BBB-4TG Instructor Manual Table of Contents
Chapter A — Managing the Park Tool School
Chapter B — Teaching the Park Tool School
Chapter C — Curriculum Options
Chapter 1 — Basic Mechanical Skills
Chapter 2 — Tires & Tubes
Chapter 3 — Rear Sprockets
Chapter 4 — Hubs
Chapter 5 — Wheel Truing
Chapter 6 — Wheel Building
Chapter 7 — Cranksets
Chapter 8 — Chains
Chapter 9 — Pedals
Chapter 10 — Derailleur Systems
Chapter 11 — Electronic Derailleur Systems
Chapter 12 — Internal Gear Systems
Chapter 13 — Caliper Disc Brake Systems
Chapter 14 — Caliper Rim Brake Systems
Chapter 15 — Handlebars, Stems, Saddles, & Seatposts
Chapter 16 — Headsets
Chapter 17 — Frame & Fork
Chapter 18 — Suspension
Chapter 19 — On-Ride Repair
Appendices A–F — Reference Materials
Chapter A — Managing the Park Tool School
- Selecting a Course Structure
- Description of Curriculum Options
- New Rider Maintenance
- Novice Class
- Intermediate Class
- Advanced Class
- À La Carte Class Descriptions
- Tires and Tubes Class
- Caliper Disc Brake Class
- Wheel Class
- Wheel Building Class
- Derailleur Systems Class
- Retail Store Mechanic Training
- Class Structure
- Class Tuition
- Class Location
- Class Scheduling Options
- Instructor and Staff Selection
- Staff Responsibilities
- Park Tool School Manager
- Park Tool School Manager Duties and Tasks
- Skills and Knowledge
- Class Instructor
- Class Instructor Duties and Tasks
- Skills and Knowledge
- Class Assistant
- Class Assistant Duties and Tasks
- Skills and Knowledge
- Staff Pay
- Promoting and Marketing the Park Tool School
- Press Release
- In-Store Promotion
- Internet
- Website
- Direct Email
- Social Media
- Direct Mail
- Signage
- Television and Radio
- Direct Promotion to Teams, Clubs, and Organizations
- Marketing to Specialty Groups
- Newspaper
- Store Policies and Student Registration
- Student Bicycle Inspection
- Payment
- Student Cancellation / Missed Class
- Store Cancellation Policy
- Student Age Limitations
- Liability Issues
- Safety and Health Issues
- Class Preparation
- Classroom Equipment, Tooling, and Supplies
- Loaner Bikes for Lab Work
- Pre-Class Student Information
- Certificates of Completion
- Planning Timeline
- 2 Months to Go
- 1 Month to Go
- 2 Weeks to Go
- 1 Week to Go
- 1 Day to Go
- Day of Class
Chapter B — Teaching the Park Tool School
- Pacing
- Student Learning Styles
- Presenting to the Class
- Visual Aids and Props
- Class Safety Issues
- Class Session
- Lecturing and Discussion Skills
- Discussion Skills
- Demonstration Skills
- Hands-On Labs
- Managing Difficult Classroom Situations
- Classroom Arrangement
- Final Class Conclusion and Summary
- Class Evaluation
- Student Evaluation
- Peer Evaluation
- Employer Evaluation
- Self-Evaluation
- BBB-4 Text Correction & Erratum
Chapter C — Curriculum Options
- New Rider Maintenance Class
- Novice Class
- Intermediate Class
- Advanced Class
- Tires and Tubes Class
- Caliper Disc Brake Class
- Wheel Class
- Wheel Building Class
- Derailleur Systems Class
Chapter 1 — Basic Mechanical Skills
- Overview
- Shop Mechanic Training
- Common Misconceptions
- All Classes
- Lesson Objectives
- Equipment
- Instructor
- Student
- Instructor’s Introduction to Class
- Threaded Fastener Tension & Torque
- Lubrication, Threadlockers, & Cleaners
- Bearing Systems
- Diagnosing & Solving Mechanical Problems
- Tool Selection
- Tool Use and Tool Fittings
- Repair Stands
- Home Shop Setup
- Work Procedures and Safety
Chapter 2 — Tires & Tubes
- Overview
- Common Misconceptions
- Novice Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Intermediate Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Advanced Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Tire & Tube Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Wheel Removal
