENSIONS (cont.)
Pivot
to Adjust-
brake ability
shoe Toe-In
Center clamp Straddle- (T) Spring
Make & Model of bolt Cable Shoe Reach Tension
Model Number Reach hole* Heads Type (R) Wrench
POLYGON
• (steel) 25 20-30 single nut T1,R none
• (marked CANTISAFE) 27 24-30 single stud T,R 2.5mm allen
SCOTT U.S.A.
• Pederson SE-
'89 front 6 ,7 24.5 21-28 single stud T,R none
'89 rear6 ,7 24.5 21-28 single stud T,R none
'90 front 6 ,7 24.5 21-28 single stud T,R none
'90 rear6 ,7 24.5 21-28 single stud T,R 7/8"
'91 front 6 ,7 07013000 24.5 21-28 single stud T,R 5/8"8
'91 rear6,7 07013100 24.5 21-28 single stud T,R 5/8,,8
SHIMANO
• Deore XT II BR-M732 25.5 22-29 double9 stud T,R 2mm allen
• Deore XT BR-M730 25.5 22-29 double9 stud T,R 2mm allen
• Deore XT BR-MC70 24.5 22-27 single stud T,R none
• Deore DX BR-MT62 25.5 22-29 single stud T,R 2mm allen
• Deore BR-MT60 25.5 22-29 single stud T,R 2mm allen
• Deore LX BR-M550 24 19-29 single bolt T,R 2mm allen
• Exage Mountain (alloy) BR-M454 24 19-29 single bolt T1,R 2mm allen
• Exage Mountain (plastic) BR-M450 24 19-29 single bolt T1,R 2mm allen
• Exage Trail (plastic) BR-M350 24 19-29 single bolt T1,R 2mm allen
• Exage Country (plastic) BR-M250 24 19-29 single bolt T1,R none
• Exage 400 LX (plastic) BR-M351 24 19-29 single bolt T,R 2mm allen
• 200 GS BR-M200 25.5 22-29 single stud T,R none
· -
SUNTOUR See Dia-Compe for
BR-AT50 24.5 22-27 single stud T,R 2mm allen
other models.
·· XC Pro
XC 9000
CT-XPOO
CT-XCOO
25
25
22-28
22-28
single
single
stud
stud
T,R
T,R
19mm lO
19mm lO
XC 9000 (SE) CT-XPI0(SE) 25 22-28 single stud T,R 16mm
XC Comp CT-XC01, 11 25 22-28 single stud T,R 19mm lO
· XCD
XCD(SE)
CT-XDOO,ll
CT-XD20(SE)
25
25
22-28
22-28
single
single
stud
stud
T,R
T,R
19mm lO
16mm
· XCD 6000 CT-XD10 25 22-28 single stud T,R
* If conical washers are used the brakes were measured with the stack of conical washers "squared".
19mm lO
Wider adjustment can be made by tilting the conical washer stack.

6. Due to the unique design of this brake, fronts and rears are different internally, and must not be
interchanged.
7. To ensure safe performance follow this adjustment procedure: With mounting pivot bolt
loose, rotate arm until pad is against the rim. Adjust shoe so that it is at the same angle as the
rim, then rotate arm until shoe just clears tire (for easy wheel removal), and tighten pivot bolt.
8. 16mm is close.
9. Brake cable is connected directly to cable anchor on arm; "link cable" connects the other arm and
a movable carrier that rides on brake cable. "Link cable" actually has three heads, the third serves
as a finger-grip for releasing the cable.
10. Use SunTour 16/19mm TA-210 wrench.
1990 rev. 13-15

. CALIPER BRAKES
NON-STANDARD BRAKE SHOES AND PADS - Partial List

C/) Many are not interchangeable although similar in appearance.
U
.... Make & Brake Shoe/Pad
z Model Model No. Notes Part No.
«
:c
DIA-COMPE
• BRS 500, Aero-Compe BA50, AC 300 "aero" style bolt type shoe w/eccentric AGC76
MODOLO
u • Kronos caliper arm takes shoeless pad M0030
w WEINMANN
~ • Delta II 576 "aero" style bolt type 1772
U.) SHIMANO
• Dura-Ace AX BR-7300 caliper arm takes shoeless pad 3-815 9803
...l • 600 AX BR-6300, - caliper arm takes shoeless pad 3-815 9803
U 6310
> • AdamasAX BR-AD20 caliper arm takes shoeless pad 3-867 9801
....
U SUNTOUR
=
• XC Power CB-6000 used special threaded shoes; normal stud Original shoes are no
type shoes don't look like they fit, but do. longer available.
~
o
LI..
NON-STANDARD BRAKE STRADDLE CABLES - Partial List
Many are not interchangeable although similar in appearance.
~ Make & Brake Straddle Cable
o Model Model No. Notes Part No.
o CHANG STAR
·- 880A, 860A double-headed straddle-cables see Dia-Compe 980
=
Q
Z
CLB
• all cantilevers
• CLB-1, -2, Racing
double-headed straddle-cables
18201, 18202, 18203
18204, 18205
«
:c
DIA-COMPE
• New Gran-Compe 450 double-headed straddle-cables 1273.100
with tiny heads
.C/)
~.
·· -
-
610, 750
960, 980
1270.100, -.110
1271.250, -.330
Q GRAFTON -·all models double-headed straddle-cables
Z
«
...l
IRD - all "U" brakes
LEE CHI
unique, double-headed straddle-cables
~ MAFAC
·- 700A double-headed straddle-cables see Dia-Compe 980
W
:cE- • GT
• Competition, 2000, S
• Cantilevers, Racer, Raid
unique, double-headed straddle-cables
double-headed straddle-cable
straddle-cable with a tiny head & "spool"
5469E
4069
see Weinmann CC-420
:J MODOLO
C/) • Cross two identical, double-headed straddle-cables M0376, M0377,
per brake. M0413 (bridge)
• Kronos Kronos levers require special ferrule M0156
WEINMANN
• Vainqueur 610, 750 double-headed straddle-cables 1270.110, -.150
NCL 620 integrated straddle bridge/cables 1242.120, -.140, -.170
GRB 430 integrated straddle bridge/cables 1242.120, -.140, -.170
CC-420 straddle-cable with a tiny head & "spool" 1276.350 & 1277
13-16 rev. 1990

HEADSETS, STEMS, HANDLEBARS ~
HEADSET STANDARDS ~
National Standards
Head Crown
Race Race
Outside Inside Stem
~
Diameter Diameter Outside Common
Standard Thread Sizes K* L* Diameter Use
1
IS0 1" (25.4mm) x 24 TPI 30.0mm
Japanese (JIS)2 1" (25.4mm) x 24 TPI 30.0mm 27.0mm 22.2mm
English2,3 1" (25.4mm) x 24 TPI 30.0mm 27.0mm2 22.2mm
26.5mm
U.S.A.2,4 1" (25.4mm) x 24 TPI varies varies .833" Lower-priced
.. (21.15mm) models
Italian2 25.4mm (1 If) x: 24 TPI5 30.2mm 27.0mm2 22.2mm
26.5mm
French 25mmx 1.0mm 30.2mm 27.0mm2 22.0mm
26.5mm
Austrian2,6 26mmx 1.0mm 30.8mm 26.7mm 22.0mm Some Sears
~
models6
Additional (De Facto) Standards

Professional/Campagnolo 1" (25.4mm) x 24 TPI 30.2mm 26.4mm 22.2mm High quality .
BMX 1" (25.4mm) x 24 TPI 32.7mm 29· 4mm 21.15mm Most models.0.. . .
2
Raleigh ,7 1" (25.4mm) x 26 TPI 30.2mm 27.0 2,7 See notes 2 & 7
ChaterLea 31/32" x.30 TPI --.
8
Alex Moulton 1" (25.4mm) x 24 TPI 30.0mm 29.5mm 22.2mm Moulton MK III
.36.4mm8 & Earlier
Oversized
Tioga Avenger 1-1/8" (28.6mm) x 26 TPI 34.0mm 30.0mm 1" (25.4mm) ATB, Tandem
Fisher Evolution 1-1/4" (31.8mm) x 26 TPI 37.0mm 33.0mm 1-1/8" (28.6mm) ATB
10 A check with a thread pitch gauge will separate the French from other headsets and forks. Italian
and English/Japanese steering columns have the same diameter and number of threads per inch.
The thread profile is, however, slightly different. See section on measuring threads. In ;)practice
these sizes are interchangeable.
* See'''Headset Key," page 14-6. The numbers in these columns are nominal dimensions; the
races' actual dimensions vary, depending on quality and manufacturing variations; see
"Headset Press Fit Dimensions & Tolerances," page 14-2.
1. See Appendix for more details on ISO Standards.
2. Professional models are often manufactured using Professional/Campagnolo standard.
3. Includes·Dunelt and Phillips prior to 1963; after 1963 see Raleigh.
4. Higher-priced models are often manufactured using Japanese or Professional/Campagnolo
standards.
5. Frequently marked 25.4 x 24F.
6. Found on Sears models made by Steyr of Austria.
7. Raleigh, Rudge, Humber and brands made by Raleigh in Nottingham after 1963. Brands made
by Raleigh that had a 71 or 76mm bottom bracket shell generally used 26 TPI on the headset as
well as the bottom bracket. Bikes with 67 or 68mm shells used 24 TPI in both the headset and
bottom bracket.
8. Upper and lower races differ in size (head tube is tapered).
rev. 1985 14-1

~HEADSET, STEM, HANDLEBARS
JF MIXING PARTS WITHIN STACKS
There is a risk of incompatibility when mixing headset
parts, and the practice should be avoided when possible.
However, with care, mixing parts can work. Use the fol-
lowing factors to catch problems early in the job.
1. Are parts of a similar design? For example, you can't
replace a Peugeot screwed race with a Campagnolo
screwed race.
2. Are mating parts designed to use the same size and
number of balls?
3. Do the parts nest properly? Most headsets are de-
signed so that the cups and cones overlap slightly to
help keep dirt out.
4. Will the centerpull brake hanger fit properly? Some
will not seat properly without washers or different
parts.
+ Try it. Before installing a mixed headset, try it out off
the bike (or half off the bike if it's easier). First put the
cup and cone pieces together without the balls to make
sure that they nest. Then try the fit again with balls.
Under pressure the parts should rotate smoothly on each
other; and although they can rock slightly, they should
not feel unstable. This also gives you a chance to check
the stack heights.
If possible, avoid mixing a high and low quality race in
one bearing since performance and reliability will be
limited by the low quality part. Using one high quality
stack (both races) in a low quality headset can give
greatly improved performance, especially if the lower,
more heavily loaded stack is the good one.
INCORRECT STEERER LENGTH
Steerer too short (Top locknut must engage at least 3
full turns on good threads).
1. Remove any extra locknuts or spacers (be sure
brake hanger still clears headset).
2. Find a headset with shorter stacks.
3. If the bicycle was assembled correctly in the first
place and the fork isn't absolutely too short, enough
metal can be milled from top and bottom of the
head tube to accommodate a thicker headset. (For
example, Campagnolo Strada). Milling the frame is
time consuming but preferable to stripping the end
of the steerer.
4. Change to side pull brakes that don't require brake
cable hanger.
Steerer too long
1. Add extra lockwasher.
2. Cut or file shorter.
3. Use a taller locknut.
14-4
HEADSETS, STEMS, HANDLEBARS
HEADSET BINDING-CAUSES
1. Bent fork, head tube or steering column
2. Improperly milled head tube and/or crown race
3. Poorly fitting parts
4. Worn or damaged parts
5. Dirt, chips or other contamination
6. Cross threaded, crooked, or wrong threads
7. Poor adjustment
8. Too. man.y balls
9. Wrong size balls
10. No lubrication
11. Poor quality headset-some aren't meant to work
REPLACING STACKS
The "fit" of a headset is so complicated that an exact
replacement unit should be used unless there is a very good
reason for using a different type. In most worn-out headsets,
only the lower races are impaired. The chances of running
into problems during replacement are minimized if only the
"lower stack" is replaced. The top stack usually outlasts the
lower stack by 2 to 1 (or more).
Replacing, the lower stack _. Points to check
1. Total height of the replacement stack.
2. Crown race inside diameter should be 0.025mm to 0.05mm
(.001" to .002") smaller than crown race seat. Be sure to
note if crown race has a shoulder that will prevent it from
seating properly.
3. Lower pressed race diameters should be 0.025mm to
O.lmm (.001" to .004") larger than inside head tube.
Milled portion of inside head·tube must be de,ep enough.
Replacing the top stack - Points to·check
1. Threads of screwed race and locknut must match threads
of steering column.
2. Total height of replacement stack. Don't forget center
pull brake hanger thickness.
3. Upper pressed race diameter should be 0.025mm to O.lmm
(.001" to .004") over inside head tube diameter. Milled
portion inside head tube must be deep enough.
4. Lock washer or brake hanger diameter and locking device
must be compatible with grooves or flats in steering
column as well as with column diameter.
5. Stem must fit in hole in top locknut.
. . Campagnolo aluminum headset pressed tube races have a

radiused edge where it mates with the inside edge of the head
tube. The Campagnolo head tube cutter cuts the head tube
to match this radiused portion of the head tube race. When
installing aluminum headsets be sure to ,break the inside
edge of the head. tube with a hard deburring tool or file.
f. rev. 1990 14-3

...
I--'
I
Q\ .
· T
~
~
\0
o
a-:.
HEADSET CHART KEY
Upper stack mmus B
locknut lip thickness ~
:t
tT1
»
o
(f)
tT1
~
(f)
.....
A upper and lower stack height minus (f)
locknut lip thickness ~
B upper stack height minus locknut lip tT1
thickness
locknut
~
C lower stack height (f)
.....
D locknut height minus lip thickness
E locknut stem hole - generally O.2mm :t
or more larger than the stem diameter. r---J
washer
»
z
See page 14-1 for stem diameters.
o~
F locknut flat dimension - F indicates
wrench flats, <p indicates diameter with @J ~ screwed race
+ With the fork crown race seat

against the bottom of the head G
pin-tool holes in edge
washer thickness (over teeth, if any)
tT1
»
OJ
tube the length of steerer tube
protruding from the top should
be about 2mm less than A.
H
J
washer locking method. French use
flats. Others use tang.
screwed race dimension - F indicates
wrench flats, <p indicates diameter with
pin-tool holes or notches
4~K4
~
upper pressed
race (f)
::::0
K upper and lower press race diameter

lower pressed
L crown race seat diameter
race
M crown race seat depth
o N upper race-number and size of loose

balls
~ ~~
o lower race-number and size of loose
balls crown race
~L--I T
\
HEADSET, STEM, HANDLEBARS

