Pantour PANTOUR SUSPENSION HUB User manual

Pantour
Suspension
Hubs
Pantour Rocklite
front suspension disc hub
1 inch travel, 100 mm axle
Rohloff 4 bolt rotor
Pantour Delite
front suspension hub
1/2 inch travel, 74 mm axle
Pantour Prolite
front suspension hub
1/2 inch travel, 100 mm axle
This manual contains important safety, performance and
maintenance information.
The Pantour front hubs are 74 mm and 100 mm axle.
Bicycling can be a hazardous activity even under the best
circumstances. Disregard of our instructions can change
the characteristics of our product, which may cause loss
of control and injury.
Wheel Building and Installation.
Wheel building is a skill that requires proper training and
specialized tools.We recommend using your bike dealer.
Pantour suspension hubs are designed to be used with
quick release and for lacing with 14 or 15 gauge spokes.
Pantour Delite and Prolite may be laced all heads out
radial or cross,Pantour Rocklite is recommended to be
laced double or triple cross.
The way the spokes are installed and the tension applied
to the spokes have a great effect on the strength of the
wheel and also on the force applied to the area around the
spoke holes in the flange of he hub.Wheels must be true
and round for the brakes to work effectively. Spin the
wheel and check clearance.The brake shoes must contact
the wheel rim within an inch of brake lever movement.
To install the FRONT WHEEL make sure the dust cap
screw (one side only) is at the
back facing straight up, which is the median trajectory
position. Fit the wheel into the dropouts.To fasten the
wheel use only skewers with correct length.Turn release
lever outward until it is at least at a right angle to the bike.
Tighten adjusting nut as much as possible by hand. Turn
release lever to the closed position, after closure, the
release lever should be parallel to the drop out. If the
release lever can be closed relatively easily, the tension
force is inadequate. Open release lever, tighten adjusting
nut slightly and close release lever.
Adjusting the Brakes.
The brake shoes should be set so that without the rider on
bike the brake pad are set slightly above the outer edge of
the rim.We recommend rims with 10 - 12 mm braking sur-
face, narrower should not be used. Riding with improperly
adjusted brakes or worn brake pad is dangerous and can
result in serious injury.
Installation of the rotor for the Pantour Rocklite disc
suspension hub.
Pantour suspension hub is designed for 4 bolt rotors in
standard sizes 160, 165, 180, 185 and 203 mm. If the rotor
is not already installed, place the adaptor onto the flange.
Line up the threaded holes, install and tighten evenly the
socket screws. Rotor mounting bolts must be thread 10 -
13 mm into the hub flange.
1

All models are sold with a trajectory feature, adjustable to every fork drop out angle on
the market.This influences the spring rate of the suspension in relation to the
rider. Different screw positions change how the hub is held in the dropouts and results
in more vertical or horizontal travel. For natural bump absorption the best set up is with
a rearward position of the screws.The location of the trajectory screws on both end caps
must be consistent.
Elastomer.
The Pantour suspension hub is assembled with replaceable elastomers,
recommended for rider's weight 100 - 200 lb. For over 200 lb a special (harder)
elastomer is recommended, please contact your bike dealer for having a harder
elastomer installed.
We have engineered the shape and material of the elastomer to bring the best
performance. We will not be liable for any changes made to the elastomers.If you
notice a change in performance it may be caused by elastomer wear and it must be
replaced.
Forkdropoutalignment.
Whenassembled,the hub should berotated slightlyto
ensurethatthe trajectoryscrew heads areheld fully
forwardtothe front ofthe dropout.This ensures that
the suspensionworks properly.Beforethe QRskewer
istightened onthe fork,the wheel alignment mustbe
straight.
Travel is vertical. 1/2 Vertical travel and 1/2 horizontal. Horizontal travel.
Pantour Trajectory Feature.
2

3
Pivot rod.
Axle rod.
Quick release.
B
A
PANTOUR SUSPENSION HUB DISASSEMBLY
Elastomer replacement.
Loosen end cap (with slit) screw using 2.5 mm Allen wrench
(Rocklite thicker end cap). Remove end cap and washers from
pivot rod. Make sure to keep them separate for reassembly. Pull
end cap assembly (end cap and axle rods) out of center tube.
Do not disassemble the rod assembly any further ! Remove
elastomer and rebound (negative) spring (round or square)
from center tube. If you are replacing the elastomer or re-
bound springs do not disassemble the hub any further.
To continue go to assembly § *.
Bearing replacement.
Delite and Prolite hub - use A) socket, tube or round object less
than 30 mm diameter, Rocklite 35 mm diameter. Delite and Pro-
lite hub - use B) a hollow round object with an inside diameter
between 45 - 55 mm, Rocklite 50 - 65 mm. Place the hub be-
tween these two tools and press center tube (with bearing) out
of hub shell as shown in the picture. Set c enter tube in the vise.
IMPORTANT! The jaws of the vise s hould not be clamped tight,
but just slightly touching the centertube. Use round object 32
mm diameter to remove the second bearing from hub shel.
Bushing replacement.
Loosen end cap (with slit) screw using 2.5 mm Allen wrench
(Rocklite thicker end cap). Remove end cap and washers from
pivot rod. Make sure to keep them separate for reassembly. Pull
end cap assembly (end cap and axle rods) out of center tube.Do
not disassemble the rod assembly any further ! Use a hollow
round object to remove the bushing. Place new bushing be-
tween the hub shell and vise and press the bushing into the hole
until flush.
ASSEMBLY
Using a vise press the first bearing into hub shell until flush.
Align center tube with second bearing. Insert center tube with
bearing into hub shell. Important! Center tube and bearings must
be centered. Press together until flush.
§* Slide a rebound (negative) spring into left pocket of center
tube and center it. Slide a rebound spring i nto right pocket of
center tube, push it almost to the end of center tube.Insert rod
assembly into center tube as shown on picture. Insert cube
elastomer into center tube under quick release axle rod. It must
be centered in the hub. Axle rod should be between negative
spring and elastomer. Press in the elastomer .It must be centered
in the hub.Notice the correct position of quick release axle rod.
It must be resting on negative spring. Place remaining washers
on pivot axle rod. Slide end cap onto axle rods as far as possible.
Using vise, clamp the hub.Tighten end cap screw.

