Disassembly instructions for zipp rear cassette hubs

  1. Loosen set screws in right and left axle spacers and remove both spacers from axle.
  2. Slide right and left axle bearings from their flange recesses and remove from axle.
  3. Obtain a wood block at least 1" thick for use as a support for the hub in step #4 below (A 3" or 4" section of 2x4 lumber is satisfactory). Bore a 1" hole through the center thickness of the block to allow the axle and bearing to pass while being driven out.
  4. Place the hub vertically with the left (non-drive) hub flange centered over the hole in the support block.
  5. The right hand bearing retaining ring against the end of the freewheel body fixing bolt.
  6. Strike the end of the axle with a ball-pein hammer (wear safety glasses during this procedure) to drive the axle out of the hub. The freewheel body fixing bolt will force the retaining ring out of its groove and off of the axle.
  7. Withdraw the axle from the left end of the hub shell leaving the remaining bearing retaining ring in place on the axle.
  8. Using a 10mm allen wrench, loosen and remove the freewheel body fixing bolt.
  9. The freewheel body and cassette bearing adaptor can now be separated and removed from the hub shell.
  10. Reassemble hub by following assembly instructions and omitting step #4.

NOTE: Each bearing retaining ring is good for only one installation and removal once removed from its axle, a bearing ring must be discarded and replaced with a matching new part upon reassembly of the hub.

* Required tools available from Compositech

Assembly instructions for zipp rear cassette hubs

  1. Remove Shimano freewheel body from plastic bag. Install inboard rubber seal, then pry out plastic bearing dust cap from opposite (outboard) end.
  2. Place cassette bearing adaptor H0010 into bearing cup in outboard end of freewheel body. Next, insert the Shimano freewheel body fixing bolt through the center of the bearing adaptor from the outboard side.
  3. Clean grease and oil from bolt and hub flange threads, then insert the bolt into the splined end of the hub body and tighten firmly with a 10mm allen wrench. The cassette hub body is now assembled.
  4. Ensure that the circular wave spring is located in the machined groove in the left side hub flange bearing recess, then place the axle (end without retaining ring first) through the hub, entering on the left.
  5. Lubricate the right end (tapered end) of the axle with grease. Stand the hub and axle vertically with the right end up. Place a bearing retaining ring directly on to the tapered end of the axle. Use the Zipp hub tube tool* to press the ring down over the axle and taper and into the ring's groove in the axle.
  6. Slip a bearing onto each end of the axle and push up to retaining rings.
  7. Slide the aluminum axle spacer onto the left axle end. Ensure that spacer, bearing and retaining ring are all in contact with each other, then tighten the set screw.
  8. Slide the knurled steel spacer onto the right axle end and stand the hub assembly vertically right end up. Gently press down on the hub shell and steel spacer to compress the wave spring (the assembly should compress 1.5mm). Tighten the spacer set screw.
  9. Check for free axle rotation. The axle can be pushed to the side by compressing the wave spring, this is normal and will not occur during use.
  10. Install Cassette Cog set using a Dura-Ace lockring (Shimano part #11w-0100) or a threaded 1st position cog. For 7sp. Use, install the included 4.5mm spacer on the freewheel body behind the cog set.

* Required tools are available from Compositech.