TIPS AND PROBLEMS TO AVOID
When cutting a steer tube, use a threaded fork miter block to

insure the cut is square and the threads are clean (United
Bicycle Tool UB-FMl). If you don't have a miter block, run a en
screwed race on below where you intend to cut. When you are c::
finished you can unscrew the race to clean up the threads. ~
:t
Whenever a headset is disassembled, it is a good practice
m
to replace all the balls. Headset balls carry the load and
road shocks without rolling and are therefore likely to
become deformed.
=
r-
>
Putting a Campagnolo headset in a bike designed for :2
another headset frequently results in a too-short steerer.
One solution is to mount a Campagnolo track headset.
o,.
Another is to mill the upper and lower head lugs by a . en
distance equal to the difference in thicknesses. Using
either method, the frame will remain level and the steer-
:t
ing geometry won't be changed. >
:2
Lockwashers should just fit over the zsteerer. If the hole
o
is too large, the locking tang or flat will tend to rotate
and damage the threads. Avoid the temptation to use
an English or Italian lockwasher on a French bike. The
=
o
flat can be filed to do the job of a tang. Don't file the o
lockwasher round. It must have a tang or flat to do its ~
job. You can simply use the old washer.
."
The parabolic cup and cone design of most headsets o
allows the bearing to function even with a slightly crooked
steerer, steerer thread, or mis-milled frame or fork.
Headsets with cones which are truly conical or which have
=
=
....
u-shaped or v-shaped races require more critical align- n
ment if the races are going to contact all the balls without
having tight spots. -<
n
When mounting FT headsets or Stronglight V-4, or others r-
of this type, it is important to mill the head tube and m
crown race seat to ensure the best performance from
these designs. 3:
m
. . . If the frame is straight and the original headset binds,
it is more likely due to imprecision in milling the frame
n
than the original imprecision of the headset. Changing :t
headsets without milling the head tubes and fork crown >
:2
is not recommended. ....
On some frames, usually less expensive French and some n
Japanese, the ends of the head tube are milled slightly
concave. This is to give better support to the pressed races
en
of an inexpensive headset. If you plan to change to a more
expensive headset, the head tube should be milled flat
to match the new headset. Good head sets are usually
thicker than cheap ones, so milling the head lug will also
prevent the steering column from being too short.
rev. 1985 14-5

~
.&;;..
I
QrJ
Make &
~:t
\0
\0 Model
o
Model
AVOCET
No. A B C D F G H* J M
N**O 0**0
2
• Sealed 42.0 27.2 14.8 5.2 32 F 4.1 1 32 F 11.93 sealed sealed
BIANCHI (old)
("V-race") 46.7 29.7 17 9 32.<1> 2.0 tang 32<1> 9.9 31-1/8" 31-1/8" [T]
CAMPAGNOLO :J>
• Record (1990)-w/seal 41.4 26.2 15.2 7.3 32 F .44 tang 32 F 7.5 22-3/16" 22-3/16" o
en
• (C-)Record -1982-89 Road 41.4 26.2 15.2 7.3 32 F .44 tang 32 F 7.5 25-5/32" 25-5/32"
[T]
(C-)Record -1982-89 Track 38.5 26.3 12.2 7.3 32 F .3 4 tang 32 F 5.6 25-5/32" 25-5/32"
• Super Record-Road 4041 42.2 27.2 15.0 7.0 32 F 4.0 tang 32 F 7.9 22-3/16" 22-3/16" ~~
Super Record-Track 4141 33.7 22.3 11.4 7.0 32 F 2.1 tang 32 F 6.0 25-5/32" 25-5/32" en
• Nuovo Record (pre- '85) 1039 39.1 24.6 14.5 5.7 32 F 2.1 tang 32 F 9.9 22-3/16" 22-3/16" t ~
L~ ~ ~
Victory, Triomphe- [T]
Road
Nuovo Record -Track 1040/A 33.7 22.3 11.4 5.7 32 F 2.1 tang 32 F 7.0 25-5/32" 25-5/32"
(pre-1985), Gran Sport
• Chorus, Croce, D'Aune
1040
41.2 25.6 15.6 7.1 32 F .3 4 tang 32 F 7.8 22-3/16" 22-3/16" r-f=~~11 :t :J>
• Athena 41.0 25.8 15.2 7.2 32 F .44 tang 32 F 7.5 22-3/16" 22-3/16" ~i '~D Z
• Xenon
• Euclid, Centaur (alloy)
39.5
40.6
24.5
25.6
15.0
15.0 7.2
32
32
F
F 2.2
tang
tang
32
32
F
F 10.0
22-3/16"
22-3/16"
22-3/16"
22-3/16"
T
-.i
o
~
va I? ?I G
• Centaur (steel) 40.7 26.0 14.7 [T]
• Olympus (alloy) 40.5 25.5 15.0 32 F tang 32 F
I-J----.jT CO
22-3/16" 22-3/16"
~ ~
• Olympus (steel) 39.0 24.3 14.7 32 F tang 32 F 22-3/16" 22-3/16" :J>
Oversized Models ~
• All models 39.5 26.5 13.0
en
CYCLE PRO
• Deluxe Sealed 63-02-501 36.7 24.7 12.0 6.7 32 F 2.0 tang 32 F 8.1 25-5/32" 25-5/32"
• MX alloy (Hatta) 63-02-230 41.3 28.3 13.0 9.1 30 F 2.6 tang 30 F 5.9 22-3/16" 22-3/16"
FISHER ~K~
Oversized Models ~~>'"'~
• Evolution " /1/'~f
I;!fj 46.1 32.3 13.8 8.1 40 F 2.0 tang 40 F 8.4 31-5/32" 31-5/32"
w/o cable hanger 40.7 26.9
GALLI
• Criterium 41.7 27.3 14.4 7.8 32 F 2.5 flat 32 F 6.2 rollef rollef
~ ~~
• Conical 44.5 29.7 14.8 7.7 32 F 2.5 tang 32 F 11.1 rollef rollef
• Sport 42.2 27.7 14.5 7.7 32 F 2.5 flat 32 F 6.2 rollef rollef
~L~ T
~
~Q~~~ -+1~~
It
~~
T
~
T
~
T~
~ 1 1 1 C/)
c:~
~=~ :x
m
0 0
=
r-
)-
2:
0 0
z
C/)'"
:x
)-
~
2:
0
=
~
0
= 0
~
~
."
0
~
=
=
....
Q
n
~
u n
r-
m
==
3:
m
< n
z= :x
)-
~
~
Q 2:
....
~
~
C/)
rev. 1990 14-7