- Thru Axle Systems
- Removal of Tire & Tube From Rim
- Inner Tube Inspection
- Cut at Valve Base
- Leaky Valve Core
- Large Shredded Hole
- Hole on Rim Strip Side of Tube
- Long Cut or Rip
- Single Puncture or Small Hole
- Double Slits
- Tire Inspection
- Rim Strip
- Inner Tube Repair
- Pre-Glued Patch Repair
- Inner Tube Repair with Self-Vulcanizing Patches
- Inner Tube Sealants
- Tire Liners
- Temporary Tire Repair with Tire Boot
- Inner Tube Valves
- Tire & Tube Sizing
- Installation of Tire & Tube on Wheel
- Tubeless Tire Systems
- Tubeless Conversion Systems
- Wheel Installation
- Front Wheels with Disc Brakes and Open Dropouts
- Thru Axle Systems
- Solid Axle Types
Chapter 3 — Rear Sprockets
- Overview
- Common Misconceptions
- Novice Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Intermediate Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Advanced Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Cassette Sprocket Removal & Installation
- Freewheel Sprocket Removal & Installation
- Single-speed Sprocket Removal
- Sprocket Inspection & Cleaning
- Fixed Gear Sprockets
Chapter 4 — Hubs
- Overview
- Common Misconceptions
- Intermediate Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Advanced Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Hub Bearing Service for Adjustable Cup-and-Cone Type
- Disassembly
- Parts Inspection
- Assembly
- Hub Adjustment
- Oversized Axle Service: Campagnolo® and Shimano®
- Hub Adjustment: Solid Axle Cup-and-Cone
- Freehub Removal & Installation
- Cartridge Bearing Hubs
- Freehub Bearings
- Assembly
Chapter 5 — Wheel Truing
- Overview
- Common Misconceptions
- Novice Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Intermediate Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Advanced Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Wheel Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Wheel Truing Overview
- Radial True
- Rim Centering (Dish)
- Tension
- Truing Procedures
- Lateral Truing
- Radial Truing
- Wheel Centering (Dishing)
- Spoke Tension
- Tension Relieving of Spokes
- Spoke Tension Balance
- Broken & Damaged Spoke Replacement
- Wheel Wear, Damage, & Repair
Chapter 6 — Wheel Building
- Overview
- Common Misconceptions
- Wheel Building Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Spokes
- Hub
- Rim
- Spoke Cross Patterns
- Wheel Lacing
- First of Four Sets
- Second of Four Sets
- Third of Four Sets
- Fourth of Four Sets
- Bring Wheel to Tension
- Wheel to Rim Transfer
Chapter 7 — Cranksets
- Overview
- Common Misconceptions
- Novice Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Intermediate Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Advanced Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Crank Types
- Crank Removal & Installation
- Self-Extracting Crank Systems
- Three-Piece Cranks
- Two-Piece Compression Slotted Cranks
- Two-Piece Cranks Using Wave Washer
- Straight Spindle Cranks
- Stepped Spindle Cranks
- Two-Piece Cranks: Preload Adjuster Ring
- Campagnolo® and Fulcrum® Ultra-Torque® Cranks
- Campagnolo® Power Torque™ Cranks
- Specialized® S-Works® Cranks
- Bottom Bracket System Types
- Threaded Standards
- Non-Threaded Standards
- PF41 (also known as BB86, BB89.5, BB92, BB107, BB121, BB132)
- BB90 and BB95
- PF42, BB30, BB30a
- PF46, PF30, PF30a
- 386EVO, 392EVO
- BBright™
- Bottom Bracket Bearing Service for Non-Threaded Shells
- 30mm Spindle System Bearing Removal
- 28.99mm Spindle System (Dub™) Bearing Adaptor Removal
- 22/24 And 24mm Spindle System Bearing Adaptor Removal
- Press Fit Bearing Installation
- Press Fit Adaptors And Conversions
- Thread-Thru Bottom Brackets
- Campagnolo® Ultra-Torque® and Fulcrum® Bearings
- Campagnolo® Power Torque™ Bearings
- Bottom Bracket Bearing Service for Threaded Shells
