Bicycle Technology and Patents » Recumbents & HPVs

Removing / Replacing cartridge bearings in Rear Wheels, by Trikebldr

shaver — Mon, 16 Jan 2012 04:42:07 +0000

This how-to is aimed primarily at the Shimano-made cartridge-bearing rear hubs used in the majority of Catrikes for the last several years. Speeds, Expeditions and 700′s used the Shimano “Deore” branded hubs mostly, and those have cup/cone hubs, making their bearings easily adjustable for play or preload. Roads, Trails and Pockets used primarily the “Catrike” branded hubs that had cartridge bearings in them. There are many exceptions to which hubs were used in all of the models, but this is what will be found in the majority of cases. Other brands of cartridge-bearing hubs may be the same.

Replacing the bearings in a rear wheel hub that uses cartridge bearings is pretty easy, but not without pitfalls. If done correctly using the right tools, it should only take about five minutes.

Almost all of Catrike’s hubs, either cup/cone or cartridge, came with rubber conical boots over the ends of the axles. These are critical on cup/cone bearings because they keep the dirt out of the bearings. However, they are not necessary on cartridge-bearing-hubs as the bearings have their own seals. For simplicity I have left the rubber covers out of any pics. I also do not run those covers on my own cartridge-bearing-hubs.

There are two problems that can complicate removal of the cartridge bearings. First, some of the 130mm wide hubs have the inner lock nut on the drive side (the side where the cassette is) recessed so far inside the freehub that you cannot get a wrench on it. The second problem is being sure to remove the washer that spaces the bearing from the axle’s shoulder on the non-drive side. I will address each one of these problems separately.

First, the picture below shows the inner lock nut so far inside the freehub that you cannot get even a thin cone wrench on it.

The above is on a 130mm wide hub. On a 135mm wide hub, the nut would not be quite so recessed. A good, thin cone wrench can grab those flats on the 135mm hub, but on the 130mm hub, you must first back the inner lock nut off just a bit on the non-drive side (picture below), ….

…then, using a rubber or plastic-faced hammer, or a press (for ceramic bearings), drive the axle toward the drive side enough to expose the inner lock nut (picture below) so it can be loosened.

This is how to remove the drive side lock nuts first. It is recommended to use a good quality cone wrench (By Park Tools or Pedro’s, for examples) on the inner lock nuts because they are properly hardened to take the abuse of such a thin wrench being used to loosen and tighten these nuts.

Some of you may say, “Well, just remove the non-drive side nuts completely first and drive the axle out toward the drive side.”. This brings us to the second problem. There is a small washer between the non-drive side bearing and a shoulder machined on the axle. The picture below shows the whole assembly laid out as it assembles, with the non-drive side to the right in the picture.

There is no washer on the drive side. The Picture below shows this washer on the non-drive side, and the next picture below hows no washer on the drive side. This washer MUST be kept oriented exactly as it is from the factory!

Non drive side with washer

Drive side with no washer.

The two pictures below show that the washer is not symetrical. One side is convex and one side is flat. The convex side also has a small radius on it’s inner edge that matches the radius next to the shoulder on the axle (picture 10). If it gets flipped over during reassembly it will cause serious problems. Mostly, it will space the bearings farther apart, and this means the bearings’ outer race edges will no longer seat properly against the hub body’s bearing pockets. Under load, the bearings will “walk” side-to-side, slowly wearing the pockets larger until the bearings will be sloppy inside the pockets.

The next pictures show the groove for the washer, the washer assembled correctly on the axle, and a cross section of the axle and the washer, with exaggerated curvature of the washer.

The picture above show the distance between the bearings being 3.224″, which is correct for this hub, axle, and bearing assembly.

The pictures below show the washer and axle assembled with the washer reversed, showing a distance between bearings of 3.236″. For precision bearings, this a big difference.

It should be apparent to the reader that this washer MUST be kept oriented correctly during reassembly. The problem is that if you remove the non-drive side lock nuts first and drive the axle out toward the drive side, that washer will then be floating inside the hub body and can be flipped around freely. It is important to keep the axle, washer, bearing and inner lock nut together until the axle is removed and the washer is examined for correct orientation.

Again, the reader may ask, “Why not just place it with the convex side away from the bearing all the time, then?”. Because sometimes Shimano flips these washers themselves to obtain a correct spacing between the bearings to suit the hub body they will be going into. Both the axle and the hub body have tolerances that are kept within limits during manufacture, but the axles and bodies still have to be matched somehow, and these spacers (washers) are how they make everything fit correctly. Hence, we run into another small problem. Hub bodies, axles and washers must be kept as a “set” to be sure of a correct fit for the bearings, and that washer must be installed the same every time! If the washer is replaced with one that is thinner, you could actually put so much preload on the bearing to burn it out shortly. Ceramic bearings have been crushed from too much preloading due to replacing that washer with a thinner one!

