ZIPP 404 BEARING REPLACMENT GUIDE Tools Needed: Bearing Press with bushing to fit 6803 bearing size. Hammer Flat head screwdriver Bearing puller (included with bearings) Use high quality bearing puller if possible. 2mm and 4mm Allen keys

ZIPP 404 BEARING REPLACMENT GUIDE FRONT HUB Step 1. Use 2mm Allen key to loosen set screw on Clinch nuts (end caps). Step 2. Use 4mm Allen to unscrew axle from hub, then remove axle.

ZIPP 404 BEARING REPLACMENT GUIDE FRONT HUB Step 3. Insert bearing puller (supplied with bearings) and line flat head screwdriver up with puller. Step 4. Tap gently the end of the flat head screwdriver with a hammer, dislodging the bearing from the hub. Bearings are not held in with much force. *Repeat steps 3 and four for both sides of the hub.

ZIPP 404 BEARING REPLACMENT GUIDE FRONT HUB Step 4. Place greased 6803 bearing on proper sized bushing for use with bearings press. Step 5. Use bearings press to install bearings, stop when bearing is fully seated. Be sure to align the bearing properly and press in straight . *Only press in one bearing at a time.

ZIPP 404 BEARING REPLACMENT GUIDE FRONT HUB Step 7. Place seals back over the bearings and re-install axle. Align aero clinch nuts. Step 8. To return to the factory-set pre-load, tighten the non-drive clinch nut until you just feel it touch the bearing. Then turn it counter-clock-wise 1/8 of a revolution to back it off the bearing. Once the quick release is loaded, the clinch nut will contact the bearing and provide a small amount of pre-load. -Secure clinch nut by tightening set screw to 0.8 Nm.

ZIPP 404 BEARING REPLACMENT GUIDE REAR HUB Step 1. To disassemble the rear hub, pull the non-drive end cap out of the axle. Remove cassette. Use a 2mm Allen key to loosen the set screw in the non-drive clinch nut. Remove the clinch nut (standard right-hand threads). Slide the axle with cassette body and cassette body dust cap out of the main hub shell. Do NOT lose the small washer that fits between the main hub shell and cassette body!

ZIPP 404 BEARING REPLACMENT GUIDE REAR HUB Step 2. Insert bearing puller (supplied with bearings) and line flat head screwdriver up with puller. Tap gently the end of the flat head screwdriver with a hammer, dislodging the bearing from the hub. Bearings are not held in with much force. *Repeat steps above both sides of the hub. Step 3. Place greased 6803 bearing on proper sized bushing for use with bearings press. Use bearings press to install bearings, stop when bearing is fully seated. Be sure to align the bearing properly and press in straight . *Only press in one bearing at a time.

ZIPP 404 BEARING REPLACMENT GUIDE REAR HUB Step 4. Remove freehub from hub axle. Step 5. Hold freehub in your hand and insert bearing puller (supplied with bearings) and line flat head screwdriver up with puller. Tap gently the end of the flat head screwdriver with a hammer, dislodging the bearing from the hub. Bearings are not held in with much force. *Repeat above for both sides of the freehub.

ZIPP 404 BEARING REPLACMENT GUIDE REAR HUB Step 5. Place greased 6803 bearing on proper sized bushing for use with bearings press. Use bearings press to install bearings, stop when bearing is fully seated. Be sure to align the bearing properly and press in straight . *Only press in one bearing at a time. Step 6. Re-install Freehub onto hub axle. Be sure to install washers in the right orientation.

ZIPP 404 BEARING REPLACMENT GUIDE REAR HUB Step 7. To reassemble the rear hub, insert the axle/cassette body/cassette body dust cap assembly in to the hub shell, making sure that the small washer is between the cassette body and main hubshell. Push the three pawls down with your fingers and rotate the cassette body counterclockwise as it is inserted. Next slide the hub bearing shield (with or without lip seal on OD of shield) over the axle so that the shoulder of the shield faces the hub shell. Step 8. Thread the nondrive clinch nut onto the axle, making sure not to cross thread it. The degree to which you tighten the clinch nut will determine how much pre-load is on the bearing and how much play you will feel in the wheel.

ZIPP 404 BEARING REPLACMENT GUIDE REAR HUB Step 7. To return to the factory-set pre-load, tighten the non-drive clinch nut until you just feel it touch the bearing. Then turn it counter-clock-wise 1/8 of a revolution to back it off the bearing. Once the quick release is loaded, the clinch nut will contact the bearing and provide a small amount of pre-load. -Secure clinch nut by tightening set screw to 0.8 Nm. Additional Information: http://www.zipp.com/_media/pdfs/manuals/88-188_hub_manual.pdf