Zipp ZM2 User manual

SERVICE MANUAL
GEN.0000000006444 Rev C© 2022 SRAM, LLC
ZM2 Hubs

SRAM® LLC WARRANTY
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AGAINST SRAM, LLC. YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM
STATE TO STATE, COUNTRY, OR PROVINCE. THIS WARRANTY DOES NOT AFFECT YOUR STATUTORY RIGHTS. TO THE EXTENT THIS
WARRANTY IS INCONSISTENT WITH THE LOCAL LAW, THIS WARRANTY SHALL BE DEEMED MODIFIED TO BE CONSISTENT WITH SUCH
LAW. FOR A FULL UNDERSTANDING OF YOUR RIGHTS, CONSULT THE LAWS OF YOUR COUNTRY, PROVINCE, OR STATE.
THIS WARRANTY APPLIES TO SRAM PRODUCTS MADE UNDER THE SRAM®, ROCKSHOX®, TRUVATIV®, ZIPP®, QUARQ®, AVID® AND TIME®
BRAND NAMES.
EXTENT OF LIMITED WARRANTY
Except as otherwise set forth herein, SRAM warrants its bicycle components to be free from defects in materials or workmanship for a period of two
(2) years after original purchase of the product.
SRAM warrants all Zipp MOTO Wheels and Rims to be free from defects in materials or workmanship for the lifetime of the product.
SRAM warrants all non-electronic Zipp branded bicycle components, Model Year 2021 or newer, to be free from defects in materials or workmanship
for the lifetime of the product.
GENERAL PROVISIONS
This warranty only applies to the original owner and is not transferable. Claims under this warranty must be made through the retailer where the
bicycle or the SRAM product was purchased or a SRAM authorized service location. Original proof of purchase is required. All SRAM warranty claims
will be evaluated by a SRAM authorized service location whereupon acceptance of the claim the product will be repaired, replaced, or refunded at
SRAM's discretion. To the extent allowed by local law claims under this warranty must be made during the warranty period and within one (1) year
following the date on which any such claim arises.
NO OTHER WARRANTIES
EXCEPT AS DESCRIBED HEREIN, AND TO THE EXTENT ALLOWED BY LOCAL LAW, SRAM MAKES NO OTHER WARRANTIES, GUARANTIES, OR
REPRESENTATIONS OF ANY TYPE (EXPRESS OR IMPLIED), AND ALL WARRANTIES (INCLUDING ANY IMPLIED WARRANTIES OF REASONABLE
CARE, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE) ARE HEREBY DISCLAIMED.
LIMITATIONS OF LIABILITY
EXCEPT AS DESCRIBED HEREIN, AND TO THE EXTENT PERMITTED BY LAW, IN NO EVENT SHALL SRAM OR ITS THIRD PARTY SUPPLIERS BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. SOME STATES (COUNTRIES AND PROVINCES) DO NOT
ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL DAMAGES, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
LIMITATIONS OF WARRANTY
This warranty does not apply to products that have been incorrectly installed, adjusted, and/or maintained according to the respective SRAM user
manual. The SRAM user manuals can be found online at sram.com/service.
This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance with manufacturer's
specifications of intended usage, or any other circumstances in which the product has been subjected to forces or loads beyond its design.
This warranty does not apply when the product has been modified, including but not limited to, any attempt to open or repair any electronic and
electronic related components, including the motor, controller, battery packs, wiring harnesses, switches, and chargers.
This warranty does not apply when the serial number or production code has been deliberately altered, defaced, or removed.
SRAM components are designed for use only on bicycles that are pedal powered or pedal assisted (e-Bike/Pedelec).
Notwithstanding anything else set forth herein, the battery pack and charger warranty does not include damage from power surges, use of improper
charger, improper maintenance, or such other misuse.
This warranty shall not cover damages caused by the use of parts of dierent manufacturers or parts that are not compatible or suitable for use with
SRAM components.
This warranty shall not cover damages resulting from commercial (rental) use.
WEAR AND TEAR
This warranty does not apply to normal wear and tear. Wear and tear parts are subject to damage as a result of normal use, failure to service
according to SRAM recommendations, and/or riding or installation in conditions or applications other than recommended.
WEAR AND TEAR PARTS INCLUDE:
• Aero bar pads
• Air sealing o-rings
• Batteries
• Bearings
• Bottomout pads
• Brake pads
• Bushings
• Cassettes
• Chains
• Cleats
• Corrosion
• Disc brake rotors
• Dust seals
• Free hubs, Driver bodies, Pawls
• Foam rings, Glide rings
• Handlebar grips
• Jockey wheels
• Rear shock mounting
hardware and main seals
• Rubber moving parts
• Shifter and Brake cables
(inner and outer)
• Shifter grips
• Spokes
• Sprockets
• Stripped threads/bolts (aluminum,
titanium, magnesium or steel)
• Tires
• Tools
• Transmission gears
• Upper tubes (stanchions)
• Wheel braking surfaces
ZIPP IMPACT REPLACEMENT POLICY
Zipp branded products, Model Year 2021 or newer, are covered under a lifetime impact-damage replacement policy. This policy can be used to obtain
a replacement of a product in the event of non-warranty impact damage occurring while riding your bicycle. See www.zipp.com/support for more
information.

