Reynolds RZR 46 User manual

ReynoldsCycling.com
Thank you for becoming part of the Reynolds family!
By choosing Reynolds, you have purchased one of the best wheelsets in the world for quality,
performance, and overall value. This manual is an essential part of the product, carefully read and
follow instructions provided herein. Please keep this manual in a safe place for future reference.
CONTENTS
1. TECHNICAL SPECIFICATIONS |02
2. TECHNICAL WHEEL SPECIFICATIONS |03
3. CLINCHER TIRES |03–04
4. TUBULAR TIRES |04–07
5. CASSETTE INSTALLATION |07–08
6. USING THE QUICK RELEASE |08–09
7. BRAKES |10
8. PERIODIC WHEEL AND BRAKE PAD MAINTENANCE |10-11
9. OPERATING PRESSURES |12

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MECHANIC QUALIFICATION
Please be advised that many bicycle service and repair tasks require specialized knowledge, tools and
experience. General mechanical aptitude may not be sufficient to properly service or repair your bicycle
and/or Reynolds wheels. If you have any doubt regarding your service or repair ability, please take your
bicycle to a qualified mechanic or an authorized Reynolds dealer/distributor.
INTENDED USE
• Useofroadwheels: For road racing or general cycling on smooth, dry road surfaces only.
Not intended for use on motorized vehicles or for use on vehicles carrying more than one
operator/rider.
• Useofmountainwheels: Only use on open, and approved, trails and public lands.
Not intended for use on motorized vehicles or for use on vehicles carrying more than one
operator/rider. Any such use constitutes misuse which will void the Reynolds warranty and
may result in an accident, serious personal injury, death or property damage.
COMPONENT WEAR INSPECTION REQUIREMENT
The longevity of your Reynolds wheels depends on many factors. Factors that will determining their
longevity are: rider size and riding style, environmental conditions, tire specifications and air pressure, terrain
and geography, cleanliness and maintenance, brake pad composition, and impacts or falls. Improper or
harsh use may also compromise the structural integrity and significantly reduce the lifespan of your wheels.
Some components of the wheels are subject to wear over time and are not covered under warranty because
this is not due to defect. These items not covered under warranty due to normal wear and tear include:
bearings, brake pads and rim braking surface. Use only Reynolds recommended brake pads. Perform routine
maintenance and cleaning on brake pads and braking surface of rim.
Forcareandusagerecommendations,seeSection8ofthismanualorrefertotheReynoldswebsiteat
www.reynoldscycling.com/maintenance.
Have your wheels regularly inspected by a qualified mechanic for impact and stress marks, cracks,
deformations, and signs of fatigue or wear. If the inspection reveals any damage, no matter how slight,
immediately replace the component. Components that have experienced excessive wear also need
immediate replacement. Frequency of inspection depends on many factors; see Section 8 of this manual
for further assistance. Contact your authorized Reynolds dealer/distributor for suggested inspection/
maintenance schedule that is best fit for your use, riding style and conditions. If you weigh 82kg/180 lbs or
more, you must be especially vigilant and have your bicycle and components inspected more frequently.
Before using Reynolds wheels please recognize that there are risks inherent in bicycle riding. A bicycle
component can fail while riding resulting in an accident, injury or possibly death. By your purchase and use
of Reynolds wheels you expressly, voluntarily and knowingly accept and assume these risks including,
but not limited to: the risk of passive or active negligence of Reynolds or hidden, latent or obvious defect
in the product. Furthermore, you agree to hold Reynolds harmless to the fullest extent permitted by law
against any resulting damages.
WARNING: Failure to follow any of the instructions in this manual could result in failure of the
product, resulting in an accident, personal injury or death.
Ifyouhaveanyquestionspleasecontactanauthorizeddealer/distributoror
Reynoldscustomerserviceat866-798-3040;[e-mail].