,.. SUTHERLAND'S HANDBOOK FOR BICYCLE MECHANICS
~
,..•
=
~:c
Make & Model
~
\0
0
Model No. A B C D F G H* J M N**() 0**0
OFMEGA
• Ofmega 39.6 28.4 11.2 10.3 32 F 2.0 tang 32 F 6.2 26-5/32" 26-5/32"
• Competizione 40.9 26.2 14.7 7.4 32 F 2.2 tang 32 F 9.1 22-3/16" 22-3/16"
• Sport 38.8 27.0 11.8 8.9 32 F 1.3 tang 32 F 6.6 26-5/32" 26-5/32" rn
OMAS :J>
• Art 120 40.1 26.6 13.5 7.0 32 P 1.6 tang 32 F 8.1 31-1/8" 31-1/8"
0
(J)
PEUGEOT 38.5 26.5 12.0 10.8 32 F 2.5 tang 45.7«> 7.0 26-5/32" 26-5/32" rn
RALEIGH ~
(J)
• Rat 101 37.0 23.7 13.3 8.2 30.2 F 2.7 - 41.3 F 6.1 25-5/32" 25-5/32" .....
• Pat 803 41.1 28.1 13.0 12.8 30.4 F 2.7 -- 41.2 F 6.0 25~5/32" 25-5/32" (J)
• Aletet 36.1 24.6 11.5 7.3 30.6 F 3.3 - 42.0 F 6.7 26-5/32" 26-5/32" t ~
RITCHEY
C
t
rn
• Logic 34.4 22.0 12.3 6.8 32 F 1.4 15 tang 32F 6.8 31-1/8"16 22-3/16"16 ~.
(J)
• Logic Comp 34.0 22.0 12.0 6.6 32 F 1.3 15 tang 32F 6.8 31-1/8"16 22-3/16"16 .....
SCHWINN
• Deluxe l7
:c
• Standard I8
36.7 26.4 10.3 10.9 30 P 2.0 tang 41.2«> 5.6 25-5/32" 25-5/32" :J>
(Made in U.S.A.)
36.9 26.9 10.0 10.9 30F 2.0 tang 45.3q> 5.8 22-3/16" 22-3/16" Z
Standard 56-710 39.4 27.9 11.5 11.0 30F 2.0 tang 7
6.0 22-3/16" 22-3/16"
pz. 0
r'
(Made in Japan)
rn
SHIMAN0 19 to
• Dura-Ace HP-7600 31.0 19.5 11.5 32 F tang 32 F 25-5/32" 25-5/32" :J>
Dura-Ace HP-7400 36.7 20 23.1 20 13.4 5.1 32 F 1.1 15 tang 32 F 6.4 22-3/16" 22-3/16" ::0
21 (J)
Dura Ace EX 19 HP-7200 37.9 23.1 14.8 4.5 21 2.0 tang - 22-3/16" 22-3/16"
Dura Ace HP-7100 39.7 24.7 15.0 5.4 32 F 2.1 tang 32 F 9.6 22-3/16" 22-3/16"
• 600 Ultegra HP-6400 33.8 22.2 11.6 6.6 32 F 0.9 15 tang 32 F 6.0 25-5/32" 25-5/32"
600 HP-6207 39.9 25.1 14.8 21 tang 21 22-3/16" 22-3/16"
60019 21 - 21
HP-6200 39.9 25.1 14.8 22-3/16" 22-3/16" [ ~K~
• Sante HP-5000 33.4 23.3 10.1 8.5 30 p 22 2.8 23 tang 32 F 5.9 25-5/32" 25-5/32"
• 105 SC HP-1055 33.3 21.6 11.7 8.0 32 F 0.6 15 tang 32 P 6.7 25-5/32" 25-5/32"
105 19 HP-I050 32.7 21.2 11.5 32 F tang 32 F 25-5/32" 25-5/32"
• DeoreXT HP-M735 34.0 22.4 11.6 7.0 32 F 2.0 tang 32 F 5.4 17-1/4" 17-1/4"
DeoreXT HP-M730 32.1 20.6 11.5 6.5 32 P 0.1 IS tang 32 F 6.7 25-5/32" 25-5/32"
I
~ ~~
DeoreDX HP-M650 33.8 22.2 11.6 6.6 32 P 1.9 tang 32 F 5.4 17-1/4" 17-1/4"
Deore HP-MT60 32.5 20.8 11.7 5.9 32 F 2.0 tang 32 F 6.7 25-5/32" 25-5/32"
~L~ t
• Exage HP-R500 32.7 22.0 11.5 32 F tang 32 F 25-5/32" 25-5/32"
Exage HP-A450 33.5 22.0 11.5 32 F tang 32 F 25-5/32" 25-5/32"
Exage HP-M450 33.5 22.0 11.5 32 F tang 32 F 25-5/32" 25-5/32"
Exage HP-M350 33.5 22.0 11.5 32 F tang 32 F 25-5/32" 25-5/32"
• Le Tour (OEM- 42.5 31.5 11.0 10.9 30 F 1.9 tang 45 4> 6.7 25-5/32" 25-5/32"
SCfl\vinn)
Oversized Models
HP~M737
rt
• DeoreXT 40.3 27.3 13.0 36 F tang 36 F 22-7/32 22-7/32"
t
• DeoreXT HP-M736 33.9 22.3 11.6 6.7 36 F 2.0 tang 36 F 5.4 19-1/4" 19-1/4" c
• DeoreDX HP-M651 34.0 22.4 11.6 7.2 36 F 2.0 tang 36 F 5.4 19-1/4" 19-1/4" ~
SPECIALIZED
~~~i
• Pro-Compact, anoy 35.3 23.4 11.9 6.0 32 F 1.1 15 tang 32 F 6.4 25-5/32" 25-5/32"
• Channel-Seal, alloy 45.1 29.6 15.5 7.2 32 F 2.0 tang 32 F 10.2 25-5/32" 25-5/32"
• Channel-Seal, steel 35.0 23.3 11.7 6.3 32 F 1.0 15 tang 32 F 6.3 25-5/32" 25-5/32"
• Standard,. steel 38.2 25.8 12.4 7.4 32 F 2.0 tang 32 F 7.9 25-5/32" 25-5/32" T
STEYR PUCH 81716 35.4 24.8 10.6 11.9 30 F 3.0 tang 46.54> 6.7 25-5/32" 25-5/32" uo 1(0 ~G
Notes ~J-IT
~ ~
*There are more exceptions than rules here; French threaded headsets tradition-
ally had washers that locked via flats, but even this varies.
**On some models it may be possible to add "one last ball," but it is usually bet-
ter to resist the temptation; too many bans can damage the bearing.
~
7. Simply knurled.
15. Washer is almost completely recessed into screwed race.
16. Note difference in ball size between upper and lower races.
17. Pressed races not identical.
18. Pressed races identical.
4 ~K~
19. Some Pre-1985 Shimano headsets have a 26.36 crown race - smaller than any
other. To salvage a fork that these were fitted to, try using .a Stein kurling tool
to expand the crown race seat.
20. Supplied with extra washer (measured with only a single washer).
21. To avoid damage to aluminum surface, use two Shimano wrenches TL-HPI0.
~ ~~
(A 32mm wrench will work in a pinch.).
22. Remove plastic cap to expose locknut's wrench-flats.
23. Serrated.
~ 24. Washer locks to both fork and screwed race. When adjusting headset, washer ~L~ T
8
~ must be lifted 3mm so as to disengage screwed race.
~ See page 14-6 for more detailed key.
•
~
~
S31NVH3:1W :ll::lA:lIH HO.:l >lOOHONVH S,ONVl:H:lH.LnS

...•
~
~:c
~
N Make & Model No.
:0
\0
o Model
STRONGLIGHT
A B C D F G H* J M
N**O 0**0
• Delta 40.7 25.7 15.0 7.5 32 F 0.64 - 32 F 7.6 tapered tapered
• Mountain Delta 45.0 30.4 14.6 12.6 36 F - - 36 F 7.3 tapered tapered
[T]
·A9
·V4
39.8
39.3
27.2
25.3
13.9 8.2
14 7.5
32
32
F
F
2.6
4.9 23
tang
flat 24
32 F
45<1>
6.4
5.2 max
rolle~
25-5/32"
rolle~
25-5/32"
»
o
·B10 39.5 25.6 13.9 7.5 31 F 5.3 flat 4.6 max
• P3 34.0 22.9 11.1 6.4 28 F 4.5 23 flat 24
45<1>
45<1> 5.2 max
25-5/32"
25-5/32"
25-5/32"
25-5/32"
en
[T]
• S5 40.6 26.8 13.8 7.1 32 F 2.7 32 F 7.5 25-5/32" 25-5/32" ~
SUNTOUR
• Superbe Pro HS-SBOO 37.0 23.5 13.5 6.8 32 F 2.1 tang 32.3 7.8 25-5/32" 25-5/32" t
-en
TANGE-SEIKI C
en
~
• G-Master TR-2000 43.9 28.6 15.3 7.2 32 F 2.0 tang 32 F 8.8 roller roller + [T]
• Levin CD 35.8 23.6 12.2 6.5 32 F 1.2 15 tang 32 F 6.9 25-5/32" 25-5/32" ~
• Levin
• Falcon FL-250S
37.8
40.1
25.7
25.9
12.1 6.7
14.2 7.3
32
32
F
F
2.1
2.0
tang
tang
32
32
F
F
7.6
10.1
25-5/32"
25-5/32"
25-5/32"
25-5/32"
1;=:~Il en
-
· - MA-60 36.0 25.0 11.0 9.5 32 F 4.0 23 tang 24 7 ~I '~D :c
l-TT »oz
7.1 25-5/32" 25-5/32"
· - AW27 38.9 27.7 11.2 11.1 30 F 2.0 tang 30 F 6.0 22-3/16" 22-3/16"
·TIOGA
- MX2 39.1 28.3 10.8 10.1 30 F 2.8 tang 30 F 6.0 22-3/16" 22-3/16" va e?l G
~J~ ~
• MTB Expert 37.1 25.3 11.8
~ l~
7.2 32 F 2.1 tang 32 F 8.0 25-5/32" 25-5/32" [T]
·• Beartrap 2
- MTB-KT-AL 40.8 26.4 14.4 7.3 32 F 2.1 tang 32 F 8.2 22-3/16" 22-3/16" OJ
· - MX-2
39.5
39.3
28.4
28.1
11.1
11.2
10.6
10.2
32
30
F
F
4.2 23
2.6
tang 24
tang
32
30
F
F
6.8
6.3
22-3/16"
22-3/16"
22-3/16"
22-3/16"
»
~
· en
~
- MX101 43~1 31.9 11.2
4
13.3 32 F 2.0 tang 32 F 6.0 22-3/16" 22-3/16"
·Oversized Models
- MX-600 39.3 28.1 11.2 10.1 30 F 1.7 tang 30 F 6.1 22-3/16" 22-3/16"
• Avenger OS-HI 35.1 24.2 10.9 6.9 36 F 1.2 15 tang 36 F 6.5 29-5/32" 29-5/32" ~K~
Avenger OS-H3 32.7 21.7 11.0 6.5 36 F 1.1 15 tang 36 F 6.2 29-5/32" 29-5/32"
WHW 37.5 26 11.5 8.5 31 F 4.1 23 tang 24 7
5.0 26-3/16" 26-3/16"
~ ~~
~L~ T
WILDERNESS
TRAIL BIKES
• Grease Guard8 42.8 28.0 14.8 8.0 32 F - - 32 F 5.5 sealed sealed
YST
• Antech 8703 39.3 25.9 13.4 6.0 32 F 2.1 tang 32 F 9.2 25-5/32" 25-5/32"
7
·BMX 39.8 28.6 11.2 8.6 30 F 2.1 tang 6.0 22-3/16" 22-3/16"
ZEUS 40.7 25.8 14.9 6.4 32 F 2.0 flat 32 F 9.1 22-3/16" 22-3/16"
Notes
*There are more exceptions than rules here; French threaded headsets tradition-
ally had washers that locked via flats, but even this varies. t
• ~ ~
**On some models it may be possible to add "one last ball," but it is usually C
better to resist the temptation; too many balls can damage the bearing.
4. Washer fits almost flush in locknut.
~~=Qi
5. Conical steel washers must be installed between bearings and races.
7. Simply knurled.
8. To avoid damage to the bearings use the appropriate adapter bushing set for the
following cup presses (each also includes bushing for crown race installation):
Campagnolo King 300/C T
Bicycle Reasearch King 300/B V7I----- =0 l-G
Var King 300NP T
f-J---l
Park None needed
15. Washer is almost completely recessed into screwed race.
23. Serrated.
24. Washer locks to both fork and screwed race. When adjusting headset, washer
~ ~
must be lifted 3mm so as to disengage screwed race.
"0" Rings
Headset
Aprox.
Aprox. Aprox. Cross-
4 ~K-4
~
Brand Model No I.D. O.D Section
Mavic 312 21 26 2.5
Tange TR 2000 21 25 2
Ritchey Logic Comp 21 25 2
Stronglight Delta (locknut) 22 25 1.5
Shimano
Tioga
HP-7400
OS-H6
22
24
26
29
2
2
~ ~~
~L-4 T
~
Stronglight Mountain 35 39 1.5
~
~
Stronglight Delta (crown race) 35 39 1.5
~ See page 14-6 for more detailed key.
I Campagnolo Euclid 38 41 2
~
~
S3INVH3=tW =t'3A3IH HOd >lOOH<INVH S,<INV'H=tHlnS

~ HEADSETS, STEMS, HANDLEBARS
en STEMS-STEERING COLUMNS centi-

inches meters
U
.....
z STEM DIAMETER
«
:c Imported Bicycles 6
u + These figures can serve only as a rough guide.

LIJ Stem diameter Used in the following countries*
~ 22.2mm (7/8 ") England, Belgium, Italy, Japan
LIJ (see also 21.15) 5
~ 22mm** Germany, Austria, Denmark,
U Switzerland, France, Spain
>-
U
21.15mm (.833") Japan (on many bicycles for U.S.
market)
.....
=
=:
*Countries not listed generally use national standards
listed on page 0-4.
**Older French and Spanish stems may be 21.9 mm.
4 10
o
~ U.S. Bicycles (including Schwinn) 8
~ Before 1966: 7/8" (22.2mm) 3
o 1966 and after: .833" (21.15mm)-frequently listed as .......- 7
o 13/16" although it is actually .020"
=
Q
(0.50mm) larger than 13/16".
2
6
5
Z
«
:c -NOTES-
4
en 3
""
Q 1
2
Z
«
~
1
=: o 0
LIJ
:cE- THIS SCALE
MAYBE
USED FOR
::J MEASURING
en
14-14 1990
HEADSETS, STEMS, HANDLEBARS ~
HANDLEBARS-.STEMS
Handlebar Diameters - Brake Clamp, Grip and Clip-on Diameters

22mm Italy, Germany, Switzerland, Northern Europe (also
children's handlebars in France)
22.2mm England, U.S. steel, BMX
23.5mm France, Belgium, Spain, North Africa
23.8mm England, U.S. alloy
24mm Belleri, Mavic, Modolo, many Cinelli-style bars
24.2mm Cinelli
Handlebar Center Diameters - Stem Clamp Hole Diameter

These figures can serve only as a rough guide. No hard and fast
rules can be made.
Standard Center Diameter Notes

ISO 25.4mm (1")
English 25.4mm, 23.8mm Generally 23.8 is found on 3-
(1 ", 15/16") speed and coaster brake bikes.
French 25.0mm, 23.5mm Belleri -- 26.0, Mavic -- 26.0
Italian 25.0mm, 23.5mm Exceptions: Cinelli -- 26.4,
TTT -- 26.0, Modolo -- 26.0,
some Italmanubri 25.6
Japanese 25.4mm Exception: Dura-Ace stems 26.0*,
Cinelli Copies -- 26.4,
other quality bars 26.0
u.S. 25.4mm Exception: Schwinn used 15/16"
on Randonneur bars in 1971
Other exceptions: Titan makes 27mm and 25mm centers. The
27mm center fits only Titan stems.
MOUNTAIN BIKE HANDLEBARS-STEMS

Mountain bike handlebars are generally 22.2mm in diameter with a
25.4mm (1 ") center.
*Dura-Acestems can accept 25.4 bars by changing the internal

push-plate. Likewise the 600 model stems can be changed to 26.0.
1990 14-15
,..
-p HEADSETS, STEMS, HANDLEBARS
14-16 1990 rev.

P HEADSETS, STEMS,. HANDLEBARS
~ Juvenile
Most juvenile bikes use standard headset threading. Some,
, however,use the following:
English 7/8 "x 24 TPI
French 23mm x' I.Omm
Italian 22.2mm x 24TPI
Tandems
Tandems are using over-sized headsets currently. In the
past many tandems used standard headsets. Some, however,
use 28mm x 1.0mm. Older English tandems used 1-1/8" x
26TPI which was also used on motorcycles.
Other
Some older English headsets (Chater Lea) were 31/32" x
30TPI.
ID.MARKINGS ON THREADED HEADSET PARTS

Campagnolo, Dura Ace, Tange Levin and others mark
headsets as follows:
English 1" x 24 TPI ENGLAND
French 25 x 1.00 FRANCE
Italian 25.4x24 F ITALY
Stronglight S5
English 25.4x 1.058
French 25 xl,
Zeus
English BSC
French no mark
HEADSET PRESS FIT DIMENSIONS AND TOLERANCES

Inside head tube should be
0.025mm to O.lmm (.001" to
.004") smaller than the pressed
race.
Crown race seat
should be 0.025mm
to 0.05mm (.001" to,
.002") larger than the
crown race.
14-2 1990 rev.

FRAME TUBES, FORK ENDS
centi-
TUBING OUTSIDE DIAMETERS inches meters
69 C/'J
STANDARD TUBING FRAMES 27 c:
68 ~
Frame member
Top Tube
English
25.4mm
French
26mm
Italian
25.4mm
USA
22.2mm 67
:crn
Down Tube
Seat Tube
Head Tube
28.6
28.6
31.75
25.4
28
28
32
25
28.6
28.6
31.75*
25.4
25.4
25.4
Varies
25.4
26 66 =
r-
~
Steering Column
Mixte Tubes 13 or 14 13 or 14 13 or 14 --
65 Z
64
0
*Bianchi with special Bianchi headset uses 30mm head
2S C/'"J
tube.
63 :c
Chain Stay, Seat Stay, and Fork Blade dimensions vary
62 ~
between tubing manufacturers and it is difficult to make
generalizations.
Z
24 61 0
ca
60 0
59
0
~
23
58 ."
0
22
57
56
=
ca
.....
n
55
-<
n
54
r-
21
53 rn
3:
52 rn
n
20
51
:c
50 >
Z
.....
49
n
19 48 C/'J
47
46
COMPARATIVE 18
SCALE ONLY 45
rev_ lQRii 15.1

GEAR HANGERS
THREAD'SIZES
French lOmmxlmm
Italian lOmm x 26 TPI
Forkend gear hangers are most often French threaded.
French, Spanish, and Japanese Equipment is all French
threaded.
Dan1age to the threads of both the Gear hanger bolt and

the fork ends occur when threading a lOmm x lmm gear
hanger bolt into a lOmm x 26 TPI hole and vise versa. The
damage is slight however because 26 TPI is very close to 1
thread per millimeter or 25.4 TPI. Running a tap of the
correct size through the fork end will minimize the damage.
ii FORK END THREADS

Gear hanger Rear Tip MudGuard
Threads Adjusters Eyes
Campagnolo lOmm x 26 TPI 3mmxO.Smm SmmxO.8mm
Huret lOmm x 1.Omm 3mmxO.6mm 4mm hole with
no threads tapped
easily to
SmmxO.8mm
Shimano lOmm x 1.Omm 3mmxO.Smm SmmxO.8mm
Simplex 9mm hole with 3mmxO.Smm S.Omm hole with
no threads no threads
tapped easily
to lOmm x 1.Omm
Sun Tour lOmm x 1.Omm 3mmxO.Smm SmmxO.8mm
Zeus lOmm x 1.Omm 3mmxO.Smm SmmxO.8mm
,..
REPLACING FORKS
+ Viscount and Lambert aluminum forks break without warning and should be replaced with
steel forks.
The main problem in replacing a fork is that the original is often damaged in such a way
that it is difficult to determine its characteristics.
Factors That Affect Handling
Rake. The rake of the fork should approximate that of the old. Small changes in rake will
quicken (less rake) or slow (more rake) the handling slightly. Larger changes will gener-
ally make the bike uncomfortable to ride since the relationship between head angle and
fork rake will be disturbed.
Length. The length of the fork-measured from the crown race seat to the axle-should
also be the same. If the new fork is shorter than the old, the head of the frame will be
lower and the effective head angle will be increased. The reverse is true if a longer fork
is used. As with a change in rake, a change in head angle affects the handling of the bike.
Small changes are less likely to be unpleasant than large ones.
If you have to change one, change both. Using a repair fork with less length and less rake
will often give a faster handling but still balanced bicycle. Using a fork with more length
and more rake results in slower bike handling.
Rigidity. Unlike other frame members the fork is not triangulated. It functions as a beam.
The fork receives stresses from the wheel and either transmits them to the frame or dis-
sipates them by flexing. (Rigidity is sideways as well as fore-aft). A replacement fork
should match the original in construction and mat~rials unless a change in ride is desired.
Factors That Affect Fit

Wheel. The forkends should be the same distance apart as the hub locknuts so the
wheel can be installed and removed easily.
The slots in the forkend should be approximately the same width as the diameter of the
hub axle so that the axle can fit into the slot yet locate accurately. The forkends should
be thick enough for the quick release to clamp them firmly. If necessary, the ends of the
axle can be filed or ground slightly shorter so that the quick release can be adjusted close
enough to clamp tight on the forkends.
Frame. The steerer must be enough longer than the headtube to allow the headset to be
fitted. See table in headset section.
Threads. If the steerer needs to be cut to length, enough threads must remain after cutting
to allow the headset to be installed. The steerer can, of course, be tapped to increase the
