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Bontrager Aeolus TLR Bike Accessory Service Manual PDF
Summary of Content for Bontrager Aeolus TLR Bike Accessory Service Manual PDF
Page 1 of 22
Aeolus TLR Service Manual
Page 2 of 22
/ 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
Page 3 of 22
/ 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
Page 4 of 22
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
Page 5 of 22
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
Page 6 of 22
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
Page 7 of 22
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
Page 8 of 22
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
Page 9 of 22
/ 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
Page 10 of 22
/ 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
Page 11 of 22
/ 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
Page 13 of 22
/ 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
Page 14 of 22
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
Page 15 of 22
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
Page 16 of 22
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
Page 17 of 22
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
Page 18 of 22
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
Page 19 of 22
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
Page 20 of 22
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
Page 21 of 22
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
Page 22 of 22
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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