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1. TECHNICAL SPECIFICATIONS
PRE-RIDE SAFETY CHECK
• Always wear a helmet when riding a bicycle. See the owners manual that came with your bicycle
for additional safety recommendations and mechanical warnings.
• Check to see that all quick release levers, nuts and bolts are properly adjusted. See the “Quick
Release” instructions in Section 6 of this manual. While bouncing the bike on the ground, look and
listen for anything that may be loose.
• Be sure that your tires are properly inflated to the correct pressure and that there is no damage to
the tread or sidewall.
• Be sure that none of the spokes are damaged, loose or missing. Make sure there also is no
deformation, cracks or sign of fatigue or stress on the rims.
• Be sure that the wheels are exactly centered in both frame and fork. Spin wheels to be sure that
they do not wobble up and down or side to side, and that there is no contact with brake pads
during rotation.
• Check your brake pads and cables to be sure that they are in good condition and free of debris.
• Test your brakes prior to your ride to ensure that they are operating properly.
• Check reflectors and lights to ensure that they are clean, straight, securely mounted and
operating properly where require by law. Reynolds wheels do not include reflectors.
Proper reflectors meeting the Consumer Product Safety Commission (CPSC) regulation should be
installed if bicycle will be used on public roads.
• Learn and follow the local bicycle laws and regulations, and obey all traffic signals, signs and
laws while you ride.
WARNING: Do not ride your bicycle if it does not pass the pre-ride safety check listed above.
Correct any deficient condition(s) before you ride.
GENERAL SAFETY RECOMMENDATIONS
• Always wear a properly fitted and fastened bicycle helmet that has been approved by
ANSI or SNELL.
• Be sure that the periodic maintenance is strictly followed (see Section 8 of this manual).
• Always use original Reynolds, or Reynolds-approved replacement parts.
• DONOT make modifications to Reynolds wheels. Modification, improper service, alteration or use
of aftermarket parts voids the warranty and could cause wheel malfunction resulting in an accident,
injury or death.
• Components that are bent, cracked or otherwise damaged in an accident or as a result of impact
must not be straightened. They must be replaced immediately with original Reynolds parts.
• Wear clothing that will make you visible to traffic such as neon, fluorescent or other bright colors.
• Avoid bicycle riding at night. It’s harder to see obstructions on the ground as well as be seen by
traffic once it becomes dusk. If you do ride at night, you should equip your bicycle with headlights,
taillights and reflectors, as required by law.
• When riding in wet conditions, the stopping power of your brakes is greatly reduced and the
adherence your tires have to the ground is considerably reduced. Your braking power may also
vary sharply, due to the progressive drying of the braking surface during brake use. This will make
it harder to predict performance and control of your bicycle, making it harder to stop. When riding
your bicycle in wet conditions, use extra caution to avoid an accident.
• Please get in touch with your local dealer/distributor, or contact Reynolds directly with any
questions, comments or concerns.

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2. TECHNICAL WHEEL SPECIFICATIONS
WHEEL SPECIFICATIONS
• E.T.R.T.O. (European Tire and Rim Technical Organization) WHEEL RIM DIAMETER INFORMATION
— 700c Carbon road tubular 633 x 20.5c
— 700c Carbon road clincher 622 x 15c
— 700c Alloy road clincher 622 x 15c
— Mountain tubular 571 x 25
— Mountain clincher 559 x 17c
• Inflation pressures: See “Operating Pressures” Table in Section 9 of this manual
• Hub Specifications/Axle spacing
— Front axle = 100mm +/- 0.5mm
— Road cassette = 130mm +/- 0.5mm
— Mountain cassette = 135mm +/- 0.5mm
— Track rear axle = 120mm +/- 0.5mm
3. CLINCHER TIRES
WARNING: CLINCHER RIM/TIRE COMPATIBILITY
All Reynolds rims are built in strict accordance with E.T.R.T.O. specifications, and are very
dimensionally precise. If a clincher tire is too easy to install on a Reynolds rim, that tire is
probably too big and will not seat properly on the rim, which constitutes a significant safety
concern. Use only high quality clincher tires that require use of tire levers and reasonable
installation effort. Using a tire that fits loosely on the rim can cause unexpected tire failure
resulting in an accident, injury or death.
• The clincher wheel you have purchased is designed to use clincher tires only.
• Before installing the tires, cover the exposed spoke holes in the tire bed using Reynolds supplied rim
strips.
• Ensure that the tire and wheel are compatible in accordance with E.T.R.T.O. standards before
installing the wheel. Check that the diameter indicated on the tire is 622 and that the cross section is
between 23mm and 25mm, mountain tire diameter indicated should be 559 and the cross section is
between 32mm and 60mm (1.25˝–2.35˝).
• Use inner tubes with a long valve stem (at least 43mm), or Reynolds supplied valve extenders.
WARNING: Failure to properly install the tire can cause sudden and unexpected loss of tire
pressure, resulting in an accident, injury or death.
INSTALLING CLINCHER TIRES
Be sure that you do not damage, scratch, crush or otherwise distort any portion of the rim when installing
the tire. Use only plastic or nylon tire levers when installing.
• Before installing tires onto new Reynolds wheels, take note of the serial numbers located in the
tire bed opposite the valve stem hole. These serial numbers are required to register your Reynolds
Cycling warranty or RAP.
• Confirm installation of Reynolds supplied rim strip onto tire bed.
• Install one side of the clincher tire into the tire seat provided on the rim (Fig.1).
• Slightly inflate the inner tube to facilitate assembly.
• Toinatethetire: remove the valve cap, unscrew the presta-valve and inflate tire using a
compressor or pump with a pressure gauge to obtain the required pressure. Tighten the valve and
replace the cap.
• Insert the valve stem through the hole in the rim, and position the remainder of the partially inflated
inner tube inside of the tire, between the tire and rim seat (tire bed).
• Install the second side of the tire into the rim seat.