length of the threaded portion. See section on thread cutting, pages 0-8,0-9, and 0-17.
Stem. Steerer inner diameter must correspond with stem diameter. There are three common
sizes of stem, and each requires a different steerer bore. The fit between stem and steerer
should be a close sliding fit; there should be no wobble between stem and steerer. See stem
diameters page 14-14.
It is not safe to shorten the stem to install it in a steerer which does not allow it to enter
at least 2".
Brake Fit. This can be estimated by subtracting the rim center line radius from the distance
from the axle center line to the brake hole.
If this measurement is well within range (see the tire size chart) the brake will fit. If this
measurement indicates that the brake shoes will be at or near (within 2mm) the limit of
the travel, the wheel and brake should be tried on the fork before proceeding.
Headset Fit. See headsets.
15-3
SEAT POSTS
SEAT POST SIZES

Tubing inside diameters vary so much from maker to maker that no
size listed can be considered correct until actually tried in the bicycle.
Conventional Steel Tubing Frames

National Quality Tubing
Standard Common Tubing Plain Gauge Butted
English 25.4 (1 ") 26.4 27.0
25.8 (1-1/64") 26.6 27.2*
26.2 (1-1/32") 27.4
French 25.0 26.2 26.4
25.5 26.6*
25.8
26.0
Italian 25.0 26.0 26.8
25.8 26.2 27.0
26.0 27.2
Japan 25.8 26.2 26.4
26.2 26.8 26.6
26.8
27.0
27.2
USA 22.2 (7/8") (.875") See English
20.6 (13/16") (.812")
*Most common
Other Tendencies
Most Common Next Most Common
BMX
steel .875" (7/8") (22.2mm) .812" (13/16") (20.6mm)
Mountain
steel 26.8 26.6
Aluminum
glued 25.4 25.0
welded 27.2 27.4
15-4 rev. 1990

,...
SEAT POSTS
SOME UNUSUAL SEAT POST SIZES

Fisher Mountain Bikes
Steel- 28.6mm
Aluminum - 31.6mm
Titanium (current production) - 27.4mm
(earlier production) -- 29.4mm
Mongoose Ibox Signature

Titanium with CroMo rear triangle: -- 29.4mm
Older, all-titanium model- 27.2mm
Alex Moulton AM Series

1-3/8" /35.0mm
Charlie Cunningham and Indian

Oversized -- 1-3/8" (34.9mm)
Some road bikes - 1-1/4" (31.77mm)
Klein
Current production - 27.2mm
Ealier production -- 27.4mm
Cannondale
Current production - 27.2mm
1985 model 500 used 7/8" seat post and shim
Schwinn M.O.S.
29.8mm
Raleigh Twenty, Bridgestone Picnica and many other folding bikes with
oversized posts
28.6mm
Bikes with square seatposts

lit square
SEAT POST CLAMP BOLT

IS08mmx Imm
rev. 1990 15-5

..
SE~AT POSTS
15-6 1990 rev.

,...
APPENDIX
APPENDIX CONTENTS
*
Markings and Abbreviations 16.. 1
ISO Standards 16-2.. .··16..
..... 4
Recommended Books 16-5
Wire Gauge Comparison 16.. 6
Weight Conversions 16-7
Tap Drill Sizes • Spoke Length Formula 16-8
Bicycle Assembly Check List 16-9
Parts Guide in 6 Languages 16 10, 16-11 .
Length Conversions
mm-inches.. fractions 16 12, 16-13
Gearing
Formulas • gear selection 16-14
Gear charts~ metric and English,
wheels 680mm thru 400mm,
26" thru 16" 16-15-16-23
wheels 27" back cover
Index 16-25-16-27
MARKINGS AND ABBREVIATIONS

where used
A British Standard Cycle French parts
B British
BSC British Standard Cycle
D Right-handed threads French parts
F Thread Italian parts
FF French threads Italian parts
FI English threads Italian parts
G Left-handed threads French parts
I Left-handed threads Spanish p'arts
JIS Japan Industrial Standard
L Left-handed threads English parts
LH Left hand
M Metric
OEM Original Equipment Manufacturer
R Right-.handed threads English parts
RH Right hand
S Left-handed threads Italian parts
TPI Threads per inch
rev. 1985 16·1

APPENDIX
* INTERNATIONAL STANDARDS ORGANIZATION (ISO) STANDARDS
The following standards for bicycles have been approved:

ISO NO. TITLE AND DESCRIPTION OF STANDARD COMMENTS
DIS 6692 Marking of Components for Identification of Threading
Metric* British*
M 34.7 x 1 B 1.375 x 24 Where there is ample space.
M34.7 Bl.375 Less space.
M B Very little space.
DIS 6693 Cottered Crank and Axle Attachment
Axle diameter 16mm
Flat for cotter
Depth 3mm
Width 8mm
Cotter pin
Diameter 9.5mm (.374") ISO cotter interchanges with
Length 43mm British 3/8" (.375 "). All other
Taper 60 common sizes are smaller;
Thread M7x 1 cranks can be drilled out to
standard size.
DIS 6695 Cotterless Crank (Square-End) Fitting
Included-taper Taper angle is compatible with
angle 4 0 ± 10 minutest most cranks. Axle flats are long
Length of flat enough at inside for all cranks,
Right 18mm + 0.5 - 0 but axle may protrude into
Left 16mm + 0.5 - 0 extractor hole of a few cranks.
Dimension across 12.6mm + .02 - .05 Grind axle end if necessary
flat 1.5mm
from end
Spindle' end to bolt seat
Loose 3mm
Tightened 1.5mm min.
Crank-fixing threads
Bolt-type M 8x 1 Same as existing axles.
Nut-type M 10 x 1.25 Fits all except Campagnolo
Super Record.
Crank bolt or nut size 14mm
Dustcap threads M 22 x 1 Fits all except TA, pre-1982
Stronglight.
DIS 6696 Bottom Bracket Threads
Left side B 1.375 x 24 Compatible with British.
Right side B 1.375 x 24L
*See pages 0-2 and 0-3 for an explanation of thread designation and measure.
t 2 0 on each side.
16-2 1985
ISO STANDARDS (cont.)
APPENDIX *
DIS 6694 Pedal to Crank Thread
Primary standard (left pedal left-threaded)
Threading B .500 x 20 Smaller diameter was chosen for
Thread Length 12.5mm + 0.5 - 0 compatibility with I-piece
Thread angle 60 0 ISO cranks.
Alternate standard (left pedal left-threaded)
Threading B .562 x 20 Compatible with British.
Thread length 12.5mm + 0.5 - 0 For aluminum cranks.
10mm + 0.5 - 0 For steel cranks.
Thread angle 60 0 ISO
DIS 6697 Hub Axle Threading
Solid
Front M8x 1 Compatible with French.
Rear M9x 1 No current com.patibility.
Hollow
Front (and M9x 1 Compatible with French.
BMX solid)
Rear M lOx 1 Compatible with many brands
but not Campagnolo; Zeus:
10mm x 26 TPI.
Hub Width Between Dropouts
Front Freewheel
Width Space
(± 1) (+ 1- 0)
Primary standard 100
Secondary standard 91
Rear
Single freewheel, 110 21
coaster hub
3-, 4 -speed 117 28
freewheel,
geared hub
4-, 5-speed 122 34
freewheel
5-7-speed 126 36
freewheel
DIS 6698 Freewheel Threads
Threading B 1.375 x 24 Compatible with British
Thread angle 60 0 ISO and Italian: thread diameter
Length of thread is intermediate. Thread form
Freewheel 10mm min. slightly different.
Hub 10mm
1985 16-3
* APPENDIX
ISO STANDARDS (cont.)

DIS 4881 Spoke Diameter and Threads
1.• 8. m
..•. m
.•. 56 T. I}.. Compatible with existing U.S.
2.0mm 56TPI and British spokes and nipples.
p.
2.3mm 56 TPI
2.6mm 56 TPI
DIS 6701 Exterior Dimensions of Spoke Nipples
Spoke Wrench Nipple Nipple Rim To compare other standards
diameter flat shank head hole see chart on page 11.. 3.
1.8mm 3.3 4.0 6.0 5.0
2.0mm 3.3 4.0 6~O 5.0
2.3mm 3.8 4.8 6.5 5.5
2.6mm4.5 5.5 7.5 6.5
DIS 6699 Seatpost Clamp Bolt M 8 x 1
DIS 6700 Brake Bolt Hole 6.2mm
Handlebar Diameter
25.4mm +0 --- ,,020mm
Threading of Fork and Headset Compatible with British,

Italian.
Headset
TPI 24
Major diameter (mm) 25.522
Pitch diameter (mm) 24.836
Minor diameter (mm) 24.379
Fork min max
Major diameter (mm) 25.316 25.496
Pitch diameter (mm) 24.685 24.810
Minor diameter (mm) 24.209
Thread form ISO 965/1 (60 0 modified
to H/6 truncation at root)
Safety Standards
ISO 42101 The ISO has established tests for manufacturing quality assurance related
to safety and integrity. Bicycles identified as meeting ISO 4210 conform to
these standards.
Lighting and Reflectorization Standards ISO 6742
ISO 6742 ISO 6742 refers to lighting and reflectorization. Equipment bearing ISO
6742 markings conform to these standards. In particular, ISO standards
for generator and battery lights are considerably higher than pre.. existing
national standards.
16·4 1985
,...
APPENDIX
RECOMMENDED BOOKS
Barnett's Manual-·Analysis and Procedures for Bicycle Mechanics,

*
John Barnett 1989
Vitesse Press
A division of FPL Corporation
P.O. Box 1886
Brattleboro, VT 05302
Shimano Service Handbook, 1988, 1989

Shimano American Corporation
One Shimano Drive
Irvine, CA 92718
Shimano (Europa) GmbH.
Kleinhiilsen 1-3 4010 Hilden
West Germany
Delong's Guide to Bicycles and Bicycling-the Art and Science,

Fred Delong 1974, 1978
Chilton Book Co.
Sales Service Department
Chilton Way
Radnor, PA 19089
Bicycling Science-Ergonomics and Mechanics, Frank R. Whitt

and David Wilson 1974
MIT Press
28 Carleton St.
Cambridge, MA 02142
Bicycles and Tricycles-An Elementary Treatise on Their Design

and Construction, Archibald Sharp 1896
MIT Press
28 Carleton St.
Cambridge, MA 02142
The Paterek Manual for Bicycle Framebuilders,

Tim Paterek 1985
Framebuilders Guild
River Falls, WI 54022
The Ten Speed Commandments-·An Irreverent Guide to the

Complete Sport of Cycling, (humor), Mike Keefe 1987
Doubleday & Company, Inc.
Garden City, New York
1985 16-5
APPENDIX
* WIRE GAUGE COMPARISON CHART
British Standard Wire Gauge

English Gauge (SWG) French Wire Gauge No
No. mm/inches (Jauge de Paris) mm/inches
27 0.41 0.016 P 0.5 .020
26 0.46 0.018 1 0.6 .024
25 0.51 0.020 2 0.7 .028
24 0.56 0.022 3 0.8 .031
23 0.61 0.024 4 0.9 .035
22 0.71 0.028 5 1.0 .039
21 0.81 0.032 6 1.1 .043
20 0.91 0.036 7 1.2 .047
19 1.02 0.040 8 1.3 .051
18 1.22 0.048 9 1.4 .055
17 1.42 0.056 10 1.5 .059
16 1.63 0.064 11 1.6 .063
15 1.83 0.072 12 il .071
14 2.03 0.080 13 2.0 .079
13 2.34 0.092 14 2.2 .087
12 2.64 0.104 15 2.4 .095
11 2.95 0.116 16 2.7 .106
10 3.25 0.128 17 3.0 .118
SPOKE SIZES
Note the underlined sizes in the chart above. They are a
source of a lot of confusion. English gauge numbers get
smaller as wire gets larger. French gauge numbers get
larger as wire gets larger. The gauge numbers cross
about where cycle spokes are.
16-6 rev. 1985

APPENDIX
WEIGHT CONVERSIONS
pounds ounces grams pounds kilograms

C/)
1000 50
C
~
:crn
2lbs. 900 20
=
r-
;I>
40
2
1 lbs. 12 oz. 800 0 ~
C/)
700
:c;I>
1 lbs. 8 oz. 15 2
0
600 30
t:a
0
11bs. 4 oz. 0
~
500 ."
0
1 lbs.
400 20
10
=
....t:a
n
-(
12 oz.
n
r-
300
rn
8 oz. 5 3:
rn
200 10
n
:c;I>
4 oz.
100 ....2
n
C/)
0 0 0 0
16-7
APPENDIX
TAP DRILL SIZES

METRICS SIZES
Nearest U.8. Tap Metric Tap
Thread Size Drill Size Drill Size
5.0mm x O.8mm #19 4.20mm
6.0mm x 1.0mm #9 5mm
10mm x 1.0mm "T" 9mm
AMERICAN SIZES
U.S. Tap Drill
Thread Size Size
6~32 #36
8-32 #29
10-32 #21
10-24 #25
X-20 #7
SPOKE LENGTH FORMULA
where:
L ;;; spoke length
r1 ::;: rim radius (to end of spoke position)
r2 ::;: Y2 hub diameter measured to spoke hole centers
w :::: Y2 hub width
x ;;; 3600 x number of crosses
Y2 (number of holes in hub)
y == diameter of spoke hole in hub
16-8 rev. 1985

Take this page to your local quick printer and run off
enough for several months worth of bicycle assemblies.
ASSEMBLY CHECK LIST - WORK NOT DONE FEEDBACK SHEET

Make Model...........-...-_.. . . . . . . Box # ......---
Frame Size Mens Ladies_ _.. . . . . . . . . . . . . . ._..............-_ Color _
Time Started_ _.. . . . . . . _
o brake cables greased o rubber lever covers

o derailleur cables greased o caliper mounting bolt tight
o stem greased o caliper pivot bolts tight
o seat post greased or adjusted
o seat binder bolt greased o customer brake adjustment
o saddle clamp binder bolt greased screwed all the way down
o handlebar binder bolt greased
o brake pads adjusted and tight
o stem bolt tightened
o brakes toed in
o seat post bolt tightened with o brake cables stressed to handle
bar
brake hanger in correct positions
o head set adjusted
D seat level
o seat clamp bolt tight o chainwheel bolts tight
o bottom bracket adjusted
o shift lever tight o cotters or crank bolts tight
o cable stops and guides tight o chainwheels true
o pedal threads oiled o derailleurs adjusted
o pedals attached and tight o front derailleur 1/16" over teeth
D derailleur hanger bolt tight
o excess grease wiped off
o drop outs parallel o toe clips and straps installed
o fender attaching bolts tight o kickstand tight
o freewheel threads greased
o put in easy gear to ride
o wheel bearings adjusted
o air in tires
D wheels centered
o valve caps on
o axle nuts or quick releases tight D warranty card filled in with
o reflectors installed date assembled and your initials
D brake lever bolts tight
Time finished_...---.- ---...---. _
Total Time -----..-
seat (GB-saddle)
seat post(GB-seat pin, seat pillar) selle
tige de selle .sella
cannotto reggisella top tube
Sattelstutze sillin tube horizontal seat tube
tija del sillin it ~J~ tubo orizzontale tube de selle
~- ~ t:~ (~- ~ t:7-) Oberrohr tubo verticale
tubo superior Sattelrohr
~ ''I 7°7- ~ -7" tubo del sillln
seat stays ~-~7-~
rear dropout, rear fork tip haubans V'
patte arriere tubi posteriore verticale

forcellino obere Hinterradgabel
hinteres Ausfallende horquilla superior
pata de cuadro ~- ~AT-'
fi'/;{ (fi ~ [J ''17°77 ~) back brake
fro'nt derailleur frein arriere
(GB-front changer) freno posteriore
gear cable derailleur avant Hinterbremse
cable de derailleur freno trasero
cavo per cambio deragliatore ~:K7" l/-:f"".
vorderer Umwerfer 'I~ "
Schaltungskabel "
~sv~,ador central~,~~~.~ ."'.
cable del cambio
=¥ -\7"Jr -7" J~ J=JIJ~~~ ''"%~"., '"
freewheel or bloc
roue libre
ruota Ii
Freilauf
rueda libre
7'1) -*1 J~
rear derailleur (GB-rear changer)
derailleur arriere
cambio
hinterer Umwerfer
cambio de marchas
fi~ij~
chainstays
bases
tubi posteriore orizzontale
untere Hinterradgabel
horquilla inferior crank
7-I.-/AT- mani\
manovella-'"
Tretkurbel
va chainrL02 biela
plat~~2i"ux crankset toeclip toestra p
valve
jeu de pedalier cale-pied courroie '77/'7
valvola ingranaggi
Kettenrader guarnitura fermapiede cinghietta
Ventil Pedalhaken Pedalriemen
platos Tretlager-Ga rn itu r
valvula movimento central calapie correa del calapie
7-I- / I) /1]"
J\J~ 7" ~ -A I' '7 ''I 7°
~-vt& ~ -'7 I) ''I 7°
pedal bottom bracket

boTte de pedalier
BICYCLE pedale
pedale
Pedale
serie movimento
Tretlager
PARTS GUIDE pedal
"9~ J~
caja de pedalier
J\ /71'-
16-10
bicycle --English
down tube bicyclette, velo -French
tube diagonal stem handlebars bicicletta -Italian
tubo obliquo potence guidon Fahrrad -German
Unterrohr ~lattacco manubrio bicicleta -Spanish
tubo inferior li' Lenkervorbau kstange ElfiIfI ---Japanese
9~r'J /7-.:1 -7" ,/l' potencia manillar
,l~ A - .b.. J\/ ~)(..,J\-
/ T
ll~ #~~~~~~-----~~.~~-~-~
brake cable-outer
brake cable-inner gaine
cable de frein guaina
cavo del freno Bremszug-HUlle
Bremszug funda de freno
cable de freno 7" I/-:\=- '7-7")(..,-7 r'J '9-
7"1/-:\=-'7-7")(..,-1' /-r-
''''-1~_=_'''__>'.''="=~''_''''N'''''''_.'=''''-"'.=''=W'''"~*_*="'W~'_*'*"_ _""WN••_'X"W.'.~_='*"«."~'__W"N.',".V~Wh' ='N'~"=_'~=_' 'W'~~="h_"'_"'_= bra ke Ieve r
poignee de frein
head tube
leva freni
tube de direction
Bremshebel
tubo sterzo
maneta de freno
Rah mensteuerroh r
tuba de direcci6n 7' I/-:\=- I/J\-
~ ''/ ~7- .:1-7"
~~~~~~§;:=-------~--------
h eadset
jeu de direction
front bra ke serie sterzo
frein avant Steuersatz
freno anteriore juego de direcci6n
Vorderbremse ~ ''/ ~ JJ\~
freno delantero
M7"I/-~
. *'\t\\''''''--'«'==''-'-~'*'-'='=--'._~--''-----'=»---'==----~' w,__=,,,._ for k crow n
tete de fourche
testa forcella
fork Gabelkrone
fourche amarre de tijera
forcella *-?J;§I
Vordergabel
horquilla
*-?
-""~'_"'X._' =-*_h"_=~'__~~"*'_A"»' _ _'='~'X_'=_' for k tip
inner tube patte avant
chambre a air punta forcella
camera d'aria vorderes Ausfallende
Schlauch puntera de horquilla
ub camera M*-?'/ ;c
moyeu 7-.:1-7"
mozzo
gear lever rim Nabe ti re (G B-tyre)
manette de derailleur jante buje pneu
leva del cambio cerchio J\7" pneumatico
Schalthebel Feige Reifen
maneta del cambio IIanta neumatico
~iI I/J\- I) .b.. '91-\7
spoke
quick release rayon
blocage rapide raggio
bloccaggio' rapido Speiche
Schnellspanner radio
cierre rapido A~-?
? 1 ''/ ? I) I) -~'
16-11
APPENDIX CONVERSION CHART
Millimeters to Inches
Imm == 0.0394 inches
en 1 inch == 25.4 millimeters

