Zipp ZR1 User manual

SERVICE MANUAL
GEN.0000000006195 Rev A © 2020 SRAM, LLC
ZR1 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.
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, MERCHANTIBILITY, 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 INCIDENTIAL 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
• 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 (aluminium,
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 occuring while riding your bicycle. See www.zipp.com/support for more
information.

3Table of Contents
TABLE OF CONTENTS
FRONT HUB SERVICE.........................................................................................................................................................................................6
PARTS, TOOLS, AND SUPPLIES..................................................................................................................................................................................................................6
EXPLODED VIEW  FRONT HUB.................................................................................................................................................................................................................. 7
FRONT HUB END CAPS ................................................................................................................................................................................................................................. 7
FRONT HUB BEARING REMOVAL ..............................................................................................................................................................................................................8
FRONT HUB BEARING INSTALLATION.................................................................................................................................................................................................... 11
REAR HUB SERVICE..........................................................................................................................................................................................14
PARTS, TOOLS, AND SUPPLIES................................................................................................................................................................................................................ 14
EXPLODED VIEW  REAR HUB................................................................................................................................................................................................................... 15
REAR HUB END CAPS .................................................................................................................................................................................................................................. 15
REAR HUB BEARING REMOVAL................................................................................................................................................................................................................ 16
REAR HUB BEARING INSTALLATION.....................................................................................................................................................................................................20

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.
Use aluminum soft jaws when placing a part in a bench vise.
Tighten the part with a torque wrench to the torque value listed in the red bar.
When using a crowfoot socket and torque wrench, install the crowfoot socket
at 90 degrees to the torque wrench.
Specified torque value in N·m (in-lb)

6Front Hub Service
Front Hub Service
Component Removal
The hub can be serviced while in the wheel. However, if your spokes or rim are damaged, you can remove the hub from the wheel which will make
servicing your hub easier. To remove the hub, use a spoke wrench to de-tension the spokes, then use a pair of metal snips to cut the spokes, remove
the hub from the wheel, and remove the spoke ends from the hub (not pictured).
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 Hubs, 61903
Safety and Protection Supplies
• Apron
• Clean, lint-free shop towels
• Nitrile gloves
• Safety glasses
Lubricants and Fluids
• Isopropyl alcohol
• Klüber Staburags NBU30 grease
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 30x17/61903 bearing press adapters (x2)
• T-handle threaded bearing press
Common Tools
• Bench vise
• Flat blade screwdriver
• Grease brush
• Rubber or plastic mallet
SAFETY INSTRUCTIONS
Always wear nitrile gloves when working with bicycle grease.

7Exploded View - Front Hub
Exploded View - Front Hub
End Cap
Wave Spring
Zipp 6903/61903 Hub Bearing
Hub Shell
Axle
Zipp 6903/61903 Hub Bearing
End Cap
Front Hub End Caps
The end cap identification number is laser etched onto the end cap.
Drive Side Non-Drive Side
Quick
Release
Rim Brake
2018-252-000
Centerlock 2018-252-000 2018-270-000
15x100
2018-165-000 2018-267-000

8Front Hub Bearing Removal
Front 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 the non-drive side end cap into the vise insert tool and
pull up on the wheel/hub to remove the end cap.
Gently tap the exposed axle end with a plastic mallet to dislodge the
axle from the hub bearings.
Use your thumb to push the axle through the hub shell and remove the
wave spring from the non drive side hub shell.
Remove the front axle from the drive side of the hub.
Use your fingers to remove the end cap from the drive side of the axle.
1
AV-4 / AV-5 36/14
12
Plastic Mallet
3

9Front Hub Bearing Removal
Spray isopropyl alcohol onto the axle and clean it with a shop towel.
NOTICE
To prevent damage to the hub surfaces, do not use acetone or similar
products to clean parts.
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 hub shell.
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, and not the hub shell.
4
Isopropyl Alcohol
5
17 mm Slotted Attachment