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• To properly set the tube and tire onto the rim, inflate the inner tube to between 2-3 atmospheres.
Next, manually set the tube and tire on the rim, ensuring that the tire bead is evenly positioned
around the outside circumference of the rim. Make sure that the tube is correctly positioned
within the tire and that the tire is correctly positioned onto the rim. Lastly, inflate the tube fully
to the correct pressure. Please inflate the tube slowly, making sure that you maintain the correct
positioning of the valve stem, tube and tire on the rim.
• Todeatethetire: remove the valve cap, unscrew the presta-valve, press and hold down the valve
core to obtain required pressure. Tighten the presta-valve and replace the cap.
WARNING: Check that the clincher rim shows no sign of significant wear, contamination, damage
or deformation along the sidewall or brake track. This could cause the rim to unexpectedly break
resulting in an accident, injury, or death.
WARNING: Never exceed the maximum inflation pressure recommended by the tire manufacturer
for the cross section of the clincher tire that you are using. See the “Opearting Pressures” table in
Section 9 of this manual. Excess tire pressure reduces the tire’s grip on the road and increases the
risk of the tire unexpectedly bursting. Inflation pressure that is too low reduces tire performance
and increases the probability of sudden and unexpected loss of tire pressure. In addition,
premature wear and damage to the rim may occur. Incorrect tire pressure could cause tire failure
or loss of control of the bicycle resulting in an accident, injury or death.
WARNING: Replace the wheel when the distance between the shoulders/hook beads of a road
rim is greater than 15mm mountain rim greater than 17mm (Fig. 2). A deformed rim may cause
the clincher to suddenly fail resulting in an accident, personal injury or death.
4. TUBULAR TIRES
WARNING: TUBULAR RIM/TUBULAR TIRE COMPATIBILITY
All Reynolds rims are built in strict accordance with E.T.R.T.O. specifications, and are very
dimensionally precise. Use only high quality tubular tires, tubular tire glue and follow
manufacturer’s recommended installation procedure. Take your time and use extra care to
ensure correct installation of the tire and glue onto the rim. Tires that lack sufficient glue bond,
fit loosely on the rims, have defective base tape, are improperly installed or ridden before glue
has sufficiently dried, can cause unexpected tire failure or separation from wheel resulting in an
accident, injury or death.
• Before gluing and mounting tires to your new Reynolds wheels, take note of the serial numbers
located in the tire bed opposite the valve stem hole. These serial numbers are required to register
your Reynolds Cycling warranty.
• The tubular wheel you have purchased is designed to use 28˝ X 22mm diameter tubular tires.
• Before fitting the tires, check that the diameter indicated on the tire is 633/28˝ and that the cross
section is approximately 22mm to ensure that the tire and wheel are compatible in accordance with

