Bontrager Aeolus TLR Bike Accessory Service Manual PDF

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Summary of Content for Bontrager Aeolus TLR Bike Accessory Service Manual PDF

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Aeolus TLR Service Manual

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/ Aeolus TLR

/ TLR rims allow for quick transition from traditional tires to tubeless systems

/ OCLV Carbon 27mm outer, 19.5mm inner width

/ Carbon hub shells, DT Swiss internals featuring 36 tooth star ratchets

/ Stacked Lacing - Provides a better spoke bracing angle for a stiffer wheel

/ No rider weight restrictions

/ Designed, manufactured, and built in Waterloo, WI

/ OCLV is ultra-light, compliant and durable, the most advanced carbon available

/ D3 Dual Directional Design profile cuts drag at tire-leading and rim leading edge

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/ Table Of Contents

/ Wheel Spec Sheets / Aeolus 3 TLR 4 / Aeolus 5 TLR 5 / Aeolus 7 TLR 6 / Aeolus 9 TLR 7

/ Hub Exploded Diagrams 8 / Tools To Service 9 / Service Instructions

/ Front Hub Disassembly 10-11 / Front Hub Assembly 12-13 / Rear Hub Disassembly 14-17 / Rear Hub Assembly 18-22

Aeolus TLR Service Manual

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Spokes/Nipples/Washers

Front Drive W313345

Front Non-Drive W313345

Rear Drive W313346

Rear Non-Drive W313345

Nipples 415761

Washers W316459

Size Specifications

Front Drive Spoke 277mm

Front Non-Drive Spoke 277mm

Rear Drive Spoke 284mm

Rear Non-Drive Spoke 277mm

Rim Width 26.5mm

Rim Height 35mm

Front Weight 604g

Rear Weight 752g

Build Specifications

Hop 0.3mm

Wobble 0.3mm

Wheel stress level right side up front 300

Wheel stress level left side up front 300

Wheel stress level right side up rear 550

Wheel stress level left side up rear 300

Dish 0.6mm

Spoke Tension Front 220-290lbs 99.8-131.5Kgf

Spoke Tension Rear Drive 253-340lbs 114.8-154.2Kgf

Spoke Tension Rear Non-Drive 100-122lbs 45.4-55.3Kgf

Tubeless Parts

Tubeless Valve W512884

Tubeless Rim Strip W433383

Lacing Pattern

Front Drive Radial

Front Non-Drive Radial

Rear Drive Spokes woven, pulling spoke on the outside of first cross, inside of the second. 2 cross. Second hole CW from the valve is a pulling spoke

Rear Non-Drive Radial

/ Aeolus 3 TLR

Aeolus TLR Service Manual

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Spokes/Nipples/Washers

Front Drive W311201

Front Non-Drive W311201

Rear Drive W315215

Rear Non-Drive W516245

Nipples 415761

Washers W316459

Size Specifications

Front Drive Spoke 262mm

Front Non-Drive Spoke 262mm

Rear Drive Spoke 270mm

Rear Non-Drive Spoke 263mm

Rim Width 26.5mm

Rim Height 50mm

Front Weight 650g

Rear Weight 790g

Build Specifications

Hop 0.3mm

Wobble 0.3mm

Wheel stress level right side up front 300

Wheel stress level left side up front 300

Wheel stress level right side up rear 550

Wheel stress level left side up rear 300

Dish 0.6mm

Spoke Tension Front 220-290lbs 99.8-131.5Kgf

Spoke Tension Rear Drive 253-340lbs 114.8-154.2Kgf

Spoke Tension Rear Non-Drive 100-122lbs 45.4-55.3Kgf

Tubeless Parts

Tubeless Valve W436111

Tubeless Rim Strip W433383

Lacing Pattern

Front Drive Radial

Front Non-Drive Radial

Rear Drive Spokes woven, pulling spoke on the outside of first cross, inside of the second. 2 cross. Second hole CW from the valve is a pulling spoke

