Bontrager Race XXX Lite Road Crankset 283415 User manual

Part Number 283415

Race XXX Lite Road Crankset
Owner's Manual

Please read this instruction manual thoroughly before using your new
Bontrager part; it contains important safety and maintenance informa-
tion. Also check our web site for further information or updates. If you
do not understand the information, or you have a question about this
part that this manual does not cover, consult your Bontrager dealer.
If you have a question or problem that your Bontrager dealer can’t
handle, contact us at:
Bontrager Components 920.478.4678
Attn: Customer Service http://www.bontrager.com
801 W. Madison Street
Waterloo, Wisconsin 53594



Read this manual before you ride ................................................... 1
Conditions for Use ...................................................................... 1
Introduction .................................................................................... 2
Carbon fiber composite ............................................................... 2
Maintenance .................................................................................... 3
Inspection ................................................................................... 3
Lubrication ................................................................................. 4
Adjustment.................................................................................. 4
General care and maintenance ................................................... 4
Installation instructions.................................................................. 6
Troubleshooting .............................................................................. 8
Bontrager Limited warranty........................................................... 9
Carbon crash replacement policy ............................................... 9







Each Bontrager part is intended to be used in a specic set of conditions. Riding a Bontrager
part in a Use Condition that is more stressful (higher number) than that for which it is
intended can cause the part to fail. Determine the type of Bontrager part you have pur-
chased, and avoid conditions higher than the intent of your part, as listed below:
 
For riding on pavement only
Riding on a paved surface
where the tires do not lose
ground contact
Race XXX Lite road crankset
For riding on improved
paths and roadways only
No jumping
Condition  plus smooth gravel
roads and improved trails with
moderate grades where the
tires do not lose ground contact
For riding on unimproved
trails with small obstacles
Conditions  and 2 plus rough
trails, small obstacles, and
smooth technical areas, includ-
ing areas where momentary
loss of tire contact with the
ground may occur.
 jumping.
Race XXX Lite ATB crankset
For riding on rough trails
with medium obstacles
Conditions , 2, and 3 plus rough
technical areas, moderately
sized obstacles, and small
jumps.
Race XXX Lite ATB crankset
For extreme riding
User caution advised
Jumping, hucking, high speeds,
or aggressive riding on rougher
surfaces, or landing on at
surfaces. This type of riding
is extremely hazardous and
puts unpredictable forces on a
bicycle which may overload the
frame, crankset, or parts.
Big Earl crankset
Conditions for use

2

The drivetrain consists of the parts of the bicycle that transmit power
to the rear wheel:
• Pedals (and toe-clip assemblies on some models)
• Crankset and bottom bracket- left and right crank arms,
chainring(s), and bottom bracket (the axle and bearings on which
the crankset rotates)
(Figure 1)
• Cassette and chain
When the drivetrain is
working properly, shift-
ing is easy, your bike is
quiet, and its efficiency can
reach its maximum. Read
and follow the sections
that discuss the parts that
comprise the drivetrain to
make sure all the parts are
working properly.

The Bontrager Race XXX
Lite crankset is made from
OCLV carbon fiber com-
posite. Carbon fiber is among the strongest materials used in bicycle
manufacture. However, carbon fiber has unique qualities, different from
metal parts, and must be inspected carefully for damage. Follow the
inspection procedures in the Maintenance section.
Figure  Exploded diagram of Race XXX Lite crankset







Introduction

3

Correct maintenance of the crankset and other parts of the drivetrain
will make the shift system work better and pedalling smoother, and
increase the life of the parts. Maintenance includes Inspection, Lubrica-
tion, and Adjustment.

 check that the chain is clean, free
of rust, and properly oiled. A dirty chain can pre-
maturely wear the chainrings. All links of the chain
should pivot smoothly and without squeaking, and
no links of the chain should be deformed.
, a more thorough inspection
is recommended. Check your chain for wear with
a chain wear gauge or a ruler. Each full link of a
new chain measures one inch. If 12 links of your
chain measures 121/8 inches or more, it should be
replaced. With good maintenance, a chain usually
lasts 1000 to 1500 miles. A worn chain will cause
the chainrings of your crankset to wear prema-
turely. Replacing the chain takes special tools and
training and should only be done by your dealer.
Tighten the pedals into the crank arms; turn the right pedal clock-
wise, but the left pedal counter-clockwise (Figure 2):
• Pedals: 350-380 lb•in (40.2-42.9 N•m).
Clean the chainrings and inspect them for damage. If any teeth are
bent or broken, have the chainring replaced by your dealer. Note that
a few teeth have a special shape to enhance shifting. Also check the
bottom bracket adjustment, and tighten the crank bolts:
• Crank bolt (Figure 2): 360-415 lb•in (41-47 N•m)
• Chainring bolts (steel): 70-95 lb•in (7.9-10.7 N•m)
• Chainring bolts (aluminum alloy): 72-80 lb•in (8-9 N•m)
Check the bearings of the bottom bracket. Lift the chain from the
chainrings, and rotate the crank so that one of the arms is parallel the
seat tube. Put one hand on the crank arm and one hand on the seat
tube, and attempt to move the crank arm laterally toward and away
from the seat tube. Then spin the cranks. If the crank feels or sounds
loose, or if the motion stops abruptly or you hear a grinding noise
coming from the bearings, the bearings need to be adjusted or replaced.
Inspect the crankset for fatigue or impact damage:
• Dents
• Cracks
• Scratches
• Deformation
• Discoloration
• Noise
Figure 2 Tightening pedals
Maintenance