....
U
Z
-(
:cu Milli-
meter
Dec.
Equiv.
Frac-
tional
Milti..
meter
Dec.
Equiv.
Frac..
tional
Milli-
meter
Dec.
Equiv.
Frac..
tional
(.IJ .1 .0039 3.18 .1250 1/8 6.35 .2500 1/4

.2 .0079 3.2 .1260 .2520
:I: .25
.3
.0098
.01 18
3.25
3.3
.1279
.1299
6.4
6.5
6.6
.2559
.2598
(.IJ .39 .0156 1/64 3.4 .1338 6.7 .2638
.01 57 3.5 .1378 6.75 17/64
...1 .4
.5 .0197 3.57 .1406 9/64 6.8
.2656
.2677
U .6 .0236 3.6 .1417 6.9 .2716
~
.7 .0275 3.7 .1457 7.0 .2756
.75 .0295 3.75 .1476 7.1 .2795
.... .79 .0312 1/32 3.8 .1496 7.14 .2812 9/32
=
.8 .031 5 3.9 .1535 7.2 .2835
.9 .0354 3.97 .1562 5/32 7.25 .2854
1.0 .0394 4.0 .1575 7.3 .2874
=
ou..
1.1
1.19
1 .2
1.25
1.3
1.4
.0433
.0469
.0472
.0492
.0512
.0551
3/64
4.1
4.2
4.25
4.3
4.37
4.4
.1614
.1654
.1673
.1693
.1719
.1732
11/64
7.4
7.5
7.64
7.6
7.7
7.75
.2913
.2953
.2969
.2992
.3031
.3051
19/64
~ 1.5 .0591 4.5 .1772 7.8 .3071
o 1.59
1 .6
.0625
.0630
1/16 4.6
4.7
.181 1
.1850
7.9
7.94
.31 10
.3125 5/16
o 1.7 .0669 4.75

4.76
.1870
.1875 3/16
8.0
8.1
.3150
.3189
=
1.75 .0689
1.8 .0709 4.8 .1890 8.2 .3228
1.9 .0748 4.9 .1929 8.25 .3248
Q 1 .98 .0781 5/64 5.0 .1968 8.3 .3268
21/64
Z 2.0
2.1
.0787
.0827
5.1
5.16
.2008
.2031 13/64
8.33
8.4
.3281
.3307
-( 2.2 .0866 5.2 .2047 8.5 .3346
:c 2.25
2.3
.0886
.0905
.0937 3/32
5.25
5.3
5.4
.2067
.2087
.2126
8.6
8.7
8.73
.3386
.3425
.3437 1 1/32
en 2.38
2.4 .0945
.0984
5.5
5.56
.2165
.2187 7/32
8.75
8.8
.3445
.3465
" 2.5
Q 2.6
2.7
.1024
.1063
5.6
5.7
.2205
.2244
8.9
9.0
.3504
.3543
Z 2.75 .1083
7/64
5.75 .2264
.2283
9.1 .3583
-( 2.78
2.8
.1094
.1 102
5.8
5.9 .2323
...1
=
2.9 .1 142 5.95 .2344 15/64
3.0 .1 181 6.0 .2362
3.1 .1220 6.1 .2401
(.IJ 6.2 .2441
:c
~
6.25
6.3
.2461
.2480
;:)
en
16·12 1990 rev.

APPENDIX
Milli- Dec. Frac.. Milli.. Dec. Frac.. Milli- Dec. Frac-

meter Equiv. tional meter Equiv. tional meter Equiv. tional
9.13 .3594 23/64 15.88 .6250 5/8 23.81 .9375 15/16

9.2 .3622 16.0 .6299 24.0 .9449
9.25 .3641 16.27 .6406 41/64 24.21 .9531 61/64
9.3 .3661 16.5 .6496 24.6 .9646
9.4 .3701 16.67 .6562 21/32 24.6 .9687 31/32
9.5 .3740 17.0 .6693 25.0 .9843
9.53 .3750 3/8 17.06 .6719 43/64 25.0 .9844 63/64
9.6 .3780 17.46 .6875 11/16 25.4 1.0000 1
9.7 .3819 17.5 .6890 25.6 1.0079
9.75 .3838 17.86 .7031 45/64 25.8 1.0157 1-1/64
9.8 .3858 18.0 .7087 26 1.0236
9.9 .3898 18.26 .7187 23/32 26.19 1.0312 1-1/32
9.92 .3906 25/64 18.5 .7283 26.2 1.0315
10.0 .3937 18.65 .7344 47/64 26.4 1.0394
10.32 .4062 13/32 19.0 .7480 26.5 1.0433
10.5 .4134 19.05 .7500 3/4 26.59 1.0469 1..3/64
10.72 .4219 27/64 19.45 .7656 49/64 26.6 1.0472
11.0 .4330 19.5 .7677 26.8 1.0551
11.1 1 .4375 7/16 19.84 .7812 25/32 26.99 1.0625 1..1/16
11.5 .4528 20.0 .7874 27 1.0629
11.51 .4531 29/64 20.24 .7969 51/64 27.2 1.0708
11.9 .4687 15/32 20.5 .8071 27.38 1.0781 1..5/64
12.0 .4724 20.64 .8125 13/16 27.4 1.0787
12.30 .4843 31/64 21 .0 .8268 27.78 1.0937 1-3/32
12.5 .4921 21 .03 .8281 53/64 28.18 1.1094 1-7/64
12.7 .5000 1/2 21 .15 .8327 28.58 1.1250 1..1/8
13.0 .51 18 21 .43 .8437 27/32 28.97 1.1406 1-9/64
13.10 .5156 33/64 21 .5 .8465 29.37 1.1562 1..5/32
13.49 .5312 17/32 21 .6 .8504 29.77 1.1719 1..11/64
13.5 .531~ 21 .7 .8543 30.16 1.1875 1..3/16
13.89 .5469 35/64 21 .83 .8594 55/64 30.2 1.1889
14.0 .5512 21 .85 .8602 30.56 1.2031 1-13/64
14.29 .5625 9/16 21 .9 .8622' 30.95 1.2187 1-7/32
14.5 .5709 22.0 .8661 31.35 1.2344 1..15/64
14.68 .5781 37/64 22.23 .8750 7/8 31.75 1.250 1..1/4
15.0 .5906 22.5 .8858 32 1.2598
15.08 .5937 19/32 22.62 .8906 57/64 34.7 1.3661
15.48 .6094 39/64 23.0 .9055 34.92 1.3750 1-3/8
15.5 .6102 23.02 .9062 29/32 35 1.3779
23.42 .9219 59/64 36 1.4173
23.5 .9252
For larger numbers, move
decimals to the right:
e.g., 220 mm:::: 8.661 inches
rev. 198516.. 13
* APPENDIX
GEAR RATIO FORMULAS
ENGLISH
Diameter of tire in inches

x number of teeth on front chainwheel
number of teeth on.rear sprocket
. Cycle gears are given in "inches". This dates to the time
of the"Ordinary" or "Pennyfarthing" Bicycle and re-
fers to the diameter of the big wheel. In the present
chain, driven bicycle the term "inches" is still used but
it now refers to the size of an "Ordinary" wheel which
would be required to move the same distance forward
for one pedal revolution. To calculate the distance trav-
elled for one revolution of the pedals, multiply the gear
in inches by pi, i.e. 3.14.
From Raleigh Catalog, England
METRIC
Diameter of tire in meters x 3.14 (pi)

x number of teeth on front chainwheel
number ofte.eth on rear sprocket
The metric gear ratio formula gives you the number of
meters traveled per pedal revolution.
GEAR TABLE FOR INTERNALLY GEARED HUBS

Multiply by gear value obtained from chainwheel and sprocket sizes.
GEAR 2 3 4 5
HUB
Bendix
Red Band 0.68 1.00
Yellow Band 0.68 1.00
Blue Band 1.00 1.47
F&S
2-speed 1.00 1.36
3-speed 0.73 1.00 1.36
Shimano 3-speed 0.75 1.00 1.33
Sturmey-Archer
and im'itations
3-speed 0.75 1.00 1.33
4-speed 0.67 0.79 1.00 1.27
5-speed 0.67 0.79 1.00 1.27 1.50
16-14 1985
680 mm WHEEL GEAR CHART*
REAR SPROCKET
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 38
1.95 1.74
n 2.01 1.80
=
>
....
Z
2.69 2.59 2.50 2.42 2.34 2.27 2.14 1.91
2.77 2.67 2.58 2.49 2.41 2.34 2.20 1.97
~
=~
~
~
37
38 1
7.19 6.59 6.08 5.65 5.27 4.94 4.65 4.39 4.16 3.95 3.76 3.59 3.44 3.29 3.16 3.04 2.93 2.82 2.73 2.63 2.55 2.47 2.32 2.08
7.38 6.76 6.24 5.80 5.41 5.07 4.78 4.51 4.27 4.06 3.87 3.69 3.53 3.38 3.25 3.12 3.01 2.90 2.80 2.71 2.62 2.54 2.39 2.14
..-...
~
4.27 2.85 2.76 2.67 2.51 2.25
==
0 2.92 2.83 2.74 2.58 2.30
Z
~
00
~ 3.06 2.96 2.87 2.70 2.42
3.13 3.03 2.94 2.76 2.47
==
0
n
~ 4.09 3.93 3.78 3.64 3.51 3.39 3.28 3.17 3.07 2.89 2.59
~
~
~ :.-.: .... _ . . . :.;,;",;; . . . . . _.~ . .'r . _ ~._ _ ..........._ '-. ....... ~ '--.... :.-.: .......
4.18 4.02 3.86 3.72 3.59 3.46 3.35 3.24 3.14 2.95 2.64
4.36 4.19 4.03 3.88 3.74 3.61 3.49 3.38 3.27 3.08 2.75
4.45 4.27 4.11 3.96 3.81 3.68 3.56 3.45 3.34 3.14 2.81
11 12 13 14 15 16 17 18 19 20 21 22
~
~
I
I *For 680 mm (26.8 ") tire outside diameter; gives distance traveled in meters for one turn of the pedals.
~
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~ I 26" WHEEL GEAR CHART*
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00
Vl
I 11 12 13 19 27 28 29 30 31 32 34 38
25
26
I
27.8 26.9 26.0 25.2 23.7 21.21 31