3Table of Contents
TABLE OF CONTENTS
ZIPP SERVICE.......................................................................................................................................................................................................5
PART PREPARATION .......................................................................................................................................................................................................................................5
SERVICE PROCEDURES.................................................................................................................................................................................................................................5
RIM AND WHEEL BUILDING SPECIFICATIONS..............................................................................................................................................5
REAR HUB SERVICE............................................................................................................................................................................................6
COMPONENT REMOVAL...............................................................................................................................................................................................................................6
PARTS, TOOLS, AND SUPPLIES..................................................................................................................................................................................................................6
EXPLODED VIEW  REAR HUB.....................................................................................................................................................................................................................7
REAR HUB END CAPS ....................................................................................................................................................................................................................................7
REAR HUB BEARING REMOVAL..................................................................................................................................................................................................................8
REAR HUB BEARING INSTALLATION...................................................................................................................................................................................................... 12
DRIVER CLEANING OPTIONAL  COIL SPRING DRIVER................................................................................................................................................................. 16
DRIVER CLEANING OPTIONAL  LEAF SPRING DRIVER ................................................................................................................................................................ 19
DRIVER BEARING REPLACEMENT OPTIONAL .................................................................................................................................................................................. 21
FRONT HUB SERVICE...................................................................................................................................................................................... 23
COMPONENT REMOVAL............................................................................................................................................................................................................................ 23
PARTS, TOOLS, AND SUPPLIES............................................................................................................................................................................................................... 23
EXPLODED VIEW  FRONT HUB............................................................................................................................................................................................................... 24
FRONT HUB END CAPS .............................................................................................................................................................................................................................. 24
FRONT HUB BEARING REMOVAL ........................................................................................................................................................................................................... 25
FRONT HUB BEARING INSTALLATION.................................................................................................................................................................................................. 28

SAFETY FIRST!
We care about YOU. Please, always wear your safety glasses
and protective gloves when servicing SRAM® products.
Protect yourself! Wear your safety gear!

5Zipp Service
Zipp Service
We recommend that you have your Zipp compononets serviced by a qualified bicycle mechanic. Servicing Zipp compononets requires the use of
specialized tools. Failure to follow the procedures outlined in this service manual may cause damage to your component and void the warranty.
Visit www.zipp.com/support for the latest Zipp Spare Parts catalog and technical information. For order information, please contact your local Zipp
distributor or dealer.
Information contained in this publication is subject to change at any time without prior notice.
Your product's appearance may differ from the pictures contained in this publication.
For recycling and environmental compliance information, please visit www.sram.com/company/environment.
Part Preparation
Remove the component from the bicycle before service.
Clean the exterior of the product with mild soap and water to avoid contamination of internal sealing part surfaces.
Service Procedures
The following procedures should be performed throughout service, unless otherwise specified.
Clean the part with isopropyl alcohol and a clean, lint-free shop towel.
Clean the sealing surface on the part and inspect it for scratches.
Rim and Wheel Building Specifications
For spoke lengths, tension, rim ERD, hub dimensions, and technical specifications, please refer the the Zipp Wheel Specifications document
available at sram.com/service.