- Threaded External Bearing Bottom Brackets for Two-Piece Cranks
- Threaded Cartridge Bottom Brackets for Three-Piece Cranks
- Threaded Adjustable Bottom Bracket Bearings
- Bottom Bracket Removal
- Bottom Bracket Installation
- Bottom Bracket Adjustment
- Chainrings
- Chainring Replacement with Mounting Arms
Chapter 8 — Chains
- Overview
- Common Misconceptions
- Novice Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Intermediate Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Advanced Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Chain Sizing for Derailleur Bikes
- Chain Sizing with Chain Retention System
- Chain Removal
- New Chain Installation on Derailleur Bikes
- Shimano® Chains with Connecting Rivet
- Campagnolo® 11 and 12-speed Chains
- Setting or Peening of 11 or 12-Speed Coupling Rivet
- Chains with Quick Links
- Chains with Reusable Rivets
- Tight Link Repair
- Chain Sizing and Tension Adjustment for Two-Sprocket Bikes
- Chain Length Sizing for Two-Sprocket Bikes
- Chain Tension for Two-Sprocket Bikes
- Chain Tension for Two-Sprocket Bikes With Chain Tension Idler Device
- Chain Tension for Eccentric Bottom Brackets on Tandems and Single-Speeds
- Chain Wear and Damage
- Chain Cleaning Chain Lubrication
Chapter 9 — Pedals
- Overview
- Common Misconceptions
- Novice Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Pedal Removal
- Pedal Installation
- Damage to Crank Pedal Threads
- Pedal Bearing Service
Chapter 10 — Derailleur Systems
- Overview
- Common Misconceptions
- Novice Class
- Lesson Objectives
- Equipment
- Instructor
- Student
- Intermediate Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Advanced Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Derailleur Systems Class
- Lesson Objectives
- Cable System
- Cable Housing Length and Routing
- Cable Lubrication
- Shift Levers
- Flat Bar Trigger Shifters
- Twist Grip Shifters
- Above-the-Bar Shifters
- Drop Bar Integrated Brake / Shift Levers
- Down Tube Shifters
- Bar End Shifters
- Front Derailleur
- Derailleur Design
- Derailleur Cable Attachment
- Height Adjustment
- Rotational Adjustment
- Limit Screw Adjustment
- L-Limit Screw
- H-Limit Screw
- Front Index Adjustment: Three-Chainring Bikes
- Front Index Adjustment: Two-Chainring Bikes
- Shimano® Toggle Front Derailleurs
- Shimano® Long Arm Dual Cable Mount Front Derailleur
- Front Derailleur Performance
- Rear Derailleur
- Derailleur Capacity and Maximum Sprocket Size
- Derailleur Installation
- Derailleur Cable Attachment
- Limit Screw Adjustment
- H-Limit Screw
- Index Adjustment
- L-Limit Screw
- B-Screw Adjustment
- Clutch System Rear Derailleurs
- Chainline
- Derailleur Hanger Alignment & Repair
- Derailleur Wear & Service
Chapter 11 — Electronic Derailleur Systems
- Overview
- Optional Class
- Lesson Objectives
- Equipment
- Instructor
- Shimano® Di2® Electronic Intelligent System
- Levers
- Battery
- Front Derailleur
- Rear Derailleur
- Di2® Crash Feature
- SRAM® eTap®
- Levers
- Batteries
- Front Derailleur
- Rear Derailleur
- FSA® K-Force® WE®
- Levers
- Battery
- Front Derailleur
- Rear Derailleur
- Derailleur Adjustment
- Rear Derailleur Limit Screws
- B-Screw
- Troubleshooting
Chapter 12 — Internal Gear Systems
- Overview
- Shop Mechanic Training
- SRAM® DualDrive™
- SRAM® I-Motion® 9
- Shimano® Nexus® Inter-7, Nexus® Inter-8, & Alfine® Hubs
Chapter 13 — Caliper Disc Brake Systems
- Overview
- Common Misconceptions
- Novice Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Intermediate Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Advanced Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Caliper Disc Brake Class
- Lesson Objectives
- Caliper Types
- Brake Pads
- Brake Pad Removal and Replacement
- Pad Installation
- Disc Brake Rotors
