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The BBB-2TG Instructor's Guide
Table of Contents

Chapter A: MANAGING THE PARK TOOL SCHOOL
Chapter B: TEACHING THE PARK TOOL SCHOOL
Chapter 1: BASIC BICYCLE MECHANICAL SKILLS
Chapter 2: TIRE AND TUBES
Chapter 3: HUBS, REAR SPROCKETS
Chapter 4: WHEEL TRUING
Chapter 5: PEDALS, CRANKS, & BOTTOM BRACKETS
Chapter 6: CHAINS
Chapter 7: DERAILLEUR SYSTEMS
Chapter 8: RIM CALIPER BRAKE SYSTEMS
Chapter 9: CALIPER DISC BRAKE SYSTEMS
Chapter 10: HANDLEBARS, STEMS, SADDLES & SEAT POSTS
Chapter 11: HEADSETS
Chapter 12: BIKE WASHING
Chapter 13: ON-THE-RIDE-REPAIRS
Appendixes: A THROUGH J

Chapter A: MANAGING THE PARK TOOL SCHOOL

  • SELECTING A COURSE STRUCTURE
  • DESCRIPTION OF CURRICULUM OPTIONS
    • Novice Class
    • Intermediate Class
    • Advanced Class
    • Drive Train Class
    • Rim Brake and Disc Brake Class
    • Wheel Truing Class
    • Bearing Class
    • Derailleur Systems Class
    • Tires and Tubes Class
    • Retail Mechanic Training
  • CLASS STRUCTURE
    • Class Size
    • Class Tuition
    • Class Location
    • Class Scheduling Options
  • INSTRUCTOR SELECTION
    • Staff Responsibilites
    • Assistant Staff
    • Staff Pay
  • PROMOTING AND MARKETING THE PARK TOOL SCHOOL
    • In Store Promotion
    • Newspaper
    • Direct Mail
    • Newsletters
    • Signage
    • Telephone Directory
    • Internet
    • Television & Radio
    • Direct Promotion to Teams, Clubs and Organizations
    • Word of Mouth
    • Marketing to Specialty Groups
    • Press Release & Sample
  • STORE POLICIES AND REGISTRATION
    • Registration Sample
    • Payment Policy
    • Student Cancellation/Missed Class Policy
    • Store Cancellation Policy
    • Student Age Limits
    • Liability Issues
    • Safety and Health Issues
  • Liability Waiver
  • Pre-Class Information
  • Bicycle Examination Form
  • Certificates of Completion
  • Equipment and Supplies
  • Time Line

Chapter B: TEACHING THE PARK TOOL SCHOOL

  • INSTRUCTOR'S ROLE
  • THE MAKING OF AN INSTRUCTOR
  • USING THE TEXT BOOK & INSTRUCTOR'S GUIDE
  • BBB-1 TEXT CORRECTION
  • TIME MANAGEMENT AND TOPIC PACING
  • VISUAL AIDS
  • CLASS CONTENT AND STUDENT ABILITY ISSUES
  • CLASS SAFETY ISSUES
  • PREPARING FOR A CLASS SESSION
  • STUDENT LEARNING STYLES
  • MEETING THE CLASS FOR THE FIRST TIME
  • KEEPING STUDENTS INVOLVED
  • LECTURING SKILLS
  • DEMONSTRATION SKILLS
  • DISCUSSION SKILLS
  • LAB OR HANDS-ON SKILLS
  • LAB OUTLINE
  • POSITIVE FEEDBACK
  • MANAGING DIFFIUCLT SITUATIONS
  • CLASS CONCLUSION AND SUMMARY
  • CLASS EVALUATION
  • SUMMARY

Chapter 1: Basic Bicycle Maintenance

Instructor Notes
  • 1-1 Threaded Fastener Tension and Torque
  • 1-2 Lubrication, Thread lockers, & Cleaners
  • 1-3 Diagnoising Mechanical Problems
  • 1-4 Tools and Tool Selection
  • 1-5 Repair Stands
  • 1-6 Home Shop Set Up

Chapter 2: Tires and Tubes

Instructor Notes

  • 2-1 Remvoing Wheels
  • 2-2 Removing Tire & Tube from Rim
  • 2-3 Inspecting the Inner Tube
  • 2-4 Inspecting the Tire
  • 2-5 Rim Strip
  • 2-6 Repairing Inner Tubes
  • 2-6.1 Pre-Glued Patch Repair
  • 2-6.2 Repairing Inner Tube with Self-Vulcanizing Patches
  • 2-6.3 Liquid Inner Tube Sealant
  • 2-7 Tempory Repair of Tire with Boot
  • 2-8 Inner Tube Valves
  • 2-9 Tire & Tube Sizing
  • 2-10 Installing Tire & Tube on Wheel
  • 2-11 Installing Wheels on Bike
  • 2-12 Tubelss Systems
    • Top of Page

