Zipp 404 Firestrike User manual

Service Manual
404 Firestrike
GEN.0000000004724 Rev B
© 2015 SRAM, LLC

SRAM LLC WARRANTY
EXTENT OF LIMITED WARRANTY
Except as otherwise set forth herein, SRAM warrants its products to be free from defects in materials or workmanship for a period of two years after
original purchase. 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 component was purchased. Original proof of purchase is required. Except as described herein, 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.
LOCAL LAW
This warranty statement gives the customer specic legal rights. The customer may also have other rights which vary from state to state (USA), from
province to province (Canada), and from country to country elsewhere in the world.
To the extent that this warranty statement is inconsistent with the local law, this warranty shall be deemed modied to be consistent with such law, under
such local law, certain disclaimers and limitations of this warranty statement may apply to the customer. For example, some states in the United States
of America, as well as some governments outside of the United States (including provinces in Canada) may:
a. Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of the consumer
(e.g. United Kingdom).
b. Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations.
For Australian customers:
This SRAM limited warranty is provided in Australia by SRAM LLC, 1333 North Kingsbury, 4th oor, Chicago, Illinois, 60642, USA. To make a warranty
claim please contact the retailer from whom you purchased this SRAM product. Alternatively, you may make a claim by contacting SRAM Australia, 6
Marco Court, Rowville 3178, Australia. For valid claims SRAM will, at its option, either repair or replace your SRAM product. Any expenses incurred in
making the warranty claim are your responsibility. The benets given by this warranty are additional to other rights and remedies that you may have
under laws relating to our products. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to
a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the
goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
LIMITATIONS OF LIABILITY
To the extent allowed by local law, except for the obligations specically set forth in this warranty statement, in no event shall SRAM or its third party
suppliers be liable for direct, indirect, special, incidental, or consequential damages.
LIMITATIONS OF WARRANTY
This warranty does not apply to products that have been incorrectly installed and/or adjusted according to the respective SRAM user manual. The SRAM
user manuals can be found online at sram.com, rockshox.com, avidbike.com, truvativ.com, or zipp.com.
This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product, non-compliance with manufacturers
specications of 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 modied, 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.
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 are identied as:
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 different manufacturers.
This warranty shall not cover damages caused by the use of parts that are not compatible, suitable and/or authorised by SRAM for use with SRAM
components.
This warranty shall not cover damages resulting from commercial (rental) use.
• Dust seals
• Bushings
• Air sealing o-rings
• Glide rings
• Rubber moving parts
• Foam rings
• Rear shock mounting hardware
and main seals
• Upper tubes (stanchions)
• Stripped threads/bolts (aluminium,
titanium, magnesium or steel)
• Brake sleeves
• Brake pads
• Chains
• Sprockets
• Drivers
• Shifter and brake cables (inner
and outer)
• Handlebar grips
• Shifter grips
• Jockey wheels
• Disc brake rotors
• Wheel braking surfaces
• Bottomout pads
• Bearings
• Bearing races
• Pawls
• Transmission gears
• Spokes
• Free hubs
• Aero bar pads
• Corrosion
• Tools
• Motors
• Batteries

3Table of Contents
TABLE OF CONTENTS
REAR HUB SERVICE.......................................................................................................................................................................... 5
TOOLS NEEDED FOR SERVICE.......................................................................................................................................................................................................5
REPLACEMENT PARTS .......................................................................................................................................................................................................................5
REAR HUB EXPLODED VIEW ......................................................................................................................................................................................................... 6
REAR HUB BEARING REMOVAL ....................................................................................................................................................................................................7
DRIVER BODY BEARING REMOVAL...........................................................................................................................................................................................10
DRIVER BODY BEARING INSTALLATION.................................................................................................................................................................................13
REAR HUB BEARING INSTALLATION........................................................................................................................................................................................16
FRONT HUB SERVICE ..................................................................................................................................................................... 19
TOOLS NEEDED FOR SERVICE.....................................................................................................................................................................................................19
FRONT HUB EXPLODED VIEW .....................................................................................................................................................................................................19
REPLACEMENT PARTS .....................................................................................................................................................................................................................19
FRONT HUB DISASSEMBLY...........................................................................................................................................................................................................20
FRONT HUB ASSEMBLY..................................................................................................................................................................................................................22

