Park Tool Big Blue Book of Bicycle Repair Table of Contents
Chapters 1 through 17
Chapter 1 — Basic Mechanical Skills
Chapter 2 — Tires & Tubes
Chapter 3 — Rear Sprockets
Chapter 4 — Hubs
Chapter 5 — Wheel Truing
Chapter 6 — Pedals
Chapter 7 — Cranksets
Chapter 8 — Chains
Chapter 9 — Derailleur Systems
Chapter 10 — Internal Gear Systems
Chapter 11 — Caliper Disc Brake Systems
Chapter 12 — Caliper Rim Brake Systems
Chapter 13 — Handlebars, Stems, Saddles, & Seatposts
Chapter 14 — Headsets
Chapter 15 — Frame & Fork
Chapter 16 — Suspension
Chapter 17 — On-Ride Repair
Appendices A–J — Reference Materials
CHAPTER 1 — BASIC MECHANICAL SKILLS
Overview
Common Misconceptions
All Classes
Lesson Objectives
Equipment
Instructor
Student
Instructor’s Introduction to Class
Threaded Fastener Tension & Torque
Lubrication, ThreadLockers, & Cleaners
Bearing Systems
Diagnosing & Solving Mechanical Problems
Tools & Tool Selection
Repair Stands
Home Shop Setup
Maintenance Schedule
CHAPTER 2 — TIRES & TUBES
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Samples
Student
Intermediate
Lesson Objectives
Equipment
Instructor
Samples
Student
Advanced
Lesson Objectives
Equipment
Instructor
Samples
Student
Wheel Removal
Removal of Tire & Tube from Rim
Inner Tube Inspection
Cut at Valve Vase
Leaky Valve Core
Large Shredded Hole
Hole on the Rim Strip Side of Tube
Long Cut or Rip
Single Puncture or Small Hole
Double Slits
Tire Inspection
Rim Strip
Inner Tube Repair
Pre-Glued Patch Repair
Inner Tube Repair with Self-Vulcanizing Patches
Inner Tube Sealants
Tire Liners
Temporary Tire Repair with Tire Boot
Inner Tube Valves
Tire & Tube Sizing
Installation of Tire & Tube on Wheel
Wheel Installation
Front Wheels with Disc Brakes
Solid Axle Types
Thru-Axle Systems
Tubeless Systems
Tubeless Conversion Systems
Tubular Tires
CHAPTER 3 — REAR SPROCKETS
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Samples
Student
Intermediate
Lesson Objectives
Equipment
Instructor
Samples
Student
Advanced
Lesson Objectives
Equipment
Instructor
Samples
Student
Cassette Sprocket Removal & Installation
Freewheel Sprocket Removal & Installation
Single-Speed Removal
Sprocket Inspection & Cleaning
Fixed Gear Sprockets
CHAPTER 4 — HUBS
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Student
Intermediate
Lesson Objectives
Equipment
Instructor
Student
Advanced
Lesson Objectives
Equipment
Instructor
Student
Hub Bearing Service: Adjustable Cup-and-Cone Type
Disassembly
Parts Inspection
Assembly
Hub Adjustment
Oversized Axle Service: Campagnolo® and Shimano®
Hub Adjustment: Solid Axle Cup-and-Cone
Freehub Removal & Installation
Cartridge Bearing Hubs
Mavic® Hub (Level 1 Type)
CHAPTER 5 — WHEEL TRUING
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Intermediate
Lesson Objectives
Equipment
Instructor
Student
Advanced
Lesson Objectives
Equipment
Instructor
Student
Wheel Truing Overview
Lateral True
Radial True
Rim Centering (Dish)
Tension
Truing Procedures
Lateral Truing
Radial Truing
Wheel Centering (Dishing)
Spoke Tension
Broken & Damaged Spoke Replacement
Wheel Wear, Damage, & Repair
CHAPTER 6 — PEDALS
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Samples
Student
Intermediate
Lesson Objectives
Equipment
Instructor
Samples
Student
Advanced
Lesson Objectives
Equipment
Instructor
Samples
Student
Pedal Removal
Pedal Installation
Damage to Crank Pedal Threads
Pedal Bearing Service
CHAPTER 7 — CRANKSETS
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Samples
Student
Intermediate
Lesson Objectives
Equipment
Instructor
Samples
Student
Advanced
Lesson Objectives
Equipment
Instructor
Samples
Student
Crank Types
Crank Removal & Installation
Self-Extracting Crank Systems
Three-Piece Cranks: Octalink®, ISIS Drive, Square Spindle, Power Spline™, and Power Drive™