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E.T.R.T.O. standards. Before installing tubular tires, carefully read and fully understand tire gluing
instructions provided in this manual.
• Use tubular tires with a long valve stem (at least 43mm) or Reynolds valve extenders.
WARNING: TUBULAR TIRE INSTALLATION
Failure to properly install tubular tires can cause sudden and unexpected loss of tire pressure or
separation of the tubular tire from the wheel resulting in an accident, injury or death.
• Gluing tubular tires is multi-day procedure requiring specific mechanical skills and an attention
to detail. Closely follow the instructions provided in this manual for gluing tubular tires to your
Reynolds wheels. Follow tire manufacturer’s instructions to prepare tire prior to gluing.
• Carefully follow the steps in specific order to properly glue tires.
Ifyouhavecomments,questionsorconcernsaboutyourabilitytoproperlyandsafelygluetubulartires
toyourwheelset,pleasecontactyourauthorizeddealer/distributororReynoldsdirectlyforassistanceat
866-798-3040oremail[e-mail].
REQUIRED TOOLS
• Truing or similar stand to hold wheel during glue application. Use rags to protect stand from
glue drips
• Acid brush or similar
• Acetone and clean cotton rags (it is safe to use acetone on Reynolds carbon rims)
• Floor pump
• Latex gloves
• 120 grit sandpaper or emery cloth
• Tubular glue/rim cement. We recommend using Vittoria, Continental, or Challenge
tubular cement.
Carefully read the instructions on the label for drying times and other useful tips.
PREPARATION
• Begin the day before you plan to use your wheels for the first time (24 HOURS). Place your new
tubular tires on the set of corresponding tubular wheels.
• Inflate the tires to within 10-20 psi of their max pressure. This will help stretch the tire, making it
easier to install once glue has been applied.
• To inflate the tire: remove the valve cap, unscrew the presta-valve and inflate the tire using a
compressor or pump with a pressure gauge to obtain the required pressure, tighten the presta-valve
and replace the cap.
• After stretching the tires for a day you are ready to begin gluing. Be sure to have all of your tools set
out and easy to access. Work in a well ventilated area. Keep glue, acetone and sharp objects out of
the reach of small children.
• Remove the tires from the rims and place them aside. It is recommended that you wear latex gloves
during the gluing process.
• Abrade the tubular tire bed using 120 grit sandpaper/emery cloth; starting at the valve hole, sand
around the circumference of the rim. Lightly sand the entire tire bed. This procedure creates a
tactile surface for glue adhesion and aids in removing any mold release left on the carbon rim during
production or contamination from handling.
• Apply a light amount of acetone to a clean cotton rag. Starting again at the valve hole, wipe the
entire rim’s tire bed until no carbon residue is visible on the cloth.

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GLUING RIMS AND TIRES
• Prior to installing tubular tires onto wheels, you will apply two thin coats of glue to both the rims
and tires.
• Place the front wheel in the truing stand. Begin at the valve hole by applying a small amount of glue
from the brush onto the rim’s tire bed. Brush the glue until complete coverage is achieved across the
width of tire bed. Continue around the circumference of the wheel applying a thin layer of glue
(Fig. 7).
• Allow glue to dry. Repeat this gluing step on the front wheel a total of two times; applying thin
layers of glue with complete coverage across tire bed surface. Follow same gluing steps for the rear
wheel. Set both wheels aside to allow glue to completely dry and move to gluing the tires.
• Inflate tire until inverted; the base tape will roll over to the outside, becoming exposed and
facilitating gluing.
• Starting at the valve stem and working 360 degrees around the tire, apply a thin layer of glue to the
base tape until complete surface coverage is achieved—similar to the technique used to apply glue
to the rims.
• Allow first layer of glue to dry and repeat, adding a second layer to the base tape. Repeat gluing
process on the other tire.
• Do not start mounting new tires until the glue has fully dried. See glue manufacturer’s suggested
drying times, which usually ranges from a few hours or overnight.
INSTALLING TUBULAR TIRES
• Apply one final layer of glue to the rim’s tire bed surface on both front and rear wheels.
This final layer of glue will facilitate tire installation and “true up” of tire to the wheel.
• Place the front wheel at your feet on a clean, dry surface (like a linoleum floor). With the valve-hole
facing up, use the same technique used during the preparation process, referring to the illustration
(Fig 8). Deflate the tire and slip the valve into the rim. Grab the outside of the tire to the right and
left of the valve hole and slide the tire onto the rim bed in a smooth, downward motion, stretching
the tire as you go (Fig. 9). Continue working the tire onto the wheel in the slowly downward
direction until there are only a few inches of tire remaining unseated. Pick up the wheel up and work
the remaining tire onto the rim using your thumbs (Fig. 10).
• Now it’s time to center the tire on the wheel, you must work fast to avoid the glue drying too quickly.
Place the wheel in a truing stand and rotate slowly. While the wheel rotates, inspect the base tape
on the side of the tire near the outer diameter of the rim. The amount of base tape exposed at the
outer edge of the rim should be equal on both sides of the tire. True up the tire by twisting it
side-to-side on the rim. Check that the valve stem is centered and straight in the valve hole.
• Inflate the tire close to its recommended pressure. Check the base tape again to make sure it is
centered and equal in height on both sides of the tire. Also check the tire’s “true” by inspecting the
center of the tread pattern for smooth and symmetrical appearance as the tire rotates.
• Check to make sure that there are no glue deposits on the braking surface or sidewall of wheel.
Use acetone and a clean rag to remove residual glue.
• Set the freshly glued wheel aside for roughly 24 hours to fully cure.
• Repeat this final step in its entirety on the rear wheel and tire.