28.7 27.7 26.8 26.0 24.5 21.9 32
n -- I
=
.>.. 34 I 80.4 73.7 68.0 63.1 58.9 55.3 52.0 49.1 46.5 44.2 42.1 40.2 38.4 36.8 35.4 34.0 32.7 31.6 30.5 29.5 28.5 27.6 26.0 23.3 I 3435
Z 35 82.7 75.8 70.0 65.0 60.7 56.9 53.5 50.6 47.9 45.5 43.3 41.4 39.6 37J) 36.4 35.0 33.7 32.5 31.4 30.3 29.4 28.4 26.8 23.9
.~
= 3738 I 87.5
~
~
~
89.8
80.2 74.0 68.7 64.1 60.1 56.6 53.4 50.6 48.1 45.8 43.7 41.8 40.1 38.5 37.0 35.6 34.4 33.2 32.1 31.0 30.1 28.3 25.31 37
82.3 76.0 70.6 65.9 61.8 58.1 54.9 52.0 49.4 47.0 44.9 43.0 41.2 39.5 38.0 36.6 35.3 34.1 32.9 31.9 30.9 29.1 26.0 38
~
~
==
0
40
41
I 94.5
96.9
86.7 80.0 74.3 69.3 65.0 61.2 57.8 54.7 52.0 49.5 47.3 45.2 43.3 41.6 40.0 38.5 37.1 35.9 34.7 33.5 32.5 30.6 27.41 40
88.8 82.0 76.1 71.1 66.6 62.7 59.2 56.1 53.3 50.8 48.5 46.3 44.4 42.6 41.0 39.5 38.1 36.8 35.5 34.4 33.3 31.4 28.1 41
Z
~
00 43 1 101.6 93.2 86.0 79.9 74.5 69.9 65.8 62.1 58.8 55.9 53.2 50.8 48.6 46.6 44.7 43.0 41.4 39.9 38.6 37.3
~
44 104.0 95.3 88.0 81.7 76.3 71.5 67.3 63.6 60.2 57.2 54.5 52.0 49.7 47.7 45.8 44.0 42.4 40.9 39.4 38.1
==
0
n 44.3 42.7 41.2 39.9
~
~ 45.3 43.6 42.1 40.7
~
~
47.2 45.5 43.9 42.5 41.1 39.8 37.5 33.51 49

48.1 46.4 44.8 43.3 41.9 40.6 38.2 34.2 50
52
53
17
*For 26" (660 mm) tire outside diameter; gives diameter in inches of equivalent direct-drive wheel. Multiply by pi (3.14) to obtain distance traveled
for one turn of the pedals (in inches).
REAR SPROCKET
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 38
4.78 4.39 4.05 3.76 3.51 3.29 3.10 2.92 2.77 2.63 2.51 2.39 2.29 2.19 2.10 2.02 1.95 1.88 1.81 1.75 1.70 1.64 1.55 1.38
4.35 4.08 3.84 3.63 3.43 3.26 3.11 2.97 2.84 2.72 2.61 2.42 2.33 2.25 2.18 2.10 2.04 1.92
4.49 4.21 3.96 3.74 3.55 3.37 3.21 3.06 2.93 2.81 2.69 2.49 2.41 2.32 2.25 2.17 2.10 1.98
n
=
=:
z
34
35
.1 6.51 5.96 5.51 5.11 4.77 4.47 4.21 3.98 3.77 3.58 3.41 3.25 3.11 2.98 2.86 2.75 2.65 2.56 2.47 2.39 2.31 2.24 2.10 1.88.1 34
6.70 6.14 5.67 5.26 4.91 4.60 4.33 4.09 3.88 3.68 3.51 3.35 3.20 3.07 2.95 2.83 2.73 2.63 2.54 2.46 2.38 2.30 2.17 1.94 35
~
~ 37 I 7.08 6.49 5.99 5.56 5.19 4.87 4.58 4.33 4.10 3.89 3.71 3.54 3.39 3.25 3.12 3.00 2.88 2.78 2.69 2.60 2.51 2.43 2.29 2.05 1 37
~ 38 7.27 6.67 6.15 5.71 5.33 5.00 4.70 4.44 4.21 4.00 3.81 3.64 3.48 3.33 3.20 3.08 2.96 2.86 2.76 2.67 2.58 2.50 2.35 2.10 38
t-4
;401
~
7.65 7.02 6.48 6.01 5.61 5.26 4.95 4.68 4.43 4.21 4.01 3.83 3.66 3.51 3.37 3.24 3.12 3.01 2.90 2.81 2.72 2.63 2.48 2.221 40
o 41 7.85 7.19 6.64 6.16 5.75 5.39 5.08 4.79 4.54 4.31 4.11 3.92 3.75 3.60 3.45 3.32 3.20 3.08 2.98 2.88 2.78 2.70 2.54 2.27. 41
Z
~
~
~
43
44
.1 8.23 7.54 6.96 6.46 6.03 5.66 5.32 5.03 4.76 4.53 4.31 4.11 3.94 3.77 3.62 3.48 3.35 3.23 3.12 3.02 2.92 2.83 2.66 2.38
8.42 7.72 7.12 6.62 6.17 5.79 5.45 5.15 4.87 4.63 4.41 4.21 4.03 3.86 3.70 3.56 3.43 3.31 3.19 3.09 2.99 2.89 2.72 2.44
I 4344
o
~ 46 1 8.80 8.07 7.45 6.92 6.45 6.05 5.70 5.38 5.10 4.84 4.61 4.40 4.21 4.03 3.87 3.72 3.59 3.46 3.34 3.23 3.12 3.03 2.85 2.551 46
~ 47 8.99 8.24 7.61 7.07 6.60 6.18 5.82 5.50 5.21 4.95 4.71 4.50 4.30 4.12 3.96 3.80 3.66 3.53 3.41 3.30 3.19 3.09 2.91 2.60 47
~
'-"
9.12 8.42 7.82 7.30 6.84 6.44 6.08 5.76 5.47 5.21 4.98 4.76 4.56 4.38 4.21 4.05 3.91 3.77 3.65 3.53 3.42 3.22 2.88
9.30 8.58 7.97 7.44 6.97 6.56 6.20 5.87 5.58 5.31 5.07 4.85 4.65 4.46 4.29 4.13 3.98 3.85 3.72 3.60 3.49 3.28 2.94
.., 9.65 8.91 8.27 7.72 7.24 6.81 6.43 6.09 5.79 5.51 5.26 5.03 4.82 4.63 4.45 4.29 4.13 3.99 3.86 3.73 3.62 3.40 3.05
n
~ 9.82 9.07 8.42 7.86 7.37 6.93 6.55 6.20 5.89 5.61 5.36 5.12 4.91 4.71 4.53 4.37 4.21 4.06 3.93 3.80 3.68 3.47 3.10
~
00
v. 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 38
~
~ *For 670 mm (26.4") tire outside diameter; gives distance traveled in meters for one turn of the pedals.
I
~
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24" WHEEL GEAR CHART*
~
REAR SPROCKET
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 38
n
=
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~
=
~
~
~
~
==
o
z
~
00
~
==
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n
=
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~
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 38
REAR SPROCKET
11 12 13. 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 38
=
>
~
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~
=
~
~
~
~
o==
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1-3
00
~
==
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~
.... SUTHERLAND'S HANDBOOK FOR BICYCLE MECHANICS
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REAR SPROCKET
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 38
n
.>=.
Z
~
=
~
~
~
~
==
o
z
~
00
~
==
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n
=
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11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 38
REAR SPROCKET
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 38
=
>
~
Z
~
=
~
~
~
~
~
o
z~
rIJ.
~
=
o
~
=
~
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11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 38
*For 500 mm (19.7") tire outside diameter; gives distance traveled in meters for one turn of the pedals .
..
~
~
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00
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REAR SPROCKET
9 10 11 12 14 15 17 30
-=
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~
~
~
~
,-....
~
o==
z
~
00
~
o==
~
~
~
~
'-'
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
REAR SPROCKET
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
n
=
>
~
z
~
=
~
~
~
~
==
o
z
~
rI1
~
==
o
n
~
~
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10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32
*For 400 mm (15.7") tire outside diameter; gives distance traveled in meters for one turn of the pedals.
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,..
INDEX Bicycle
assembly check list 16-9
Abbreviations 16-1 parts names 16-10
Adjustable wrench 0-1 R Block British for multispeed freewheel, see freewheel
Alignment Bottom bracket
of bearings 0-12 ball size 3-1
bottom bracket 0-16 cottered crank
hub 0-13,0-7 axle sizes 3-4 thru 3-7
head tube 0-14 cotter sizes 2-0
fork crown 0-15 cotterless crank
steer tube 0-15 axle
Alloy 0-7, O-X interchangability chart, bolt type 3-14 thru 3-18
crank bolts 2-6 bolt and nut threads 2-1
Aluminum 0-7 tapers 2-7
Anneal ing O-X type 3-10, 3-19 thru 3-21
Assembly checklist bicycle 16-9 markings 3-19, 3-28
Axle maxy-type 3-19
bearing alignment 0-12, 10-7 Campagnolo 3-28
bottom bracket extractors 2-2, 2-3
bearing race diameter 3-8 fit and installation 2-2
ball track 3-8 sizes 2-2, 2-3
cottered 3-4 thru 3-9 cups 3-1, 3-2, 3-8, 3-9, 3-12, 3-13, 3-19
cotterless 3-R thru 3-31 facing tool, use of 0-16
cup compatibility 3-R, 3-9, 3-28 one-piece crank 3-3
one-piece 3-3 spacer 3-13
end factor 3-10 thru 3-12 shell width 3-6, 3-19
front hub 10-1 thru 10-3 tapping stripped threads 0-16
rear hub thread sizes 3-1
freewheel clearance 5-7, 10-4 thru 10-6 Books, list 16-5
thread size 10-6 Brake, caliper or rim
thread chaser center-pull 13-7 thru 13-9
markings on 10-10 cantilever 13-12 thru 13-15
use of 0-10 delta 13-9
non standard shoes 13-16
Ball bearing see bearing non standard straddle cables 13-16
Ball cage British fnr ball retainer roller cam 13-10, 13-11
Ball retainer sizes 10-1 u brakes 13-9
Ball sizes side-pull 13-1 thru 13-6
hubs 10-1 British see also nationality, standard, thread
hottom bracket 3-1 standard wire guage 11-3, 16-6
freewheel 4-1
headset 14-8 thru 14-13 Cable, indexing 5-1, 5-2, 5-3, 5-4, 5-5
Bead see tire cable casing 5-4, 5-5
Bearing casing caps 5-4, 5-5
aligning races 0-13 thru 0-16 Cadence pedal speed in RPM, see gear size
bottom bracket Cartridge
retapping 0-16, 0-17 bearing
sizes 3-1 thru 3-5 bottom bracket 3-1, 3-22 thru 3-27
widths 3-5 hubs 10-7 thru 10-9
cartridge 0-12,3-22 thru 3-27, 10-7 thru 10-9 Chain
headset alignment 10-5
mounting 0-14, 0-15 length 5-3
o rings 14-13 recommendations, indexing 5-7, 6-1, 7-1, 8-1, 9-1
sizes 14-8 thru 14-13 size 2-16
hub Changer see derailleur
cartridge 10-7 thru 10-9 Chainline 10- 5
rear, mounting 0-13 Chainring see chainwheel
sizes 10-1 Chainstay, tube size 15-1
life 0-13 Chainwheel
mounting 0-13 thru 0-17 alignment 10-5
retainers 10-1 measuring 2-9
sealed 0-12,3-22 thru 3-27, 10-7 thru 10-9 bolts 2-9
types and design 0-12 interchangeability 2-10 thru 2-15
16-24 1990 rev.

Clincher see tire
Cluster see freewheel
INDEX
Cog see sprocket Freewheel
Cone wrench sizes 10-2 clearance 5-7. 10-5
Conversion see units derailleur capacity see derailleurs
Cotters, sizes 2-0, see also bottom bracket interchangability 4-1
Cotterless see bottom bracket markings 4-2
Crank mounting 4-3
fit on axle 2-4 thru 2-7 removering 4-4
installing cotterless 2-4 removers 4-4 thru 4-9, 10-10
interchangeability 2-4 thru 2-8 single-speed 4-30
low profile vs high profile 2-8 spacer 4-3, 4-13, 4-15, 4-19. 4-2 L 4-23. 4-25. 4-27
one-piece 3-3 spacing, frewheel-dropout 5-7
pedal sizes and markings 1-1 sprocket
Crossing pattern see spokes assembly and removal 4-4, 4-10
Crown race cutter, use of 0-15 interchangeability 4-11 thru 4-29
Crown race sizes 14-1, 14-2, 14-3
Cutting operations 0-8 thru 0-11 Gauge
wire size designation 11-3, 16-6
Derailleur, indexing derailleur see Indexing fork tip alignment tool 0-13
Campagnolo Section 6 pressure conversion 12-14
front 6-6 Geared hub
rear non-indexing 6-5 fixed gear 4-30
Sachs-Huret Section 6 page 6-7 gear ratios 16-14
front 6-10 Gear hanger derailleur mounting lug 15-2
rear non-indexing 6-9 Gear size
Shimano Section 7 formula 16-14
front 7-9 thru 7-11 charts 16-15 thru 16-23
rear non-indexing derailleurs 7-7, 7-8 27" wheels, back cover
Simplex derailleurs 9-5, 9-6 Gooseneck see stem
SunTour Section 8 Grinding
front 8-10 thru 8-13 bearing production 0-12
rear non-indexing 8-8, 8-9 tool sharpening 0-9
Handlebars 14-15
Development, metric gear formula 16-14 Hanger
Drilling 0-9 derailleur mounting lug 15-2
Dropout alignment 0-13 British for bottom bracket
English see standard, nationality, thread Hand tools, list of essentials 0-18, 0-19
ETRTO European Tire and Rim Technical Organisation Hardening 0-7, 0-8
Headset
Facing, head tube 0-10, 0-14 aluminum 14-3
Fender eyelet size 15-2 bearing alignment 0-14
Filing 0-11 binding 14-3, 14-5
Fit see also part name installing 14-3 thru 14-5
classes of 0-2 markings 14-2
thread 0-2 mixing parts 14-4
tolerances 0-11 o rings 14-13
Fixed cup see bottom bracket cups press fit 14-2
Fixed gear hubs 4-30 size chart J 4-1, 14-6 thru 14-13
Fork tandems 14-2
rake 15-3
replacement 15-3 Head tool 0-14, 0-15
Four-speed, freewheels 4-16, 4-24 Head tube 15-1
Fractions Heat treating 0-7
conversion 16-12, 16-13 High pressures British for high pressure wired-on tires, see tire
in tire marking 12-3 Hooked bead tire type 12-1 thru 12-4
French see also nationality, standard, thread Hooked edge rim type 12-1 thru 12-4
freewheel threads 4-1 Hub
wire gauge sizes 11-3, 16-6 ball sizes 10-1
Frame bearing alignment 0-13, 10-7
illustration 16-10, 16-11 flange height 11-1, 11-2
tube size 15-1 geared see geared hub
measuring 11-4, 11-5, 11-7
rev. 1990 16-25

