40 Hour Class

In This Class You Will Learn 

CHAPTER 1 - Basic Mechanical Skills
Threaded Fastener Tension & Torque..............................................................................................2
Lubrication, Thread Lockers, & Cleaners ....................................................................................... 4
Diagnosing Mechanical Problems................................................................................................... 6
Tools and Tool Selection .................................................................................................................. 6
Repair Stands .....................................................................................................................................7
Home Shop Set Up.............................................................................................................................8
CHAPTER 2 - Tires & Tubes
Removing Wheels ............................................................................................................................ 12
Removing Tire & Tube from Rim.................................................................................................... 13
Inspecting the Inner Tube...............................................................................................................14
Inspecting the Tire ........................................................................................................................... 15
Rim Strip ........................................................................................................................................... 16
Repairing Inner Tubes...................................................................................................................... 16
Pre-Glued Patch Repair ................................................................................................................... 17
Repairing Inner Tubes with Self-Vulcanizing Patches ................................................................ 17
Inner Tube Sealants.......................................................................................................................... 18
Tire Liners.......................................................................................................................................... 18
Temporary Repair of Tire with Tire Boot ...................................................................................... 18
Inner Tube Valves ............................................................................................................................. 19
Tire & Tube Sizing ...........................................................................................................................20
Installing Tire & Tube on Wheel.................................................................................................... 22
Installing Wheels on Bike............................................................................................................... 23
Installing Front Wheels with Disc Brakes .................................................................................... 25
Solid Axle Types.............................................................................................................................. 25
Through Axle System...................................................................................................................... 25
Tubeless Systems ............................................................................................................................ 26
Tubular Tires .................................................................................................................................... 27
CHAPTER 3 - Hubs, Rear Sprockets
Cassette Sprocket Removal & Installation................................................................................... 32
Freewheel Sprocket Removal & Installation..................................................................................... 34
Rear Sprocket Inspection & Cleaning .................................................................................................35
Fixed Gear ........................................................................................................................................ 36
CHAPTER 4 - Hubs
Bearing Service-cup and cone adjustable...................................................................................40
Dissasembly-cup and cone adjustable hubs.....................................................................................40
Parts Inspection-cup and cone adjustable hubs ...............................................................................41
Assembly-cup and cone adjustable hubs.......................................................................................... 42
Hub Adjustment-cup and cone adjustable hubs .............................................................................. 42
Hub Adjustment-Solid Axle-cup and cone........................................................................................ 45
Campagnolo® and Shimano® Dura-Ace 7800 and 7801 Oversized Hub Service......................... 45
Parts Inspection .................................................................................................................................... 46
Campagnolo® Oversized Axle and Shimano® 7800/7801............................................................... 47
Adjustment............................................................................................................................ 47
Freehub Removal & Installation .................................................................................................... 48
Cartridge Bearing Hubs.................................................................................................................. 48
Mavic® Hub (Level 1 Type) ................................................................................................................... 49ontents page
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CHAPTER 5 - Wheel Truing
Wheel Truing Overview.................................................................................................................. 54
Truing Procedures ........................................................................................................................... 56
Lateral Truing..........................................................................................................................................57
Radial Truing...........................................................................................................................................58
Wheel Centering (Dishing).................................................................................................................. 59
Spoke Tension .......................................................................................................................................60
Replacing Broken or Damaged Spokes ....................................................................................... 62
Wheel Wear, Damage & Repair ..................................................................................................... 62
CHAPTER 6 - Pedals
Pedal Removal ................................................................................................................................. 66
Pedal Installation............................................................................................................................. 67
Damage to Crank Pedal Threads................................................................................................... 67
Pedal Bearing Service..................................................................................................................... 67
Shimano® Pedals-axle-bearing assembly type..................................................................................67
Shimano® Pedals-lockring and cup type........................................................................................... 69
Cartridge Bearing Pedal Service-Crank Brothers®........................................................................... 69
CHAPTER 7 - Cranksets
Crank Removal (three piece cranks) ............................................................................................ 74
Crank Removal: Octalink® or ISIS® Drive Spline................................................................................75
Crank Installation—Octalink® or ISIS Drive® Splined........................................................................75
Crank Installation: 3-piece Square Spindle........................................................................................77
External Bearing Crankset Systems.............................................................................................. 77
Bearing Cup Installation .......................................................................................................................78
Crank Installation & Removal of Compression Slotted Arm Cranks: Shimano® & FSA®.....................79
Installation & Removal of Shimano® Octalink External Bearing Crank......................................... 80
Installation & Removal of Race Face® X-type Cranks ........................................................................... 81
Campagnolo® & Fulcrum®: Ultra-Torque Crank..................................................................................82
Non-Threaded Crankset-BB30 & BB90........................................................................................ 82
Bottom Bracket Bearing System................................................................................................... 83
Bottom Bracket Tool Selection........................................................................................................... 84
Cartridge Bottom Brackets ................................................................................................................. 86
Cartridge Bottom Bracket Removal & Installation ......................................................... 86
Adjustable Bottom Brackets ................................................................................................................87
Adjustable Bottom Bracket Removal.................................................................................88
Adjustable Bottom Bracket Installation ........................................................................... 89
Adjustable Bottom Bracket Adjustment .......................................................................... 89
Chainrings ........................................................................................................................................90
Chainring Replacement........................................................................................................................90
Chainring Wear & Damage ................................................................................................................... 91
CHAPTER 8 - Chains
Chain Sizing for Derailleur Bikes...................................................................................................94