1. Quick release.
2. End cap.
3. Washers..
4. Bearing.
5. Debris guard.
6. Center tube.
7. Pivot rod.
8. Axle rod.
9. Elastomer.
10. Negative spring.
11. Hub shell.
12. Bushing.
13. QR nut.
Prolite and Delite
suspension
hub.
4
1
2
3
5
4
12
6
78
12
10
9
11
4
35
2
13
13
2
5
3
4
12
6
8
7
12
9
10
11
4
5
3
2
1
Rocklite
suspension
hub.

FRONT PANTOUR SUSPENSION HUB
YEAR 2001 - 2003
FRONT PANTOUR SUSPENSION HUB
YEAR 2004 - PRESENT
FRONT
OF BIKE
TRAJECTORY SCREW
QUICK RELEASE AXLE
SLIT
FRONT
FORK
END CAP
HUB SHELL
FRONT
OF BIKE
SCREW
QUICK RELEASE AXLE
FORK
SLITS
TRAJECTORY SCREW
HUB SHELL
END CAP
FRONT
SCREW
Bike fork positioning and Pantour end cap alignment.
Maintenance of Pantour suspension hubs:
The front hubs are essentially maintenance free. Riding conditions will determine
how often to maintain your hub. In wet or muddy conditions maintain the hub
every 3 - 6 months. To remove dirt from inside of the hub shell you may need to
disassemble the hub, please follow our assembly and disassembly instructions.
We have engineered the shape and material of the elastomer to bring the best
performance. We will not be liable for any changes made to the elastomers.
If you notice a change in performance it may be caused by elastomer wear and
should be replaced. Life expectancy of the elastomer is 1 year.The sealed cart-
ridge bearings life will wary depending on conditions. In normal dry conditions
the bearings should last for at least 5 years. The seal bearing debris guard is
greatly increasing the life of bearings. Bearing noise will signal that replacement
is needed. Ask your bike dealer for part replacement.
PANTOUR WARRANTY & RETURN POLICY.
Warranty for Pantour hub is 2 years from the original date of purchase. Eligibility
for warranty is determined at the factory by the Pantour returns personnel. If a
manufacturing problem is determined the policy is to repair or replace the pro-
duct at no charge.The warranty does not cover damage from misuse, abuse,
reasonable wear and tear, crash or failure to perform routine maintenance as
instructed, or use other than that for which the product was intended. We will not
be liable for any changes made to the product or incorrect hub assembly damage.
If you notice a change in performance, please inspect the hub and do not continue
riding if service is needed. Spare elastomers, negative (rebound) springs, bearings,
washers or other replacement can be purchased from your bike dealer.
CONTACT in USA.
Pantour Tel. Fax [phone]
3029 Palm Hill Dr.
Vista, CA 92084
www.pantourhub.com
[e-mail]
5

6
QUICK RELEASE ROD
CLAMP SCREW
END CAP
SPLIT WASHER
AXLE ROD
PIVOT ROD
WASHERS
PIVOT ROD
End cap assembly.
Troubleshooting.
The suspension is locking up.
Step 1. Check if the pivot rod has 2 washers on each side.
Step 2. If the pivot rod washers are missing please order the washers from Pantour or
your local bike shop and install the washers as shown.
Step 3. If washers are not missing, please call Pantour to order split washers. These
washers will extend the length of the axle and pivot rod and prevent hub from locking.
Install the split washers in axle rod hole located on the end cap.
The suspension is bottomed out.
Step 1. Check the elastomer and replace it as described in the instructions on page 3 of
our Manual. For your best riding performance use the elastomer Pantour selected for your
weight category.
Bearings replacement.
Step 1. Call Pantour or your local bike shop to order new bearings. Replace the bearings
as described in the instructions on page 3 of our Manual.
Loosed bearing.
Step 1. Remove the bearing from hub shell bearing pocket. Spread a lactate around the
bearing and bearing pocket and press fit the bearing in as described in the instructions
on page 3 of our Manual (bearing installation).
Hub wobble.
Step 1. Check if the bearings are not loose.
Step 2. Check if the bushings (part No.12 on pg. 4) are not loose. Use lactate around
the bushing and press fit it into the center tube until flush.
Step 3. If the bushings are wear out, please call Pantour or your local bike shop for
new parts. Follow step 2. for installation.
Elastomer replacement.
Step. 1 Call Pantour or your local bike shop to order new elastomer. Replace the elastomer
as described in the instructions on page 3 of our Manual.
Bushing replacement.
Step 1. Follow our instructions under Hub wobble.
Missing part.
Step 1. Call Pantour or your local bike shop to order the part you need.

Hub with no load.
Brake pad with hub with no load.
POSITIONS OF THE BRAKE PAD.
A HUB WITH AN ELASTOMER WITH NO LOAD, THE BRAKE PAD IS AT THE TOP OF THE BRAKE BAND.
A HUB WITH AN ELASTOMER WITH PRELOAD, THE BRAKE PAD IS RIGHT IN THE MIDDLE OF THE BRAKE BAND.
Hub with preload.
Brake pad with hub with preload.
7