Once the non-drive side bearing, washer and lock nuts are removed from the axle, the axle can be used to drive the drive-side bearing out of it’s seating.

Once the bearings are removed, if you want you can pop the coverings, clean out the old grease, put in new grease and reinstall the old bearings. We have experience with relubing ceramic bearings in this way with no ill effects, through at least 3 relubes. See how to do the relubing step in this article.

On reassembly, it is easiest to start by assembling the drive side. Slide the bearing onto the axle, then put the inner lock nut on. Using both lock nuts on the non-drive side, tighten them together for use to hold the axle still while you tighten the inner lock nut on the drive side against the bearing. Then, tighten the outer lock nut against the inner lock nut. The drive side is done. Take both non-drive side lock nuts off the axle. Insert the axle from the drive side. It should now look like the picture below on the drive side, and the second picture below is how the non-drive side should look.

Drive side of hub

Non drive side of hub.

No need to drive the bearing into it’s pocket at this time. It will slowly be pressed it in as we tighten the inner lock nut on the non-drive side. Now, install the washer (picture below) the bearing (second picture below), and the inner lock nut (third picture below).

Using this lock nut, and a wrench on the outer lock nut of the drive side, tighten this inner nut (picture 18) to draw both bearings into their pockets until this nut is tight against the bearing. Now install the spacer (picture below) and outer lock nut (second picture below) and tighten everything on the non-drive side.

Be sure that the amount of axle threads showing is even from one side to the other, and that neither side extends outside of the dropouts of the trike/bike. On cartridge bearing axles, the shoulders that the bearings ride against will almost always keep this axle protrusion correct if the correct bearings, original nuts and spacers are used.

Index to Catrike Maintenance Posts

shaver — Sat, 29 Oct 2011 03:08:41 +0000

Catrike Maintenance and Repair topics are listed below. If I have a blog post on one of these topics, this contents list will serve as a link to each topic. Submissions of posts by any Catrike rider for inclusion here are welcomed. FYI, Catrikes are recumbent tricycles, with more information available at the Catrike Performance Trikes site.

Basic Setup and Maintenance”

Catrike Performance Trike Official 2004 Manual

Catrike Performance Trike Official 2005 Manual

Catrike Performance Trike Official 2006 Manual

Catrike Performance Trike Official 2007 Manual

Catrike Performance Trike Official 2009 Manual
Catrike Performance Trike Official 2010 Manual

removing the master link on the chain, and replacing it (page 18 of the above manual).
checklist of initial setup items
removing a front wheel
replacing front wheel bearings
replacing rear wheel bearings
adjusting rear derailer (link to Sheldon Brown’s instructions)
adjusting disk brakes (link to Park Tool page)
replacing disk brake pads (link to manufacturers or Park page)
Bruce’s advice on adjusting Avid BB7 brakes on Catrikes
installing front fenders
fixing a flat tire in front, rear wheels
installing teflon bushings in front headsets
cleaning a chain, and lubrication

Troubleshooting section:

rear wheel squeek: lube rubber weather seal
Bottom bracket not horizontal when trike is on flat surface: loosen boom clamp, reorients boom, or file guide tooth
after removing a front wheel, my brake pad rubs: adjust brakes, per this link:___________
shimmy in steering: check x, y, and Z, and purchase teflon bushings from catrike
chain routing
brake cable routing
shifter cable routing
setting toe on front wheels of a trike

Upgrades:

Facing the bottom bracket edges

Discussion of After market items and FAQs:

Jerry’s flags
Locking brake levers. These are great!
What is Schlump and other drives?
what would Schlump or Roloff give me over the stock gearing?
Terracyle idlers discussion
Super bright (240 lumens) flashlight for use as headlight, tail light
what size bearings does my (year) (model) Catrike use in the front, rear wheel?
where does one get replacement steel or ceramic bearings (link, or part number)
ceramic bearing installations in front hubs
options for mounting both a light and a speedometer
list of all tools needed
chain guards, bash guards: Purely Custom, with Catrike Logo available, and many colors, Trice (Utah Trikes) Chain Guard Ring
- Cables: how to order replacements, how to cut to length, how to install end pieces on housing and cable, what tools are needed
- Chains: how to order (how many chains needed/length), brand, types
- Articles on component upgrades (brakes, shifters, derailleurs, etc)
- Common accessories: what has worked well (lights, racks, bags, pedals, mirrors, etc)

- Arizona Whip lighted flagpole

- Tactical Flashlights for lighting system

1936 French SWB Recumbent

shaver — Fri, 22 Jul 2011 02:49:09 +0000

The question is, when was was the first recumbent made? This is the earliest bent of the short wheel base (SWB) variety I have seen, by a Mr. Albert Raymond. I know of an earlier long wheel base bent invented by Jarvis in the U.S., from 1902, but this is the earliest SWB I have found. That it was from France should be no surprise, since Charles Mochet was making recumbents in France about that time period.

