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 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

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

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