Chapter 3: HUBS, REAR SPROCKETS

Instructor Notes

  • 3-1 Rear Sprockets
  • 3-2 Cassette Sprocket Removal & Installation
  • 3-3 Freewheel Sprocket Removal & Installaton
  • 3-4 Rear Sprocket Inspection & Cleaning
  • 3-5 Adjustable Hub Bearing Service
  • 3-6 Cartridge Bearing Service
  • 3-7 Campagnolo Hub Service
  • 3-8 Freehub Removal & Installation
  • Top of Page

Chapter 4: Wheel Truing

Instructor Notes

  • 4-1 Truing Procedure
  • 4-1.1 Lateral Truing
  • 4-1.2 Radial Truing
  • 4-1.3 Wheel Centering (Dish)
  • 4-1.4 Spoke Tension
  • 4-2 Replacing Broken or Damaged Spokes
  • 4-3 Wheel Wear, Repair & Damage
    • Top of Page

Chapter 5: PEDALS, CRANKS, & BOTTOM BRACKETS

Instructor Notes

  • 5-1 Pedals and Riding Shoes
  • 5-1.1 Pedal Removal
  • 5-1.2 Pedal Installation
  • 5-1.3 Damage to Crank Pedal Threads
  • 5-2 Cranks
  • 5-2.1 Crank Removal- Square Hole
  • 5-2.2 Crank Installation-Square Hole
  • 5-2.3 Crank Removal- Splined Hole
  • 5-2.4 Crank Installation-Splined Hole
  • 5-3 Bottom Bracket Bearings & Spindle
  • 5-4 Bottom Bracket Tool Selection
  • 5-5 Cartridge Bottom Brackets
  • 5-5.1 Cartridge Bottom Bracket Removal
  • 5-6 Adjustable Bottom Brackets
  • 5-6.1 Adjustable Bottom Bracket Removal
  • 5-6.2 Adjustable Bottom Bracket Installation
  • 5-6.3 Adjustable Bottom Bracket Adjustment
  • 5-7 External Bearing Crankset Systems
  • 5-7.1 Bearing Installation
  • 5-7.2 Crank Installation and Removal of Shimano and FSA
  • 5-7.3 Installation and Removal of Race Face X-Type Cranks
  • 5-7.4 Crank Installation and Removal fo Truvativ Giga X Pipe
  • 5-8 Chainrings
  • 5-8.1 Chainring Installation
    • Top of Page

Chapter 6: CHAINS

Instructor Notes

  • 6-1 Chain Sizing
  • 6-2 Chain Cutting
  • 6-2.1 Shimano Chain Service with Replacement Rivet
  • 6-2.2 Campagnolo Chain Service
  • 6-2.3 Chain with "Master Link"
  • 6-2.4 Chain with Reuseable Rivet
  • 6-3 New Chian Installation on Derailleur Bikes
  • 6-4 Tight Link Repair
  • 6-5 Chain Wear and Damage
  • 6-6 Chain Cleaning
  • 6-7 Chain Lubrication
    • Top of Page

Chapter 7: DERAILLEUR SYSTEMS

Instructor Notes

  • 7-1 Cable System
  • 7-1.1 Housing Length
  • 7-1.2 Cable Lubrication
  • 7-2 Shift Levers
  • 7-2.1 Flat Bar Trigger Shifters
  • 7-2.2 Twist-grip Shifters
  • 7-2.3 Above-the-bar Shifters
  • 7-2.4 Drop Bar Integral Brake and Gear Shifts
  • 7-2.5 Down Tube Shift Levers
  • 7-2.6 Bar-end Shift Levers
  • 7-3 Front Derailleur
  • 7-3.1 Derailleur Cable Attachment
  • 7-3.2 Height Adjustment
  • 7-3.3 Rotational Angle Adjustment
  • 7-3.4 Limit Screw Adjustment
  • 7-3.5 Index Adjustment (Three Chainring Bikes)
  • 7-3.6 Index Adjustment (Two Chainring Bikes)
  • 7-3.7 Front Derailleur Performance
  • 7-4 Rear Derailleur
  • 7-4.1 Derailleur Capacity & Maximim Sprocket Size
  • 7-4.2 Derailleur cable Attachement
  • 7-4.3 Limit Screw Adjustment
  • 7-4.4 B-Screw Adjustment
  • 7-4.5 Index Adjustment
  • 7-5 Chainline
  • 7-6 Derailleur Hanger Alignment and Repair
  • 7-7 Derailleur Inspections
  • 7-8 Troubleshooting
    • Top of Page

