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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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Chapter 12 — Internal Gear Systems

  • Overview
    • Shop Mechanic Training
  • SRAM® DualDrive™
  • SRAM® I-Motion® 9
  • Shimano® Nexus® Inter-7, Nexus® Inter-8, & Alfine® Hubs

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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 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

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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

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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

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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

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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

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Chapter 18 — Suspension

  • Overview
    • Common Misconceptions
  • Advanced or Optional Class
    • Lesson Objectives
    • Equipment
      • Samples
  • Suspension Forks
  • Shocks (Rear Shocks)
  • Suspension Linkages

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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

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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

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