This course will provide the student with the skills required for bicycle assembly and conducting bicycle tune-ups. The course follows established standards as laid out on the Barnett Manual DX, covering everything to so with bicycle assembly, adjustments, lubrication, and rebuilding, all the skills needed to maintain a new bicycle.
Bicycle Assembly & Maintenance consists of consists of six class days of eight hours each.
SOME TOPICS COVERED:
- How to size up a bicycle for potential issues
- Tools, Techniques and Troubleshooting
- Torque settings and Torque Wrench Selections
- Proper pedal removal and installation
- Crank arm removal and installation
- Bottom bracket removal and installation & bearing replacement
- Wheel hub servicing
- Cassette and Freewheel removal and installation
- How to install chains, sizing and gauge alignment
- Tire and tube selection, installation and flat repair
- Assessing and correcting dropout alignment
- Wheel installation
- Seat posts section, sizing and proper installation
- Steering assembling, stem selection, installation, greasing and handlebar alignment for all designs.
- Headset/head tube servicing, (bearings, greasing, adjustments)
- Thread-less headset adjustment
- Shift lever installation, optimal cable routing installation & stressing
- Rear derailleur installation and proper setup and shift recovery
- Front derailleur installation and proper shift recovery
- Brake lever installation and alignment, cable routing and installation
- Dual-pivot brake installation and adjustment
- V-brake installation and adjustment
- Mechanical and Hydraulics disc-brake installation and adjustment
- Seat post selection and saddle installation
- Tension settings to specifications
Lessons
CABS-100 – Mechanical Skills
CABS-100 – Seats, Seat Posts and Loose Ball Bearing Hubs
Having the ability to size up a person’s bicycle for safety, comfort and service requirements draws on the fundamentals of the bicycle. In these chapters you will learn how to look at the bicycle beyond just the beauty. You will look at seat posts, and wheels hubs with safety and even ergonomics. Fully read Chapters…
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CABS-100 – The Headset
Read Chapter 11, Barnett’s Bicycle Repair Manual The headset is tricky component. A faulty install of the headset can lead to injury in the rider. This this chapter you will learn about bearing types, torque settings, installation stack heights and stems. The following article will help you answer the questions in this lesson. As a…
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CABS-100 – Wheel Removal & Installation
Often overlooked by riders, this chapter covers the most common question asked a mechanic by a rider. It deals with removal and installing wheels. The quick release and common practices. Fully read Chapter 18 in the Barnett Manual, and complete the questions in this section. The following article with help you answer the question in…
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CABS-100 – Bottom Brackets
Fully read these Chapters 9 and 110 in the Barnett Manual, and complete the questions in this section. Also read Chapter 22 covering BMX cranks. Study those pages as needed. In this lesson, we will explore the adjustable-cup bottom bracket, a common component found in many standard bicycles. Understanding the key elements and terminology associated…
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CABS-100 – Crank Arms
The most neglected bearing system on the bicycle is the bottom bracket. But you can’t get to it without first effectively removing the cranks. In this chapter you will learn how to remove the cranks, the torque settings needed to ensure safe riding and tools needed. Fully read Chapter 20 in the Barnett Manual, and…
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CABS-100 – Brake Systems, Rim Brakes and Mechanical Disc Brakes
It’s good to stop, and riders need proper braking systems to do just that. In these chapters you will cover off cantilever, dual pivot, disc, v-brakes and linear pull brake systems. Fully read Chapters 36 and 37 in the Barnett Manual, and complete the questions in this section. The following information will hep you with…
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CABS-100 – Servicing the Hydraulic Brake System
Bleeding bicycle hydraulic brakes are a skill that is perfected over time. You can learn the basic principles, but the real lessons takes place in the floor. The reason; there are many different makes, models and each one will throw you a curve. The art here is to understand how these closed systems work and…
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CABS-100 – Derailleurs Systems
So often shift recovery is a perplexing yet so simple a procedures. But to make it so, you first must have an understanding of proper derailleur installation. In these chapters you will cover both the front and rear derailleurs, the set screens, bump screws, and tolerances. Fully read Chapters 32 and 33 in the Barnett…
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CABS-100 – Chains
The drivetrain of a bicycle includes many components, none more important and under more stress than the bicycle chain. Manufactured in many widths and link designs, this component can fail under harsh conditions. In this chapter you will learn the different types of chains, how to detect wear, how to install and assess length and…
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CABS-100 – Cable Systems – Derailleur Cables – Brake Cables
Installing cables and housing is really an art form, but an art that deals with component efficiency and longevity. In these chapters you will learn the importance of routing, types of housing, cable types and when uses ferrules. Fully read Chapters 31 and 35 in the Barnett Manual, and complete the questions in this section.…
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CABS-100 – Shifters and Brake Levers
Proper setup of shifters and brake levers speaks to rider comfort, and overall physiological health. So often you will encounter new bicycles from manufacturers as well as used bikes with these components improperly installed and setup. In this these chapters you will understand these uses and know how to properly address them. Fully read Chapter…
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CABS-100 – Handlebars, stems, handlebar extensions
The cockpit of a bicycle is central to the rider, providing control, comfort and stamina. Selection and assembly of this control system encompasses several components that have difference tolerances and specifications. In this chapter you will learn about bar-centre diameter, torque specifications for stem bolts, and proper handlebar installation and alignment. Fully read Chapter 28…
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