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BEFORE YOU RIDE
• Wait 24 hours before riding freshly glued tubular tires.
• With tires inflated, inspect both front and rear wheels for safe glue bond and proper tire adhesion.
Take the front wheel in both hands. Applying pressure sideways to the tire with both thumbs, try
to roll the tire off the rim using a moderate amount of force. Continue testing adhesion around the
circumference of the wheel. Repeat process on rear wheel. If tires hold securely to wheels, verify tire
pressure, install onto bicycle and ride safely.
• If tire adhesion is insufficient, do not ride. Repeat gluing process from beginning or contact your
mechanic, authorized dealer/distributor or Reynolds directly for direction and recommendations.
• Be sure that you do not damage, scratch, crush or otherwise distort any portion of the rim when
installing the tire.
WARNING: Check that the side of the tubular rim shows no sign of significant wear,
contamination, damage or deformation on the sidewall or brake track. This could cause the rim to
unexpectedly break resulting in an accident, injury or death.
WARNING: Never exceed the maximum inflation pressure recommended by the tire manufacturer
for the cross section of the clincher tire that you are using. See the “Opearting Pressures” table in
Section 9 of this manual. Excess tire pressure reduces the tire’s grip on the road and increases the
risk of the tire unexpectedly bursting. Inflation pressure that is too low reduces tire performance
and increases the probability of sudden and unexpected loss of tire pressure. In addition,
premature wear and damage to the rim may occur. Incorrect tire pressure could cause tire failure
or loss of control of the bicycle resulting in an accident, injury or death.
5. CASSETTE INSTALLATION
WARNING: Always wear protective gloves and glasses when working on cassette and cogs.
Always tighten cassette lock ring to manufacturer’s recommended specification.
• Shimano 10 speed cassette systems require a single 1mm spacer installed behind the largest cassette
cog on all Shimano 9/10 speed hubs (Fig. 3).
• Install individual or preassembled spacers and cassette cogs onto cassette body of the hub by
aligning the spline patterns.
 —InstallationofSRAM/Shimanocassette: locate the widest spline on cassette cog and match it with
the widest groove on the cassette body. The profile of the cassette body ensures automatic cassette
cog alignment since there is only one installation option (Fig. 4).
 —InstallationofCampagnolocassette: locate the narrowest spline on cassette cog and match it
with the narrowest groove on the cassette body. The profile of the cassette body ensures automatic
cassette cog alignment since there is only one installation option (Fig. 5).
• Apply grease/lubricant to lock ring threads located inside outer edge of cassette body.

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• Use a torque wrench to properly tighten cassette lock ring into place. Tighten Shimano and SRAM
lock rings to 40Nm; and Campagnolo 50Nm. Always use correct lock ring tools (Fig. 6)
NOTE: Tools supplied by manufacturers may not be compatible with Reynolds wheels. Always check
with your mechanic, authorized dealer/distributor, Reynolds directly or the tool manufacturer to
insure compatibility before using tools supplied by one manufacturer on wheels or components
supplied by another.
WARNING: Failure to insure compatibility between tools and wheels/components could result in
improper operation or the failure of the componenet, and accident, injury or death.
6. USING THE QUICK RELEASE
WARNING: Reynolds Quick Release (QR) skewers are designed and manufactured solely for
fixing a commercially manufactured quick release hub to a commercially available bicycle frame
or fork.
• DONOT make modifications to Reynolds QR skewers. Any modification, alteration or misuse of QR
is considered as not in conformance and is strictly prohibited, voids the warranty and could cause
wheel malfunction resulting in an accident, personal injury or death.
• DONOTUSE tools to operate QR. Installing and removing, as well as opening and closing QR should
always be done by hand.
• DONOTUSE your Reynolds QR skewers in combination with bicycle trailer.
• Verify wheel centering position, adjustment and tightness of QR onto frame and fork.
Also check skewers for damage (damaged threads, bent/deformed components, cracks and
corrosion). DONOTUSE QR if you are in any doubt of its intact state.
• Install the QR with shorter axle to the front wheel hub.
• The axle nuts (1) of either QR are located on the right–hand side (Fig 12).
• The smaller diameter of the centering spring (2) must face toward the hub.
• Locking the handle must be possible with only moderate pressure.