Shimano® Chain with Connecting Rivet............................................................................................. 96
Campagnolo® 10-speed Chain ............................................................................................................ 97
Chain with “Master-link”...................................................................................................................... 98
Chain with Reusable Rivets ................................................................................................................. 99
New Chain Installation on Derailleur Bikes ................................................................................. 99
Tight Link Repair................................................................................................................................. 100
Chain Sizing and Tension Adjustment: Two-Sprocket Bicycles .............................................. 101
Chain Tension-Two Sprocket Bikes without Tension Idler Device................................................ 101
Chain Tension Using Idler Chain Tension Device ............................................................................102
Chain Tension: Eccentric Bottom Brackets on Tandem and Single Speeds................................102
Chain Wear and Damage...............................................................................................................103
Chain Cleaning............................................................................................................................... 104
Chain Lubrication ...........................................................................................................................105ontents
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CHAPTER 9 - Derailleur System
Cable System ..................................................................................................................................108
Cable Housing Lengths .......................................................................................................................109
Cable Lubrication................................................................................................................................. 110
Shift Levers....................................................................................................................................... 111
Flat Bar Shifters......................................................................................................................................111
Twist-Grip Shifters ................................................................................................................................112
Above-The-Bar Shifters........................................................................................................................112
Drop Bar Integral Brake & Gear Shifters............................................................................................113
Down Tube Shifters...............................................................................................................................113
Bar End Shifters.....................................................................................................................................114
Front Derailler ................................................................................................................................ 114
Derailleur Cable Attachment...............................................................................................................115
Height Adjustment .................................................................................................................................115
Height Adjustment................................................................................................................................116
Limit Screw Adjustment.......................................................................................................................117
L-limit Screw.........................................................................................................................117
H-limit Screw ........................................................................................................................118
Index Adjustment-Three Chainring Bikes .............................................................................................119
Index Adjustment-Two Chainring Bikes.............................................................................................119
Front Derailleur Performance .............................................................................................................119
Rear Derailleur ................................................................................................................................120
Derailleur Capacity & Maximum Sprocket Size...................................................................................120
Derailleur Cable Attachment...............................................................................................................121
Limit Screw Adjustment.......................................................................................................................121
H-limit Screw ........................................................................................................................117
L-limit Screw.........................................................................................................................118
B-limit Screw ....................................................................................................................... 123
Index Adjustment................................................................................................................ 123
Shimano® “Rapid Rise™” Derailleur—Indexing Adjustment ............................................................... 125
Chainline ................................................................................................................................................ 126
Derailleur Hanger Alignment & Repair........................................................................................ 127
Derailleur Wear & Service................................................................................................................... 129
Troubleshooting Derailleur Systems ...........................................................................................129
CHAPTER 10 - Internal Gear Systems
SRAM DUALDRIVE®........................................................................................................................134
SRAM® I-Motion 9...........................................................................................................................136
Shimano® Inter-7 or Inter-8 Hub................................................................................................... 137
CHAPTER 11 - Caliper Disc Brake System
Caliper Types ...............................................................................................................................142
Rotors .............................................................................................................................................143
Hydraulic Brake Levers ............................................................................................................ 144
Hydraulic Disc Calipers ............................................................................................................ 144
Hydraulic Brake Caliper Alignment...................................................................................................145
Shimano® Hydraulic Brakes ................................................................................................................146
Magura® Hydraulic Caliper Brakes.....................................................................................................149
Hayes® Hydraulic Caliper Brakes .......................................................................................................150
Avid Hydraulic Caliper Brakes .................................................................................................151
Avid® Brake Bleeding .......................................................................................................................... 152
Mechanic Disc Calipers .............................................................................................................154
Brake Levers .........................................................................................................................................154
Caliper Pad Alignment & Clearance..................................................................................................154
Shimano® Mechanical Disc Calipers ................................................................................. 155
Tektro® Mechanical Disc Calipers ..................................................................................... 156
Hayes® Mechanical Disc Calipers...................................................................................... 156
Avid® Mechanical Brake ..................................................................................................... 156ontents page
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CHAPTER 12 - Caliper Rim Brake System
Brake Levers .................................................................................................................................162
Upright Bar Brake Levers.................................................................................................................... 162
Drop Bar Brake Levers ........................................................................................................................ 163
Cable System ..................................................................................................................................163
Cable Lubrication................................................................................................................................. 162
Cable Housing Length......................................................................................................................... 163
Caliper Brakes.................................................................................................................................166
Brake Pads ............................................................................................................................................166
Vertical Height Alignment ................................................................................................. 167
Tangent Alignment ............................................................................................................. 167
Vertical Face Alignment .................................................................................................... 168
Pad Toeing ........................................................................................................................... 168
Cantilever Caliper Adjustment........................................................................................................... 168