Chapter 8: RIM CALIPER BRAKE SYSTEMS

Instructor Notes

  • 8-1 Brake Levers
  • 8-2 Cable System
  • 8-2.1 Cable Lubrication
  • 8-3 Caliper Rim Brakes
  • 8-3.1 Cantilever Caliper Adjustment
  • 8-3.2 Linear Pull Caliper Adjustment
  • 8-3.3 Dual Pivot Caliper Adjustment
    • Top of Page

Chapter 9: CALIPER DISC BRAKE SYSTEMS

Instructor Notes

  • 9-1 Rotor
  • 9-2 Hydraulic Disc Brakes
  • 9-2.1 Brake Lever Adjustment
  • 9-2.2 Brake Caliper Adjustment
  • 9-2.3 Brake Pad Removal and Replacement
  • 9-2.4 Brake Fluid Bleeding and Replacement
  • 9-2.5 Resetting Brake Pads
  • 9-3 Mechanical Disc Brakes
  • 9-3.1 Brake Lever Adjustment
  • 9-3.2 Brake Caliper Adjustment
  • 9-3.3 Mechanical Brake Pad Removal and Replacement
    • Top of Page

Chapter 10: HANDLEBARS, STEMS, SADDLES & SEAT POSTS

Instructor Notes

  • 10-1 Handlebar Adjustment
  • 10-2 Stem Adjustment
  • 10-3 Saddle & Seat Post Adjustment
    • Top of Page

Chapter 11: HEADSETS

Instructor Notes

  • 11-1 Headset Types
  • 11-2 Headset Service
  • 11-2.1 Threadless Headset Disassembly & Assembly
  • 11-2.2 Threadless Heaset Adjustment
  • 11-2.3 Threaded Headset Disassembly & Assembly
  • 11-2.4 Threaded Headset Adjustment
  • 11-3 Headset Replacement & Installation
  • 11-3.1 Headset Stack Height
  • 11-3.2 Headset Removal
  • 11-3.3 Pressed Headset Installation
  • 11-3.4 Fork Crown Installation
  • 11-3.5 Star Nut or Compression Plug Installation
  • 11-3.6 Fork Sizing and Cutting
  • 11-3.6.1 Unthreaded Steering Columns
  • 11-3.6.2 Threaded Steering Columns
    • Top of Page

Chapter 12: BIKE WASH

Instructor Notes

Chapter 13: ON-THE-RIDE-REPAIRS

Instructor Notes

  • 13-1 Tool Choices
  • 13-2 Repair Procedures
  • 13-2.1 Flat Tire
  • 13-2.2 Cut or Ripped Tire
  • 13-2.3 Broken Spoke
  • 13-2.4 Dented Rim
  • 13-2.5 Broken Chains
  • 13-2.6 Chian Suck
  • 13-2.7 Twisted Chain
  • 13-2.8 Squeaky and Noisy Chain
  • 13-2.9 Rear Derailleur Shifting into the Spokes or Frame
  • 13-2.10 Derailleur not Indexing Properly
  • 13-2.11 Broken Derailleur Body, Cage, or Hanger
  • 13-2.12 Missing Derailleur Pulleys
  • 13-2.13 Front Derailleur Cage Bent or Twisted
  • 13-2.14 Crank Falling Off
  • 13-2.16 Bent Crank
  • 13-2.17 Bottom Bracket Loose or Falling Apart
  • 13-2.18 Broken Derailleur Cable
  • 13-2.19 Broken Brake Cable
  • 13-2.20 Twisted or Bent Handlebars or Stem
  • 13-2.21 Bent Frame or Fork
  • 13-2.22 Bent Saddle or Seat Post
    • Top of Page
Appendixes
  • Appendix A--Tool List
  • Appendix B-- Glossary
  • Appendix C--Recommended Torque for Bicycle Components
  • Appendix D--Curriculumn Bike Tables
  • Appendix E--Bike Evaluation Form
  • Appendix F--Class Evaluation Form
  • Appendix G-- Basic Positioning
  • Appendix H-- Basic Assembly Training
  • Appendix I -- Fact Sheet for Retailer
  • Appendix J-- BBB-1 Text Corrections
    • Top of Page