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

5Rear Hub Service
Rear Hub Service
You can service your hub while the hub is still 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 detension 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).
Tools Needed for Service
• Safety glasses
• Clean, lint-free rags
• Nitrile gloves
• 5 mm hex wrench
• 20 mm hex bit socket
• 5 mm hex bit socket
• Socket wrench
• Wheels Manufacturing Press-1 Sealed Bearing Press Kit
(2) 6803 Adapters from Press-1 Kit
• Flat blade screwdriver
• (2) 6803 and (2) 6903 Hub bearings
• Driver body
• Driver body pawls
• Driver body leaf springs
• SRAM® Butter
• Grease brush
• Torque wrench
• Needle nose pliers
• Pick
• Grease syringe
• Enduro Universal Blind Hole Bearing Puller Set
• 17 mm slide hammer bearing puller attachment
• Driver body seal
• Flat washer
For part numbers, please 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.
Replacement Parts

6Rear Hub Exploded View
Rear Hub Exploded View
Cap nut
Bearing shield
6903 Bearing
Rear hub
Spacer tube
6903 Bearing
6803 Bearing
Flat washer
Driver body seal
Driver body
Inside Diameter Spacer
Axle
6803 Bearing
Dust Shield

7Rear Hub Bearing Removal
Rear Hub Bearing Removal
Insert a 5 mm hex wrench into the axle while holding the non-drive
side cap nut with a 20 mm hex bit socket and socket wrench. Hold
the socket wrench in place and use the hex wrench to turn the
non-drive side cap nut counter-clockwise to remove it.
Use your fingers to remove the driver body assembly from the hub
shell.
Remove the axle, by hand, from the driver body.
A flat washer rests on the bearing located on the side of the driver
body with the pawls and leaf springs. If this washer falls o when
you remove the axle, set it aside until you are ready for assembly.
Use your finger to remove the bearing shield from the non-drive
side of the hub.
20 mm hex bit 5 mm Hex
1
2
3
4

8Rear Hub Bearing Removal
Insert the 17 mm Slide Hammer Bearing Puller slotted attachment
through the non-drive side bearing. Align the slotted attachment
with the bottom of the bearing, and tighten the slotted
attachment to expand the puller inside the bearing.
NOTICE
Do not over tighten the slotted attachment.
Over tightening the bearing puller can damage the hub shell or
bearing.
For more detailed assembly and usage, see your bearing puller's
manufacturer's instructions.
Thread the rod of the bearing puller into the attachment. Grip the
slide hammer and forcefully pull away from the slotted attachment
to remove the bearing from the hub shell.
Remove the bearing from the slide hammer bearing puller.
5
17 mm Slide Hammer Bearing Puller
6
17 mm Slide Hammer Bearing Puller

9Rear Hub Bearing Removal
Remove the bearing spacer tube.
Repeat steps 6 and 7 to remove the drive side bearing.
7
8

10Driver Body Bearing Removal
Driver Body Bearing Removal
Use your fingers or a pick to carefully remove the pawls and leaf
springs.
Inspect the pawls and leaf springs for signs of damage or wear.
N O T I C E
If any of the pawls or leaf springs exhibit signs of damage or wear,
replace all of them. Otherwise, remove any grease on the pawls
and leaf springs with a clean rag.
Use a lint-free rag to clean the driver body and pawl slots.
Remove any grease on the driver body seal with a clean rag.
Inspect the driver body seal for signs of damage or wear.
If there are any signs of damage or wear, replace the driver body
seal.
Press the driver body seal, with the smooth side facing the driver
body, over the leaf spring and pawl carrier.
The driver body seal must be fully seated against the thin shoulder
of the driver body.
1
2
3
4
Pawl
Leaf
spring

11Driver Body Bearing Removal
Insert the 17 mm Slide Hammer Bearing Puller slotted attachment
through the outboard bearing. Align the slotted attachment with
the bottom of the bearing, and tighten the slotted attachment to
expand the puller inside the bearing.
NOTICE
Do not over tighten the slotted attachment. For more detailed
assembly and usage, see your bearing puller's manufacturer's
instructions.
Thread the rod of the bearing puller into the attachment. Grip the
slide hammer and forcefully pull away from the slotted attachment
to remove the bearing from the driver body.
17 mm Slide Hammer Bearing Puller
5
6
17 mm Slide Hammer Bearing Puller