Linear Pull Caliper Adjustment ...........................................................................................................171
Dual Pivot Caliper Adjustment........................................................................................................... 173
Side Pull Caliper Adjustment ............................................................................................................. 174
CHAPTER 13 - Handlebars, Stems, Saddles & Seatposts
Upright Bars ................................................................................................................................. 178
Drop Style Handlebars (Road Bars) ............................................................................................179
Stems ...............................................................................................................................................180
Quill Stems............................................................................................................................................180
Threadless Stems ..................................................................................................................................181
Saddles ............................................................................................................................................ 182
Seat Post ......................................................................................................................................... 183
CHAPTER 14 - Headsets
Headset Types .............................................................................................................................186
Headset Service .......................................................................................................................... 187
Threadless Headset Service ............................................................................................................... 187
Threaded Headset Service .................................................................................................................190
Headset Replacement & Installation ....................................................................................192
Headset Stack Height..........................................................................................................................194
Headset Removal .................................................................................................................................194
Pressed Headset Installation.............................................................................................................. 195
Fork Crown Race Installation............................................................................................................. 197
Star Nut & Compression Plug Installation........................................................................................ 197
Fork Sizing and Cutting ...................................................................................................................... 198
Unthreaded Steering Columns.......................................................................................... 198
Threaded Steering Columns..............................................................................................199
CHAPTER 15 - Frame and Fork
Fork......................................................................................................................................204
Head Tube...........................................................................................................................204
Top Tube..............................................................................................................................204
Down Tube ..........................................................................................................................204
Seat Tube ............................................................................................................................205
Chain Stay ...........................................................................................................................205
Seat Stay .............................................................................................................................205
Dropouts..............................................................................................................................205
Bottom bracket shell.........................................................................................................205
Swing arm ...........................................................................................................................205
Frame Construction and Service ......................................................................................................205
Steel .....................................................................................................................................206
Aluminum............................................................................................................................206
Titanium...............................................................................................................................206
Carbon .................................................................................................................................206ontents
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CHAPTER 16 - Suspension
Shocks (Dampers) ...........................................................................................................................211
Suspension Linkages .....................................................................................................................212
Service and Tuning ........................................................................................................................212
Spring Preload...................................................................................................................................... 212
Fluid Viscosity ...................................................................................................................................... 213
Valving................................................................................................................................................... 213
Linkage .................................................................................................................................................. 213
Cyclist Posture...................................................................................................................................... 213
Tire Contact .......................................................................................................................................... 213
CHAPTER 17 - On-Ride Repair
Tool Choices .........................................................................................................................................216
Repair Procedures ...............................................................................................................................216
Flat Tire ................................................................................................................................216
Cut or Ripped Tire ..............................................................................................................216
Broken Spoke ......................................................................................................................216
Dented Rim ..........................................................................................................................216
Broken Chains...................................................................................................................... 217
Chain Suck ........................................................................................................................... 217
Twisted Chain ...................................................................................................................... 217
Squeaky and Noisy Chain .................................................................................................. 217
Rear Derailleur Shifting into the Spokes or Frame........................................................ 217
Derailleur not Indexing Properly ...................................................................................... 217
Broken Derailleur Body, Cage, or Hanger .......................................................................218
Missing Derailleur Pulleys ..................................................................................................218
Front Derailleur Cage Bent or Twisted............................................................................218
Crank Falling Off.................................................................................................................218
Pedals Falling Off................................................................................................................218
Bent Crank ...........................................................................................................................218
Bottom Bracket Loose or Falling Apart ..........................................................................218
Broken Derailleur Cable.....................................................................................................218
Broken Brake Cable ............................................................................................................219
Twisted or Bent Handlebars or Stem...............................................................................219
Bent Frame or Fork.............................................................................................................219
Bent Saddle or Seat Post...................................................................................................219
CHAPTER 18 - Bike Wash
Appendix A - Tool List
Appendix B - Glossary
Appendix C - Recommended Torque for Bicycle Components
Appendix D - Bike Map

http://www.parktool.com/uploads/files/BBB-2_Table_of_Contents.pdf

In this forty hour course 

• Level- Beginner to Expert

An in-depth look at the Park Tool book, going into detail on each of the 18 chapters. 

$999

This 40 hour course covers the 18 chapters in the Park Tool Big Blue Book of Repair. Park Tool Certificates provided. Starting with Basic Bicycle Maintenance, flat repairs, derailleurs, brakes, headsets, bottom bracket to bike washing. You will have an opportunity to a full hands on experience while working on your own bike in a small classroom setting. There is no crowding here, past students were able to perform all 40 hours (and 70 hr) with a one on one learning experience. You may already know how to perform some of the procedures but there is always something to learn that will fill in the gaps, simplify and expedite the next job. This can be performed in 5 consecutive days (M-F, weekends) or tailored to your schedule for days, evenings and weekends.

Recommendations: Purchase the

. This can be found at some bike shops or online.

A deposit of $100 is required to hold your space for this class. Ask about payment options.