6Rear Hub Service
Rear Hub Service
Component Removal
Prior to service, remove the wheels from the bicycle according to the bicycle manufacturer's instructions and thoroughly clean the exterior of the
product to avoid contamination of internal sealing part surfaces.
For additional information about Zipp wheels and hubs, user manuals are available at www.Zipp.com.
Parts, Tools, and Supplies
Parts
• WHEEL BEARING KIT FRONT/REAR FOR ZIPP ZR1/ZM2 HUBS, 61903
• WHEEL FREEHUB KIT - ZIPP ZM2 XD (optional)
• WHEEL FREEHUB KIT - ZIPP ZM2 10 SPD (optional)
Safety and Protection Supplies
• Apron
• Clean, lint-free shop towels
• Nitrile gloves
• Safety glasses
Lubricants and Fluids
• Isopropyl alcohol
• Zipp Cognition or Klüber Staburags NBU30 grease
• SRAM Butter grease
Zipp/SRAM Tools
• Zipp 61903 Bearing Press Tool (x2)
or
Zipp 61903 Bearing Press Tool (x1) and
SRAM 6903 Bearing Press Tool (x1)
Bicycle Tools
• Axle and Spindle Vise Inserts - Park Tool AV-4 or AV-5
• Blind Hole Bearing Puller Set
• 17 mm slotted attachment
• Wheels Manufacturing Press-1 Sealed Bearing Press Kit or similar
• 6903 30x17 bearing press adapters (x2)
• 6803 26x17 bearing press adapters (x2) (optional)
• T-handle threaded bearing press
Common Tools
• Bench vise
• Flat blade screwdriver
• Needle-nose pliers
• Grease brush
• Rubber or plastic mallet
• Vise soft jaws (aluminum)
SAFETY INSTRUCTIONS
Always wear nitrile gloves when working with bicycle grease.

7Exploded View - Rear Hub
Exploded View - Rear Hub
Zipp 6903/61903 hub bearing
Zipp 6903/61903 hub bearing
End Cap
Axle
End Cap
Wave Spring
Ratchet Ring
Hub Shell
Rear Hub End Caps
DRIVE SIDE NON DRIVE SIDE
Hub Variants
Current
Identification
Text On End Cap
Previous
Identification
Text On End Cap
Spare Part Kit
Number
Current
Identification
Text On End Cap
Previous
Identification
Text On End Cap
Spare Part Kit
Number
ZM2 REAR 12 X 148 6B
10SPD
151-030 12x(142/148) DS XD(R) 11.2018.064.007 212-000 — 11.2018.064.007
XD
Driver Body
SRAM XD
Driver Body
SRAM 10/11 Speed

8Rear Hub Bearing Removal
Rear Hub Bearing Removal
Procedures are the same for rim brake and disc brake rear hubs. Disc brake hub pictured.
Insert the Park Tool AV-4 or AV-5 Axle and Spindle Vise Insert tool into
a vise. Clamp one end cap into the vise insert tool and pull up on the
wheel/hub to remove the end cap.
Repeat to remove the other end cap.
Pull the driver body from the hub by hand.
Inspect the rubber seal for damage. If the seal is damaged, replace the
driver body.
Use a plastic mallet to tap the non-drive side end of the axle to remove
the axle and bearing from the hub.
Pull the axle and drive side bearing out of the drive side of the hub.
If the drive side bearing was not removed with the axle, it must be
removed with the Bearing Puller tool as instructed in step 7.
1
AV-4 / AV-5 AV-4 / AV-5
2
3
4
Plastic Mallet

9Rear Hub Bearing Removal
The wave spring installed on the non-drive side of the axle will slide o
when the axle is removed. Set the wave spring aside.
NOTICE
Do not discard or misplace the wave spring. It is crucial to hub
performance and the hub will not fuction properly without the spring.
Note: If the drive side bearing is not removed with the axle, a bearing
puller must be used to remove the bearing from the hub.
Place the axle in between flat aluminum vise soft jaws, drive side
down, with the bearing resting on top of the soft jaws. Make sure the
axle bearing step does not contact the soft jaws. Use a plastic mallet
to gently tap on the top of the non-drive end of the axle until it is
dislodged from the bearing. Discard the bearing.
NOTICE
To avoid damage to the axle, do not allow the axle to contact the
vise soft jaws. If the axle bearing step is damaged, the axle must be
replaced.
Clean the axle with isopropyl alcohol and a shop towel.
NOTICE
To prevent damage to the hub surfaces, do not use acetone or similar
products to clean parts.
5
6
Plastic Mallet
7
Isopropyl Alcohol Shop Towel

10Rear Hub Bearing Removal
Insert the 17 mm Bearing Puller slotted attachment through the drive
side bearing. Align the slotted attachment with the bottom of the
bearing, and expand it inside the bearing.
Do not over tighten the slotted attachment. For more detailed assembly
and usage, see the bearing puller manufacturer's instructions.
Grip the slide hammer and forcefully pull away from the slotted
attachment to remove the bearing from the driver body.
Insert the 17 mm Bearing Puller slotted attachment through the non-
drive side bearing. Align the slotted attachment with the bottom of the
bearing, and expand it inside the bearing.
Do not over tighten the slotted attachment. For more detailed assembly
and usage, see the bearing puller manufacturer's instructions.
Grip the slide hammer and forcefully pull away from the slotted
attachment to remove the bearing from the driver body.
8
17 mm Slotted Attachment
9
17 mm Slotted Attachment