Rear Non-Drive Radial

/ Aeolus 5 TLR

Aeolus TLR Service Manual

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Spokes/Nipples/Washers

Front Drive W315339

Front Non-Drive W315339

Rear Drive W324599

Rear Non-Drive W315339

Nipples 415761

Washers W316459

Size Specifications

Front Drive Spoke 243mm

Front Non-Drive Spoke 243mm

Rear Drive Spoke 250mm

Rear Non-Drive Spoke 243mm

Rim Width 26.5mm

Rim Height 70mm

Front Weight 736g

Rear Weight 872g

Build Specifications

Hop 0.3mm

Wobble 0.3mm

Wheel stress level right side up front 300

Wheel stress level left side up front 300

Wheel stress level right side up rear 550

Wheel stress level left side up rear 300

Dish 0.6mm

Spoke Tension Front 220-290lbs 99.8-131.5Kgf

Spoke Tension Rear Drive 253-340lbs 114.8-154.2Kgf

Spoke Tension Rear Non-Drive 100-122lbs 45.4-55.3Kgf

Tubeless Parts

Tubeless Valve W513945

Tubeless Rim Strip W433383

Lacing Pattern

Front Drive Radial

Front Non-Drive Radial

Rear Drive Spokes woven, pulling spoke on the outside of first cross, inside of the second. 2 cross. Second hole CW from the valve is a pulling spoke

Rear Non-Drive Radial

/ Aeolus 7 TLR

Aeolus TLR Service Manual

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Spokes/Nipples/Washers

Front Drive W314031

Front Non-Drive W314031

Rear Drive W315222

Rear Non-Drive W314031

Nipples 415761

Washers W316459

Size Specifications

Front Drive Spoke 223mm

Front Non-Drive Spoke 223mm

Rear Drive Spoke 230mm

Rear Non-Drive Spoke 223mm

Rim Width 26.5mm

Rim Height 90mm

Front Weight 840g

Rear Weight 972g

Build Specifications

Hop 0.3mm

Wobble 0.3mm

Wheel stress level right side up front 300

Wheel stress level left side up front 300

Wheel stress level right side up rear 550

Wheel stress level left side up rear 300

Dish 0.6mm

Spoke Tension Front 220-290lbs 99.8-131.5Kgf

Spoke Tension Rear Drive 253-340lbs 114.8-154.2Kgf

Spoke Tension Rear Non-Drive 100-122lbs 45.4-55.3Kgf

Tubeless Parts

Tubeless Valve W513946

Tubeless Rim Strip W433383

Lacing Pattern

Front Drive Radial

Front Non-Drive Radial

Rear Drive Spokes woven, pulling spoke on the outside of first cross, inside of the second. 2 cross. Second hole CW from the valve is a pulling spoke

Rear Non-Drive Radial

/ Aeolus 9 TLR

Aeolus TLR Service Manual

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Front Hub

Diagram # Description Part #

1, 5 Axle End Cap W244298

2 Ball Bearing 6803 (Steel, stock) 410428

2 Ball Bearing 6803 (Ceramic, upgrade option) 414055

4 Axle W244299

Rear Hub

Diagram # Description Part #

1 End Cap Non-Driveside 429650

2 Ball Bearing 6802 (Steel, stock) 72447

2 Ball Bearing 6802 (Ceramic, upgrade option) 510976

3 Axle W244301

NA NDS Spacer (Required w/ axle replacement) 429646

5 Ball Bearing 6902 (Steel, stock) 413573

5 Ball Bearing 6902 (Ceramic, upgrade option) 413574

6 Shim Ring 406899

7 Ring Nut 406903

8 Seal Hub Shell/Rotor W211591

9 Spring 406901

10 Star Ratchet (36T, stock) 515907

11 Spacer W276495

12 Freehub, Shimano, 9/10/11 Speed W431448

13 End Cap Driveside (Included with Freehub) W319636

NA Cassette Spacer for 9/10 Speed W321126

NA Freehub, Campy, 10/11 Speed 276362

/ Aeolus TLR Hub Exploded Diagrams 1

2

3

4

2

5

1

2

3

4

5

6 7

8

10

10

11

12

13

9

9

Aeolus TLR Service Manual

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/ Hubs

Part Number Description

W211415 DT Swiss 240 Hub Tool Kit *Note: This is a general DT Swiss hub tool kit. It includes several tools that are not necessary to service Aeolus hubs. Below is a list of the specific DT Swiss hub tools needed and their corresponding photos referenced.

Ring nut installation tool Figure 1.

Axle disassembly tool Figure 2.

Radial bearing removal tool Figure 3.

Long installation cylinder Figure 4.

Seal installation tool Figure 5.

Short installation cylinder Figure 6.

