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Zipp 404 Firestrike Service Manual
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Zipp 404 Firestrike Service Manual

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404 Firestrike
Service Manual
GEN.0000000004724 Rev B
© 2015 SRAM, LLC

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Summary of Contents for Zipp 404 Firestrike

  • Page 1 404 Firestrike Service Manual GEN.0000000004724 Rev B © 2015 SRAM, LLC...
  • Page 2 This warranty does not apply to products that have been incorrectly installed and/or adjusted according to the respective SRAM user manual. The SRAM user manuals can be found online at sram.com, rockshox.com, avidbike.com, truvativ.com, or zipp.com. This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance with manufacturers specifications of usage or any other circumstances in which the product has been subjected to forces or loads beyond its design.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS REAR HUB SERVICE ..................................5 TOOLS NEEDED FOR SERVICE ........................................5 REPLACEMENT PARTS ............................................5 REAR HUB EXPLODED VIEW ......................................... 6 REAR HUB BEARING REMOVAL ........................................7 DRIVER BODY BEARING REMOVAL ......................................10 DRIVER BODY BEARING INSTALLATION....................................13 REAR HUB BEARING INSTALLATION ......................................16 FRONT HUB SERVICE ..................................

  • Page 4: Safety First

    SAFETY FIRST! We care about YOU. Please, always wear your safety glasses and protective gloves when servicing ZIPP products. Protect yourself! Wear your safety gear!

  • Page 5: Rear Hub Service

    • Driver body pawls • Driver body leaf springs For part numbers, please refer to the Zipp Spare Parts Catalog in the Support section of www.zipp.com. S A F E T Y I N S T R U C T I O N S Always wear nitrile gloves when working with bicycle grease.

  • Page 6: Rear Hub Exploded View

    R e a r H u b E x p l o d e d V i e w Bearing shield 6903 Bearing Rear hub Spacer tube 6903 Bearing 6803 Bearing Flat washer Inside Diameter Spacer Cap nut Axle Dust Shield Driver body seal 6803 Bearing Driver body...

  • Page 7: Rear Hub Bearing Removal

    R e a r H u b B e a r i n g R e m o v a l Insert a 5 mm hex wrench into the axle while holding the non-drive side cap nut with a 20 mm hex bit socket and socket wrench. Hold the socket wrench in place and use the hex wrench to turn the non-drive side cap nut counter-clockwise to remove it.
  • Page 8 Insert the 17 mm Slide Hammer Bearing Puller slotted attachment through the non-drive side bearing. Align the slotted attachment with the bottom of the bearing, and tighten the slotted attachment to expand the puller inside the bearing. N O T I C E Do not over tighten the slotted attachment.
  • Page 9 Remove the bearing spacer tube. Repeat steps 6 and 7 to remove the drive side bearing. Rear Hub Bearing Removal...

  • Page 10: Driver Body Bearing Removal

    D r i v e r B o d y B e a r i n g R e m o v a l Use your fingers or a pick to carefully remove the pawls and leaf springs. Inspect the pawls and leaf springs for signs of damage or wear. N O T I C E If any of the pawls or leaf springs exhibit signs of damage or wear, replace all of them.
  • Page 11 Insert the 17 mm Slide Hammer Bearing Puller slotted attachment through the outboard bearing. Align the slotted attachment with the bottom of the bearing, and tighten the slotted attachment to expand the puller inside the bearing. N O T I C E Do not over tighten the slotted attachment.
  • Page 12 Use your fingers to remove the Inside Diameter (ID) spacer. Insert the 17 mm Slide Hammer Bearing Puller slotted attachment through the inboard bearing. Align the slotted attachment with the bottom of the bearing, and tighten the slotted attachment to expand the puller inside the bearing.

  • Page 13: Driver Body Bearing Installation

    D r i v e r B o d y B e a r i n g I n s t a l l a t i o n N O T I C E To prevent damage when pressing the bearings into the driver body hub, make sure that the drift contacts both the inner and outer bearing races.
  • Page 14 Insert the ID spacer tube. Align the ID spacer tube with the inside race of the previously installed bearing. ID spacer tube Install a new 6803 bearing into the outboard side of the driver body. SRAM 6803 Bearing press tool Slide a Wheels Manufacturing 6803 bearing press tool onto the threaded rod of the Wheels Manufacturing Press-1 Sealed Bearing Press tool.
  • Page 15 Insert the leaf springs into the spring slots. Orient the long edge of each spring along the inside of the carrier so that it points clockwise. Insert the pawls into the pawl slots. You may need to use a pick or flat blade screwdriver to compress each leaf spring to assist with inserting the pawls.

  • Page 16: Rear Hub Bearing Installation

    R e a r H u b B e a r i n g I n s t a l l a t i o n N O T I C E To prevent damage when pressing the bearings into the rear hub, make sure that the bearing press adaptors contact both the inner and outer races of the bearing.
  • Page 17 Insert a new 6903 bearing into the non-drive side of the hub. N O T I C E The spacer tube can be crushed during bearing installation if it is not aligned with the inside race of each bearing. 6903 Bearing Slide a SRAM 6903 bearing press tool onto the threaded rod of the Wheels Manufacturing Press-1 Sealed Bearing Press tool.
  • Page 18 Insert the axle through the driver body. Make sure the black dust shield is installed on the axle on the outboard side. Make sure the driver body seal is seated into the seal groove on the axle. Slide the axle and driver body, ratchet side first, into the rear drive side hub shell.

  • Page 19: Front Hub Service

    • (2) 6803 Hub bearings For part numbers, please refer to the Zipp Spare Parts Catalog in the Support section of www.zipp.com. S A F E T Y I N S T R U C T I O N S Always wear nitrile gloves when working with bicycle grease.

  • Page 20: Front Hub Disassembly

    F r o n t H u b D i s a s s e m b l y Insert a 5 mm hex wrench into both end caps. Hold one wrench in place while turning the other wrench counter-clockwise to remove the end cap.
  • Page 21 Thread the shaft of the bearing puller into the attachment. Forcefully pull back on the slide of the bearing puller to remove the bearing from the hub shell. Remove the bearing from the slide hammer bearing puller. Use a lint-free rag to remove any existing grease. Slide Hammer Bearing Puller Front Hub Disassembly...

  • Page 22: Front Hub Assembly

    F r o n t H u b A s s e m b l y Apply a thin layer of SRAM® Butter to the outside of each new bearing and each bearing bore. Install the drive side bearing first. Insert a new 6803 bearing into the drive side bearing bore of the front hub.
  • Page 23 Insert a 5 mm hex wrench into the drive side end cap. Hold the hex wrench in place and use the torque wrench with a 5 mm hex socket to tighten the non-drive side end cap to 5 N·m (45 in-lb). This concludes the service for Zipp 404 hubs. Front Hub Assembly...
  • Page 24 “We will revolutionize the relationship that our users have with SRAM products, cultivating a bond between the rider and bicycle. Our technical communication will be delivered in innovative and exciting ways, with deliberation and accuracy that inspires loyalty and trust across the globe.” -SRAM TechCom Vision Statement WORLD HEADQUARTERS ASIAN HEADQUARTERS...

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