Even if you perform regular inspections, if you exceed the limit of
strength of a given part, it may fail if overloaded. After any high force
load, thoroughly inspect all the parts of your bike. High force loads
include crashes, but you don't have to crash to put a high force load
on your bike. For example, hitting a large hole in the road or a sharp
bump such as a railroad track can put large forces on your bike.
The manner in which you ride will determine whether your bike and
its parts will last. If you ride hard or aggressively, you should replace
the bike and/or its parts more often than riders who ride smoothly or
cautiously. When evaluating your use of the crankset, there are many
variables: weight, speed, technique, terrain, maintenance, riding envi-
ronment (humidity, salinity, temperature, etc.), and the frame or part
itself—so it is impossible to give a precise timetable for replacement.
But as a rule, it is better to err on the safe side and replace the bike or
parts more frequently. If you aren't sure, ask your dealer.
Unlike metal parts, carbon fiber parts that have been damaged may
not bend, bulge, or deform; a damaged part may appear to be normal to
a cursory glance. Use the following procedures to inspect carbon fiber
parts:
• Check for scratches, gouges, or other surface problems.
• Check the part for loss of rigidity.
• Check the part for delamination.
• Listen for unusual creaking or clicking noises.
These tests may not be conclusive.
The tests are difficult to describe, so as an aid to describing the tests
we provide a movie of inspecting a carbon fiber part in the owner's
manual section of the Bontrager web site. If you have any doubts about
the integrity of a part, do not ride the bicycle.

 clean and oil the chain. Place a rag behind the chain to
avoid getting oil on the rest of the bicycle. Use a synthetic chain lube or
similar lubrication. See your dealer for a recommended oil. After oiling
your chain, wipe off the excess oil with a rag.
When installing a threaded part, apply a small amount of bicycle
grease to the threads, except for aluminum chainring bolts. With alumi-
num chainring bolts apply a drop of Loctite 222 to the threads.

The bearings in the bottom bracket of the Race XXX Lite crankset are
permanently sealed. If the bearings are too tight or loose, follow the
instructions in the Installation section. If this does not solve the prob-
lem, replace the bearings.
Maintenance



This section provides information about general maintenance.
General care and maintenance (cont.)
 Bontrager carbon
fiber or aluminum cranksets, and their aluminum dropouts, are not as
ductile as steel. Never attempt to make adjustments to a part by bend-
ing or twisting it. If the crankset has been damaged, take it to your
Bontrager dealer for inspection.
 Do not use solvents or harsh chemicals
on the crankset, as they can damage the finish and also the adhesive
which joins the crankset parts. Excessive heat over 180ºF. (82ºC.) can
also damage the adhesive.
 Modifying the crankset in
any way will void the manufacturer's warranty and may be unsafe.
Removing paint from a Bontrager carbon crankset requires special
techniques, so should only be done at the Bontrager factory. See your
Bontrager dealer for more information.
Maintenance



The correct installation of your new Bontrager crankset is critical to
your safety, so this work should be performed only by an experienced
mechanic. If you are not sure of your ability to correctly install this
crankset, have the crankset installed by your Bontrager dealer.

Before installing this crankset on any bike, check with your dealer
or the Bontrager technical service department to ensure that this
Bontrager crankset is compatible with your bicycle frame.
This crankset has the following dimensions, which cannot be modi-
fied:
• “English” bottom bracket, 1.27 x 24 tpi threading
• 68 mm bottom bracket shell (67.25 to 68.25 mm)
Italian-threaded cups that fit this crankset are available from Race Face.
• “English” pedals, 9/16 x 20 tpi threading

1. Clean the bottom bracket threads.
2. Firmly snap the bottom bracket sleeve
(black plastic) into the right cup.
3. Start the threads of the right cup by hand
(Figure 3). The right cup has normal
threading.
3. Tighten the right cup to 430 lb•in (17-19
N•m) (Figure 4).
4. Start the threads of the left cup by hand
(Figure 5). The left cup has left-hand
threads.
5. Tighten the left cup to 430 lb•in (17-19
N•m) (Figure 6). Figure 3 Start the threads
of the right cup by hand
Figure  Tighten the right
cup
Figure  Start the threads
of the left cup by hand
Figure  Tighten the left
cup
Installation



