This manual provides comprehensive instructions for the bearing replacement of Prime SR1, SR1D, SR2, and SR2D rear hubs. It is a technical guide designed for individuals performing maintenance on these specific bicycle components.

Function Description:

The Prime rear hubs are critical components of a bicycle's wheelset, facilitating the rotation of the wheel and housing the freehub mechanism, which allows the rider to coast without pedaling. The bearings within these hubs ensure smooth, low-friction rotation of the axle and freehub body. Over time, these bearings can wear out, necessitating replacement to maintain optimal performance and prevent damage to other hub components. This manual details the process of replacing these worn bearings, ensuring the continued smooth operation and longevity of the Prime rear hubs.

Important Technical Specifications:

The manual provides a detailed table of required bearings for different models of Prime Star Ratchet rear hubs, categorized by hub shell (Drive Side and Non-Drive Side) and Freehub type (HG (Shimano®), XDR (SRAM®), NEW (Campagnolo®), and Campagnolo®). The bearing specifications are given in terms of ID (Internal Diameter), OD (Outer Diameter), and W (Width), all in millimeters (mm).

For the hub shell:

SR1 (Straight Pull - Rim Brake):
- Drive Side (Right): 1 x 17287 (17.0mm ID x 28.0mm OD x 7.0mm W)
- Non-Drive Side (Left): 1 x 6802 (15.0mm ID x 28.0mm OD x 7.0mm W)
SR1D (Straight Pull - Disc Brake):
- Drive Side (Right): 1 x 17287 (17.0mm ID x 28.0mm OD x 7.0mm W)
- Non-Drive Side (Left): 1 x 6802 (15.0mm ID x 28.0mm OD x 7.0mm W)
SR2 (J-Bend - Rim Brake):
- Drive Side (Right): 1 x 17287 (17.0mm ID x 28.0mm OD x 7.0mm W)
- Non-Drive Side (Left): 1 x 6802 (15.0mm ID x 28.0mm OD x 7.0mm W)
SR2D (J-Bend - Disc Brake):
- Drive Side (Right): 1 x 17287 (17.0mm ID x 28.0mm OD x 7.0mm W)
- Non-Drive Side (Left): 1 x 6802 (15.0mm ID x 28.0mm OD x 7.0mm W)

For the Freehub:

HG (Shimano®): 2 x 6802 (15.0mm ID x 28.0mm OD x 7.0mm W)
XDR (SRAM®): 2 x 15267 (15.0mm ID x 26.0mm OD x 7.0mm W)
NEW (Campagnolo®): 2 x 6802 (15.0mm ID x 28.0mm OD x 7.0mm W)
Campy (Campagnolo®): 2 x 15267 (15.0mm ID x 26.0mm OD x 7.0mm W)

The manual also includes an exploded diagram with a parts list, detailing each component of the hub and its corresponding quantity. Key components include:

Non Drive Side End Cap (Right) - Quantity: 1
O-Ring (Pre Fitted in End Caps) - Quantity: 1
Bearing Dust Cover - Quantity: 1
Non Drive Side Bearing - Quantity: 1
Hub Shell - Quantity: 1
Axle - Quantity: 1
Drive Side Bearing - Quantity: 1
Ratchet Washer - Quantity: 1
Ratchet Ring - Quantity: 1
Star Ratchet - Quantity: 2
Star Ratchet Bushing - Quantity: 1
Hubshell Seal - Quantity: 1
Star Ratchet Spring - Quantity: 2
C-Ring (Pre Fitted to Freehub) - Quantity: 1
Freehub - Quantity: 1
Freehub Bearing - Quantity: 2
Bearing Retaining Circlip - Quantity: 1
Freehub Bearing Spacer - Quantity: 1
Freehub Bearing Dust Cover - Quantity: 1
Drive Side End Cap (Left) - Quantity: 1
Freehub Spacer (Only Required on HG Freehubs for use with 10 Speed) - Quantity: 1

Usage Features:

This manual is specifically for maintenance, not general usage. However, proper bearing replacement ensures the optimal "usage" of the bicycle's rear wheel. The smooth rotation provided by correctly installed bearings contributes to efficient power transfer and a more enjoyable riding experience. The different freehub options (HG, XDR, Campagnolo) indicate compatibility with various drivetrain systems, allowing riders to use Prime hubs with their preferred gear setups. The distinction between rim brake and disc brake models highlights the adaptability of these hubs to different braking systems.

Maintenance Features:

The manual is a comprehensive guide for bearing replacement, a crucial maintenance task. It emphasizes safety warnings and cautions throughout the process.