1886 MASA Slingshot?

shaver — Mon, 18 Jul 2011 03:51:33 +0000

Well, if its not a MASA Slingshot from 1886, at least its a tadpole trike with similar general appearance.

Tadpole Upright Trike, Underseat Steering

shaver — Tue, 31 May 2011 16:19:09 +0000

Here is a comfy looking tadpole trike.

This looks like its chain drive, single speed, the rider’s back would be straight up, not leaning forward. I don’t see any brakes, but if it was direct drive, you could brake by resisting the pedals turning. This would work well today.

The MASA Slingshot, by Trikebldr

shaver — Fri, 01 Apr 2011 19:17:43 +0000

In 1974 MASA (Multi-Advanced Sports Action) (of Japan) created a new class of closed-course track racing. They set up the rules so tight that only one trike would qualify,……their’s! Japanese companies could do that in those days.

MASA was a Japanese company, but targeted the US with this form of racing. In 1975 they finally brought a few of these over here and did some exhibition races between their own staff. It never really caught on, but they still imported about 1500 of these into the US over a three year period.

There were some very minor changes made to the trikes over the three years they were produced, like the rear dropouts, the chain tensioners, seat materials, colors, elimination of a lot of the original chrome parts, and the elimination of the use of a mid-drive that followed the rear der’s movements (called a reciprocal-gearing system).

Since these trikes were focused on track racing only against like trikes, the lack of braking and their size was not a problem. Their wide, long front end was thought to be better protection for the rider.

Two major problems that kept them from becoming popular was the single, minimally effective rear brake and their humongous size (56+lbs). The Slingshot really was intended solely for track racing where braking was only used to adjust speed entering the corners. Even the disc brake on the rear of earlier models was way less than effective for street use. Later models tried the Bendix drum brake on the rear wheel, but still fell short of being able to lock up the wheel. The trike’s 56-65lb weight didn’t help with it’s stopping problems either.

Earlier models came with an aluminum ‘wing” over the front axle, probably more for looks than anything, and a bullet-shaped, sports car-styled rear mirror on the left side. The chain and front sprocket was also completely enclosed in an aluminum guard. They were very high tech looking machines, but too heavy to compete with any other HPV around.

The first year only came in red or yellow, with lots of chrome on the front end. The second and third years offered the orange and black colors, with the loss of all chrome on them, except the rims. The one you have there now is a very late first year model, with a tan seat and simpler, single cog rear jack-shaft on the driveline. It still has some of the chrome on the steering components, but not all. It is a transition model. The seller claims it to be original paint, but that’s not true. Orange wasn’t introduced until all chrome was eliminated. Black also came out first, with all parts painted black, then the orange was added to the frame only.

One last feature that also killed it was it’s tendency to flip over in high speed corners! The rider’s center of mass was closer to the rear wheel than the fronts so it wanted to tip that rear wheel over, and the front wheels couldn’t stop it with so little weight on them. It as about a 30/70% weight distribution on them, front to back, whereas our current generation of tadpole trikes average about 60/40% front to back.

Innesenti Trikes

shaver — Sat, 12 Mar 2011 22:04:10 +0000

This has got to be the Ferrari of trikes, but at $11,000 it should look sexy. I don’t know if it is a trike or a work of art, or both. Check it out at Innesenti trikes.

Bruce’s trike carrier

shaver — Sat, 26 Feb 2011 22:22:07 +0000

Bruce has recently shared pictures of his trike carrier, which mounts in a hitch reciever, and carries two trikes. Nice.

Below is the structure of the hitch receiver 2 trike rack.

An earlier rack held 2 trikes on a small car roof.

Another still is this 3 trike roof top carrier.

Chainlines for 2 wheeled ‘bents

shaver — Thu, 23 Sep 2010 02:49:13 +0000

Not to leave the 2 wheelers out of the collection, here are some chain lines of two wheel recumbents.

Says Bruce: Stephen (tennbent) and I wanted to eliminate the inherent problems on his Optima Baron that also exist with the chainlines on a lot of mid and low racers. The picture above shows the chain crossover between idlers.