Two-Piece Compression Slotted Cranks: Shimano® and FSA®
Two-Piece Cranks Using Wave Washer: FSA® MegaExo® and SRAM® GXP® PF
Two-Piece Self-Extracting Cranks: Truvativ®, SRAM® GXP®
Two-Piece Pre-Load Adjuster Nut Cranks: Truvativ®, SRAM® BB30 I-A, and FSA® Afterburner™
Campagnolo® and Fulcrum® Ultra-Torque® Cranks
Campagnolo® Power Torque™ Cranks
Specialized® S-Works® Cranks
Bottom Bracket System Types
Threaded Standards
Non-Threaded Standards
BB86 and BB92
BB90 and BB95
BB30
PF30
386EVO
BBright®
Bottom Bracket Bearing Service for Non-Threaded Shells
BB30 Bearings
PF30 and BBRight® Bearings
BB30 and PF30 Adaptors for Non-BB30 Cranks
BB86, BB90, BB92, BB95 Bearings (Shimano® PF and GXP® PF)
Campagnolo® Ultra-Torque® and Fulcrum® Bearings
Campagnolo® Power Torque™ Bearings
Campagnolo® BB30 Bearing Adaptors
Bottom Bracket Bearing Service for Threaded Shells
Threaded Bottom Bracket with Two-Piece Cranks
Threaded Cartridge Bottom Brackets: ISIS Drive, Octalink®, and Square Spindle
Threaded Adjustable Bottom Bracket Bearings
Bottom Bracket Removal
Bottom Bracket Installation
Bottom Bracket Adjustment
Chainrings
Chainring Replacement
Chainring Wear and Damage
CHAPTER 8 — CHAINS
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Samples
Student
Intermediate
Lesson Objectives
Equipment
Instructor
Samples
Student
Advanced
Lesson Objectives
Equipment
Instructor
Samples
Student
Chain Sizing for Derailleur Bikes
Chain Sizing with Chain Retention System
Chain Removal
New Chain Installation on Derailleur Bikes
Shimano® and FSA® Chains with Connecting Rivet
Campagnolo® 10-speed Chain
Campagnolo® 11-speed Chain
Setting or Peening of 11-Speed Coupling Rivet
Chains with Master Link
Chain with Reusable Rivets
Tight Link Repair
Chain Sizing and Tension Adjustment: Two-Sprocket Bicycles
Chain Tension: Two-Sprocket Bikes
Chain Tension: Two-Sprocket Bikes with Chain Tension Idler Device
Chain Tension: Eccentric Bottom Brackets on Tandem and Single-Speeds
Tandem Crank Synchronizing
Chain Wear and Damage
Chain Cleaning
Chain Lubrication
CHAPTER 9 — DERAILLEUR SYSTEMS
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Intermediate
Lesson Objectives
Equipment
Instructor
Samples
Student
Advanced
Lesson Objectives
Equipment
Instructor
Samples
Student
Cable System
Cable Housing Length and Routing
Cable Lubrication
Shift Levers
Flat Bar Trigger Shifters
Twist Grip Shifters
Above-the-Bar Shifters
Drop Bar Integral Brake / Shift Levers
Campagnolo®
Down Tube Shifters
Bar End Shifters
Front Derailleur
Derailleur Cable Attachment
Height Adjustment
Rotational Adjustment
Limit Screw Adjustment
L-Limit Screw
H-Limit Screw
Front Index Adjustment: Three-Chainring Bikes
Front Index Adjustment: Two-Chainring Bikes
Front Derailleur Performance
Shimano® Front Derailleur FD-9000
Shimano® FD-9000 Front Derailleur Adjustment
Rear Derailleur
Derailleur Capacity and Maximum Sprocket Size
Derailleur Installation
Derailleur Cable Attachment
Limit Screw Adjustment
H-Limit Screw
L-Limit Screw
B-Screw Adjustment
Index Adjustment
Shimano® Rapid Rise™ Derailleurs
Clutch System Rear Derailleurs
Chainline
Derailleur Hanger Alignment & Repair
Derailleur Wear & Service
Troubleshooting Derailleur Systems
Electronic Shift Derailleurs
Shimano® Di2® Intelligent System
Shifters
Di2® Battery
Front Derailleur
Rear Derailleur
Crash Feature
Campagnolo® EPS® Derailleurs: Super Record®, Record®, and Athena®
EPS® Rear Derailleur Adjustment
EPS® Front Derailleur Adjustment
EPS® Derailleur Ride-Setting
Crash Mode and Ride Home Mode
EPS® Battery and Charging Unit
Troubleshooting
CHAPTER 10 — INTERNAL GEAR SYSTEMS
Overview
Advanced or Optional Class
Lesson Objectives
Equipment
SRAM® DualDrive™
SRAM® I-Motion® 9
Shimano® Nexus Inter-7®, Nexus Inter-8®, & Alfine® Hubs
CHAPTER 11 — CALIPER DISC BRAKE SYSTEMS