Radial short installation cylinder Figure 7. *Note: The short installation cylinder and radial short installation cylinder are different (Figure 8). The short installation cylinder features a smaller inside diameter and is the same inside diameter through the length of the tool. The radial short installation cylinder features a larger inside diameter at the top of the tool and a smaller inside diameter lip about halfway down the tool. See Figure 8. for reference.

421730 Park Tool Shop Hammer

262228 Park Tool P-Handled Hex Wrench 4mm

262231 Park Tool P-Handled Hex Wrench 8mm

/ Spokes & Nipples

79189 Wrench Force Nipple Driver 5.5mm Figure 9.

516765 DT Swiss Aerolite Spoke Holder Figure 10.

419678 Park Tool TS-2.2 Professional Wheel Truing Stand

76998 Park Tool WAG-4 Wheel Alignment Gauge

83746 Park Tool Spoke Tension Meter *Note: Refer to the wheel spec sheets in this manual for spoke part numbers, nipple part numbers, and tension values.

Figure 1. Figure 2.

Figure 4.Figure 3.

Figure 5. Figure 6.

Figure 8.

Figure 10.Figure 9.

Figure 7.

/ Aeolus TLR Tools to Service

Aeolus TLR Service Manual

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/ Aeolus TLR Front Hub Disassembly

Figure 1.

2. Place a Park Tool 4mm P-handle in one side of the hub so that the ball end rests against one end cap. Hold it off-center so it grabs the lip of the end cap (Figure 1). Push the end cap out by hand.

1. Remove the wheel from the bike and remove the skewer.

3. Place a Park Tool 8mm P-handle in through the hub from the side missing the end cap so that the ball end rests against the end cap (Figure 2). Push the end cap out by hand.

4. Insert the radial bearing removal tool into one side of the axle. With a mallet, tap the tool to remove the axle and one bearing (Figure 3, 4).

Figure 2.

Figure 3.

Aeolus TLR Service Manual

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/ Aeolus TLR Front Hub Disassembly

Figure 4.

5. Remove the bearing removal tool from the axle, and the tool from the hub shell. Insert the axle back into the hub so that it presses into the bearing. Insert the radial bearing tool into the axle, and with a mallet, tap the second bearing out (Figure 5, 6).

6. Clean all parts and inspect for wear. If the axle has been damaged or worn it should be replaced. If the bearings feel loose, gritty, or make noise they should be replaced.

Figure 5.

Figure 6.

Aeolus TLR Service Manual

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/ Aeolus TLR Front Hub Assembly

Figure 1.

2. Clamp the radial short installation cylinder into the vise. Place the bearing on top of the cylinder so it is flush with the edge (Figure 1).

3. Set the hub onto the bearing and use just enough force to start pressing the bear- ing into the hub shell (Figure 2).

1. Apply a light coat of grease to the inside of the hub shell where the bearings are pressed in.

4. Place the additional radial short installation cylinder into the opposite side of the hub shell. It will stop against the bearing lip inside the hub shell. Use a mallet to tap this cylinder to drive the hub down onto the bearing (Figure 3).

Figure 2.

Figure 3.

Aeolus TLR Service Manual

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/ Aeolus TLR Front Hub Assembly

Figure 4.

6. Place the second radial short installation cylinder on top of the bearing so it lines up with the edge. Using a mallet carefully drive the bearing into the hub shell and over the axle (Figure 4, 5).

5. Remove the hub from the installation cylinder. Flip the wheel over and insert the axle through the hub shell so it sits flush against the bearing pressed into the hub shell. Set the hub shell bearing side down onto the cylinder clamped into the vise. Place the second bearing into the hub shell keeping it as flat as possible to aid in installation.

7. Re-install the end caps by hand and check the hub for smooth operation (Figure 6). Disassemble and re-assemble if the hub does not operate smoothly.

If the hub operates smoothly insert the skewer and re-install the wheel onto the bike.

Figure 5.

Figure 6.

Aeolus TLR Service Manual

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Figure 1.

2. Place a Park Tool 4mm P-handle in through the drive side of the hub so that the ball end rests against the non-drive side end cap. Hold it off-center so it grabs the lip of the end cap (Figure 1). Push the end cap out by hand.

3. Place a Park Tool 8mm P-handle in through the non-drive side of the hub so that the ball end rests against the drive side end cap (Figure 2). Push the end cap out by hand.

1. Remove the wheel from the bike and remove the skewer and cassette.

4. Remove the freehub body, star ratchet springs, star ratchets, and axle spacer and set aside (Figure 3).

Figure 2.

Figure 3.