1. Apply a thin film of bicycle grease to the entire axle, including the
splines.
2. Slide the elastomer washer (A, Figure 7) and the 1.0 mm spacer (B,
Figure 7) onto the axle until they touch the crank.
3. Gently guide the axle through the left cup (Figure 7). Keep the axle
centered and aligned.
If needed to push the axle through, lightly tap the axle end with a plastic
mallet.
Make sure the axle is aligned with the right cup. If misaligned, the axle could
damage the bearings.
4. Slide the elastomer washer onto the axle (Figure 8) until it touches
the cup.
5. As you hold the right crank at 180 degrees with the left crank
(Figure 9), push the crank onto the axle splines. When the crank
stops (a shallow distance) turn the axle bolt to start the threads.
6. Tighten the axle bolt until the crank stops, between approximately
360-600 lb•in (34- 68 N•m).

Rotate the cranks so that one of the arms
is parallel the seat tube. Put one hand on the
crank arm and one hand on the seat tube, and
attempt to move the crank arm laterally toward
and away from the seat tube. Then spin the
cranks. Some seal drag is normal, especially
with new bearings.
If the crank feels or sounds loose, or if the
motion stops abruptly or you hear a grinding
noise coming from the bearings, refer to the
Troubleshooting chart.
Figure 0 Tighten the crank
bolt
Figure  Insert the axle with
the washers
A: Elastomer washer
B: .0 mm spacer washer
A
B
Figure 8 Attach the right
elastomer (A)
A
Figure 9 Align the right
crank at 80 degrees to the
left crank
Installation

8

  
Assembly
too tight
• Bottom bracket
shell too wide
• Bottom bracket
shell not faced
• Bottom bracket
shell threads mis-
aligned
• “Stack” of parts is
wrong
Face the bottom bracket shell
to remove all paint and
square the surface.
Make sure the bottom bracket
shell is within tolerance (see
page 6).
If shell is faced and tolerance
is correct, remove the 1.0
mm spacer and reassemble.
If this does not correct the
problem, change the stock
elastomer washer on the left
side to the thinner, 2.5 mm
(available as an accessory-
see your dealer).
If this assembly is loose, switch back
to the standard 3.5 mm elastomer.
Assembly
too loose
• Bottom bracket
shell is too narrow
• Bottom bracket
shell not faced
• Bottom bracket
shell threads mis-
aligned
• “Stack” of parts is
wrong
Face the bottom bracket shell
to remove all paint and
square the surface.
Make sure the bottom bracket
shell is within tolerance (see
page 6).
If shell is faced and tolerance
is correct, add an additional
1.0 mm spacer (available
as an accessory- see your
dealer) to the left side and
reassemble.
If this assembly is too tight, change
the stock 3.5 mm elastomer to a
2.5 mm elastomer, available as an
accessory- see your dealer.
Chain-line
incorrect
• Incorrect bottom
bracket shell align-
ment
• Incorrect chain-
rings
• Incorrect spacers
on axle
If the chain-line is incorrect,
shifting performance may be
impaired. The 1.0 mm spacers
can be moved from side-to-
side or removed as necessary,
as long as correct bearing
adjustment is achieved. The
spacer arrangement used in
this manual should result in a
chain-line of 43.5 mm.
Troubleshooting

9

Bontrager warrants each new Bontrager component or wheelset
against defects in workmanship and materials:

• All Bontrager components and accessories, except consumables
such as tires and inner tubes.

• Bontrager consumables such as tires and inner tubes.

• Normal wear and tear
• Improper assembly
• Improper follow-up maintenance
• Installation of parts or accessories not originally intended for or
compatible with the Bontrager fork, components, or wheelsets as
sold
• Damage or failure due to accident, misuse, abuse, or neglect
• Labor charges for part replacement or changeover
This warranty is void in its entirety by any modification of the wheel-
set or components.
This warranty is expressly limited to the repair or replacement of a
defective item and is the sole remedy of the warranty. This warranty
extends from the date of purchase, applies only to the original owner,
and is not transferable. Bontrager is not responsible for incidental
or consequential damages. Some states do not allow the exclusion of
incidental or consequential damages, so the above exclusion may not
apply to you.
Claims under this warranty must be made through an authorized
Bontrager dealer. Proof of purchase is required.
This warranty gives the consumer specific legal rights, and those
rights may vary from place to place. This warranty does not affect the
statutory rights of the consumer.

Assessing any damage done to a carbon fiber part requires more
experience than is needed to inspect metal parts. If you crash or impact
your bike and the force of the impact is absorbed by a carbon part, we
strongly encourage you to replace the part, even if there are no indica-
tions of damage.
If such a crash or impact occurs, Bontrager offers a crash replace-
ment program for carbon parts, substantially reducing any replace-
ment cost. To take advantage of this program, contact us using the
information listed in the front of the manual, and ask for the Warranty
department.

0