12Driver Body Bearing Removal
Use your fingers to remove the Inside Diameter (ID) spacer.
Insert the 17 mm Slide Hammer Bearing Puller slotted attachment
through the inboard bearing. Align the slotted attachment with
the bottom of the bearing, and tighten the slotted attachment to
expand the puller inside the bearing.
NOTICE
Do not over tighten the slotted attachment. For more detailed
assembly and usage, see your bearing puller's manufacturer's
instructions.
Thread the rod of the bearing puller into the attachment. Grip the
slide hammer and forcefully pull away from the slotted attachment
to remove the bearing from the driver body.
7
17 mm Slide Hammer Bearing Puller
8

13Driver Body Bearing Installation
Driver Body Bearing Installation
NOTICE
To prevent damage when pressing the bearings into the driver body hub, make sure that the drift contacts both the inner and outer
bearing races.
Apply a thin layer of SRAM® Butter to the bearing bores.
Install a new 6803 bearing into the inboard side of the driver body.
Slide the Wheels Manufacturing 6803 adapter onto the threaded
rod of the Wheels Manufacturing Press-1 Sealed Bearing Press tool.
Insert the threaded rod of the bearing press through the inboard
side of the driver body. Slide the SRAM 6803 bearing press tool
onto the threaded rod.
Thread the bearing press handle onto the threaded rod.
Turn the threaded handle clockwise to press the bearing into the
outboard bearing bore until it is hand-tight.
Remove the bearing press tool.
NOTICE
Do not overtighten the bearing.
1
SRAM® Butter
2
6803 Bearing
SRAM 6803 Bearing Press tool
3

14Driver Body Bearing Installation
Insert the ID spacer tube.
Align the ID spacer tube with the inside race of the previously
installed bearing.
Install a new 6803 bearing into the outboard side of the driver
body.
Slide a Wheels Manufacturing 6803 bearing press tool onto the
threaded rod of the Wheels Manufacturing Press-1 Sealed Bearing
Press tool. Insert the threaded rod of the bearing press through
the outboard side of the driver body. Slide the SRAM 6803 bearing
press tool onto the threaded rod.
Thread the bearing press handle onto the threaded rod.
Turn the threaded handle clockwise to press the bearing into the
outboard bearing bore until it is hand-tight.
Remove the bearing press tool.
NOTICE
Do not overtighten the bearing.
Applying excessive force while installing the second bearing may
result in damage to one or both bearings.
Use a syringe to apply a small amount of SRAM® Butter into the
pawl pocket
4
ID spacer tube
5
SRAM 6803 Bearing press tool
SRAM 6803 Bearing press tool
6
SRAM® Butter
7

15Driver Body Bearing Installation
Insert the leaf springs into the spring slots. Orient the long edge
of each spring along the inside of the carrier so that it points
clockwise.
Insert the pawls into the pawl slots. You may need to use a pick or
flat blade screwdriver to compress each leaf spring to assist with
inserting the pawls.
Orient the cambered edge (the edge that is slightly more curved)
of each pawl along the outside of the carrier so that it points
counter-clockwise.
8
9

16Rear 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 adaptors contact both the inner and
outer races of the bearing.
Apply a thin layer of SRAM® Butter to the bearing bores on either
side of the hub.
Install a new 6903 bearing into the drive side of the hub.
Slide the SRAM 6903 bearing press tool onto the threaded rod of
the Wheels Manufacturing Press-1 Sealed Bearing Press tool. Insert
the threaded rod of the bearing press through the non-drive side
of the hub shell. Slide the SRAM 6903 bearing press tool onto the
threaded rod.
Thread the bearing press handle onto the threaded rod.
Turn the threaded handle clockwise to press the bearing into the
hub until it is hand-tight.
NOTICE
Do not overtighten the bearing.
Remove the bearing press tool.
Insert the spacer tube through the non-drive side of the hub.
1
SRAM® Butter
2
6903 Bearing
3
SRAM 6903 bearing press tool
4