Required Tools for Assembly and Disassembly:

Isopropyl Alcohol
Cleaning Cloth
Anti-Seize Grease (Teflon based)
Star Ratchet Grease
Star Ratchet Ring Removal Tool
Bearing Removal Tool - Compatible with all necessary bearings
Dead Blow Mallet or Rubber Mallet
Drift
Bearing Press Fit Tool - Compatible with all necessary bearings
Circlip Pliers
Vice
Workshop or Latex Gloves
Protective Eye Wear
Small Flat Head Screw Driver
Torque Wrench with 24mm Socket or Crow Foot Spanner
Hub Support Tool

Specific Tool Links Provided:

Star Ratchet Ring Removal Tool:
- Lifeline: https://www.wiggle.com/p/lifeline-pro-inner-ratchet-hub-nut-removal-tool
- Bearing Pro: https://www.bearingprotools.com/products/ring-nut-locking-tool-star-ratchet-for-dt-swiss-180-240-240s-350-rear-hubs?variant=39277209967541
Bearing Press Fit Tool:
- Lifeline: https://www.wiggle.com/p/lifeline-pro-bearing-press-set
- Wheels Manufacturing: https://wheelsmfg.com/presses-tools/presses-extractors/bearing-press-pro-kit.html
Bearing Removal Tool:
- Bearing Pro: https://www.bearingprotools.com/products/bearing-puller?variant=39277209967541

Disassembly Steps (Overview):

Remove both non-drive side and drive side end caps.
Slide the freehub off the axle and place to one side.
Slide off both ratchet springs and star ratchets.
Pull off the star ratchet bushing that seats over the axle on the drive side.
Using a small flat head screwdriver, remove the hubshell seal.
Use the Ratchet ring removal tool to loosen and remove the ratchet ring.
Slide off the ratchet washer.
Place the hub/wheel on the hub support tool, knock out the axle, non-drive side bearing, and bearing dust cover using a dead blow mallet or rubber mallet.
Remove the dust seal and bearing off the axle.
Flip the axle 180 degrees and reinsert into the hubshell from the non-drive side.
Place the hub/wheel on the hub support tool, knock out the drive side bearing using the axle as a drift.
For freehub bearing removal (XDR/SRAM freehub illustrated):
- Remove the freehub seal using a small flat head screwdriver.
- Take the correct bearing extractor tool, drift it into the back of the freehub, and use a dead blow mallet to remove the outer bearing.
- Use circlip pliers to remove the bearing retaining circlip.
- Take the correct bearing extractor tool, drift it into the back of the freehub, and use a dead blow mallet to remove the inner bearing.

Assembly Steps (Overview):

Apply Teflon anti-seize grease to the drive side hubshell bearing area. Press the correct bearing into the hubshell.
Place the ratchet washer over the drive side bearing.
Screw in the ratchet ring into the hubshell, turning it clockwise using the ratchet ring removal tool. Ensure the recessed side of the ratchet ring faces the ratchet washer. Tighten to 20Nm with a torque wrench.
Apply Teflon anti-seize grease to the non-drive side bearing surface on the axle. Fit the replacement non-drive side bearing, bearing dust seal, and non-drive side end cap onto the axle.
Apply Teflon anti-seize grease to the hubshell area. Place the hub/wheel on the hub support tool, knock the axle and hardware into the hubshell using a dead blow mallet.
Press in the hubshell seal, ensuring it is pressed evenly and flat against the hubshell.
Apply a thin layer of ratchet grease over the surface of the star ratchet bushing. Slide the bushing over the axle until it seats against the drive side hubshell bearing.
Apply a thin layer of ratchet grease across any contacting surfaces of both ratchet springs and star ratchets. Lubricate the springs and ratchets and slide them into the correct order.
For freehub bearing installation (XDR/SRAM freehub illustrated):
- Apply Teflon anti-seize grease to the freehub body. Use a bearing press to insert the inner freehub bearing until it is fully seated.
- Use circlip pliers to re-fit the bearing retaining circlip.
- Apply Teflon anti-seize grease to the freehub body. Use a bearing press to insert the bearing spacer and outer freehub bearing until it is fully seated.
- Press in the bearing dust seal into the freehub, ensuring it is pressed evenly and seated against the outer bearing.
Slide the freehub onto the axle of the main hub, ensuring the ratchets seat correctly within the hubshell and the freehub is pushed as far as it will sit on the axle.
Press on the drive side endcap, ensuring it is firmly positioned on the axle.

Important Warnings and Cautions:

Always wear protective eyewear, gloves, and appropriate clothing.
The manual is intended for professional mechanics; failure to follow instructions may result in serious injury or void warranty.
Incorrect use of tools can lead to premature failure of Prime products and void warranty.
Ensure the hubshell seal is fitted correctly and evenly to prevent friction and drag on the freehub.
Star ratchets and springs must be fitted with the correct orientation to prevent premature failure.
A test ride is advised after re-assembly to ensure everything has been fitted correctly, and all necessary safety gear should be used.
Different bearing specifications are required depending on the freehub type (HG, XDR, Campagnolo), so always refer to the bearing chart.

This manual is a critical resource for anyone undertaking bearing replacement on Prime SR series rear hubs, providing detailed, step-by-step instructions and essential safety information to ensure a successful and safe maintenance procedure.

Prime SR1 - Page 7

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