11Rear Hub Bearing Removal
Clean the bearing bores with isopropyl alcohol and a shop towel.
Clean the ratchet ring and hub internals with isopropyl alcohol, a shop
towel, and cotton swabs. Do not remove the ratchet ring.
10
Isopropyl Alcohol Shop Towel
11

12Rear Hub Bearing Installation
Rear Hub Bearing Installation
NOTICE
To prevent damage when pressing the bearings into the rear hub, make sure that the bearing press tool contacts both the inner and outer races of
the bearing.
Install a new Zipp 6903/61903 hub bearing into the non-drive side of
the hub with the black seal facing outward.
Note: Ceramic bearings have blue seals on both sides of the bearing;
installation orientation is not important.
Install a 6903 30x17 tool into the drive-side bearing bore.
Insert the threaded rod through the drive side of the hub shell. Slide a
second 6903 30x17 tool onto the threaded rod.
Thread the Press Tool handle onto the threaded rod.
Turn the handle clockwise to press the bearing into the hub until it is
hand-tight.
Do not overtighten the bearing.
Remove the tools.
NOTICE
To prevent damage when pressing the bearing into the hub, make
sure that the bearing press tools contact both the inner and outer
bearing races or bearing bores and not the hub shell.
Install a new bearing onto the longer, non-drive side of the axle, with
the blue bearing seal facing away from the raised step on the axle.
Note: Ceramic bearings have blue seals on both sides of the bearing;
installation orientation is not important.
Insert the non-drive side of the axle into a Zipp 61903 tool, with the flat,
non-stepped end of the tool against the bearing.
1
2
6903 30x17 6903 30x17
3
Zipp 61903

13Rear Hub Bearing Installation
Use a rubber or plastic mallet to tap the drive side of the axle until the
raised step on the axle contacts the bearing
Remove the axle from the tool.
Insert a SRAM 6903 tool into the non-drive side bearing bore with the
flat, non-stepped end of the tool against the bearing.
Install the non-drive side end of the axle through the hub and into the
SRAM 6903 tool.
Install a Zipp 61903 tool onto the drive side end of the axle with the
stepped end of the tool contacting the bearing.
Use a rubber mallet to tap the drive side of the axle until the raised
step on the axle contacts the bearing
Remove the tool from the axle.
4
Plastic Mallet
5
SRAM 6903
6
Zipp 61903 Stepped End
7
Plastic Mallet

14Rear Hub Bearing Installation
Apply grease to the ratchet ring (a) and the seal surface (b) of the hub
shell.
NOTICE
If a brush is used to apply grease, confirm there are no loose bristles
in the grease or on the part.
Apply grease to the last 10-15mm of the axle. Installation of the driver
body will distribute the grease on the entire hub axle.
NOTICE
If a brush is used to apply grease, confirm there are no loose bristles
in the grease or on the part.
Install the driver body onto the axle and twist it counter-clockwise to
seat the driver body and driver body seal.
Make sure the driver body seal is fully seated into the seal groove.
The installation process is the same for 10 speed and XD driver bodies.
Install the wave spring onto the non-drive side of the axle. You may
need a tool to press the wave spring against the bearing face.
NOTICE
Do not scratch the axle when using a tool to install the wave spring.
The wave spring is crucial to hub performance and must be installed
onto the axle.
8
SRAM Butter Grease
9
Cognition / Klüber Staburags NBU30 grease
10
11

15Rear Hub Bearing Installation
Apply grease to the following locations on the drive side and non-drive
side axle end:
• Axle front surface (a)
• Axle radial surface (b)
• Bearing front face across bearing seal, inner- and outer ring (c)
NOTICE
If a brush is used to apply grease, confirm there are no loose bristles
in the grease or on the part.
Press the end caps onto the axle.
Clean the hub with isopropyl alcohol and a shop towel.
Cognition / Klüber Staburags NBU30 grease
a
c
b
12
a
c
b
13
14
Shop towel Isopropyl alcohol

16Reinigung des Freilaufs (optional)– Freilauf mit Schraubenfedern
Reinigung des Freilaufs (optional)– Freilauf mit Schraubenfedern
HINWEIS
Die Wartung eines 11-Gang-Freilaufs ist identisch mit der nachfolgend gezeigten Wartung eines XDR-Freilaufs.
Prüfen Sie die Gummidichtung auf Beschädigungen. Wenn die
Dichtung beschädigt ist, tauschen Sie den Freilauf aus.
Heben Sie mit den Fingern oder einem kleinen Schlitzschraubendreher
den Sprengring aus dem Freilauf.
Entfernen Sie mit den Fingern, einem Dorn oder einer Spitzzange die
Sperrklinken und Schraubenfedern aus dem Freilauf.
Säubern Sie die Sperrklinken-Nuten mit einem Wattestäbchen und den
Freilauörper mit Isopropyl-Alkohol und einem Werkstatttuch.
1
2
3
4

