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PICTORIAL INSTALLATION MANUAL
REAL WORLD CYCLING ENDURO® OUTBOARD BOTTOM
BRACKET REBUILD KIT
INSTRUCTIONS FOR THE
RACE FACE® X-TYPE BEARING SYSTEM
RECOMMENDED TOOLS AND SUPPLIES
• Enduro® Outboard Bearing Replacement Kit
• Bottom Bracket Bearing Puller/Press Tool
• 8mm Allen wrench
• 10mm Allen wrench
• Outboard bearing cup tool (Park BBT-9 or similar)
• Rubber-faced mallet
• “Pocket” screw driver (very small, flat blade)
• Silicone grease or anti-seize compound
• Torque wrench
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
NOTE: REMOVE YOUR BICYCLE CHAIN BEFORE BEGINNING
1) Loosen the right side crank
arm and spider assembly using an 8mm
Allen wrench (turn counter-clockwise).
NOTE: The 8mm wrench will pass straight
through the 10mm hex in the extractor
cap, which is to be left in place.
2) Remove right crank arm
2 and spider assembly.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
3) Remove left crank
arm and spindle assem-
bly.
a) Remove all the drive side
spacers, making a note of
them for re-assembly.
3a
3b
b) Use a rubber mallet to
“start” the spindle if it won’t
pull out by hand.
c) Set the left crank arm and
spindle assembly aside.
3c
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
4) Remove the left, or
non-drive side bearing
cup.
Make a note of the spacers
for re-assembly.
6) Place a large
screwdriver into the
“V” opening of the
puller and use it as a
“T” handle to pull the
dust cap off. Repeat
for the other side.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
5) Remove the DRIVE
(right) side cup.
a) Turn the bottom bracket cup
wrench clockwise.
5a
5b
b) Set the inner sleeve and the spacers aside (take note of the spacers for proper re-assembly).
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
6) Set one of the bearing cups down
on a flat surface and insert the Collet
from the Bearing Puller/Press Tool.
“COLLET”
Insert the collet narrow-end-first. The rub-
ber ring holding the collet halves together is
not necessary. Particularly when removing
bearings from the Race Face cups, it will be
easier to expand the collet with the rubber
ring removed.
“COLLET
EXPANDER”
7) Start the collet expander into
the collet.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
8) Apply pressure to the Collet Ex-
pander until it “seats” between the
collet halves.
If you encounter difficulty in
getting the expander to seat
between the collet halves, lift
the cup off of the flat surface
and push on the expander until it
fully seats as shown.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
9) Set the bearing cup (with
collet and expander) into the
Cup Holder.
“CUP
HOLDER”
10) Press out the bearing and
plastic cap by inserting the
Bolt and using an 8mm Allen
wrench to turn it clockwise
until you hear and feel the
bearing “drop out” of the cup.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
11) Lift the cup off of the Collet Expander.
12) Unthread the
Bolt from the
Cup Holder and
remove the old
bearing and plas-
tic cap.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
13) Remove the
sealing ring from the
outer circumference
of the bearing cup.
( If not removed, this ring
will interfere with the new
sealing system)
“BEARING GUIDE”
14) Place one of the
bearings from the
Enduro® Kit onto
the 24mm side of the
Bearing Guide.
(The other side of the Guide
is for installing OE bear-
ings)
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
15) Place the Bearing
Guide into the Cup Holder.
16) Place the bearing
cup on top of the new
bearing.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
“SUPPORT”
17) Place the Support into the
threaded end of the bearing
cup.
18) Insert the Bolt and turn it
clockwise with the 8mm Allen
wrench until it “bottoms.”
Then, remove the bolt and take
out the bearing cup.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
19) The bearing will not yet be fully seated in the cup. To
accomplish this, place the old bearing in the Guide and repeat
the pressing process as shown in “A-E” below:
“BEFORE” A B
“AFTER” E
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
20) Re-install the left (non-drive side) cup and spacer(s).
a) Apply anti-seize compound to the b) Replace original spacer(s).
cup threads.
c) Start the cup into the frame by
hand. The left side threads in normal-
ly (clockwise).
d) Use a proper BB Cup Tool
to tighten the cup firmly in
place.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
21) Re-install the right (drive
side) cup and spacer(s).
Remember:
1) Apply anti-seize to the cup threads.
2) Replace the proper number of spacers.
3) Install the inner sleeve!
Remember that the drive side cup
has reverse, or left-hand threads.
Tighten by turning counter-clock-
wise.
You will notice that the Enduro® BB
system does not use plastic shims
for the spindle. The inner race of
our bearings has a smaller ID that
directly contacts the spindle. This
allows room for larger ball bearings,
improving strength and stiffness.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
22) Place a seal on the spindle and slide it up to the left crank arm spacers.
Orient the seal so that the silicone side will face away from the bearing.
23) Lubricate the spin-
dle with grease and in-
sert it through the bear-
ings (starting with the
left cup!).
If your bike’s bottom bracket
faces are parallel and the bear-
ings are properly seated, the
spindle should line up with
the opposite bearing and come
through with very little effort.