17Rear Hub Bearing Installation
Insert a new 6903 bearing into the non-drive side of the hub.
NOTICE
The spacer tube can be crushed during bearing installation if it is
not aligned with the inside race of each bearing.
Slide a SRAM 6903 bearing press tool onto the threaded rod of
the Wheels Manufacturing Press-1 Sealed Bearing Press tool. Insert
the threaded rod of the bearing press through the drive side of the
hub shell. Slide the second SRAM 6903 bearing press tool onto the
threaded rod.
Thread the bearing press handle onto the threaded rod.
Turn the threaded handle clockwise to press the bearing into the
hub until it is hand-tight.
NOTICE
Do not overtighten the bearing.
Applying excessive force while installing the second bearing may
result in damage to one or both bearings.
Remove the bearing press tool.
Install a new bearing shield onto the non-drive side.
Use the SRAM® Butter grease syringe to dispense 1 gram of grease
onto the ratchet ring. Then using your finger or a brush to spread
the grease around the ratchet ring.
5
6903 Bearing
6
SRAM 6903 Bearing Press tool 22 mm
7
8
SRAM® Butter
Insert the pawls into the pawl slots.
You may need to use a pick to compress each leaf spring to assist
with inserting the pawls.
Orient the cambered edge (the edge that is slightly more curved)
of each pawl along the outside of the carrier so that it points
counter-clockwise.
Apply a light coat of grease to the leaf springs and pawls.
Insert the axle through the driver body.
Slide the flat washer over the axle until it rest on the inner race of
the bearing.
5
22 mm 20 mm or 15 mm Thru Axle 22 mm
6
22 mm 20 mm or 15 mm Thru Axle 22 mm
7
8

18Rear Hub Bearing Installation
Insert the axle through the driver body.
Make sure the black dust shield is installed on the axle on the
outboard side.
Make sure the driver body seal is seated into the seal groove on
the axle.
Slide the axle and driver body, ratchet side first, into the rear
drive side hub shell.
Use your fingers to compress the pawls to allow the driver body to
fully seat inside the hub shell.
Thread the cap nut onto the non-drive side axle by hand.
Insert a torque wrench with a 5 mm hex bit socket into the drive
side axle while holding the non-drive side cap nut with a 20 mm
hex bit socket and socket wrench. Hold the cone wrench in place
and use the torque wrench to tighten the cap nut to
10 N·m (88.5 in-lb).
9
10
11
20 mm hex bit 10 N·m (88.5 in-lb) 5 mm hex bit

19Front Hub Service
Front Hub Service
You can service your hubs while the hub is still 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. Use a spoke wrench to detension the spokes, and 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.
Tools Needed for Service
• Safety glasses
• Nitrile gloves
• Clean, lint-free rags
• (2) 5 mm hex wrenches
• 5 mm hex bit socket
• Enduro Universal Blind Hole Bearing Puller Set
• Plastic mallet
• Torque wrench
• Wheels Manufacturing Press-1 Sealed Bearing Press Kit
(2) 6803 Adapters from Press-1 Kit
(2) 17 mm Spacers from Press-1 Kit
• SRAM® Butter
• Grease brush
• 17 mm slide hammer bearing puller
• Bench vise
• Axle and Spindle Vise Insert
• (2) 6803 Hub bearings
For part numbers, please 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.
Front Hub Exploded View
Replacement Parts
End cap
6803 Bearing
Axle
Hub shell
6803 Bearing
End cap

20Front Hub Disassembly
Front Hub Disassembly
Insert a 5 mm hex wrench into both end caps. Hold one wrench in
place while turning the other wrench counter-clockwise to remove
the end cap.
Use a plastic mallet to gently tap exposed axle end to dislodge the
bearing.
Remove the bearing and slide the axle out of the hub shell.
Clamp the axle into the Park Tool AV-5 Axle and Spindle Vise. Use
a 5 mm hex wrench to unthread and remove the end cap.
NOTICE
Do not damage the axle threads.
Insert the 17 mm Slide Hammer Bearing Puller slotted attachment
through the outboard bearing. Align the slotted attachment with
the bottom of the bearing, and tighten the slotted attachment to
expand the puller inside the bearing.
NOTICE
Do not over tighten the slotted attachment. For more detailed
assembly and usage, see your bearing puller's manufacturer's
instructions.
5 mm hex 5 mm hex
1
2
Plastic mallot
3
5 mm hex AV-5 Axle and Spindle Vise
4
17 mm Slide Hammer Bearing Puller