/ Aeolus TLR Rear Hub Disassembly

Aeolus TLR Service Manual

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Figure 4.

6. Insert the hub, driveside down, to engage the drive ring onto the ring hut tool (Figure 5). With hands at 12 and 6 oclock rotate the wheel counter clockwise.

5. Clamp the ring nut installation tool into the axle vise (Figure 4).

7. Rotate the wheel until the drive ring is removed (Figure 6, 7). Note: This will also remove the hub seal and shim ring.

Figure 5.

Figure 6.

/ Aeolus TLR Rear Hub Disassembly

Aeolus TLR Service Manual

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Figure 7.

8. Insert the axle disassembly tool into the drive side end of the axle. Tap on the axle disassembly tool with a mallet from the drive side to remove the non-drive side bearing and the axle (Figure 8).

9. Remove the axle and rotate it 180 degrees to insert it back through the non-drive- side of the hub shell. Insert it into the drive side bearing and insert the axle disas- sembly tool into the exposed end of the axle. Tap on the axle disassembly tool with a mallet to remove the driveside bearing (Figure 9, 10).

Figure 8.

Figure 9.

/ Aeolus TLR Rear Hub Disassembly

Aeolus TLR Service Manual

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Figure 10.

10. Clean all parts and inspect for wear. If the axle has been damaged or worn it should be replaced. If the bearings feel loose, gritty, or make noise they should be replaced. If the bearings inside the freehub body feel loose, gritty, or make noise the freehub body should also be replaced. If the star ratchets show signs of wear they should be replaced along with their springs.

/ Aeolus TLR Rear Hub Disassembly

Aeolus TLR Service Manual

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Figure 1.

2. Clamp a short installation cylinder into the vise (Figure 1). Note: This is not the same cylinder as the radial short installation cylinder.

3. Insert the drive side bearing onto the long side of the axle and place the long side of the axle through the short installation cylinder so the bearing rests against the cylinder (Figure 2).

1. Apply a light coat of grease to the inside of the hub shell where the bearings are pressed in and also on the threads for the drive ring.

4. Place the drive side of the hub over the axle and insert the long installation cylin- der into the non-drive side of the hub. Tap on the long installation cylinder to drive the drive side bearing down into the hubshell (Figure 3).

Figure 2.

Figure 3.

/ Aeolus TLR Rear Hub Assembly

Aeolus TLR Service Manual

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Figure 4.

6. Insert the drive ring and shim ring onto the ring nut installation tool (Figure 5).

5. Clamp the ring nut installation tool back into the vise. Ensure it is clamped so that the splines rest directly on the vise. This will support the drive ring when it is initially threaded into the hub (Figure 4).

7. Insert the axle with the long side through the drive side bearing. This will help guide the drive ring into place. Place the drive side of the hub over the drive ring installa- tion tool and carefully rotate the wheel clockwise to tighten the drive ring (Figure 6). Ensure the drive ring is tightened all the way. Note: The drive ring installation tool will need to be adjusted before the drive ring is tightened all the way (Figure 7).

Figure 5.

Figure 6.

/ Aeolus TLR Rear Hub Assembly

Aeolus TLR Service Manual

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Figure 7.

8. Remove the axle. Clamp the long installation cylinder into the vise (Figure 8).

9. Place the non-drive side of the hub over the long installation cylinder so the cylin- der rests against the bearing lip on the non-drive side of the hub shell (Figure 9).

Figure 8.

Figure 9.

/ Aeolus TLR Rear Hub Assembly

Aeolus TLR Service Manual

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Figure 10.

10. Snap the rubber side of the hub seal onto the hub seal installation tool (Figure 10, 11).

11. Start the seal into the drive side of the hub shell and carefully tap on the hub seal installation tool to seat the seal completely (Figure 12)

Figure 11.

Figure 12.

/ Aeolus TLR Rear Hub Assembly

Aeolus TLR Service Manual

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Figure 13.

12. Insert the long side of the axle through the hub shell and drive side bear- ing. Clamp the ring nut installation tool back into the vise. Place the drive side of the hub onto the ring nut installation tool engaging the drive ring (Figure 13).

13. Place the non-drive side bearing into the non-drive side of the hub shell. Place the long installation cylinder onto the bearing. Tap on the long instal- lation cylinder with a mallet to carefully drive the bearing down into the hub shell and over the axle (Figure 14).

14. Re-install the axle spacer, star ratchets, star ratc

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