17Reinigung des Freilaufs (optional)– Freilauf mit Schraubenfedern
Tragen Sie mit einer Fettspritze ein wenig SRAM Butter-Schmierfett auf
die Sperrklinkennuten auf.
Setzen Sie eine Schraubenfeder in eine der unteren Federnuten
ein und montieren Sie dann eine schwarze Sperrklinke in der
Sperrklinkennut.
Hinweis: Die Federn und Sperrklinken sind symmetrisch und können in
einer beliebigen Ausrichtung montiert werden.
Drücken Sie die Feder mit einem kleinen Schlitzschraubendreher
zusammen, damit die Sperrklinke in die Nut fallen kann, und
justieren Sie dann die Feder so, dass sie senkrecht zur Rückseite der
Sperrklinke steht.
Setzen Sie eine Schraubenfeder in die obere Federnut über der
zuvor installierten Sperrklinke/Feder ein und montieren Sie dann eine
silberne Sperrklinke in der Sperrklinkennut.
Hinweis: Die Federn und Sperrklinken sind symmetrisch und können in
einer beliebigen Ausrichtung montiert werden.
5
SRAM Butter-Schmierfett
6
7
Schlitzschraubendreher
8

18Reinigung des Freilaufs (optional)– Freilauf mit Schraubenfedern
Drücken Sie die Feder mit einem kleinen Schlitzschraubendreher
zusammen, damit die Sperrklinke in die Nut fallen kann, und
justieren Sie dann die Feder so, dass sie senkrecht zur Rückseite der
Sperrklinke steht.
Wiederholen Sie die Schritte 6 bis 9, um die anderen Federn und
Sperrklinken einzubauen.
Stellen Sie sicher, dass die schwarzen Sperrklinken in der unteren
Nutenreihe installiert werden.
Richten Sie das Ende des Sprengrings auf die Bohrung im Freilauf
aus und drücken Sie den Sprengring in den Kanal des Freilaufs, bis er
ordnungsgemäß sitzt.
9
Schlitzschraubendreher
10

19Reinigung des Freilaufs (optional)– Freilauf mit Schraubenfedern
Reinigung des Freilaufs (optional)– Freilauf mit Schraubenfedern
HINWEIS
Die Wartung eines 11-Gang-Freilaufs ist identisch mit der nachfolgend gezeigten Wartung eines XDR-Freilaufs.
Prüfen Sie die Gummidichtung auf Beschädigungen. Wenn die
Dichtung beschädigt ist, tauschen Sie den Freilauf aus.
Heben Sie mit den Fingern oder einem kleinen Schlitzschraubendreher
den Sprengring aus dem Freilauf.
Entfernen Sie mit den Fingern, einem Dorn oder einer Spitzzange die
Sperrklinken und Schraubenfedern aus dem Freilauf.
Säubern Sie die Sperrklinken-Nuten mit einem Wattestäbchen und den
Freilauörper mit Isopropyl-Alkohol und einem Werkstatttuch.
1
2
3
4

20Reinigung des Freilaufs (optional)– Freilauf mit Schraubenfedern
Tragen Sie mit einer Fettspritze ein wenig SRAM Butter-Schmierfett auf
die Sperrklinkennuten auf.
Setzen Sie eine Schraubenfeder in eine der unteren Federnuten
ein und montieren Sie dann eine schwarze Sperrklinke in der
Sperrklinkennut.
Hinweis: Die Federn und Sperrklinken sind symmetrisch und können in
einer beliebigen Ausrichtung montiert werden.
Drücken Sie die Feder mit einem kleinen Schlitzschraubendreher
zusammen, damit die Sperrklinke in die Nut fallen kann, und
justieren Sie dann die Feder so, dass sie senkrecht zur Rückseite der
Sperrklinke steht.
Setzen Sie eine Schraubenfeder in die obere Federnut über der
zuvor installierten Sperrklinke/Feder ein und montieren Sie dann eine
silberne Sperrklinke in der Sperrklinkennut.
Hinweis: Die Federn und Sperrklinken sind symmetrisch und können in
einer beliebigen Ausrichtung montiert werden.
5
SRAM Butter-Schmierfett
6
7
Schlitzschraubendreher
8