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Samples
Intermediate
Lesson Objectives
Equipment
Instructor
Samples
Student
Advanced
Lesson Objectives
Equipment
Instructor
Samples
Student
Caliper Types
Brake Pads
Disc Brake Rotors
Hydraulic Brake Systems
Hydraulic Brake Levers
Hydraulic Disc Calipers
Hydraulic Brake Caliper Alignment
Hydraulic Brake Fluid Service
Shimano® Hydraulic Brakes
Brake Pad Removal and Replacement
Brake Bleeding
Magura® Hydraulic Caliper Brakes
Hayes® Hydraulic Caliper Brakes
Avid® Hydraulic Caliper Brakes
Tektro® Hydraulic Caliper Brakes
Mechanical Disc Brake Systems
Brake Lever
Caliper Pad Alignment and Clearance
Shimano® Mechanical Disc Brakes
Tektro® Mechanical Disc Brakes
Hayes® Mechanical Disc Brakes
Avid® Mechanical Disc Brakes
CHAPTER 12 — CALIPER RIM BRAKE SYSTEMS
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Samples
Student
Intermediate
Lesson Objectives
Equipment
Instructor
Samples
Student
Advanced
Lesson Objectives
Equipment
Instructor
Samples
Student
Brake Levers
Upright Handlebar Brake Levers
Drop Bar Brake Levers
Cable System
Cable Lubrication
Cable Housing Length
Caliper Rim Brakes
Brake Pads
Brake Pad Alignment
Vertical Height Alignment
Tangential Alignment
Vertical Face Alignment
Pad Toe
Linear-Pull Caliper Adjustment
Cantilever Caliper Adjustment
Dual-Pivot Caliper Adjustment
Side-Pull Caliper Adjustment
CHAPTER 13 — HANDLEBARS, STEMS, SADDLES, & SEATPOSTS
Overview
Common Misconceptions
All Classes
Lesson Objectives
Equipment
Instructor
Samples
Upright Handlebars
Bar Grips
Drop Style Handlebars (Road Bars)
Clip-On and Aero Handlebars
Stems
Quill Stems
Threadless Stems
Saddles
Seatposts
CHAPTER 14 — HEADSETS
Overview
Common Misconceptions
Novice
Lesson Objectives
Equipment
Instructor
Samples
Intermediate
Lesson Objectives
Equipment
Instructor
Samples
Student
Advanced
Lesson Objectives
Equipment
Instructor
Samples
Student
Headset Types
Headset Service
Threadless Headset Service
Threadless Headset Adjustment
Threaded Headset Service
Threaded Headset Adjustment
Headset Replacement & Installation
Headset Stack Height
Pressed Headset Removal
Pressed Headset Installation
Fork Crown Race Installation
Fork Steering Column Sizing
Threadless Steering Columns
Star Nut and Compression Plug Installation
Threaded Steering Columns
CHAPTER 15 — FRAME & FORK
Overview
Optional Class
Lesson Objective
Equipment
Samples
Frame Components
Fork
Head Tube
Top Tube
Down Tube
Seat Tube
Chain Stay
Seat Stay
Dropouts
Bottom Bracket Shell
Swing Arm
Frame Construction & Service
Steel
Aluminum
Titanium
Carbon Fiber
CHAPTER 16 — SUSPENSION
Overview
Optional Class
Lesson Objectives
Equipment
Samples
Spring Systems
Helical Compression Springs
Elastomer and Rubber Springs
Air (Gas) Springs
Shocks (Dampers)
Suspension Linkages
Service & Tuning
Spring Preload
Fluid Viscosity
Valving
Linkage
Cyclist Posture
Tire Contact
CHAPTER 17 — ON-RIDE REPAIR
Overview
Tool Choices
Repair Procedures
Flat Tire
Cut or Ripped Tire
Broken Spoke
Dented Rim
Broken Chains
Chain Suck
Twisted Chain
Squeaky and Noisy Chain
Rear Derailleur Shifting Into the Spokes or Frame
Derailleur Not Indexing Properly
Broken Derailleur Body, Cage, or Hanger
Missing Derailleur Pulleys
Front Derailleur Cage Bent or Twisted
Crank Falling Off
Pedals Falling Off
Bent Crank
Bottom Bracket Loose or Falling Apart
Broken Derailleur Cable
Broken Brake Cable
Twisted or Bent Handlebars or Stem
Bent Frame or Fork
Bent Saddle or Seat Post
APPENDICES A–J — REFERENCE MATERIALS
A: Tool List
B: Glossary
C: Torque Recommendations
Torque Conversion Scale
D: Headset Standards
E: Bike Map
F: Bike Examination Form
G: Park Tool School Evaluation
H: FAQ Sheet for Retail Staff
I: Basic Mechanic Training for the Bicycle Retailer
New Bicycle Assembly
Basic Assembly Checklist
J: Registration Form