The picture above shows the revised chainline, with crossover issue resolved. First, we wanted to clear the front tire/fork, and also to eliminate any chain cross-overs. We also did some other minor chainline mods to clean up the line. I won’t go into all of the details of HOW we did this, but the pics show the results. And, it works quite well. Stephen says it quieted the whole chainline a lot.

Admittedly, the change added another small bend in the power chain line, which technically adds pedal effort, but Stephen says he can’t feel any extra effort, and most folks won’t either. Maybe Lance Armstrong could feel it. The extra bend is about what most trikes experience in chain line bend. Bruce

The picture above shows one wheelbase-version of the Musashi, with chain crossover problems.

Another version of the Musashi, with chain crossover issues.

Chainlines, Idlers, and Tubes, oh my!

shaver — Wed, 22 Sep 2010 01:47:41 +0000

Chain lines on trikes seem to generate a lot of experimenting and novel approaches. The pictures below show a bunch of different approaches to making a chainline quiet and efficient, on all Catrikes I believe.

Hopefully the creators of these setups or those who have tried similar ones will comment on the likely quietness and efficiency of each of these setups. Send additional pics of chainlines of any type of bent, and I’ll post them.

Above: Bruce’s Speed. Bruce says this is the cleanest, quietest, most efficient setup he has used.

Above: Dr. Duk’s version of chain tubes. Says Bruce: “…shows the easiest, and best way to give the tubes the loosest float possible, and this is a good thing.”

Above: Flying Tiger’s version

Bruce’s orange Catrike. “This is the overly complex, and expensive, chainline that I tried on two of my Speeds. I had four goals for it: lift the return chain higher off the ground, push the power chain under the front axle, raise everything above the bottom of the main frame tube, and eliminate all tubes. It did all four quite well, but at the expense of expense and more noise. Both trikes are back to a single tube on the return chain, with just some tape on top of the axle to protect against the power chain slap. ”

another trike set up, by Jerry Mckee.

Bruce: “Jerry McKee’s is close, but the idlers should have been placed behind the front axle. Also, by pushing the power chain under the front axle, you alter the angle of the power chain to the der post and der. This can hurt the shifting, and at the least, it limits how small you can go on the small ring. I know this because on my Tony Trike, I couldn’t go smaller than a 30 tooth ring when I did this arrangement.”

Above: John Rooker’s Expedition. Says John: “I have the same setup on my present Trail. This is simple, effective, quiet and costs almost nothing once you’ve purchased the return side idler.”

Utah Trikes photo, on an Expedition. “…just insanely wrong! All of the Expo’s cherished ground clearance is lost with that arrangement. That idler should have been placed in front of the axle, as Pat Franz has designed those clamp-ons to be placed.”

photofinish

photofinish 2

photofinish 3

Bruce’s opinion – “Photofinish’s setup is a good example of a common myth about chainlines, that running the return chain in a straight line gives less drag. Wrong! It increases the drag compared to a slightly curved tube run underneath. If you let the chain hang naturaly with no tube, it has no frictional drag, so what better way to “tube” it than to run it through a tube that follows it’s natural curve as much as possible. Ideally, if the tube’s curve matches the chain’s curve, the tube will not be supporting the chain at all, and therefore will not induce any drag. But, if you lift the chain up and run it through a straight tube above where it wants to hang naturally, the tube is then carrying all of the chain’s weight, and that creates a LOT of drag, not to mention more noise. It may look cool, but it will cost you in pedal effort and extra noise. If you look at the first pic of my Holey Spokes, the tube has been curved to match the natural droop of the return chain as close as possible. With generous flares, it is almost silent all the time.”

rexpedition

Bruce’s Opinion – “pretty close to stock and about the best you can get. Quiet and efficient!”

another one from Utah Trike

Chain tube attachment by HP – Velotechnik, sold at Hostel Shoppe. A long spoke held under the idler bolt and tied to the tube as far along the tube as possible will allow the tube to move around as much as it needs to in reaction to chain movement, with very little restriction. The longer the spoke, the more flex is would have.

Terracycle floating tube holder. They also sell flared sections of chain tube. Although the floating tube holder is cool, the bike has chain routing and crossover issues. Without tubes the chain would rub itself, causing it to “snag” on itself as the pin ends catch each other. Also, the chain runs along the side of the fork, rubbing it almost constantly. Even with a tube, the tube rubs the fork. It also limits the turn radius, because the tire will rub the chain with very little turn input. Bruce

PhattKat’s setup, from his blog. Note the attachment of both the power side tube and the return side tube to the idler. These attachments look solid. Also full coverage of the chains, as shown below. How does one keep a chain so clean!!?? My trike is a mess by comparison.

Phatkatts chain tubes.

Chainlines for 2 wheeled ‘bents