,...
INDEX bottom bracket

markings 3-3
Indexing use thread chasing 3-1
adjustments fixed gear 4-30
derailleurs 5-3, 5-11, see also various makes below Lubrication
frames 5-3 machining and cutting operations 0-8, 0-9
checklist 5-1 Materials 0-7, 0-8
shift lever see also various makes below Metric see units, threads
brazed-on bosses 5-6 Milling 0-10
trouble shooting 5-8 bottom bracket tool 0-16
trouble shooting 5-10 head tube 0-14
various makes Mud guard British for fender 15-2
Campagnolo Syncro and SyncroII Section 6 Nationality see also units, threads, standards
Syncro levers 6-1, 6-2, 6-3 of parts 0-4
lever inserts 6-3 Nipple see spoke nipple
rear indexing derailleur 6-4 Numbered drill sizes 16-8
Grip Shift 9-1 One-piece crank 3-3
Mavic 9-3 thru 9-5 One-speed
Sachs-Huret ARIS Section 6 page 6-7 fixed gear hub 4-30
chain 6-7 freewheel 4-30
rear indexing derailleurs 6-8
shift levers indexing 6-8 Parts see also part name
Shimano Section 7 of bicycle 16-10, 16-11
dropout recomendations 7-3 Pedal 1-1
chain recommendations 7-1 Pedal arm see crank
SIS levers 7-2 Pilot
Rapidfire levers 7-3 in bottom bracket tool 0-10, 0-16
rear indexing derailleurs 7-4 thru 7-6 hole, use of 0-9
front indexing 7-9 Pitch of chain 2-16, see also threads
SunTour Section 8 Pressure, units conversion 12-14
Accushift levers 8-2, 8-3 psi pounds per squareinch, unit of pressure 12-14
dropout recomendations 8-4
rear indexing derailleurs 8-5, 8-6, 8-7 Quality control 0-11
Inflation 12-14 Quick release 10-10
Inner tube Race see bearing
fit 12-1 Radial bearings 0-12
inflation 12-14 Rake, fork 15-3
ISO· International Standards Organisation Reaming 0-10
background 0-5, 0-6 stripped bottom bracket threads 0-16
bottom bracket 3-1, 3-5 with head tool 0-14
crank taper 2-7 Rear hub dimensions 10-4 thru 10-6
crank cotters 2-0 Retainer sizes 10-1
freewheel 4-1 Rim
pedal 1-1 brake radius 12-6, 12-8 thru 12-13
rim 12-2, 12-8 thru 12-13 rim cross sections" classic 12-7
spokes 11-3 measuring 12-5
summary of standards 16-2 thru 16-4 size and tire fit 12-1,12-3
tires 12-1 thru 12-14 size chart 12-8 thru 12-13
Italian see standard, nationality, thread spoke length correction factors see spokes
Jauge de Paris French wire gauge designations 11-3, 16-6 Roller chain 2-16
JIS Japan Industrial Standard 10-6, 14-1
Saddle pillar 15-4
Left-handed threads Safety, in cutting operations 0-9, 0-10
markings on 3-2, 16-1 Sealed bearings 0-12,3-22 thru 3-27, 10-7 thru 10-9
use on Seat tube 15-1
bottom bracket 3-1 Seat post 15-4, 15-5
crank extractors 2-2 Sew-up tire with inner tube sewn in 12-1, 12-14
freewheel sprockets 4-11, 4-16, 4-17, 4-29 Sharpening 0-9
fixed gear lockrings 4-30 Shift levers see indexing
pedals 1-1 Side-pull brake 13-1
Length see units Single-speed
Lockring fixed gear hub 4-30
freewheel 4-30
16-26 1990 rev.

,...
Spanner British for wrench

Spindle see bottom bracket axle
INDEX
Spokes Terminology
large flange hubs 11-1 bike parts, in six languages 16-10, 16-11
lengths Section 11 Thread
calculating lengths 11-4 chasing 0-10
hub diameters 11-4 BRP tool markings 10-10
first step charts for various hubs 11-4 thru 11-13 cutting 0-9
second step charts for spoke patterns gauge 0-3
27", 28", 700C 11-14 measuring 0-3
26", 700D, 650 11-30 sizes see part name
24", 22", 600, 550 11-40 standards 0-2
20" 11-50 Three-speed, freewheels 4-16, 4-24
18" 11-58 Thrust bearing 0-12
16", 400 11-60 Tip adjusters 15-2
14" 11-62 Tire
12" 11-64 ISO size designation 12-3
10" 11-65 markings 12-3, 12-4
third step charts for rim listings measuring 12-5
27", 28", 700C 11-16 thru 11-29 rim fit 12-1, 12-2
26", 700D, 650 11-32 thru 11-39 sizes 12-6 thru 12-14
24", 22", 600, 550 11-42 thru 11-49 types 12-1
20" 11-52 thru 11-56 width 12-1, 12-2
18" 11-59 Tolerance 0-11 see also part name
16", 400 11-61 Toe Clip 1-1
14" 11-63 Tool
12" 11-64 bottom bracket 0-16
10" 11-65 cone wrench 10-2
sew-ups see end of listings for nearest inch size crown race cutter 0-15
calculating rim correction factors 11-66 essential, list of 0-18, 0-19
length formula 16-8 fork end alignment 0-13
nipple 11-3 head 0-14
number of spokes 11-67 Tool steel 0-8
radial patterns 11-2 TPI threads per inch 0-3
threads 11-3 Track hub 4-30
Tube
Sprints British for sew-ups frame tube size 15-1
Sprocket inner tube
chainline 10-5 fit 12-1
freewheel inflation 12-14
assembly 4-10, 4-11 Tubulars British for sew-ups 12-1, 12-14
interchangeability 4-11 thru 4-29 Tyre British for tire
removal 4-10
Standard see also units, threads Units, conversion scales
de facto 0-5, 14-1 length 16-12, 16-13
ISO see ISO pressure 12-14
national 0-4 weight 16-7
thread profile 0-2 wire sizes 11-3, 16-6
tire size designation, 12-3
wire sizes 11-3, 16-6 Valve hole sizes 12-14
Steel 0-7, 0-8
Steering column Weight conversions 16-7
diameter 14-14, 15-1 Wheel building see spokes
tapping 0-15 Wheelsmith spoke length calculator 11-1, 11-4
threads 14-1 Wheel, grinding 0-10
Stem, diameter 14-14, 14-15 Wire gauge sizes 11-3, 16-6
SWG Standard Wire Guage 11-3, 16-6 Work hardening 0-8
Symbols 0-2 Wrench, list of essentials 0-18
Tapping
bottom bracket 0-16
steer tube 0-15
drill sizes 16-8
use of taps 0-9
rev. 1990 16-27

Bicycle Inventory / Sales Tag (4-1/4" x 10-5/8")
See Imprinting section for special Bike description at top is List accessories sold Easy to read 1" number at-
format and messages easytoreadwhentagisin with bi e here taches to box or bicycle
to go here tag rack or file cabinet with transfer tape attached.
• 0979
YOUR SHOP NAME HERE
123 Main Street
Your Town, Your State 12345
Phone: (111) 123-1234
Assembler writes in serial Assembler initials Check here when tested New! Column for labor makes
number here work here it easier to charge for time-
consuming bike assembly and
accessory installation
4 Parts-white copy showing in- Easy-Put bike boxes directly into If this system saves you one (1)
dicates bike is in box; yellow copy storage. Boxes that are already in- minute per bike (I think it will save
showing indicates it's assembled; ventoried have big 1" self-adhesive much more) it's worth having. Say
pink copy showing means it's sold. number attached. Boxes without you sell 600 bikes, that's 600
Hard copy is for your file. Has com- number need to be inventoried. minutes or 10 hours. If your shop
plete record all filled out. Bottom tear-off stub attaches to rate is $20.00/hour, that's $200.00
bike when assembled for positive saved!
Fast-when sale is made, form is
already filled out-just fill in identification. There is space to Serves two functions: 1.) It's an in-
customer name and address and write in status of bike. ventory tag to help you keep track of
total. Fits in repair tag rack for planning stock. 2.) It's a sales slip. The
customer gets a complete descrip-
set-ups and repairs-makes the best
use of mechanic's labor time. tion of bike with serial number and
accessories.
Layaway payment record on back.
Layaway Tag
(4-1/4" x 10-5/8")
Designed to work with
Sutherland's Bicycle C
Inventory Tags
..J
Simplifies layaways-
2 copies plus ID tag
o
DO
en
• Customer gets top (blue) copy.
• Attach canary copy to
Sutherland's Inventory/Sales
tag. Prevents the bike from being Make it easy for your
sold again. customers to buy that
• Sold tag with name goes on the bike! Turn "lookers"
bike or item. (Fold the customer into buyers. Each
name so it doesn't show if it's a order comes with two
surorise oresentn tent signs for your
counter.
Back has place to list alterations
and installations
New Type Double A Repair Tag (8" x 9-3/16", 3-Part)
Write more-sell more
Now Sutherlands has combined the Type A and Type B

repair tags into one easy to use tag. Sutherland's New
tag, Type AA, is more spacious than the smaller tags.
Call and ask for free samples. We will be happy to send
you a few.
Tear off stub goes on

the bi ke so you can Find the bike by the
find the bike by the easy to read 1"
customer's name number
o
NAME _
H2 0 Bottle 1 3 27 26 24 20 16 HOOK PR<NSED

COLOR # OUT /
Tire & Tube NARROW
OR Freewhl.
YOUR SHOP NAME HERE

123 Main Street
Your Town, State 12345 • Phone: (111) 123-1234 Carbonless
Your message here.
3 parts-customer
gets a copy of the
Tune Up 10+
work to be done
Camp. O'Haul 1 10+
Install Tire R
Install Tube R
Install Cable FB RB FD RD
Adjust Hand Brake R
True Wheel R
Folds to fit in
Respoke Wheel R Sutherland's Tag
Adjust Derail R Rack with the full
Adjust Hub F 1 3 R customer name
OHaul Hub F 1 3 R
showing
Adjust: Head Bottom Bracket
OHaul Head Bottom Bracket
INSTALL Plenty of space to

write additional work
SAVE OLD PARTS YEsD NoD
MECHANIC SIGN OFF

Customer signs off
x ~=--..--for recommended
work refused
EST. BY AMT. $
NOT RESPONSIBLE FOR GOODS LEFT
--SUTHERLANO'7§-OODEFfoESK----- 0--(800) 248-2510

o
(415) 547-3966
01ZLl:O
Special Order Tag
768758
(4-1/4" x 10-5/8")
YOUR SHOP NAME HERE
Make those special orders 123 Main Street
easy to handle. Save time- Phone: (111) 123-1234 Item listed here
End special order confusion.
o
3 Parts-Customer copy SPECIAL
ORDER
Shop copy
Postcard and 10 stub TOTAL
DEPOSIT
CUSTOMER BALANCE DUE

Top copy- COpy
Customer fills out
name and address,
signs name
Pick-up date
Second copy-
Big 1" number
Ordering info here. 763758
Shows in tag rack makes it
or file easy to find
'It
Third copy- r:;OR;r;;DE'ru'RE~DFrn,RO;:;;-;M--~-----t=DAT;-;-E=OR=DE=RE-;::-D ---Ii
-f:,-PO"""N7."::UM=SE=R-I77;NO=TIF='E:::-D l''''''cu=ST=OM=ER,,"","",NA=M:::-EI =Plea...,..se-;::"P'-,..,,'nll-------
When item comes in, 7687 58 DATE RECEIVED INVOICE NO PICKED UP _ I :x

tear off orderi ng ::::::::.::::::::::,:::=::::.::::.::::::.::::::::::::::::::::::=::~ 17;cu;MST'ru'OM;r;ER;"""OSI;r:";:GN;;"TAT;mURc
E --------
info and drop postcard
in the mail
PLACE !i-;;-;DA;;-;yp;;-;;HO'""NE,...--------~==;::---
YOUR SHOP NAME HERE
123 Main Street
STAMP !,1.C;.:~7C.~.~MSPErnRSffiON;:;----------",=---
Your Town, Your State 12345 HERE !IB·~g.·. • • •HII.IIIIUI-__
II
Phone: (111) 123-1234
Dear Customer, : l----------I--+-----l
The merchandise we ordered for you has arrived o II
I :----------I--+-----l
I.
CPleasePickitupassoonasPossible
II----------I--+-----l
CWewilldeliver
I I----------+--+-----l
II
C , ,_ _ POST ! :-----------+--+-----1
Thank you for your patronage I
CARD !! T_Ot_AL-+-_+---1
: I OEPOSIT
II------B-A-LA-N-CE-O-U-JE--+----.1
I
Back of postcard
!
SPECIAL INSTRUCTIONS
1..- o .......
Large stub attaches to bike or part so it doesn't get sold accidentally to the wrong person.
Imprinting ~~4385
6DJ0771
Not Responsible For Goods Left Over 30 Days. 6 a0771
Special imprint formats available at
no additional cost. * Save time and
money with special messages. Here
are some helpful formats:
o
PALO ALTO BICYCLE
171 University Avenue
Palo Alto, CA 94301
Phone: (415) 328-7411
!KkIay maximum layaway. 10% restocking fee charpd,
CYCLE WORLD
8627 Reseda Blvd, • Northridge; CA 91324 Extra lines for Extra line for
Phone: (818) 349-6900
Storagechargesof$1/day storage charges layaway message
will apply 10days after completion
Not Responsible For Goods Left Over 30 Days 6 aa781

TOWNER'S
710 University Avenue
Rochester, NY 14607 • Phone: 271-4553 Extra lines for
Hours: 10-8 Mon. thru FrI., Sat. 10-6, Sun. 12-6
Call for winter hours. store hours
BIKE AMERICA
2 stores
o Elk Grove 0 Sacramento
6 aa790
9032 Elk Grove Blvd. 6531 Bruceville Rd.
Not Responsible For Goods Left Over 30 Days, 685-5021 423-3035
Sonny's
BICYCLE WORLD Extra line
6103-A Wesley
Greenville, TX 75401 for name
Phone: (214) 454-3030
2 stores and
Not Responsible For Goods Left Over 30 Days 6 a0795 extra message SCHWINN CYCLERY
ORMOND SCHWINN VOLUSJA SCHWINN
2 stores 205 S. Yonge (US #1) 3132 S. Ridgewood (US #1)
BYRD'S BICYCLES, INC. Ormond Beach· 677-2425 So. Daytona· 756-0008
11314th St. N, 1506 54th Ave. N. lay-away deposits are non-refundable.
St. Pete, FL 33701 St. Pete, FL 33704 * Logos and trademarks can also be printed ($35.00 one-time
Ph. 896-3791 Ph,522-5606 set-up charge). If you have special artwork you would like to
include, please call for our logo guidelines sheet.
Sutherland's Bicycle Repair Tags (4-1/4" x 10-5/8", 2-Part)
Neat and efficient-saves time and money • Easy to fill out 2 Types: Type A-Service work prelisted
and use-just circle items • Makes work flow smoothly Type B-Service work not listed
• Reduces customer complaints • Numbered claim check
for customer • Big one-inch-high numbers on bike tag Type B
locates bikes quickly. Two complete copies. of work done
Type B is the same as
Type A except service
work is not listed.
ORDER DESK (800) 248-2510 (415) 547-3966
YOUR SHOP NAME HERE Sutherland's REPAIR TAGS make