- Hydraulic Brake Systems
- Hydraulic Brake Levers
- Hydraulic Brake Caliper Alignment
- Hydraulic Brake Levers
- Hydraulic Brake Fluid Service
- Shimano® Hydraulic Brakes
- Magura® Hydraulic Caliper Brakes
- Hayes® Hydraulic Caliper Brakes
- Hayes® Bleeding
- SRAM® and Avid® Hydraulic Caliper Brakes
- Tektro® Hydraulic Brakes
- Mechanical Disc Caliper Systems
Chapter 14 — Caliper Rim Brake Systems
- Overview
- Common Misconceptions
- Novice Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Intermediate Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Advanced Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Brake Levers
- Upright Handlebar Brake Levers
- Drop Bar Brake Levers
- Cable System
- Cable Housing Length
- Cable Lubrication
- Caliper Rim Brakes
- Brake Pads
- Brake Pad Alignment
- Vertical Height Alignment
- Tangential Alignment
- Vertical Face Alignment
- Pad Toe
- Linear Pull Caliper Adjustment
- Cantilever Caliper Adjustment
- Dual Pivot Caliper Adjustment
- Direct Mount Rim Calipers
- Side Pull Caliper Adjustment
- Brake Pads
Chapter 15 — Handlebars, Stems, Saddles, & Seatposts
- Overview
- Common Misconceptions
- All Classes
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Upright Handlebars
- Bar Ends
- Bar Grips
- Drop Handlebars (Road Bars)
- Clip-On and Aero Handlebars
- Stems
- Quill Stems
- Threadless Stems
- Saddles
- Seatpost
Chapter 16 — Headsets
- Overview
- Common Misconceptions
- Novice Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Intermediate Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Advanced Class
- Lesson Objectives
- Equipment
- Instructor
- Samples
- Student
- Headset Types
- Headset Service
- Threadless Headset Service
- Threadless Headset Adjustment
- Threaded Headset Service
- Threaded Headset Adjustment
- Headset Replacement & Installation
- Headset Stack Height
- Pressed Headset Removal
- Pressed Headset Installation
- Fork Crown Race Installation
- Fork Steering Column Sizing
- Threadless Steering Columns
- Star Nut and Compression Plug Installation
- Threaded Steering Columns
- Threadless Steering Columns
Chapter 17 — Frame & Fork
- Overview
- Common Misconceptions
- Advanced or Optional Class
- Lesson Objectives
- Equipment
- Samples
- Frame Components
- Fork
- Head Tube
- Top Tube
- Down Tube
- Seat Tube
- Chain Stay
- Seat Stay
- Dropouts
- Bottom Bracket Shell
- Swing Arm
- Frame Construction & Service
- Steel
- Aluminum
- Titanium
- Carbon Fiber
Chapter 18 — Suspension
- Overview
- Common Misconceptions
- Advanced or Optional Class
- Lesson Objectives
- Equipment
- Samples
- Suspension Forks
- Shocks (Rear Shocks)
- Suspension Linkages
Chapter 19 — On-Ride Repair
- Overview
- Tool Choices
- Repair Procedures
- Flat Tire
- Cut or Ripped Tire
- Broken Spoke
- Dented Rim
- Broken Chains
- Chain Suck
- Twisted Chain
- Squeaky and Noisy Chain
- Rear Derailleur Shifting into the Spokes or Frame
- Derailleur Not Indexing Properly
- Broken Derailleur Body, Cage, or Hanger
- Missing Derailleur Pulleys
- Front Derailleur Cage Bent or Twisted
- Crank Falling Off
- Pedal Falling Off
- Bent Crank
- Bottom Bracket Loose or Falling Apart
- Broken Derailleur Cable
- Broken Brake Cable
- Twisted or Bent Handlebars or Stem
- Bent Frame or Fork
- Bent Saddle or Seat Post
Appendices A–F — Reference Materials
- A: Tool List
- B: Glossary
- C: Torque Recommendations
- Torque Conversion Scale
- D: Bottom Bracket Tool Selection
- E: Headset Standards
- F: Bike Map
- G: Basic Class Tool List
- H: FAQ Sheet for Retail Staff
- I: Registration Form
- J: Bike Examination Form
- K: Park Tool School Evaluation
- L: Basic Mechanic Training for the Bicycle Retailer
- New Bicycle Assembly
- Basic Assembly Checklist
- Basic Assembly Checklist
- New Bicycle Assembly