10Front Hub Bearing Removal
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 hub shell.
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, and not the hub shell.
Clean the hub shell with isopropyl alcohol and a shop towel.
6
17 mm Slotted Attachment
7
Isopropyl alcohol Shop towel

11Front Hub Bearing Installation
Front Hub Bearing Installation
Install a new Zipp 6903/61903 hub bearing into the drive side of the
hub with the black seal facing outward.
Slide a 6903 30x17 tool onto the Press Tool threaded rod.
Insert the threaded rod through the bearing on 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 Zipp 6903/61903 hub bearing into the non-drive side of
the hub with the black seal facing outward.
1
2
6903 30x17 6903 30x17
3

12Front Hub Bearing Installation
Slide a 6903 30x17 tool onto the Press Tool threaded rod.
Insert the threaded rod through the bearing on the non-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.
Apply grease to the non-drive side axle bearing race.
Insert the non-drive side end of the axle into the drive side of the hub,
through the drive side bearing, through the hub, and through the
non-drive side bearing. Press the axle into the hub bearing with your
thumb until the axle bearing step fits flush into the bearing.
4
6903 30x17 6903 30x17
5
Klüber Staburags NBU30 grease
6

13Front Hub Bearing Installation
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.
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)
Press the end caps onto the axle.
Clean the hub with isopropyl alcohol and a shop towel.
7
8
Klüber Staburags NBU30 grease
a
cb
9
10
Isopropyl alcohol Shop towel

14Rear 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 Hubs, 61903
• Wheel Freehub Kit - XDR Driver Body Kit - 12x142 / QR - Zipp ZR1
(optional)
• Wheel Freehub Kit - 11 Speed Driver Body Kit - 12x142 / QR - Zipp ZR1
(optional)
• Wheel Freehub Kit - Campagnolo Driver Body Kit - Centerlock Disc /
Rim Brake - Zipp ZR1 (optional)
Safety and Protection Supplies
• Apron
• Clean, lint-free shop towels
• Nitrile gloves
• Safety glasses
Lubricants and Fluids
• Isopropyl alcohol
• Zipp Cognition or SRAM Butter grease
• Klüber Staburags NBU30 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 30x17/61903 bearing press adapters (x2)
• T-handle threaded bearing press
Common Tools
• Bench vise
• Flat blade screwdriver
• Grease brush
• Rubber or plastic mallet
• Vise soft jaws (aluminum)
For part numbers, refer to the Zipp Spare Parts Catalog in the Support section of www.zipp.com.
SAFETY INSTRUCTIONS
Always wear nitrile gloves when working with bicycle grease.

15Exploded 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
Driver Body
SRAM XDR
Driver Body
SRAM 10/11 Speed
Driver Body
Campagnolo
Rear Hub End Caps
The end cap identification number is laser etched onto the end cap.
Driver Body Drive Side Non-Drive Side
Quick
Release
Rim Brake
XDR
SRAM 11 SPD
Campangolo
2018-249-000
Centerlock
XDR
SRAM 11 SPD
Campangolo
2018-127-000 2018-269-000
12x142 XDR
SRAM 11 SPD
2018-151-030 2018-251-000

16Rear 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.
Use a soft face 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.
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.
1
AV-4 / AV-5 36/14 AV-4 / AV-5 36/14
2
3
Plastic Mallet
4

17Rear Hub Bearing Removal
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.
Spray isopropyl alcohol onto the axle and clean the axle with a shop
towel.
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.
Spray isopropyl alcohol onto the axle and clean it with a shop towel.
NOTICE
To prevent damage to the hub surfaces, do not use acetone or similar
products to clean parts.
5
Plastic Mallet
6
Isopropyl Alcohol

18Rear 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.
7
17 mm Slotted Attachment
8
17 mm Slotted Attachment

19Rear Hub Bearing Removal
Clean the bearing bores with 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.
9
Isopropyl Alcohol Shop Towel
10

20Rear 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 drive side of the
hub with the black seal facing outward.
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.
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