123 Main Street
the work flow smoothly through
Phone: (111) 123-1234 your shop. New work is quickly
"booked," saving on mechanic's
Type A ----11-+-11--+--17 expensive labor time. Accessor-
ies that are likely to come in on
SMOCOPARTS ,"sU "00 ~_I- ~!; the bike are listed on this tag-
1'-- Check Over
ES" '"T$ §~ you simply circle it. This way, a
61'i~'l:.lsUNI"ONITUESIWEOTHURI [-
Service work is bike that comes in with a pump
prelisted. Simply goes out with a pump.
circle repair to
be done. Saves - Each tag includes the original
time. Use as a and one copy. When the repair is
service checklist Description of bike, finished you have two complete
~and parts it came in records of the work done; one for
---------1r--+-----tf-~____1 0 w
with, goes here.
....,..' --=-':'INS=TALL--,==--.c::..::..:.:.:-=-=='----II--+----tl----tl----I ~ ~
+
your customer and one for your
file. The bottom copy is printed
on heavy stock and includes a
tear-off claim check and a tear-off
Place for mechanic job tag which can be attached to
to sign off on j O b " SAVE OLD PARTS YES 0 NO 0 " _ _I~I----I ~~~ ~~ the bike with ordinary shower cur-
i'MECHANIC SIGN OFF
,.-
~ _
tain hooks (not supplied). The
large red numbers on the job tag
' t ~~
623a
PI ace f or es t Ima e -~SI BY AMI $ TOTAL
f-
~~ can easi Iy be seen across the
b~t~~ I I I
SUN. MON. ITUES WED. THURI FR!. I SAT II::~ ----~I---J-____ll-~ ~ ~ ~
room. Additional parts and labor
can be listed on the back of the
:=::~ ~ 0 11-:--allS--tt--+--I ~ :
fLO
YESO
tag.
Big 1"
time number
finding saves
bike ---+-- UQJ x --;r
Keep your repair tag work orders
all in one place. Use our special
V
Customer claim ~--------------.----------------------------------
check has your name, Not Responsible For Goods Left Over 30 Days. 586230
~5UN/-/n"'l~/-/-/s,4:.::-/ TAG RACKS or simply hang them
on a hook or nail. Group them
EST BY AMTS _
address, phone and YOUR SHOP NAME HERE MEN'S LADIES WHl F R MISC.
together according to the way the
message. See _ _-+-__ 123 Main Street NO GOODS RETURNED WITHOUT THIS CLAIM CHECK work is to be finished. You'll be
Imprinting for Your Town, Your State 12345
other ideas Phone: (111) 123-1234
able to see your work load at a
glance and avoid overbooking.
Room on back for more work to be listed
Sutherland's • Entirely new, in-depth section with the latest rim types.
Handbook covering index shifting. For the
first time, accurate informa-
Accurate numbers for your
spoke-length computer have
for Bicycle tion on how to adjust, service been added, over 65 pages.
and repair index systems from • Plus the tables and charts
Mechanics Shimano, SunTour, Sachs, and Sutherlands is famous for-
Campy. Also a troubleshoot- coveri ng Bottom Bracket
ing chart that will save hours axles, Stem and Headset
"The Mechanics on repairs! sizes, Chainwheel sizes, Brake
sizes and much, much more.
• Revised spoke length tables
Bible"
Racks for Sutherland's Tags
All of our tags fit in these racks
Your work load at a glance • For most efficient work load
scheduling • Prevents under- and overbooking of repairs and
new bike set-ups • Handy dividers keep work organized
• Locate customer tags quickly
For efficient service management, you can't take on more work for that
use Sutherland REPAIR TAG RACKS day.
to hold and organize your repair tags These sturdy grey painted steel
and inventory tags. Three (3) racks racks will last a lifetime. Outside
are pictured here. Tags are inserted dimensions: height 44", width 9",
horizontally with numbers showing depth 1-1/16". Pocket dimensions:
in the 40-slot rack. height 2-7/16", width 8-5/16", depth
For repairs: When a customer 3/8". Shipping weight is 12-3/4
File Cabinets comes in for his bike you can put
your hand on the tag quickly, tell
pounds.
how much the repairs cost and then Divider Cards

• Nylon guide for smooth go get the bike while they write their Heavy-duty varnished DIVIDER
operation check. CARDS (sold separately) aid in
• Will hold about 450 completed grouping tags according to the day
forms For new bike set-ups: Pull the inven-
tory tag for the bike to be set up and the work is to be done. These cards
• Outside dimensions- are pri nted in bold, easy-to-read let-
7-3/16" x 9-1/2" x 16"D put it in the rack along with the
repai r tags. ters. Each set contains seven day
• Convenient and good-looking cards (SUNDAY, MONDAY, TUES-
file for storing inventory tags When you've promised all the work DAY, etc.), seven DONE/FULL cards,
• Your bike inventory at your you can for any day, put in the FULL and seven MORNING/AFTERNOON
fingertips sign. During the busy summer cards. 4-1/4" x 7-3/4" long, the
• Your model mix at a glance season it's easier to point to that cards fit into the same slots as the
• Simplifies ordering new bikes FULL sign than try to explain why repai r tags.
File Guides
• Arrange your inventory tags by
model and frame size
• Simply write in model and size
• Made of card stock for long use
• Just the right size for your
inventory forms
• 100 to box
To Order Call:
Sutherland's Bicycle
Shop Aids, Inc.
800-248-251 0
FAX: (415)655-5445
Dear People,
I have some suggestions that will improve your book:
Technical Information: Source of
Page Corrections - Additions Information
Name and Address
Suggestions: _
_ _ _ _ _ _ _ _ _ _ _ _ Phone: _
Dear People,
Name and Address
Suggestions: _
Phone: _
Dear People,
Name and Address
Suggestions: _
_ _ _ _ _ _ _ _ _ _ _ _ Phone: - - - - ~--------- ~___J

NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
BUSINESS KEPLY MAIL

FIRST CLASS PERMIT NO. 2612 BERKELEY, CA
POSTAGE WILL BE PAID BY ADDRESSEE
SUTHERLAND'S BICYCLE SHOP AIDS

BOX 9061
BERKELEY, CALIFORNIA 94709-9980
11.1 ••• 1•• 11 ••• 111 ••• 1.1 •• 1.1 •• 1.1 •• 1•• 1.11 •••• 1.1.1
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
BUSINESS REPLY MAIL


BOX 9061
11.1 ••• 1•• 11 ••• 111 ••• 1.1 •• 1.1 •• 1.1 •• 1•• 1.11 •••• 1.1.1
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
BUSINESS KEPLY MAIL


BOX 9061
11.1 ••• 1•• 11 ••• 11111.1.1'11.1'11.1'11'11.11111111111

Please send current price list to:
Shop name or your name:. _
Address: _
Phone: ( ) _
area code
Attention: _
................................................................
' .

Shop name or your name: _
Address: _
Phone: ( ) _
area code
Attention: _
................................... ~ .

Shop name or your name: _
Address: --------
Phone: ( ) _
area code
Attention: . ------- _
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
BUSINESS KEPLY MAIL


BOX 9061
11.1 ••• 1•• 11 ••• 111 ••• 1.1 •• 1.1 •• 1.1 •• 1•• 1.11.1 •• 1.1.1
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
BUSINESS KEPLY MAIL

SUTHERLAND'S BICYCLE SHOP AIDS'

BOX 9061
11.1.1.1 •• 11 ••• 111 ••• 1.1 •• 1.1 •• 1.1 •• 1•• 1.11 •••• 1.1.1
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
BUSINESS KEPLY MAIL


BOX 9061
11.1.111 •• 11.,.111 ••• 1.1 •• 1.1 •• 1.1 •• 1•• 1.1111111.1.1

'.
REAR SPROCKET
, 63.0 58.2 54.0 50.4 47.3 44.5 42.0 39.8 37.8 36.0 34.4 32.9 31.5 30.2 29.1 28.0 27.0 26.1
65.3 60.2 55.9 52.2 35.6 34.0 32~6 31.3 30.1 29.0 28.0 27.0
69.8 64.4 59.8 55.8 52.3 46.5 44.1 41.9 39.9 38.0 36.4 34.9 33.5 32.2 31.0 29.9 28.9 .!-/.'-I L/_ ~ L.O.L LLf.O ~"",vl 07.1.1 n
72.0 66.5 61.7 57.6 54.0 50.8 48.0 45.5 43.2 41.1 39.3 37.6 36.0 34,,6 33.2 32.0 30.9 29.8 28.8 27_ ~ 27.0 25.4 7~·7'k_32... ~
~
76.5 70.6 65.6 61.2 57.4 54.0 51.0 48.3, 45.9 43~7
." 41.7 39.9
. . 36.7
38.3 . .35.3
. 34.0 32.8 31.7 30.6 29. «5 . 28.7 27.0 24~134i
· Z
:;;
~ 78.8 72.7 67.5 63.0 59.1 55.6 52.5 49.7 .47.3 45.0 43.0 41.1 39.4 37.8 36.3 35.0 33.8 32.6 31.5 30. .::5 29.5 27.8 74 .2 35 ;
tjJ
83.3 76.8 71.4 66.6 62.4 58.8 55.5 52.6 50.0 47.6 45.4 43.4 41.6 40.0 38.4 37.0 35.7 34.4 33.3 32. -'2 31.2 29.4 2b.Jj 37 J ~
85.5 78.9 73.3 68.4 64.1 60.4 57.0 54.0 51.3 48.9 46.6 44.6 42.8 41.0 39.5 38.0 36.6 35.4 34.2 33. -=t 32.1 30.2 ~7.0 38 ~
o
90.0 83.1 77.1 72.0 67.5 63.5 6C.0 56.8 54.0 51.4 49.1 47.0 45.0 43.2 41.5 40.~ 38.6 37.2 36.0 34. 8 33.8 31.8 2~'lI40 I ~
, 92.3 85.2 79.1 73.8 69.2 65.1 61.5 58.3 55.4 52.7 50.3 48.1 46.1 44.3 42.6 41.(\) 39.5 38.2 36.9 35. '7 34.6 32.6 29.1 41 ~
~
96.8 89.3 82.9 77.4 72.6 68.3 64.5 61.1 58.1 55.3 52.8 50.5 48.4 46.4 44.7 43.<)l 41.5 40.0 38.7 37. ~ 36.3 34.1 ::;U.ol 43 I g
99.0 91.4 84.9 79.2 74.3 69.9 66.0 62.5 59.4 56.6 54.0 51.7 49.5 47.5 45.7 44.ID 42.4 41.0 39.6 38.:3 37.1 34.9 3~1L44J ~
~
~
103.5 95.5 88.7 82.8 77.6 73.1 69.0 65.4 62.1 59.1 56.5 54.0 51.8 49.7 47.8 46.0 44.4 42.8 41.4 -- ~ ,..,..,.. -- - r~'. 'II .1 I ~
105.8 97.6 90.6 84.6 79.3 74.6 70.5 66.8 63.5 60.4 57.7 55.2 52.9 50.8
'''".~<~ ~. V" .':" , .,"' ~': /~/: '
110.3 101.8 94.5 88.2 82.7 77.8 73.5 69.6 66.2 63.0 60.1 57.5 55.1 52.9 50.9 49.0 47.3 45.6 44.1 42.-:;7 41.3
42.2
117.0 108.0 100.3 73.9 70.2 66.9 63.8 61.0 58.5 56.2 54.0 52.0 50.1 48.4 46.8
~
119.3 110.1 102.2 89.4 84.2 75.3 71.6 68.1 65.0 62.2 59.6 57.2 55.0 . v_=
~ ~~=-;!j =: --~ . ,: ,,- . .~
:~~»' ~ Jllb-~
=-_ ~ ""
123.8 114.2 106.1 99.0 92.8 87.4 82.5 78.2 74.3 70.7 67.5 64.6 61.9 59.4 57.1 55.0 53.0 51.2 49.5 47.~ 46.4 43.7 55
126.0 116.3 108.0 100.8 94.5 88.9 84.0 79.6 75.6 72.0 68.7 65.7 63.0 60.5 58.2 56.0 54.0 52.1 50.4 48.~ 47.3 44.5 56
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34
,,, (68.6mm) tire outside diameter; gives diameter in inches of equivalent direct-drive wheel. Multiply bipi (3.14) to obtain distance traveled for ~ne tum of the pec::=:=:3- als
:hes).

Sutherlands Handbook - 5th Edition

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Sutherlands Handbook - 5th Edition

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With thanks to the following people and organizations:

My father, William H. Sutherland

Virginia Villani Rigida, France Egbert Eghart-Steyr Daimler Puch

INDEXING INDEXING • Checklist • About Indexing • Adjustments • Cable Casing and 5 0

+ Things to watch for; helpful information

ID The easiest way to identify a part

International Standards British Standard Cycle (B.S.C.),

0-2 rev. 1985

. . HOW TO USE THIS BOOK

Parts will be listed as English, French, Italian, Swiss,

0-4 rev. 1985

. . HOW TO USE THIS BOOK

International Standards and de facto Standards

International Standards and de facto Standards (cont.)

. . HOW TO USE THIS BOOK

Working on bicycles requires some basic knowledge of

. . HOW TO USE THIS BOOK

. . HOW TO USE THIS BOOK

. . HOW TO USE THIS BOOK

When threading, the tool should be reversed periodically to

MILLING (FACING) & REAMING

FITS AND TOLERANCES

Unfortunately, poor quality control in manufacturing can

Bicycle bearings are lightly loaded and rotate slowly. This

Cartridge or sealed bearings are finding their way into

Figure 2. Fork ends out of alignment

Figure 1. Fork end alignment

Figure 3. Fork ends aligned

flat milling cutter

BEARING MOUNTINGS (cont.)

Inspect the inside of the bottom bracket shell to make

A bottom bracket shell that has stripped or badly damaged

Figure 10. Installing double-sided

Figure 11. Starting taps

Figure 12. Milling assembly

Figure 13. Milling bottom bracket

Figure 14. Reaming bottom bracket

. . HOW TO USE THIS BOOK

Screwdrivers, pliers, wrenches, hammers and various special

For a shop doing repair work on all makes of bicycles many

0-18 1990 rev.

rev. 1990 0-19

BALL SIZES: Most pedals use 10 to 15 - 5/32" balls

<C CRANK COTTERS

Q *S.R. alloy cottered cranks use extra long cotters.

2-0 rev. 1985

COTTERLESS CRANK EXTRACTORS (cont.)

1 See page 2-1 for drawings of axle types.

3 Extractors: Pre-1982 Stronglight extractors have a

diameter no larger than 20.8mm. If you ever get the bolt

and Deore used a built-in extractor that didn't work very

~~ CRANKS, CHAINWHEELS, CHAIN

Adjust the chainline by selecting the appropriate parts-

FIT BETWEEN COTTERLESS CRANKS AND AXLES

Axle end and crank hole dimensions vary considerably

2-4 rev. 1985

+ When using the interchangeability charts, tighten the

Drawing A Drawing B Drawing C

COMBINATIONS THAT DON'T WORK

USEFUL COMBINATIONS THAT DO WORK

CRANK ARM PROFILES

COMPARISON OF HIGH PROFILE AND LOW PROFILE CRANK ARMS

The crank arm on the left is an old-style crank arm. A newer,