If you encounter some resis-
tance, be sure the spindle is
lined up and then tap the left
crank arm with the heel of your
hand to help it through.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
24) Place the other
seal over the end of
the spindle and slide
it up to the bearing.
25) Replace the
original spacers.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
26) For easier drive-
side installation,
remove the crank
extraction cap from
the crank arm. Turn
the cap clockwise
with a 10mm Allen
wrench to loosen.
“EXTRACTOR CAP”
With the crank extractor cap
removed, the crank bolt can be
removed.
“CRANK BOLT”
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
27) Lubricate the spindle
splines and crank bolt threads.
28) Aline the splines
and start the drive
side assembly onto
the spindle.
29) Start the crank bolt
by hand (it threads in
clockwise).
30) Tighten the crank bolt until the splines
“bottom out.” Final torque should be 30 Foot
Pounds (NOT Inch Pounds).
NOTE: IF YOU NOTICE ANY UNUSUAL TIGHTNESS, OR
IF THERE IS TOO MUCH PLAY, PLEASE SEE THE FAC-
TORY TROUBLE-SHOOTING GUIDE ON PAGE 21.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
31) Lube the threads of the extractor
cap and thread it into the crank arm.
Remember it has left-hand threads, so
turn counter-clockwise.
32) Tighten the ex-
tractor cap by turning
it counter-clockwise
with a 10mm Allen
wrench. Maximum
torque is 160 Inch
Pounds. Remember
that the purpose of this
cap is just to make the
crank bolt self-extract-
ing. It is not helping
to keep the crank arm
attached, so not much
torque is required.
Replace the chain and
go ride!
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
RACE FACE® FACTORY TROUBLE-SHOOTING GUIDE
CONDITION: CAUSE: FIX:
ASSEMBLY • BB shell width too wide 1) Ensure BB shell threads are chased cleanly and that BB shell is faced (after
“TOO TIGHT” (out of tolerance) painting).
• Excessive Ro- • BB shell not faced or 2) Ensure BB shell width is within tolerance. If too wide, face-mill BB shell
tational Friction milled correctly to re- down until it is within required spec.
(beyond reason- move all paint
able amount of 3) If #1 and #2 above are correct, proceed to on the of the following options:
initial seal drag) • BB shell threads mis-
aligned OPTION 1:
• Bearing Side- - Remove assembly from bike.
Loading • Extra chainline spacer - Remove 1 x 1mm chainline spacer (preferably from non-drive side so chain-
Apparent is mistakenly added. line isn’t affected).
- Re-install remaining spacers and re-install assembly into bike as per installa-
• Assembly tolerance tion instructions #5 and #6 above.
stack-up on all parts
OPTION 2:
- Remove assembly from bike.
- Remove all spacers and seals from LH (non-drive) side of spindle assembly.
- Remove 3.5mm Quad-Ring preload elastomer from recess in LH crank and
replace with supplied 2.5mm pre-load elastomer (flat shape, black rubber)
into recess in LH crank.
- Re-install spacers and re-install assembly into bike as per installation instruc-
tions #5 and #6 above.
CONDITION: CAUSE: FIX:
ASSEMBLY • BB shell width too nar- 1) Ensure BB shell threads are chased cleanly and that BB shell is faced (After
“TOO LOOSE” row (out of tolerance) painting).
• Excessive side • BB shell not faced or 2) Ensure BB shell width is within tolerance. If too narrow, proceed to step #3.
to side “Play” is milled correctly to
noticable in the remove all paint 3) If #1 and #2 above are correct, proceed as follows:
BB spindle / cup - Remove assembly from bike.
assembly when • BB shell threads mis- - Add supplied extra 1mm spacer seal (black) to non-drive side of
grabbing opposing aligned assembly (so chainline isn’t affected).
ends of crank - Re-install assembly into bike as per installation instructions # 5 and #
arms and rock- • Required chainline 6 above.
ing back and forth spacer or spacer seal
laterally. is missing from in- 4) If assembly is “loose” with optional 2.5mm pre-load elastomer installed, pro-
stalled assembly ceed as follows:
• (Note: a small - Remove assembly from bike.
amount of detect- • Assembly tolerance - Remove all spacers and seals from LH (non-drive) side of spindle assembly.
able movement is stack-up on all parts - Remove 2.5mm preload elastomer from recess in LH crank and replace with
normal and ac- supplied 3.5mm Quad-Ring pre-load elastomer into recess in LH crank.
ceptable.) - Re-install spacers and re-install assembly into bike as per installation
instructions #5 and #6 above.
• Generally the as-
sembly rotates
very freely with
little or no detect-
able rotational fric-
tion or drag.
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enduro fork seals .com RACE FACE® X-Type
REAL WORLD CYCLING PICTORIAL INSTRUCTIONS
Outboard Bottom Bracket
Bearing Replacement Kit
by Enduro Bearings
Outboard Bottom Bracket
Bearing Puller/Press
by Sonny’s Bike Tools
These great procucts available at:
www.enduroforkseals.com
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